In this article, we will introduce the five most common types of electrical generator failure.
1. Overheating
Overheating is a common and easily preventable cause of generator malfunctions, usually manifesting itself in other seemingly unrelated problems such as the high fuel alarms. Generators aren’t designed to run at full capacity indefinitely, much like a vehicle that is left running. Occasionally this problem is caused by overfilling the fuel tank, which in certain weather conditions can cause the fuel to expand, tripping the high fuel level alarm. Don’t panic, overheating can be solved by checking with a generator expert about the electrical load on your generator and making sure it conforms to your managers specifications.
2. Wet Stacking
Wet stacking, or ‘engine slobber’ in industry jargon, is the result of excessive no-load runtime: when generators operate below their rated output. When generators aren’t run to their full capacity, a variety of issues can arise, including buildup of unburned fuel, lube oil condensed water, and acids in the exhaust system. This issue can be solved easily by loading the unit for a few hours to burn off the excess fuel. Alternatively, you can pair the generator with an automatic load bank, which places a false load bank on the generator system, keeping it properly loaded.
3. Contamination
Commonly, air can contaminate the fuel system, especially problematic with generators that aren’t run regularly. Even a small bubble of air in a unit injector solenoid can cause an injector not to fire at startup, the problem can multiply, and suddenly your engine won’t start. This type of problem can easily be avoided by periodically running the engine during weekly inspections.
4. Mechanical Part Failure
A common failure relates to the jacket water heater, a device that keeps the engine block warm – which is a necessity to maintain proper oil temperature. In addition to this, engine parts, cooling systems and other auxiliary mechanisms might cause issues. A robust testing schedule and a reliable inspector can detect these sorts of breakdowns early so technicians can replace the faulty parts and prevent larger issues later on.
5. Human Error
Human error is a very common reason behind breakdown or nonfunctioning of generators. Thankfully this is one of the easiest issues to remedy, and many issues can be prevented by properly training your staff to handle the generator. Some common issues to watch out for are: ensuring no one has pushed a remote emergency power off switch, staff neglecting to add fuel, setting the transfer switch or breakers, among others. All of these usually boil down to simple forgetfulness, and can be avoided through diligence and proper training.
Have you experienced a recent generator failure? Tell us about it by commenting here, and get in touch with one of our experts if you are currently looking for a solution!
