I. Source Protection: Optimize Equipment Selection and Installation Environment
Avoiding corrosion risks during equipment selection and installation is the core of reducing subsequent maintenance costs, adapting to the high-humidity and high-ammonia environmental characteristics of pig farms.
1. Equipment Selection: Prioritize Anti-Corrosion Special Configurations
- Sealed Protection Type for Excitation Modules: As the "heart" of the generator, the excitation module should select models with a complete protective shell and a protection level of IP54 or higher. The shell is equipped with ammonia-resistant sealing rings to block the intrusion of ammonia gas and water vapor. Terminal blocks should be equipped with plastic sealed protective shells, which are fastened and sealed after wiring to avoid oxidation of exposed copper cores and formation of patina.
- Anti-Corrosion Materials for Body: For sufficient budget, stainless steel body is preferred, which is suitable for the year-round humid pig house environment, not easy to be corroded by ammonia gas, and the surface is easy to clean; for cost-effective choice, medium hot-dip galvanized body can be selected, whose surface protective layer can effectively isolate corrosive media. Avoid ordinary iron sheet painted with anti-rust paint (the iron sheet will rust quickly after the paint layer falls off).
- Anti-Corrosion Upgrade of Auxiliary Components: Select waterproof air filters, install water accumulation detection devices on fuel filters, use corrosion-resistant materials for water tanks and equip them with high-quality seals to reduce corrosion caused by cooling water leakage.
2. Installation Environment: Build Isolated Protection Space- Independent Machine Room Construction: Set up a separate generator room, away from the pig house flushing area and manure treatment area. The floor of the machine room is raised by more than 30cm to prevent rainwater backflow and ground moisture penetration, and the wall is coated with ammonia-proof and anti-corrosion paint.
- Environmental Control Equipment: Install industrial dehumidifiers in the machine room to control the relative humidity at 40%-60%RH, and cooperate with timed exhaust fans for ventilation; install sealing strips on doors and windows, and seal wall-penetrating holes with fire clay to block the intrusion of external humid air and ammonia gas.
- Rainproof and Anti-Spray Design: If a machine room cannot be built, a rain shelter should be installed for the unit, and rain caps should be installed at the inlets and outlets of the intake and exhaust pipes to avoid direct rainwater scouring the body or backflow into the cylinder. The position of the exhaust pipe should be appropriately raised to prevent water accumulation and backflow.
II. System-Specific Treatment: Precisely Solve Corrosion Problems of Each ComponentTargeted treatment measures are taken according to the different corrosion causes of the metal body, electrical system, fuel system and cooling system of the generator set to achieve full-system protection.
1. Metal Body and Structural Components: Block Electrochemical Corrosion
- Surface Protection Enhancement: Inspect exposed metal components (chassis, brackets, fuel tanks, etc.) quarterly. Immediately sand and clean rust spots when found, and apply epoxy zinc-rich primer and ammonia-resistant topcoat; apply vaseline or special anti-rust grease to screws, bolts and other connectors to isolate water vapor and ammonia gas.
- Regular Cleaning and Decontamination: Wipe the surface of the body with a dry cloth every week to remove dust, ammonia crystals and residual water droplets, avoiding the accumulation of corrosive media; if the body is contaminated with pig house flushing sewage, clean it with a neutral cleaning agent in time, dry it and spray silicon-based anti-corrosion agent.
2. Electrical System: Dual Protection Against Moisture and Ammonia
- Insulation Detection and Drying: Test the insulation resistance of generator windings and control lines with a megohmmeter every month to ensure it is ≥50MΩ; if the insulation drops, use a hot air blower (temperature ≤60℃) to dry the electrical cabinet and junction box for 2-3 hours after shutdown to remove internal moisture.
- Terminal Block Protection: Wrap waterproof tape around the wiring interface, and spray moisture-proof insulating sealant on key terminals; inspect terminals for patina every month, wipe slight oxidation with a dry cloth, and replace terminals and reseal if severely oxidized.
- Battery Maintenance: Wipe the surface of the battery with a dry cloth every week. If white/yellowish-green sulfate is generated on the electrode terminals, rinse with high-temperature hot water, dry it, and apply butter or vaseline to prevent secondary corrosion. Follow the principle of "remove the negative electrode first, then the positive electrode; install the positive electrode first, then the negative electrode" when disassembling and assembling the terminals to avoid sparks.
3. Fuel System: Protection Against Water, Bacteria and Corrosion
- Fuel Purification Treatment: Regularly drain water and sediments at the bottom of the fuel tank, clean the fuel tank and fuel filter every month to avoid acidic substances generated by the mixture of water and diesel corroding fuel injectors and high-pressure oil pumps. Select high-quality low-sulfur diesel to reduce the risk of sulfuric acid formation when sulfur-containing diesel meets water.
- Microbial Control: If the fuel turns black and smelly and the filter is clogged, it is likely due to microbial growth. It is necessary to thoroughly clean the fuel system, add special fuel bactericide, and check the sealing of the fuel tank to prevent rainwater infiltration.
4. Cooling System: Protection Against Scaling, Corrosion and Leakage
- Standard Use of Antifreeze: Avoid using ordinary tap water as cooling fluid. Select ethylene glycol or propylene glycol-based antifreeze and add it in proportion to lower the freezing point and inhibit corrosion. It is strictly prohibited to mix antifreezes of different formulas. Test the concentration with a refractometer every month and adjust it to the standard range in time.
- Scaling and Corrosion Treatment: Clean the water tank and water channels every six months to remove internal scaling and rust; check whether the cylinder liner sealing ring and cylinder head gasket are aging, and replace failed components in time to prevent cooling water from infiltrating into the cylinder and causing cylinder liner corrosion and water hammer accidents.
III. Daily Operation and Maintenance: Establish a Normalized Protection Mechanism
Corrosion protection requires long-term adherence. Through standardized inspections and regular maintenance, corrosion signs can be found in advance to avoid small problems from expanding into major failures.
1. Regular Inspection List
- Weekly Inspection: Wipe the body and excitation module shell, check for residual water droplets and rust spots; clean the battery surface and check the status of electrode terminals; check the operation of the dehumidifier in the machine room to ensure the humidity meets the standard.
- Monthly Inspection: Check terminals for oxidation and seals for aging; drain water at the bottom of the fuel tank and check the status of the fuel filter; test the insulation resistance of the electrical system and dry parts with reduced insulation in time.
- Quarterly Inspection: Conduct a comprehensive inspection of the body coating and metal components for rust, timely treat rust spots and touch up anti-rust paint; clean the cooling system and test the antifreeze concentration and cylinder liner sealing performance.
2. Emergency Treatment Measures
If the unit is accidentally soaked in rainwater or flushed with water, shut down immediately and take the following measures:
- Drain water from the oil pan, fuel tank and water channels, blow off residual water with compressed air, and clean the air filter (wash plastic foam filter elements with soapy water, dry and soak in oil; replace paper filter elements directly).
- Remove the intake and exhaust pipes, rotate the main shaft to drain water from the cylinder, add a little engine oil to the air inlet and reassemble. Start the unit and run it at idle speed, medium speed and high speed for 5 minutes each for running-in, and replace with new engine oil after shutdown.
- Dry the electrical system, put it into use only after the insulation resistance test is up to standard, check all seals, and replace aging or damaged components.
3. Management System Construction
Establish a special "three-prevention" (moisture prevention, ammonia prevention, corrosion prevention) file for generator sets to record protection measures, inspection records and maintenance history; formulate standardized operating procedures to clarify preventive maintenance content before winter and rainy seasons; conduct training for operators to standardize inspection and emergency treatment processes and improve protection awareness.
| Core Principle: The corrosion protection of diesel generator sets in pig farms adheres to the principle of "prevention first, combination of prevention and treatment". It is necessary to first block corrosive media through equipment selection and environmental control, and then cooperate with system-specific precise treatment and normalized operation and maintenance, which can significantly extend the service life of the unit and avoid production impact caused by shutdown due to corrosion. |
Post time: Jan-26-2026
