COURSE OVERVIEW:

Diesel generators are the primary line of defense for emergency power and off-grid operations, requiring a high degree of mechanical readiness. This course provides a technical deep dive into the internal combustion engine and its auxiliary systems, focusing on the mechanical components that are most susceptible to wear and failure. Participants will learn to balance time-based preventive tasks with modern predictive technologies to ensure that the generator set remains in an "always-ready" state.

The mechanical focus of the training emphasizes the critical systems that sustain engine operation: fuel delivery, air intake, cooling, and lubrication. Attendants will explore the science of diesel engine combustion and the mechanical stresses placed on pistons, valves, and turbochargers during rapid load changes. The scope includes a detailed analysis of how fuel quality and filtration efficiency directly impact the longevity of high-pressure injection systems and the overall reliability of the prime mover.

Coverage of predictive techniques introduces participants to non-invasive diagnostics such as vibration monitoring of main bearings, borescope inspections of cylinders, and the interpretation of oil chemistry trends. The course outlines the development of a robust maintenance schedule that complies with international standards while addressing site-specific environmental challenges. By the end of this program, participants will be able to diagnose mechanical abnormalities before they lead to starting failures or engine seizures, ensuring maximum availability of the power generation system.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Explain the mechanical operating cycle of a four-stroke diesel engine.

2.  Identify and inspect all mechanical components of the fuel injection system.

3.  Perform a comprehensive preventive maintenance service (PM-1 to PM-4).

4.  Analyze engine oil reports to detect internal wear and coolant leaks.

5.  Utilize borescopes to inspect cylinder liners and valves for carbon buildup.

6.  Troubleshoot mechanical issues in the turbocharger and intercooler.

7.  Maintain the cooling system integrity: Pumps, thermostats, and radiators.

8.  Execute a load bank test to prevent "Wet Stacking" and carbon fouling.

9.  Inspect and adjust valve clearances (overhead) for optimal performance.

10.  Diagnose the causes of abnormal exhaust smoke (Black, White, Blue).

11.  Monitor engine vibration and noise to identify bearing or mounting issues.

12.  Manage the maintenance requirements for starting systems and governors.

13.  Implement a long-term storage and preservation plan for standby generators.

TARGET AUDIENCE:

Mechanical Technicians, Generator Operators, Facility Engineers, and Fleet Maintenance Supervisors involved in power plant and standby power operations.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.