In the hospitality industry, uptime is everything. From small inns to sprawling Vegas hotels, an unexpected power outage can result in lost revenue, frustrated guests, and reputational damage.
These concerns explain why so many hotels across the United States install onsite generators to provide backup power. In the event of a grid failure, these tried and trusted pieces of equipment come online within seconds, keeping the lights on and ensuring operational continuity.
Because backup generators operate under different conditions than primary equipment, they must maintain peak readiness while spending most of their time on standby. Therefore, it’s important to know what the best way is to ensure that on-site generators are always primed and ready for action during their moment of need.
The key is to implement a planned and well-structured maintenance approach that not only enhances reliability but also extends equipment life. This approach supports lower lifecycle costs and ensures more resilient, profitable operations over the long term.
Choosing the Right Generator
Before considering maintenance, it is critical that hospitality organizations firstly select the correct generator for the task at hand. This means ensuring that the generator is rightsized and can cope with the full range of operational demands. An undersized generator will be unable to power all the necessary electrical loads, potentially resulting in a loss of power for essential systems. Meanwhile, an oversized generator will be unnecessarily expensive and inefficiently operated.
It is also about ensuring robust design. Modern generators are the sum of many parts, including an engine, alternator, fuel system, voltage regulator, cooling system, exhaust system, lubrication system, and controllers. Each of these technologies must be constructed from the highest quality materials and components to ensure reliability under rigorous operating conditions.
Precision manufacturing is critical, too. Vital equipment, such as generators, must be built in modern, high-tech plants that adopt a culture of repetitive processes and a set of deliverables to ensure consistent build standards. At the end of the build process, generators are extensively tested before final on-site installation and commissioning.
Established manufacturers like Rehlko offer an end-to-end service, working closely with hospitality customers throughout the design, construction, and delivery process—ensuring onsite equipment meets all requirements.
Implementing Routine Maintenance Plans
Once operational, proactive generator maintenance becomes critical in safeguarding hospitality operations against costly downtime. Here, practical strategies such as routine inspection and load testing can ensure that backup power systems are always ready when needed.
While every generator application is different, there are common areas of good practice when it comes to maintenance strategies. Firstly, it is recommended that regular maintenance be scheduled and performed to ensure equipment remains in optimal condition. Routine inspections—daily, weekly, and monthly—might include visual inspections and more in-depth checks.
The most important component on a generator is arguably the engine. During maintenance activities, it is essential to refer to the engine operations manual and generator manual for detailed information and to follow the strict instructions provided to ensure a seamless, error-free process. It is also advisable to have standby electrical components, such as sensors, controllers, and injectors, readily available in case a faulty part needs to be replaced urgently. To better understand what components require prompt attention and replacement, it is recommended to run a diagnostic test on equipment.
Another important area of routine maintenance is the fuel—specifically, ensuring that onsite fuel hasn’t oxidized, which could clog vital generator systems. It is also advisable to check the fuel filter to ensure that impurities cannot infiltrate the engine and to be aware of the problem of fuel dilution, which can occur when diesel fuel contaminates the engine’s lubricating oil by infiltrating the engine’s oil sump. Excessive dilution typically occurs over time and can lead to significant engine wear.
Other routine maintenance checks should include the battery and electrical components, as they have a fixed lifespan of between two and three years. Also, diesel power generators require fresh air for the combustion process. Therefore, it is essential to regularly check the air filter, which plays a crucial role in sifting out unwanted particles and preventing them from entering the combustion chamber.
Avoiding Running Generators Without Load or With Low-Load
More in-depth maintenance activities must also be considered. Most generator manufacturers recommend starting up standby generators and allowing them to run for a few minutes to keep components lubricated and ensure the equipment is functioning correctly. However, it is crucial to avoid running them without a load or with a low load for an extended period. Doing so can cause wet stacking—a condition where unburned fuel passes into the exhaust system.
Diesel power generators must maintain the correct air-to-fuel ratio and sustain optimal operational temperature to ensure complete fuel combustion and operate at maximum efficiency. However, it will not reach its correct operating temperature when operating on a light load. When this occurs for extended periods, unburned fuel will be present in the exhaust manifold. Hence, the phrase “wet stacking”.
As the unburned fuel begins to accumulate in the exhaust side of the engine, it will result in fouled injectors and a buildup of carbon in the internal combustion components. These excess deposits can affect the engine performance, as gases bypass valve seatings, exhaust buildup produces backpressure, and deposits on the turbo blades reduce turbo efficiency. Over time, the deposits will scar and erode crucial engine components’ surfaces.
Moreover, when the engine is running below the designated operating temperature, the piston rings do not expand adequately to seal the space between the cylinder walls and pistons. This leads to unburned fuel and gases escaping into the oil pan, diluting the lubricating properties of the oil and causing premature engine wear.
However, with the emergence of newer engines featuring improved technologies and tighter tolerances, the possibility of wet stacking, fuel leakage, and other issues is significantly reduced. This allows more flexibility in the maintenance schedule and loading running. For more details, refer to the KD Series Generator Conscious Care Program.
Working with a Maintenance Partner
There are other important points to consider. Most importantly, personnel maintaining industrial generators should always be trained professionals familiar with the equipment. Ensure they have the correct tools on hand, enabling quick and accurate identification of the root cause of any issues.
Many companies in the hospitality sector prefer to contract generator maintenance out to specialist organizations. At Rehlko and our distribution partners, we offer one-stop maintenance solutions for various Rehlko generator models, providing technical expertise and high-quality components that meet the highest standards for operation and durability. Rehlko’s distribution partners are strategically located to meet the response time of our customers’ needs.
With proper maintenance, generators in hospitality applications can last for years, safeguarding operations in the event of a power outage. By being mindful of equipment needs and implementing proactive maintenance strategies, it is possible to rectify issues that may arise, thereby reducing downtime and keeping your business running.
About the Author
Bruce Yee is based in Seattle, and covers Washington, Oregon, Idaho, Montana, Wyoming, Utah and Colorado. He joined Rehlko in 2016. Yee has also worked as a Senior Sales Engineer at Emerson’s Electrical Reliability Services and at the General Electric Company as a Distribution Sales Engineer. Yee is a graduate of the University of Washington, with a bachelor’s degree in Aeronautical Engineering. He can be reached at (360) 979-9343 or by e-mail at Bruce.Yee@rehlko.com.
