Recently, users have reported that the turbocharger of a 150 KW Cummins generator set has insufficient boost pressure during operation, mainly manifested as insufficient diesel power and black smoke from the exhaust. According to the analysis of professional technical engineers at Dingbo, the main reasons for the decrease in turbocharger boost pressure are as follows:
1. The increase in intake resistance is due to the presence of dirt in the air filter, intercooler, and intake volute;
2. The compressor speed has decreased due to carbon deposits in the turbine, increased exhaust resistance, bearing wear, and scratches and collisions between the rotor and the casing;
3. An increase in altitude.
Troubleshooting: When the boost pressure of the Cummins generator set booster is insufficient, the following maintenance should be emphasized:
1. Clean the air filter and intake duct. After the air filter or intake channel is blocked, the intake resistance of the compressor increases, leading to a decrease in boost pressure. The air filter of a turbocharged diesel engine must be cleaned in a timely manner, and the indicator of the air filter should be checked regularly to maintain its cleanliness.
2. Clean the intercooler and compressor. The accumulation of oil sludge and dust inside the intercooler and compressor will increase the intake resistance. When the pressure difference between the inlet and outlet of the intercooler exceeds 27kPa, its internal flow channels should be cleaned. When the volute and impeller of the compressor are stained with oil sludge and dust, they should be disassembled and cleaned regularly.
3. Remove carbon deposits. The carbon buildup inside the turbocharger increases the rotational resistance of the rotor, causing a decrease in the turbocharger speed and pressure. Carbon deposits usually accumulate in turbine blades, shafts, sealing rings, and other parts, usually due to poor sealing, oil leakage, sintering, and incomplete combustion of diesel engines.
4. Check the axial and radial clearances of the rotor to eliminate scratches and collisions. Excessive radial clearance of the rotor will result in the loss of lubrication conditions for the liquid, increasing the rotational resistance of the rotor and reducing the rotational speed; Excessive axial clearance or deformation of the rotor can cause scraping and collision, and the rotor speed will also decrease, leading to a decrease in boost pressure. So when disassembling and maintaining the turbocharger, the radial and axial clearances of the rotor should be carefully measured, and attention should be paid to observing whether there are any scratches or collisions. If the clearance exceeds the standard, the bearings should be replaced in a timely manner; If rotor scratches are found, the cause should be identified and replaced; The axial and radial clearances of the rotor should meet the standards.
Guangxi Dingbo Power Equipment Manufacturing Co.,Ltd is an early professional manufacturer of generators and diesel generator sets in China. The company has first-class national-level large-scale production and load testing equipment. Provide users with long-term diesel generator set sales, leasing, technical consultation, commissioning, maintenance, training services and generator set trusteeship business. If you would like to get more information welcome to contact us via sales@dieselgeneratortech.com.
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