Maintenance of diesel power plants — nuances and mandatory points

Maintenance of diesel power plants in industry includes a set of measures aimed at maintaining their performance, reliability and durability. It is important to understand that regular and high-quality maintenance, use of appropriate quality spare parts for diesel power plants helps prevent sudden breakdowns and minimize equipment downtime. Here are the main stages and procedures that are included in the maintenance of diesel power plants:

Visual inspection and diagnostics:

• checking the general condition of the power plant.
• Inspect for fuel, oil and coolant leaks.
• checking the condition of all visible connections, fasteners and mounting units.

Replacing consumables:

• changing engine oil.
• replacing fuel filters.
• replacing air filters.
• replacing coolant filters.

Checking systems and components:

• checking and adjusting cooling and ventilation systems.
• checking the fuel system for contaminants and removing them.
• checking the intake and exhaust system.

Testing and adjustment:

• testing engine operation at idle and under load.
• checking and adjusting generator operating parameters (voltage, frequency).
• testing of automatic control and protection systems.

Electrical part:

• checking and tightening electrical connections.
• checking the condition of the batteries and their charger.
• testing the operation of automatic switches and synchronization systems.

Diagnostics and performance analysis:

• Using diagnostic tools to check the condition of the engine and generator.
• exhaust gas analysis to determine the condition of the fuel and ignition systems.
• maintaining a maintenance log and recording all work performed and identified faults.

Corrective Maintenance:

• elimination of faults identified during diagnostics and testing.
• carrying out repair work, including replacement or repair of failed components and assemblies.

Update and modernization:

• carrying out activities to update the software of control systems.
• modernization of equipment to improve its characteristics and increase operational efficiency.

Regular servicing of diesel power plants is usually carried out according to a schedule that may depend on the manufacturer’s recommendations, operating conditions and equipment operating hours (for example, every 250, 500 or 1000 hours of operation).

Completing these procedures helps ensure uninterrupted operation of a diesel power plant, which is especially important in the industrial sector, where equipment downtime can lead to significant financial losses.

After-sales service — who does it?

Servicing of diesel power plants in industry is carried out by qualified specialists, who can be either full-time employees of the enterprise or external professionals from specialized service companies. Depending on the specific situation and company preferences, maintenance may be performed by one of the following groups:

Internal personnel of the enterprise:

• These can be company employees who have the necessary qualifications and experience working with diesel power plants.
• Typically, enterprises with large equipment fleets have their own service departments that deal with scheduled and unscheduled maintenance.

Specialized service companies:

• These are companies that specialize in the maintenance and repair of diesel power plants.
• They provide contract services, performing routine maintenance, diagnostics, repairs and upgrades to equipment.
• The advantages of such companies include the availability of qualified personnel, specialized tools and equipment, as well as access to original spare parts and upgrades from manufacturers.

Equipment Manufacturers:

• Some businesses prefer to enter into service contracts directly with diesel power plant manufacturers or their official dealers.
• Manufacturers provide high quality service, as their specialists have access to the most up-to-date information and technologies, as well as original spare parts.

Companies offering service outsourcing:

• These are companies that provide a full range of maintenance outsourcing services, including parts inventory management, maintenance planning and all necessary procedures.

Each of these groups has its own advantages and can be selected depending on the specific needs and capabilities of the enterprise. It is important that the selected service provider has the necessary qualifications, experience and resources to provide reliable and quality service for diesel power plants.

Spare parts for diesel power plants are an important component of service. Ensuring the availability of high-quality and original spare parts is a critical aspect affecting the reliability and longevity of the equipment. Here are the main aspects related to spare parts for diesel engines in the context of service:

Classification of spare parts:

• Consumables: oil, fuel and air filters, oil, coolant, etc.
• wear parts: belts, gaskets, glow plugs, valves, piston rings, etc.
• main components: fuel pumps, turbochargers, injectors, batteries, generator brushes, etc.

Purchase and storage:

• original spare parts: It is preferable to use spare parts from the manufacturer as they provide maximum compatibility and reliability.
• analog spare parts: In some cases, you can use high-quality analogues, which may be cheaper, but it is important to ensure their quality and compatibility.
• Inventory Management: Businesses often maintain a certain level of inventory of critical parts to minimize downtime during breakdowns.

Suppliers and logistics:

• selection of suppliers: It is important to choose reliable suppliers who can provide timely delivery and warranty on spare parts.
• logistics: Efficient logistics plays a key role in ensuring timely availability of spare parts, especially in the event of emergency repairs.

Quality and certification:

• quality of spare parts: the use of certified and tested spare parts guarantees a long service life of the equipment and reduces the risk of breakdowns.
• serti fication: Certification of spare parts to quality standards (eg ISO) helps ensure their reliability.

Update and modernization:

• technical updates: some spare parts can be replaced with more modern analogues as part of equipment updates and modernization.
• compatibility: It is important to ensure that new parts are compatible with existing equipment.

Control and accounting:

• accounting for spare parts use: Maintaining detailed records of spare parts usage helps in planning future purchases and cost analysis.
• monitoring the condition of spare parts: regular monitoring of the condition of replaced spare parts allows you to identify and eliminate possible problems in a timely manner.

Thus, ensuring timely and high-quality supply of spare parts is a key element of servicing diesel power plants, contributing to their uninterrupted and efficient operation.

Spare parts for diesel power plants — purchase

The acquisition of spare parts for diesel power plants (DPS) is an important aspect to ensure their reliable and uninterrupted operation. There are several main sources for purchasing spare parts, each of which has its own advantages:

Official dealers and manufacturers:

• advantages: original spare parts, quality assurance, compliance with technical requirements.
• flaws: usually higher cost, possible delays in delivery.

Authorized distributors:

• advantages: good value for money, availability of certified spare parts, warranty support.
• flaws: limited range compared to the manufacturer.

Online stores and online platforms:

• advantages: wide selection, ability to compare prices, ease of ordering.
• flaws: the risk of purchasing non-original or low-quality spare parts, possible problems with returns and warranty.

Local suppliers and parts stores:

• advantages: fast delivery, possibility of personal inspection and verification of spare parts.
• Flaws: possible restrictions on assortment, varying quality.

Parts markets and brokers:

• advantages: opportunity to find rare or discontinued spare parts, competitive prices.
• flaws: high risk of counterfeits, lack of guarantees and returns.

Diesel power station repair and maintenance companies:

• advantages: comprehensive service, including installation and configuration of spare parts, professional advice.
• flaws: Possibly higher cost due to inclusion of services.

When choosing a supplier of spare parts for diesel power plants, it is important to consider several key factors:

• quality and originality: It is preferable to use original spare parts or certified analogues.
• warranty and return: availability of warranty service and the possibility of returning defective parts.
• price and delivery terms: comparison of prices and delivery conditions from different suppliers.
• supplier reputation: Check reviews and recommendations about the supplier.

Entering into long-term contracts with trusted suppliers can also help ensure stability and reliability of supply.