How can we enhance the dependability of standby generators? Standby generators serve a crucial role in case of power outages or emergencies. Yet, what if your generator fails to start during an outage? Surprisingly, the leading cause of generator failure is often related to battery issues. This article explores several strategies to improve the reliability of your generator.
Reliability and MTBF According to the Nuclear Regulatory Commission, the reliability of diesel generators hinges on factors such as design, testing, operational history, inspections, maintenance, and operator qualifications (NRC Docket Nos 50-443/444). Proper maintenance can prevent 95% of generator failures. Mean Time Between Failure (MTBF) measures the time between system breakdowns or a failure to start. A longer MTBF increases the likelihood that your generator will start in an emergency.
Location Indoor generators offer a controlled environment, keeping the generator warmer and reducing the risk of corrosion. However, indoor generators may decrease reliability due to the complexity of supporting systems, potential oversights, and vulnerability to structural fires. Outdoor generators, while exposed to a less controlled environment, use original equipment manager (OEM) systems, eliminating the need for complex aftermarket support. They also address issues related to fuel and exhaust piping, air flow, fire isolation, and limited human accessibility.
Multiple Generator Solutions Enhancing reliability can involve having a backup generator for your backup generator. Paralleling two or more generators can provide 99.99% or higher reliability compared to 98% with just one. While paralleling generators can be complex, integrating controls directly into one generator and utilizing digital controls for interconnection can streamline the process. Mounting the paralleling switch directly onto the generator optimizes the setup for reliable switching.
Serial Components Simplifying the integration of control functions, fuel systems, exhaust systems, cooling systems, and starting systems can improve reliability. Using a complete factory system ensures that all components are designed to work seamlessly together, reducing the risk of problems.
Starting Systems A well-designed and maintained starting system is crucial for generator reliability. Battery issues are the primary cause of generator failure, and measures such as using high-quality lead-acid batteries, maintaining connections, employing battery heaters, and addressing charger and alternator issues can mitigate failures.
Engines Investing in high-quality engines optimized for standby generation is essential. Regular maintenance, including fluid and filter changes, visual checks, operation checks, weekly no-load tests, monthly load tests, and periodic full-load tests by certified technicians, ensures engine reliability.
Alternators While alternators are generally reliable, ensuring proper cooling air and balanced loads optimizes their performance. Regular checks of load balance can prevent overloading specific coil groups.
Fuel Systems Fuel system issues are the second most common cause of generator failure. For diesel generators, maintenance is critical to combat moisture, gelling, biomass, and fuel instability. Storage solutions like sub-base fuel tanks and day tanks with a main storage tank can prevent fuel-related problems.
Cooling Closed cooling systems are more reliable than off-engine systems, as they involve fewer parts and potential failure points.
Air Flow Optimizing air flow through the generator system, including a short, straight exhaust discharge and proper sizing of inlet and outlet openings, enhances reliability.
Controls Controls play a significant role in generator failure, with 20-40% of failures related to control issues. Integrated controls reduce the likelihood of operator error. Regular checks and turning the system back on after maintenance are crucial.
In conclusion, maximizing standby generator reliability involves a comprehensive approach, addressing various factors such as location, multiple generators, serial components, starting systems, engines, alternators, fuel systems, cooling, air flow, and controls. Implementing these strategies can significantly enhance the dependability of standby generators during critical situations.
