1. Post-Shutdown Operation Procedures for Generators
After the generator completes its operation and is ready to shut down, the following standardized operations must be carried out in sequence to ensure the safe and stable operation of the equipment and extend its service life:
(1) Deceleration, Unloading and Shutdown Preparation
Upon receiving the "Ready for Disconnection" signal from the control system or the on-site command, the operator shall first reduce the generator speed and unload the load in a gradual manner to avoid sudden load changes causing impact damage to the diesel engine and generator components. After the generator is successfully disconnected from the power grid (i.e., "after disconnection"), keep the unit running at a reduced speed to cool down naturally. During this period, carefully listen for any abnormal noises (such as abnormal friction, knocking or buzzing sounds) of the unit, accurately identify the location and cause of the abnormal noises, and shut down the unit only after confirming that there is no potential fault.
(2) Normal Shutdown Operation
For normal shutdown under non-emergency conditions, first turn off the fuel pump to cut off the fuel supply of the diesel engine, ensuring that the engine stops stably. After the engine is completely shut down, turn off the external circulating water pump to stop the cooling system operation, preventing the cooling water from remaining in the pipeline and causing corrosion or freezing damage (especially in low-temperature environments). Under special circumstances (such as equipment failure, fire or other emergencies), the fault shutdown or emergency shutdown button can be used to stop the unit immediately to avoid further expansion of losses.
(3) Barring-Over Operation for Long-Term Shutdown
If the generator is expected to be shut down for more than 1 hour, a barring-over operation must be performed in accordance with the manufacturer's specifications. The barring-over operation can effectively prevent the internal components of the diesel engine (such as pistons, crankshafts and bearings) from jamming due to long-term static state, and ensure that the lubricating oil can fully cover all friction surfaces, laying a good foundation for the next startup of the unit.
(4) Post-Shutdown Maintenance and Cleaning
After the generator is completely shut down and cooled, the operator shall conduct targeted maintenance and servicing according to the actual operating conditions of the unit (such as operating time, load status and equipment temperature). Specific work includes checking the oil level, coolant level and fuel level of the unit, cleaning the surface of the generator and diesel engine to remove dust, oil stains and other impurities, and tightening any loose fasteners to keep the equipment in good operating condition and the surrounding working environment clean and tidy.
(5) Regular Comprehensive Inspection
To timely discover potential faults and hidden dangers of the unit, a comprehensive inspection of all rotating parts and key components of the diesel engine must be carried out at least once a week. The inspection scope includes the engine cylinder, crankshaft, connecting rod, bearing, cooling system, lubrication system and electrical system. Any abnormal phenomena (such as oil leakage, water leakage, loose parts or abnormal wear) found during the inspection shall be handled in a timely manner, and detailed records shall be made to avoid fault accumulation affecting the normal operation of the unit.
2. Precautions for Generator Shutdown
In the process of generator shutdown and post-shutdown work, the operator must strictly abide by the following precautions to ensure personal safety, equipment safety and standardized operation:
(1) Post Duties and Operation Specifications
On-duty personnel must adhere to their posts and perform their duties conscientiously, and shall not leave their posts without permission during the operation and shutdown process. In the work, we must achieve "frequent listening, frequent observation and frequent inspection": frequently listen to the running sound of the unit, frequently observe the operation parameters (such as temperature, pressure and speed) and frequently inspect the equipment status. At the same time, strictly abide by the relevant operating procedures and safety regulations, and shall not operate in violation of regulations to avoid safety accidents and equipment damage.
(2) Shift Handover Management
On-duty personnel shall carefully and truthfully fill in the shift handover records, including the operating status of the unit, shutdown time, operation content, existing problems and handling progress. For any problems occurring during the operation of the unit, they must be handled within the on-duty shift as much as possible; if it is impossible to handle them on the spot, detailed written explanations shall be made to the next shift, including the problem description, handling suggestions and precautions. For critical and major problems that affect the safe operation of the unit, they shall be reported to the superior leadership in a timely manner to ensure that the problems are handled efficiently and in a timely manner.
(3) Tool and Part Management
After completing the post-shutdown operation and maintenance work, the operator shall count all used tools one by one and place them in the designated position to ensure that there is no loss or misplacement. For any lost or forgotten tools and parts, it is necessary to trace their whereabouts in a timely manner, find out the cause of loss or forgetting, and take corresponding preventive measures to avoid affecting the subsequent maintenance work and causing economic losses.
(4) Workplace Safety and Environmental Requirements
Smoking is strictly prohibited in the main generator room, and obvious "No Smoking" signs shall be posted to prevent fire accidents caused by open flames (the generator room contains flammable substances such as fuel). The working site shall be kept clean and tidy at all times, and sundries, oil stains and other debris shall be cleaned up in a timely manner to avoid affecting the operation and maintenance work. At the same time, active measures shall be taken to reduce noise pollution (such as installing noise reduction equipment, optimizing the layout of the unit), ensuring that the noise meets the relevant national environmental protection standards and protecting the physical and mental health of the operators.
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