Prevent the risk of costly power failures and maximize efficient production during routine maintenance

Energy on Call 400kW Mobile Resistive Load Bank
      400kW - 50Hz 
ASCO 1000kW Skid Mount Resistive Load Bank  
      1000kW - 50Hz


Low Load Profile. How does it negatively affect a generator set?

What are the consequences of operating a generator in low load mode? What damage can the equipment cause? What corrective measures should we carry out?
The endothermic engines that are used in generator sets have been designed to use as much power as possible, from 30 to 100% of the declared maximum power.

The actual engine load depends on the power that the installation demands. The engine and its components are primarily designed to operate in the high load or power range rather than in continuous low load mode.

Operating uninterruptedly in low load mode can lead to higher oil consumption and consequently to a manifestly greater deposit of carbonized oil or oil residue in the engine, as well as in the suction and exhaust system.

The emergence and persistence of residue has a negative impact on the functional behaviour and on the lifetime of the engine. As a result, maintenance tasks tend to increase.

In addition, when an engine is operating in low load mode, it cools down, which means that the fuel is only partially burned, which can in turn produce a white smoke with high hydrocarbon emissions.

Due to the low fuel temperature, the percentage of unburned fuel in the oil increases. These problems are due to the fact that the piston rings, the piston itself and the cylinder do not dilate enough to ensure a good seal and as a result the oil rises and is expelled through the exhaust valves. This means that the diesel oil passes into the crankcase, degrading the quality and the properties of the lubricant.

Frequent and continued use of generator sets with power loads of less than 30% of the maximum power value can lead to the following failures over time:

1:Increase of exhaust smoke.

2: The presence of traces of fuel in the engine oil.

3: Excessive wear of the turbocharger.

4: Oil leaks in the body of the turbocharger.

5: Increased pressure in the gearbox and the crankcase (Blowby).

6: Excessive deposit of carbon residue on the surfaces of the valves, valve seats, pistons and the exhaust manifold.

7: Hardening of the surfaces of the cylinder liners.

8: If such a system exists, lower efficiency of the exhaust gas treatment system (ATS) which may activate the forced regeneration cycle of the DPF.

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