Notes for Generator Sets Working at High Altitude

Key challenges: Thin air, power derating, poor heat dissipation, low boiling point of coolant, difficult cold start, reduced electrical insulation & arc-extinguishing capacity, strong ultraviolet radiation and heavy sand/dust.

1. Model Selection & Power Derating (Most Important)

1. Turbocharged & intercooled engines are preferred. Naturally aspirated engines suffer severe power loss at high altitude and are not recommended for long-term operation.

1. Power derating reference:
   • Naturally aspirated: 7%～12% power loss per 1000 m elevation gain
   • Turbocharged: 4%～7% power loss per 1000 m elevation gain

1. Provide the actual altitude to the manufacturer for plateau calibration (fuel supply adjustment, injection advance angle modification). Do NOT operate at the rated power for plain areas, otherwise black smoke, high exhaust temperature and heavy carbon deposition will occur.
2. Enclosure / container ventilation area must be enlarged. The intake & exhaust air margin should be larger than plain version to guarantee sufficient fresh air. Insufficient ventilation will cause overheating and unstable voltage.

2. Cooling System (Easy to boil over at high altitude)

1. Atmospheric pressure is low at high altitude, which reduces coolant boiling point. Closed pressurized cooling system + high boiling point long-life antifreeze is mandatory. Plain water is not allowed.
2. Larger radiator and intercooler are required. Clean dust and sand regularly; shorten maintenance interval in dusty regions.
3. Monitor water temperature, exhaust temperature and turbocharger temperature during operation. Reduce load immediately if exhaust temperature keeps high.

3. Air Intake, Air Filter & Turbocharger

1. Heavy-duty two-stage air filter for plateau is required due to heavy sand and dust. Inspection and replacement cycle shall be shortened (1/2～2/3 of plain cycle). Clogged filter leads to oxygen shortage, black smoke and turbocharger overspeed damage.
2. Check turbocharger speed and lube oil pressure frequently for turbo models. Turbochargers are prone to overspeed and overheating at high altitude; reliable lubrication is essential.
3. Keep intake pipeline well sealed to avoid air leakage.

4. Fuel, Lubricating Oil & Antifreeze Selection

• Diesel fuel: Select low pour-point diesel according to the local minimum temperature (-10# / -20# / -35#). Drain water from fuel tank and water-oil separator frequently to prevent wax blockage.
• Lube oil: Multi-grade oil with good low-temperature fluidity, such as 10W-30 / 5W-40 / 0W-40. Shorten maintenance cycle by 25%～40%, because incomplete combustion easily forms carbon deposit and sludge.
• Antifreeze: Match the lowest ambient temperature meanwhile meet high boiling point requirement for plateau. Test concentration regularly.

5. Starting System (Hard cold start at high altitude)

1. Preheating system is standard: water jacket heater, lube oil preheater, intake glow plug / flame preheater. Preheating is recommended even in daytime above 3000 m.
2. Batteries lose capacity greatly in low temperature. Low-temperature batteries with thermal insulation box are suggested. Keep terminals tightly connected. Do not crank continuously for long time (≤5 seconds per attempt, interval ≥2 minutes) to avoid starter burnout.
3. Run at low speed for warm-up after start. Gradually apply load when water temperature reaches above 40℃. No full load directly after cold start.

6. Electrical System (Easily ignored point)

1. Air insulation drops and arc extinguishing ability weakens at high altitude. Circuit breakers, contactors and insulation parts shall be plateau type (derated for use or with plateau certification), otherwise arc discharge, burnt contacts and false tripping may happen.
2. Strong UV accelerates aging of cables, harness and rubber seals. UV-resistant cables are required, and terminals shall be well protected against water and dust.
3. Voltage and frequency stability become worse. Avoid sudden load impact; reserve extra margin for inductive loads.

7. Exhaust, Generator Room & Safety

1. Insulate exhaust pipe, install expansion joint and drain port. Raise chimney outlet height to prevent exhaust gas backflow into the room. Exhaust gas poisoning risk is higher together with thin plateau air.
2. Never seal the generator room tightly. Separate air intake and exhaust ducts: cool fresh air inlet on one side, hot air direct outlet on the other side.
3. Plateau environment is oxygen-deficient. Do NOT stay inside the generator room for long time. Install carbon monoxide alarm.

8. Operation & Maintenance

1. Regular inspection items: air filter, lube oil, oil filter, fuel filter, water-oil separator, valve clearance, injector carbon deposit, turbocharger and wiring terminals.
2. Incomplete combustion easily causes carbon deposit on injector and combustion chamber; clean and inspect periodically.
3. Carry out load test before overhaul or reusing at different altitude. Run stably under derated power, and record exhaust temperature, water temperature, voltage and current.

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Lead Time & Warranty:

• Lead Time: Around 20-35days, call to see if we have the stock available
• Warranty: One year / 1000hours operation time which comes first

Each generators will be tested before shipping.