燃气发电机作为分布式能源系统的核心设备，其稳定运行直接关系到供电可靠性。在实际运维中，设备可能因环境、燃料质量或操作不当引发故障。以下从专业角度解析五类典型故障及其处理方案。

　　As the core equipment of distributed energy systems, the stable operation of gas generators is directly related to the reliability of power supply. In actual operation and maintenance, equipment may malfunction due to environmental factors, fuel quality, or improper operation. Below are five typical types of faults and their solutions from a professional perspective.

　　一、点火系统失效

　　1、 Ignition system failure

　　故障现象：机组启动困难或运行中突然熄火，伴随点火线圈过热。

　　Fault phenomenon: The unit has difficulty starting or suddenly shuts down during operation, accompanied by overheating of the ignition coil.

　　原因分析：

　　Cause analysis:

　　火花塞间隙积碳导致电火花强度不足，常见于含硅沼气或天然气。

　　Carbon buildup in the gap between spark plugs leads to insufficient electrical spark intensity, commonly found in silicon containing biogas or natural gas.

　　点火线圈绝缘层老化，在湿度高于80%环境下易引发短路。

　　The insulation layer of the ignition coil is aging, which can easily cause short circuits in environments with humidity above 80%.

　　处理方式：

　　Handling method:

　　每运行200小时用砂纸清理火花塞电极，间隙调整至0.7-0.8mm。

　　Clean the spark plug electrode with sandpaper every 200 hours of operation, and adjust the gap to 0.7-0.8mm.

　　更换耐高温点火线圈，采用环氧树脂灌封工艺提升防潮性能。

　　Replace the high-temperature resistant ignition coil and use epoxy resin encapsulation technology to improve moisture resistance.

　　安装点火能量检测模块，当单次点火能量低于50mJ时触发报警。

　　Install the ignition energy detection module to trigger an alarm when the single ignition energy is below 50mJ.

　　二、燃料供应异常

　　2、 Abnormal fuel supply

　　故障现象：机组功率波动超过±10%，或燃料压力表指针剧烈摆动。

　　Fault phenomenon: The power fluctuation of the unit exceeds ± 10%, or the fuel pressure gauge pointer swings violently.

　　原因分析：

　　Cause analysis:

　　燃料过滤器堵塞导致压降超过0.5bar，常见于含杂质生物质气。

　　Fuel filter blockage leads to a pressure drop exceeding 0.5 bar, commonly seen in biomass gas containing impurities.

　　燃料调压阀膜片破裂，在0.3MPa以上压力工况下易发生。

　　The rupture of the fuel pressure regulating valve diaphragm is prone to occur under pressure conditions above 0.3 MPa.

　　处理方式：

　　Handling method:

　　配备双联过滤器并联运行，单组堵塞时自动切换至备用滤芯。

　　Equipped with dual filters for parallel operation, it automatically switches to the backup filter element when a single group is blocked.

　　调压阀选型时考虑1.5倍安全系数，膜片材质升级为氟橡胶。

　　When selecting a pressure regulating valve, consider a safety factor of 1.5 times and upgrade the diaphragm material to fluororubber.

　　安装燃料质量在线监测仪，实时显示甲烷浓度及杂质含量。

　　Install an online fuel quality monitor to display methane concentration and impurity content in real-time.

　　三、排气背压过高

　　3、 Excessive exhaust back pressure

　　故障现象：机组排烟温度突增至600℃以上，伴随涡轮增压器喘振。

　　Fault phenomenon: The exhaust temperature of the unit suddenly increases to over 600 ℃, accompanied by turbocharger surge.

　　原因分析：

　　Cause analysis:

　　催化转化器载体堵塞，在硫含量超标燃料中运行2000小时后易发生。

　　Catalytic converter carrier blockage is prone to occur after 2000 hours of operation in fuels with excessive sulfur content.

　　消音器内部填充材料板结，导致实际背压超过设计值30%。

　　The internal filling material of the muffler is laminated, resulting in an actual back pressure exceeding the design value by 30%.

　　处理方式：

　　Handling method:

　　催化转化器前加装颗粒捕集器，每500小时用压缩空气反吹清理。

　　Install a particle trap before the catalytic converter and clean it with compressed air every 500 hours.

　　消音器改用不锈钢丝网结构，替换传统岩棉填充材料。

　　The muffler has been replaced with a stainless steel wire mesh structure, replacing the traditional rock wool filling material.

　　安装排气背压传感器，当压力超过3kPa时启动保护性停机。

　　Install exhaust back pressure sensor and initiate protective shutdown when the pressure exceeds 3kPa.

　　四、冷却系统泄漏

　　4、 Cooling system leakage

　　故障现象：冷却液液位每小时下降超过0.5L，机组高温报警频繁触发。

　　Fault phenomenon: The coolant level drops by more than 0.5L per hour, and the unit's high temperature alarm is frequently triggered.

　　原因分析：

　　Cause analysis:

　　水泵机械密封失效，在含氯冷却液中腐蚀速率加快。

　　The mechanical seal of the water pump fails, and the corrosion rate accelerates in chlorine containing coolant.

　　散热器翅片倒伏率超过20%，导致实际散热面积不足设计值80%。

　　The lodging rate of the radiator fins exceeds 20%, resulting in the actual heat dissipation area being less than 80% of the design value.

　　处理方式：

　　Handling method:

　　水泵选型时采用碳化硅机械密封，耐温范围扩展至150℃。

　　When selecting water pumps, silicon carbide mechanical seals are used, and the temperature resistance range is extended to 150 ℃.

　　散热器加装防倒伏导流板，每运行1000小时用高压水枪清理翅片间隙。

　　Install anti lodging deflectors on the radiator and clean the fin gaps with a high-pressure water gun every 1000 hours of operation.

　　冷却系统改用乙二醇型防冻液，冰点降至-35℃以适应极端环境。

　　The cooling system has been replaced with ethylene glycol antifreeze, with a freezing point lowered to -35 ℃ to adapt to extreme environments.

　　五、电气系统接地故障

　　5、 Electrical system grounding fault

　　故障现象：机组控制柜报“接地故障”，绝缘电阻低于0.5MΩ。

　　Fault phenomenon: The unit control cabinet reports a "grounding fault" with insulation resistance below 0.5M Ω.

　　原因分析：

　　Cause analysis:

　　电缆接头防水失效，在湿度95%以上环境中24小时内即可能击穿。

　　The waterproof failure of cable joints may cause breakdown within 24 hours in environments with humidity above 95%.

　　变频器功率模块绝缘损坏，常见于雷电活动频繁区域。

　　The insulation damage of the power module of the frequency converter is common in areas with frequent lightning activity.

　　处理方式：

　　Handling method:

　　电缆接头采用双层热缩管密封，外层加装不锈钢防水接头。

　　The cable joint is sealed with double-layer heat shrink tubing, and a stainless steel waterproof joint is installed on the outer layer.

　　变频器输入端加装I级试验浪涌保护器，残压控制在1.5kV以下。

　　Install a Class I test surge protector at the input end of the frequency converter, with residual voltage controlled below 1.5kV.

　　每月用500V兆欧表检测绝缘电阻，建立绝缘性能衰减曲线。

　　Use a 500V megohmmeter to measure insulation resistance every month and establish an insulation performance attenuation curve.

　　燃气发电机的稳定运行依赖于预防性维护与快速故障处置的结合。通过建立设备健康档案，实施基于状态的维护（CBM）策略，可降低非计划停机率60%以上。运维人员需重点监控点火能量、燃料压力、排气背压等关键参数，结合红外热成像、振动分析等预测性维护技术，构建起涵盖设计、安装、调试、运维全生命周期的可靠性保障体系。

　　The stable operation of gas generators relies on the combination of preventive maintenance and rapid fault handling. By establishing equipment health records and implementing state based maintenance (CBM) strategies, unplanned downtime rates can be reduced by over 60%. Operation and maintenance personnel need to focus on monitoring key parameters such as ignition energy, fuel pressure, and exhaust back pressure, and combine predictive maintenance technologies such as infrared thermography and vibration analysis to build a reliability assurance system covering the entire life cycle of design, installation, commissioning, and operation and maintenance.

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