Procurement and Operating Costs of Industrial Generators

Maintenance and repair costs of industrial generators

Maintaining your generator can reduce maintenance costs and ensure reliable power supply during power outages. Most generator manufacturers have announced maintenance schedules. This schedule lists the maintenance to be carried out on the generator set (by day or hour), as well as the annual maintenance costs of diesel generators for different operating time spans. The maintenance cost of diesel generators remains unchanged throughout the entire scale. The maintenance costs of all other systems increase over time.

Monthly, quarterly, semi annual, and annual inspections are normal manufacturer requirements. Usually, the operating generator set and its supporting equipment are inspected daily or hourly. Hospitals, data centers, and municipal authorities with strict requirements for electricity will conduct generator load testing. The generator operates at different load percentages.

Generators and related systems that have not completed maintenance according to the prescribed time intervals may shut down due to malfunctions.

Malfunctions caused by lack of maintenance

The generator cannot be started in a timely manner during power outages in public facilities. Some users' generator inspections have found that the engine starting battery is dead, the electrolyte level in each battery unit is low, and the battery charger circuit breaker has tripped. After adjustment, the electrolyte level of the battery increases with the increase of distilled water, the charger circuit breaker resets, and the battery accepts charging and completes the charging cycle. However, the next power failure caused the generator to fail to start and run out of power again.

After inspection by Dingbo Power, it was found that the generator did not check the proportion of each battery unit, nor did it conduct a load test, and the battery did not pass the load test and was replaced. The maintenance program includes checking the battery density and charging system, as low electrolyte levels caused the initial battery failure. In two separate incidents of utility failures, the negligence of the inspection resulted in the loss of emergency power supply. If there is a complete maintenance plan, battery downtime and additional repair costs can be avoided. By signing service contracts with qualified companies, unplanned maintenance and repair costs can be reduced, while Dingbo Power provides service contracts, troubleshooting and repair, and installation services.

Operating costs during power outages of industrial generators

These costs are attributed to operation during power outages. The fuel for the engine of the generator set is the main cost. Most generator manufacturers release a fuel consumption chart. The charts are different, but most of them divide the amount of fuel used by the engine under different load conditions.

During long-term power outages, fuel and transportation prices may increase. Installing additional fuel storage tanks can eliminate extra costs and long waiting periods during downtime. Facilities with critical power requirements typically have maintenance personnel to perform operational checks, typically visual inspections of generators and support systems. Checking and adding extra fuel can help increase costs, enhance reliability, and allow for longer operating times.

Industrial generator condition

The fuel consumption of the engine is directly proportional to the overall condition of the generator. The device consists of an engine and an AC generator. Each system is composed of moving parts, and all moving parts will wear out. When the parts begin to reach their wear limit, the engine will consume more fuel.

The generator that supplies power to the malfunctioning motor will experience more wear and tear. In this case, both the engine and the AC generator will experience additional wear and tear, and the consumption will also increase with the increase of symptoms. Once the motor fails completely, the system circuit breaker will trip to eliminate this situation.

There are many factors that can interfere with the cost of the power system. Diesel generators are the most economical in terms of procurement, installation, maintenance, and operation. The cost of emergency or backup power systems is the lowest compared to power losses in facilities with critical power demands. The system has correct design, installation, and maintenance, which can reduce operating costs and improve reliability.

Dingbo Power was founded in 1974 and is one of the earliest manufacturers of generators and diesel generator sets in China. If you want get more information, please feel free to send email to sales@dieselgeneratortech.com we will pay highly attention on your question.