Common Faults in Gas Generators and Corresponding Solutions

Gas generators, known for their efficiency and eco-friendliness, have become an important power source in modern energy industries. By effectively utilizing fuels like natural gas, these generators not only provide reliable electricity but also contribute to combined heat and power (CHP) systems, improving resource utilization. As their application grows, gas generators are widely used in large power plants and industrial systems. However, in practical operations, various factors can cause a range of faults, affecting the stability and efficiency of the unit. Timely identification and resolution of these faults are crucial to ensure the long-term operation of the equipment.

Insufficient Load and Load Fluctuation

Insufficient load or fluctuating load is a common issue during the operation of gas generators. Load fluctuation usually means the generator cannot maintain a steady output, affecting power efficiency and causing frequent adjustments.

1. Causes

Clogged Exhaust Pipe: Blocked exhaust valves or pipes can hinder the exhaust flow, destabilizing the generator's load.
Misfiring Cylinders: If one or more cylinders fail to ignite properly, it can cause temperature instability and result in either low or high heat values.
Clogged Air or Fuel Filters: Blocked filters can disrupt proper air intake or fuel supply, destabilizing the generator's load.

2. Solutions

Check Pressure Difference and Airflow: Inspect the intake manifold pressure and the compressor's exhaust pressure. Low pressure differences may indicate a stuck bypass valve, which should be adjusted.
Inspect the Exhaust System: Ensure that the exhaust pipe and valves are clear of blockages and replace any damaged components.
Replace Faulty Sensors and Valves: If power signals, gas pressure, or filter pressure differences are abnormal, replace the relevant sensors, valves, or fuel filters.

Abnormal Cylinder Water Temperature

Both excessively high and low cylinder water temperatures can prevent the generator from operating properly and may lead to shutdowns. Temperature anomalies are often caused by failures in the cooling system, such as thermostat malfunctions, temperature sensor issues, or faulty cooling fans.

1. Causes

Thermostat Failure: A faulty thermostat may cause water temperature to drop, affecting engine start-up and performance.
Cooling Fan or Radiator Issues: Malfunctioning fans or accumulated dust in the radiator can reduce cooling efficiency, raising the cylinder water temperature.
Faulty Temperature Sensors: A defective sensor can lead to incorrect temperature readings, causing improper temperature control.

2. Solutions

Inspect the Cooling System: Check the temperature sensor, thermostat, and the cooling system's circuitry to ensure proper function.
Clean the Cooling Fan: Remove dust from the radiator and verify that the fan motor is operating correctly to ensure efficient cooling.
Replace Damaged Components: Replace any faulty thermostats or sensors and ensure proper electrical connections for optimal cooling system operation.

Abnormal Exhaust Temperature

Abnormal exhaust temperatures, either too high or too low, are usually caused by issues such as low cylinder pressure, ignition system failures, or clogged exhaust pipes. Such temperature abnormalities can degrade performance and may lead to overload conditions, damaging the generator.

1. Causes

Low Cylinder Pressure: Insufficient cylinder pressure can cause abnormal exhaust temperatures, often coupled with ignition issues, such as high-voltage coil or spark plug failures.
Clogged Exhaust Pipe: Blockages in the exhaust pipe can prevent smooth exhaust flow, leading to higher temperatures and overload conditions.
Ignition System Failure: Faults in the ignition system, such as malfunctioning spark plugs or ignition coils, can cause unstable ignition, leading to temperature issues.

2. Solutions

Inspect the Ignition System: Check and replace faulty components in the ignition system, including the high-voltage coil and spark plugs, to ensure proper ignition.
Clear the Exhaust System: Inspect and clean the exhaust pipe to ensure smooth airflow, preventing overload-related temperature problems.
Replace Faulty Sensors: Check the exhaust temperature sensor and replace it if necessary to ensure accurate temperature readings.

Difficulty Starting

Starting difficulties in gas generators are often caused by insufficient battery charge, ignition system failures, or electrical connection problems.

1. Causes

Low Battery Charge: Insufficient battery power can prevent the starter motor from generating enough power to start the generator.
Damaged Cables or Electrical Issues: Broken cables or circuit issues can affect the motor's ability to start.
Ignition System Problems: Faults in the ignition system or insufficient start-up pressure can cause difficulty in starting the generator.

2. Solutions

Check the Battery and Electrical System: Ensure the battery is sufficiently charged and inspect cables and motors for proper function to ensure smooth starting.
Inspect the Ignition System: Check the ignition system and fuel supply to ensure proper ignition and fuel flow.
Replace Damaged Batteries and Cables: If the battery is weak or cables are damaged, replace them promptly to ensure proper starting function.

Controller Alarms

Controller alarms are triggered when a system component fails and cannot function properly. Common causes include improper heating value settings, knock sensor failures, or carbon buildup.

1. Causes

Improper Heating Value Settings: If the heating value is set too high or too low, combustion efficiency may suffer, potentially leading to knocking.
Carbon Build-up: Carbon deposits in the combustion chamber or on the piston top can affect combustion efficiency, causing system faults.
Knock Sensor Failure: A malfunctioning knock sensor may fail to detect abnormal combustion, preventing precise control adjustments.

2. Solutions

Check Heating Value and Gas Concentration: Ensure that the heating value settings are appropriate and check the gas concentration to avoid incomplete or excessive combustion.
Clean Carbon Deposits: Remove carbon buildup from the cylinders, valves, and valve seats to ensure optimal combustion conditions.
Inspect Sensor Systems: Check the knock sensors and associated circuits to ensure proper functioning, replacing or adjusting them as necessary.

Conclusion

Gas generators, known for their efficiency and eco-friendliness, face some operational risks due to faults such as load fluctuations, abnormal cylinder water temperature, exhaust temperature anomalies, starting difficulties, and controller alarms. If not addressed promptly, these issues can lead to unstable operation, reduced efficiency, and even severe breakdowns. To ensure the proper functioning of gas generators, regular maintenance and timely fault resolution are essential. By following effective diagnostic and repair practices, the service life of the equipment can be extended, ensuring its stability and reliability and supporting the sustainable development of the energy industry.