Is your pump station’s back-up generator leaking? If so, it’s probably the heat exchanger! We talked to our Co-Owner, Justin Feeleus, to find out what might be causing generator heat exchanger leaks and cracks. Plus what you can do to prevent them.
When a back-up generator’s heat exchanger fails, oil and gas operations like pumpjacks, pump stations and/or compressor stations are suddenly at risk.
Without proper cooling, generators can overheat, shut down, or fail entirely.
At West End Rad, we specialize in repairing industrial generator cooling systems for all heavy-duty OEMs, including:
So, we asked our Director of Technical Innovation & Co-Owner, Justin Feeleus, to share the three most common reasons heat exchangers in heavy-duty back-up generators start to fail.
Here’s what he had to say!
Reason 1: Lack of Generator Use
Because pump station back-up generators (are designed to protect operations during unpredictable outages, they often sit unused for long periods of time.
Ironically, not running your genset is actually one of the leading causes of heat exchanger leaks.
Why? Because when an industrial generator isn’t run regularly, coolant sits inside the system instead of circulating throughout it. When the coolant stays in the same spot, it can quickly corrode internal metal surfaces in the heat exchanger.
“By the time an oil & gas site needs emergency power, the genset heat exchanger may already be weakened and susceptible to cracking and leaking from lack of use,” said Justin.
Therefore, our shop technicians recommend running your back-up generator for at least 30 minutes every month to confirm everything’s working as it should.
Reason 2: Internal Rusting
The metals inside a genset heat exchanger are constantly exposed to coolant, air and fluctuating temperatures.
Unfortunately, this creates the perfect environment for rust.
Over time, small amounts of oxygen and moisture can get trapped in your pump station’s generators cooling system and react with metal surfaces, forming rust. And once rust starts, it quickly eats away at the metal inside of the back-up generator’s heat exchanger.
“Rust is one of those things you don’t see until it’s too late,” Justin said. “By the time we open the unit, the damage is already done on the inside.”
Even minor rust buildup can cause a genset to run hotter, potentially pushing its heat exchanger past its limits.
Reason 3: Contamination From Improper Fluid Levels
Maintaining the correct coolant level is one of the simplest ways to protect a pump station’s back-up generator’s heat exchanger.
Why? Because low coolant exposes parts of your genset’s heat exchanger to air instead of fluid.
This creates two common back-up generator problems:
First, those exposed surfaces begin to oxidize much faster.
And second, air pockets reduce the system’s ability to transfer heat.
On the other hand, overfilling the system can create excessive pressure as the coolant heats and expands.
That pressure forces stress onto the heat exchanger tanks and core, increasing the risk of cracks and leaks.
“This is a perfect example of why back-up generators need custom-built heat exchangers,” said Justin. “OEM parts can work for light or moderate conditions, but backup generators operate at a completely different level.”
West End Radiator’s Solution: Custom Aluminum Coolant Reservoirs
Luckily, we manufacture a long-term, cost-effective fix for leaky gensets: Custom aluminum coolant reservoirs.
“These reservoirs not only solve existing leaks, but help prevent future failures caused by rust, contamination, or long periods of inactivity,” said Justin.
Our aluminum coolant reservoirs provide extra room for coolant to help your back-up generator maintain proper fluid levels. Additionally, the aluminum reservoirs are more resistant to cracks compared to their plastic OEM counterparts.
Less cracks = less leaks!
How Does West End Rad Manufacture Custom Aluminum Reservoirs?
Our mobile service team can visit your site to take precise measurements of the existing genset heat exchanger, ensuring the new components fit exactly as they should.
Then, using those measurements, we manufacture a custom aluminum reservoir and return to install it along with a new heat exchanger core as needed for your pump station generator.
Dealing With a Leaking Backup Generator?
If your business is experiencing issues with your on-site generator’s cooling system, our safety-certified mobile service technicians can come to your site to assess your heat exchanger.
Curious about what oil & gas heat exchanger services are available in Western Canada? Contact our team for more information.
Toll-free: 1-877-RAD-CORE (723-2673)
Winnipeg: 1-204-633-5648
Estevan: 1-306-634-2055
Saskatoon: 1-306-934-7005
