Our 1750kW diesel generators feature a 16 cylinder V-type engine coupled to a generator for emergency power supply. The engine is started by an air motor, which cranks it for approximately 4-5 seconds (up to 8 seconds max) before the engine kicks in on its own. Recently, we encountered an issue where the air motor failed to start the engine after 3 months of service. We replaced the air motor after ensuring adequate air pressure was available for normal cranking, and the second motor successfully started the engine. As a crucial emergency device, we aim to prevent future failures. How can we verify that the engine is not experiencing excessive torque during cranking? Which routine checks can help identify engine or air motor issues? Any assistance is greatly appreciated. Thank you.
It appears that you are in search of identifying the underlying reason.
Did you refer to the original equipment manufacturer's manual for guidance on conducting air motor inspections?
Have you been regularly running the generator? You mentioned it has been in service for the past 3 months, so I'm curious if it is still within the warranty period.
Did you perform a thorough inspection on the old air motor that was removed for any signs of damage? What caused it to malfunction? Were the issues resolved simply by replacing the old air motor with a new one? Is that the solution to the problem?
1. Was the air pressure adequate during start-up? 2. Was the SV energized? 3. Make sure to clean the teeth of the gear or pulley on the engine to prevent any foreign material from interfering with the engagement of the motor pinion. It is possible that there is an issue with the control valve. Generally, the motors are highly reliable and can run for many years without any issues. Kind regards, Irshad.
Periodic checks can go a long way in preventing future failures. For verifying the engine's torque during cranking, consider utilizing a torque meter; this tool can give you precise feedback. Overheating and unusual noises are also indicators of excessive torque. It's also worth checking if the engine compressor is functioning at its optimal level, as an underperforming compressor could increase the stress on the air motor. To identify potential issues with the engine or air motor, regular oil checks (for any metal debris which might hint at internal erosion) and vibration monitoring (to identify any imbalance in the system) could be insightful. Implementing a preventive maintenance schedule with these checks can really help extend the service life of your units.
You might want to consider monitoring the current draw of the air motor during the cranking operation as part of your routine checks. An unusually high current draw may suggest excess mechanical resistance during the engine start-up, which could indicate excessive torque. Additionally, carrying out a trend analysis on the cranking durations over time may help highlight issues. As for the air motor itself, a regular inspection for any signs of wear and tear, and verifying its operation under load conditions could be beneficial. Just remember, regular and proactive maintenance is crucial to preventing unforeseen failures in emergency power equipment.
Interesting scenario you're dealing with here. One way to check if the engine is experiencing excessive torque during cranking could be to install a torque transducer between the air motor and the engine. The torque transducer can continuously monitor and record the torque output, giving you real-time data to help identify potential issues. For routine checks, aside from the regular maintenance of the overall generator set, specific attention on the air starter system might be beneficial. Check for leaks, ensure all fittings are tight, and routinely test the air pressure. An inspection of the motor's inlet air filter could be helpful too, as a clogged filter could lead to insufficient air flow causing the motor not to start. An oil analysis of the engine could also be beneficial to detect any underlying engine issues. I hope this helps!
To verify that the engine isn't experiencing excessive torque during cranking, I'd suggest using a torque meter. It is a device that can measure and record the torque on a rotating system, like a generator. Also, to avoid repeated failures, you may think about implementing predictive maintenance which uses monitoring tools to track the condition of your engine and air motor. Regularly monitor the operating temperature, vibrations, and noise levels of the air motor. Over time, you'll likely be able to identify any patterns or anomalies that could signal a potential issue. Always remember, proactive maintenance is better than reactive.
It sounds like you're taking the right steps by replacing the air motor and ensuring proper air pressure! To monitor excessive torque during cranking, you might consider installing a torque sensor that can provide real-time data on the cranking process. Regularly inspecting the air motor's connection and ensuring all components are well-lubricated can also help. Don't forget to check for any air leaks in the system that could affect performance, as well as performing routine voltage and current checks to ensure the motor is drawing the correct power. Keeping a detailed log of these checks can also help spot patterns over time, which might lead to identifying underlying issues before they become critical.
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Answer: - To verify that the engine is not experiencing excessive torque during cranking, you can monitor the cranking speed and listen for any unusual sounds that may indicate excessive resistance. Additionally, checking the engine's manual for recommended cranking specifications can help ensure that the torque is within acceptable limits.
Answer: - Routine checks that can help identify engine or air motor issues include monitoring air pressure levels to ensure adequate cranking power, inspecting the air motor for any signs of wear or damage, testing the electrical connections for proper functioning, and conducting regular maintenance such as lubrication of moving parts. Keeping a log of these checks and promptly addressing any abnormalities can help prevent future failures.
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