1、 Security Warning
1. Before starting the diesel generator, all protective devices must be intact and undamaged, especially the rotating parts such as the cooling fan protective cover and the generator heat dissipation protective net, which must be correctly installed for protection.
2. Before operation, the control and protection electrical appliances and connection lines of the generator set should be installed and connected, and a comprehensive inspection of the generator set should be carried out to ensure that the diesel generator is in a safe state.
3. All grounding devices of the generator set should be ensured to be in good condition and reliably connected.
4. All lockable doors and covers should be secured before operation.
5. Maintenance procedures may involve heavy parts or life-threatening electrical equipment. Therefore, operators must undergo professional training, and it is recommended not to operate the equipment alone. Someone should assist during work to prevent accidents and promptly handle various situations.
6. Before equipment maintenance and repair, the battery power of the diesel generator starting motor should be disconnected to prevent accidental operation and personal injury caused by the diesel generator starting.
2、 Safe use of fuel and lubricants
Fuel and lubricating oil will irritate the skin, and long-term contact will cause damage to the skin. If the skin contacts the oil, it should be thoroughly cleaned with cleaning gel or detergent in time. Personnel who come into contact with oil related work should wear protective gloves and take appropriate protective measures.
1. Fuel safety measures
(1) Fuel addition
Before refueling, it is necessary to know the exact type and quantity of oil stored in each fuel tank, so that new and old oil can be stored separately. After determining the fuel tank and quantity, check the oil pipeline system, correctly open and close valves, and focus on inspecting areas where leakage may occur. Smoking and open flame operations should be prohibited in areas where oil and gas may spread during oil loading. Oil loading personnel should stick to their posts, strictly follow operating procedures, grasp the progress of oil loading, and prevent running, leaking, and leaking. Smoking is prohibited when adding fuel, and fuel should not be overfilled. After adding fuel, the fuel tank cap should be securely sealed.
(2) Selection of fuel
If low-quality fuel is used, it can cause the control rod of the diesel generator to stick and the diesel generator to rotate excessively, causing damage to the diesel generator set. Low quality fuel can also shorten the maintenance cycle of the diesel generator set, increase maintenance costs, and reduce the service life of the generator set. So it is best to use the fuel recommended in the operation manual.
(3) There is moisture in the fuel
When using commonly used generator sets or when the water content of fuel is relatively high, it is recommended to install an oil-water separator on the generator set to ensure that the fuel entering the body is free of water or other impurities. Because water in the fuel can cause rusting of metal components in the fuel system, and can also lead to the growth of fungi and microorganisms in the fuel tank, thereby blocking the filter.
2. Oil safety measures
(1) Firstly, oil with slightly lower viscosity should be selected to ensure normal lubrication of the machinery. For some generator sets with severe wear and heavy loads, slightly higher viscosity engine oil should be used. When injecting oil, do not mix dust, water, and other debris into the engine oil;
(2) Oil produced by different factories and of different grades can be mixed when necessary, but cannot be stored together.
(3) To extend the service life of the engine oil, the old oil should be drained when changing the oil. The used engine oil, due to high-temperature oxidation, already contains a large amount of acidic substances, black sludge, water, and impurities. They not only cause damage to diesel generators, but also pollute newly added engine oil, affecting their performance.
(4) When changing the oil, the oil filter should also be replaced. After long-term use, there will be a large amount of black sludge, particulate matter, and other impurities stuck in the oil filter element, which will weaken or completely lose its filtering function, fail to provide the necessary protection, and cause blockage of the lubricating oil circuit. In severe cases, it can cause damage to the diesel generator, such as shaft holding, tile burning, and cylinder pulling.
(5) Regularly check the oil level, and the amount of oil in the oil pan should be controlled within the upper and lower markings of the oil dipstick, not too much or too little. If too much lubricating oil is added, the operating resistance of internal components of the diesel generator will increase, causing unnecessary power loss. On the contrary, if too little lubricating oil is added, some components of the diesel generator, such as camshafts, valves, etc., cannot receive sufficient lubrication, resulting in component wear. When adding for the first time, slightly increase it;
(6) Observe the pressure and temperature of the engine oil at any time during operation. If any abnormalities are found, stop the machine immediately for inspection;
(7) Regularly clean the coarse and fine filters of the engine oil, and regularly inspect the quality of the engine oil.
(8) Thickened engine oil is suitable for severe cold areas and should be used reasonably. During use, thickened engine oil is prone to turning black, and the pressure of the engine oil is lower than that of regular oil, which is a normal phenomenon.
3、 Safe use of coolant
The effective service life of coolant is generally two years, and it needs to be replaced when the antifreeze expires or the coolant becomes dirty.
1. The cooling system must be filled with clean coolant in the radiator or heat exchanger before the generator set operates.
2. Do not start the heater when there is no coolant in the cooling system or the engine is running, otherwise it may cause damage.
3. High temperature cooling water can cause serious burns. When the diesel generator is not cooled, do not open the high heat and high pressure cooling water tank covers in the closed cooling system, as well as the plugs of the water pipes.
4. Prevent coolant leakage, as the result of leakage not only causes loss of coolant, but also dilutes engine oil and causes lubrication system malfunctions;
5. Avoid contact with skin;
6. We should adhere to using coolant year-round and pay attention to the continuity of coolant usage;
7. Select the type of coolant according to the specific structural characteristics of various diesel generators;
8. Purchase cooling liquid products that have been tested and qualified;
9. Different grades of coolant cannot be mixed and used;
4、 Safe use of batteries
If the operator follows the following precautions when using lead-acid batteries, it will be very safe. To ensure safety, it is necessary to operate and maintain the battery correctly according to the manufacturer’s recommendations. Personnel in contact with acidic electrolytes must wear protective clothing, especially to protect their eyes.
1. Electrolyte
Lead acid batteries contain toxic and corrosive dilute sulfuric acid, which can cause burns when in contact with the skin and eyes. If sulfuric acid splashes on the skin, it should be immediately washed with clean water. If electrolyte splashes into the eyes, it should be immediately washed with clean water and sent to the hospital for treatment.
2. Gas
Batteries can release explosive gases. So it is necessary to isolate flashes, sparks, fireworks from the battery. Do not smoke near the battery while charging to prevent injury accidents.
Before connecting and disconnecting the battery pack, follow the correct steps. When connecting the battery pack, connect the positive pole first and then the negative pole. When disconnecting the battery pack, remove the negative pole first and then the positive pole. Before closing the switch, ensure that the wires are securely connected. The storage or charging area for battery packs must have good ventilation.
3. Mixed electrolyte
If the obtained electrolyte is concentrated, it must be diluted with water recommended by the manufacturer before use, preferably with distilled water. A suitable container must be used to prepare the solution, as it contains considerable heat, ordinary glass containers are not suitable.
When mixing, the following preventive measures should be followed:
First, add water to the mixing container. Then add sulfuric acid slowly, carefully, and continuously. Add a little at a time. Never add water to containers containing sulfuric acid, as splashing out can be dangerous. Operators should wear protective goggles and gloves, work clothes (or old clothes), and work shoes when working. Cool the mixture to room temperature before use.
5、 Electrical maintenance safety
(1) All screens that can be locked should be locked during operation, and the key should be managed by a dedicated person. Do not leave the key in the lock hole.
(2) In emergency situations, all personnel must be able to use the correct methods of treating electric shock. Personnel engaged in this work must be trained and recognized.
(3) Regardless of who connects or disconnects any part of the circuit while working, insulated tools must be used.
(4) Before connecting or disconnecting a circuit, it is necessary to ensure the safety of the circuit.
(5) No metal objects are allowed to be placed on the diesel generator starter motor battery or left on the wiring terminals.
(6) When strong current flows towards the battery terminals, incorrect connections can cause metal melting. Any outgoing line from the positive pole of the battery,
(7) It is necessary to go through insurance (except for the wiring of the starting motor) before leading to the control equipment, otherwise a short circuit will cause serious consequences.
6、 Safe use of degreased oil
(1) Skimmed oil is toxic and must be strictly used according to the manufacturer’s instructions.
(2) Avoid touching the skin and eyes.
(3) Wear work clothes when using, remember to protect hands and eyes, and pay attention to breathing.
(4) If degreased oil comes into contact with the skin, it should be washed with warm water and soap.
(5) If degreased oil splashes into the eyes, rinse with plenty of clean water. And immediately go to the hospital for examination.
7、 Noise
Noise refers to sounds that are harmful to human health. Noise can interfere with work efficiency, cause anxiety, distract attention, and especially affect difficult or skilled work. It also hinders communication and warning signals, leading to accidents. Noise is harmful to the operator’s hearing, and sudden bursts of high noise can cause temporary hearing loss for workers for several consecutive days. Frequent exposure to high levels of noise can also lead to damage to the internal tissues of the ear and persistent, incurable hearing loss. Due to the noise generated during the operation of the generator set, operators should wear soundproof earmuffs and work clothes while working next to the generator set, and take corresponding safety precautions.
Regardless of whether soundproofing devices are installed in the generator room, soundproofing earmuffs should be worn. All personnel near the generator set must wear soundproofing earmuffs. Here are several methods to prevent noise damage:
1. Hang safety warning signs prominently in workplaces where soundproof earmuffs need to be worn,
2. Within the working range of the generator set, it is necessary to control the entry of non workers.
3. Ensure the provision and use of qualified soundproof earmuffs.
4. Operators should pay attention to protecting their hearing while working.
8、 Firefighting measures
In places with electricity, the presence of water is a deadly danger. Therefore, there should be no faucets or buckets near the placement of generators or equipment. When considering the layout of the site, attention should be paid to potential fire hazards. Cummins engineers will be happy to provide you with the necessary methods for special installation. Here are some suggestions worth considering.
(1) Everywhere daily fuel tanks are supplied by gravity or electric pumps. Electric pumps from long-distance large oil tanks should be equipped with valves that can automatically cut off sudden fires.
(2) The material inside the fire extinguisher must be made of foam and can be used directly.
(3) Fire extinguishers should always be placed near the generator set and fuel storage facility.
(4) A fire that occurs between oil and electricity is very dangerous, and there are very few types of fire extinguishers available. In this case, we recommend using BCF, carbon dioxide, or powder desiccants; Asbestos blankets are also a useful extinguishing material. Foam rubber can also extinguish oil fires far away from electrical equipment.
(5) The place where oil is placed should always be kept clean to prevent oil splashing. We recommend placing small granular mineral absorbers around the site, but do not use fine sand particles. However, absorbents like these also absorb moisture, which is dangerous in areas with electricity, as are abrasives. They should be isolated from fire extinguishing equipment, and staff should be aware that absorbents and abrasives cannot be used on generator sets or joint distribution equipment.
(6) Cooling air can flow around the desiccant. Therefore, before starting the generator set, it is advisable to clean it as thoroughly as possible or remove the desiccant.
When a fire occurs in the generator room, in some places, regulations stipulate that in the event of a fire in the computer room, it is necessary to remotely emergency stop the operation of the generator set to eliminate the occurrence of circuit leakage during the computer room fire. Cummins has specially designed remote shutdown auxiliary input terminals for generators with remote monitoring or self starting, for customer use.
Post time: Mar-06-2024