As a common backup or primary power source, the continuous operation time of a diesel generator directly impacts the stability of the power supply system. Based on practical application scenarios, this article explores the key factors affecting the generator’s continuous operation and provides operational recommendations to extend its service life.
I. Core Limitations of Continuous Operation
- Equipment Design and Cooling System
Industrial-grade generator sets typically use a forced circulation water-cooling system, allowing continuous operation for over 500 hours, while household air-cooled models should not exceed 12 hours of continuous work. A 350kW unit from an international brand set a record of 672 hours of continuous operation at a mining site in Brazil, thanks to its dual-cycle cooling system and intelligent temperature control module. - Fuel Supply and Filtration System
Each liter of diesel can generate approximately 3.5 kWh of electricity, but actual consumption is significantly affected by load levels. At 80% load, a 200kW generator consumes 48L/h, whereas at full load, consumption rises sharply to 62L/h. It is recommended to equip an automatic fuel level monitoring system to prevent sudden fuel depletion, which could damage the equipment.
II. Operating Strategies in Different Scenarios
- Emergency Power Supply
The backup power system for hospital ICU wards requires generator sets to provide continuous power for 72 hours. A tertiary hospital implemented a dual-generator parallel scheme with an automatic switching device to ensure seamless power transfer while maintaining an underground fuel storage tank to guarantee fuel supply. - Power Supply for Construction Machinery
During the construction of the Qinghai-Tibet Railway at an altitude of 4,500 meters, generator sets were equipped with turbocharged modifications to reduce the air-fuel ratio and increase air intake, extending continuous operation from the standard 8 hours to 16 hours. The engineering team adopted a “12-hour operation – 4-hour cooling” rotation strategy, effectively prolonging equipment lifespan.
III. Practical Techniques for Extending Operation Time
- Dynamic Load Management Technology
Installing an intelligent load distributor allows the generator to switch to a single-cylinder energy-saving mode when power demand drops below 40%. A data center that applied this technology extended its generator’s continuous operating cycle from 120 hours to 200 hours. - Preventive Maintenance Plan
A maintenance schedule of “changing oil filters every 50 operating hours and cleaning fuel injectors every 200 hours” is recommended. Maintenance records from a gold mine in South Africa showed that generators strictly adhering to this schedule had a 3.2-fold increase in mean time between failures. - Environmental Adaptation Modifications
Generators operating in tropical regions saw a 25% increase in continuous runtime after being equipped with anti-salt mist coatings and air pre-filters. A seawater desalination plant in the Middle East modified its intake system, extending maintenance intervals in dusty environments from weekly to monthly.
IV. Typical Warning Signs of Generator Failures
- Abnormal exhaust smoke color (blue smoke indicates oil combustion, black smoke suggests incomplete combustion)
- Coolant temperature consistently exceeding 95°C
- Output voltage fluctuations exceeding ±5%
- Unusual metallic knocking sounds (potentially indicating connecting rod bearing wear)
- A case from a marine power station demonstrated that early intervention in knocking phenomena helped avoid major repairs. By adjusting the fuel injection timing by 3°, technicians restored stable generator operation.