Maintenance Program Whitepaper v6 CK Power

GUIDE TO MAINTENANCE FOR
POWER GENERATION EQUIPMENT

Maintenance programs shouldn’t be cut-and-paste. Real power generation equipment

functions under real circumstances, which cause equipment real stress. While there
are certain industry-standard preventative maintenance procedures, the real work of
designing a comprehensive maintenance program lies in working with equipment
owners to design a program that matches their needs.
Because environmental and use factors vary so widely across power generation
applications, equipment everywhere is subject to different types and degrees of
stress and wear. It’s important that maintenance programs reflect those differences.
A generator that’s frequently light-loaded, for instance, should not be approached the
same way as one that’s rarely called to duty all. Generator efficiency will determine a
large portion of what maintenance is required in a given situation. Similarly, a prime
power generator keeping the lights on at a construction site and one in the belly of a
pushboat on the Mississippi face different stressors from their environments. Planned
maintenance should reflect that.
And so, while all maintenance programs must take into account the unique
circumstances of the equipment they’re designed for, there are a few elements of any
maintenance program that must be present for it to be called complete. A maintenance
program isn’t worthy of the name if it doesn’t specify transfer switch maintenance,
for instance.
Here are some of the elements that should always be present in maintenance programs
for power generation equipment, while keeping in mind that, as conditions vary, so should
the specifics of the program.
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PLANNED SERVICE AGREEMENTS

Whether for a generator or another piece of power generation equipment, the purpose
of a planned service agreement is to enhance the performance and reliability. By
providing regular maintenance, these programs minimize the likelihood of an equipment
malfunction. Planned service agreements must be executed as a combination
of inspection and services by trained technicians to be effective. Following these
inspections, the technician should be able to deliver a detailed status report to the
asset owner.
Following is a list of services typically rendered as a part of planned service agreement:
• Change engine oil and filter(s) • Air filter replacement

• Record lube oil pressure • Air cleaners–check/oil for element
• Clean crankcase breather • Check for fuel leaks
• Record coolant level and mixture • Change fuel filter
• Record coolant temperature • Check exhaust system for leaks
• Check belt tension and condition • Check battery specific gravity, electrolyte
• Change water filter(s) level and clean connections
• Check duct work for defects • Check battery charger operation
• Check block heater operation • Inspect ignition wiring, if equipped
• Check coolant hoses and connections • Check ignition timing, points and plugs,
• Check for oil/coolant leakage if equipped
• Change lube, oil and filter(s) • Battery replacement
• Belt and hose replacement • Coolant removal and replacement
• Thermostat replacement • Radiator hose and fitting replacement
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The above is a partial list of some of the services and inspections equipment owners
may expect to be covered as a part of a planned service agreement. Other services like
antifreeze sampling, oil sampling and load bank testing for generators are recommended
on an annual basis. Things like battery and belt and hose replacements are generally
scheduled at longer, but still regular intervals.
TRANSFER SWITCH PREVENTATIVE MAINTENANCE

In the case of emergency generators, transfer switch preventative maintenance is an
essential element in verifying equipment health. Transfer switches are responsible for
ensuring a continuous source of power to a facility by automatically transferring from
a prime power source to an emergency one in the event the primary power source
falls below a predetermined voltage. In other words, if a transfer switch is faulty, your
emergency generator will fail to kick on when your primary power source fails. Hence, it’s
absolutely critical that preventative maintenance plans are in place for this crucial piece
of equipment. In fact, National Fire Protection Association (NFPA) code 110 mandates
that transfer switches be maintained at least annually.
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Here are the procedures a trained technician would generally follow for the cleaning and
systems checks for a transfer switch:
1. De-energize the engine start signals

2. Check interior of transfer switch cabinet
3. Clean control board areas and relay cases, check for loose or missing relays
4. Check control wiring connections and wire bundle runs for abrasions
5. Lubricate necessary moving parts with manufacturer’s recommended
lubrication where applicable
6. Test all lights and note which are in need of replacement
7. Inspect mechanical and electrical interlocks where applicable
8. Inspect timing functions and record if possible
9. Inspect arc shields for proper installation and condition
10. With the customer’s consent, inspect emergency and main contactors
(contactors on non bypass switches will necessitate operation of transfer
switch in the bypass side of switch only).
11. Inspect control contacts
12. Bypass switches will be placed in bypass to inspect main contacts by means
of placing bypass to the preferred source (utility) and placing the auto part of
the switch disconnect and removing from the ATS cabinet.
13. Indicate deficiencies and recommend repairs
14. Re-energize the engine start signals
15. Initiate by pass switches in test mode. Non bypass switches will not be
actuated unless authorized.
16. Thermal imaging of ATS only
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ECO-FRIENDLY OPTIONS
Some companies which offer power generation maintenance programs are beginning to
think about ways the process can be made to have less of an impact on the environment.
Luckily, the best of these programs also actually help equipment owners save money
on operating expenses. It’s an example of innovation that’s mutually beneficial for both
people and the planet.
CK Power, for instance, has partnered with Chevron to use a motor oil that’s
environmentally friendlier than alternatives, allowing for three years between oil changes,
as opposed to the more common one-year life. Rivaling synthetic motor oils in engine
tests, this motor oil provides several other benefits, in that it:
• Provides exceptional internal engine component protection

• Meets demands of EGR and SCR engines
• Provides exceptional performance in conventional engines
• Formulated to be compatible with exhaust after-treatment devices
• May be used in older diesel and gasoline engines
• Provides longer oil drains that saves you money in maintenance cost
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Of course, responsible maintenance contractors, whether designing an eco-friendly

program or not, should take care to recycle or properly dispose of all chemicals such
as oil, coolant and fuel. Besides keeping them from running afoul of regulators, doing
so reduces waste and keeps these substances from entering the environment in any
unplanned way.
FINDING YOUR MAINTENANCE PARTNER

A maintenance contractor who’s not interested in the specific circumstances of your
power generation equipment should set off some immediate red flags. It’s imperative
that a planned maintenance program is tailored to your needs.
Trained, certified and experienced technicians should be the next element customers
insist upon. Without expertise, it’s far too easy for potential issues to go unnoticed, for
repairs to be botched or for the wrong procedures to be conducted.
When you’re ready to think about planned maintenance for your power generation
equipment, no matter the manufacturer or where it was purchased, we’d like to talk.
Contact CK Power with your maintenance questions, concerns or just to get your
program off the ground.
7
LET’S TALK
CK Power is a leading supplier of generators for both prime and standby applications.
Our staff of engineers is made up of experts experienced in helping our customers
choose and maintain the equipment that’s right for them.
Visit our generator services page for more information on running your generator
efficiently, or get in touch with CK Power today to discuss your generator needs.
Contact
Operator: (314) 868-8620
Toll Free: 1-855-CKPOWER / 1-855-257-6937
Fax Number: (314) 868-9314
Address: 1100 Research Blvd. St. Louis, Missouri 63132

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GUIDE TO MAINTENANCE FOR

POWER GENERATION EQUIPMENT

Maintenance programs shouldn’t be cut-and-paste. Real power generation equipment

PLANNED SERVICE AGREEMENTS

Following is a list of services typically rendered as a part of planned service agreement:

• Change engine oil and filter(s) • Air filter replacement

TRANSFER SWITCH PREVENTATIVE MAINTENANCE

1. De-energize the engine start signals

• Provides exceptional internal engine component protection

Of course, responsible maintenance contractors, whether designing an eco-friendly

FINDING YOUR MAINTENANCE PARTNER

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