Fuel Issue at a Pump Station

A newly installed generator at a municipal pump station began experiencing significant operational issues, including difficulty starting and maintaining consistent performance. Given that the equipment was less than a year old, these problems were unexpected and raised concerns about the generator’s reliability.

What Did We Do?

• Facilitated Equipment Purchase: Weld Power Generator collaborated with a local town to assist them in acquiring a new generator for one of their critical pump stations. The town chose to purchase the generator, valued at approximately $80,000, through Weld Power Generator, while opting to utilize another contractor for the installation.
• Post-Installation Consultation: After the generator was installed, our sales team proactively reached out to discuss a preventative maintenance plan. Despite our recommendations, the town decided to handle the maintenance internally using their own staff.
• Emergency Response: Recently, the town contacted us with concerns about the generator’s performance—specifically issues with starting and running. Our skilled technicians promptly responded and conducted a thorough diagnostic evaluation.
• Root Cause Identification: The investigation revealed that the generator had been running on contaminated fuel, which had caused significant damage to critical components, including the fuel rail, injectors, and injection pump. These parts required replacement to restore the generator to operational status.
• Temporary Power Solution: Understanding the importance of maintaining power to the pump station, we swiftly provided a portable rental generator to ensure uninterrupted service during the repair process.
• Comprehensive Repairs: Our team efficiently replaced the damaged components and successfully restored the generator to full working condition. However, the cumulative repair costs amounted to approximately $40,000—half the price of the original generator.

Weld Power Generator’s rapid response and expertise in generator maintenance ensured that the town’s pump station continued to function without prolonged interruption. This case underscores the importance of regular preventative maintenance, as the issues caused by contaminated fuel could have been prevented through routine fuel sample analysis, a standard part of our maintenance plans.