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Analysis of 11 incorrect operating methods of diesel generators
2024-02-22
Analysis of 11 incorrect operating methods of diesel generators
Diesel generator set is a power supply equipment that uses a diesel engine as the prime mover to drive a synchronous generator to generate electricity. This is a power generation device that starts quickly, is easy to operate and maintain, has low investment, and has strong adaptability to the environment. Nowadays, generators are used more and more widely, so you will definitely encounter various faults during use and operation. Here are 11 incorrect operating methods of diesel generators:
(1) Running under load without warming up after cold start
When the diesel engine is cold started, due to the high viscosity and poor fluidity of the oil, the oil pump supplies insufficient oil. The friction surface of the machine is poorly lubricated due to lack of oil, causing rapid wear and even malfunctions such as cylinder pulling and tile burning. Therefore, after the diesel engine is cooled and started, it should be run at idle speed to warm up, and then run under load when the standby oil temperature reaches above 40°C; the machine should be started in low gear, and sequentially drive for a certain mileage in each gear until the oil temperature is normal and the oil supply is sufficient. After that, you can switch to normal driving.
(2) The diesel engine runs when there is insufficient engine oil.
At this time, insufficient oil supply will cause insufficient oil supply to the surfaces of each friction pair, resulting in abnormal wear or burns. For this reason, it is necessary to ensure that there is sufficient engine oil before starting the machine and during the operation of the diesel engine to prevent cylinder pulling and tile burning failures caused by lack of oil.
(3) Emergency stop with load or stop immediately after sudden load removal
After the diesel engine stalls, the circulation of cooling water stops, the heat dissipation capacity decreases sharply, and the heated parts lose cooling, which can easily cause the cylinder head, cylinder liner, cylinder block and other mechanical parts to overheat, produce cracks, or cause the piston to overexpand and get stuck in the cylinder liner. On the other hand, if the diesel engine is stopped without idling to cool down, the friction surface will be insufficiently oiled. When the diesel engine is started again, poor lubrication will aggravate wear and tear. Therefore, the load should be unloaded before the diesel engine stalls, and the speed should be gradually reduced and run without load for a few minutes.
(4) The diesel engine slams the accelerator after cold start
If the accelerator is pressed hard, the diesel engine speed will increase sharply, which will cause some friction surfaces on the engine to wear violently due to dry friction. In addition, when the throttle is hit, the force received by the piston, connecting rod and crankshaft changes greatly, causing violent impact and easily damaging the parts.
(5) Operation when the cooling water volume is insufficient or the cooling water and engine oil temperatures are too high
Insufficient cooling water of the diesel engine will reduce its cooling effect, and the diesel engine will overheat because it cannot be effectively cooled; too high temperatures of cooling water and engine oil will also cause the diesel engine to overheat. At this time, the cylinder head, cylinder liner, piston components and valves are mainly subjected to large thermal loads, and their mechanical properties such as strength and toughness decrease sharply, which increases the deformation of the parts, reduces the fitting clearance between parts, accelerates the wear of the parts, and in severe cases Failures such as cracks and mechanical parts getting stuck may also occur. Excessively high temperatures of cooling water and engine oil will accelerate the aging, deterioration and burning loss of the engine oil, and the viscosity of the engine oil will decrease. The lubrication conditions of the cylinder, piston and main friction pairs will deteriorate, resulting in abnormal wear. Overheating of the diesel engine will also worsen the combustion process of the diesel engine, causing the injector to work abnormally, causing poor atomization and increasing carbon deposits.
(6) Operating when the cooling water and engine oil temperatures are too low
During the operation of the diesel engine, the cooling water temperature is too low, and the cylinder wall temperature drops accordingly. The water vapor generated by combustion condenses into water droplets, and contacts with the exhaust gas to generate acidic substances, which adhere to the cylinder wall, causing corrosion and wear. Practice has proved that when a diesel engine is often used at a cooling water temperature of 40°C to 50°C, the wear of its parts is several times greater than when it is operated at a normal operating temperature (85°C to 95°C). At this time, when the water temperature is too low, the temperature in the cylinder is low, and the ignition delay period of the diesel engine is extended. Once it catches fire, the pressure rises rapidly, and the diesel engine fuel is rough, which can easily cause mechanical damage to parts. The diesel engine has been running at a low temperature of the cooling water for a long time, and the gap between the piston and the cylinder liner is large, causing cylinder knocking and vibration, causing cavitation in the cylinder liner. The engine oil temperature is too low, the oil viscosity is high, the fluidity is poor, and the oil quantity in the lubricating parts is insufficient, which makes the lubrication worse, causing increased wear of the friction pair and shortening the service life of the diesel engine.
(7) Operating when the oil pressure is too low
If the oil pressure is too low, the lubrication system cannot perform normal oil circulation and pressure lubrication, and each lubricated part will not receive sufficient oil. Therefore, when the machine is driving, pay attention to the oil pressure gauge or oil pressure indicator light. If it is found that the engine oil pressure is lower than the specified pressure, stop the engine immediately and continue driving after troubleshooting.
(8) The machine is overspeeding or overloaded
If the machine is seriously overspeeded or overloaded, the diesel engine will operate under excessive load and high speed, which may easily lead to rough work. The thermal and mechanical loads on the cylinder liner, piston, connecting rod, etc. will increase, which may easily cause pulling. Cylinder, burning tiles and other faults. Frequent overload operation causes long-term rough combustion in the cylinder, which can easily damage the cylinder gasket.
(9) Press the accelerator hard before turning off the engine
If a high-speed diesel engine suddenly stops running, its huge inertia will damage the parts of the crank connecting rod mechanism and valve mechanism, shortening the service life. At the same time, slamming the throttle means that too much fuel enters the cylinder and has no time to be completely burned, so it flows down the cylinder wall, diluting the lubricating oil. In addition, it will also significantly increase the carbon deposits on the piston, valve and combustion chamber, causing the fuel injection nozzle to become clogged and the piston to become stuck.
(10) Suddenly add cooling water when the temperature of the diesel engine is too high
If cooling water is suddenly added when the diesel engine is short of water and overheated, cracks will occur in the cylinder head, cylinder liner, cylinder block, etc. due to drastic changes in cold and heat. Therefore, when the temperature of the diesel engine is too high, the load should be removed first, the speed should be slightly increased, the diesel engine should be turned off after the water temperature drops, and the water radiator cap should be loosened to remove water vapor. If necessary, slowly pour cooling water into the water radiator.
(11) Long-term idling operation
When the diesel engine is idling, the lubricating oil pressure is low and the cooling effect of the oil injection on the top of the piston is poor, resulting in a sharp increase in wear and easy cylinder pull. It can also cause poor atomization, incomplete combustion, severe carbon deposits, and sometimes even cause valves and piston rings to become stuck. , Cylinder liner cavitation. For this reason, some diesel engine operating instructions clearly stipulate that the idle running time of the diesel engine shall not exceed 15 to 20 minutes.
The above is an analysis of 11 incorrect operating methods of diesel generators. I hope it will be helpful to all customers and friends in their purchase and use operations.
Diesel generator set is a power supply equipment that uses a diesel engine as the prime mover to drive a synchronous generator to generate electricity. This is a power generation device that starts quickly, is easy to operate and maintain, has low investment, and has strong adaptability to the environment. Nowadays, generators are used more and more widely, so you will definitely encounter various faults during use and operation. Here are 11 incorrect operating methods of diesel generators:
(1) Running under load without warming up after cold start
When the diesel engine is cold started, due to the high viscosity and poor fluidity of the oil, the oil pump supplies insufficient oil. The friction surface of the machine is poorly lubricated due to lack of oil, causing rapid wear and even malfunctions such as cylinder pulling and tile burning. Therefore, after the diesel engine is cooled and started, it should be run at idle speed to warm up, and then run under load when the standby oil temperature reaches above 40°C; the machine should be started in low gear, and sequentially drive for a certain mileage in each gear until the oil temperature is normal and the oil supply is sufficient. After that, you can switch to normal driving.
(2) The diesel engine runs when there is insufficient engine oil.
At this time, insufficient oil supply will cause insufficient oil supply to the surfaces of each friction pair, resulting in abnormal wear or burns. For this reason, it is necessary to ensure that there is sufficient engine oil before starting the machine and during the operation of the diesel engine to prevent cylinder pulling and tile burning failures caused by lack of oil.
(3) Emergency stop with load or stop immediately after sudden load removal
After the diesel engine stalls, the circulation of cooling water stops, the heat dissipation capacity decreases sharply, and the heated parts lose cooling, which can easily cause the cylinder head, cylinder liner, cylinder block and other mechanical parts to overheat, produce cracks, or cause the piston to overexpand and get stuck in the cylinder liner. On the other hand, if the diesel engine is stopped without idling to cool down, the friction surface will be insufficiently oiled. When the diesel engine is started again, poor lubrication will aggravate wear and tear. Therefore, the load should be unloaded before the diesel engine stalls, and the speed should be gradually reduced and run without load for a few minutes.
(4) The diesel engine slams the accelerator after cold start
If the accelerator is pressed hard, the diesel engine speed will increase sharply, which will cause some friction surfaces on the engine to wear violently due to dry friction. In addition, when the throttle is hit, the force received by the piston, connecting rod and crankshaft changes greatly, causing violent impact and easily damaging the parts.
(5) Operation when the cooling water volume is insufficient or the cooling water and engine oil temperatures are too high
Insufficient cooling water of the diesel engine will reduce its cooling effect, and the diesel engine will overheat because it cannot be effectively cooled; too high temperatures of cooling water and engine oil will also cause the diesel engine to overheat. At this time, the cylinder head, cylinder liner, piston components and valves are mainly subjected to large thermal loads, and their mechanical properties such as strength and toughness decrease sharply, which increases the deformation of the parts, reduces the fitting clearance between parts, accelerates the wear of the parts, and in severe cases Failures such as cracks and mechanical parts getting stuck may also occur. Excessively high temperatures of cooling water and engine oil will accelerate the aging, deterioration and burning loss of the engine oil, and the viscosity of the engine oil will decrease. The lubrication conditions of the cylinder, piston and main friction pairs will deteriorate, resulting in abnormal wear. Overheating of the diesel engine will also worsen the combustion process of the diesel engine, causing the injector to work abnormally, causing poor atomization and increasing carbon deposits.
(6) Operating when the cooling water and engine oil temperatures are too low
During the operation of the diesel engine, the cooling water temperature is too low, and the cylinder wall temperature drops accordingly. The water vapor generated by combustion condenses into water droplets, and contacts with the exhaust gas to generate acidic substances, which adhere to the cylinder wall, causing corrosion and wear. Practice has proved that when a diesel engine is often used at a cooling water temperature of 40°C to 50°C, the wear of its parts is several times greater than when it is operated at a normal operating temperature (85°C to 95°C). At this time, when the water temperature is too low, the temperature in the cylinder is low, and the ignition delay period of the diesel engine is extended. Once it catches fire, the pressure rises rapidly, and the diesel engine fuel is rough, which can easily cause mechanical damage to parts. The diesel engine has been running at a low temperature of the cooling water for a long time, and the gap between the piston and the cylinder liner is large, causing cylinder knocking and vibration, causing cavitation in the cylinder liner. The engine oil temperature is too low, the oil viscosity is high, the fluidity is poor, and the oil quantity in the lubricating parts is insufficient, which makes the lubrication worse, causing increased wear of the friction pair and shortening the service life of the diesel engine.
(7) Operating when the oil pressure is too low
If the oil pressure is too low, the lubrication system cannot perform normal oil circulation and pressure lubrication, and each lubricated part will not receive sufficient oil. Therefore, when the machine is driving, pay attention to the oil pressure gauge or oil pressure indicator light. If it is found that the engine oil pressure is lower than the specified pressure, stop the engine immediately and continue driving after troubleshooting.
(8) The machine is overspeeding or overloaded
If the machine is seriously overspeeded or overloaded, the diesel engine will operate under excessive load and high speed, which may easily lead to rough work. The thermal and mechanical loads on the cylinder liner, piston, connecting rod, etc. will increase, which may easily cause pulling. Cylinder, burning tiles and other faults. Frequent overload operation causes long-term rough combustion in the cylinder, which can easily damage the cylinder gasket.
(9) Press the accelerator hard before turning off the engine
If a high-speed diesel engine suddenly stops running, its huge inertia will damage the parts of the crank connecting rod mechanism and valve mechanism, shortening the service life. At the same time, slamming the throttle means that too much fuel enters the cylinder and has no time to be completely burned, so it flows down the cylinder wall, diluting the lubricating oil. In addition, it will also significantly increase the carbon deposits on the piston, valve and combustion chamber, causing the fuel injection nozzle to become clogged and the piston to become stuck.
(10) Suddenly add cooling water when the temperature of the diesel engine is too high
If cooling water is suddenly added when the diesel engine is short of water and overheated, cracks will occur in the cylinder head, cylinder liner, cylinder block, etc. due to drastic changes in cold and heat. Therefore, when the temperature of the diesel engine is too high, the load should be removed first, the speed should be slightly increased, the diesel engine should be turned off after the water temperature drops, and the water radiator cap should be loosened to remove water vapor. If necessary, slowly pour cooling water into the water radiator.
(11) Long-term idling operation
When the diesel engine is idling, the lubricating oil pressure is low and the cooling effect of the oil injection on the top of the piston is poor, resulting in a sharp increase in wear and easy cylinder pull. It can also cause poor atomization, incomplete combustion, severe carbon deposits, and sometimes even cause valves and piston rings to become stuck. , Cylinder liner cavitation. For this reason, some diesel engine operating instructions clearly stipulate that the idle running time of the diesel engine shall not exceed 15 to 20 minutes.
The above is an analysis of 11 incorrect operating methods of diesel generators. I hope it will be helpful to all customers and friends in their purchase and use operations.
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