What Causes 1500kVA Generator Set Turbocharger to Overheat

Turbocharger is a very important component of diesel generator set, its quality directly affects the power and economy of diesel generator set. According to user feedback, the Turbocharger of some diesel generators often overheats or even burns red during use. This will affect the normal operation of the air intake system of the unit, reduce the power of the diesel generator set and increase the fuel consumption rate. The high exhaust gas energy of the unit is the main reason for the overheating of the turbocharger. This article focuses on introducing the main factors that cause the high exhaust gas energy of the 1500kVA generator.

1.Fuel leaking into the cylinder

When the relevant parts and components of the fuel injection system are damaged due to wear, corrosion, deformation, cracks, etc. during operation, the fuel leaks into the cylinder, resulting in too much fuel involved in combustion, and the atomization quality is poor, so that part of the fuel enters the exhaust manifold or turbine for combustion, resulting in too much waste gas energy. For example:

1) The sealing surface of the injector plunger and plunger sleeve is worn, and the amount of fuel leaked to the measuring cup is too much;

(2) The measuring cup of the fuel injector is cracked or seriously deformed;

(3) The sealing ring between the outer side of the fuel injector and the cylinder head mounting hole failed, and the fuel leaked into the cylinder from the copper sleeve of the fuel injector;

(4) The cylinder head has cracks, and the fuel directly leaks into the cylinder from the inlet and return passages.

2. A large amount of oil is involved in combustion

The fault is characterized by high temperature of cooling water and oil, black smoke from exhaust, and obvious diesel traces in the exhaust pipe in serious cases.

Oil is involved in combustion, usually in two aspects:

First, the turbocharger rotor shaft seal device failed due to wear, scratch, improper assembly and other reasons, and the oil leaked to the turbine to participate in combustion.

Second, there is too much oil in the cylinder, which may be caused by the fracture of the piston oil ring and the large amount of oil sprayed from the cooling nozzle under the cylinder sleeve entering the cylinder; It is also possible that the cylinder head is cracked and the pressure oil leaks into the cylinder from the lubricating oil passage. In severe cases, the temperature of the turbine will increase sharply, resulting in overheating or even burning red.

The fault is characterized by supercharger shell, oil temperature exceeding the normal temperature, blue smoke in the exhaust, and obvious oil traces in the exhaust pipe in serious cases.

3. The tightness of cylinder decreases

The fault is characterized by the power reduction of the diesel generator, black smoke from the exhaust, black smoke from the crankcase and irritating smell, and sometimes a dull knocking sound in the cylinder.

4. Injection timing is too late

If the fuel injection timing of the fuel injector is too late, the combustion process will be delayed, the explosion pressure in the cylinder will decrease, the indicated thermal efficiency will decrease, and the exhaust gas energy will increase. The failure is often caused by the wear of the components of the fuel injector drive mechanism and the improper adjustment of the fuel injection timing.

The fault is characterized by the reduction of the power of diesel generator set, the black smoke exhaust, and even the emergence of sparks.

5. Insufficient air intake

The insufficient amount of new air entering the diesel generator set will lead to incomplete fuel combustion. The common faults are air filter blockage, excessive valve clearance or incorrect valve opening.

The fault is characterized by the inability of diesel generator set to work and black smoke.

It is worth noting that in addition to the high exhaust gas energy mentioned above, which will cause the supercharger to overheat, the poor cooling quality of the unit and the improper operation and management of the unit will also cause the supercharger to overheat. In order to quickly and accurately determine the cause and location of the fault, users need to have a relatively clear understanding of the structure, connection relationship and working principle of the diesel generator, and have some working experience in managing the diesel generator, If you cannot handle the unit failure by yourself, Dingbo Power recommends that you seek professional help in time.