Use of clean diesel for your generator

Diesel Generators are robust and very much dependable when maintained properly. Enough has been said about maintenance of a diesel generators. The maintenance programs primarily suggest timely replacement of Lube oil, Coolant, Filters, Gaskets and other worn out parts. These are important, but diesel fuel management is also equally important.

Diesel does not have an unlimited shelf life. Over time it starts to deteriorate. The older generation of diesel engines could run on pretty much anything. With the advancement in diesel technology the chances of failure due to poor diesel quality increased. Modern diesel engines operate at a much higher injection pressure compared to the older generation engines. At very high pressure even a microscopic particle will case accelerated wear and tear to the fuel injection components.

If stored under normal conditions, diesel will have 6 to 12 months of useful life. As the fuel gets older it will be contaminated mainly by three reasons:

1. Water condensation

2. Bacterial growth

3. Solid particulates

The diesel fuel naturally attracts water and it is the biggest enemy of diesel. The water particles present in the diesel will cause corrosion of metallic parts of the fuel system. Contaminated diesel can be supplied by the diesel supplier, condensation could be collected from the air inside the storage tank or rainwater can enter the diesel tank through vent holes. The microbes feed on the hydrocarbons of diesel. The water works as a catalyst allowing the microbial growth. It forms a sludge in the diesel. The sludge can get sucked into the engine and choke the Fuel Filters and damage the Injectors. Solid dirt particles can be present in the diesel from poorly sealed air vents or rusty walls of the fuel tank. These particles will block the Fuel Filter and damage the Injectors.  

The nozzle openings of the Fuel Injectors are extremely precise. They deliver precisely measured quantity of fuel in a well-defined spray pattern. A smallest dirt particle can pose serious threat to these high precision modern Fuel Injectors. Electronically controlled engines will have more precision engineered fuel system components compared to mechanical engines. Dirt particles in the fuel may cause very costly damage. 

There are simple ways to prevent these problems.

• Always use genuine Fuel Filters prescribed by the engine manufacturer.
• Follow the maintenance schedule of the filters.
• Regularly drain water from Water Separator.
• Buy diesel from reputed suppliers.
• Always keep the fuel tank full to prevent water condensation from the trapped air.
• If you are not using the Generator for long time, do consider the shelf life of the diesel.
• Clean the Fuel Tank once a year. Do not allow any rust formation on the tank.

To know more about our products visit us at www.mahindrapowerol.com  or call us at 1800-419-1999 

Causes of Voltage Drop in Diesel Generators

Voltage drops can have an adverse effect on productivity and profit and to make sure that they don’t happen too often, we must understand what causes the drops. 

It is well known that a voltage drop in diesel generators is mainly caused by the speed and frequency of the generator system. However, there are many other reasons that can cause a dip in voltage. 

1.  A main reason is that the load applied to the generator is greater than the capacity. This slows the machine down, drops frequency and voltage and leads to exhaust black stacking. The machine could eventually stall. 
2. The Automatic Voltage Regulator (AVR) voltage gain is set too low to respond to load being applied which will put pressure on the genset affect the life of the machine.
3. Clogged fuel injectors and fuel filters will supply less than required fuel to handle the load - this can cause the machine to slow down which will result in the reduction of hertz and volts.
4. Sometimes the speed control setting is not accurately set, and this may cause the generator to trip. 
5. If Automatic Voltage Regulator (AVR) feedback is from generator bus voltage transformer and voltage dips too far, all excitation could be lost and would typically result in an under voltage and over current trip.
6. A loose cable connection in the output terminal can also lead to voltage drops. 

Mahindra Powerol offers 25 kVA & 125 kVA Gas gensets, apart from diesel generators ranging from 5 kVA to 625 kVA. To know more about genset maintenance visit us at www.mahindrapowerol.com/ or call us at 1-800-419-1999

Tips for Generator Maintenance

Mahindra Powerol gensets are engineered to require as little maintenance as possible. Below are some regular steps that will help improve your gensets’ life and efficiency. 

1. Routine General Inspection :-

When the diesel genset is being operated, several systems need to be closely monitored for leaks. These include exhaust, fuel and DC electrical systems. Since the diesel genset is similar to an internal combustion engine, it is important to check it periodically and ensure that oil is changed after every 100 hours of operation.

2. Lubrication Service :-  

It is essential to check the level of the engine oil. You may let the oil in the upper parts of the engine drain back into the crankcase. It is advisable to keep the oil as close to the full level as possible and follow Mahindra Powerol’s recommendations for API oil classification and viscosity. You should also use the same brand of oil as far as possible. 

Mahindra Powerol has a set of procedures for draining and disposing of the oil in an environment friendly way. 

3. Cooling System :- 

During regular shutdowns, make it a point to check the coolant level. (Remove the radiator cap only after allowing the engine to cool.) The coolant can be a mixture of water, antifreeze and coolant additives. The exterior should be examined for obstructions and all foreign material should be removed with a soft brush. You can also use low-pressure compressed air or a stream of water. 

4. Fuel System :- 

Since diesel is subject to contamination, it is not advisable to use diesel that has been stored for a long time. Water vapour accumulates and condenses in the fuel tank, hence fuel filters should be cleaned at regular intervals. Preventive maintenance should also be undertaken in the form of general inspections and checking of coolant level, oil, fuel and starting systems. 

5. Testing Batteries :- 

One of the most common reasons gensets fail are undercharged batteries, so make sure batteries are charged. It is also advisable to keep batteries clean by wiping them with a damp cloth. 

A battery hydrometer can be used to check the specific gravity of the electrolyte in each battery cell.  A fully charged battery will have a specific gravity of 1.260 and the battery should be charged if the specific gravity reading is below 1.215.

The level of electrolyte should be verified after every 200 hours of operation. If the level is low, distilled water should be filled to the bottom of the filler neck. 

6. Keep your Generator Clean :- 

It is highly recommended to check your genset periodically and ensure it is kept clean. Hoses and belts are subject to wear and tear - they should also be inspected thoroughly. Sometimes wasps can rest inside, regular checks will take care of such pests. 

Mahindra Powerol offers 25 kVA & 125 kVA Gas gensets, apart from diesel generators ranging from 5 kVA to 625 kVA. To know more about genset maintenance visit us at www.mahindrapowerol.com/ or call us at 1-800-419-1999

Diesel Generator Fuel Cleaning and Polishing

Diesel fuel lasts for over 6 to 12 months without any maintenance and even longer in some applications but it certainly does not last forever. However, just because lasts for a year doesn’t mean that you keep it that way for a year. All diesel fuel deteriorates over time, and the longer it sits inside of a storage tank or within your idle diesel generator, the more likely it will begin to degenerate. So what does degenerated diesel do to you?

When a diesel power generator runs on dirty diesel fuel, sludge builds-up & clogs filters. Sludge build-up and clogged filters inside a diesel generator can cause the generator to function inefficiently or not function at all during a power outage. The result of a dysfunctional power generator can be extensive, from causing damage to the unit to not providing enough power to cover all primary systems, and most importantly stop functioning during an emergency.

Here are some other benefits of running a backup diesel power generator  with clean diesel fuel

• Cleans and lubricates the injection system
• Fuel injectors are far less likely to fail
• Maintenance expenses can be kept lower
• Sludge build-up (sediment, rust, water, etc...) becomes less of a problem
• The diesel power generator will run with less smoke
• More reliable fuel for outages and emergencies

If you have not had the diesel fuel in your diesel generator and/or fuel storage tank sampled, analyzed, and monitored, the following may occur either within the fuel tank or within the generator itself:
• The fuel inside the tank will appear dark
• The tank will emit an unusual odour
• Sediment will develop at the bottom of the tank
• Exhaust from the generator engine will be dark in colour while running
• The generator's fuel lines and/or filters will appear clogged
• Starting system damage (battery, relays and electrical components)
• Fuel injection pump and injectors clogged or damaged
• The generator output and engine performance may be intermittent

Diesel fuel is an organic substance that naturally begins to degrade over time. This process cannot be avoided, at some point water typically finds a way in either during fuel delivery or condensation and that is what starts the bacterial growth. The only defence against the breakdown of diesel fuel over time is regular fuel evaluation and cleaning - often referred to as fuel polishing.  Fuel polishing usually involves fuel sampling, testing, and analysis plus sterilising and cleaning particulates, bacteria, fungi, and rust out with chemicals and filters and sometimes algae based solutions, depending on the product or provider you are using for this type of service.