Haixing Power Sharing: Installation Specifications for Diesel Generator Units

The correct installation of generator sets is the prerequisite for its operation. There are many contents involved in standard installation. You might as well take a look at the complete collection of diesel generator sets organized by the staff of Haixing Power. It is of great reference value.

1. Preparation work before unit installation:

⑴ Transport of units

When handling, please pay attention to the lifting ropes that should be tied in an appropriate position and lifted and placed gently. When the unit is transported to the destination, it should be placed in the warehouse as much as possible. If there is no warehouse that needs to be stored in the open air, the fuel tank should be raised to prevent rainwater from soaking. A rainproof tent should be covered on the box to prevent sun and rain from damaging the equipment.

Because the unit is large in size and heavy in weight, the transport route should be arranged before installation, and a transport port should be reserved in the computer room. If the doors and windows are not large enough, you can use the doors and windows to reserve a larger handling port. After the unit is moved in, then repair the walls and install doors and windows.

⑵ Unboxing

Before unboxing, you should clean the dust and check whether the box is damaged. Verify the box number and quantity, and do not damage the machine when unboxing. The order of unboxing is to fold the top plate first and then remove the side plate. After unboxing, you should do the following:

①Calculate all units and accessories based on the unit list and the packing list;
② Check whether the main dimensions of the unit and accessories are consistent with the drawings;
③ Check whether the unit and accessories are damaged or rust;
④ If the unit cannot be installed in time after inspection, the disassembled parts should be re-applied with anti-rust oil to properly protect. Do not rotate the transmission and sliding parts of the unit until the anti-rust oil has not been cleared. If the anti-rust oil has been removed after the inspection, the anti-rust oil should be re-applied after the inspection.
⑤ The unit after unboxing should be kept and placed horizontally. The flanges and various interfaces must be sealed, bandaged, and prevent rainwater and gray sand from being immersed in.

⑶ Scribing positioning

Define the vertical and horizontal reference lines of the unit installation location according to the relationship dimensions between the unit and the wall or column center and between the unit as indicated in the unit plan layout diagram. The allowable deviation between the unit center and the wall or column center is 20mm, and the allowable deviation between the unit is 10mm.

⑷ Check the equipment to be installed

Check the equipment, understand the design content and construction drawings, prepare materials according to the materials required for the design drawings, and send the materials to the construction site in sequence according to the construction plan.

If there are no design drawings, refer to the instructions, and consider the water source, power supply, maintenance and use, determine the size and location of the civil engineering plane, and draw a plan of the unit layout according to the purpose and installation requirements of the equipment.

⑸ Prepare lifting equipment and installation tools

2. Installation of unit

⑴ Measuring the vertical and horizontal center line of the foundation and unit

Before the unit is in place, the vertical and horizontal center lines of the foundation and unit and the vibration damper positioning line should be drawn according to the drawings.

⑵ Hoisting unit

When lifting, use a wire rope of sufficient strength to be placed on the lifting position of the unit. It cannot be placed on the shaft. It should also prevent damage to the oil pipe and dial. The unit should be lifted as required, aligned with the foundation center line and the vibration damper, and level the unit.

⑶ Unit leveling

Use the horn to level the machine. The installation accuracy is the vertical and horizontal deviations of 0.1mm per meter. There cannot be a spacing between the hose and the base to make it subject to even force.

Installation of smoke exhaust pipe

The exposed part of the smoke exhaust pipe should not come into contact with wood or other flammable substances. The bearing of the smoke pipe must allow thermal expansion to occur and the smoke pipe can prevent rainwater from entering.

There are two ways to lay the smoke exhaust pipe:

⑴. Horizontal overhead: The advantages are few turns and small resistance; the disadvantages are poor indoor heat dissipation and high temperature in the computer room.

⑵. Laying in the trench: The advantage is good indoor heat dissipation; the disadvantages are many turns and large resistance.

The temperature of the smoke exhaust pipe of the unit is high. In order to prevent scalding operators and reduce the increase in the temperature of the machine room, insulation treatment should be carried out. The insulation and heat-resistant materials can be wrapped with glass wire or aluminum silicate, which can act as heat insulation and noise reduction.

3. Installation of exhaust system

⑴. The working definition of the exhaust system of a diesel generator set refers to the exhaust pipe connected to the computer room by the engine exhaust port after the diesel generator set is installed on the basis of the machine room.

⑵. The exhaust system of the diesel generator set includes the exhaust pipe connected to the computer room outside the computer room with the engine standard configuration muffler, corrugated pipe, flanges, elbows, pads and exhaust pipes connected to the computer room.

The exhaust system should reduce the number of elbows as much as possible and shorten the total length of the exhaust pipe, otherwise it will increase the exhaust pipe pressure of the unit, causing excessive power loss to the unit, affecting the normal operation of the unit and reducing the normal service life of the unit. The exhaust pipe diameter specified in the technical data of diesel generator sets is generally based on the installation of the total length of the exhaust pipe of 6m and an elbow and a muffler. When the exhaust system has exceeded the specified length and number of elbows when actually installed, the exhaust pipe diameter should be appropriately increased, and the increase depends on the total length of the exhaust pipe and the number of elbows. The first section of the pipe connected from the exhaust main pipe of the unit supercharger must contain a flexible corrugated pipe section. The bellows have been randomly matched to the customer. The second section of the exhaust pipe should be elastically supported to avoid unreasonable installation of the exhaust pipe, or additional side stress and compressive stress caused by the relative displacement caused by the thermal effect of the exhaust system during operation are applied to the unit. All support mechanisms and suspension devices of the exhaust pipe should have corresponding elasticity. When there are more than one unit in the computer room, remember that the exhaust system of each unit should be independently designed and installed. It is never allowed to share an exhaust pipe between different units to avoid abnormal movement caused by different exhaust pressures of different units during operation, increase the exhaust back pressure and prevent waste smoke and exhaust gas from flowing back through the shared pipeline, affecting the normal power output of the unit or even causing damage to the unit.

4. Installation of electrical systems

⑴ Cable laying method

The laying methods of cables include direct burial, cable trench and wall laying.

⑵ When selecting the laying path of the cable, the following principles should be considered:

① The power path is short and there are few turns;
② Make the cable less damaged by mechanical, chemical and intraterrestrial currents; try to avoid crossing with other pipelines; avoid where the soil is to be excavated in the plan.

⑶ General requirements for cable laying

When laying cables, you must comply with the planning and design requirements of relevant technical regulations.

① Under the conditions permitted by laying conditions, the cable length can be considered as a margin of 1.5%~2% as a backup for maintenance. Direct buried cables should be buried in waves.

② For cables are introduced into or out of a building or structure, cables are led through floor slabs and main walls, from cable channels to poles, or cables laid along the walls are 2m above the ground and buried 0.25m deep underground. The cable should be protected by steel pipes, and the inner diameter of the steel pipe shall not be less than twice the outer diameter of the cable.

③ When the cables and different pipelines are buried in the first phase, cables are not allowed to be laid in the channels where gas pipes, natural gas pipes and liquid fuel pipelines are laid; a few cables are allowed to be laid in open trenches or tunnels of water pipes or ventilation channels, or intersecting with these trenches. Generally, cables are not laid in open trenches or tunnels of thermal pipelines; if the cables are not overheated, a few cables can be allowed to be laid in the channels of thermal pipelines, but they should be separated on different sides, or the cables should be installed under the thermal pipelines.

④The buried depth of the direct buried cable shall not be less than 0.7m, and the trench shall not be 0.6m away from the foundation of the building.

⑤ The structure of the cable trench should take into account the problems of fire protection and waterproofing.

⑥ The metal outer skin, metal cable head, protective steel pipe and metal support of the cable should be reliable grounded.
For convenience and safety reasons, it is recommended that customers pre-laid the cable in the cable duct and perform anti-seepage and leakage treatment when connecting the unit to the ATS distribution board and the vehicle-mounted cabinet. The electrical connection must be reliable in contact to prevent loosening, twisting and insulation damage caused by vibration.

5. Installation of oil pipes

The oil pipe should be black iron seamless steel pipes and galvanized pipes should not be used. The direction of the oil pipe should be avoided as much as possible from excessive fuel being affected by engine heat dissipation. The allowable fuel temperature before the fuel injection pump is 60 to 70, depending on the model. It is recommended to use a soft connection between the engine and the oil pipeline to ensure that the oil pipeline between the engine and the fuel tank does not leak.

6. Installation work adjustment test and collection

1. Unseal of the unit

When the unit leaves the factory, in order to prevent external metal parts from rusting, some parts are oil sealed. Therefore, the new unit has been installed and passed the inspection. After meeting the installation requirements, it must be opened before starting. Clean and wipe the external anti-rust oil of the unit; add 60℃ hot water to the cooling system to flow out from the water pump, body and the oil cooler drain switch for the full loss system, flush the cooling system, and soften the anti-rust oil of the crankshaft connecting rod mechanism. Clean the oil pan with cleaning diesel and add the clean diesel.

2. Unit inspection

Check the diesel engine
to check whether the surface of the unit is clean, whether the anchor nut is loose, and find problems and tighten them in time;

Check the cylinder compression force and rotate the crankshaft to see if there is any abnormal sound when the cylinder parts are running, and whether the crankshaft rotates freely. At the same time, pump the full loss system into each friction surface with oil. Pry the crankshaft by manpower, which feels very laborious and has reverse thrust (elastic force), indicating that the compression is normal;

Check the fuel supply system

Check whether the ventilation holes on the fuel tank are unobstructed and clean if there is any dirt. Whether the added diesel meets the required grade, whether the oil volume is sufficient, and then turn on the oil circuit switch;

Loosen the bleed screws of the diesel filter or oil injection pump, use a hand pump to pump oil, and remove air in the oil circuit;
check whether there is water leakage at each oil pipe joint, and if there is any problem, it should be dealt with in time.

Check the water cooling system

Check the water tank. If the water volume is insufficient, you should add enough clean soft water or antifreeze;
check whether there is any leakage in each water pipe joint. If there are any problems, you should deal with it in time;
check whether the tightness of the transmission belt is appropriate. The method is to press the middle of the transmission belt with hand, the transmission belt

Check the lubrication system

a. Check whether there is any oil leakage in the oil pipe joints for each full loss system. If there is any problem, it should be dealt with in a timely manner;
b. Check the oil volume of the oil pan of the oil pan, extract the dipstick for the full loss system, and observe the full loss system c. Whether the height of the oil meets the specified requirements, and if it does not meet, adjust it.
a. Check the density of the battery electrolyte, its normal value is 1.24-1.28. When the density is less than 1.180, b. It indicates that the battery is insufficient and the battery should be charged;
c. Check whether the circuit is connected correctly;
d. Check whether there is any dirt and oxidation on the battery terminals, and if so, it should be cleaned;
e. Check whether the starting motor, electromagnetic operating mechanism and other electrical contact are good.

2. Inspection of alternator;

Special attention should be paid to the mechanical coupling of single-bearing generators, and the breath between the rotors should be uniform;
according to the schematic diagram and wiring diagram, select the appropriate power cable and use a copper connector to connect the wiring. After the copper connector and busbar, the busbar and busbar are fixed, the gap between the connectors is greater than 0.05mm. The distance between the conductors must be greater than 10mm, and corresponding grounding wires must be installed;
the terminals in the generator outlet box are marked: U, V, W and N, which do not represent the actual phase sequence. The actual phase sequence depends on the steering of the generator. The certificate of conformity refers to the phase when UVW is represented by the phase when rotating clockwise; the sequence is represented by the actual phase when rotating counterclockwise;