Safety Hazards and Preventive Measures of Diesel Generators

In modern industry and life, diesel generators play an important role. They not only provide emergency power support for many places but also serve as the main power source in some remote areas. However, there are some safety hazards in the use of diesel generators. If these hazards are ignored, they may lead to serious consequences. This article will analyze in detail the common safety hazards of diesel generators and put forward preventive measures according to relevant standards to ensure their safe operation.

Diesel generators generate high temperatures during operation. If the heat dissipation is poor or the circuit short-circuits, it is very easy to cause a fire. According to relevant regulations, if diesel generators are installed in Class A or B factories or warehouses, the sparks generated may ignite combustible materials, causing fires or even explosions.

Diesel generators generate high temperatures during operation. If the cooling system is not properly designed or the cooling effect is poor, it is easy to cause the equipment to overheat. At the same time, circuit short circuits are also one of the common causes of fire. When the circuit short-circuits, the current increases sharply, and the heat generated may ignite surrounding combustible materials, thus causing a fire.

If the diesel generator is installed in a Class A or B factory or warehouse, these places usually store large quantities of flammable and explosive materials. The sparks generated by the diesel generator during operation may ignite these materials, leading to fire or even explosion. Therefore, choosing a suitable installation location is very important.

Unreasonable design of the fuel storage room is also an important factor leading to fire. For example, if the amount of fuel stored is too large and not separated from the generator room by firewalls, the sparks produced during the operation of the generator may ignite the stored diesel fuel. In addition, if the fuel tank is not effectively grounded, not equipped with a vent pipe leading outdoors or the vent pipe is not provided with a breather valve with a flame arrester, and the lower part of the fuel tank is not equipped with facilities to prevent oil spillage, fires may also occur due to the flammable nature of diesel fuel.

In order to prevent fire, the design and manufacture of generators should fully consider these fire hazard factors and strictly comply with relevant standards to ensure the safety performance of the product. At the same time, users should regularly check the cooling system and circuit during use to ensure their normal operation. In addition, the diesel generator room should be equipped with sufficient ventilation facilities to maintain air circulation and avoid use in enclosed or partially ventilated areas.

Poor Ventilation: Diesel combustion produces carbon monoxide and other toxic gases. When using diesel generators in enclosed environments, if the ventilation is poor and toxic gases cannot be discharged in time, poisoning of indoor personnel is very likely to occur. Therefore, the diesel generator room must be equipped with sufficient ventilation facilities to ensure air circulation.

Preventive Measures: It is recommended that users install diesel generators outdoors or in well-ventilated places whenever possible. If it must be used indoors, forced ventilation equipment should be installed to ensure that toxic gases can be discharged in time. At the same time, when operators enter the diesel generator room, they should first open doors and windows to discharge exhaust gases to prevent carbon monoxide poisoning.

Poor Equipment Insulation: The generator set involves a large amount of electrical work. Poor equipment insulation, unreliable grounding, or improper operation by personnel may cause electric shock hazards. If the insulation performance of the equipment decreases, it may cause leakage, leading to electric shock accidents.

Preventive Measures: According to electrical safety requirements, the insulation performance of generator sets must be tested regularly to ensure good grounding. Operators should wear insulating gloves, insulating boots, and other protective equipment during operation, and strictly follow operating procedures. Diesel generator sets undergo strict electrical safety testing before leaving the factory to ensure insulation performance and grounding reliability.

Fuel System Leakage: The fuel system of diesel generators is prone to leakage problems. Fuel leakage not only makes the working area slippery but also increases the risk of fire. If fuel leaks onto high-temperature components, it may cause a fire.

Cooling System Leakage: Cooling system leakage is also a problem that cannot be ignored. Coolant leakage may cause the engine to overheat, affect the normal operation of the generator, and even cause failure.

Preventive Measures: Users should regularly check the fuel pipeline and cooling system to prevent fuel and coolant leakage caused by aging, cracking, or loose connections. Once leakage is found, the generator set should be shut down immediately, blocking measures should be taken, and the leaked fuel or coolant should be professionally treated.

Power Access and Grid Connection: The power output of the diesel generator set must pass through a mechanically interlocked transfer switch to ensure separation from the mains supply. When it is necessary to connect to the grid, approval from the relevant professional department (power supply bureau) is required, and special grid connection equipment must be used. Otherwise, there will be serious risks of equipment damage and personal injury.

Reliable Grounding: The diesel generator set must have reliable grounding. When repairing live equipment, insulated tools must be used, and in humid environments, particular attention must be paid to the risk of electric shock. All electrical regulations must be observed, and electrical installation and maintenance must be carried out by qualified professional electrical personnel.

Preventive Measures: There should be a proper exhaust discharge system to ensure that engine exhaust gases are vented outdoors. The exhaust discharge system should be checked regularly for leaks. When there are exhaust gases in the diesel generator room, doors and windows should be opened to discharge exhaust gases before entering the room to prevent carbon monoxide poisoning.

Hazardous Areas: Do not use generator sets in places with explosion hazards. It is dangerous to be close to an operating diesel generator. Loose clothing, hair, and falling tools can cause serious personal injury and equipment accidents. Some exposed pipes and parts of operating diesel generators are at high temperatures, and burns should be prevented.

Preventive Measures: Metal objects can cause wire short circuits, leading to fire hazards. The engine of the diesel generator should be kept clean, as excessive oil contamination may cause overheating and fire. Several dry powder or carbon dioxide fire extinguishers should be placed in convenient locations in the diesel generator room.

Electrolyte Hazards: The dilute sulfuric acid electrolyte in lead-acid batteries is toxic and corrosive. Contact with skin can cause burns and should be washed immediately with clean water. If it splashes into the eyes, rinse immediately with plenty of clean water and seek medical treatment.

Preventive Measures: During use, the battery releases explosive gases, so the room must be well ventilated, and open flames are strictly prohibited nearby. In extremely cold environments, a preheating device is required to start the diesel generator set. Never use open flames to heat the machine body. The temperature of the battery electrolyte should be kept above 10°C to ensure sufficient power supply.

The operating specifications of diesel generators are key to ensuring safe operation. Correct operating procedures can not only extend the service life of the equipment but also effectively prevent safety accidents. The following are some basic specifications that must be followed when operating diesel generators.

For generators powered by diesel engines, the engine operation should be carried out in accordance with the relevant regulations of internal combustion engines. Before starting the generator, carefully check whether the wiring of each part is correct, whether all connections are secure, whether the brushes are normal, whether the pressure meets the requirements, and whether the grounding wire is in good condition. Before starting, set the resistance of the excitation rheostat to the maximum position, disconnect the output switch, and disengage the clutch for generators with a clutch. Start the diesel engine under no load, and after it runs smoothly, start the generator.

After the generator starts running, attention should be paid to whether there are mechanical noises or abnormal vibrations. After confirming that the situation is normal, adjust the generator to the rated speed, the voltage to the rated value, and then close the output switch to supply power externally. The load should be increased gradually, striving for a three-phase balance. Parallel operation of generators must meet the conditions of the same frequency, voltage, phase, and phase sequence. Generators prepared for parallel operation must have entered normal and stable operation. After receiving the "ready for parallel operation" signal, adjust the diesel engine speed according to the overall device and close the circuit breaker at the moment of synchronization. When operating generators in parallel, the load should be reasonably adjusted to balance the active and reactive power of each generator. Active power is adjusted through the diesel engine throttle, and reactive power through excitation. During operation, close attention should be paid to the engine sound and whether the indications of various instruments are within the normal range. Check whether the running parts are normal and whether the temperature rise of the generator is too high, and make operational records.

When shutting down, first reduce the load, return the excitation rheostat to reduce the voltage to the minimum value, then cut off the switches in sequence, and finally stop the diesel engine. When one generator in parallel operation needs to be stopped due to load reduction, the load of that generator should first be transferred to other running generators, and then shut down according to the method for a single generator. If all need to be stopped, first cut off the load, then stop each generator as for a single unit. Mobile generators must be placed on a stable foundation before use and must not be moved during operation. When the generator is running, even if not excited, it should be considered as having voltage. It is forbidden to work on or touch the leads of a rotating generator or clean it by hand. Covering a running generator with canvas or other materials is prohibited. After maintenance, the rotor and stator slots should be carefully checked for tools, materials, or other debris to avoid damage during operation. All electrical equipment in the machine room must be reliably grounded. It is forbidden to stack debris and flammable or explosive materials in the machine room. Except for on-duty personnel, no one else is allowed to enter without permission. The room should be equipped with necessary firefighting equipment. In case of fire, the power supply should be stopped immediately, the generator shut down, and the fire extinguished with carbon dioxide or carbon tetrachloride extinguishers.

The safe operation of diesel generators is essential for ensuring power supply and personnel safety. By understanding common safety hazards and related standards and taking corresponding preventive measures, accident risks can be effectively reduced. During use, users should strictly follow operating procedures, perform regular maintenance and inspection, and ensure the equipment is in good working condition. At the same time, when purchasing equipment, they should choose products produced by formal manufacturers that meet national standards to avoid safety hazards caused by poor equipment quality. Only in this way can diesel generators provide convenience for our lives and work while ensuring the safety of personnel and equipment.