Generator Overhaul

[Anita Damelio]

Manufactured within our state-of-the-art production facility, these generator sets are proven and trusted to provide reliable power for critical applications including: mini power stations, data centres, airports, hospitals and large retail stores.

Need support in buying a FG Wilson generator set? Our dealers offer expert local advice, assistance with sales and parts & service support. FG Wilson Dealer Locator will help you find a dealer local to you.

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An overhaul of the engine fitted on your FG Wilson generator may only be needed once during its life, and it is not the easiest job to do. However, there are significant advantages in overhauling the engine. It restores the engine performance to - or close to - the performance of a new engine.

If you follow the recommended service schedules for your FG Wilson generator, it will give you thousands of hours of service, just like it is designed and built to do. But even with a good maintenance routine, at some point the engine may need to be overhauled.

What parts are replaced during the overhaul depends on the areas where engine performance is less than it was. A generator set overhaul can typically involve boring out the cylinders, along with the installation of new piston rings, bearings and gaskets.

The engine overhaul restores engine compression, the efficiency of which means the engine will generate more power. And because the engine is operating more efficiently you will have improved fuel economy.

If you rely on diesel generators to power your business, it is essential to ensure they are operating at their best. In addition to providing diesel generators for rent or purchase, we offer comprehensive diesel generator overhaul services to help extend the lifespan and performance of your equipment.

For a recent overhaul project, we supplied and changed an industrial silencer to a high-efficiency residential silencer. We also installed a hot air discharge acoustic attenuator. These upgrades significantly reduced noise emissions to 77.5 dB at 7 meters distance at full load capacity, while also ensuring optimal performance. In addition, we offer a warranty to provide our customers with added peace of mind.

Essentially a form of engine overhaul, the process involves stripping down the generator to its component parts, cleaning/inspecting/repairing as necessary, and rebuilding the generator using approved procedures. Knowing how to overhaul an engine and generator requires in-depth knowledge and skill.

What generator overhaul and refurbishment do is restore the unit to optimal operating condition, providing you with an opportunity to extend its life by many years. The generator refurbishment process also helps in reducing generator running costs besides improving generator efficiency.

In general, if facing major engine or electrical repairs to a generator more than five years old, replacement should at least be considered. Depending on the extent of the repairs, you may find that the cost of replacement versus repairs is not that far apart. Here are some other factors that can effectively reduce this gap even further.

Replacing an old generator lets you enjoy the latest technology, from greener footprints and improved fuel efficiency to less vibration and quieter operation. These benefits will typically be delivered in a smaller, lighter package than your existing generator, one providing easier access for maintenance, such as having all service points located on one side.

In addition to the green side of things, one of the most visible benefits offered by a new generator is the use of digital remote-control panels. Simple on/off switches have gone the way of mustache wax as manufacturers hop on the digital panel express.

All machines, no matter their brand and quality, experience issues throughout their lifetimes. Electrical and engine issues are inevitable in machines, and generators are no exception to this. Generators, just like all machines, can experience failure and operational downtime at some point.

Nonetheless, although they are inevitable, the chances of operation failures and other issues in generators can be avoided with proper maintenance and repair. Generator overhauling, particularly, is an important procedure in detecting and fixing various problems in a generator, which are often serious in character.

Blow-by gas occurs when there is a leakage of combustion gases between a piston and the cylinder wall of a generator. It happens normally because a perfect sealing between a piston and cylinder wall is not possible.

Sometimes, however, the emission of these combustion gases can go above normal. When this occurs, it could be a sign of a faulty component in a generator, and to be sure, a generator overhauling may be necessary. Regular inspection of a generator and measurement of the blow-by gas it emits are important to make sure that it does not discharge excessive gas.

While generally, the size of the electric load is determinative of fuel consumption. If the load is large, fuel consumption is also large. On the other hand, if the load is small, the fuel consumption is also relatively small.

It can be a worn-out compression system, a piston assembly error, damaged seals of the joints of the body, and others. To find out exactly what issue needs repairing, generator overhauling should be conducted. In doing so, you will then be able to determine if generator rewinding or a complete replacement is needed.

This can be done by: measuring the compression pressure through removing the nozzle holder and connecting a pressure gauge fitted with an adaptor in its place; and starting the engine with a starter and running it at the specific idle speed to make sure that the compression pressure falls within the specified value.

Finally, the Jenbacher gas engine has a full overhaul at 60,000 hours of operation. At the 60,000-hour overhaul ideally the engine will be taken away from the site to be stripped down and fully serviced with specialised machinery. This either occurs at the authorised rebuild centre in Liverpool, UK or Jenbach, Austria depending upon the geographical location of the unit. If we are provided enough notice, a reconditioned swing engine can be brought in at the corresponding time for the engine overhaul. This provides the lowest down-time for your generation plant. Alternatively, where it is not possible to remove the engine, it can be overhauled in situ. This is not an ideal situation and will take longer than using a swing-engine.

The Jenbacher gas engine product is renowned for its reliability, however from time to time there will be a need for unscheduled maintenance. This could be due to trips, problems with the fuel gas quality or problems with components. The best solution to counter any unscheduled maintenance is to ensure your gas meets the Jenbacher technical instruction for fuel gas quality and support this with a full maintenance agreement with Clarke Energy. It is also possible to set up remote monitoring of your Jenbacher gas generation facility. Remote monitoring enables you to monitor performance of your generator and to be notified via text message or e-mail about trips or unplanned shutdowns.

When your engine is overhauled it may be possible to upgrade all components to the latest versions. This may provide additional benefits to the customer from increased generating efficiency. Please speak to your local Clarke Energy office to determine whether there are any upgrades available for your generation equipment.

Clarke Energy is committed to delivering the highest levels of after-sales support to our customers. Our view is the highest levels of equipment availability supports the highest levels of return on investment for our customers.

GEN-TECH offers diagnostic services, troubleshooting and repairs of single and multi-unit power plants including generators, voltage regulators, transfer switches, auto start-stop systems and generator parallel controls.

OPG respectfully acknowledges that the lands on which its generating stations and other assets are located are within the traditional and treaty territory of many Indigenous communities. Click to read more.

Southwestern Ontario is host to our NSS - Western Waste Management Facility in Bruce County, our Eugenia hydroelectric station near Meaford, and our Nanticoke Solar Facility on the site of the former Nanticoke coal station.

An overhaul of a hydroelectric generator can include the repair or replacement of parts like the stator, rotor, shaft, wicket gate, turbine, bearings and other major components. The work can take anywhere from six months to a year depending on the scope of work, as well as the age and condition of the unit.

To support this major capital project, OPG will be looking to expand its list of specialized engineering and manufacturing vendor partners, who will help design and replace the turbines and generator parts.

Through its partners and direct hiring, OPG also anticipates more skilled workers will be needed to support these refurbishments. In particular, there will be an increased need for jobs in engineering, project management, manufacturing, machining, construction trades, and quality control.

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