What are the negative impacts of low load operation on generator sets?

The design of the heat absorbing engine used in the generator set aims to generate electricity at the highest possible power from 30% to 100% of the rated maximum power. The actual load of the engine depends on the installation requirements of the power.

Consequences of uninterrupted operation in low load mode:

Continuous operation in low load mode can lead to an increase in fuel consumption, greatly increasing the deposition of carbonized oil or oil residue in the engine and exhaust system. The appearance and residue of oil residue can have adverse effects on the working performance and service life of the engine, often increasing maintenance work and costs.

In addition, when the engine is running in low load mode, the temperature cools down and the fuel can only be partially burned, while producing white smoke containing higher hydrocarbons.

Due to the lower fuel temperature, the proportion of unburned fuel in the fuel increases. These problems arise due to insufficient expansion of the piston ring, piston itself, and cylinder to ensure good sealing, resulting in an increase in oil level and discharge through the exhaust valve. Diesel entering the crankcase reduces the quality and performance of the lubricating oil.

Frequent and continuous use of generator sets with power loads less than 30% of the maximum power value may result in the following faults:

Increased smoke exhaust

There is a small amount of fuel in the engine oil

Excessive wear of turbocharger

Turbocharger body leaking oil

Transmission and crankcase pressure increase (air leakage)

Excessive carbon deposits on the surfaces of valves, valve seats, pistons, and exhaust manifolds

Cylinder liner surface hardening

If equipped with an exhaust gas treatment system (ATS), the reduced efficiency of the system may activate the forced regeneration cycle of the DPF

Suggested corrective measures:

To avoid accidents, please ensure the correct use of the generator set. It is recommended to avoid uninterrupted operation of the unit in low load mode or reduce such applications to the shortest possible time. Avoid using the generator set for more than 15 minutes under low load conditions.

During the weekly running test, the no-load running time should be limited to a maximum of 15 minutes until the battery level returns to normal levels.

The generator set should be operated at full load once a year for several hours to clean the engine, that is, to remove carbon oil deposits from the engine and exhaust system. This may require a resistive load, which should be gradually increased from zero to full load during the four hour operation.

If the above faults occur and the generator is used under low load conditions for a long time, it should be operated at full rated load. If possible, use a resistive load box to correct the problem before replacing any components.

Jiangsu Meao Power Technology Co., Ltd. is an important manufacturer of diesel generators. The company mainly manufactures and sells diesel generator sets with power of 3-3000kW, mobile power station of 24-600kW, Marine emergency diesel generator set of 24-800kW, gas generator set, heavy oil generator set and all kinds of imported series, special series (trailer, static speaker, mobile lighthouse, container, etc.) diesel generator At the same time, we are engaged in generator set maintenance and after-sale service of generator set accessories.