TECHNICAL BULLETIN

BULLETIN ID : SSHTB-100701EN DATE: 09.07.2010

SUBJECT : LOW LOAD OR NO LOAD OPERATION

This bulletin aims to define the precautions to be taken to avoid possible problems and damages in
case of generator sets do run with no load or low load even if operation is for a limited period of time.

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To operate the generator set out of its category (ESP/PRP/COP) and capacity specified on the product
label is hazardous as much as low load operation of generator sets.

Extra-attention must be paid for this situation in case of using of large power generator set.

For ESP and PRP generator sets, the minimum allowable amount of load is 30% of rated power.

For COP generator sets, it is 25% of rated load.

Due to an operation under minimum load limits, the symptoms and problems to be faced are as below:

Oil leakage in exhaust and air inlet system

As a result of a long time operation in low load or without load;

 Since the temperature inside cylinders will be less than normal level, the fuel delivered to cylinders
cannot be combusted properly. Unburned fuel and oil steam become condensed in the exhaust
system.

 Turbocharger oil seals cannot isolate as efficiently in low load operation and this situation causes the
leaking of the oil together with air to inlet and outlet manifolds.

 Then, oil leakages can be seen on the exhaust and air inlet manifolds. So, it results in displeasing oil
drops on the exhaust manifold connection points.

 This situation is faced especially on Standby(ESP) generator sets which are operated with no load
during weekly test running.

Carbon residues on cylinder covers and exhaust manifolds

 Unburned fuel, oil steam and soot create contamination on the valves and valves’ slots in cylinder
heads, bearings, exhaust manifold, nozzles and so, reduce the engine performance.

 Moreover, by blocking the exhaust pipes and silencers it causes degraded engine performance again.
In later stages it can cause serious damage in the engine.

Abrasive damage

 Low temperature exhaust gas causes sulfuric acid condensation in the exhaust system and gives
abrasive damage to the engine.

PUBLISHED BY : TEKSAN After Sales Services PAGE 1/2

Yenidogan Mahallesi, Edebali Caddesi, No:12 T. : +90 216 312 05 50 e-mail : info@teksanjenerator.com.tr
34791 Sancaktepe – Istanbul / TURKIYE F. : +90 216 312 69 09 web : www.teksanjenerator.com.tr

F19-06- 00- 09/06 TEKSAN reserves the right to make changes and corrections on this document at any time and without any notice.
 TECHNICAL BULLETIN

BULLETIN ID : SSHTB-100701EN DATE: 09.07.2010

SUBJECT : LOW LOAD OR NO LOAD OPERATION

Deterioration of lubrication oil

 Due to loss of combustion performance, unburned fuel mixed with oil in the cylinder makes the oil
deteriorated. Spoiled oil causes early abrasion of the moving parts and bearings.

 Abrasion will firstly affect the bearings of turbocharger operating at very high speed and this
situation results in oil leakage and damage.

 By this operation, oil consumption in the engine dramatically raises.

White smoke

 Unburned fuel is to be discarded from exhaust as white smoke.

Points to be considered:

 It is recommended to avoid the generator sets to be operated without load or low load, or if not
possible, this operation should be ended within short time.

 If weekly test must be performed without load, testing period of time should be limited to 10
minutes.

 For an engine operated at 30% or less load for 1 hour, it is recommended to run the engine at 60%
or more load for 30 minutes or longer.

 To burn the carbon residues in the exhaust system, generator set should be operated every year for
4 hours at 75% load level. Load level should be raised gradually from zero level.

 In particular intervals, possible oil leakages should be observed, exhaust manifold should be
removed and cleaned against to carbon residues.

 If sufficient load cannot be provided for generator set, dummy load should be connected to
generator set in order to prevent negative effect of low load operation.

 Maintenance periods of the generator sets operating with low load should be performed within
shorter time than specified in timetable. In parallel, oil and fuel filters should be replaced once a half
year. Fuel injectors and turbocharger should be checked bi-yearly.

PUBLISHED BY : TEKSAN After Sales Services PAGE 2/2

Yenidogan Mahallesi, Edebali Caddesi, No:12 T. : +90 216 312 05 50 e-mail : info@teksanjenerator.com.tr
34791 Sancaktepe – Istanbul / TURKIYE F. : +90 216 312 69 09 web : www.teksanjenerator.com.tr

F19-06- 00- 09/06 TEKSAN reserves the right to make changes and corrections on this document at any time and without any notice.