Common Issues in Generator Maintenance Practices 2

Continuing from the previous text, we will introduce the possible issues in generator maintenance for diesel generator users.

1. The phenomenon of "replacement repair" exists to varying degrees.

It is relatively difficult to judge and eliminate equipment faults. Some maintenance personnel have always adopted the method of replacement test. Regardless of large or small parts, as long as they think they may be the parts causing the fault, they replace them one by one for testing. As a result, not only the fault is not eliminated, but also the parts that should not be replaced are replaced at will, increasing the maintenance cost.

Some faulty parts can completely restore their technical performance through repair. For example, when faults occur in burners, gear oil pumps, etc., they can be repaired without complex repair processes. During maintenance, the cause and location of the fault should be carefully analyzed and judged according to the fault phenomenon. For parts that can be repaired, repair methods should be adopted to restore their technical performance, and the practice of blindly replacing parts should be eliminated.

2. Parts are often installed in reverse during equipment installation.

When repairing equipment, some parts have strict direction requirements for installation; only correct installation can ensure the normal operation of the parts. Some parts have no obvious external characteristics and can be installed in both directions. In actual work, reverse installation often occurs, leading to early damage of parts, abnormal operation of machinery, equipment damage, etc. For example, parts such as engine cylinder gaskets, fan blades, gear oil pump side plates, skeleton oil seals, thrust washers, thrust bearings, thrust pads, oil retaining rings, fuel injection pump plungers, etc., are most likely to be installed in reverse if the structure and installation precautions are not understood. As a result, the operation is abnormal after installation, leading to equipment failures.

3. Some maintenance units have irregular maintenance methods, "treating the symptoms but not the root cause".

When repairing diesel power generation equipment, some maintenance personnel do not adopt correct maintenance methods, replacing "repair" with "emergency treatment", resulting in "treating the symptoms but not the root cause". For example, "welding instead of repair" is a common case. Some irregular maintenance methods can only be used for emergency, but cannot be used for a long time. It is necessary to find out the root cause of the fault fundamentally and adopt regular maintenance methods to eliminate the fault, which should attract the attention of maintenance personnel. When determining equipment faults, the "exclusion method" and "comparison method" are generally used, following the order from simple to complex, from surface to internal, and from assembly to component. It is strictly forbidden to "blindly dismantle without asking the reason".

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