Top 10 generator operating errors

Generators are powerful industrial machines that will keep your site running when you need it most. However, you need to ensure that your generators are in good working order if you want them to operate at full capacity. Downtime can be easily avoided if owners, building engineers, maintenance staff and plant managers repair generators correctly. Here are the most common generator maintenance mistakes you need to avoid to keep your site up and running in an emergency.

1: Lack of maintenance
The most obvious maintenance mistake you can make is not regularly servicing your generator set. Carrying out regular preventive maintenance ensures that you identify problems before they become major issues, and it keeps your equipment in good working order.

2: Inadequate generator maintenance
Even if you maintain your generator, you still need to repair it properly. This includes burning off unburnt fuel, replacing filters and fluids as necessary, testing fuel, starting and cooling systems and checking the engine.

3: Don't hire specialists
Generator maintenance and repair specialists can advise you exactly what maintenance you need and how often. Attempting generator maintenance yourself can be risky as you are likely to miss problems or maintenance checks that a generator specialist would recognise.

4: Fuel quality
When you don't use your generator regularly, it's common for fuel to develop problems in the tank. If you do not maintain good fuel quality, condensation will cause microbes to proliferate and eventually contaminate the tank. This contamination will lead to damage to the fuel injection system. Fuel injection pumps can be very expensive to replace.

5: Incorrect fuel supply
Just as the quality of the fuel is important, so too is the quantity. There must be enough fuel reaching the tank in the first place. When there isn't enough fuel, the generator stops. It's important to have your fuel tank at 90%, leaving room to compensate for fuel expansion.

6: Never operate the generator
Just as you wouldn't leave a car for weeks or months without switching off the engine, you shouldn't leave your generator off all the time. Running your generator regularly reduces the risk of your generator shutting down and draws your attention to other faults in the system.

7: The generator is too large
You might think it's a good idea to buy the biggest generator you can afford so you never run out of power. However, it's not as simple as that. When you buy a generator that's too big for your operational needs, you're always running the generator at lower loads than it was designed for. This can lead to excessive fuel wastage and wet stacking.

Generally, passing too light a load through your generator causes wet stacking, which is an accumulation of unburnt fuel in the exhaust system that can be a fire hazard.

8: Failure to plan for future needs
You can buy a generator that is currently too large for your operational needs if you plan to expand and add equipment in the near future.

Regular load testing will help to mitigate any wet stacking that may occur before other equipment is installed.

9: Neglecting oil changes
You change the oil in your car frequently, and a generator engine should be no exception. Regular oil changes will keep your engine running at its best.

10: Insufficient lubrication
Undertaking tasks such as oil changes keeps your generator's components working properly. A lack of lubrication inside the generator causes corrosion and unnecessary wear on parts.

Translated from Top 10 Generator Service Mistakes to Avoid: https://duthiepower.com/generator-service-mistakes-to-avoid/