燃气发电机组作为能源领域实现能量高效转换的关键设备，在长时间不间断运行过程中，不可避免地会遭遇一系列复杂的技术问题，这些问题涵盖机械、电气、控制系统以及燃气系统等多个重要方面，以下将进行全面且深入的解析。

As a key equipment for achieving efficient energy conversion in the energy field, gas generator sets inevitably encounter a series of complex technical problems during long-term uninterrupted operation. These problems cover multiple important aspects such as mechanical, electrical, control systems, and gas systems. The following will provide a comprehensive and in-depth analysis.

在机械系统故障层面，发动机异常振动是较为突出的问题之一。其产生的根源主要涉及曲轴不平衡，当曲轴因制造缺陷或长期使用出现质量分布不均时，在高速运转下便会引发振动；轴承磨损也是重要原因，长期的摩擦使得轴承间隙增大，无法有效支撑曲轴运转，从而产生振动；飞轮松动会破坏整体转动的稳定性，进而导致振动；基础固定不牢，地脚螺栓松动或基础结构设计不合理，无法为发动机提供稳固支撑，同样会引发振动。针对这些问题，有效的解决方案包括使用激光对中仪对曲轴同心度进行精准校正，将偏差严格控制在≤0.05mm 的范围内，以确保曲轴运转平稳；选用 SKF、FAG 等高品质品牌轴承，并且建议在运行 8000 小时后进行强制更换，保证轴承的可靠性；采用扭矩扳手按照厂家规定的扭矩值紧固地脚螺栓，增强基础的稳固性。而缸体过热（温度＞95℃）同样是机械系统常见故障，其原因主要有冷却系统故障，当水泵效率下降超过 15% 时，冷却液循环不畅，无法及时带走热量；缸套结垢，若水垢厚度超过 0.5mm，会严重影响热传导效率；润滑油路堵塞，导致润滑不良，部件摩擦产生大量热量。对应的解决措施为使用高压水枪配合专用清洗剂对散热器进行彻底清洗，恢复其散热性能；选用浓度在 40%-60% 的乙二醇基冷却液，保证冷却效果；安装在线油压监测系统，将预警值设定为＜2bar，以便及时发现润滑油路异常。

At the level of mechanical system failures, abnormal engine vibration is one of the more prominent issues. The root cause of its occurrence mainly involves the imbalance of the crankshaft. When the crankshaft has uneven mass distribution due to manufacturing defects or long-term use, it will cause vibration during high-speed operation; Bearing wear is also an important cause. Long term friction increases the clearance between bearings, which cannot effectively support the operation of the crankshaft, resulting in vibration; Loose flywheels can disrupt the overall stability of rotation, leading to vibration; Poor foundation fixation, loose anchor bolts or unreasonable foundation structure design, which cannot provide stable support for the engine, can also cause vibration. Effective solutions to these issues include using a laser alignment instrument to accurately correct the concentricity of the crankshaft, strictly controlling the deviation within a range of ≤ 0.05mm to ensure smooth operation of the crankshaft; Select high-quality brand bearings such as SKF and FAG, and it is recommended to replace them forcibly after 8000 hours of operation to ensure the reliability of the bearings; Use a torque wrench to tighten the anchor bolts according to the manufacturer's specified torque value, enhancing the stability of the foundation. Overheating of the cylinder body (temperature>95 ℃) is also a common fault in mechanical systems, mainly caused by cooling system failures. When the efficiency of the water pump decreases by more than 15%, the circulation of coolant is not smooth, and heat cannot be taken away in a timely manner; If the thickness of the scale on the cylinder liner exceeds 0.5mm, it will seriously affect the thermal conductivity efficiency; The blockage of the lubrication oil circuit leads to poor lubrication and generates a large amount of heat due to component friction. The corresponding solution is to thoroughly clean the radiator with a high-pressure water gun and a specialized cleaning agent to restore its heat dissipation performance; Select ethylene glycol based coolant with a concentration of 40% -60% to ensure cooling effect; Install an online oil pressure monitoring system and set the warning value to<2 bar to promptly detect any abnormalities in the lubrication system.

电气系统故障方面，输出电压波动（±10%）是常见问题。AVR 调节器响应延迟（＞50ms），在负载变化时无法及时调整励磁电流，导致电压波动；转子绕组匝间短路，使得绕组阻抗变化超过 15%，影响发电性能；负载突变，当负载变化超过 30% 额定负荷时，超出了发电机的调节能力，也会造成电压波动。解决这些问题需要升级数字式 AVR，将响应时间缩短至＜20ms，提高调节灵敏度；采用 Megger 对转子绝缘进行测试，若阻值＜1MΩ 则需及时检修，避免短路故障扩大；加装负载缓冲装置，减小负载突变对电压的影响。

In terms of electrical system faults, output voltage fluctuations (± 10%) are a common problem. AVR regulator response delay (>50ms), unable to adjust excitation current in a timely manner when load changes, resulting in voltage fluctuations; Short circuit between turns in the rotor winding causes a change in winding impedance exceeding 15%, affecting power generation performance; Load mutation, when the load changes by more than 30% of the rated load, exceeds the regulating capacity of the generator and can also cause voltage fluctuations. To solve these problems, it is necessary to upgrade the digital AVR, shorten the response time to<20ms, and improve the adjustment sensitivity; Use Megger to test the rotor insulation. If the resistance value is less than 1M Ω, timely maintenance is required to avoid the expansion of short circuit faults; Install load buffering devices to reduce the impact of sudden load changes on voltage.

控制系统故障中，PLC 误动作较为常见。EMI 干扰，当场强＞10V/m 时，会对 PLC 的正常运行产生干扰；程序死循环，导致扫描周期超过 200ms，影响系统响应；通讯中断，误码率＞10?? 时，数据传输不准确。改进措施包括实施三级屏蔽，对信号线、柜体以及接地进行全面屏蔽，减少电磁干扰；优化 PLC 程序，增加看门狗功能，防止程序死循环；改用光纤通讯，将衰减控制在＜0.5dB/km，提高通讯的稳定性和准确性。燃气阀组故障也是控制系统的常见问题，伺服电机过载，当电流超过额定值 120% 时，会影响燃气阀的正常调节；位置传感器漂移，偏差超过 ±1% FS，导致燃气流量控制不准确。针对这些问题，可通过加装力矩限制器，保护伺服电机；采用非接触式磁编码器，其分辨率达 0.1°，提高位置检测的精度。

PLC misoperation is more common in control system failures. EMI interference, when the field strength is greater than 10V/m, will interfere with the normal operation of PLC; Program dead loop, resulting in a scanning cycle exceeding 200ms, affecting system response; Communication interruption, error rate>10?? At that time, the data transmission was inaccurate. Improvement measures include implementing three-level shielding, comprehensively shielding signal lines, cabinets, and grounding to reduce electromagnetic interference; Optimize PLC program, add watchdog function to prevent program dead loop; Switch to fiber optic communication and control attenuation to<0.5dB/km to improve communication stability and accuracy. Gas valve group failure is also a common problem in control systems. When the servo motor is overloaded and the current exceeds 120% of the rated value, it will affect the normal adjustment of the gas valve; The position sensor drifts with a deviation exceeding ± 1% FS, resulting in inaccurate gas flow control. To address these issues, torque limiters can be installed to protect servo motors; Adopting a non-contact magnetic encoder with a resolution of 0.1 °, it improves the accuracy of position detection.

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