In the power supply system, diesel generator sets play a crucial role as backup or main power sources. They not only provide emergency power support when the power grid fails but also serve as the primary power source in many remote areas or special occasions. However, when diesel generator sets operate under overload, a series of potential hazards will gradually emerge, causing incalculable losses to the equipment itself, the power system, and even the entire social economy. This article explores the hazards of diesel generator overload operation and proposes effective preventive measures, aiming to provide valuable references for relevant practitioners and users.

Overload operation, as the name implies, refers to the operation of a diesel generator set beyond its rated load capacity. This state not only damages the generator set itself but also adversely affects the connected power equipment and the entire power system. Specifically, the hazards of diesel generator overload operation mainly include the following aspects:

Increased engine wear and shortened service life: The core component of a diesel generator set is the engine, whose operating status directly determines the overall performance of the generator set. During overload operation, the engine speed and load increase significantly, subjecting internal components to greater pressure and friction. Long-term high-load operation accelerates the wear of these components and may even cause severe failures such as breakage, thereby shortening the service life of the generator set.

Damaged electrical system and increased safety risks: Overload operation causes the current and voltage output by the diesel generator set to exceed the normal range, exerting great pressure on the electrical system. Electrical components are prone to heating, aging, or damage under long-term overload, leading to faults such as short circuits and open circuits.

Increased fuel consumption and deteriorated emissions: To maintain the output power required for overload operation, the diesel generator set must increase fuel supply, resulting in a significant rise in fuel consumption.

Increased load on the cooling system and higher overheating risk: Overload operation of the diesel generator set leads to a substantial increase in heat generated by the engine, placing a heavy burden on the cooling system. Overheating not only reduces engine performance but also may cause a series of severe faults, such as cylinder head deformation and seal failure.

Then, what are the preventive measures for diesel generator overload operation?

Given the severe hazards of diesel generator overload operation, we must take effective preventive measures to ensure its safe and stable operation. The following are key preventive measures:

Reasonable configuration of generator set capacity: First, the capacity of the generator set should be reasonably configured based on actual power demand. When selecting a generator set, full consideration should be given to the power and quantity of electrical equipment as well as future expansion needs, ensuring that the generator set capacity can meet current needs with a certain margin. Meanwhile, the redundancy design of the generator set should also be considered to cope with emergencies or peak power demand.

Enhanced maintenance: Regular maintenance of diesel generator sets is crucial to ensuring their stable operation. Maintenance work includes oil replacement, carbon deposit cleaning, and electrical component inspection. Through maintenance, potential problems of the generator set can be detected and resolved in a timely manner, preventing damage caused by overload. In addition, equipment such as smart electricity meters and energy consumption monitoring systems can be installed to monitor power consumption in real time and address overload issues promptly.

Installation of overload protection devices: Installing overload protection devices in the electrical system of diesel generator sets is a direct and effective means to prevent overload operation. These devices can automatically cut off the power supply or issue an alarm when the output current of the generator set exceeds the rated value, thus avoiding long-term overload operation. Common overload protection devices include overload relays and thermal relays.

Reasonable load arrangement: Reasonable load arrangement is an important measure to avoid overload operation of diesel generator sets. The load should be distributed according to the rated load capacity of the generator set, avoiding long-term full-load or overload operation. For scenarios with large loads, multiple generator sets can be used in parallel to meet load demand and reduce the load pressure on a single generator set.

Strengthened monitoring and early warning: Strengthening the operation monitoring and early warning of diesel generator sets is an important means to prevent overload operation. By installing monitoring instruments and sensors, the operating status and various parameters (such as voltage, current, power, and temperature) of the generator set can be monitored in real time, and abnormal situations can be detected and addressed promptly. Meanwhile, big data analysis and artificial intelligence technology can be used to establish early warning models, predict and evaluate the operating status of the generator set, and detect and resolve potential problems in advance.

With the advancement of technology and the acceleration of industrialization, electricity has become an indispensable infrastructure in modern society. As an important part of the power supply system, the stability and reliability of diesel generator sets are directly related to the continuity and safety of power supply. Faced with the many hazards caused by overload operation, we must maintain a high degree of vigilance and responsibility and take effective measures to prevent it.

By reasonably configuring the capacity of generator sets, enhancing maintenance, installing overload protection devices, arranging loads reasonably, improving the quality of operators, and strengthening monitoring and early warning, we can effectively reduce the risk of overload operation of diesel generator sets and ensure their safe and stable operation.