冷卻水溫度高

　　High cooling water temperature

　　現(xiàn)象：站控值班人員發(fā)現(xiàn)燃?xì)獍l(fā)電機(jī)水溫偏高，相關(guān)人員隨即赴現(xiàn)場(chǎng)對(duì)發(fā)電機(jī)組進(jìn)行檢查，風(fēng)扇等冷卻系統(tǒng)正常，控制面板無(wú)報(bào)警。半小時(shí)之后，上位機(jī)出現(xiàn)該燃?xì)獍l(fā)電機(jī)冷卻水溫度高報(bào)警， 進(jìn)而造成停機(jī)。

　　Phenomenon: The station control duty personnel found that the water temperature of the gas generator was too high. Relevant personnel immediately went to the site to inspect the generator set. The cooling system such as the fan was normal, and there was no alarm on the control panel. Half an hour later, the upper computer triggered a high temperature alarm for the cooling water of the gas generator, resulting in a shutdown.

　　造成此次冷卻水溫度高原因分析：該燃?xì)獍l(fā)電機(jī)正常運(yùn)行時(shí)冷卻水溫度在89℃左右，當(dāng)負(fù)載有較大幅度的提升時(shí)，冷卻水溫度隨即上升，超過(guò)臨界值導(dǎo)致報(bào)警停機(jī)。

　　Analysis of the reasons for the high cooling water temperature this time: When the gas generator is running normally, the cooling water temperature is around 89 ℃. When the load increases significantly, the cooling water temperature immediately rises, exceeding the critical value and causing an alarm shutdown.

　　其他原因分析：（1）冷卻水管路存在結(jié)垢現(xiàn)象，導(dǎo)致冷卻水散熱不佳；（2）冷卻風(fēng)扇電機(jī)損壞，導(dǎo)致散熱不佳；（3）節(jié)溫器卡住或者其他原因?qū)е挛创蜷_(kāi)；（4）冷卻水管路或者接頭處漏水，冷卻水自然損耗液位降低導(dǎo)致冷卻水缺失；（5）冷卻水溫度傳感器故障，導(dǎo)致檢測(cè)結(jié)果失準(zhǔn)。

　　Other reasons analysis: (1) There is scaling in the cooling water pipeline, which leads to poor heat dissipation of the cooling water; (2) The cooling fan motor is damaged, resulting in poor heat dissipation; (3) The thermostat is stuck or not opened due to other reasons; (4) Leakage at the cooling water pipeline or joint, resulting in natural loss of cooling water and a decrease in liquid level, leading to a shortage of cooling water; (5) The cooling water temperature sensor has malfunctioned, resulting in inaccurate detection results.

　　功率轉(zhuǎn)換模塊故障

　　Power conversion module malfunction

　　現(xiàn)象：現(xiàn)場(chǎng)燃?xì)獍l(fā)電機(jī)奇才控制屏顯示“逆功”故障報(bào)警停機(jī)。站控上位機(jī)發(fā)電機(jī)功率曲線在停機(jī)瞬間有一處異常跳變現(xiàn)象。

　　Phenomenon: The control screen of the on-site gas generator shows a "reverse power" fault alarm and shutdown. There is an abnormal jump phenomenon in the power curve of the generator on the station control upper computer at the moment of shutdown.

　　原因分析：相關(guān)人員查看現(xiàn)場(chǎng)接線柜，檢測(cè)功率轉(zhuǎn)換模塊，4～20mA輸出存在問(wèn)題。經(jīng)過(guò)分析，可能沖擊電流導(dǎo)致功率轉(zhuǎn)換器故障。

　　Cause analysis: Relevant personnel inspected the on-site wiring cabinet, tested the power conversion module, and found that there was a problem with the 4-20mA output. After analysis, it is possible that the surge current caused the power converter to malfunction.

　　電機(jī)控制故障

　　Motor control malfunction

　　現(xiàn)象：奇才控制屏顯示“Motor Control Fault”故障報(bào)警信息。

　　Phenomenon: The Qicai control screen displays a "Motor Control Fault" fault alarm message.

　　原因分析：根據(jù)顯示屏提示的消息，打開(kāi)燃?xì)獍l(fā)電機(jī)組電機(jī)控制柜，經(jīng)過(guò)檢查陸續(xù)排除接線松動(dòng)及其他部件的損壞情況，針對(duì)IMO TDMD-X延時(shí)繼電器進(jìn)行檢測(cè)，發(fā)現(xiàn)延時(shí)繼電器ATR上電到指定時(shí)間后不能正常吸合，確認(rèn)為延時(shí)繼電器故障。更換延時(shí)繼電器之后，燃?xì)獍l(fā)電機(jī)正常運(yùn)行。

　　Cause analysis: According to the message displayed on the screen, open the motor control cabinet of the gas generator set, and after inspection, gradually eliminate loose wiring and damage to other components. Conduct a test on the IMO TDMD-X delay relay and find that the ATR delay relay cannot be closed normally after being powered on for the specified time, confirming a fault in the delay relay. After replacing the delay relay, the gas generator operated normally.

　　其他原因分析：冷卻風(fēng)扇故障。由于冷卻風(fēng)扇長(zhǎng)時(shí)間運(yùn)轉(zhuǎn)，軸承可能變形導(dǎo)致風(fēng)扇不工作， 此種情況同樣會(huì)引起電機(jī)控制故障報(bào)警。

　　Other cause analysis: Cooling fan malfunction. Due to prolonged operation of the cooling fan, the bearings may deform and cause the fan to malfunction, which can also trigger motor control failure alarms.

　　啟機(jī)失敗

　　Startup failed

　　現(xiàn)象：燃?xì)獍l(fā)電機(jī)在啟動(dòng)怠速轉(zhuǎn)動(dòng)一陣子后自動(dòng)停機(jī)。

　　Phenomenon: The gas generator automatically shuts down after idling for a while.

　　原因分析：（1）蓄電池電壓不足以帶動(dòng)燃?xì)獍l(fā)電機(jī)啟機(jī)；（2）燃?xì)獍l(fā)電機(jī)燃?xì)夤芫€至燃燒室之間的管路富含燃?xì)?，空氣不足，不足以點(diǎn)火燃燒；（3）點(diǎn)火系統(tǒng)故障，如點(diǎn)火線圈故障，火花塞受潮，火花塞端部孔隙堵塞；（4）啟動(dòng)馬達(dá)故障；（5）氣源壓力不足；（6）熱備系統(tǒng)未投用，導(dǎo)致燃?xì)獍l(fā)電機(jī)本體溫度過(guò)低；（7）陰潮環(huán)境，應(yīng)注意燃?xì)獍l(fā)電機(jī)的定期熱機(jī)。

　　Reason analysis: (1) Insufficient battery voltage to drive the gas generator to start; (2) The pipeline between the gas pipeline of the gas generator and the combustion chamber is rich in gas, and there is insufficient air to ignite combustion; (3) Ignition system malfunction, such as ignition coil failure, spark plug moisture, and blockage of spark plug end pores; (4) Start motor malfunction; (5) Insufficient gas source pressure; (6) The hot standby system has not been put into use, resulting in a low temperature of the gas generator body; (7) In cloudy and humid environments, attention should be paid to the regular heating of gas generators.

　　爆震

　　detonation

　　現(xiàn)象：現(xiàn)場(chǎng)控制屏出現(xiàn)“Knocking”故障報(bào)警信息。

　　Phenomenon: A "Knocking" fault alarm message appears on the on-site control screen.

　　原因分析：（1）氣缸燃燒室內(nèi)積碳過(guò)多，容易在積碳表面形成高溫著火點(diǎn)；（2）點(diǎn)火提前角過(guò)于提前，導(dǎo)致點(diǎn)火引燃混合燃?xì)獾臅r(shí)間早于活塞到達(dá)上止點(diǎn)的時(shí)間，從而在活塞壓縮沖程中壓力急劇升高導(dǎo)致爆燃的發(fā)生。同時(shí)，爆燃產(chǎn)生的壓力作用于活塞，影響活塞的沖程，導(dǎo)致爆震現(xiàn)象；（3）冷卻水溫度過(guò)高導(dǎo)致發(fā)動(dòng)機(jī)機(jī)體溫度高，散熱不良，產(chǎn)生高溫而發(fā)生爆震；（4）空燃比不正確等其他情況。

　　Cause analysis: (1) Excessive carbon deposition in the combustion chamber of the cylinder can easily form high-temperature ignition points on the surface of the carbon deposition; (2) The ignition advance angle is too early, resulting in the ignition of the mixed gas earlier than the time when the piston reaches the top dead center, leading to a sharp increase in pressure during the piston compression stroke and the occurrence of detonation. At the same time, the pressure generated by detonation acts on the piston, affecting its stroke and causing detonation phenomenon; (3) Excessive cooling water temperature leads to high engine body temperature and poor heat dissipation, resulting in high temperature and detonation; (4) Incorrect air-fuel ratio and other situations.

　　機(jī)組不能正常帶載

　　The crew cannot carry the load normally

　　現(xiàn)象：機(jī)組在切機(jī)加載過(guò)程中不能同步并機(jī)，無(wú)法帶載運(yùn)行。

　　Phenomenon: The unit cannot synchronize and operate with load during the cutting and loading process.

　　原因分析：（1）燃?xì)獍l(fā)電機(jī)輸出空氣開(kāi)關(guān)是否閉合狀態(tài)；（2）發(fā)電機(jī)出口斷路器系統(tǒng)GCB 復(fù)位按鈕是否彈出，如果彈出，直接按壓，然后再進(jìn)行同步并機(jī)加載。

　　Reason analysis: (1) Whether the output air switch of the gas generator is closed; (2) Does the GCB reset button of the generator outlet circuit breaker system pop up? If it pops up, press it directly and then perform synchronous parallel loading.

　　低油壓報(bào)警

　　Low oil pressure alarm

　　現(xiàn)象：站控上位機(jī)系統(tǒng)出現(xiàn)燃?xì)獍l(fā)電機(jī)低油壓報(bào)警，參照Wilson PG345B3型燃?xì)獍l(fā)電機(jī)正常運(yùn)行時(shí)油壓基本處于4.5MPa左右。

　　Phenomenon: The station control upper computer system has a low oil pressure alarm for the gas generator. Referring to the normal operation of Wilson PG345B3 gas generator, the oil pressure is basically around 4.5MPa.

　　原因分析：（1）機(jī)油管路滲漏導(dǎo)致機(jī)油壓力降低；（2）機(jī)油泵密封損壞或者機(jī)械損壞，導(dǎo)致 機(jī)油泄漏；（3）機(jī)油壓力探頭損壞，數(shù)據(jù)傳導(dǎo)出錯(cuò)。機(jī)油壓力探頭安裝在燃?xì)獍l(fā)電機(jī)機(jī)油濾芯附近，在震動(dòng)環(huán)境下易損壞，可以考慮將機(jī)油壓力探頭移出本體，架設(shè)在一個(gè)相對(duì)震動(dòng)不大的地方，以延長(zhǎng)探頭的使用壽命，減少故障發(fā)生。

　　Cause analysis: (1) Leakage in the oil pipeline leads to a decrease in oil pressure; (2) Oil pump seal damage or mechanical damage, resulting in oil leakage; (3) The oil pressure probe is damaged and the data transmission is incorrect. The oil pressure probe is installed near the oil filter element of the gas generator, which is prone to damage in a vibrating environment. It can be considered to remove the oil pressure probe from the body and install it in a relatively low vibration area to extend the service life of the probe and reduce the occurrence of faults.

　　防范措施

　　preventive measures

　　加強(qiáng)日常巡檢

　　Strengthen daily inspections

　　每日定點(diǎn)巡檢，重點(diǎn)檢查機(jī)組的各項(xiàng)參數(shù)，上位機(jī)系統(tǒng)可設(shè)置報(bào)警值。重點(diǎn)檢查燃?xì)獍l(fā)電機(jī) 的轉(zhuǎn)速、頻率、出口電壓、功率、機(jī)油壓力、冷卻水溫度以及蓄電池電壓等參數(shù)?，F(xiàn)場(chǎng)查看燃?xì)獍l(fā)電機(jī)冷卻風(fēng)扇的運(yùn)轉(zhuǎn)情況，冷卻水管路和機(jī)油管路的滲漏情況，同時(shí)查看機(jī)油液位和冷卻水液位。現(xiàn)場(chǎng)辨聽(tīng)燃?xì)獍l(fā)電機(jī)運(yùn)行時(shí)有無(wú)異常聲響。手持測(cè)溫槍對(duì)冷卻風(fēng)扇電機(jī)殼和氣缸進(jìn)行溫度檢測(cè)。

　　Daily fixed-point inspection, focusing on checking various parameters of the unit, and the upper computer system can set alarm values. Focus on checking parameters such as speed, frequency, outlet voltage, power, oil pressure, cooling water temperature, and battery voltage of the gas generator. On site inspection of the operation of the cooling fan of the gas generator, leakage of the cooling water pipeline and oil pipeline, as well as checking the oil and cooling water levels. Listen for any abnormal sounds during the operation of the gas generator on site. Use a handheld thermometer to measure the temperature of the cooling fan motor casing and cylinder.

　　維護(hù)保養(yǎng)

　　maintenance

　　參考Wilson廠商提供的燃?xì)獍l(fā)電機(jī)維保手冊(cè)，結(jié)合現(xiàn)場(chǎng)實(shí)際運(yùn)營(yíng)經(jīng)驗(yàn)，制定并嚴(yán)格執(zhí)行合規(guī)的維保規(guī)程。維保級(jí)別一般有首保，500h維保，1000h維保，2000h維保，4000h維保，8000h維保以及中修和大修維保。不同的維保級(jí)別對(duì)應(yīng)不同的項(xiàng)目檢查和部件更換。維保要做到全面，重點(diǎn)檢查氣門(mén)間隙，氣門(mén)凸出量調(diào)整，曲軸箱呼吸器清潔，火花塞檢查，正時(shí)傳感器清潔，延時(shí)繼電器和其他電氣元件的檢查，水路和油路的檢查等。同時(shí)，控制系統(tǒng)接線松緊度以及各傳感器探頭的檢查校準(zhǔn)。

　　Based on the maintenance manual provided by Wilson manufacturer for gas generators and combined with on-site operational experience, develop and strictly implement compliant maintenance procedures. The maintenance levels generally include first maintenance, 500h maintenance, 1000h maintenance, 2000h maintenance, 4000h maintenance, 8000h maintenance, as well as medium and major maintenance. Different maintenance levels correspond to different project inspections and component replacements. Maintenance should be comprehensive, with a focus on checking valve clearances, adjusting valve protrusion, cleaning crankcase respirators, checking spark plugs, cleaning timing sensors, checking delay relays and other electrical components, and inspecting water and oil circuits. At the same time, check and calibrate the tightness of the control system wiring and the probes of each sensor.

　　意外事件記錄分析

　　Analysis of Unexpected Event Records

　　生產(chǎn)運(yùn)營(yíng)過(guò)程中難免會(huì)遇到燃?xì)獍l(fā)電機(jī)意外停機(jī)現(xiàn)象，對(duì)故障問(wèn)題的精準(zhǔn)判斷直接關(guān)系到生 產(chǎn)經(jīng)營(yíng)活動(dòng)的恢復(fù)快慢。在燃?xì)獍l(fā)電機(jī)組運(yùn)行過(guò)程中，注重常見(jiàn)故障和其他故障的分類(lèi)總結(jié)、歸類(lèi)，制定一套事件應(yīng)急處置卡，針對(duì)不同的故障類(lèi)型編制不同的操作要求及部件更換。經(jīng)過(guò)長(zhǎng)期的意外停機(jī)事件積累，對(duì)于燃?xì)獍l(fā)電機(jī)的故障處理能力會(huì)有明顯的提升。

　　During the production and operation process, it is inevitable to encounter unexpected shutdowns of gas generators, and accurate diagnosis of the fault directly affects the speed of recovery of production and operation activities. During the operation of gas generator sets, attention should be paid to the classification and summary of common and other faults, and a set of emergency response cards should be developed. Different operation requirements and component replacement should be formulated for different types of faults. After long-term accumulation of unexpected shutdown events, the fault handling ability of gas generators will be significantly improved.

　　加強(qiáng)人員培訓(xùn)考核加強(qiáng)站場(chǎng)相關(guān)人員對(duì)燃?xì)獍l(fā)電機(jī)的掌握，逐步提高意外停機(jī)事件的應(yīng)急響應(yīng)機(jī)制和處理能力。通過(guò)崗位練兵和培訓(xùn)考核，保證專(zhuān)業(yè)人員對(duì)燃?xì)獍l(fā)電機(jī)的熟悉掌握。同時(shí)，可以定期舉辦人員交流，分享彼此燃?xì)獍l(fā)電機(jī)運(yùn)維經(jīng)驗(yàn)。

　　Strengthen personnel training and assessment, enhance the mastery of gas generators by station personnel, and gradually improve the emergency response mechanism and handling capabilities for unexpected shutdown events. Through job training and assessment, ensure that professionals are familiar with and proficient in gas generators. At the same time, regular personnel exchanges can be held to share each other's experience in gas generator operation and maintenance.

　　其他設(shè)備管理提升方面

　　Improvement in other device management aspects

　　針對(duì)站場(chǎng)燃?xì)獍l(fā)電機(jī)的實(shí)際情況，鼓勵(lì)相關(guān)人員提升設(shè)備管理能力。由于Wilson燃?xì)獍l(fā)電機(jī)的監(jiān)測(cè)系統(tǒng)并不完善，可以增設(shè)各種傳感器探頭完善相關(guān)的監(jiān)測(cè)功能，比如缸溫缸壓，廢氣溫度及燃燒點(diǎn)火時(shí)間等。同時(shí)，可以開(kāi)發(fā)專(zhuān)用軟件用于監(jiān)測(cè)燃?xì)獍l(fā)電機(jī)其他參數(shù)，比如維保參數(shù)，部件使用壽命參數(shù)等，可以合理有效地加強(qiáng)設(shè)備的管理水平，降低故障的發(fā)生。

　　Encourage relevant personnel to improve their equipment management capabilities based on the actual situation of gas generators in the station. Due to the incomplete monitoring system of Wilson gas generators, various sensor probes can be added to improve related monitoring functions, such as cylinder temperature and pressure, exhaust gas temperature, and combustion ignition time. At the same time, specialized software can be developed to monitor other parameters of gas generators, such as maintenance parameters, component service life parameters, etc., which can effectively strengthen the management level of equipment and reduce the occurrence of faults.

　　結(jié)束語(yǔ)

　　Conclusion

　　綜上所述，導(dǎo)致Wilson燃?xì)獍l(fā)電機(jī)運(yùn)行故障有多種原因，為了減少故障問(wèn)題的發(fā)生，需要加強(qiáng)相關(guān)人員的培訓(xùn)，嚴(yán)格執(zhí)行巡檢要求和維護(hù)保養(yǎng)規(guī)程。同時(shí)，善于總結(jié)各類(lèi)故障問(wèn)題，加強(qiáng)故障診斷能力，保障燃?xì)獍l(fā)電機(jī)的安全平穩(wěn)運(yùn)行。

　　In summary, there are multiple reasons for the operation failure of Wilson gas generators. In order to reduce the occurrence of failure problems, it is necessary to strengthen the training of relevant personnel, strictly implement inspection requirements and maintenance procedures. At the same time, being good at summarizing various fault problems, strengthening fault diagnosis capabilities, and ensuring the safe and stable operation of gas generators.

　　本文由  燃?xì)獍l(fā)電機(jī)組配件 友情奉獻(xiàn).更多有關(guān)的知識(shí)請(qǐng)點(diǎn)擊  http://www.dgtmcnc.com/   真誠(chéng)的態(tài)度.為您提供為全面的服務(wù).更多有關(guān)的知識(shí)我們將會(huì)陸續(xù)向大家奉獻(xiàn).敬請(qǐng)期待.

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