Installation process of diesel generator set

A diesel generator set is a small power generation equipment that refers to a power machinery that uses diesel as fuel and diesel engine as the prime mover to drive the generator to generate electricity. The Cummins diesel generator set refers to the Cummins diesel engine manufactured by Cummins, a leading global power equipment manufacturer. The following will explain the installation process of diesel generator sets:

1、 Basic production: Determine the elevation and geometric dimensions of the diesel generator on the concrete foundation according to the design requirements and product technical documents. Reserve anchor bolt holes for the unit on the foundation. After the generator enters the site, embed the anchor bolts according to the actual installation hole spacing. The strength grade of the foundation concrete must meet the design requirements.

2、 Diesel generator unboxing inspection

1. Equipment unboxing inspection shall be jointly carried out by the construction unit, supervising engineer, construction unit, and equipment manufacturer, and inspection records shall be kept.

2. Verify the diesel generator, accessories, and spare parts according to the equipment packing list, construction drawings, and equipment technical documents.

3. The nameplate of the diesel generator and its auxiliary equipment is complete, and the appearance inspection shows no damage or deformation.

4. The capacity, specifications, and model of the diesel generator must meet the design requirements and have a factory certificate of conformity and technical documents.

3、 Installation of diesel generator host

1) Before installing the unit, a detailed on-site inspection must be conducted, and a detailed transportation, lifting, and installation plan must be prepared based on the actual situation on site.

2) Inspect the construction quality and vibration prevention measures of the foundation to ensure compliance with design requirements.

3) Select appropriate lifting equipment and rigging according to the installation position and weight of the unit, and lift the equipment in place. The transportation and lifting of the unit must be operated by a crane operator with the cooperation of an electrician.

4) Use shims and other fixed iron components to carry out stable machine leveling operations, and pre tighten the anchor bolts. The leveling operation must be completed before tightening the anchor bolts. When using wedges for leveling, a pair of wedges should be connected by spot welding.

4、 Installation of generator exhaust, fuel, and cooling systems

1) Installation of exhaust system: The exhaust system of diesel generator set consists of flange connected pipes, supports, corrugated pipes, and mufflers. Asbestos gaskets should be added at the flange connection, and the outlet of the exhaust pipe should be polished. The muffler should be installed correctly. The corrugated pipe connected between the unit and the smoke exhaust pipe should not be subjected to force, and the outer side of the smoke exhaust pipe should be wrapped with a layer of insulation material.

2) The installation of fuel and cooling systems mainly includes the installation of oil storage tanks, oil tanks, cooling water tanks, electric heaters, pumps, instruments, and pipelines.

5、 Installation of electrical equipment

1) The generator control box (screen) is a supporting equipment for the generator, mainly used to control the power supply and voltage regulation of the generator. According to the actual situation on site, the control box of the small capacity generator is directly installed on the unit, while the control screen of the large capacity generator is fixed on the ground foundation of the machine room or installed in the control room isolated from the unit. The specific installation method should comply with the installation process standards of the composite power distribution control cabinet (screen, table).

2) For diesel generator sets below 500KW, a matching control box (screen) is provided randomly. For units above 500KW, the unit manufacturer generally proposes a control screen.

3) According to the installation position of the control screen and the unit, metal cable trays should be installed in accordance with the cable tray installation process standards.

6、 Unit wiring

1) The cables for power and control circuits should be laid and connected to the equipment in accordance with the cable laying process standards.

2) The wiring of the generator and control box should be correct and reliable. The phase sequence at both ends of the feeder must be consistent with the phase sequence of the original power supply system.

3) The wiring of the random distribution cabinet and control cabinet of the generator should be correct and error free, and all fasteners should be firm without missing or falling off. The models and specifications of switches and protective devices must meet the design requirements.

7、 Ground wire installation

1) Connect the neutral wire (working neutral wire) of the generator to the grounding busbar with a dedicated ground wire and nut, and ensure that the bolt anti loosening device is complete and labeled.

2) The accessible conductors of the generator body and mechanical parts should be reliably connected to the protective grounding (PE) or grounding wire (PEN).

The above is a brief introduction to the installation steps and process of diesel generator sets, hoping to be helpful for the operation and use of customers.