In short. A RECD only protects the environment while it works. Monitor differential pressure and temperature, plan regeneration and ash cleaning, check sensors and reagent, and keep records that show the system performs.
Reading to verification
Reading → trend → deviation → diagnosis → intervention → verification. Log differential pressure and temperature at set loads and watch the trend.
| Observation | Possible meaning | Action |
|---|---|---|
| Rising differential pressure | Filter loading or ash | Regenerate or clean |
| Low exhaust temperature | Light load, poor regeneration | Load bank run or adjust strategy |
| Visible smoke | Bypass, damaged filter or engine fault | Inspect urgently |
| Sensor drift or alarm | Fouled or failed sensor | Check and calibrate |
Routine tasks
- Monthly check of logs and alarms.
- Run on load to reach regeneration temperature. See load bank testing.
- Inspect piping, joints and insulation.
- Clean or replace filters per maker schedule.
- Check reagent quality and stock, if SCR.
Engine health matters
Oil consumption, injector condition and fuel quality directly affect device life. Include the device in the generator preventive maintenance plan and AMC.
Records
Keep logs, cleaning dates and test results. See monitoring and documentation.
Illustrative example
Differential pressure creeps up each month on a lightly used set. A scheduled on-load run clears soot and the trend resets. Without the trend, the filter would have blocked during an outage.
A monthly check routine
- Read the log: differential pressure at a reference load, exhaust temperature, alarms.
- Compare with last month and with the baseline.
- Inspect the housing, joints, supports and insulation for cracks, leaks or heat damage.
- Check the urea level and quality, if fitted.
- Run the set on load long enough to reach regeneration temperature.
- Record the result.
Trend interpretation
| Trend | Meaning | Response |
|---|---|---|
| Pressure climbs steadily | Soot or ash loading | Regenerate, then clean |
| Pressure falls suddenly | Filter crack or leak | Inspect, visible smoke likely |
| Temperature lower than before at same load | Engine or turbo issue, or sensor drift | Check engine and sensor |
| Ammonia odour | Over-dosing or catalyst fault | Check dosing and catalyst |
Cleaning an ash-loaded filter
Ash comes from lubricating oil additives and cannot be burned off. Filters are removed and cleaned using methods recommended by the maker, such as controlled air or thermal cleaning, then inspected before refitting. Do not improvise cleaning with methods that can crack the ceramic.
Engine health protects the device
- Control oil consumption; excessive oil shortens filter life.
- Keep injectors and turbocharger in good order.
- Use fuel of proper quality; low-quality fuel can poison catalysts.
Spares and consumables
Keep a stock of sensors, gaskets and a spare filter or clear arrangement for exchange units, so a failure does not leave the set non-compliant or out of service for weeks.
Integration with maintenance contracts
Add the device to the scope of your AMC, with clear responsibilities for monitoring, cleaning and records. Without a named owner, such systems drift into neglect.
The master engineering question
Does the log prove the device is working, or are we assuming it is?
What to send us
Send logs and device data. Send your application details.
Questions engineers ask
How often to clean ash?
Per maker, trended by pressure.
Can I bypass during an outage?
Only if design and regulation allow; do not assume.
What if the sensor fails?
Treat as a fault; repair promptly.
Does fuel matter?
Yes, quality affects catalysts and ash.
General guidance only. Follow maker schedules.