INTRODUCTION
A generator set is a key, reliable element designed for the generation of electric power in projects requiring an uninterrupted or emergency power supply. However, there are a series of necessary maintenance recommendations and measures to take into account if we want this reliability to remain unalterable.
There are two aspects to keep in mind when it comes to maintenance:
- What use are we going to give the generator set? Continuous operation is not the same as the occasional use. This is vital because it will determine what maintenance has to be carried out, how, and when.
- Specific care: the maintenance process of the generator set must take each part into account: the engine, alternator, etc… Each component is different and must recieve its own specific, correct maintenance care.
GENERATOR SET USE
When a generator set is purchased, it’s with an objective in mind, so that it can become part of the electricity supply of a remote system, or an emergency supply system, a mains backup system, etc. Each one of these entail specific needs and thus, their operation is also vastly different.
Nowadays, a wide array of different solutions are available. From systems that operate continuously, as they’re part of the electricity supply in an area where it’s difficult to guarantee doing so, to emergency generator sets which only start up when there is a mains failure. But even in these cases, if it’s a critical supply, a generator set will be required as a backup system. And so, the maintenance plan must be designed according to the predicted use.
GENERATOR SET CHARACTERISTICS
A diesel generator set consists of different parts. Mainly, the diesel engine and the alternator, as well as its chassis and canopy if it has one.
Inside of the engine are different systems: cooling and lubricatio, fuel… and all of them have their own filters, pumps, belts and subsystems. On the other hand, we’ll also find electrical systems like the wiring box, electrical protections, startup system and batteries, connection system, regulation and control system to which, at present, remote communication and SCADA systems are added.
GENERATOR SET MAINTENANCE
Just as we’ve stated before, a diesel generator set is needed to ensure electric power, which makes it a critical power system in multiple facilities. It’s a complex piece of equipment, composed of many different components, each with its own maintenance needs.
There are various types of maintenance which keep a generator set in good shape:
Corrective maintenance. If at any point a failure should occur, depending on how critical the facilities are, repairs will be required more or less urgently, whether the system be mechanical, electric, electronic… For this reason it’s essential to be able to count on the availability of correct spare parts and qualified staff to carry out the repairs. They can be carried out by the owner with their own resources, or through a reliable company which will guarantee correct maintenance.
Preventive maintenance. That is, a series of maintenance measures carried out periodically depending on the generator set and its use. Before any kind of failure appears, the generator set is revised, its spares changed and consumables renewed in order to lengthen the life and use of the genset. Amongst these measures are oil, coolant, fuel and air filter changes, as well as revisions and measures of all kinds: from inspection of the chassis and frame, to test startups, control of levels and operational parameters, to the revision of the control panel and electrical protections.
Both types of maintenance processes are updated day by day and, thanks to modern digitalization systems, we can reach very precise maintenance levels, which are so very important in critical energy systems.
Finally, there is a third maintenance measure: retrofit. When a generator set is purchased, it includes technology corresponding to that year of purchase, but as time goes by and needs change, the genset’s systems can be updated to, for example, be adapted to new legislation or to improve upon operation and possibilities. This can entail, amongst other things, updating the control software, renewal of control panels, repowering the control system, or other complex operations.
TECHNICAL ASSISTANCE
In order to carry out correct maintenance, a highly qualified staff is needed, a team of trained professionals in broad fields of knowledge: mechanical, combustion engines, electric generators and their protections, electronic control systems, etc. On the other hand, its necessary to have spare parts or the capability to identify and obtain the required pieces quickly. Agility in the search for solutions is key in keeping a generator set running.
In a critical installation, quick response time is the most important factor, and to achieve it, maintenance services with high availability, preparation and sufficient resources are needed.
DIGITALIZATION OF MAINTENANCE – REMOTE MANAGEMENT
The arrival of digitalization has caused diesel genset maintenance to quickly transform. Current gensets can feature control and electronic systems which through numerous sensors are capable of seeing the status of the genset, how many hours it’s been running and in which conditions. Additionally, they can communicate its status in real time.
In the event of a failure, this can allow for the technical service team to be notified immediately, granting them the capability of carrying out corrective maintenance from the start. Technologies such as Virtual Reality (VR) and Augmented Reality (AR) allow for the technical service team to carry out protective measures along with the property’s own technicians, to repare or identify the issue at hand with precision, using the VR and/or AR systems serve as maintenance manuals, or through direct communication, leading people to carry our the necessary oprations in order to reestablish service immediately.
As well as these technologies, access to data and digital models through big-data and digital twins grant the possibility to create extremely precise preventive maintenance models which allow the equipment to continue running.
These models are capable of identifying problems before they even occur, foreseeing when maintenance tasks must be carried out within the client’s desired time frames, optimizing the equipments’ life cycle. Without a doubt, the current digitalization model makes the reliability and availability of generator sets even greater.
GENESAL ENERGY CAN HELP YOU
Quick response time, high tech and maximum precision are key in the correct maintenance of diesel generator sets. At Genesal Energy we meet each of these requirements thanks to the hard work and constant innovation of a highly qualified staff which supervises every detail. Our technicians and engineers receive constant training in order to offer the client the best solution, which best adapts to the real requirements of each case.
This level of specialization guarantees our maintenance services 24/7, 365 days a year. Furthermore, the use of the latest technology for remote management and our high availability (we have a great amount of stock) allows us to offer the most advanced and specialized services in the market.
Genesal Energy is always ready to provide the most efficient solution. A bespoke generator set adapted to each client. You can find us at consultas@genesal.com.