Technical Report: Natural Gas Genset Maintenance in High-Humidity Environments (Sichuan Basin Case Study)

Technical Report: Specialized Maintenance for Natural Gas Generator Sets under High-Humidity Conditions (Sichuan Basin)

Project Background:Due to the unique topography of the Sichuan Basin, ambient humidity levels consistently remain above 80% year-round, leading to frequent condensation on both the exterior and interior of the equipment. This high-humidity environment not only accelerates metallic oxidation but also poses severe challenges to the insulation performance of precision electronic control systems and the accuracy of air-fuel ratio (AFR) management.

I. Specialized Inspection and Technical Assessment

Upon arrival at the site, engineers conducted a multi-dimensional, in-depth inspection focusing on the potential impacts of the high-humidity environment:

• Moisture Resistance Assessment of Electronic Control Systems:

• Inspected the integrity of control cabinet seals and utilized infrared thermography to monitor electrical components for any localized overheating risks induced by moisture.

• Performed static insulation resistance tests on control modules (ECU/PLC) and their peripheral circuits to verify the signal stability of shielding and grounding systems under humid conditions.

• Reliability of Electrical Wiring and Connections:

• Conducted a point-by-point inspection of the wiring harness wrapping, focusing on critical components such as sensor plugs and high-voltage spark plug leads.

• Investigated the risk of water ingress within wiring terminals caused by capillary action to prevent signal drift or intermittent connections (loose contact).

• Gas Mixing and Combustion Efficiency Analysis:

• Validated the sensitivity of mixers, throttle valves, and actuators, accounting for the impact of high humidity on intake oxygen content.

• Analyzed air-fuel ratio (AFR) optimization by monitoring operational parameters to ensure the combustion chamber remains free from misfires or power degradation due to excessive intake humidity.

• Structural Inspection and Corrosion Assessment:

• Conducted a detailed survey of the protective coatings on the unit base, housing, and fasteners.

• Performed rust-level assessments on metal contact points vulnerable to electrochemical corrosion.

II. Maintenance Actions and Preventive Reinforcement

Comprehensive testing indicates that all operational parameters (oil pressure, coolant temperature, vibration, etc.) are within healthy ranges; therefore, no major overhaul is required. To address the trend of rising humidity, the following reinforcement measures were implemented:

• Terminal Reinforcement and Sealing: Verified the tightening torque of all critical wiring terminals and applied specialized Dielectric Grease to the connection points. This provides a physical barrier against moisture ingress and prevents poor contact caused by oxidation.

• Moisture Resistance Optimization: Installed heat-shrink tubing for protection on exposed harness ends and replaced or regenerated the desiccants within the control cabinets.

• System Parameter Fine-tuning: Adjusted the intake system compensation parameters based on current ambient humidity levels. This optimized the unit’s response time under extreme humidity and ensured a continuous, stable power output.

III. Conclusions and Recommendations

The specialized inspection and maintenance have been successfully completed. Following the technical moisture-proofing treatments, the units have demonstrated excellent adaptability to the specific humid climate of the Sichuan Basin.

Recommendations: During subsequent operations, personnel should increase the frequency of inspections regarding moisture accumulation in air filters. Additionally, condensation in the exhaust manifolds and silencers should be drained regularly to ensure the units remain in optimal long-term operating condition.