Diesel generators are complex machines that demand particularized knowledge of how to keep them in good running order. A failure to recognize warning signs that your generator is experiencing an issue can potentially spell ruin for your project, backing up production or extraction and resulting in a myriad of knock-on effects that can severely cut into your bottom line. There is little worse that having your workforce standing around as a result of an outage or breakdown, especially a breakdown that was entirely preventable. A key component of preventing critical breakdowns is knowing the warning signs that your unit will show when it is experiencing an issue, and in this article we'll take you through some common ones.
1. Sound
Although it might be a stretch to say that your diesel generator should purr like a cat, it is fair to say that the unit should emit a healthy and regular sound. A diesel generator's mechanics are very similar to a car engine, and if you're familiar with the difference between a healthy car engine and one that it struggling then you'll be able to tell when your diesel generator is having issues. Any spurting, turning over, or irregular emissions are a sure sign that you should have a trained technician give your unit a once over. Given the loudness of a generator in proper functioning order, it will actually be quite obvious when it is having issues so rely on intuition and if something sounds off then play it on the safe side.
2. Warning Lights
Warning lights are some of the more straightforward ways to tell that your generator unit is experiencing issues. Each generator will have a varying range of warning lights depending on the size and complexity of the unit. Suffice to say, warning lights will be easy to spot and should be addressed no matter what. Common warnings include battery failure, coolant level warnings, fuel leaks, and other similar types of issues. While a warning light might not necessarily indicate that your unit is out of order, it should be addressed before things get worse. If it's a recurring problem, replacement or prevention may be in order.
3. Smoke
Put simply, your generator should not emit smoke beyond the regular off-gassing of the diesel engine. Commonly, diesel engines can suffer damage from misapplication or misuse, which results in internal glazing and carbon buildup. If generators are not run at least 60 to 70% of their maximum load, then low cylinder pressures caused by poor composition can result in the aforementioned build-up, which then burns and smokes. There are three types of smoke which your generator can emit, each of which indicate different issues:
Black smoke is the most common type of smoke you will encounter, and can occur in a variety of different generators. It usually happens when the unit is under full power and when the turbocharger boosts air supply to match the fuel usage. If this occurs, damaged components will need to be replaced, and can be mitigated by regular tuning, adjustment and servicing. Sometimes black smoke can be caused by second-rate or impure fuel, so ensure you buy fuel for your generator from a reputable supplier.
Blue smoke is caused by the lubricating oil in your engine burning, which can make its way into the combustion chamber through worn valves, incorrect oil, and other mechanical wear. It is most commonly apparent at a cold start, which reflects reduced oil control. Your engine should never, ever, be emitting blue smoke, as a properly serviced engine should burn oil quite cleanly. If blue smoke is apparent, replace parts where necessary and ensure that your unit is properly cleaned and serviced.
White smoke, or sometimes greyish smoke, is caused when raw, unburnt fuel passes into the exhaust stream due to incorrect or defective fuel injection. It is also caused by low cylinder compression. The underlying cause of these issues are often leaks in the unit's valves, sticking piston rings, and other types of wear. The smoke usually occurs at a cold start but goes away as the engine warms up. If you continue to see white smoke at start up be sure to contact a service provider, as allowing it to continue without servicing could severely damage the unit.
Are you seeing any of the above warning signs? Depco has a multitude of offerings, from replacement parts to whole new systems. Get your replacement and prevention power before your core production systems start slowing down or shutting down. Contact Us to see how we can help!
