Explained by Coco, Customer Service Manager of Huipu Power: How to Avoid Major Losses from Diesel Generator Cooler Failure?

--The Value of Rapid Troubleshooting and Preventive Maintenance from a Real Case in a Philippine Plant

By: Coco Wang, Customer Service Manager, Huipu Power  

Radiator Failure - The "Invisible Killer" of Diesel Generators

As a core member of Huipu Power's service team, I am exposed to radiator problems on a daily basis. Data shows that more than 60% of unplanned diesel generator downtime is directly related to the cooling system. Today, I would like to share with you the common causes of cooler failures through real-life examples and how Huipu Power protects your power safety through "Professional Overhaul Service and Smart Technology".  

Here are three common causes of failure and real response cases:

1. Dust Clogging: Seemingly small problems, but big hidden dangers

Case background: In March 2024, the Huipu HP-600 unit of a food processing factory in the Philippines had a sudden high temperature alarm.  The customer's production line had to be interrupted because of this, and if the freshness of the food dropped, it would cause serious losses for the customer.

Huipu's solution:

Remote Diagnosis: The radiator fins were completely covered by dust (the dust concentration in the local sugar factory was 3 times the standard). The fan speed decreased, which resulted in a sudden drop in cooling efficiency.

24-hour Response: Engineers got to the site within 48 hours with high-pressure cleaning equipment.

Remote monitoring intervention: We added a new "real-time cooling efficiency monitoring" module to the control system of the unit.

Customer feedback: "The fuel consumption of the unit was reduced by 12% after cleaning, and Huipu's retrofit program solved our seasonal problems."  

Coco suggests doing an external radiator flush at least once a quarter in areas with a lot of dust and willow floss, and regularly checking the sealing of the filter.

2. Coolant leakage: from "more than a drip" to "zero leakage."

Case background: In November 2023, the coolant of Huipu HP-300 unit of a hotel backup power supply in Vietnam was abnormally depleted and needed to be replenished by 2 liters per day.

The root cause: minor cracks appeared in the radiator weld joints due to coastal salt spray corrosion, and the leakage worsened during low-frequency operation at night.  

Huipu program:  

- QUICK REMOVAL: After you've given the radiator a good cleaning, it's time for a leak check! This will help you find the three spots where the leak might be.

NOTE: When you're checking, please make sure to block all the other ports, except for the water inlet and outlet. Then, place the radiator in the water. Then, use an inflatable pump or a high-pressure air cylinder to pump in compressed air of about 0.5kg/cm2 from the water inlet or outlet. If you find bubbles coming out, it means that there is a crack or breakage at the place.

- Material Upgrade: Replace with corrosion-resistant copper alloy heat pipe to extend the service life by 30%.

- Energy consumption optimization: synchronized calibration of intelligent temperature control system, reducing the pressure of coolant circulation.

Comparison of results: Zero coolant replenishment within 8 months after the retrofit, saving about US$1,800 in annual maintenance costs.  

3. Scale Deposits: A Neglected Chronic Disease

Background: In June 2024, a rubber factory in Malaysia used groundwater for direct cooling. Unfortunately, the cooling water had too many impurities and salts, which led to a build-up of scale on the inner wall of the cooling pipe of the Huipu HP-450 unit. This caused the pipe wall to become corroded and broken.

Risk analysis: Scale can reduce the heat exchange efficiency by 40%, and long-term over-temperature operation of the diesel engine may lead to cracking of the cylinder block.  

Huipu Response:  

Cleaning + Repair: We'll give your radiator a good scrub to get rid of any metal paint and rust. Then, we'll use solder to fix it up.

Water quality treatment program: We'll set you up with water softening treatment devices and show you how to test the water quality.

Preventive Maintenance Agreement: We'll check your cooling system every six months to make sure it's running smoothly.

Customer comment: "Huipu's engineers were so helpful! They not only solved the problem, but they also taught us a simple way to overhaul the radiator. This kind of service is truly heartwarming!"  

Huipu Power radiator overhaul service is here to help you with four major advantages:

1. Accurate diagnosis: we've got you covered with infrared thermal imaging, endoscopes, and other professional equipment to find the issue in as little as 30 minutes.

2. Fast troubleshooting: We've got over 50 certified engineers in the Asia-Pacific region, and we'll be with you within 72 hours (or even within 24 hours for emergencies).

3. We'll keep making your unit even better: We'll make custom protection solutions (dustproof, anti-corrosion, moisture-proof) to fit your needs and help your unit deal with whatever the environment throws at it.

Here are Coco's maintenance recommendations, which we've put together to help you keep your radiator in top shape!

- Monthly: Take a quick look at the outside of the radiator to check for any blockages. Use a flashlight to check the fins for even light transmission.

- Every six months: Use water hardness test paper to test the Here are some tips to keep your radiator in top shape:

- Every month, give the outside of the radiator a good once-over.

- Every six months, check the coolant. If the TDS value is over 400, it's time to take action.

- If the high temperature alarm goes off, stop the machine and close the shutters to keep the hot air from getting back in and making things worse.

And don't hesitate to visit Huipu Power's website to let us know what you need.