ATEX Zone 2 Explosion-Proof Generator Set Daily Maintenance and Precautions
--PartⅡ
4. Fuel and Hydraulic System Leakage Prevention and Control
1) Fuel Line Inspection: Inspect the fuel tank, lines, and joints weekly to confirm no leaks and that fuel valves operate smoothly. Replace the installed explosion-proof fuel filter regularly (e.g., every 500 hours) to prevent fuel impurities from clogging the fuel lines and causing abnormal fuel supply.
2) Hydraulic/Lubrication System: If the genset has hydraulic components, check the sealing of the hydraulic lines to prevent hydraulic oil leakage and the formation of flammable oil mist; the lubricating oil must be changed regularly according to the instruction manual to prevent lubricating oil deterioration from causing overheating of engine components.
5. Special Maintenance for Positive Pressure/Special Explosion-Proof Types
1) Positive Pressure Gensets: Check the air source pressure daily (usually maintain the internal pressure 50-100Pa higher than the external pressure) to ensure the air supply pump and pressure monitor are working properly; clean the internal ventilation channels quarterly to prevent dust blockage affecting airflow circulation; after shutdown, stop air supply first, and wait for the internal and external pressures to balance before opening the cover for maintenance.
2) N-type Non-Sparking Gensets: Check vulnerable components (such as contactor contacts) monthly to ensure there is no burning or carbon buildup to prevent sparks; unauthorized changes to circuit parameters (such as increasing the operating current) are strictly prohibited, as this will compromise the safety design of the N-type explosion-proof system.
6. Maintenance of Emergency and Monitoring Devices
1) Emergency Shutdown Device: Test the sensitivity of the explosion-proof emergency shutdown button weekly to ensure it immediately cuts off fuel and power supply upon pressing. The device must be unobstructed and easily operable.
2) Gas Detection Alarm: Calibrate the combustible gas detector monthly to confirm its accurate identification of combustible gas concentration in Zone 2 environment. It should automatically trigger an alarm and shut down the genset when the concentration exceeds the limit. Detector sensors should be replaced according to their lifespan (usually 1-2 years).
Maintenance Precautions:
All maintenance operations must be carried out in non-explosive environments or after confirming the absence of combustible gases on site. Power and fuel must be disconnected before opening the cover for maintenance, and warning signs must be displayed.
When replacing parts, only original manufacturer explosion-proof certified parts must be used. It is strictly forbidden to substitute ordinary parts (such as non-explosion-proof bolts or ordinary gaskets), otherwise the explosion-proof performance will be directly lost.
Establish a maintenance log to record data from each inspection (such as temperature, insulation resistance, grounding resistance) and fault handling details. This facilitates tracking of genset status and passing explosion-proof compliance inspections.
