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Wrong Operation of Diesel Generator Sets

Sep. 03, 2018

Diesel generator set is a kind of power equipment which uses diesel engine as prime mover and drives synchronous generator to generate electricity. It is a power generating device with quick start, convenient operation and maintenance, less investment and strong adaptability to the environment. Nowadays, the application of generators is more and more extensive, and there will be a variety of faults in the process of using them. Here is a brief description of some of the wrong ways to operate a diesel generator:

Wrong Operation of Diesel Generator Sets.jpg



1. After cold start, the machine is running with load. When the cold diesel engine starts, the engine oil viscosity is large, the fluidity is poor, the oil supply of the engine oil pump is insufficient, the machine friction surface is poor because of the lack of oil lubrication, resulting in sharp wear, even the trouble of pulling the cylinder and burning the tile. Therefore, the engine should be heated up at idle speed after cooling start, and the engine oil should be operated with load when the engine oil temperature reaches more than 40 ℃. The machine should start at a low speed, and run in sequence in each position for a period of mileage until the oil temperature is normal and the oil supply is sufficient before turning to normal operation.



2. When the diesel engine is running under the oil supply, the surface of the friction pairs will be insufficient, resulting in abnormal wear or burn. Therefore, it is necessary to ensure that the engine oil is sufficient before the start of the machine and during the operation of the diesel engine, so as to prevent the cylinder drawing and tile burning failure caused by the lack of oil.



3. The cooling system water circulation of the diesel engine stopped immediately after the sudden unloading of the load, the cooling system water circulation stopped, the heat dissipation capacity decreased sharply, the heating parts lost cooling, which easily caused the cylinder head, cylinder liner, cylinder block and other machine parts to overheat and produce cracks, such as the cylinder head, the cylinder liner, the cylinder block, and the other parts, such as the cylinder head, cylinder liner, cylinder block, etc. Or cause the piston to become too inflated and stuck in the cylinder liner. On the other hand, if the engine stops cooling without idle speed, the friction surface will lack of oil, and when the diesel engine starts again, it will be aggravated by poor lubrication. Therefore, the diesel engine should remove the load before flameout, and gradually reduce the speed, no load for a few minutes.



4. If the throttle of diesel engine starts at cold start, the speed of diesel engine will increase sharply, which will cause some friction surfaces on the diesel engine to be worn out because of dry friction. In addition, the piston, connecting rod and crankshaft accept great changes during throttle detonation, causing severe impact and easily damaging parts.



5. When the temperature of cooling water and oil is too low, the temperature of cooling water is too low, the temperature of the cylinder wall decreases, the water vapor produced by combustion condenses into water droplets and contacts with the exhaust gas to form acidic substances, which are attached to the cylinder wall. Cause corrosive wear and tear. It is proved by practice that when diesel engine is often used at 40 ℃ ~ 50 ℃ of cooling water, the wear of its parts is several times greater than that at normal working temperature (85 ℃ ~ 95 ℃). At this time, when the water temperature is too low, the cylinder temperature is low, the ignition delay period of the diesel engine is prolonged, the pressure rises rapidly once the engine is on fire, and the diesel engine fuel is rough, which can easily cause mechanical damage to the components. For a long time, the diesel engine operated under the condition of lower cooling water temperature, the gap between piston and cylinder liner was large, the phenomenon of cylinder knocking and vibration had occurred, and the cavitation corrosion appeared in the cylinder liner. The oil temperature is too low, the oil viscosity is large and fluidity is bad, and the lubrication part is insufficient, which makes the lubrication worse, increases the wear of friction pair, and shortens the service life of diesel engine.



6. The oil temperature is too low, the oil viscosity is large and fluidity is bad, and the lubrication part is insufficient, which makes the lubrication worse, increases the wear of friction pair, and shortens the service life of diesel engine. Cooling water, oil temperature is too high, will also cause the diesel engine overheating. At this time, the cylinder head, cylinder liner, piston assembly and valve are under heavy heat load. Excessive temperature will also cause diesel engine overheating. At this time, the main heating load of cylinder head, cylinder liner, piston assembly and valve is large, its mechanical properties such as strength, toughness and so on dramatically decreased, so that the deformation of parts increased, reduced the gap between parts, accelerated wear and tear parts, serious cracks will also occur, the parts stuck fault. In cooling water, excessive oil temperature will speed up the deterioration and burning of oil, and the viscosity of oil will decrease, and the condition lubrication conditions of cylinder, piston and main friction pairs will deteriorate, resulting in abnormal wear. The overheating of diesel engine will worsen the combustion process of diesel engine, make the injector work malfunction, bad atomization, and increase coke deposition.



7. When the temperature of diesel engine is too high, if the cooling water is suddenly added when the diesel engine is short of water and overheating, cracks will occur in the cylinder head, cylinder liner and cylinder block due to the drastic changes of cold and heat. Therefore, when the temperature of the diesel engine is too high, the load should be removed first, the rotational speed should be raised slightly, the diesel engine should be extinguished when the water temperature drops, and the cap of the water radiator should be unscrewed to remove the water vapor. If necessary, water radiators can be slowly injected into cooling water.



8. If the oil pressure is too low, the lubricating system can not carry out the normal oil circulation and pressure lubrication, and the lubricating parts do not have enough oil. Therefore, the machine in the course of driving, pay attention to observe the oil pressure gauge or oil pressure indicator. If the oil pressure is lower than the specified pressure, stop immediately, troubleshooting and then continue.



9. If the machine overspeed and overdrive, the diesel engine will run under the condition of excessive load and high speed, which will easily lead to rough work. The heat load and mechanical load of cylinder liner, piston, connecting rod, etc., will be increased. Easy to pull cylinder, burning tile and other failures. Often overload operation, resulting in a long period of rough combustion in the cylinder, easy to damage the cylinder pad.



10. If a diesel engine with heavy throttle running at high speed before flameout suddenly stops running its inertia will damage the parts of crank linkage and valve train and shorten its service life. At the same time, the throttle is that the fuel oil flows down the cylinder wall and dilutes the lubricating oil because there is too much time to completely burn into the cylinder. In addition, the piston, valve and combustion chamber will cause a significant increase in carbon deposits, causing nozzle blockage and piston jam.



11. When the engine runs at idle speed for a long time, the pressure of lubricating oil is low and the cooling effect of fuel injection on the top of piston is poor, which results in a sharp increase in wear and easy to pull the cylinder. It can also cause poor atomization, incomplete combustion, serious carbon deposition, and sometimes even lead to valve and piston ring stuck, cylinder casing cavitation corrosion.



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