Haixing Power shares: Diesel generator set installation specifications

Generator setCorrect installation is the prerequisite for its operation. Standard installation contains a lot of content. You may wish to take a look at the complete installation specifications of diesel generator sets compiled by the staff of Haixing Power. It is of great reference value.

1. Preparation work before unit installation:

⑴ Transportation of the unit

When transporting, attention should be paid to tying the lifting rope in an appropriate position and lifting it gently. After the unit is transported to the destination, it should be stored in a warehouse as much as possible. If there is no warehouse and it needs to be stored in the open air, the fuel tank should be elevated to prevent it from being soaked by rain. The tank should be covered with a rainproof tent to prevent it from being exposed to the sun and rain. Damage equipment.

Due to the large size and heavy weight of the unit, the transport route should be arranged before installation, and a transport port should be reserved in the machine room. If the doors and windows are not large enough, you can use the location of the doors and windows to reserve a larger port. After the standby unit moves in, you can then build the wall and install the doors and windows.

⑵ Unpacking

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

① Inventory all units and accessories according to the unit list and 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 rusted;
④ If the unit cannot be installed in time after inspection, the finishing surface of the disassembled parts should be re-coated with anti-rust oil for proper protection. Do not rotate the transmission part and sliding part of the unit before the anti-rust oil is removed. If the anti-rust oil has been removed after inspection, it should be re-applied after the inspection.
⑤ The unit after unpacking must be carefully stored and placed horizontally. The flange and various interfaces must be capped and bandaged to prevent rainwater and sand from infiltrating.

⑶ Marking and positioning

Delineate the vertical and horizontal datum lines of the unit installation location according to the relationship dimensions between the unit and the center of the wall or column, and between the units marked on the unit floor plan. The allowable deviation between the center of the unit and the center of the wall or column is 20mm, and the allowable deviation between the units is 10mm.

⑷ Check equipment and prepare for installation

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

If there are no design drawings, you should refer to the instructions and determine the size and location of the civil construction plane according to the purpose and installation requirements of the equipment, taking into account the water source, power supply, maintenance and use, etc., and draw a unit layout plan.

⑸ Prepare lifting equipment and installation tools

2. Installation of the unit

⑴ Measure the vertical and horizontal center lines of the foundation and the unit

Before the unit is in place, the vertical and horizontal center lines of the foundation and the unit and the positioning line of the shock absorber should be drawn according to the 'layout' drawing.

⑵ Hoisting unit

When hoisting, a steel wire rope of sufficient strength should be used at the lifting position of the unit. It should not be placed on the shaft, and the oil pipe and dial should be prevented from being damaged. Lift the unit as required, align it with the centerline of the foundation and the shock absorber, and cushion the unit. flat.

⑶ Unit leveling

Use the shims to level the machine. The installation accuracy is 0.1mm per meter in longitudinal and transverse horizontal deviations. There should be no gap between the pad iron and the machine base to ensure even stress.

Installation of exhaust pipe

Exposed parts of the exhaust pipe should not come into contact with wood or other flammable materials. The extension of the smoke pipe must allow thermal expansion to occur, and the smoke pipe must prevent rainwater from entering.

There are two ways to lay exhaust pipes:

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

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

The exhaust pipe of the unit has a high temperature. In order to prevent the operator from being scalded and reduce the increase in temperature of the machine room caused by radiant heat, it should be insulated. The heat-insulating and heat-resistant material can be wrapped with glass fiber or aluminum silicate, which can play a role in heat insulation and noise reduction.

3. Installation of exhaust system

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

⑵. The exhaust system of the diesel generator set includes the standard muffler, bellows, flange, elbow, gasket and exhaust pipe connecting the engine room to the outside of the engine room.

The exhaust system should reduce the number of elbows and shorten the total length of the exhaust pipe as much as possible. Otherwise, the exhaust pipe pressure of the unit will increase, causing excessive power loss of the unit, affecting the normal operation of the unit and reducing the unit's performance. Normal service life. The exhaust pipe diameter specified in the technical data of the diesel generator set is generally based on the total length of the exhaust pipe being 6m and the installation of an elbow and a muffler. When the exhaust system exceeds the specified length and number of elbows during actual installation, the exhaust pipe diameter should be appropriately increased. The extent of the increase depends on the total length of the exhaust pipe and the number of elbows. The first section of piping from the unit's supercharger exhaust manifold shall include a flexible bellows section. This corrugated pipe has been supplied to the customer. The second section of the exhaust pipe should be elastically supported to avoid additional lateral stress and pressure caused by unreasonable installation of the exhaust pipe or relative displacement of the exhaust system due to thermal effects when the unit is running. When stress is added to the unit, all supporting mechanisms and suspension devices of the exhaust pipe should have corresponding elasticity. When there is more than one unit in the machine room, remember that the exhaust system of each unit should be designed and installed independently. It is never allowed to allow different units to share an exhaust pipe to avoid abnormal fluctuations caused by different exhaust pressures of different units when the unit is running, increase exhaust back pressure and prevent waste smoke from flowing back through the shared pipe. Affect the normal power output of the unit or even cause damage to the unit.

4. Installation of electrical system

⑴ Cable laying method

There are several ways to lay cables: directly buried in the ground, using cable trenches and laying along walls.

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

① The power path is short and there are few turns;
② Make the cables less likely to be damaged by mechanical, chemical, ground current and other factors; try to avoid crossing with other pipelines; avoid planned excavation areas.

⑶ General requirements for cable laying

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

① If the laying conditions permit, a margin of 1.5﹪~2% can be considered for the cable length as a backup during maintenance. Directly buried cables should be buried in a wave shape.

② For cables leading in or out of buildings or structures, cables passing through floors and main walls, leading from cable trenches to poles, or cables laid along walls at a height of 2m above the ground and buried 0.25m deep underground. The cable should be protected by a steel pipe, and the inner diameter of the steel pipe should not be less than 2 times the outer diameter of the cable.

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

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

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

⑥The metal sheath of the cable, the metal cable head, the protective steel pipe and the metal bracket should all be reliably grounded.
For the sake of convenience and safety, it is recommended that customers pre-lay the cables in the cable trough when connecting the unit to the ATS switchboard and parallel cabinet, and perform anti-penetration and anti-leakage treatments. The electrical connection must be reliable to prevent vibration. caused by loosening, twisting and insulation damage.

5. Installation of oil pipes

The oil pipe should be a black iron seamless steel pipe instead of a galvanized pipe. The direction of the oil pipe should be as much as possible to prevent the fuel from being excessively affected by the heat dissipation of the engine. The allowable temperature of the fuel in front of the fuel injection pump is 60 to 70 degrees Celsius, depending on the model. It is recommended to use a soft connection between the engine and the fuel pipe, and ensure that there is no leakage in the fuel pipe between the engine and the fuel tank.

6. Debugging and acceptance of installation work

1. Unpacking the unit

When the unit leaves the factory, some parts are oil-sealed to prevent external metal parts from rusting. Therefore, after the new unit has been installed and passed inspection, it must be unsealed before it can be started after meeting the installation requirements. Clean and wipe off the anti-rust oil on the outside of the unit; add 60°C hot water to the cooling system so that it flows out from the water pump, the body and the oil cooler drain switch for the total loss system, rinse the cooling system, and soften the anti-rust of the crankshaft connecting rod mechanism. Rust oil. Clean the oil pan with clean diesel and add clean diesel.

2. Inspection of the unit

Diesel engine inspection
Check whether the surface of the unit is clean and whether the anchor nuts are loose. If any problems are found, tighten them in time;

Check the cylinder compression, rotate the crankshaft and check whether there are any abnormal noises in the operation of each cylinder's parts, and whether the crankshaft rotates freely. At the same time, pump the oil for the full-loss system into each friction surface, and manually pry the crankshaft. It feels very laborious and has reverse thrust (elasticity). ), indicating normal compression;

Check the condition of the fuel supply system

Check whether the vent hole on the fuel tank is clear and clean it if there is any dirt. Check whether the added diesel meets the required grade and whether the amount of oil is sufficient, and then turn on the oil circuit switch;

Unscrew the bleed screw of the diesel filter or fuel injection pump, pump oil with a hand pump, and remove the air in the oil line;
Check each oil pipe joint for leaks. If there is any problem, deal with it in time.

Check the condition of the water cooling system

Check the water tank. If there is insufficient water, add enough clean soft water or antifreeze;
Check all water pipe joints for leaks, and deal with them promptly if there are any problems;
Check the drive belt for proper tightness. The method is to press the middle part of the transmission belt with your hands.

Check the condition of the lubrication system

a. Check the oil pipe joints of each total loss system for oil leakage. If there are any problems, they should be dealt with in time;
b. Check the amount of oil used by the total loss system in the oil pan, pull out the oil dipstick for the total loss system, and observe whether the oil height of the total loss system meets the specified requirements. If it does not, make adjustments.
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 dirt or oxidation on the battery terminals, and if so, clean them;
e. Check whether the starter motor, electromagnetic operating mechanism and other electrical contacts are in good contact.

2. Inspection of alternator;

Special attention must be paid to the mechanical coupling of single-bearing generators, and the air between the rotors must be uniform;
According to the schematic diagram and wiring diagram, select the appropriate power cable and use copper connectors for wiring. After the copper connectors are firmly fixed to the busbar and the busbar to the busbar, the gap between the connectors should be greater than 0.05mm. The distance between wires must be greater than 10mm, and corresponding grounding wires need to be installed;
The terminals in the generator outlet box are marked: U, V, W and N, which do not indicate the actual phase sequence. The actual phase sequence depends on the rotation of the generator. UVW is quoted on the certificate to indicate the phase sequence when rotating clockwise, and VUW indicates the actual phase sequence when rotating counterclockwise;