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Wednesday, June 24, 2020

Planned Preventive Maintenance (PPM) Checklist for Standby Generators

Emergency Diesel Power Generators are mostly used for standby power generators due to their reliability, durability and better performance under load. Diesel generators are utilized for back-up power systems in the most critical facilities mentioned below: 
  1. Government Buildings 
  2. Telecommunications Facilities
  3. Nuclear Power Plants
  4. Banks
  5. Hospitals
  6. Airports
  7. Heavy Industries
In standby power installations, diesel generators have the full-rated load capability in less than 10 seconds, and they generally can provide back-up for more than 25,000 hours or more between major reconstruct. This exceptional and unique credit goes to diesel generators, but as being machinery, proper maintenance and overhauling are mandatory to ensure that emergency powered diesel standby generator will work and run whenever required at the time of critical emergency as back-up expectations.

Proper Maintenance for Emergency Generators

Emergency Generator sets on continuous standby must have the capacity to go from a cold start to fully operational just in a few seconds. This type of functionality can establish a serious and critical overload on generator parts. However, regular maintenance and care keep generator parts lubricated prevent mold or oxidation of electrical contacts, utilizes up the fuel before lower and, in general, helps provide reliable engine start-up.

Preventative Diesel Generator Maintenance

Planned Preventative Maintenance (PPM) for diesel operated generators plays a vital role to enhance reliability, reduction repairs and long term costs. By adopting a diesel generator Planned Preventative Maintenance (PPM) schedule and adhering to specific diesel generator manufacturer recommendations and information, you can be sure that your standby power back-up system will start and run when you required it most.
Due to the durability of diesel generators, basic and primary maintenance is preventive. Diesel Generator’s Planned Preventative Maintenance (PPM) consists of the following action:
  1. General inspection
  2. Lubrication service
  3. Cooling system service
  4. Fuel system service
  5. Servicing and testing starting batteries
  6. Regular engine exercise

Back-Up Diesel Generator Planned Preventative Maintenance (PPM) Checklist

For the back-up generator to function properly, it is required to create a standby diesel generator Planned Preventative Maintenance (PPM) schedule that keeps the back-up generator in good working condition. When the standby generator is purchased, there will be maintenance guidelines from the manufacturer in owners’ manual. This should provide a guide for emergency generator maintenance checklist. Back-up diesel generators that are used frequently for emergency purposes need more servicing and overhauling. If it’s mandatory that the emergency generator is dependable in emergencies, and will require a rigorous maintenance plan and schedule. 

How PPM is Conducted for Emergency Diesel Generator?

While carrying out Planned Preventative Maintenance (PPM) for diesel operated generators, it should start with visual observation and inspection. Most of the mechanical issues such as leaks, battery, dust, corrosion, wires and damaged parts can be detected with a regular daily look. After looking at every part of the back-up diesel generator, Tasks outlined a complete maintenance checklist must be fused and filled.
The following methods as per the duration and period must be followed by checklist formats:
  1. Randomly
  2. Daily or Weekly
  3. Monthly
  4. Every 6 Months
  5. Annually
Now here we will discuss all above in the short description. 

Randomly

Such type of inspection and maintenance is conducted randomly; no specific period is required. Overall inspection including outer physical condition and housekeeping is carried out.

Daily or Weekly

The periodicity of the generator’s consistent maintenance will depend on the generator’s usage. After carrying out a visual inspection:
  • Check fluid levels
  • Inspect the battery and charging system
  • Check hoses
  • Belts for damages
  • Remove the sediment from the fuel tank
  • Start the generator and rectify any warning.

Quarterly

  • Change filters oil, coolant, air, fuel
  • Check ignition mechanism and change spark plugs
  • Start the generator and rectify any warning.

Annually

  • Refurbish generator’s diesel fuel
  • Service external parts, e.g., alternator & transfer switch
  • Conduct the Load test the back-up generator and rectify the warning or any alerts indicators
  • After carrying out Planned Preventative Maintenance (PPM) for back-up generators, proper housekeeping should be done around the generator, and ensure the back-up generator is turned to “AUTO” instead of “OFF” so it can run properly as expected during a power failure.
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