Frequently Asked Questions

This is a complex question. The size of generator set required will depend on a number of individual factors.

To ensure that your generator set is correctly sized you should contact our office in order for us to do a site assessment to come out and help identify the kVA or wattage rating for all the equipment and appliances on your premises that need to be powered by the generator. This will enable them to provide you with details of both the type and size of the generator which suits your requirements.

Constant mains electricity is supplied into premises via electrical cabling. When this mains electricity is disrupted due to a power failure, a signal is sent from the transfer switch to the generating set which then starts up and sends generated electricity back into the premises. When the mains supply is restored the transfer, switch blocks the power from the generating set and reverts to the main supply.

A transfer switch is a panel that is wired into the premises’ electrical distribution system to allow a generator to be used. It prevents the generator from back feeding into the mains power supply, which could cause serious injury to line workers trying to restore utility power supplies etc.

The time a generator will run on a tank of fuel depends on the size of the tank, the amount of time in which the generator is in use and the load that the generator is supplying.

A generator is designed to operate for extended periods of time and function full-time in heavy duty operations. However, it is important that the set is inspected regularly between uses, to fuel, oil and if any maintenance is due

The primary difference between kW (kilowatt) and kVA (kilovolt-ampere) is the power factor.  kW is the unit of real power and kVA is a unit of apparent power (or real power plus re-active power).  The power factor, unless it is defined and known, is therefore an approximate value (typically 0.8), and the kVA value will always be higher than the value for kW.  

In relation to industrial and commercial generators, kW is most used when referring to generators in the United States, and a few other countries that use 60 Hz, while the majority of the rest of the world typically uses kVa as the primary value when referencing generator sets

Regular maintenance is crucial for the reliable operation of a diesel generator. Key maintenance tasks include:

• Regular Inspections: Check for leaks, loose connections, and wear.
• Oil Changes: Replace engine oil and oil filters according to the manufacturer’s recommendations.
• Fuel System Maintenance: Inspect and clean the fuel system, including filters and injectors.
• Cooling System Checks: Monitor coolant levels and check for leaks or blockages.
• Battery Maintenance: Ensure the battery is charged and connections are secure.
• Air Filter Replacement: Replace air filters to ensure proper air intake.
• Exhaust System Inspection: Check for blockages and damage.
• Load Testing: Perform regular load tests to ensure the generator can handle the required load.

15W40 ENGINE OIL

If the generator is operated under low load, the lifecycle will decrease and serious damaged might occur.

This is especially more important in larger power.

Minimum permitted load for standby generators is 30% of the standby power. If the generator is operated under no-load or low load, there might be:

• Corrosive damage on engine parts
• Decreased greasing quality due to thinning in greasing oil
• White smoke
• Oil or liquid leakage in the exhaust and air suction system
• Carbon accumulation on cylinder covers or exhaust manifold.

• Standby Power: The power to operate for a limited time under variable load. Total of 200 hours per year operation is possible under a 70% load value. It is used as a back-up power when there are grid energy cuts. There is no overloading.
• Prime Power: The power to operate constantly under variable load. The average load value should be 70%. 10% overloading is possible for 1 hour every 12 hours.
• Continuous Power: The power to operate constantly under constant load. The average load value could be 100%. There is no overloading.

A diesel generator combines a diesel engine and an electric generator (alternator) designed to generate electrical energy. It is used as a primary power source or as backup power in case of power outages. Diesel generators are widely used in various applications, including residential, commercial, and industrial settings.

A diesel generator operates by converting the chemical energy in diesel fuel into mechanical energy through combustion in the engine. This mechanical energy then drives the alternator to produce electricity. The process involves several stages:

• Fuel Injection: Diesel fuel is injected into the engine’s combustion chamber.
• Combustion: The fuel ignites under high pressure, creating a controlled explosion that drives the engine’s pistons.
• Mechanical Energy Conversion: The movement of the pistons turns the crankshaft, converting chemical energy into mechanical energy.
• Electricity Generation: The rotating crankshaft drives the alternator, which converts mechanical energy into electrical energy.

A diesel generator comprises several key components:

• Diesel Engine: The primary source of mechanical energy.
• Alternator: Converts mechanical energy into electrical energy.
• Fuel System: Stores and supplies diesel fuel to the engine.
• Cooling System: Maintains optimal operating temperature.
• Lubrication System: Reduces friction and wear in the engine.
• Exhaust System: Expels exhaust gases from combustion.
• Control Panel: Manages and monitors generator functions.
• Battery: Starts the engine and powers control systems.
• Frame/Skid: Provides structural support and stability.

Diesel generators can be classified into various types based on their design, size, and application:

• Portable Diesel Generators: Small, mobile units for temporary power needs.
• Standby Diesel Generators: Permanently installed systems for backup power.
• Prime Power Diesel Generators: Designed for continuous operation as a primary power source.
• Industrial Diesel Generators: Large-scale units for industrial applications requiring high power output.

Diesel generators offer several benefits:

• Fuel Efficiency: Diesel engines are more fuel-efficient than petrol engines, providing longer runtime for the same amount of fuel.
• Durability: Diesel engines are built to withstand heavy use and harsh conditions.
• Lower Operating Costs: Lower fuel consumption and longer engine lifespan reduce overall operating costs.
• Reliable Power: Diesel generators provide consistent and stable power output.
• Safety: Diesel fuel is less flammable than petrol, reducing fire risk.

Selecting the appropriate diesel generator involves several considerations:

• Power Requirements: Determine the total wattage needed to power your equipment or facility.
• Application: Consider whether the generator will be used for standby, prime, or continuous power.
• Fuel Consumption: Evaluate the generator’s fuel efficiency and runtime.
• Size and Portability: Assess the physical size and portability requirements based on your application.
• Noise Levels: Check the generator’s noise output, especially if it will be used in residential or noise-sensitive areas.
• Emissions Compliance: Ensure the generator meets local emissions regulations.
• Budget: Consider the initial cost, maintenance expenses, and operating costs.

Common issues with diesel generators and their troubleshooting steps include:

Failure to Start

• Check the battery and connections.
• Ensure there is sufficient fuel.
• Inspect the starter motor and solenoid.

Overheating

• Check coolant levels and radiator condition.
• Ensure proper ventilation and airflow.
• Inspect the water pump and thermostat.

Low Power Output

• Check the fuel system for clogs or leaks.
• Ensure the air filter is clean.
• Inspect the alternator and voltage regulator.

Excessive Noise

• Excessive Noise
• Check for loose components.
• Ensure proper lubrication.

Oil Leaks

• Check seals and gaskets.
• Inspect the oil filter and drain plug.
• Ensure adequate oil levels.

Safety is paramount when operating diesel generators. Key precautions include:

• Proper Ventilation: Ensure the generator is used in a well-ventilated area to prevent carbon monoxide buildup.
• Fuel Handling: Store diesel fuel in approved containers and away from ignition sources.
• Electrical Safety: Use appropriate electrical cords and connections to prevent shocks and fire hazards.
• Routine Maintenance: Regularly maintain the generator to prevent malfunctions and accidents.
• Fire Safety: Have fire extinguishers readily available and ensure the area around the generator is free of flammable materials.
• Training: Ensure operators are trained on safe operation and emergency procedures.

Diesel generators can have significant environmental impacts, including:

• Emissions: Diesel engines emit pollutants such as NOx, PM, and sulphur dioxide (SO2). Using low-sulphur diesel fuel and installing emissions control devices can mitigate these effects.
• Fuel Spills: Proper fuel handling and storage practices are essential to prevent spills and contamination.
• Noise Pollution: Noise from diesel generators can be mitigated using soundproof enclosures and silencers.
• Waste Disposal: Dispose of used oil, filters, and other waste materials according to local regulations.