BEEM 2395 GENERATOR SYSTEM OPERATION, MAINTENANCE & SERVICING

TOPIC 1: Introduction to Generator

1.0 What Is a Genset?

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The term genset is an abbreviation of generator set, which refers to a generator and
engine combination. The engine drives the generator, which provides the power
used to run other equipment. Depending on the application, the genset may run
construction equipment, appliances, cooling systems or other devices.
Each genset consists of two main components, the generator – or alternator – and
the engine. The engine runs on fuel and drives the generator, which in turn provides
electricity to run other equipment. Typically, large gensets such as those used in
transport use diesel fuel, though they can often also run on JP-8 fuel.
An ideal genset should be reliable. These power sources often provide reserve
power in case of local outages or during travel when local power is no longer
available — so you need to know they are going to work as needed.
Also, due to their operation in remote places and possibly tough conditions, gensets
must have a robust construction that will stand up to the elements. Low-emissions
are another bonus of some gensets, but as with every type of engine, gensets
require adequate ventilation, no matter where someone operates them.
1.1 How a Genset Works

The genset’s operation starts with its engine. Typically, diesel fuel powers these. The
engine burns the fuel, which creates rotational energy that powers the generator and
allows the generator to provide electricity. Rotational energy transforms into
electricity by spinning a coil through a magnetic field. When the generator connects
to an electrical load, the voltage created passes to the load to drive it.

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For diesel gensets, the units run as long as the fuel lasts. Therefore, these types of
completely portable generators require a steady supply of fuel. The advantage of
these gensets, though, is their ability to go anywhere and provide electricity, even in
places that do not have a connection to a power grid.
1.2 What Are Gensets Used for?

Several industries require gensets to provide power and backup electricity. Gensets
are also used to keep refrigerated loads cold during road transport when shore or
vessel power is not available. Reasons for needing the gensets depend on the
operations and location of a business. In fact, many applications of gensets do not
have an application in a single industry but can have applications across many
sectors that have shared purposes.
1.2.1 Data Centers
Data centers require constant power to ensure uptime of their servers. Power
outages can impact server availability. For companies that have in-house servers,
those outages could result in lost productivity. Companies that host servers for
others will lose business if a power outage impacts their servers.
For data centers and any other businesses that require constant power for their
technology, gensets prevent lost business and productivity.
1.2.2 Healthcare Facilities

In healthcare, keeping power running could become a matter of life or death.

Hospitals, for instance, frequently have backup power sources, such as gensets.
These types of power sources provide electricity if a storm or area blackout causes
electrical problems.
For these types of facilities, the generators may connect to a natural gas supply to
ensure an unending supply of fuel from the local gas lines. These types of
generators do not require refilling with fuel. They can also automatically turn on when
the main power shuts off.
1.2.3 Emergency Power Operations
Backup power for businesses in emergencies can keep them running. This type of
backup power can allow for operations to continue after storms for essential
operations. For instance, emergency departments or news stations that need to keep
operating in critical situations to keep the population informed may require backup
generators. Even farms might require backup generators to provide power for
incubators, ventilators and other support systems for keeping livestock safe and
healthy.
1.2.4 Power in Remote Locations

In remote locations not connected to the power grid, gensets can offer a way of
getting electrical power. Examples include rural mountainous regions or even remote
island locations. Gensets can help emergency response teams offer assistance in

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areas after a natural disaster. Military operations in locations without access to a

power grid can also use a genset to run necessary equipment.
1.2.5 Power for Cooling or Heating Units on Reefer Containers
Gensets are also extremely useful with reefer containers. Many ships will have a
power source for cooled or heated reefer containers. However, for highly sensitive
materials that could spoil outside of a set temperature range, gensets provide a
backup means of powering the heating or cooling units on the reefer. When shipping
cargo that has posed a hazard from a cooling power disruption, the reefer may
include redundant gensets, one as a backup to the other.
1.3 How to Operate a Genset
The correct way to operate a genset depends on the model. Some will have
automatic or remote starting capabilities, especially those used for backup power.
On ships, reefers will use the electrical power from the ship for cooling. Some reefer
containers can even have a pair of gensets, like some systems from Klinge
Corporation. if one of those fails, the backup genset will start. Therefore, the integrity
of the reefer container remains protected, even in extreme conditions.
This type of cooling system from Klinge Corporation successfully transferred delicate
ice cores from Antarctica north to the United States and across the deserts of the
American southwest. During the month and a half-long journey, the ice cores
remained below -20 degrees Celsius (-4 degrees Fahrenheit) the entire time.

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1.4 What is a genset used for?

Modern society can’t run without electricity. From Wi-Fi and communications to
lighting and climate control, businesses and homes require a steady stream of power
to function.
Generator sets can add an extra layer of security in the event of brownouts or power
outages. Standby generators can keep critical systems running at medical facilities,
businesses, and homes in case utility power gets knocked out.
Gensets also can provide a self-contained power supply in remote places off the
power grid. These include construction sites, campsites, rural areas, and even mines
deep underground. They enable people to harness power to build, explore, or live off
the beaten path.
There are different types of electric generators. All have similar components, require
some type of fuel, and are set in a base frame. But there are some key differences,
too.
1.5 How does a genset work?
Electrical generators work in a similar way that cars do. They have a ―prime mover‖
(engine) and an alternator.
The engine converts a fuel such as gasoline, diesel, biogas, or natural gas (chemical
energy) into mechanical energy.
The mechanical energy spins the alternator rotor to create electrical energy.
Alternators have two parts: a rotor and a stator. When the rotor spins, a magnetic
field between the rotor and stator creates voltage (electromagnetic induction).

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When the voltage on the stator connects to a load, it creates a stable electrical
current.
Many homes and businesses find using gensets to be invaluable because when
power is produced, it can immediately be used. Gensets effectively put an end to any
disruptions due to power loss.
1.6 AC vs. DC gensets: What is the difference?

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All generators use electromagnetic induction, but different setups can produce two
different kinds of electrical energy — alternating current (AC) or direct current (DC).
The overwhelming majority of gensets are the AC type, but it’s worth knowing the
difference.
As its name implies, alternating current changes direction. It oscillates back and forth
dozens of times a second. AC electricity can travel at a high voltage, making it useful
for long-distance delivery on the electric grid. A transformer ―steps down‖ voltage for
smaller-scale use. AC generators are used to run small motors, household
appliances, computers, and office equipment.
Direct current flows in a single direction at a lower voltage. It stays consistent from
the generator to the final destination. DC generators power large-scale electric
motors (such as subway systems), banks of batteries and solar cells, and LED lights.
1.7 What are the components of a genset?

Generator sets typically have these components:

 Engine/motor. The primary genset component, it runs on fuel. Good engines

are built strong enough to meet demand and function in adverse conditions
(i.e., bad weather).
 Alternator. This component converts mechanical energy into electricity;
without it, there is no power.
 Control panel. This acts as the ―brain‖ of the genset, controlling and regulating
all the other components.
 Fuel system. This component consists of the storage tanks and hoses that
send fuel to the engine.
 Voltage regulator. This controls the amount of voltage the genset produces
and converts an A/C current to a D/C current.
 Base frame/housing. The base frame supports the generator and holds the
components together. It also serves as an anti-vibration and grounding
system, and may or may not house the fuel tank. It may be set upon wheels to
make it portable.
 Pull-cord mechanism or battery. An initial spark is needed to start a portable
generator’s combustion process. This usually happens either through a pull
cord mechanism (like a lawnmower) or a starter motor powered by a DC
battery.
 Manual or automatic transfer switch. The transfer switch directs power
between the main source (utility power) and the auxiliary one (the generator).
This keeps the electricity flow consistent and prevents dangerous disruptions.
 Baffle box or enclosure. Often made of stainless steel, this container reduces
noise, prevents corrosion, and facilitates airflow to cool the engine.
Generators don’t require intensive maintenance, but it’s important to understand their
internal mechanisms. This way, you can perform preventative and general
maintenance as needed, along with knowing how to order replacement parts.

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1.8 What are the types of gensets?

Generators come in different sizes and can use different fuel sources. The following
are the different generator fuel systems, including pros and cons of each.
1.8.1 Gasoline generators
Gasoline generators are the most popular option because gasoline is readily
available. Gas-operated gensets also are low on the price scale, and they’re
extremely portable.
However, usage time for a gas genset can be short-lived and fuel inefficient.
Gasoline stays viable in storage for about a year. But it’s also highly flammable,
which could create a hazard in certain environments.
1.8.2 Diesel generators

Diesel engines are more powerful than gasoline engines. Diesel fuel is also less
flammable, and availability of it is pretty widespread. With proper maintenance,
diesel gensets can last a long time.
Major drawbacks are that diesel fuel is only good for about two years, and extensive
use gets expensive. Diesel engines also create heavy emissions.
1.8.3 Biodiesel generators
Biodiesel fuel is a mixture of diesel and other biological sources, like animal fat or
vegetable oil. Since it burns with lower petroleum emissions, it’s more
environmentally friendly, creating less waste and a smaller fossil fuel footprint.
A big drawback, though, is the noise levels associated with biodiesel engines.
Low-emissions options

Generators can also be run with low-emissions options, including natural gas,
propane, or solar energy.
Natural gas is widely available and affordable, and it can run right from shale
reserves, which means no refills. However, the big disadvantage is that a natural gas
generator is not easily portable and is expensive to install.
Propane burns cleanly and has a long shelf life but also is extremely flammable.
Installation costs are higher, and these generators burn three times as much fuel as
ones that run on diesel.
Solar generators are charged by the sun, so the fossil fuel footprint is nonexistent,
and operation is simple. The drawback here is the limited energy supply. Also, the
charge time is slow; if not enough charge is stored, an erratic fuel supply could be
disruptive.
Small household backup generators typically use gasoline, but larger industrial
generators generally run on diesel or natural gas.

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1.9 Genset sizes and uses

Generators have a variety of power outputs and engine speeds. They can stand
alone or be connected to buildings. Some portable generators have wheels or are
mounted on trailers so they can be towed from one location to another.
When choosing a genset, you’ll want to examine features such as power generation,
fuel efficiency, reliability, and robust construction.
Understanding electrical power output is helpful, too: Output is measured in watts or
kilowatts. Larger generators can produce more electricity but have higher fuel
consumption; however, smaller generators may not produce the power you need.
A solid grasp of your power requirements is key to helping you choose a quality
genset.
1.10 Benefits of gensets
If your home or business is served by aging power plants or lines, then you’re
familiar with disruptions. It’s the same if you live or work in a region prone to extreme
weather events like hurricanes or blizzards.
 Losing power means you’re effectively shut down. For businesses, any
interruptions or downtime can lead to major financial losses.
 Consequently, there are numerous benefits associated with using a genset.
 Can be used as a primary or backup power source.
 Serves as the main source of power for construction projects or remote
operations.
 Operates as an emergency power source in the event of an unexpected grid
power outage.
 Provides protection against brownouts, which can be disruptive.
 Produces savings for areas where peak grid demand is high — and, as a
result, costly.
Emergency power generators provide reliable power to avert financial losses and
security breaches. They can even prevent loss of life in hospitals and nursing
homes. Most businesses rely on gensets to ease the negative impacts of a power
outage. This helps them keep working, even in difficult times.
Having a genset ready in the event of a power disruption can be a lifesaver,
sometimes literally. And even in situations that are not quite life-or-death, a genset
can ensure smooth operations without interruption.

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A gas or diesel generator isn’t a ―set it and forget it‖ type of device. It pays to conduct
a visual inspection of the generator before every use, and create a maintenance
schedule that includes weekly, monthly, and annual checkups.
A regular maintenance schedule is crucial to avoid breakdowns and prolong the life
of your gas or diesel generator.
A generator maintenance checklist helps you prioritize which parts to check and
when to check them, so you can keep the generator running properly when you need
it most.

With preventive maintenance, a backup generator set can last for 20 years or more.
Of course, that depends in part on how often you use it. You might need one for as
little as 26 hours a year if you don’t have any outages and conduct a half-hour’s
worth of weekly exercise.
Without preventive maintenance, generators are susceptible to fuel problems, which
can cause breakdowns and even ruin a generator eventually. Running a gas or
diesel generator regularly is an important part of maintenance, just as it’s important
to take your car for a spin at least once a week, even just around the block.

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By keeping your generator properly maintained, you will be able to keep it running
smoothly for much longer than if you ignore maintenance tasks.
Preventive Generator Maintenance Checklist
Power generators have a lot of moving parts, from the control panel (the brains of
the generator) to the battery and cables. Here are a few tasks you’ll want to consider
for a preventive generator maintenance checklist.
Maintenance with each use
 General inspection
 Test batteries
 Check intake and exhaust
 Manual start
 Engine exercise
 Adjustments
 Maintenance as needed
 Repairs
 Replace filters
 Lubrication
 Cleaning
 Cooling system servicing
 Fuel system servicing
Weekly Generator Maintenance Checklist
During any inspection, whether weekly, monthly, or annually, begin by looking for oil
leaks or other signs of wear. It’s also important to keep your generator clean by
removing dirt and debris, and making sure no rodents, birds, or harmful insects have
infiltrated the enclosed unit (if there is one).
During weekly maintenance, you should:
 Do a visual inspection
 Run the generator
 Check fluid levels
 Check for leaks
 Check auto mode
To exercise the generator, check the fuel level and start the motor, then leave it
running for 30 minutes or so to make sure it’s working properly.
Once you’ve started the generator, check the exhaust system. Examine the muffler,
manifold, and exhaust pipe for leaks, and be sure the pipes aren’t overheating any
nearby components. Be sure the engine is purring; look and listen for signs of a
misfire, such as vibrations, smoke, or power fluctuations.
Monthly Generator Maintenance Checklist
Inspect battery cables and electrolyte levels monthly. Remove the plastic tops from
the cell ports and use a toothbrush and baking soda to clean away corrosion or dirt.

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Check engine coolant and oil levels (the oil should be close to full without
overflowing), and look for signs of leaks in the oil or coolant lines. Also check the
coolant concentration: It should be roughly half purified water and half antifreeze. If
you live where freezing is a risk, the antifreeze level can be as high as 60% (but no
higher).
Use a load bank to conduct a load test monthly for at least 1 hour to make sure
everything is in running order. You should also do an electrolyte specific gravity test
or electrical conductance test at this time.

How often you use a generator matters, and for how long. If you use the generator
more often, you’ll likely have to adjust how often you perform certain maintenance
tasks to account for wear and tear.
Here’s a list of other steps to take on a monthly basis:
 Clean generator
 Clean surrounding area
 Check engine coolant levels
 Check battery charger
 Check engine oil levels
You should change the oil after 100 hours of use, and sooner the first time. It’s
recommended that you do the first oil change after 30 hours.
Also, switch out plugs and the air filter every 200 hours. But if, on the other hand,
you keep your generator in storage and don’t use it often, you should drain it of fuel.
Annual Generator Maintenance Checklist
Once a year, focus on the generator’s electrical system. Turn off all power sources to
conduct an internal inspection. Examine the AC wiring and alternator, making sure
it’s free of dirt.
Inspect the air intake system and replace the air filter. Check the air induction piping
while you’re at it. You’ll also want to make sure the crankcase breather is in good

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shape: that’s the generator’s source of fresh air, which allows it to sweep fumes out
of the crankcase.
Steps to take annually include:

 Change oil
 Change oil filter, fuel filter, and air filter
 Flush cooling system
 Inspect wiring/electrical system
 Change spark plugs
 Test transfer switch
Also, check the transfer switch to make sure it’s functioning to transfer your home’s
power source from the grid to the generator during an outage. Finally, to simulate
operation during a power outage, perform a functional test.
Some of these inspections and tests are more complicated, and more is at stake
during the annual test: If you miss something and wait a year, there’s a greater
chance for something to go wrong. You may want to have a professional perform
your annual inspection.
Equipped with weekly, monthly, and annual maintenance checklists, you can give
your generator the regular attention that it requires. In return, it can afford you years
of safety, security, and peace of mind.

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