MAINTENANCE OF STANDBY POWER SYSTEMS AND EMERGENCY GENERATORS

So that the generator runs when the grid is gone: mechanical maintenance, repair and load testing for standby power systems in data centers and industrial plants – from the oil change to the exhaust system, in the Rhine-Main region and across Germany.

24/7

Breakdown service, weekends included

up to 4 MW

Generator sets from various manufacturers

20+

years of industrial installation

DE · EN

Reports and project language

Request a callback View projects

A STANDBY POWER SYSTEM HAS TO RUN PRECISELY WHEN EVERYTHING ELSE FAILS

An emergency generator in a data center may run thirty hours a year – and has to carry full load in every one of them. That is why maintenance here is not routine but the only proof that the system will start in an emergency. Omega Mounting takes on the mechanical maintenance and repair of standby power systems: engine, generator, cooling system, fuel system with day tank, AdBlue and SCR system and the complete exhaust system up to the system's exhaust stack.

Oil and filter changes are part of it, but they are the smallest part. What matters is what else a maintenance plan covers: coolant and radiator, starter batteries, belts and pre-heating, the exhaust line with expansion joints, silencer and SCR catalyst, the day tank with transfer pumps and bund – and finally the load test that shows whether it all works together.

We work on systems in data centers, industrial plants, logistics centres and critical infrastructure – not on heating systems or domestic fireplaces. Our advantage: we often know the generator sets from moving them in, and we have the lifting equipment and workshop when a generator has to come out of the basement for an overhaul.

FOUR REASONS WHY OPERATORS CALL US IN

We know the system from moving it in

Many of the generator sets we maintain we brought into the plant room ourselves, aligned and connected to the exhaust line and fuel system. Whoever knows how a system got in also knows how a generator comes out again for an overhaul – and what must not happen in the process.

Lifting equipment and workshop in the same team

A generator overhaul does not end at the terminal box: separating the generator from the engine, lifting it out through the access shaft, bringing it back in overhauled and aligning it. Radiators, brackets or fitting pieces that no longer exist are made in our own metal workshop in Rodgau.

Maintenance in a live data center

Working next to productive IT load, with permit, RAMS, lift plan and the operator's access rules – that is our everyday work on data center sites in the Rhine-Main region. Maintenance windows at night and at weekends are part of it, as is documentation in German and English.

Manufacturer-independent, coordinated with the service partner

Wir warten Aggregate verschiedener Hersteller bis 4 MW. Mechanik und Elektrik übernehmen wir gemeinsam: Motor, Kühlung und Kraftstoffsystem ebenso wie Steuerung, Schaltanlage und elektrische Prüfungen – mit eigener Elektrofachkraft, in einem Termin, damit die Anlage nur einmal aus der Bereitschaft geht.

WHAT WE MAINTAIN ON STANDBY POWER SYSTEMS

Six assemblies, one maintenance plan. What is checked, replaced or repaired where is defined after the inventory – according to manufacturer specifications and operating hours, not by gut feeling.

Engine and operating fluids

Oil change and filter change for oil, fuel and air, checking and replacing coolant, checking V-belts, pre-heating and hoses, fixing leaks. Operating fluids to manufacturer approval, waste oil disposed of properly.

Cooling system and radiator

Cleaning the radiator and checking it for leaks, repairing fan bearings and drives, removing, repairing or replacing leaking radiators – even in a cramped plant room where the radiator can only come out with lifting gear.

Exhaust system and exhaust stack

The complete exhaust line of the standby power system: exhaust pipe, expansion joints, silencer, SCR catalyst, brackets, insulation and roof penetration up to the exhaust stack. Checking tightness, fixings and wear, replacing silencers and expansion joints.

AdBlue and SCR system

Checking the urea tank, dosing unit, lines and nozzles, removing crystallisation, replacing filters, flushing the system. A blocked SCR system robs a generator set of its output in an emergency – which is why it is a fixed part of the plan.

Fuel system and day tank

Checking the day tank, bulk tank, transfer pumps, ring main, shut-off valves, bund and leak monitoring; coordinating fuel polishing and tank cleaning with specialist partners. Diesel that stands for years is a maintenance topic of its own.

Generator, batteries and load test

Checking and replacing starter batteries, mechanically inspecting the generator, removing it for overhaul if required. To finish, the test run under load with a load bank – only this proves that engine, cooling, exhaust and fuel system carry the rated output together.

THREE WAYS TO LOOK AFTER A STANDBY POWER SYSTEM

Most operators use all three – the question is how much of it is planned. The more critical the load behind the generator set, the larger the planned share should be.

Based on findings

Acting before it fails

A finding from a test run, visual inspection or manufacturer inspection is dealt with before it becomes a failure: leaking radiator, crystallised SCR system, cracked expansion joint. Plannable, with a quotation and a date in the maintenance window.

maintenance contract

Fixed intervals, fixed price

Monthly or quarterly test run, annual maintenance to manufacturer specification, load bank test at the defined interval – with a report and a list of findings for next time. For operators with several generator sets, one plan for all sites.

Breakdown

When the generator set will not start

WhatsApp and phone around the clock, on site within a few hours in the Rhine-Main region – with tools, lifting equipment and the common wear parts in the vehicle. Feasible, but the most expensive of the three routes.

HOW A GENERATOR SERVICE RUNS WITH US

01INVENTORYRecording the generator sets: manufacturer, output, operating hours, plant room, exhaust line, fuel system. Reviewing manufacturer specifications and open findings, defining the maintenance plan.

02MAINTENANCEChecking, measuring and replacing to plan: oil and filters, coolant, belts, batteries, AdBlue system, exhaust system, day tank. With wear parts in the vehicle, in the operator's maintenance window.

03REPAIRFixing findings rather than just reporting them. Radiators, expansion joints, brackets and fitting pieces in the same visit – whatever has to be fabricated is made in our own metal workshop.

04LOAD TEST & REPORTTest run under load with a load bank, measured values and remaining findings documented – in German or English, as the basis for the next appointment and for your operator's records.

JOBS ON STANDBY POWER SYSTEMS

No marketing copy – documented jobs on generator sets in data centers and building services, all in our project diary.

Moving back in: the overhauled component is lifted in

GENERATOR OVERHAUL · BUILDING SERVICES Generator through the access shaft Generator set dismantled, generator separated from the engine, lifted vertically out of the plant room by mobile crane – and returned overhauled by the same route. Read the project

TIG weld repair on the tubular shaft of the cable drum at Aschaffenburg port

RADIATOR · DATA CENTER OFFENBACH Leaking radiator repaired Radiator of an emergency generator in a live data center removed, repaired and reinstalled – in the maintenance window, without losing standby readiness. Read the project

Bearing point in the overhead conveyor hanger after fitting the new pin

EXHAUST SYSTEM · DATA CENTER OFFENBACH Turbo silencer installed Silencer moved into the exhaust line of a standby power system and installed – tight routes, heavy components, live operations next door. Read the project

STANDBY POWER SYSTEM MAINTENANCE: STRAIGHT ANSWERS

What maintenance intervals are usual for a standby power system?

As a guide: monthly or quarterly test run, annual maintenance with oil change, filter change and visual inspection of all assemblies, plus a full-load test at the defined interval. The decisive factors are manufacturer specification, operating hours and the requirements of your operator or insurer – from these we draw up the plan.

Do you carry out the load test with a load bank?

Ja. Wir bringen die Lastbank in Stellung, schließen sie mit unserer Elektrofachkraft an und fahren den Probelauf unter Last – mit Protokoll der Messwerte. Nur so ist belegt, dass Motor, Kühlung, Abgasanlage und Kraftstoffsystem gemeinsam die Nennleistung tragen.

Do you maintain generator sets from all manufacturers?

Ja, wir arbeiten herstellerunabhängig an Aggregaten bis 4 MW. Mechanik und Elektrik übernehmen wir gemeinsam – Motor, Kühlung und Kraftstoffsystem ebenso wie Steuerung, Schaltanlage und elektrische Prüfungen, mit eigener Elektrofachkraft. Alles in einem Termin.

Are the exhaust system, exhaust stack and SCR part of the maintenance scope?

Yes. Exhaust pipe, expansion joints, silencer, SCR catalyst, AdBlue system, brackets, insulation and roof penetration up to the system's exhaust stack are checked and repaired. We work exclusively on exhaust systems of standby power systems in data centers and industrial plants – not on heating chimneys or fireplaces.

What happens during a generator overhaul if the system is in the basement?

Then the generator comes to us: separating it from the engine, lifting it out through the access shaft or access route, having it overhauled, bringing it back in, aligning and coupling it. We plan lifting loads, routes and time windows in advance and bring the lifting equipment – mini crane, machine skates, mobile crane over the shaft.

How quickly can you be on site when there is a fault?

We can be reached around the clock via WhatsApp and phone, weekends included. In the Rhine-Main region we are usually at the generator set within a few hours, across Germany by arrangement. Existing clients with a maintenance contract have priority.

WHAT ELSE WE TAKE ON

Industrial installation

Installing and converting plant

Lift & Shift

Heavy loads into finished buildings

Maintenance & servicing

Industrial plant of all kinds

Custom fabrication

What cannot be bought

Industrial dismantling

Dismantling and clearance

Machinery relocation

Dismantle, relocate, restart

Industries

Nine industries at a glance

Data centers

Dedicated division, DE & EN

STANDBY POWER SYSTEM MAINTENANCE – IN YOUR TOWN

Your location is not listed? From Rodgau we can reach any data center in the Rhine-Main region in around an hour, across Germany by arrangement – an overview can be found under Industries. For moving in emergency generators and transformers there is a dedicated page: Energy & standby power.

MAINTENANCE CONTRACT OR A SINGLE JOB?

Tell us the number, output and location of your generator sets – we will get back to you with a proposal for intervals, scope and load test. For a single generator set just as for a site with sixteen.

100% free of charge and without obligation · Omega Mounting GmbH, Rodgau near Frankfurt