Air Fuel Ratio Controller of Diesel Generator Set

After the diesel engine is pressurized, the fuel supply of the fuel injection pump is increased, which makes it easy to generate black smoke during low speed, large load or accelerated working conditions. When operating under low speed, high load conditions, the exhaust turbine operates at low engine exhaust energy, and the compressor operates in a low efficiency zone, resulting in insufficient air supply, causing the exhaust to emit black smoke. When the load suddenly increases and the fuel supply suddenly increases, the supercharger speed cannot rise immediately, so that the amount of air entering the cylinder cannot keep up with the rapid increase of the fuel quantity, resulting in incomplete combustion and black smoke. To this end, the earlier-produced Cummins supercharged diesel engine also installed a vacuum air-fuel ratio controller (smoke limiter) on the PT pump, which can change the fuel entering the cylinder as the amount of air entering the cylinder changes. The amount of fuel is bypassed and the excess fuel supplied to the injector is bypassed to return it to the fuel tank, so that the air-fuel ratio is well controlled to match the amount of intake air to achieve fuel consumption and emissions.

The Cummins supercharged diesel engine produced in recent years uses a new air-fuel ratio controller. It can supply oil at any time according to the amount of air entering the cylinder, thus replacing the vacuum-type air-fuel ratio controller used in the early stage to limit the exhaust by means of fuel cut-off and residual oil splitting.

The air-fuel ratio controller is installed between the throttle valve and the fuel cut-off valve in the PT pump (as shown in Figure 5-84). In the PTG-AFC fuel pump, after the fuel leaves the throttle valve, it passes through the AFC unit and then reaches the shut-off valve at the top of the pump body. In the PTG fuel pump, fuel flows directly from the throttle valve through a passage to the shut-off valve.

The structure and working principle of AFC are shown in Figure 5-85. The fuel enters the AFC after it exits the governor and passes through the throttle. When the air pressure supplied by the turbocharger is not applied, the plunger 13 is in the upper end position, so that the plunger closes the main fuel circulation circuit, and the second passage of the position control of the regulating valve 6 without the inflation is supplied with fuel, such as Figure 5-85 (a). The regulator valve is installed directly on the throttle shaft in the throttle cover.

As the intake manifold pressure increases or decreases, the AFC plunger acts to proportionally increase or decrease the fuel supplied. When the pressure increases, the plunger descends, the gap between the plunger and the plunger increases, and the fuel flow increases, as shown in Figure 5-85(b). Conversely, when the pressure is reduced, the plunger gap is small and the fuel flow rate is reduced. This prevents the fuel-air mixture from becoming too rich and causing the exhaust to excessively emit black smoke. The position of the AFC plunger is determined by the interaction of the intake manifold air pressure acting on the piston and diaphragm with the proportionally moving spring.

Starlight Power Cummins generator power is 20kw to 2400kw.

Are you familiar with wind power generator and diesel generator?

There are many kinds of generator, for example, the most common generator is diesel generator, wind power generator, gasoline generator etc. Every kind of generator has its characteristic, we can know which is better by learning about them and comparing them. In this article, we mainly talk about wind power generator and diesel generator.

1.Wind power generator

Working principle:

Wind power generator is a electrical equipment which converting wind energy into mechanical work, the mechanical power drives the rotor to rotate, in finally, outputs alternating current. In generally, wind-driven generator set are composed of wind turbines, generators (including devices), directional regulators (tail wings), towers, speed-limiting safety mechanisms and energy storage devices.

The wind wheel rotates under the action of wind force, it converts the kinetic energy of the wind into the mechanical energy of the wind wheel axle, generator generate electricity driven by rotor shaft rotating. It can be devided into steam turbine, gas turnine and hydroturbine. Widely used as power engines for power generations, aviation, navigation, etc. Actually, the wind turbocharger is an air compressor, which increases the air intake through compressed air. It uses inertial impulse to increase engine output power.

Advantages :

A.Reducing environmental pollution and saving conventional energy such as coal and petroleum;

B.Clean, good environmental benefits, no harmful gases and waste are emitted;

C.Renewable, never exhausted;

D.Short construction period and flexible installation scale;

Disadvantages :

A.Ecologically, disturb birds. For example, grouse in Kansas, USA, disappeared after the windmill appeared;

B.Noise and visual pollution; Wind generators are generally relatively big and heavy;

C.It occupies a large area of land;

D.Unstable and difficult to control. In many places, winds are intermittent, if the winds are small, produced power electricity will be small, so that it maybe influence people to use electricity;

E.Not portable. If electricity supply is short, it can not be use as standby or emergency unit.

2.Diesel generator

Working principle:

In the air cylinder of diesel generator, The clean air filtered by the air filter is fully mixed with the high-pressure silent diesel fuel injected by the injector. Under the pressure of the piston upward, the volume of the diesel fuel decreases and the temperature rises rapidly, reaching the ignition point of the diesel fuel. Diesel fuel is ignited, mixed air burns rapidly and volume expands rapidly, which pushes forward plunger down, this called “ work”. Every air cylinder works in a sorted order, the thrust acting on the plunger passes through the connecting rod and becomes the force driving the crankshaft to rotate, thus driving the crankshaft to rotate. When the brushless generator is coaxially installed with the crankshaft of the diesel engine, the rotation of the diesel engine can be used to drive the rotor of the generator, using the principle of “electromagnetic induction”, the generator will emit the induced electromotive force, and the current can be generated through the closed load loop.

Advantages:

A.Fuel economy and high thermal efficiency;

B.Reliable and durable, can be used as prime, standby or emergency unit;

C.Wide range of applications. It is widely use for home, office, industry etc. Especially in some remote and power shortage places;

D.High thermal efficiency and low fuel consumption;

E.Compact structure and flexible installation location of supporting equipment.

Disadvantages:

A.The noise produced during the work is relatively large and the vibration amplitude is also large (But now there is silent type generator set, will reduce noise relatively);

B.The structure is complex, and the processing precision of parts and components is required to be high;

C.High fuel requirements. And the cleanliness of fuel is strictly required. It is difficult to use solid fuel or inferior fuel inside the cylinder.

Thus it can be seen, they all can supply power electricity, this is the same between them. The difference is : wind-driven generator is utilization of renewable resources, and very clean. While wind-driven generator set is not more portable than diesel generator set, wind generator set needs impact of airflow to drive the impeller to rotate, so that can supply electricity, it is some limited, constrained by the environment, the cost of installation is higher for home use. Diesel generator set is use diesel fuel, diesel fuel is common seen, very convenient to buy, the cost also can be accepted by many people.

Diesel generator set is limited in volume and easy to handle in daily use. In generally, we use forklift truck to handle. If some construction sites need to use diesel generators, this is also convenient to carry. Just find a car and pull it away directly. Wind generator set is bigger, after finishing installation, if we want to handle, it is more difficult.In the process of transfer, there will be a lot of constraints. In the mainland cities, this kind of wind generator set can not be used by everyone.
So if you need a generator for standby or emergency use, between wind-driven generator set and diesel generator set, it is more reasonable to choose diesel generator set.

What are the maintenance cycles of diesel generators?

Maintenance of diesel generator is always a big problem, whether before, during or after use, many users fail to maintain diesel generators regularly. However, the generator needs to be maintained and maintained regularly, otherwise it will easily cause many problems. In this article, Starlight will tell you in details about maintenance cycles and methods of diesel generator.

About diesel generator maintenance cycle, the user should should refer to manufacturer’s manual, it is mainly determined by running time. For diesel generators that are not frequently used, the maintenance cycle of generators is divided into daily, weekly, monthly, semi-annual and annual maintenance.

1.Daily maintenance of generator

A. Check fuel, coolant and lubricant leakage, whether they are leaking;

B. Check engine coolant heater. If the temperature is too low, the heater may not work, resulting in engine heating failure;

C. Check quantity of electricity of battery back.

2.Weekly maintenance of generator

A. Check generator lubricants and coolants;

B. Check quantity of electricity of battery back;

3.Monthly maintenance of generator

A. Check resistance value of air filter;

B. Check whether the generator has abnormal vibration, excessive exhaust gas, excessive noise or coolant, fuel leakage. Periodically conduct generator set test run, this can lubricate engine components, which can improve starting reliability; Prevent oxidation of circuit joints, and prevent consume fuel deterioration.When the standby genest runs without load, it the time in 10-15 minutes is good. Running at least twice a month;

C. Check whether radiator becomes less crowded and leakage;

D. Check fuel elevation and delivery system status;

E. Check the connection of battery pack line. When the proportion of battery liquid is less than 1.26, it should be charged;

F. Check whether the exhaust system leaks or has excessive resistance and discharge condensate liquid;

G. Check the resistance of intake ventilation of generating set;

H. Check whether the maintenance tools are complete.

4.Semi-annual maintenance of generator

A. Check engine lubricating oil quality and branch filter;

B. Clean or change crankcase, ventilation filter;

C. Eliminate mailbox liner, check whether oil hose is damage, check electrical safety control equipment and alarm;

D. Remove grease, lubrication, dust and other sediments from the generator set;

E. Check transmission line connectors, circuit breakers and switching switches;

F. Simulate power outage in city, verify start-up performance of unit, auto-switch for vehicle inspection and related configuration of standby power supply (this is only for generators with self-switching device).

5.Annual maintenance of generator

A. Check fan blades, pulleys and water pumps;

B. Fixture bolts of related parts of generator set;

C.Clean generator output and control box, check and tighten all line connections, measure and record generator winding resistance, check engine heater (if have). Inspection methods and standards should refer to generator operating instructions);

D. Manual operation to check main circuit breaker of generator;

E. If the generator set normally operates on no-load or light-load, the load will be increased by more than 5% at the rated load, and the unit will start for at least 4 hours a year;

F. In case of water intake or excessive humidity in the engine room, at least once a year should be thoroughly maintained, including replacement of oil, oil filters, clean air filters, replacement of water filters, diesel filters, etc.

After know about maintenance cycles of diesel generator, we should also know main points of maintenance, as follows:

1.Do well in daily inspection of diesel generators, mainly including fuel tank, fuel storage, to ensure that sufficient oil is added in time according to demand;

2.Regularly and timely inspect oil sump and engine oil level;

3.Ensure that the marking on the oil gauge can be achieved and supplemented according to the prescribed quantity in time;

4.Check water, oil and gas in time, the leakage of oil and water on sealing surfaces such as oil and water pipeline joints should be dealt with in time;

5.Eliminate the leakage of exhaust pipe, cylinder head gasket and turbocharger in time, and solve the problem from the root;

6.Aiming at installation condition, soundness, connection between anchor bolt and working machinery condition in time, to ensure reliability;

7.It is necessary to observe and inspect the instruments in time to ensure that the reading is normal and the failure is repaired and replaced in time.

The above five points are the key parts of regular maintenance and repair of diesel generators, which can ensure the timely operation of diesel generators and lay a foundation for extending the service life of generators.

Strict technical maintenance can remove potential hazard of diesel generators, ensure the generators can work normally in a good condition.

Attentions for Design of 30-3000kW Diesel Generator Parallel System and Installation

The design principles of 30-3000kw diesel generator includes: cooling system, lampstand, environmental protection equipment for diesel generators, diesel generator parallel system, flexible and reliable automatic switching system etc.

Now Starlight will share some attentions for diesel generator parallel system and installation.

1.The design of principles of diesel generator parallel system

The design of parallel optimization system for diesel generator sets adopts a parallel machine scheme with load distribution function for parallel machine monitoring system and parallel cabinet, it can be better to apply to large-scale parallel systems. We can accord to different requirement, for example, if apply to start-up of large power generator, the system can provide pre-start to meet the requirements. Aiming at the strong, weak and electromagnetic interference problems in parallel system, the design should use software filter and hardware filter to solve the problem. Adopt CAN bus methods to compare the digital quantities to achieve more effective active power allocation, this can avoid adverse effect to active power distribution by voltage loss in voltage load distributor.Aiming at different generator types to design and ensure reactive power distribution form. Aiming at the generator that uses AVR pressure regulating template, its reactive power distribution adopts software programming to increase voltage feedback to offset the adverse effects of temperature drift. In order to avoid impact on generator. In the parallel system, a zero power conversion design scheme is provided, that is, automatic synchronization between genset, zero power working for newly added genset, and then load transfer and average distribution are carried out smoothly according to the setting.

2.Attentions for parallel generator set:

(1)Before parallel genest, firstly must check whether the two genests meet follow requirements:

A.The RMS and waveform of generator voltage must be the same;

B.The phase of the voltage of the two generators is the same;

C.Two generators have the same frequency;

D.The phase sequence of the two generators is identical.

Only when meet the above four conditions and the parallel cabinet is used, the operation of diesel generating sets in parallel can be carried out.

(2)In addition to meeting the basic conditions for parallel generators, we also need to know about quasi-synchronous parallel method for generator sets, otherwise, will damage genest when doing parallel operation. Quasi-synchronous means accurate cycle. If use quasi-synchronous parallel method, the voltage of two generators must be the same, same frequency and same phase, this can be monitored by two voltmeters, two frequency meters and synchronous and non-synchronous indicator lights mounted on the synchronous disk to ensure the safe operation of generator sets..

When parallel diesel generator, it is not better to use manual parallel operation, because the success or failure of manual parallel depends on human experience, it is easy to cause safety accidents.

Generator should have installation conditions as follows:

Concrete foundation, intake louver, outlet louver, smoke exhaust outlet, smoke exhaust muffler, shock proof and expansion exhaust pipe installation location etc. And auxiliary equipment such as generator mailbox, battery, control screen, distribution cabinet should be near the generator equipment.

3.When install diesel generator, also need to attend something as follows:

A.All diesel generator has lampstand, in generally, adopt shock absorption measures on lampstand, the lampstand should be installed on concrete base;

B.The best way to install genset is to use concrete to place and fix generator set. It can make the genest run smoothly and reduce vibration. The bearing capacity of concrete foundation should be designed as 1.5 times of the genest’s dead weight in order to support the weight of the whole generator set and the dynamic impact load caused by the unbalanced force during the operation of the generator; the subsoil under the concrete foundation must also have enough bearing strength to bear the weight of the genest and the concrete foundation.

C.When the base use concrete, must measure its levelness with a level ruler when install, to let generator set is on a same level. There should be a special shock pad or sole bolt between the genest and the foundation.

D.The place of installation should keep excellent ventilation, there should be enough air intake at the generator end and good air outlet at the diesel engine end. Air outlet area should be more than 1.5 times larger than water tank (radiator) area;

E.The place around installation should keep clean, to avoid placing something which can produce acidic, alkaline and other corrosive gases and vapors;

F.Housing of generator set must have reliable protective earthing, for generator that needs neutral point direct grounding, the neutral point must be grounded by professionals and equipped with lightning protection devices. It is strictly forbidden to use the grounding device of municipal electricity for direct grounding of neutral points;

G.The arrangement of diesel generating units should conform to the essentials of process flow;

H.Before planning, designing and installing the generator set room, should select and purchase diesel generating set and control panel, know about installation engineering requirements of use instructions which provided by manufacture, if the site conditions do not meet all the requirements for generator set installation or have any question, must contact the manufacture for sure answer.

After installed genest, should use it according to the use instructions, so that can keep genest a long life service.

The cause of overspeed in a diesel generator

Diesel generating sets are mainly used in power supply of various prime, standby and emergency power sources, also can be used in electric power supply for electric propulsion system. Its importance is self-evident. When we use diesel generator set, it maybe a overspeed problem, this is a special fault, it will not only cause serious damage to spare parts, but also may endanger personal safety. What is the cause of overspeed and how to resolve the problem?

1.Fault phenomenon of diesel generator overspeed

Under normal operation, the engine speed suddenly rises, so that the engine speeds up beyond the rated speed and loses control, and emits a huge roar, the exhaust pipe emits a lot of black smoke or blue smoke.

1)Cause of failure

The fundamental cause of diesel engine overspeed is that diesel engine loses or changes its speed regulation characteristics. Faults of fuel injection pump and governor, such as stagnation or looseness of relevant components, will cause excessive oil supply and loss of normal speed regulation characteristics, while the combustion chamber entering additional diesel or oil will change the speed regulation characteristics of diesel engine.

A. Faults of Injection Pump and Speed Regulator

B. When assembling and repairing, impact the plunger, oil outlet valve seat of fuel injection pump, too much tightening torque will cause the deformation of plunger sleeve, impurities entering into the clearance of plunger pair, too thin gasket on the positioning bolt of plunger sleeve or too long bolt, which will cause the plunger of fuel injection pump to rotate inadequately or be stuck in the position of large oil supply;

C. Loosening of fixing screw for adjusting gear ring of fuel injection pump plunger which causes injection pump plunger loss control;

D. The ball head of the plunger adjusting arm or the gear rod adjusting arm of the fuel injection pump does not enter the adjusting fork groove, so that the plunger is in the position of large oil supply;

E. Accelerating pedal pull rod or oil supply adjusting gear rod and the movable part of governor are stuck, and oil quantity adjusting gear rod and speed adjusting pull rod are out of joint;

F. The excessive lubrication oil, too viscous or too dirty in the governor cause the weight of the governor can not be thrown out in time when the speed rises, which causes the pull rod or the gear rod to lose control of the governor;

G. Full speed governor can not be thrown away because of skew of flying ball seat or abrasion of inclined sliding groove of thrust plate transmission plate, which increases the sliding resistance of flying ball;

H. The springs of injectors are too weak or broken, which results in too low injection pressure and excessive fuel consumption in cylinders;

I. Flying ball Pin Shaft of governor broken off and flying ball flying off.

The above reasons make the speed of diesel engine increase, while the “speed characteristic” of plunger fuel injection pump increases the fuel supply with the increase of the speed, which leads to the vicious circle between the speed and the fuel supply, resulting in the occurrence of overspeed accidents.

2) Additional fuel enters the combustion chamber

A. Engine oil level too high causes excessive oil to rush into the cylinder then enter the combustion chamber to burn;

B. Serious wear of piston rings and excessive clearance of cylinder wall lead to a large amount of oil entering combustion chamber to burn;

C. Excessive gap between air door and its catheter coordination is too large, which cases oil for valve distribution chamber enter into combustion chamber to burn;

D. After cleaned air cleaner, the excessive residual gasoline makes the higher concentration gasoline vapor enter the combustion chamber to burn;

E. A diesel engine with a supercharger enters the combustion chamber to burn because of the damage to the oil seal of the supercharger;

F. The solenoid valve of the cryogenic starter leaks oil, which causes excess diesel oil to enter the combustion chamber to burn;

G. Horizontal diesel engine inclines seriously, causing oil to flow into the valve chamber and be sucked into the combustion chamber to burn.

3. Solution to overspeed fault of diesel generator set

1)Forced stoppage

Once the diesel engine has overspeed, the following measures should be taken promptly to force the diesel engine to stop immediately

A.Quickly retrieve the accelerating pedal to the stop position;

B.For fuel injection pumps with exposed rods or toothed rods, the rods should be quickly pulled back to the stop position;

C.For diesel engines equipped with decompression devices, the decompression handle should be quickly pulled to the decompression position, so that the diesel engine shuts down because of the uncompressed gas;

D.If a closing device is installed on the intake pipe, the extinguishing device shall be closed immediately or the intake port of the air filter shall be blocked quickly with cloth, and the fuel tank switch shall be closed to cut off the gas and oil circuit, stop the oil supply and gas supply, and cause the cylinder to be suffocated and shut down;

E.Put the transmission into the high gear in time, while trampling the brake pedal to the bottom, and slowly lift the clutch pedal, so that the engine is forced to extinguish.

2)After the generator stop working, to make a definite diagnose

A.If the acceleration pedal is raised rapidly, the engine will not continue to rise after reaching the maximum speed, the fault is the acceleration pedal rod or arm is jammed;

B.If the acceleration pedal is raised rapidly, the engine speed can not be reduced or extinguished immediately, usually the governor is out of order;

C.If the acceleration pedal is picked up, the engine speed continues to rise, indicating that the fuel injection pump has a fault;

D.If the fuel supply system is good, it means that there is extra fuel or oil entering the cylinder.

All above problems should by maintained by professional personnel.

Is it better to rent or buy diesel generator set?

600 kw Shangchai generator set manufacturer solves your worry.

To the person whose needs diesel generator set, they may meet some problem. The first problem is that whether it is better to rent diesel generators or not.It’s also expected to get you involved in this problem.

The problem seems very difficult. In fact, we can consider it from our own situation. Renting or buy diesel generator set all is to solve the problem of standby power supply. If you buy a diesel generator set by yourself, you will have the right to use it, and you put it on the place you need for a long time. If there is a blackout, the diesel generator set can immediately supply power as a standby power supply, so that you don’t need to contact the leasing company. It greatly shortens the time of power supply, it can reduce the risk brought to enterprises by unexpected situations.

This is a suggestion from a factory who produced 600kw Shangchai diesel generator set, not as a final decision to buy generators, it depends on your requirement. But whatever buy generator set or rent, we need to know some related common sense about diesel generator set. Only in this way, we can choose the right generator set and avoid unnecessary losses caused by misleading.

Starlight power company share some common sense here.

1.The demarcation power of generator set

The generator set generally supplied to customers are commonly used generator set. It can supply power to load for 12 hours with rated power. Users can use power to calibrate the generator set of the standby unit when the power failure is too frequent and the power supply time is not long. It operates at an average maximum power of 80% for no more than 200 hours per year, and at a maximum power of 100% for no more than 25 hours per year.

2.Load analysis

Many factors affect the size of selected generating units. Inside, the characteristics of system load is an important factor. Before leasing a diesel generator, users must carefully consider the following points:

3. Problems needing attention in matching generator sets with three-phase motors

Three-phase AC induction motors are the most commonly used in mechanical engineering. Because of their starting characteristics, these motors have direct power supply systems. If started directly online, surge current will be generated up to 6 times the click rated current. After the soft start device is installed, the starting current is very stable and will not impact the generator.

whether it is used as a common generator or a standby generator;
Consider the future increase in power consumption of the system;
The allowable voltage drop of the system;
The starting of the motor.

4. Care must be taken when starting an engine at low temperature

When the ambient temperature is too low or the engine does not need to be restarted for a long time, it will affect the normal establishment of the flow rate and oil pressure of the engine lubricant. At this time, it will take several minutes to idle after start-up, and it will not enter the normal working state until the oil pressure is normal.

5.At the same time, it is also necessary to avoid engine idling for a long time. The idling time should not exceed 5 minutes.

Intercooler generator oil extractor is equipped with water tank intercooler components. The air from the compressor of the supercharger does not enter directly into the intake pipe of the engine, but leads the supercharged air to the intercooler for water-air cooling. Compressed air is cooled to further increase its density, which is conducive to improving engine power and performance.

Is it better to rent or buy Diesel generators? If you are still struggling with this problem, go directly to the 600 kW Shangchai generator manufacturer Jiangsu Starlight Electricity Equipment Co.,Ltd., We will provide the best reply and service to you.

Low Voltage of Diesel Generator

Low voltage of diesel generator will affect the use of generator set, which is one of the common faults. This article will guide you to learn the factors that affect the voltage of generating set.

The unstable speed of the engine causes the unstable voltage of the generator set.

If the load on the generator set is too large, the voltage will be unstable.

The damage of the voltage regulator components of the generator causes the unit’s voltage instability.

The poor circulation of the fuel pipe of the genset causes the unstable speed of the engine, which causes voltage instability.

We recommend you to use the following methods to check and handle the low voltage fault of diesel generator sets.

If the contact surface of generator brush is too small and the voltage caused by poor contact is too low, it is necessary to check whether it is caused by the commutator surface, if it is, at low speed, to polish the commutator surface with sand cloth, or to adjust the spring pressure.

When the generator set is used, the voltage is too low. It may also be that thediesel generator speed is too low. In this case, you need to check the diesel engine speed. You only need to adjust the prime mover speed to the rated value.

During the process of using diesel generator set, the unit voltage is too low because the resistance of the excitation circuit is too large, and the resistance of the magnetic field rheostat is reduced to increase the excitation current. For semiconductor excitation generator, check if the additional winding connector is broken or connected incorrectly.

4, check whether the generator exciter brush is in the neutral line position. It is recommended to adjust the electric brush to the correct position, or to replace the brush to solve the problem of low voltage.

Check if there is a short circuit or ground fault in the stator winding or excitation winding of the generator set, and check the fault and clear faults in time.

Some rectifier diodes are broken down. It is necessary to deal with in time. Check and replace the broken diodes.

Starlight Power company mainly produces diesel generator set and has 43 years experience in power generating sets manufacturing. Main products include Volvo generator, Cummins generator, Perkins generator, Ricardo generator, and Yuchai diesel generator and so on. All our products are approved by CE/ISO. Gensets meet international applicable standard ISO 8528. According to customers’ requirements, we also provide installation, commissioning, training, and maintenance service.

DEUTZ Generator-Fuels of the Future 2018

DEUTZ continues to support the conference as one of its silver sponsors

Becoming the leading manufacturer of innovative drive systems with fuels of the future

DEUTZ presents the research results from two of its fuel projects

DEUTZ will be attending the 15th International Conference on Renewable Mobility, ‘Fuels of the Future 2018’, in Berlin on 22 and 23 January as one of the event’s silver sponsors. The Cologne-based engine manufacturer is thus underlining its commitment to the development of carbon-neutral drive systems. In combination with the electrification of its engine portfolio under the E-DEUTZ generator set strategy, DEUTZ aims to become the market leader in the field of innovative drive systems.

The conference, involving experts and representatives from industry, research institutes and trade associations, will focus on how to ‘decarbonise’ road use and on the essential transition to alternative technologies and fuels. During the conference, DEUTZ will present the results from two of its research projects.

In one project, carried out jointly with the University of Rostock, DEUTZ examined how EU IV emissions standard industrial and agricultural engines performed when run on biodiesel. The investigation concentrated, for illustrative purposes, on a DEUTZ TCD 3.6 industrial engine and on how the use of biodiesel affected exhaust after treatment. The results were used to issue approval in November 2017 for the use of biodiesel in all the latest DEUTZ model series with EU IV emissions standard exhaust after treatment systems.

The second project concerns a fundamental investigation of the injection and combustion behaviour of vegetable oil fuels and transferring their use to an EU IV/V emissions standard engine system. Partners in this project are Regensburg University of Applied Sciences in the east of Bavaria and the Straubing Technology and Support Centre. The presentation will cover the latest results of the investigation into the behaviour of modern common rail injection systems when run on vegetable oil. The second subproject then aims to demonstrate transferring the use of these fuels to an EU Stage V level DEUTZ TCD 4.1 fitted with an exhaust aftertreatment system on the engine test bench at the Regensburg University of Applied Sciences. This project is ongoing.

Alongside biofuels, which are already offering considerable potential for reducing greenhouse gases compared with fossil-based fuels, the main discussion topics to which DEUTZ will be contributing at the conference include research into, and the production of, various fuels from renewable energy sources. In future, it should be possible to achieve carbon neutrality in diesel engines by using synthetic fuels. There are already ways of producing synthetic diesel fuel using green electricity and a special electrolysis method (power-to-liquid). Because of its chemical composition, synthetic diesel fuel produced by this method can be mixed and used with fossil-based diesel in any ratio. Assuming these so-called ‘e-fuels’ can be produced on an industrial scale in future, diesel still has great potential, even in the longer term. In future, customers will be able to find the ideal system for their particular application from within the DEUTZ technology portfolio with its intelligent combination of electric and conventional drives. The aim is to achieve drive technologies that are efficient and carbon neutral in equal measure.

Normal Starting Procedure of Shangchai SC27G Diesel Engine

4.5.1 Normal starting procedure

The G series V type diesel engine can be started smoothly at temperature of -5°C and above. Starting procedure is as follows:

Disengage the diesel enginefrom the drive system. .
Put the mechanical operating devices into the ‘running’ position.
Push the governor controlling handle to unloaded position with speed at about 900 r/min.
Insert electric key and turn the switch from the OFF position to the START position to start the engine.if it cannot be started up in 10 seconds, turn the switch from the START position to the OFF position. Make another starting after 2 minutes. If the engine cannot be started up for three times, stop starting and refer to Section 6 for troubleshooting guideline to find cause. Each starting lasts 2 to 3 seconds.

Caution: The engine should be started without load.

After the engine has started up, the switch key goes back to the ON operation from the START position automatically. The oil pressure gauge should show reading within 15 seconds after the engine has started up; otherwise, stop the engine immediately to prevent damage to the engine and find the causes and remove the fault(s) according to Section 6 Troubleshooting Guidelines.
Having started up from a hot state, the engine should run at idle for l-3 minutes before being accelerated and loaded gradually. .
Having started up from a cold state, the engine should run at idle for 3-5 minutes. Increase engine speed slowly to 1,500 r/min and run the engine with partial load. Do not run the engine with full load until the outlet coolant temperature is higher than 75°C, oil temperature 50°C and oil pressure 0.40 MPa.

Caution: Especially starting the engine from a cold stat, increase the engine speed slowly as far as possible to have every bearing adequately lubricated and oil pressure stable.

Check the instruments during the engine running at idle to see whether they work normally.

Caution: Do not accelerate and load the engine immediately after it has been started up.

Caution: Do not idle the engine for a long period of time or it can cause problems to the engine. When an engine idles, the temperature in combustion chamber is low and combustion is not complete. It can cause carbon deposit in cylinder resulting in block of the orifices of fuel injector, as well as seizures of piston rings and valves, thus leading to engine performance deterioration.

Caution: If the engine is start by a jumper cable, parallel connection of the cable should be adopted by connecting the positive pole to the positive terminal and the negative pole to the negative terminal. If the engine is start by external power supply, the circuit breaker should be set to the OFF position. Take out the key to prevent accidental activation before connecting a jumper cable.

4.5.2 Cold Start

Cold start refers to starting the engine at temperature -50°C. Choose proper cold starting aid to warm the engine according to ambient temperature and then follow the normal starting procedures to start the engine. There are, in general, several ways to warm the engine:

Warming the engine oil and coolant to 40-50°C;
Installing a heating device in the air inlet pipe or heating air by fire at the entrance of the air inlet pipe, with which special precaution must be paid for safety;
Increasing the surrounding temperature of the engine room;
Using diesel fuel, engine oil and coolant that are suitable for cold areas;
Warming battery or using battery of larger capacity or having higher discharge rate (special battery for low temperature).

4.5.3 Staring after a longtime stop or replacement of lubricating oil

If the engine hasn’t been used for less than 30 days or its engine oil has just been replaced, it is necessary to fill the lubricating system with oil. Crank the engine and make oil enter moving parts. Start the engine only after you feel light when cranking the engine. Finish the following preparation before starting the engine according to the procedures of normal starting or cold starting:

Check the oil level for being within the dipstick marks range.
Check the voltage of the battery for abnormality.
Prime the fuel system. Refer to Section 5.3 for operation.
In order to have a quick starting of a standby engine for emergency need, start the engine every three to five days and operate it until its engine oil and coolant temperatures reach 60’C and above.

4.6 Engine Operation

Cautions for operation of the engine:

Pay frequent attention to oil pressure and coolant temperature. In case of any abnormality, stop the engine immediately for inspection.

Lubricating oil pressure:

150 kPa @ idle speed (minimum allowable)

300 kPa @ rated speed (minimum allowable)

500 kPa @ rated speed (maximum allowable)

Coolant temperature:

75-95°C (normal working range)

When engine overheating starts to happen that is indicated by the coolant temperature alarming, reduce engine speed or load or take the both actions until the coolant temperature falls down into the normal range; otherwise, find the cause and remove the fault as per Section 6 Troubleshooting Guidelines.
During the operation, especially sudden decrease of load, attention should be paid to avoid the failure of the governor, which can cause sudden increase of engine speed exceeding the defined value (usually called flying away).

Once such case happens, make an emergency stop first and then check for the cause.

Caution: Over-speed running will cause serious damage to the engine.

There are significant signs before most engine faults occur, such as changes in performance, sound, or engine appearance. Listening and observing will help detect in advance or predict some problems of the engine that will occur later, with which the proper measures can be taken in time to eliminate such problems as can lead to a serious engine failure.

Typical engine fault signs:

Engine misrires

Engine vibrates abnormally

Engine sounds abnormal

Engine coolant temperature and oil pressure change abruptly

Engine produces black smoke

Engine power output is insufficient

Engine oil consumption is too much

Fuel consumption is too much

There is leakage of oil, fuel or/and coolant

4.7 Engine Shutdown

4.7.1 Normal shutdown

If the engine has just worked at a high speed and heavy load for a long time, reduce its load and speed gradually and run it at idle for 5 minutes before stopping it to let the engine cool down evenly and turbocharger speed fall considerably so as to protect the engine and turbocharger. Turn off the fuel tank cock after the engine has stopped.

If the engine will not be used for a period of time (6 months at most), keep it properly. Refer to Section 7 for engine storage.

4.7.2 Emergency shutdown

Under emergency or special condition, make an emergency stop to avoid serious engine failure. Manually pulling of the emergency stop handle can achieve an emergency shutdown.

Troubleshooting Diesel Engine Cooling System

Cooling System for an engine is one of the most important parts. Each engine has its own cooling system. We use different cooling system for different engine. Water cooling, Oil cooling, Air cooling is most common cooling system. In this post I will discuss about the Diesel Engine Generator Water cooling system. If we burn diesel inside the engine then it will become hot. For this reason we use water inside the engine and it reduces engine inner temperature. This method name is Jacket Water Cooling System. Let’s learn more about this cooling system.

Shangchai W Series Engine Troubleshooting Guidelines III

Jacket Water Cooling System is normally two types: – a) Open Circuit Cooling System b) Close Circuit Cooling System.

Open Circuit Cooling System: Usually in this method the engine is cooled by water from the external source like ponds or water tanks.

Close Circuit Cooling System: In this method the water reserved inside the engine and the radiator or a heat exchanger is used to cool the water during engine running time.

Now I am going to discuss about the Engine Cooling System and I am going take an example of Caterpillar Diesel Engine Generators. Normally Caterpillar Diesel Engine Generators use Close Circuit Cooling Systems. Main parts of this cooling system includes jacket water transfer pump, radiator, coolie fan, thermostat, fan belt, radiator expansion tank, jacket water temperature sensor etc.

How Jacket Water Cooling System Works?:

Normally when the generator engine starts then the engine jacket water pump is turned on. This water pump use to drag the water from inside the engine and send it to the radiator and after cooling it send back cold water to the engine. When engine start, thermostat valve of cooling system stay closed, so that the engine water can just only flow inside the engine. After running for a while, the temperature of the water increased almost 80-850C then thermostat valve open automatically. Now the hot water from the engine goes to radiator. Air flows through the fan on the radiator and for this reason the radiator’s water become cold. After cooling, water goes back to the engine and cools the engine. However by using this cooling system some others hot areas use to cool like Lube Oil Cooler, Turbo Charger, Cylinder Head, Engine Liner and After Cooler.

Jacket Water Cooling System Problems and How to Solve?:

Fresh air movement is very important for this kind of engine. If the engine placed in a surround small place then cooling system will not work properly. The jacket water level at the engine’s radiator will be checked so that there is never water emptiness in radiator. Radiator water cannot be cold properly due to dust inside the radiator. For this problem sometimes the radiator should be cleaned. Check the radiator fan. If needed radiator fan belts need to be adjusting again. Should check jacket water pump is works properly or not. If the jacket water thermostat does not work properly then the water cannot go to radiator. Then the jacket water temperature will increase in the engine. So valve need to check and if needed change the thermostat valve. In the engine jacket water chemical must to be given. It protects the engine’s cooling system and prevents rust from other parts. In winter season the engine is usually stay cold so the engine’s jacket water temperature stay low. In this situation sometime the alarm came when the engine started. If the engine running little more time then the alarm goes away.

Five Tips for Winterizing Heavy-Duty Diesel Engines

Tip 1: Treat the fuel.

When preparing your fleet for winter, one of the most commonly overlooked items is the fuel itself. Fuel needs to be winterized, especially for trucks that are used throughout the winter.

Paraffin wax is present in all diesel fuels as a natural lubricity agent. Like any wax, as the ambient temperature of the fuel drops, the wax begins to form large square-shaped structures. These can come out of suspension and cause fuel to gel, which clogs the fuel filter.

To prevent gelling, use a cold-flow improver (CFI) that includes de-icers and wax anti-settling agents, which extend the operability of the fuel. But don’t overtreat. Additional treatments of CFI are more likely to inhibit the fuel’s performance than help.

A second option is to use a diesel fuel specially formulated for low temperatures, such as Cenex® winterized premium diesel fuels. Cold-flow improvers, de-icers and wax anti-settling agents are included in the additive packages for these fuels.

Tip 2: Drain the water separator and replace filters.

Water in the fuel system can reduce engine performance and damage components like fuel pumps and injectors. Avoid these issues by replacing water-absorbing filters and draining the water separator regularly. Fuel gelling can be an issue, but it’s water turning to ice in fuel storage tanks and filtration that typically plugs filters during the first couple of cold snaps.

Fill fuel and hydraulic oil tanks full to prevent condensation from forming during temperature and humidity changes.

Tip 3: Check the coolant system.

Regular preventive maintenance will reveal any issues before they become major problems. Check for radiator leaks, plugged or hardened hoses and cracked belts. Tighten any loose hose clamps. Check coolant levels and antifreeze strength.

Tip 4: Prepare the battery.

Old Man Winter can drain batteries quickly. If a battery is close to the end of a typical 48- to 72-month cycle, replace it. Clean battery terminals, and be sure connections are tight. If equipment will be stored over the winter, disconnect battery ground cables to prevent battery drain.

Tip 5: Clean and inspect the exterior.

Use a high-pressure washer to remove dirt, dust and residue, and grease unpainted metal parts to protect them from the elements. Then apply a wax to the surface, which will help repel snow, salt and road chemicals. Use a lanolin-based spray-on protectant to prevent rust and corrosion.