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柴油发电机常见故障维修诱因 工作原理分析

2012/5/17 9:27:43

                                       柴油发电机常见故障维修诱因 工作原理分析
 .发电机的故障检修
  为保证机组运行的可靠和性能,进行定期检查和必要时的维护是重要的,有组织的维护计划,需制定一按日程或时间排定的定期检查和测试项目表。必须强调,以下维护指导仅针对一般情况而言,由于有多种发电机组机型,任何机组的具体维护要求,需参照机其随机提供的说明书。
   柴油发电机的常见故障注意以下几点:
   1. 发电机不能起动的原因  
    (1)检查蓄电池电压是否达到额定电压DC48V  
  (2)检查蓄电池接线柱与连接电缆线是否接触不良。  
  (3)起动马达的正负极电缆线会产生接线不牢,因为在发电机运行时产生震动使接线松驰造成接触不良。  
  (4)燃油系统中有空气引起。
   2. 冷却水温度偏高故障   
  (1)通常是冷却水箱散热器表面不清洁引起冷却水箱内冷却液不足,发电机在使用较长时间后冷却风扇的皮带会逐渐老化变得毫无弹性或某条皮带断裂造成冷却风扇失去正常的吹风能力,这时需重新更换冷却风扇的皮带,更换时应该整组皮带一起更换而不是只换其中的某一条。   
  (2)冷却水泵故障导致冷却水不循环而使水温升高,是由于节温器故障不能张开,使冷却水水温变化时不能改变冷却水的循环路径,控制进入散热水箱冷却水的流量,达到调节冷却强度目的,此时需要更换节温器。   
  (3)使用不合要求的冷却液使冷却水管道积有水垢、铁锈之类等物阻碍冷却水的循环引起水温升高。
   3. 发电机排气冒黑烟   
  (1)使用燃油的质量差,含杂质多。   
  (2)环境灰尘杂物多,空气滤芯严重堵塞。   
  (3)发动机的喷油正时不对。
   4. 发电机排气冒蓝烟 
  一般都是滤清器中机油过多(在保养时机油添加过多)引起,减少机油至规定液位可解决。另外一种情况是:活塞环卡死或磨损过多,弹性不足使机油泄漏进入燃烧室燃烧所致。这需要清洗活塞环或更换泄漏部分的活塞环。
   5.发电机排气冒白烟   
  (1)燃油系统中含有水分引起。可对储油箱底部进行排放,查看有无水分。   
  (2)气缸气门磨损后对气流产生变化这时会排出带烟圈的白烟。此时必须要更换磨损部件。   
  (3)喷油嘴喷油雾化不良,柴油雾滴在燃烧室未燃烧。必须检查喷油嘴,调整至规定的喷油压力。
   .发电机的日常维护保养
   为了获得机组最大的运行安全性和使用寿命,对机组定期进行维护保养是必要的,如果能遵守机组维护保养的相关条例,就可保证机组的性能。
   (1)每天保养: 
  1、检查柴油发电机工作日报。   
  2、检查柴油发电机:机油平面,冷却液平面。   
  3、日检柴油发电机有无损坏、掺漏,皮带是否松弛或磨损。
   (2)每周保养:  
  1、重复每日的A级柴油发电机检查。   
  2、检查空气滤清器,清洁或更换空气滤清器芯子。   
  3、放出燃油箱及燃油滤清器中的水或沉积物。   
  4、检查水过滤器。   
  5、检查起动蓄电池。  
  6、起动柴油发电机并检查有无影响。  
  7、用空气枪及清水冼冷却器前后端的散热片。
   (3)有组织的维护
   有组织的维护使费用和工作量降到最低水平,因为它是有组织的定期进行,而不是在机组处于紧急状态时才要求进行的,定期维护的其它好处可能不会被明显地看见,由于潜在故障可能在其发展之前发现,这节约了大修费用。同时,由于机组总是运行在最佳状态,将减少运行费用并增加机组寿命。
   (4)维护程序  
  建议负责维护的人员,制定发电机检查和维护时间或日程表,汇总所有需于适当周期予以注意的部件。这样减少了相似项目的重复,以使机组停歇时间最少,更深层优点是这些停歇时间可调整安排在对常规现场活动影响最小时,通常是引擎或主要运动部件,需要经常注意,并建议所有维护周期应基于引擎的要求。每家引擎制造商均提供其设备维护的清楚、详细的说明,以及其维护所需周期。必须注意,引擎厂家提供的维护周期基于机房环境为清洁、干燥。如果机组运行在脏和/或潮湿的环境中,维护应该更加频繁,引擎和发电机的维护过程分别在其手册中给出,应经常观看这些维护过程和本节所述内容。
 
Principle analysis of common faults of diesel generator maintenance work incentives
I. generator troubleshooting
  To ensure reliable unit operation and performance, is important to carry out regular inspection and, if necessary, maintenance, organized maintenance plans, need to develop a schedule or time scheduled for periodic inspection and test list. It must be emphasized that following maintenance instructions are only for the General case, because of the variety of generator models, specific maintenance requirements for any unit, required reference the provided instructions.
   Common faults of diesel generator note the following several points:
   1. the generators not start because  
(1) check whether the battery voltage rated voltage DC48V  
  (2) check the battery post and the connection cable is bad.  
  (3) positive and negative pole cable starter motor wire be loose wiring because vibrates when the generator is running the wiring loose cause poor contact.  
  (4) due to air in the fuel system.
   2. high cooling water temperature fault   
  (1) usually is cooling water box radiator surface does not clean caused cooling water box within cooling liquid insufficient, generator in using more long time Hou cooling fan of belt will gradually aging became without elastic or a article belt fracture caused cooling fan lost normal of hair dryer capacity, then needed again replaced cooling fan of belt, replaced Shi should whole group belt together replaced and not only for which of a a article.   
  (2) cooling water cooling water pump failure will not cycle and increase the water temperature, is because of a thermostat failure can not open, circular path of cooling water does not change when cooling water temperature, control entry to the radiator cooling flow, achieve adjusting cooling strength of purpose, need to replace the thermostat.   
  (3) the use of unqualified cooling water pipes of cooling liquid product such as scale, rust, and so impede the circulation of cooling water temperature caused by.
   3. generator exhaust black smoke   
  (1) use poor-quality fuel, containing impurities.   
  (2) environmental dust debris, serious air filter clogging.   
  (3) fuel injection timing of the engine does not.
   4. the generator exhaust to risk blue smoke
  Are generally too much oil in the filter (adding too many maintenance timing oil) caused reduced oil to provide liquid can be resolved. Another situation is that stuck or excessive wear of piston rings, elastic due to the lack of oil leaking into the combustion chamber the burning. This needs to be cleaned or replace the leaking part of piston ring piston rings.
   5. the generator exhaust white smoke risk   
  (1) contains water in the fuel system causing.   Can storage Department of bottom emission, viewing with or without water.
  (2) the cylinder valve worn on air change now white smoke exhaust smoke rings.   You must to replace worn parts.
  (3) poor injector fuel injection spray, diesel fuel droplets in the combustion chamber is not burning. Nozzle must be checked, adjusted to the provisions of fuel injection pressures.
   II. the daily maintenance of the generator maintenance
   In order to get maximum operational safety and the use of unit life, regular maintenance is necessary on unit, if they can comply with the regulations unit maintenance, you can guarantee the performance of the unit.
   (1) daily maintenance:
  1, check the diesel generator working daily.   
  2, check the diesel generator: engine oil plane, cooling liquid plane.   
  Day 3, found mixed with diesel generators for damage, leakage, the belt is loose or worn.
   (2) the weekly maintenance:  
  1, repeat class a diesel generator to check on a daily basis.   
  2, check the air filter, clean or replace the air filter element child.   
  3, release the water in the fuel tank and fuel filter or sediment.   
  4, check the water filter.   
  5, check the starter battery.  
  6, starting of diesel generators and check for effect.  
  7, wash with air gun and water cooler before and after the end of the heatsink.
   (3) the organization maintains
   Organized maintenance workload and costs to a minimum level, because it is organized regularly, rather than request only if the unit is in a State of emergency, other benefits of regular maintenance may not be clearly seen, due to potential failures may be found to its development, which saves repair costs. At the same time, since the unit always running in an optimal state, will reduce operating costs and increase machine life.
   (4) maintenance program  
  Recommends that the persons responsible for the maintenance, inspection and maintenance time, or schedule of developed generator, summarizing all the appropriate cycle parts of the attention. This reduces duplication of similar projects, so that the unit stop time at least, deeper advantage is that these dead time arrangements can be adjusted at the time of least impact on regular on-site activities, usually the engine or the main moving parts, require constant attention, and recommends that all maintenance cycle should be based on the engine's requirements. Each manufacturer of engines provide clear, detailed descriptions of the equipment maintenance, as well as necessary for its maintenance cycle. It must be noted that engine manufacturers to provide maintenance intervals based on the room environment clean and dry. If the unit is running in dirty and/or humid environments, maintains should be more frequent, engine and generator maintenance procedures at its shown in the manual, should watch these maintenance procedures, and content in this section.

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