Causes of Redness in Exhaust Pipes and Superchargers of Cummins Diesel Genset

What is the reason for the red exhaust pipe and supercharger of Cummins diesel generator set? Next, Dingbo Power will take you to understand the causes and solutions of the red failure of the exhaust pipe and supercharger of the Cummins diesel generator set, so that you can have a better understanding of the diesel generator set.

1.Causes of red exhaust pipe

（1）Cause of surge

Generally, when selecting a supercharger, the compressor matching working line has been selected at the appropriate position on the right side of the surge line B based on the operating characteristics of different supercharging systems. At this time, it can not only ensure that the diesel generator meets the predetermined supercharging index and the supercharger operates in the high efficiency zone, but also ensure that the supercharger does not surge within the entire working range of the diesel engine.

（2） Obstructive factors

Due to the increase in fuel supply and exhaust gas energy, it is inevitable that the speed of the supercharger will increase, and the compressor exhaust volume and exhaust pressure will increase. At this time, the diesel generator has a low rotational speed and low air consumption, which breaks the balance between supply and demand between supercharger air supply and diesel generator air consumption. The back pressure of the compressor increases and the flow rate decreases, causing the supercharger to overheat and become red.

（3）Poor cooling

When the cooling capacity of the air cooler decreases, the exhaust temperature of the diesel generator increases, the compressor speed increases, and the coordinated operating point moves higher, resulting in a reduction in surge margin that can cause the turbocharger temperature to be too high.

2.Reasons for diesel generator supercharger turning red

(1)The injector or high-pressure oil pump precision coupling fails to work.

(2) The camshaft, follower arm assembly, and rocker arm assembly are excessively worn.

(3)The intercooler is too dirty and the air intake is insufficient.

(4)The supercharger fails.

(5)Poor sealing of the valve assembly.

3.How to handle the red exhaust pipe

(1)The arrangement of the exhaust pipe of the diesel generator set must be connected to the exhaust outlet of the unit through corrugated pipes to absorb thermal expansion, displacement, and vibration.

(2) When the muffler is placed in the machine room, it can be supported from the ground based on its size and weight.

(3) It is recommended to install an expansion joint at the part where the smoke pipe changes direction to offset the thermal expansion of the pipe during the operation of the diesel genset.

(4) The internal bending radius of a 90 degree elbow should be 3 times the pipe diameter. The more elbows, the greater the smoke exhaust resistance, and the greater the pipe diameter. If the design of the exhaust pipe for diesel generator sets is not reasonable, it can cause air pollution, noise, and other issues.

(5)The first stage muffler is as close to the genset as possible.

(6)When the pipeline is long, it is recommended to install a rear muffler at the end to reduce exhaust noise and eliminate sparks in the exhaust gas. The smoke exhaust terminal outlet should not be directly directed towards flammable substances or buildings.

(7) The smoke exhaust outlet of the unit shall not bear heavy pressure, and all rigid pipelines shall be supported and fixed by means of buildings or steel structures.

4.Maintenance Methods for Diesel Generator Turbocharger

(1)Observe for abnormal mechanical noise and vibration.

(2)Observe for high-frequency noise, if any, which may indicate an air or gas leak.

(3)Observe the level of periodic noise, which may indicate throttling in the air filter and pipes.

(4)Check whether nuts, bolts, pressure plates, and gaskets are missing or loose.

(5) Check the engine intake and exhaust pipes, their pipes, and fixings for looseness and damage.

(6) Check whether the lubricating oil inlet and outlet pipes are throttled or damaged.

(7) Check the turbocharger housing for cracks or damage.

(8) Check for leakage of external lubricating oil or cooling medium, and check for dirt deposits on the outer surface of the turbocharger (indicating leakage of air, lubricating oil, exhaust gas, or cooling medium).

After reading this article, we believe you have some understanding of the causes and solutions of the red exhaust pipes and superchargers of diesel generators. If you want to learn more about diesel generators, please contact us via email dingbo@dieselgeneratortech.com.