As an integral part of any power system within construction, mining and industrial industries, diesel generators must be able to perform at their best when you need them most. Lack of maintenance and choosing the wrong type of generator for your requirements not only causes disruptions but chew into project budgets.

Here, we’ll dive into everything you need to know about the average lifespan of your diesel generator, contributing factors that lead to its longevity and ways to extend overall lifetime. 

What is the Average Lifespan of a Diesel Generator? 

It varies. It largely depends on how often you service your generator, how many hours it runs for every day and making sure you get the correct sized generator.

On average, your diesel generator usually should last from anywhere from 15,000 - 50,000 before it’s due for service. However, a generator can last up to 30 years if it only runs for 650 hours per year.

Inversely, the lifespan will decrease if there is more demand on the generator to run for more hours in the year. 

Two Key Factors to Your Generator Lifespan

When it comes to your diesel generator, many factors contribute to its longevity including its environment contribute to its overall lifespan. Above all, there are two significant ways that can either optimise or deteriorate your generators lifetime:

• Generator sizing
• Maintenance scheduling 

Generator Sizing 

The right generator for you starts with understand exactly what you need it for, including the load size of the equipment, machines and items you’re planning on powering with the generator.

Ideally, generators should be running at their optimal loads of 75-100%. This guarantees there’s enough combustion pressure to keep the piston rings in place. So if the generator’s kVA output is not enough or too much for what you need, then this could lead to over- or under-loading.

This might be the case if you were to use a generator that could not meet the demand of the equipment and utilities. Similarly, by not exercising the generator to its optimal capacity it can also cause issues like wet-stacking which can subsequently cause engine failure, poor performance and cut the lifespan significantly. 

Maintenance 

Proper maintenance is key in ensuring your generators longevity. Not only that, but your generator also needs to run regularly. If you leave it to stand untouched until a power outage, you may run into some problems. Regular maintenance may include practices such as:

• Regularly using the generator, including using load banks to perform generator load tests
• Regularly servicing engine parts 

These practices will check for overall performance. If your generator is in dire need of a service, it will display signs like increased sound, smoke, vibrations or even increased fuel consumption.

Regular maintenance of the generator is essential. Not regularly exercising the mechanics and moving parts can place unnecessary stress on the unit, ultimately shortening the lifespan and create problems such as wet-stacking and other faults. 

5 Ways to Extend Your Diesel Generator Lifespan 

In addition, here are some further ways to extend the longevity of your diesel generator:

Check the Oil

This should go in hand-in-hand with regular servicing. As with any engine, not enough oil in the machine restricts the ability of the components if they are not lubricated.

Some newer generation models will automatically shut down if the oil levels are too low, nevertheless, ensure the oil is checked every few weeks. If the oil dipstick comes out clean, the generator needs an oil top up.

Perform Load Bank Testing

Regular load bank tests give you a guarantee that your generator will run optimally when you need it most. This is especially the case of standby, emergency and back-up generators that are not other in regular use.

A generator load bank test involves simulating a power demand onto the generator, bring it up to full capacity to make sure it can operate as needed. This helps identify any faults or problems with the connection, output and prevents carbon build-up in the engine. It also prevents wet-stacking. 

Prevent Wet-Stacking

Wet-stacking occurs when there is unburnt fuel left in the exhaust pipes of the engine. Over time, this will build up, leaving a thick tar-like substance that can severely damage the generator - even causing it to fail altogether. Wet-stacking can occur due to:

• Not operating at the optimal temperature, i.e. if it’s not high enough
• Continuously operating below its optimal load i.e. 60% and lower
• If the generator is being used either too much or not enough 

Ensure it’s in the Right Environment 

Different generators are designed for different environments, some including canopies to protect from dirt, dust and debris. As a general rule, generators should be installed away from:

• Doors
• Windows and air-vents
• Flammable materials and substances
• High traffic areas 

Be mindful of where the generator is installed - for instance if it’s indoors, check to ensure your ventilation system is regularly inspected and in good working order at all times to prevent health and safety problems arising with air quality.

Follow the Manufacturers Guide 

The manufacturer knows your generator best, so make sure you follow the manufacturers guide when it comes to things like:

• How to install
• Load size
• Maintenance practices
• Fuel type
• Exercise 

Need a Power Solution? Get Expert Advice.

With years of experience servicing the mining construction industries, Blue Diamond Machinery has the equipment you need and can rely on. We not only offer expert advice and industry-leading warranties, we provide an all-encompassing solution. We will customise and install your power solution to your specific power demand requirements, wherever you are. Get in touch with our team today.