Generator Maintenance UK

Generator Maintenance
Customer Care Guidance

• Prime Rated Generators are designed to run with 10% overload for 1 hour in any 12 hour period. This should not be exceeded

• Standby Rated Generators are designed to run at 100% load for the duration of an outage with no overload available.

• Load must be balanced / distributed across all three phases.

• The AMF panel should be used correctly in accordance with manufacturer’s instructions

• Maintenance must be carried out on a 6 monthly basis a qualified and fully trained generator engineer

• Ensure that only approved parts are used when repairing the generator

• Keep all maintenance and repair records in a safe place readily available to the generator engineer

• Report any irregularities (both visual and otherwise) immediately

• All fuel, oil, water and other fluid levels to be kept full

• Generator is never allowed to run out of fuel or oil whilst holding the load


• Generator is never over-loaded and never allowed to run lightly loaded for long periods

• Generator is run off load once every week for a test of 5 minutes maximum

• Generator is run with load once a month

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• Generator enclosure is checked for signs of tampering / vandalism (i.e. has the emergency stop button been pressed and not reset?)

• Appoint a responsible person for the generator management

Generator maintenance service programmes carried out regularly should include tests and checks of the following:

Cooling system
Radiator/heat exchanger, coolant, hoses and connections, fan drive pulley and fan, fan belts, jacket water heater, water pump, thermostats.

Fuel system
Fuel tank, water trap/separator, fuel lines and connections, governor and controls, fuel filters – primary/secondary, fuel pressure, air induction and exhaust system, air filter, air filter service indicator, air inlet system, turbocharger, exhaust manifold, valves and valve rotators.

Lubrication oil system
Oil, oil filters, oil pressure, crankcase breather

Starting system
Batteries, battery specific gravity, battery charger, starting motor, alternator, engine monitor and safety controls, gauges, remote announcers/alarms

Generator
Bearings, slip rings and brushes, space heaters, vibration isolators

Control panel
Start controls – manual/auto, voltmeter, ammeter, frequency meter, circuit breaker, auto transfer switch

Gas engine
Gas lines and connections, carburettor and linkage, magneto/distributor, ignition system, spark plugs

Insulation test
Main stator, main rotor, exciter stator, exciter rotor

Load testing
With full load, perform a two to four hour load test

Overall Energy Systems Testing

As well as performing the periodic Planned Maintenance of each part of the system, consideration should be given to testing the entire system on a regular basis.

An overall system test will involve putting the critical load at risk so careful arrangements and agreements must be made.

Mains Failure
Test Disconnect the mains supply to the protected power equipment for an extended period and check:
1. The Automatic Mains Fail (AMF) equipment operates correctly

2. The UPS (where installed) signals a mains failure during the changeover

3. The generator shuts down after the expected time

4. The UPS accepts the restored mains power supply and recharges the batteries

5. All alarms can be reset