#electric generators

Intelligent technology: a key driver of modern innovation

Intelligent technology, one of the most important directions in modern technological development, integrates sensors, embedded systems, big data analytics, and artificial intelligence algorithms to enable devices to self-perceive, self-learn, and self-decide. In diesel power generators, the application of intelligent technology is primarily reflected in the following areas:

Intelligent control systems

Traditional diesel generator control systems rely on mechanical or electronic controllers, which are relatively limited in functionality and complex to operate. In contrast, intelligent control systems integrate microprocessors and advanced control algorithms to achieve comprehensive monitoring and precise control of generator sets. They can monitor key genset parameters such as voltage, current, frequency, and power factor in real time and automatically adjust engine speed and output power based on load changes, ensuring optimal operation at all times.

Fault prediction and diagnostics

Intelligent diesel generator sets are equipped with advanced fault prediction and diagnostic systems. By collecting real-time operational data from various components via sensors and processing this data using big data analytics, the system can identify potential faults in advance and provide corresponding maintenance recommendations. This not only reduces losses caused by unexpected downtime but also extends the generator's lifespan.

Remote upgrades and maintenance

Smart diesel generating sets support remote upgrades and maintenance. Manufacturers can update control software and algorithms over the internet, enhancing the unit's functionality and performance. Additionally, maintenance personnel can remotely access the equipment for fault diagnosis and troubleshooting, significantly improving maintenance efficiency.

Remote monitoring technology: A pillar of intelligent management

Remote monitoring technology is a crucial means to achieve intelligent device management. It connects equipment to cloud servers via wireless networks, enabling remote monitoring, data analysis, and remote control. In the field of diesel gensets, the application of remote monitoring technology is mainly reflected in the following aspects:

Real-time data monitoring

Remote monitoring systems can monitor various operational parameters of diesel generator sets in real time, including fuel consumption, oil pressure, coolant temperature, and exhaust temperature, etc. These data are transmitted to cloud servers via wireless networks, allowing users to check the equipment's status anytime using mobile phones, computers, or other terminal devices.

Alerts and notifications

When a diesel generator experiences a fault or operational parameters exceed normal ranges, the remote monitoring system immediately sends alerts and notifies users or maintenance personnel via SMS, email and so on. This enables users to quickly address abnormalities and take appropriate action.

Data analysis and optimization

Diesel generator remote monitoring systems can perform in-depth analysis and mining of operational data to identify patterns and trends. By analyzing these data, users can optimize operational strategies, improving generator’s efficiency and reliability.

Remote control and dispatch

In emergency situations, users can remotely control and dispatch diesel generator sets via the monitoring system. For example, during power shortages, users can remotely start the generator set using a mobile phone or computer to ensure the continuous operation of critical equipment.

With the diesel generator remote monitoring and control systems, users can precisely manage the generator set's status and adjust parameters promptly, enhancing operational efficiency. The system can detect and address faults early, minimizing downtime and lowering maintenance costs. Smart diesel generator remote monitoring systems effectively prevent safety incidents caused by overloads, overheating, or other abnormalities, ensuring safe operation.

This article continues to introduce the knowledge of the crankshaft connecting rod mechanism and the crankcase ventilation device of diesel generators.

Crankshaft - flywheel group

There are seven main bearings. The fourth bearing is equipped with thrust washers. The thrust washers should be installed according to the specified method; otherwise, an incorrect axial clearance will be obtained. After installation, check the thrust clearance of the crankshaft, and the axial clearance of the crankshaft must be between 0.15 - 0.344 mm.

The front crankshaft oil seal is installed on the front oil - seal seat, and the front oil - seal seat is installed at the front end of the diesel engine block, as shown in Figure 3.10. The rear oil seal is installed on the rear oil - seal seat, and the rear oil - seal seat is installed on the flywheel housing.

When pressing in the front and rear oil seals, use special tooling to ensure that the oil seals are installed in place reliably. When tightening the front and rear oil - seal seats, tighten the bolts diagonally and cross - wise, and tighten them in two steps. The first step is to tighten to 10 - 13 N.m, and the second step is to tighten to 20 - 30 N.m. The sealing surface of the rear oil seal is mated with the timing gear. When installing the rear oil seal, first tighten the timing gear on the crankshaft with bolts to facilitate the assembly of the flywheel and prevent the O - ring from misaligning.

The flywheel is positioned and assembled with the rear flange of the crankshaft. During assembly, keep the mating surface clean and intact. Tighten the flywheel fastening bolts diagonally and cross - wise, and tighten them evenly in three steps as required in Table 2 - 5.

First step: Tighten to 150 N.m.

Second step: Tighten to 300 N.m.

Third step: Tighten to (520 - 560) N.m.

Note: After each tightening, rotate the crankshaft to check its flexibility.

The crankshaft pulley damper is connected to the crankshaft with bolts. Tighten the bolts diagonally and cross - wise, and also tighten them in three steps according to the requirements in Table 2 - 5.

When the engine is working, a part of the combustible mixture and exhaust gas leaks into the crankcase through the piston rings. The gasoline vapor that leaks into the crankcase will condense and dilute the engine oil, deteriorating its performance. The exhaust gas contains water vapor and sulfur dioxide. The water vapor will condense in the engine oil to form foam, which will disrupt the oil supply. This phenomenon is particularly serious in winter. Sulfur dioxide reacts with water to form sulfurous acid, and sulfurous acid reacts with oxygen in the air to form sulfuric acid. The presence of these acidic substances not only deteriorates the engine oil but also corrodes the parts. Due to the leakage of the combustible mixture and exhaust gas into the crankcase, the pressure in the crankcase will increase, and the engine oil will leak out from the crankshaft oil seal, the crankcase gasket, etc. The engine - oil vapor that leaks into the atmosphere will increase the engine's pollution to the atmosphere. Installing a crankcase ventilation device on the engine can avoid or mitigate the above - mentioned phenomena. Therefore, the functions of the engine crankcase ventilation device are: 1) to prevent the engine oil from deteriorating; 2) to prevent the crankshaft oil seal and the crankcase gasket from leaking.

The oil - gas separator is installed on the tappet - chamber cover on the right side of the front section of the engine block. When the engine is working, the oil - gas mixture that leaks into the crankcase enters the oil - gas separator through the pipeline. The oil - gas separator separates the oil and gas sucked from the crankcase, allowing the liquid oil to flow back to the oil pan and discharging the gaseous oil - gas mixture. This can reduce the consumption of engine oil.

Diesel generators are renowned for their robustness, reliability and longevity. They are ideal for the requirements of commercial and industrial applications of nearly every kind. How many years can a diesel generator last? In this article, we’ll introduce the average diesel generator life expectancy as well as the factors that affect its lifespan.

How many years does a diesel generator last?

Generally, the lifespan of a diesel electricity generator can be expected to last for up to 30 years. On average, diesel generators can last from 10,000 to 30,000 hours of runtime before major overhauls or replacements are necessary. Please note that this is only an approximate estimate. Many factors can affect the lifespan of a diesel engine generator, such as usage patterns, environmental conditions, and preventive maintenance practices. For example, a standby diesel generator used only for emergencies is going to hit the 10,000-hour mark a lot later than one that is used constantly.

Factors that affect your diesel generator’s longevity

The life expectancy of a diesel generator depends on three main factors: how it’s used, generator sizing and maintenance practices.

Usage patterns

If your diesel-powered generator is often overworked, there will be more wear and tear on the equipment, which can reduce the lifespan of the generator. Every machinery needs rest and it should never be left to run for weeks or months at a time. Running your standby diesel generator longer than the recommended use period can damage the generator.

On the other hand, if your generator sits idle for an extended period of time, issues such as increased friction, battery discharge or fuel degradation could arise. Over time, they could reduce the generator's lifespan. It is important to take certain measures to ensure that it is properly stored and maintained. 

Generator sizing

Improper size of your generator also reduces the generator’s longevity. Typically, standby and prime power diesel generators are designed to run optimally between 50 and 80% of their total load rating and continuous-rated diesel generator sets are optimized between 70 and 100 percent load.

An oversized diesel power generator underloads most of the time, which results in a greater internal build-up of carbon and other byproducts of combustion in the engine, causing a power loss. This phenomenon is also called wet stacking. If your diesel generator is too small and can’t meet the electricity demands, it can cause issues such as generator shutdown, damage to the internal components, engine overheating, increased fuel consumption and increased emissions.

A diesel generator too big or too small will shorten the lifespan of your generator. Thus, it’s vital to choose the right generator size when you are buying a diesel-powered generator. Read more about how to choose the right size generator.

Maintenance practices

The lifespan of a well-maintained diesel generator will be longer than a poorly-maintained one. It’s important to maintain your generator regularly to prevent potential problems and prolong its lifespan, resulting in cost savings in the long run. Routine maintenance helps to ensure that your generator will run smoothly and efficiently during a power failure.

Preventive maintenance of a diesel generator involves routine inspections, periodic analysis of fluids such as engine oil, coolant and diesel fuel, regular cleaning and maintenance of the fuel system, checking electrical system, cleaning or replacing the air filter, maintaining the battery, load bank testing, etc.  

Other factors that also affect the diesel generator life expectancy:

Generator brand and the level of quality

Size of the generator’s engine

Installation method

The quality of fuel used and fuel problems

Environmental conditions, like altitude, humidity, extreme weather and so on

Availability of spare parts, particularly for older or outdated generators

Understanding these helps you keep your generator up and running and prolong its lifespan. To extend the generator’s life expectancy, you'd better follow the instructions given by your generator’s manufacturer for guidance.  

In conclusion

The lifespan of a diesel generator depends on a number of factors, including how it’s used, generator sizing, maintenance practices, generator brand and quality, engine size, installed method, fuel quality, environmental conditions, etc. A well-maintained diesel generator can last for up to 30,000 hours. Without proper care and attention, its life expectancy will be reduced.