Diesel generator set runs under small load, as the running time continues, the following failures will occur:
1. For turbocharged diesel generator sets, due to low load, no load, and low boost pressure, it is easy to cause the sealing effect of the turbocharger oil seal (non-contact) to decrease.
2. When the oil in the pressurizing chamber of the turbocharger accumulates to a certain extent, it will leak from the joint surface of the turbocharger.
3. Part of the oil that goes up to the cylinder participates in combustion, and part of the oil cannot be completely burned. Carbon deposits are formed at the valve, intake duct, piston crown, piston ring, etc., and some are discharged with the exhaust gas. In this way, oil will gradually accumulate in the exhaust duct of the cylinder liner, and carbon deposits will also be formed.
4. Long-term low-load operation will cause more serious wear and tear of moving parts, deterioration of the engine’s combustion environment, and other consequences that lead to the advancement of the overhaul period.
Therefore, whether diesel generator manufacturers use naturally aspirated or supercharged models, they emphasize that low-load/no-load operation time should be minimized, and the minimum load must not be less than 25%-30% of the rated power of the unit.
Diesel generator set running at full load for a long time can not only improve its own performance, find potential safety hazards, but also avoid major accidents.
At present, the maintenance of diesel generators in the market refers to two aspects: damage repair and daily maintenance: repair refers to the replacement of various accessories or other methods for the failure of diesel generators or the replacement of diesel generators. The machine is overhauled to remove the carbon deposits in the unit; maintenance mainly includes regular replacement of the three filters to ensure that the unit’s various performance indicators are good.
With the development of the economy, the requirements for electricity consumption in various industries have become higher and higher, and it also reflects the current maintenance defects:
1. Maintenance is mainly aimed at repairing the unit after a failure. After repairing the failure, there is no effective means to re-test the unit with actual load. It is impossible to compare the unit before and after maintenance. Whether the unit can be used normally after the repair, I am not sure. At the end, the use of the unit after the next power outage cannot be completely worry-free. However, daily maintenance cannot simulate the operating conditions of the unit after a power outage, and failures only occur during the operation of the unit after a real power outage, so the maintenance itself cannot avoid the loss of the enterprise.
2. Maintenance refers to the replacement of the three filters and the no-load test of the unit at a specified period. From the perspective of replacing the three filters, the user is basically regular once a year, and the operating hours of the unit are the basis for replacing the three filters. Judging from the current maintenance methods, the operating time of the unit is less than 5 hours per year (without power failure), which is far less than the number of hours that need to be replaced by the third filter. Therefore, there is no scientific basis for using the annual replacement of the third filter. At the same time, it also increases the cost of the enterprise.
Therefore, the above maintenance methods are far from satisfying the needs of customers, no matter from the perspective of cost saving or electricity safety.
In response to the above situation, our company puts forward a new concept for daily maintenance: centered on preventive testing, and replacement of parts, overhaul or replacement of three filters should be based on the full load test machine. Preventive test refers to the regular full-load test of the unit that has been put into operation according to the specified test conditions, test items, and test cycle to discover the safety hazards of the unit in operation. It can simulate the real situation when the power is off and provide an objective basis.
Post time: Aug-23-2021