Genset maintenance Preventive maintenance for generator set (genset) systems is an integral part of station operation.

Engineers should do basic checks to ensure proper genset ope ration. The worst thing for a station is to discover that the genset does not wo rk when it's needed most. Figure 1 shows a functional block diagram of a typical genset system for referen ce in this discussion of preventive maintenance. Functionally, a genset is mainly composed of a dynamo and its prime mover, an en gine. The engine supplies the mechanical energy, and the dynamo turns it into el ectricity. Maintaining the engine is similar to maintaining that of a vehicle, w hile maintenance of the dynamo is the same as for an electric motor. The battery The battery provides power to the engine starter. It should be checked at least weekly for its capability to run the starter. Check the battery terminals to ens ure that they make a good mechanical and electrical connection to the starter an d the charger. Maintenance-free sealed batteries are the best to use, but lead-a cid batteries can do the job at a lower cost. Just be sure to check the electrol yte levels of the lead-acid type on a monthly basis. Coolant water The coolant is usually composed of automotive-grade glycol to prevent freezing d uring winter. Check the level on the radiator on a regular basis, similar to wha t would normally be done on a car. Use a temperature gauge to ensure that the fr eezing point of the glycol mixture is much lower than what is required in the ge nset's location. Also, check the water hoses used on the engine for wear and cra cks. Hoses can be deformed by old age and overheating, and they may need to be r eplaced before any serious leaks occur. Clean air Inspect to ensure that clean air gets into the engine through the air filter. If the genset housing has a window with a louver intake, make sure that this louve r opens when the genset is operating. The mechanical arm can sometimes become so stiff that there is not enough air coming into the genset building. Also, a scr een should be installed to prevent the intake window from being clogged by insec ts. This screen should be inspected regularly to ensure free airflow. Engine oil Preserve the genset engine by keeping an eye on its engine oil. Use the right gr ade and check regularly for the proper oil level. The oil filter should be check ed and replaced at the same time as the oil is changed. The engine manufacturer should have recommendations as to how often the oil and filter need to be replac ed. Ensure that the cap of the dipstick is properly replaced after every inspect ion to prevent spillage during operation. The fuel Depending on location, diesel is economical in the long run for big generator se ts, while propane provides longer hours for smaller gensets. The hours of genset operation need to be logged at least weekly and the tank reservoir inspected. I f using propane, check for leaks with soapy water and a sprayer at least weekly. Ensure that ice shields for any exposed part of the fuel piping are intact and can bear the brunt of ice storms in the area. The engine Have a genset dealer or representative do a load bank testing of the genset once a year. This may also include compression and timing tests to ensure that the e

ngine is operating at optimum performance. The ATS Mechanical parts of the ATS have a tendency to get stuck if not used regularly. Activate the automatic transfer switch (ATS) during a maintenance night to exerc ise it. Refer to the manufacturer's recommendations for proper lubrication of an y moving parts. Use a laser-operated pyrometer to test connector temperature. Th is is particularly useful for determining if bolted connections for wires carryi ng high current are overheating. It enables the engineer to determine if the con nection is overheating without making any physical contact with it, thereby maki ng it a safe procedure. The maintenance schedule Table 1 is a suggested genset maintenance schedule. It is divided into frequency of implementation (weekly, monthly and annually). These frequencies may vary ac cording to specific needs such as the age and size of the genset, its site locat ion and available manpower. Develop a schedule that ensures optimum genset perfo rmance.