100Kva Gen Set Failure

It sounds as though the engine is working harder as the load comes up. That would increase the amount of work the turbocharger is doing. Why should anything be wrong with that?

Has it always done this?

What does the genset manufacturer's technical helpline say on the topic?

Thanx PWslack,It has not been doing like this before just started three days ago and the manufacturer was silent about the troubleshooting in the manual.THE TURBOCHARGER BECAME RED LIKE FIRE,WHEN LOAD REDUCED 30-40% THE REDNESS DISAPEAR

Please turn off Caps Lock.

What happens when the manufacturer receives a telephone call on the topic?

Have you been following your maintenance schedule?

The troubleshooting list for overheating is pretty straight forward.

Coolant?

Oil?

Maybe some help here.

The schedule has always been carried out according to specification,Could it be nozzle problem?the line to manufacturer is not through since the problem started

Why is it perceived to be a problem? Isn't the turbocharger supposed to do some work?

Is the manufacturer on-board with this perceived problem? If not, why not?

Red hot seems like it may be running a little too warm.

Without the original poster discussing it with the manufacturer and reporting here, one might never know for certain.

It could be lots of things. Check the coolant medium/flow to the turbocharger itself.

Is the turbocharger a Honeywell? Try checking with them directly. Or try to find the nameplate on the turbocharger, and contact whoever the manufacturer is.

It sounds like you've been abandoned by the people that sold you the unit.

Your problem is probably similar to this. If you continue to run it hot, you will ruin it..........................if it isn't already too late.

If maintenance schedule is there, generator room ventilation is good and air filter doesn't choke, try to check;

1. turbocharger exhaust coupling inlet, any choked or blockage?
2. check the valve lash.
3. check individual cylinder exhaust temperature?
4. If exhaust temperature on individual cylinder in great different, check the injectors.

And also do load test on site 50%, 70% and 100%, take reading of;

1. Engine power?
2. fuel rate (LPH)?
3. intake MFLD temperature?
4. intake manifold kPa?
5. intake air-flow m3/min?
6. exhaust stack temperature?
7. exhaust gas flow m3/min?

Then made comparison base on to standard operation manual or manufacturer performance data.
Note: if your generator is using advance ECU controller, all data said can be captured, however if your generator set using conventional starter and old version its is advisable to take amp, load, kW, fuel rate and temperature.

<...the line to manufacturer is not through since the problem started...>

Is there a problem with the telephone service in that location? What is it?

deletolaide,

Maybe nothing has gone wrong.

Have you been viewing the turbocharger under medium to bright ambient light and are now for some reason viewing the turbocharge in dim or no ambient light?

Under load a turbo will glow red.

The turbo after all is handling 1100F to 1200F exhaust gas right out of the cylinders.

Just a thought.

Regards - KJK

Good thinking.

Exactly. The manufacturer will know whether this is normal or not.

I think they're out to lunch.

Perkins four stroke, basic, basic first.

Replace your air filter, even if it has been done recently. This is the first place to look when you have an overheating turbo.

Tim

Exhaust restriction AFTER turbo. Stiff bearings slowing turbo, due to cheap old oil Turbos are the worst for oil Buy the BEST available. Do you NEED the turbocharger? It just increases horsepower by stuffing more air into the cylinders.

It is over heating most likely but what ? the turbocharger or the exhaust ? For a start I would suggest trying to locate the source of o/heating. If its the engine it could be a ignition timing problem probably from a slightly worn out cam .

Red hot turbo charger is not that strange for prolonged high output operation.

We don't know whether this is now happening under the same loads where it never happened before or if the load has increased and it is now only working as hard as it was intended. Diagnosing sight unseen has its limitations.

As for contacting the manufacturer.... the OP said it was Perkins. Nuff said. Forget about any help from that lot.

Check to see if the exhaust system is restricted after the turbo. If the turbo is red hot the engine valves are also getting too hot. If there is an advance function on the fuel system maybe it is in the retard position that will heat exhaust components considerably. The plugged exhaust I have seen a lot although not on Perkins but Deutz it is quite common on older engines. Check the engine timing if exhaust is clear.

Is it a new set or was working earlier perfectly?. How much load(full or less) you are applying?. Are you applying the total load in single step?. Is the load equal to continuous or prime or standby rating?. If standby rating you should not apply full load suddenly.

problem related to red hot turbo charger problem

01) check the air system impeller side out let for any leakage if air is leaking it turn to red hot turbo charger

02) check turbo condition

03) check aftercoolar for choke

04) check tappet setting

problem is truly related to air system.

if air is not sufficient more fuel is injected to cylinder maintain rpm which cause black smoke and red hot turbo charger.

I know of one installation performed with OEM engineers where the turbo was red when the engine was performing exactly as designed. The complaint from the buyer. was solved by a cover over the turbo so the red would not be visible, since the turbo was running exactly as designed. Problem solved. (It was considerably larger than 100kva.) What exactly was the "failure"?

have u serviced the generator and changed the fuel and oil filters? Check your turbo charger if the blades of fan bearings are free or stiff or not moving.Check your air filters and change or replace with good ones if they are choked or worn out as they may not be able to take in and filter enough air.Also ensure that your gen is not overloaded beyond its rated power.

Patrick whowha

What is the actual performance data? Is the fuel consumption within specified limits? Are there unusual noises and/or vibrations connected with this "problem"? Are there other parts of of the system showing signs of overheating? Is the power output stable under constant load and responsive to varying load? Is the "redness" of the turbocharger the only sign of improper functioning?

So far there is no description of the problem.

Also check whether the current,pf,voltage,power and frequency are within nameplate limits as well as constant or varying widely.

hi Is there proper ventilation for the generator. what is ambient temperature and temperature near air filter. check for fresh air entry and hot air outlet from radiator. if hot air is recirculating rectify it.

OP has not told us what the load is or was? Has he even checked?

I wonder if he has replaced the air filter yet as rationally suggested by others.

However, I still think it's OK. My experience with choked air filters involved flames coming out of the exhaust. A little rich? Filter was choked with Bogong Moths. All good once sorted and that turbo charger (on a CAT 1MVA) always glowed at night.

I faced this kind of situation, address to one of the island that diesel generator meant as prime power to island.

After several inspections & measurements been made we founded; that diesel generator is under performance due to lack of routine an unplanned maintenance, parts of the problem contributors is air filter, diesel and air injection ratio, turbo charger bearing and contain of diesel.

What i can highlighted over here, routine and plan preventive maintenance is very critical in order to get best performance when applying load to engine.

Herewith some example of basic routine maintenance.

In mechanically called Glowing Turbo, the cause may a lot but some :

1. Too much back pressure from your exhaust

2. Less air intake

3. High ambient temperature around the set