Comprehensive Pre-Startup Inspections for Diesel Generator Sets

 
In today's rapidly developing industrial society, the stability of electricity supply is crucial for the normal operation of businesses. Diesel generator sets serve as backup power sources, providing necessary electrical support when the main power source fails. However, to ensure that they can start quickly and reliably in emergencies, meticulous inspection and maintenance are indispensable. This article will detail the various pre-startup inspection procedures for diesel generator sets, helping businesses avoid potential risks and ensure the continuity and stability of the power supply.

The Importance and Methods of Engine Oil Inspection

 
Engine oil is the lifeblood of diesel generator sets, and its quality directly affects the engine's lifespan and performance. Checking that the engine oil level reaches the static full scale line on the oil dipstick in the oil sump is a basic step. Signs of deteriorating engine oil quality include a decrease in viscosity index, color turning black, the formation of gum, or deterioration due to the entry of coolant. If diesel is mixed into the engine oil, it will also lead to a decrease in viscosity.
 
The Dangers of Not Inspecting: If the deterioration of engine oil is not detected in time, it may lead to serious faults such as engine seizure or scoring, resulting in significant economic losses.
 
Identification Methods:
 
Water Content Check: Engine oil containing water will turn milky white, and it is necessary to quickly identify the cause and eliminate the fault.
 
Rubbing Check: Take a small amount of engine oil and rub it between your fingers to feel if the viscosity is normal, to determine whether it needs to be replaced.
 
Replacement Cycle: Replace the engine oil within 70 hours after a new unit or major overhaul, ensuring that the new engine oil and diesel are mixed in the appropriate ratio before being injected.

Diesel Inspection and Fuel Tank Management

 
Check the amount of diesel in the fuel tank to ensure that the generator set does not suddenly stop due to lack of fuel during normal operation. Lack of fuel can not only lead to exciter or generator faults but also cause piston seizure or damage to the exciter.
 
The Dangers of Not Inspecting: Sudden shutdown can lead to equipment damage and economic losses.
 
Management Suggestions: Regularly check the oil level to ensure there is enough diesel supply in the fuel tank.

The Necessity of Air Elimination

 
For generator sets that have not been used for a long time, it is necessary to eliminate air in the low-pressure oil circuit. The presence of air can affect the delivery of fuel, leading to difficulties in starting the generator or unstable speed.
 
The Dangers of Not Inspecting: Not eliminating air can lead to difficulties in starting the generator, affecting the frequency and stability of power generation.
 
Elimination Method: Loosen the fuel pump vent screw, unscrew the hand pump on the top of the fuel pump, and repeatedly press until diesel without air is discharged.

Maintenance of the Water Cooling System

 
The cooling system of water-cooled diesel generators needs regular inspection and maintenance. Filling the water radiator with water is a necessary step before starting to avoid high engine temperatures due to insufficient cooling water.
 
The Dangers of Not Inspecting: Insufficient cooling water can lead to damage to the cylinder gasket, affecting engine performance.
 
Maintenance Suggestions: Regularly check the level and quality of the coolant, and replace it if necessary.

Inspection of the Starting System and Battery

 
The starting system and battery are key to whether the generator can start normally. Check for any loose connections or insulation layer peeling in the control cabinet to ensure the reliability of the starting system and battery connections.
 
The Dangers of Not Inspecting: Connection faults can lead to the generator not starting or burning out the connection terminals, card, etc.
 
Inspection Suggestions: Regularly check the tightness of the connections and the integrity of the insulation layer.

Inspection of Carbon Brushes and Compression Springs

 
For brushed synchronous generator sets, the condition of carbon brushes and compression springs directly affects the performance of the generator. Regularly check the wear of carbon brushes and the elasticity of compression springs to ensure they meet the minimum requirements.
 
The Dangers of Not Inspecting: Poor condition of carbon brushes and compression springs can lead to insufficient generator power or unstable voltage.
 
Inspection Suggestions: Regularly check and replace worn carbon brushes, and adjust the elasticity of the compression springs.
 
Through the above comprehensive inspection and maintenance, the reliability and efficiency of diesel generator sets can be significantly improved, reducing the risk of faults. Regular inspection and maintenance are not only responsible for the equipment but also a safeguard for business operations. Investing in preventive maintenance can avoid costly emergency repairs and potential production interruptions, ensuring that businesses can respond quickly in the face of unstable power supply, ensuring the continuity and stability of business operations.