How to Care For a Generator

General Care Protocol For Generators

  • Prime Rated Generators are designed to run with 10% overload for 1 hour in any 12 hour period.
  • Standby Rated Generators are designed to run at 100% load for the duration of an outage, with no overload available.
  • Load MUST be reasonably balanced/distributed across all the three phases.
  • The AMF panel is used correctly in accordance with manufacturer’s instructions.
  • Maintenance must be carried every 6 months by a qualified generator engineer.
  • A test certificate is issued each service/maintenance visit every 6 months Only approved parts are used.
  • All work and maintenance records are kept available.
  • Any irregularities visual or otherwise are reported in writing immediately.
  • All fuel,oil,water and other fluid levels to be kept full.
  • Generator is never allowed to run out of fuel or oil etc whilst holding the load.
  • Generator is never over-loaded and never allow the Generators to run lightly loaded for long periods.
  • Generator is run off load once every week for a test of 5 minutes maximum.
  • Generator is run with load once a month.
  • Generator enclosure is checked for any possible tempering ( i.e. has the emergency stop button been pressed and not reset?).
  • Someone is appointed as the responsible person to overlook implementation.

 

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Generator Service Programme

A regular generator service program should include tests and checks of the following:

Cooling System
Radiator/heat exchanger, coolant, hoses and connections, fan drive pulley and fan, fan belts, jacket water heater, water pump, thermostats.

Fuel System
Fuel tank, water trap/separator, fuel lines and connections, governor and controls, fuel filters – primary/secondary, fuel pressure, air induction and exhaust system, air filter, air filter service indicator, air inlet system, turbocharger, exhaust manifold, valves and valve rotators.

Lubrication Oil System
Oil, oil filters, oil pressure, crankcase breather.

Starting System
Batteries, battery specific gravity, battery charger, starting motor, alternator, engine monitor and safety controls, gauges, remote annunciators/alarms

Generator
Bearings, slip rings and brushes, space heaters, vibration isolators.

Control Panel
Start controls – manual/auto, voltmeter, ammeter, frequency meter, circuit breaker, auto transfer switch.

Gas Engine
Gas lines and connections, carburettor and linkage, magneto/distributor, ignition system, spark plugs.

Insulation Test
Main stator, main rotor, exciter stator, exciter rotor.

Load Testing
With full load, perform a two to four hour load test.

Overall Energy Systems Testing
As well as performing the periodic Planned Maintenance of each part of the system, consideration should be given to testing the entire system on a regular basis.
An overall system test will involve putting the critical load at risk so careful arrangements and agreements must be made.

Mains Failure Test
Disconnect the mains supply to the protected power equipment for an extended period and check, without generator:
1. If the UPS is fitted with auto-restart facilities that the system returns to normal operation automatically, otherwise all UPS modules can be re-started manually and the system restored to normal operation.
2. All alarms can be reset.

If a generator is installed:

The Automatic Mains Fail (AMF equipment operates correctly).
The UPS signals a mains failure during the changeover.
The generator shuts down after the expected time.
The UPS accepts the restored mains power supply and recharges the batteries.
All alarms can be reset.

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