Wear and Maintenance of Diesel Generator Sets

During the operation of a diesel generator set, there will be contact between relatively moving parts. Contact will lead to friction. Although lubricating oil is added and bearings are used for rolling or sliding, long-term friction will still cause wear on the contact parts of the contact components. This is called normal wear or natural wear.

You may have heard that a newly purchased diesel generator set has a certain running-in period when it is used. This is to allow a pre-wear process between the relatively moving parts, because running-in makes the operation coordination more perfect. Of course, further on, it will continue to wear until the gap increases to the point where technical requirements do not allow, and then repairs are needed.

During the entire running-in period, the load should be 50~80% of the 12h rated power, and the speed should not be greater than 80% of the rated speed. The running-in period of the diesel generator set is about 60 hours. During this period, it cannot be put into full-load operation. As long as the correct running-in specifications are adopted during this period, good running-in effect will be obtained, laying a good foundation for the stable wear of the equipment in the future.

Diesel Generator Set Stable Wear Stage

This is the normal stage of wear. If the working conditions of the parts remain unchanged or change little, the wear amount basically increases uniformly with time, and the wear rate is slow and stable. When the wear reaches a certain level and the parts can no longer work, the time of this stage is the service life of the parts. Improve the life of diesel generator parts.

There are many parts of a diesel generator, and some of these parts also rotate or move as the machine starts. Such as piston and cylinder liner, crankshaft and bearing, etc. Since these parts will move, they will naturally produce wear. We call this natural wear. This kind of wear is unavoidable, so we can only maximize their service life and exert the maximum value of these parts.

Whenever the cylinder liner, piston, piston ring, connecting rod bearing and crank are replaced, a short-term running-in should be carried out appropriately according to the above running-in conditions.

When the efficiency of the diesel generator set is significantly reduced, the accuracy is lost, and abnormal noise and vibration occur, some parts have reached their service life. It is most reasonable to carry out maintenance and replace parts. This can not only avoid accidents, but also minimize maintenance costs.

In fact, by correctly selecting the materials of the matching parts, adopting advanced and reasonable heat treatment methods, improving the processing quality and matching condition of the contact surfaces of the parts, improving cooling and lubrication, and timely maintenance, this kind of wear will be significantly reduced, thereby improving the working reliability of the diesel engine and prolonging its service life.

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