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Wet Stacking: Standby Power Systems Use The Diesel Engine. Diesel Is A Convenient

Wet stacking is a condition that can affect diesel engines, including generators, where unburnt fuel is exhausted instead of being fully combusted. It occurs when the engine runs below its optimal temperature for extended periods under a light load. This causes black residue to build up in the exhaust system. To prevent wet stacking, generators should be run under at least 75% of their maximum load to allow the engine to reach its designed operating temperature and fully burn all fuel. Automatic or portable auxiliary load banks can help ensure adequate loading of generators used primarily for standby power.

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J Alberto P Arrazate
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250 views

Wet Stacking: Standby Power Systems Use The Diesel Engine. Diesel Is A Convenient

Wet stacking is a condition that can affect diesel engines, including generators, where unburnt fuel is exhausted instead of being fully combusted. It occurs when the engine runs below its optimal temperature for extended periods under a light load. This causes black residue to build up in the exhaust system. To prevent wet stacking, generators should be run under at least 75% of their maximum load to allow the engine to reach its designed operating temperature and fully burn all fuel. Automatic or portable auxiliary load banks can help ensure adequate loading of generators used primarily for standby power.

Uploaded by

J Alberto P Arrazate
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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WET STACKING

A large percentage of standby power systems use the diesel engine. Diesel is a convenient
independent fuel source and the compression ignition systems of diesel engines have a
much higher thermal efficiency than the spark ignition system used by gas engines.
However, one factor to be considered when selecting a diesel power source is the potential
for “wet stacking.”

Wet stacking is a condition that can affect all diesel engines, not just generators. Wet
stacking means that not all the fuel is burned and the unburnt residue goes into the exhaust
side of the turbo and into the exhaust system. The main cause for diesel generators is that
the engine is running at a low proportion of its total capacity.

The symptoms of wet stacking are generally a black ooze around exhaust pipe connections
and around the turbo as well as continuous black exhaust from the stack when under a
constant load.

A diesel engine has to have exactly the right air to fuel ratio and be able to sustain the
operational temperature it was designed to run at for a complete burn of the fuel. When a
diesel generator only has light loads, it’s not able to reach the correct operating
temperature, which means not all the fuel is combusted. When the diesel engine runs below
its designed operating temperature for extended periods, unburned fuel is exhausted and
noticed as wetness in the exhaust system, hence the phrase wet stacking.

www.aksausa.com
WET STACKING

When unburned fuel is exhausted out of the combustion chamber, it starts to build up in the
exhaust side of the engine, resulting in fouled injectors and a buildup of carbon on the exhaust
valves, turbo charger and exhaust.

Excessive deposits can result in a loss of engine performance as gases bypass valve seatings,
exhaust buildup produces back pressure, and deposits on the turbo blades reduces turbo
efficiency.

Permanent damage will not be incurred over short periods, but over longer periods, deposits will
scar and erode key engine surfaces. Over time permanent damage can occur as the deposits
erode the engine surfaces. Additionally with the piston rings not getting to their designed
temperature, unburned fuel and gases can escape into the oil pan diluting the lubricating
properties of the oil, leading to premature engine wear.

The best way to avoid wet stacking is to ensure that the generator is run on load with at least
75% of its maximum load capacity so that it reaches its optimal running temperature. This can
either be achieved by doing an on load test using the building load or using an external load bank.
If wet stacking has already occurred but it is at its early stages, carrying out the same should burn
off the unburnt fuel and solve the problem. If wet stacking has occurred for some time, it might
be necessary to carry out an engine rehaul to resolve. The following load bank solutions should
prevent a reoccurrence of wet stacking.

Automatic auxiliary loading:


When the generator set is the only source of power and the connected load for periods is very
light a auxiliary load bank. The auxiliary automatically switches on when it detects the facility load
is too low to adequately load the generator. When the facility load increases the load bank will
switch off.

Facility manual load bank:


Operated as described for the automatic load bank, but a manually operated system for use with
light loads and when the larger load is also manually initiated. The load bank can also be used for
load testing a system primarily used for standby power.

Portable load bank:


The distributor for the diesel generator set is often the best qualified to undertake the
maintenance of the system. Today it is very common for the owner of a standby generator system
to outsource complete maintenance of the system and have a planned maintenance (PM)
contract with a full service generator-set supplier.

Aksa Power Generation USA Aksa Power Generation Aksa Power Generation LATAM
371 Exchange Street, West Monroe, LA 71292 USA & LATAM 12320 NW 116th Street, Miami, FL 33178
T: + 1 318 8558377 a member of T: + 1 305 5920103
[email protected] [email protected]
*Manufacturer reserves the right to make changes in model, technical specifications, color, equipment and accessories without prior notice.

www.aksausa.com
www.aksalatam.com

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