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6 Wrong Operations of Diesel Generator Set

Jul. 09, 2021

Many company did not formulate an operation specification for operate the generator set, which caused many wrong demonstrations in the actual operation, and accelerated the depreciation and damage of the unit to a certain extent. So Starlight list 6 common operating errors for everyone. We hope you could eliminate such phenomena in your work after you are familiar with them.

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1. Run with load without warming up after cold start

When a diesel engine cold engine starts, due to the high oil viscosity and poor fluidity, the oil pump is insufficiently supplied, and the friction surface of the machine is poorly lubricated due to lack of oil, causing rapid wear and even failures such as cylinder pulling and tile burning. Therefore, the diesel engine should run at idling speed and heat up after cooling and start, and then run with load when the standby oil temperature reaches 40℃ or above; the machine should start with low gear and drive for a certain mileage in each gear sequentially until the oil temperature is normal and the fuel supply is sufficient. After that, it can be switched to normal driving.


2. Diesel engine runs when the oil is insufficient

At this time, insufficient oil supply will cause insufficient oil supply on the surface of each friction pair, resulting in abnormal wear or burns. For this reason, it is necessary to ensure sufficient oil before the machine starts and during the operation of the diesel engine to prevent cylinder pulling and tile burning failures caused by oil shortage.


3. Sudden stop with load or stop immediately after sudden load removal

After the diesel engine is turned off, the circulation of the cooling water stops, the heat dissipation capacity is drastically reduced, and the heated parts lose cooling, which can easily cause the cylinder head, cylinder liner, cylinder block and other parts to overheat, produce cracks, or cause the piston to over-expand and become stuck in the cylinder liner. On the other hand, if the diesel engine is stopped without cooling at idle speed, the friction surface will not contain enough oil. When the diesel engine is restarted, it will aggravate wear due to poor lubrication. Therefore, before the diesel engine stalls, the load should be removed, and the speed should be gradually reduced and run for a few minutes without load.


4. After the diesel engine is cold started, the throttle is blasted

If the throttle is slammed, the speed of the diesel engine will rise sharply, and some friction surfaces on the engine will be severely worn due to dry friction. In addition, the piston, connecting rod, and crankshaft receive large changes when the throttle is hit, causing severe impacts and easily damaging parts.


5. Run under the condition of insufficient cooling water or too high temperature of cooling water or engine oil

Insufficient cooling water of diesel engine will reduce its cooling effect. Diesel engine will overheat because of ineffective cooling. Excessive temperature of cooling water and engine oil will also cause diesel engine to overheat. At this time, the main heat load of cylinder head, cylinder liner, piston assembly and valve is large, and their mechanical properties such as strength and toughness drop sharply, which increases the deformation of the parts, reduces the matching gap between the parts, and accelerates the wear of the parts. There will also be cracks and malfunctions such as machine parts jamming. Excessive temperature of cooling water and engine oil will accelerate engine oil aging and deterioration, and reduce engine oil viscosity. The conditional lubrication conditions of cylinders, pistons and main friction pairs will deteriorate, resulting in abnormal wear. The overheating of the diesel engine will worsen the combustion process of the diesel engine, causing the injector to work abnormally, poor atomization, and increasing carbon deposits.


6. Run under the too low temperature of cooling water and engine oil

During the operation of the diesel engine, if the temperature of the cooling water is too low, the temperature of the cylinder wall will drop accordingly. The water vapor produced by the combustion will condense into water droplets. It will contact the exhaust gas to generate acidic substances, which will adhere to the cylinder wall and cause corrosion and wear. Practice has proved that when the diesel engine is often used at the cooling water temperature of 40℃~50℃, the wear of its parts is several times larger than that of the normal operating temperature (85℃~95℃). 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 prolonged. Once a fire occurs, the pressure rises rapidly, and the diesel engine fuel is rough, which may cause mechanical damage to the parts. The diesel engine has been running under the condition of low cooling water temperature for a long time, and the gap between the piston and the cylinder liner is large, knocking has occurred, and vibration has occurred, causing the cylinder liner to appear cavitation. The oil temperature is too low, the oil viscosity is high, the fluidity is poor, and the lubrication part is insufficient oil, which makes the lubrication worse, causes the friction pair wear to increase, and shortens the life of the diesel engine.


In addition to paying attention to correcting and eliminating these irregular operating phenomena, companies should start to formulate a systematic operating specification, so that employees can be rationalized and based on evidence. There are many guidelines for the formulation on the Starlight official website for your reference, welcome to visit or send email to sales@dieselgeneratortech.com.

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