Daily Maintenance and Servicing of Gas Generator Sets

Gas generator sets burn combustible gas such as natural gas, biogas, coal bed methane and straw gas as fuel, and are widely applied in distributed energy systems, factory self-contained power stations, ships, breeding farms, mining areas and other scenarios. Compared with diesel generator sets, gas-specific components including the mixer, pressure regulating valve, intake valve and spark plug of gas units are prone to carbon deposition, corrosion and blockage. In addition, there exists explosion risk caused by gas leakage, which leads to obvious differences in maintenance priorities. Combined with the operating characteristics of gas units, classified maintenance specifications are formulated as follows:

I. Daily Static Inspection Before Startup

1. Inspection of Machine Room Safety and Ventilation

1. The machine room shall be equipped with forced ventilation. Gas alarm devices, explosion-proof exhaust fans and combustible gas detectors shall be powered on normally with accurate alarm thresholds.
2. Remove oil stains, sundries and flammable & explosive articles around the unit; ensure fire-fighting equipment is intact and effective.
3. Check the base and shock-absorbing pads of the complete unit for cracking and aging; confirm anchor bolts are tightened without unit tilting or displacement.

2. Inspection of Gas Supply System (Core Safety Item)

1. The gas pressure regulating valve, filter, solenoid valve and mixer shall be intact without rust or deformation.
2. Inspect all gas pipelines, flanges, joints and hoses for aging and cracking. Conduct leakage detection with soapy water; any air leakage is strictly prohibited.
3. Drain condensed water and impurities accumulated in the pre-gas filter and steam-water separator to prevent liquid water and tar from entering the cylinder.
4. Verify the gas pressure is stable within the rated supply range of the unit; startup is forbidden if the pressure is excessively high or low.
5. The emergency shut-off valve shall function properly both manually and automatically, capable of cutting off gas supply automatically under gas loss or power failure conditions.

3. Lubrication System Inspection

After the unit stands still for more than 10 minutes upon shutdown, check the engine oil level, which shall stay between the upper and lower scales of the dipstick. The engine oil shall not show emulsification, black thinning or excessive impurities.

Inspect the oil sump, oil seals and oil pipelines for leakage; confirm the oil filter is installed firmly.

4. Cooling System Inspection

Check the coolant liquid level in the expansion tank and replenish original special antifreeze liquid. Radiators and fins shall be free of dust and floc blockages. Cooling water pipes and water pumps shall have no leakage. Transmission belts shall maintain proper tension without cracks or tooth loss.

5. Intake and Ignition System Inspection

1. The shell of the air filter shall be well sealed without damage or air leakage.
2. Inspect high-voltage ignition coils, high-voltage wires and spark plug sleeves for damage and electric leakage.
3. Battery terminals shall be free of oxidation and corrosion with sufficient voltage to guarantee stable power supply for startup and shutdown.

6. Electrical Control System Inspection

All wiring terminals in power distribution cabinets shall be fastened without overheating. Meters displaying voltage, frequency, water temperature, oil pressure and gas inlet pressure shall work normally. Protection devices against overspeed, over-temperature, low oil pressure, gas leakage and overload shall stand by in good condition, and the emergency stop button shall function reliably.

II. Routine Patrol Inspection During Unit Operation (Once per Hour)

1. Monitoring of Operating Parameters Record rotating speed, output voltage, frequency, load current, engine oil pressure, cylinder temperature, exhaust temperature and gas inlet pressure in real time. Reduce load or shut down the unit promptly if parameters deviate from rated ranges. Long-term full-load or overload operation is forbidden.
2. Observation of Combustion and Exhaust Smoke Condition Light grey exhaust smoke indicates normal combustion:

• Black smoke: Excessively rich gas mixture, clogged air filter or weak ignition of spark plugs;
• White smoke: Excessive water content in gas or coolant leakage into cylinders;
• Pale blue smoke: Minor gas leakage or incomplete combustion; inspect the gas mixer immediately once found.

3. Inspection of Abnormal Noise, Vibration and Leakage Listen for abnormal valve noise, knocking and cylinder tapping inside the engine. The unit shall not generate severe resonance. Constantly check for gas odor; no gas leakage shall exist at pipeline joints, valves and cylinder heads, and no dripping leakage shall occur in oil and water circuits.
4. Inspection of Ignition and Exhaust System Exhaust pipes and corrugated pipes shall be free of air leakage and red-hot phenomenon. The three-way catalytic device shall operate at normal temperature without blockage and overheating. No misfire alarm shall be triggered in the ignition system.
5. Safety Monitoring Devices The combustible gas detector shall not keep alarming. In case of alarm, reduce load and shut down the unit immediately, close the main gas valve, ventilate to discharge residual gas before maintenance.

III. Daily Post-Shutdown Maintenance Work

1. Unload loads gradually, run the unit at no load for 3–5 minutes for cooling before shutdown; emergency shutdown under load is prohibited. After shutdown, close the main gas cut-off valve and disconnect the unit control power supply.
2. Clean dust, tar and oil stains on the unit surface to avoid corrosion of the fuselage and electrical components by acid gas condensate.
3. Recheck gas pipeline leakage and drain accumulated water in the steam-water separator.
4. Inspect all pipeline joints and bolts, and fasten loose components generated during operation.
5. Ventilate and dehumidify the machine room to prevent dampness and rust of gas components.
6. Fill in the operation log completely, recording running hours, gas pressure, various temperature and pressure values, alarms, abnormal phenomena and corresponding treatment measures.

IV. Standard of Periodical Classified Maintenance

1. Weekly Maintenance

1. Thoroughly blow off surface dust of the air filter; replace it directly if severely clogged. Clean radiators and ventilation filter screens of the machine room.
2. Inspect and adjust the tension of fan and generator transmission belts; replace belts with aging and cracks immediately.
3. Fully fasten gas pipeline clamps, flanges, unit anchor bolts and all wiring terminals of power distribution cabinets.
4. Test the functions of gas emergency shut-off valve, combustible gas alarm and automatic shutdown protection.
5. Drain accumulated water and impurities from gas filters and condensate separators.

2. Monthly Maintenance

1. Take engine oil samples to check emulsification and carbonization; replace engine oil and oil filter upon expiry.
2. Dismantle and inspect spark plugs, clear carbon deposits and adjust electrode gaps; replace spark plugs with ablation and excessive wear directly.
3. Clean filter screens of gas mixers and pressure regulating valves to remove tar and gelatinous sediments.
4. Insulate high-voltage ignition coils and wires, and clear surface carbon deposits.
5. Fill lubricating grease for bearings and valve transmission mechanisms; calibrate the accuracy of water temperature, oil pressure and gas pressure sensors.
6. Test the insulation resistance of the generator, clean carbon powder on slip rings and check the wear loss of carbon brushes.

3. Quarterly Maintenance

1. Thoroughly clean the whole gas supply circuit including pre-filters, steam-water separators, pressure regulating valves and mixers.
2. Dismantle intake manifolds and throttle valves to remove accumulated carbon and tar.
3. Flush and descale the cooling system, replace aging water pipes and sealing rings; inspect operating conditions of thermostats and water pumps.
4. Calibrate full-unit protection parameters including action values of overspeed, over-temperature, low oil pressure and low gas pressure protection.
5. Inspect exhaust pipes, mufflers and catalytic converters for blockage, corrosion and perforation.
6. Re-coat sealing grease on flanges and valve threads of gas pipelines, and conduct comprehensive leakage test with soapy water.

4. Annual Overhaul Maintenance

1. Dismantle and overhaul the whole engine including cylinders, pistons, valves, connecting rods and crankshafts; replace accessories exceeding wear limits.
2. Replace all wearing parts such as seals, oil seals, belts, filters, spark plugs and high-voltage wires.
3. Deeply clean carbon deposits in combustion chambers, intake ducts and exhaust ducts, and overhaul gas injection/mixing systems.
4. Fully test stator and rotor windings as well as excitation and voltage regulation systems of the generator, and repair insulation aging faults.
5. Calibrate the gas pressure regulating device and re-adjust air-fuel ratio to guarantee full combustion.
6. Derust and anti-corrode gas pipelines in the machine room, replace aging rubber hoses, and calibrate all fire-fighting and explosion-proof equipment.
7. Complete no-load and full-load loading tests, record a full set of performance parameters and file maintenance records.

V. Emergency Handling of Common Faults

1. Failure to Start the Unit First confirm normal gas pressure and zero leakage; check whether the solenoid valve opens and whether spark plugs ignite normally. Troubleshoot clogged air filters, undercharged batteries and closed emergency shut-off valves. Forced repeated ignition is forbidden to avoid gas accumulation and explosion.
2. Severe Unit Vibration and Frequent Misfire Caused mostly by carbonized aging spark plugs, unbalanced air-fuel ratio or excessive water and impurities in gas. Reduce load and shut down the unit to clean the mixer, replace spark plugs and drain condensate in pipelines.
3. Rapid Emulsification and Whitening of Engine Oil Resulted from excessive water content in gas or damaged cylinder gaskets causing water leakage. Shut down the unit immediately, separate condensate from gas and repair cylinder seals.
4. Alarm of Machine Room Gas Detector Cut off gas supply, shut down the unit and turn on all ventilation equipment at once. Switching electrical appliances and using open flame are prohibited. Ventilate for more than 30 minutes, inspect pipelines and valves section by section, and eliminate leakage before restarting the unit.
5. Over-temperature Alarm of Water/Oil Temperature Unload and run the unit at no load, clear blockages in radiators, check coolant liquid levels, water pumps and thermostats, and eliminate faults in water circulation.

VI. Mandatory Safety Maintenance Regulations

1. Any disassembly of gas components and pipeline maintenance shall be carried out after shutting down the unit, closing the main gas valve, venting residual gas in pipelines and sufficient ventilation.
2. The machine room belongs to an explosion-proof area. Copper explosion-proof tools shall be adopted for maintenance; iron tools are forbidden to strike and generate sparks.
3. Mixing engine oil, antifreeze liquid and sealant of different specifications is prohibited. Gas filters and air filters must adopt original matching models.
4. Gas pipelines, ignition components and exhaust systems shall not be disassembled during unit operation to prevent high-temperature scald and gas leakage.
5. Long-term shutdown storage: Close gas supply, exhaust residual gas in pipelines, wipe gas components and perform anti-rust treatment. Run the unit at no load for 15 minutes weekly for moisture and rust prevention.
6. All maintenance, repair and leakage detection records shall be filed uniformly, and maintenance cycles shall be checked regularly to avoid overdue maintenance.

VII. Maintenance Summary

Different from diesel generator sets, the core maintenance points of gas generator sets include explosion protection against gas leakage, air-fuel ratio adjustment, carbon deposit cleaning and condensate water treatment. Adhere to daily leakage inspection and patrol as well as classified regular maintenance, and eliminate hidden dangers of tar, carbon deposit and condensate water in a timely manner. It can not only avoid misfire, knocking and power reduction faults, but also eliminate major safety accidents such as gas explosion, ensuring long-term stable, safe and economic operation of the unit.

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Daily Maintenance and Servicing of Gas Generator Sets

Gas generator sets burn combustible gas such as natural gas, biogas, coal bed methane and straw gas as fuel, and are widely applied in distributed energy systems, factory self-contained power stations, ships, breeding farms, mining areas and other scenarios. Compared with diesel generator sets, gas-specific components including the mixer, pressure regulating valve, intake valve and spark plug of gas units are prone to carbon deposition, corrosion and blockage. In addition, there exists explosion risk caused by gas leakage, which leads to obvious differences in maintenance priorities. Combined with the operating characteristics of gas units, classified maintenance specifications are formulated as follows:

I. Daily Static Inspection Before Startup

1. Inspection of Machine Room Safety and Ventilation

1. The machine room shall be equipped with forced ventilation. Gas alarm devices, explosion-proof exhaust fans and combustible gas detectors shall be powered on normally with accurate alarm thresholds.
2. Remove oil stains, sundries and flammable & explosive articles around the unit; ensure fire-fighting equipment is intact and effective.
3. Check the base and shock-absorbing pads of the complete unit for cracking and aging; confirm anchor bolts are tightened without unit tilting or displacement.

2. Inspection of Gas Supply System (Core Safety Item)

1. The gas pressure regulating valve, filter, solenoid valve and mixer shall be intact without rust or deformation.
2. Inspect all gas pipelines, flanges, joints and hoses for aging and cracking. Conduct leakage detection with soapy water; any air leakage is strictly prohibited.
3. Drain condensed water and impurities accumulated in the pre-gas filter and steam-water separator to prevent liquid water and tar from entering the cylinder.
4. Verify the gas pressure is stable within the rated supply range of the unit; startup is forbidden if the pressure is excessively high or low.
5. The emergency shut-off valve shall function properly both manually and automatically, capable of cutting off gas supply automatically under gas loss or power failure conditions.

3. Lubrication System Inspection

After the unit stands still for more than 10 minutes upon shutdown, check the engine oil level, which shall stay between the upper and lower scales of the dipstick. The engine oil shall not show emulsification, black thinning or excessive impurities.

Inspect the oil sump, oil seals and oil pipelines for leakage; confirm the oil filter is installed firmly.

4. Cooling System Inspection

Check the coolant liquid level in the expansion tank and replenish original special antifreeze liquid. Radiators and fins shall be free of dust and floc blockages. Cooling water pipes and water pumps shall have no leakage. Transmission belts shall maintain proper tension without cracks or tooth loss.

5. Intake and Ignition System Inspection

1. The shell of the air filter shall be well sealed without damage or air leakage.
2. Inspect high-voltage ignition coils, high-voltage wires and spark plug sleeves for damage and electric leakage.
3. Battery terminals shall be free of oxidation and corrosion with sufficient voltage to guarantee stable power supply for startup and shutdown.

6. Electrical Control System Inspection

All wiring terminals in power distribution cabinets shall be fastened without overheating. Meters displaying voltage, frequency, water temperature, oil pressure and gas inlet pressure shall work normally. Protection devices against overspeed, over-temperature, low oil pressure, gas leakage and overload shall stand by in good condition, and the emergency stop button shall function reliably.

II. Routine Patrol Inspection During Unit Operation (Once per Hour)

1. Monitoring of Operating Parameters Record rotating speed, output voltage, frequency, load current, engine oil pressure, cylinder temperature, exhaust temperature and gas inlet pressure in real time. Reduce load or shut down the unit promptly if parameters deviate from rated ranges. Long-term full-load or overload operation is forbidden.
2. Observation of Combustion and Exhaust Smoke Condition Light grey exhaust smoke indicates normal combustion:

• Black smoke: Excessively rich gas mixture, clogged air filter or weak ignition of spark plugs;
• White smoke: Excessive water content in gas or coolant leakage into cylinders;
• Pale blue smoke: Minor gas leakage or incomplete combustion; inspect the gas mixer immediately once found.

3. Inspection of Abnormal Noise, Vibration and Leakage Listen for abnormal valve noise, knocking and cylinder tapping inside the engine. The unit shall not generate severe resonance. Constantly check for gas odor; no gas leakage shall exist at pipeline joints, valves and cylinder heads, and no dripping leakage shall occur in oil and water circuits.
4. Inspection of Ignition and Exhaust System Exhaust pipes and corrugated pipes shall be free of air leakage and red-hot phenomenon. The three-way catalytic device shall operate at normal temperature without blockage and overheating. No misfire alarm shall be triggered in the ignition system.
5. Safety Monitoring Devices The combustible gas detector shall not keep alarming. In case of alarm, reduce load and shut down the unit immediately, close the main gas valve, ventilate to discharge residual gas before maintenance.

III. Daily Post-Shutdown Maintenance Work

1. Unload loads gradually, run the unit at no load for 3–5 minutes for cooling before shutdown; emergency shutdown under load is prohibited. After shutdown, close the main gas cut-off valve and disconnect the unit control power supply.
2. Clean dust, tar and oil stains on the unit surface to avoid corrosion of the fuselage and electrical components by acid gas condensate.
3. Recheck gas pipeline leakage and drain accumulated water in the steam-water separator.
4. Inspect all pipeline joints and bolts, and fasten loose components generated during operation.
5. Ventilate and dehumidify the machine room to prevent dampness and rust of gas components.
6. Fill in the operation log completely, recording running hours, gas pressure, various temperature and pressure values, alarms, abnormal phenomena and corresponding treatment measures.

IV. Standard of Periodical Classified Maintenance

1. Weekly Maintenance

1. Thoroughly blow off surface dust of the air filter; replace it directly if severely clogged. Clean radiators and ventilation filter screens of the machine room.
2. Inspect and adjust the tension of fan and generator transmission belts; replace belts with aging and cracks immediately.
3. Fully fasten gas pipeline clamps, flanges, unit anchor bolts and all wiring terminals of power distribution cabinets.
4. Test the functions of gas emergency shut-off valve, combustible gas alarm and automatic shutdown protection.
5. Drain accumulated water and impurities from gas filters and condensate separators.

2. Monthly Maintenance

1. Take engine oil samples to check emulsification and carbonization; replace engine oil and oil filter upon expiry.
2. Dismantle and inspect spark plugs, clear carbon deposits and adjust electrode gaps; replace spark plugs with ablation and excessive wear directly.
3. Clean filter screens of gas mixers and pressure regulating valves to remove tar and gelatinous sediments.
4. Insulate high-voltage ignition coils and wires, and clear surface carbon deposits.
5. Fill lubricating grease for bearings and valve transmission mechanisms; calibrate the accuracy of water temperature, oil pressure and gas pressure sensors.
6. Test the insulation resistance of the generator, clean carbon powder on slip rings and check the wear loss of carbon brushes.

3. Quarterly Maintenance

1. Thoroughly clean the whole gas supply circuit including pre-filters, steam-water separators, pressure regulating valves and mixers.
2. Dismantle intake manifolds and throttle valves to remove accumulated carbon and tar.
3. Flush and descale the cooling system, replace aging water pipes and sealing rings; inspect operating conditions of thermostats and water pumps.
4. Calibrate full-unit protection parameters including action values of overspeed, over-temperature, low oil pressure and low gas pressure protection.
5. Inspect exhaust pipes, mufflers and catalytic converters for blockage, corrosion and perforation.
6. Re-coat sealing grease on flanges and valve threads of gas pipelines, and conduct comprehensive leakage test with soapy water.

4. Annual Overhaul Maintenance

1. Dismantle and overhaul the whole engine including cylinders, pistons, valves, connecting rods and crankshafts; replace accessories exceeding wear limits.
2. Replace all wearing parts such as seals, oil seals, belts, filters, spark plugs and high-voltage wires.
3. Deeply clean carbon deposits in combustion chambers, intake ducts and exhaust ducts, and overhaul gas injection/mixing systems.
4. Fully test stator and rotor windings as well as excitation and voltage regulation systems of the generator, and repair insulation aging faults.
5. Calibrate the gas pressure regulating device and re-adjust air-fuel ratio to guarantee full combustion.
6. Derust and anti-corrode gas pipelines in the machine room, replace aging rubber hoses, and calibrate all fire-fighting and explosion-proof equipment.
7. Complete no-load and full-load loading tests, record a full set of performance parameters and file maintenance records.

V. Emergency Handling of Common Faults

1. Failure to Start the Unit First confirm normal gas pressure and zero leakage; check whether the solenoid valve opens and whether spark plugs ignite normally. Troubleshoot clogged air filters, undercharged batteries and closed emergency shut-off valves. Forced repeated ignition is forbidden to avoid gas accumulation and explosion.
2. Severe Unit Vibration and Frequent Misfire Caused mostly by carbonized aging spark plugs, unbalanced air-fuel ratio or excessive water and impurities in gas. Reduce load and shut down the unit to clean the mixer, replace spark plugs and drain condensate in pipelines.
3. Rapid Emulsification and Whitening of Engine Oil Resulted from excessive water content in gas or damaged cylinder gaskets causing water leakage. Shut down the unit immediately, separate condensate from gas and repair cylinder seals.
4. Alarm of Machine Room Gas Detector Cut off gas supply, shut down the unit and turn on all ventilation equipment at once. Switching electrical appliances and using open flame are prohibited. Ventilate for more than 30 minutes, inspect pipelines and valves section by section, and eliminate leakage before restarting the unit.
5. Over-temperature Alarm of Water/Oil Temperature Unload and run the unit at no load, clear blockages in radiators, check coolant liquid levels, water pumps and thermostats, and eliminate faults in water circulation.

VI. Mandatory Safety Maintenance Regulations

1. Any disassembly of gas components and pipeline maintenance shall be carried out after shutting down the unit, closing the main gas valve, venting residual gas in pipelines and sufficient ventilation.
2. The machine room belongs to an explosion-proof area. Copper explosion-proof tools shall be adopted for maintenance; iron tools are forbidden to strike and generate sparks.
3. Mixing engine oil, antifreeze liquid and sealant of different specifications is prohibited. Gas filters and air filters must adopt original matching models.
4. Gas pipelines, ignition components and exhaust systems shall not be disassembled during unit operation to prevent high-temperature scald and gas leakage.
5. Long-term shutdown storage: Close gas supply, exhaust residual gas in pipelines, wipe gas components and perform anti-rust treatment. Run the unit at no load for 15 minutes weekly for moisture and rust prevention.
6. All maintenance, repair and leakage detection records shall be filed uniformly, and maintenance cycles shall be checked regularly to avoid overdue maintenance.

VII. Maintenance Summary

Different from diesel generator sets, the core maintenance points of gas generator sets include explosion protection against gas leakage, air-fuel ratio adjustment, carbon deposit cleaning and condensate water treatment. Adhere to daily leakage inspection and patrol as well as classified regular maintenance, and eliminate hidden dangers of tar, carbon deposit and condensate water in a timely manner. It can not only avoid misfire, knocking and power reduction faults, but also eliminate major safety accidents such as gas explosion, ensuring long-term stable, safe and economic operation of the unit.

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