Why is it more reliable to maintain generators by operating hours than by months?

Long-term spontaneous power generation sites, operating hours are closer to true wear than calendar dates. Filter elements, engine oil, fuel system, cooling system and belts should all be managed according to actual operating intensity.

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01 Running hours View content 02 Filter oil View content 03 Cooling system View content 04 Maintenance records View content

Applicable scene

Suitable for operation of more than 8 hours a day, remote mining areas, old machine replacement and multiple unit rotation operation sites.

In the same month, a standby unit may only run for a few hours, while a long-term self-generating unit may have run for hundreds of hours. If the mine site only reminds maintenance on a monthly basis, it is easy for equipment that is really high-intensity operation to be overdue.

A more secure approach is to take the running hours as the main line and then superimpose the on-site environment. Heavy dust, humidity in the rainy season, unstable fuel quality, high altitude and high load operation may all cause the maintenance cycle to need to be advanced.

Projects that must be bound to run hours

Engine oil, oil filter, diesel filter, air filter and oil-water separator.
Coolant level, coolant quality, radiator cleaning and water line clamps.
Belt tension, belt wear, fans, charging systems and starting batteries.

The on-site environment will maintain the window in advance

There is a lot of dust near the crushing and screening area, so the frequency of air filter and radiator inspections should be increased.
During the rainy season, roads and fuel storage conditions are poor, and the risks of fuel moisture and sedimentation should be focused on.
High altitude, high temperature and long-term high load operation will amplify heat dissipation and oil aging stress.

The rotation of multiple units must be recorded separately

Record the operating hours of each unit separately, do not just record the total operating hours of the power station.
Record the load factor, maintenance time, faults and replacement of spare parts of each unit.
During rotation operation, avoid a certain unit having a low load for a long time or supporting a high load for a long time.

Execution steps

On-site personnel follow fixed steps so that engineers can make judgments based on the same set of facts.

Maintenance actions must be performed repeatedly and evidence must be left. The following steps are suitable as the basic process before team handover and repair report.

Create a single unit maintenance ledger

The ledger contains at least the unit model, serial number, operating hours, maintenance items, consumables used, execution personnel, next maintenance hours and remarks.

Put production plan and maintenance plan together

The mining area cannot wait for the unit to alarm before stopping for maintenance. Low-load windows or backup unit replacement should be arranged in advance to avoid time-consuming maintenance and production.

Do loading confirmation after maintenance

After replacing the engine oil, filter element, belt or coolant, you cannot just look at the no-load condition. The actual load should be brought to confirm that the temperature, oil pressure, voltage and frequency are stable.

Exception signal

In these cases, do not just reset and continue running.

The operating hours have exceeded the plan, but the next maintenance time is not clear on site.
The model number was not recorded after the filter element was replaced. You will need to find it again for the next purchase.
The same unit has increased fuel consumption, temperature or alarms, but the maintenance records show that everything is normal.
When multiple units are rotated, if a certain unit is idle for a long time, the battery and oil conditions will deteriorate.

Record list

It is recommended to keep these data for each inspection and repair report

The current operating hours and last maintenance hours of each unit.
Replacement records of engine oil, engine filter, diesel filter, air filter, coolant, belt and battery.
Use consumable brand, specification, quantity and inventory balance.
Load test data and abnormal phenomena after maintenance.

How engineers can assist

The more complete the information, the faster the remote judgment, and the more efficient the door-to-door judgment.

If alarms, trips, starting difficulties, abnormal voltage, abnormal fuel consumption, or unstable loads have occurred on site, please give priority to retaining controller photos, fault videos, operating hours, recent maintenance records, oil status, load lists, and ATS/power distribution photos.

If the maintenance period is uncertain, the unit model, daily operating hours, load rate, dust environment and fuel source should be provided.
If there is still high temperature, low oil pressure or abnormal fuel consumption after maintenance, maintenance records, filter element models, oil photos and operating data should be provided.
If the production of old machines continues to expand, the operating hours, historical faults and spare parts availability should be evaluated at the same time, and do not just make up for one maintenance.

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