Are you aware of Diesel Generator problems during Summer Times?
Unless you use industrial diesel generators every day, Even though it is a great asset to the company, end of the day it is a machine & it will cause problems in the engine. Although a few engine problems are bigger than the others, most of the time we can prevent them if we are clear with those problems during these summer times. Here, Our Technical Experts at Shaktiman Equipments, want to share 4 Common Engine Problems Diesel generators users may face in this summertime & what causes them.
Problem #1: Engine Overheating
In the summertime, one of the major issues people face might be Engine Overheating, this is caused when the engine is pushed hard which may lead to all sorts of negative reactions. This may lead to further Diesel Generator Problems such as
Swelling, Breaking of Cylinder Heads
Bearings Damage
Crankshaft Damage
Pistons Expansion & Scraping against cylinder walls
This Overheating mainly happens when generators are used for an extended period & speedy attention has to be given when we notice an abnormal rise in temperatures.
Problem #2: High Fuel Level Alarms
When your high fuel level alarms go off adequately during summertime, there we can sense that something is wrong with the diesel generator. As we know, High Fuel level Alams are used in most generators as an indication that the tank is almost full as it activates normally when the tank level crosses 95%. In Summertime, due to the temperature rise, fuel expansion may cause the alarm to activate. So you have to either switch the alarm Off or reset it manually to solve the issue.
Problem #3: Block Heaters
One of the major misunderstandings is that the engine does not require a block heater in the summertime. There are two different metals used, i.e. aluminum is used for piston & cylinders are iron-made. During the startup of the engine, accelerated wear may occur due to the usage of those two dissimilar metals. The sudden expansion of pistons may lead to scuffing of piston skirt, Block heaters tend to release most of this scuffing by maintaining the cooling system temperature & maintaining the cylinders expanded.
Problem #4: Low Coolant Temp Alarms
Faulty Block heaters are the major reason for Low Coolant Temp Alarms.
When the block heater is exposed to an extremely warm temperature, it causes the coolant to circulate through the system. A block heater never causes the engine not to run, but when it runs 24X7 continuously, that too in sunny conditions, they will fail.
To avoid diesel generator problems, buy Mahindra Genset at shaktiman Diesel generator dealers in Chennai. They Customize your generator according to your industrial needs.
Whether you are operating a factory full of equipment or running a small/medium or large enterprise, the major issue or headache you face is the power outage. Because it not only affects your productivity but also can be costly if you are not prepared for it. Hence a generator can only be the source of keeping this nuisance aside and necessities keep running.
Why Should You Buy Cummins diesel generator?
Before making any decision on purchasing a Diesel Generators, you have to be clear on determining your core generator needs. Why should you have a generator? What are all purposes to be solved using Diesel Generators? And which brand should you go to? Even if you are confused in making decisions on the first two queries, you don’t need to have options in which brand to choose, as Cummins Rise is leading from the front in the Generator Industry in the past 8 years. As we, Shaktiman Equipments, the Original Equipment Manufacturers(OEM) of Cummins Generator & authorized Generator Dealers for the TamilNadu & Pondicherry region, we are the best choice for you to make the purchase: There are more reasons to purchase from us which are detailed in the following:
1. kVA Variations 7.5 to 3000
We address requirements from many industries such as Railway, transportation sectors, Hospitals, Petrol pumps, Factories, Supermarkets, Restaurants, Hotels, Banks & Construction sites, and many more as we have end-to-end customizable kVA variations. We first find the power calculation of what kVA actually will suit the customer requirement & deliver.
2. Best in Fuel Efficiency:
Power cuts obviously cut your profits too in the longer run. An efficient Diesel generator will simply avoid you from making losses. Shaktiman Equipments’ Electronically controlled air fuel ratio, Closed loop lambda feedback system.
3. Seamless SwitchOver:
The major advantage of using shaktiman’s Cummins diesel generator is its seamless switchover to the backup power. It is simply ensuring 100% safety of your equipment and this feature will make sure your peace of mind.
4. Sales & Service Dealership:
As we are OEM, also we have 30+ authorized dealerships all over districts of Tamil Nadu & Pondicherry. We have sales as well as service dealerships hence the annual maintenance of your Diesel Generator will be taken care of from our end.
5. Five-year Super Shield Plan:
We provide Cummins’s super shield AMC 5-year plan to our customers which includes zero repair charges, zero service charges, zero replacement costs, the whole years. This plan defies industry norms of 2 years warranty on Cummins diesel generator. Applicable for ranges from 82.5kVA & above dg sets.
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A diesel generator is used for emergency power supply in case of electricity shutdown or places where there power supply demand. Diesel generator generates electric energy by using a diesel engine along with an electric generator.
Nowadays, diesel generator usage is essential for industries backup, emergency, and electric systems in case of power failure. Hiring diesel generators for monitor electric current continuously and automatically start the generator when there is a power cut or power shutdown period and generator supply the power until the power comes back.
The diesel generator is the most important equipment for industries and helps to run the industries’ productions continuously. The favorable growth of industries such as oil & gas industries, telecom, mining, constructions, hospitals, and retail shops.
Diesel Generator Usage for Following Industries Below:
Mining
In all over the world running mining operation so diesel generator widely used for mining operations. They needed 80% of the power supply for mining operations because they are having heavy-duty equipment such as excavating machinery, drillers, conveyor belts, and cranes. Mining operations mainly used to get gas, coal, iron, and metals being mined. So, diesel generators are used always and number one option for easily used far-fetched mining zones with very extreme situations.
Healthcare
Healthcare is one of the most sensitive industries. Hospitals have a lot of medical facilities for patients and also have diesel generators facility for emergencies. If not have generators facilities in hospitals many patients lose their lives in case of power failure or interruption of electricity.
Patients are seriously ill and injured such as those patients in an intensive care unit (ICU) it would be at risk because life with the support of machines like oxygen pumps would fail to function with the slightest power outage and also used ventilators in ICU that helps to breathe when patients are in sick, injured or sedated for an operation.
In hospitals, diesel generators are widely used for backup power sources and provide uninterrupted power supply when the utility power grid fails. All-time maintain a full tank of diesel can last an entire hospital more than 8 hours depending on its size and compare to other generators, diesel generators can provide the backup power source for more than 48 hours. It depends on fuel storage.
Commercial
In the commercial industry without a power backup plan lose money in business. Power Failure can make this thorn in the flesh. Commercial industries without investing the cost in standby diesel generator, losses huge revenue at the case register, safety challenges for both people and finances, trouble for IT industries, and other automated equipment finally complete operations shutdown. So, diesel generators allow you to protect your business interests & revenues.
Oil & Gas
Diesel generators are mandatory usage for the oil & gas industry because diesel generator is an integral part of this industry all activities are based on gas fields including drilling, pumping, and loading. In most cases oil and gas exploration works remote locations with tough conditions. So, without diesel generator on-site would be quite impossible because most of the sites away from power grids. Only diesel generators fit for this site.
Manufacturing
Manufacturing industries can always need high volume productions. Sometimes slight disruption in manufacturing industries can not only low volume production and also not poor quality production. The low volume of production and low quality of the product depends on power supply interruption. The production line in the manufacturing line must be operating all the time. If blackouts occur in 24/7 manufacturing plants, then affect all the processes and affected the product quality. A diesel generator provides emergency power supply in case of blackouts and helps to prevent losses of production.
Construction
Generators will give power source support for constructions 24/7. Diesel generator helps power backup support for all construction equipments like power air conditioning, machines, power communication system, and run construction equipment such as cranes. Impossible for without power grid support for all construction sites only a few more construction sites have a power grid. If construction sites faced constant power interruptions can result in project completion time delayed due to power backup issue.
Telecommunication and Data Centers
Electronic machines, Computers, and data centers are the heart of every industry. Banks, IT industries, government sectors, railway, airways, and many industries have their own data stored servers.
Manual and cloud servers using to access data at all times for their business to operate without interruption of power supply. With constant power supply issues or power interruptions, these servers unable access and business have to halt their operations. Losing business and money in the process.
Diesel generators have provided very reliable service to telecommunication and data center industries after an interrupt in power backup or power grid failure, Automatically started and run the diesel generator.
Utilities
Sometimes Power generation plants also need generators due to emergencies. So, Power suppliers that depend on diesel generators for power productions run without interruption. Power generation plants have diesel generator standing for the main supply line emergency. They use diesel generators to produce enough electricity to power thousands of homes until they recover the main supply issue resolve.
Diesel generators help this industry allow power plant crew adequate time to work the main supply. Finally diesel generator helps to prevent the power supply problem in power generation plants.
Manual and cloud servers using to access data at all times for their business to operate without interruption of power supply. With constant power supply issues or power interruptions, these servers unable access and business have to halt their operations. Losing business and money in the process.
Diesel generators have provided very reliable service to telecommunication and data center industries after an interrupt in power backup or power grid failure, Automatically started and run the diesel generator.
Education
Nowadays, All schools, colleges, and other educational institutes of higher learning required generators. Several systems in the education system mandatory need for electricity. Causes of power outages are a lot more than students getting the rest of the day off. So, better institutes hire generators to resolve power interruption or power cut problems and serve continuous high-quality education for students. Educational institutes without power cannot provide the kind of safety they need to ensure.
Military
This industry is heavily dependent on diesel generators. Soldiers need all time good and stable power sources that can be carried the toughest environments and still function efficiently. So, the military use diesel generators for a wide range of applications including a power supply for their gear, hospitals, lighting for the training camps and Operating the IT equipment.
A Diesel generator is processing the electric generator to generate electrical energy. This is the specific case of the engine generator. A diesel compression-ignition engine often is designed to run fuel oil also some types are adapted to run with liquid fuels or natural gas.
Generator Users require less maintenance due to their durability (it means measures the length of product life), reliability (it means the product will not fail within a specific period of time), and the sturdiness characteristic (It means the durability of the product), and also they are considered cheaper to operate due to the low fuels costs as compared to the other types of fuels such as gasoline and propane. When you reach the best generator dealers they’ll guide you.
Diesel Generator
Every Business needs a Standby Diesel generator For Backup Power and the Generator Gives More power to the whole Unit. Also considered to withstand heavy loads for long hours and start off the power supply on the full load within minutes and must be regularly maintained to ensure they provide quality power throughout their service life.
The best diesel generator maintenance practice is following the maintenance schedule provided by the generator manufacturer to ensure maximum service time for the generator and proper operation when it is called upon to provide power.
The engine is the core component of the generator. If you want to run your generator well without any mechanical issues or electrical issues must maintain the generators carefully.
Once you start running the diesel generator, the exhaust system, fuel system, DC electrical system, and engine require close monitoring for any leaks that can cause hazardous occurrences. The very essential one is to maintain the internal combustion engine. A backup generator is mandatory in the industry and also proper maintenance of diesel generators is important so take a look at these steps.
Step 1: Lubrication Service
The Engine oil must be checked while powering off the generator at regular intervals using a dipstick.
Allow the oil in the upper portion of the engine to drain back into the crankcase and follow the engine manufacturer’s recommendations for API oil classification and oil viscosity.
Keep watching the oil level as near as possible to the full mark on the dipstick by adding the same quality and brand of oil. The oil and filter must also be changed at particular time intervals. Check regularly with the engine manufacturer for procedures for draining the oil and replacing the oil filter and their disposal is to be done appropriately to avoid environmental damage or liability.
Step 2: Cooling System
Check the coolant oil level during shutdown periods at the specified interval.
Must be noted these points “remove the radiator cap after allowing the engine to cool, and, if necessary, add coolant until the level is about 3/4 in” And a More critical role in balancing diesel engines require a balanced coolant mixture of water, antifreeze, and coolant additives.
Examine the exterior of the radiator for obstructions, and remove all dirt, grimy or foreign material with a soft brush or cloth with caution to avoid damaging the fins.
If available means, use the low-pressure compressed air or a stream of water in the opposite direction of normal airflow to clean the radiator.
WARNING Please don’t remove the pressure cap from a hot engine. Wait until the coolant temperature is below 120°F (50°C) before removing the pressure cap. Because heated coolant spray or steam can cause injury.
Step 3: Fuel System
This is the important point when it comes to the maintenance of diesel generators. Diesel is subject to contamination and corrosion within a period of time is one year, and therefore regular generator set exercise is highly recommended to use up stored fuel before it degrades.
The fuel filters should be drained at the designated intervals due to the water vapor that accumulates and condenses in the fuel tank.
Better check regularly testing and fuel polishing may be required if the fuel is not used and replaced in three to six months.
Step 4: Testing Batteries
If the battery’s charges reach the dead-end level is a common cause of standby power system failures.
The battery must be kept fully charged and well-maintained at an all-time 40% to 100% to avoid regular testing and inspection to know the current status of the battery and avoid low battery levels.
Do you want to increase battery performance?
Must be cleaned, and the specific gravity and electrolyte levels of the battery checked frequently.
Regular exercising keeps the engine parts lubricated and thwarts oxidation of electrical contacts, uses up the fuel before it deteriorates, and helps to provide diesel generator maintenance to reliable engine starting.
Engine exercise is recommended to be executed 15 days once or 25 days once for a minimum of 30 min
Step 6: Keep your Diesel Generator Clean
Maintain your engine all-time nice and clean because it will be taken care of Oil drips and other issues. Check day-by-day hoses and belts that are in good condition or not.
Frequent checks can keep better conditions and other nuisances from nesting in your equipment. However, the generator users thought is a generator set that is rarely used and might not need a lot of care. So, please avoid this kind of thought and keeps regular maintenance of diesel generators based on manufacturer guidelines.
Step 7: Exhaust system inspection
In case of any leaks along the exhaust line which usually occur at the connection points, the welds, and the gaskets. Find the place of leakages and repair them immediately by a technician.
Step 8: Operating Inspections
When the Diesel Generator is Running these Guidelines Should Be inspected in operation inspection.
Common Manufacturer Inspections guidelines for diesel generators are below,
Purchasing generators it’s not complicated one but before know very well about generators usages and models. There are many great advantages to purchasing generators new generators or buy a rental generator.
Mainly, Nowadays diesel generators like Mahindra powerol generators, Kirloskar generator, Ashok Leyland and Cummins used in retail shops, factory, automobile manufacturing companies, shopping malls, all commercial building, shopping complex, school and colleges mainly used generators for sudden power cuts happens on working hours it will affect the productivity. So, choosing generators models based on your usage of electricity per day because it’s used for what range of power load consuming generators you need to buy.
There are five types of generators avail, Diesel Generator, Natural gas generator, electric generator, propane generator and gas generator.
Some of the key factors must be analyzing for before purchasing a generator:
#1 Age, Hours, and Usage: First things you can try to check is the hours, age and history of the generator set. A check must how many hours generator is running then how much of fuel consumption taken on it. Usually, generator engines are just like a car and have an odometer reading.
A generator that has been used as a standby or backup power source will typically be better maintained and have much less wear than the one used as a prime power source. Only the technical expertise is to know about the full features and specification of generators. So better you have to ask to advice from technical expertise before buying generator.
#2 Manufacturer history and reputation: Nowadays, number of generator manufacturing international companies in the market some companies have good customer satisfaction, rating and have good product delivery performance other companies performing very low in last 5 years or more days.
Better learn more about company’s history it will help you to take correct decision making for purchasing the right product from the right place. Mostly prefer 10 to 20 more years of field experience in generators providing companies and know more shaktiman equipments Pvt ltd one of leading generator supplier of last 3 decades.
3# How To maintain Genset? This is much more important since a well-maintained and rebuilt generator set will have a much longer life than one that is simply changing hands from dealers to end-user.
4# Physical wear and tear on the unit
Following Steps For Maintenance:
Step 1: Visual Inspection
The generator comes under mechanical device suffers wear and tear during operation time. Check regularly all mechanical component inside the parts and spares of the generator.
Step 2: Replace bearings and bushings Replace bearing and bushings means stress during the generator operation and it is very difficult to test these parts for any stress they have been subjected to during the operation of the generator. Therefore, from a safety point of view, the replacement of bearings and bushings is the best course of action. The same goes for bolts and fasteners.
Step 3: Integrity check wiring and welds Test wire insulations for a breakdown. Any part not up to the mark should be replaced.
Step 4: Load Test Load test helps you to determine the overall efficiency in an electric power generator. The load limits specified how many power hours, electricity consumption during operation.
Step 5: Who you are purchasing it from (Genset broker vs Genset dealers)
Find before who is best dealers in the city and then choose the certified dealers who are the leading supplier of a high-quality service provider.
If you know more regarding Genset dealers and specifications contact usand respond quickly for your enquiry.
