The Ultimate Guide to Diesel Generator Installation

Table of Contents

1. Introduction
2. Requirements for Proper Installation and Commissioning
   • Importance of Proper Installation and Commissioning
   • Government Regulations for Canopy Gensets
   • Concrete Foundation Block
   • Earthling Requirements
   • Chemical Earthing
   • Unloading and Placement
   • Ventilation Considerations
   • Anti-Condensation Heaters
   • General Checks
3. Exhaust Piping
4. Earthing
5. Cabling
6. Battery Check
7. Power Cabling
8. Testing and Calibration
   • Performance Parameters
   • Sound Level Measurement
   • Load Testing
   • AMF Panel Operation
   • Alarms and Shutdown
   • Final Checks and Shutdown

Installation and Commissioning of Low to Medium KVA Canopy Gensets

Proper installation and commissioning of a genset is crucial to ensure better uptime and safety. This article provides a comprehensive guide to the installation and commissioning process of low to medium KVA canopy gensets. It covers the necessary requirements, procedures, and checks to be conducted to achieve optimal performance and reliability.

1. Introduction

The installation and commissioning of a genset involves various steps to ensure its proper functioning and longevity. From the initial groundwork and foundation preparation to the final testing and calibration, each stage plays a vital role in achieving a robust and efficient power generation system.

2. Requirements for Proper Installation and Commissioning

2.1 Importance of Proper Installation and Commissioning

Installing and commissioning a genset correctly is essential for several reasons. It ensures the genset operates safely, minimizes downtime, prevents equipment failures, and extends the lifespan of the generator. Proper installation and commissioning also help comply with government regulations and maintain the warranty of the genset.

2.2 Government Regulations for Canopy Gensets

To ensure safety and environmental compliance, government regulations in India mandate the use of enclosures called canopies for all gensets manufactured in manufacturing plants. These canopies provide protection and reduce noise levels during operation.

2.3 Concrete Foundation Block

Before the arrival of the genset, a cement concrete foundation block of adequate size should be prepared. The length and breadth of the block must be at least 12 inches more than the genset. The depth of the block should be 600 millimeters, and if the soil is loose, the depth may need to be increased. The surface of the concrete block should be flat and leveled using a spirit level.

2.4 Earthing Requirements

Proper earthing is crucial for the safe operation of a genset. Four earth pits are required, including two for body earthing and two for neutral earthing. The body and neutral earth pits should be located on opposite sides of the canopy. The body and neutral earth plates should never be interconnected. Chemical earthing is recommended in locations with low water levels and high soil resistivity.

2.5 Chemical Earthing

Chemical earthing offers several advantages over conventional methods like salt or charcoal earthing. It requires less maintenance, has a longer lifespan, and provides better conductivity. The process involves drilling a bore, inserting an earthing electrode, and creating a slurry mixture to fill the bore for efficient earthing.

2.6 Unloading and Placement

Proper unloading and placement of the genset are crucial to avoid damage and ensure optimum performance. The genset should be lifted using the hook provided on the canopy, ensuring that the lifting angle does not exceed 7 degrees. Ventilation and placement away from polluted atmospheres are important considerations to prevent overheating and fuel consumption.

2.7 Ventilation Considerations

Adequate ventilation is essential to maintain the proper temperature of the genset and prevent overheating. Improper ventilation can lead to higher fuel consumption and decreased performance. Anti-condensation heaters are recommended for alternators in humid or coastal atmospheric environments.

2.8 General Checks

Before starting the genset, several general checks must be performed. These include visually inspecting the canopy for any damages, checking the door locks, examining the base frame, fixing loose parts, aligning and fastening exhaust bellows, and ensuring the tightness of various bolts.

3. Exhaust Piping

The exhaust piping of the genset plays a crucial role in releasing exhaust gases safely and efficiently. It should be installed in a way that ensures minimal back pressure on the engine. Proper routing, using sound attenuated ducting for rooftop installations, and minimizing the number of bends are essential considerations.

4. Earthing

The proper earthing of the genset is essential for safety and smooth operation. Copper or GI strips of suitable size should be used for earthing to ensure low resistance and efficient grounding. Earthing condition tests should be conducted using specialized equipment like an earth tester, and the results should be monitored periodically.

5. Cabling

The cabling of the genset includes various connections between the alternator, control panel, changeover switch, and mains. Correct sizing of cables and thimbles is crucial to ensure safe and reliable power transmission. Loose connections and undersized cables should be avoided to prevent overheating and electrical failures.

6. Battery Check

The battery of the genset plays a vital role in starting the engine and providing backup power. It is important to clean, tighten, and apply petroleum gel to the battery terminals to prevent corrosion and ensure proper functioning. The battery should be fully charged, and the polarity of the connections should be verified before applying power.

7. Power Cabling

The power cabling between the alternator and control panel, as well as the control panel and changeover switch, must be done correctly with the appropriate size of cables and thimbles. Using the correct cable size will ensure efficient power transmission and minimize the risk of electrical failures.

8. Testing and Calibration

After the installation and connection of all components, thorough testing and calibration of the genset are essential to ensure optimal performance. This includes checking performance parameters such as RPM, frequency, voltage, oil pressure, water temperature, and sound level. Load testing, AMF panel operation, and functional checks of alarms and shutdown systems should also be conducted.

8.1 Performance Parameters

Various performance parameters need to be monitored during the testing and calibration process. These parameters include RPM, frequency, voltage, oil pressure, and water temperature. Any abnormalities or deviations from standard values should be addressed promptly.

8.2 Sound Level Measurement

The sound level of the genset should be measured using a sound level meter, commonly known as a dB meter. The noise level should comply with the Ministry of Environment and Forests guidelines. The sound level should not exceed 75 dB at a one-meter distance from the genset.

8.3 Load Testing

Applying load to the genset should be done in steps, avoiding starting with 100% load. Proper distribution of load on all phases should be ensured to maintain a balanced system. Monitoring various parameters during the load testing phase is crucial to verify the genset's performance under different load conditions.

8.4 AMF Panel Operation

If the genset is equipped with an Automatic Mains Failure (AMF) panel, it should be tested for proper operation. The AMF panel ensures automatic transfer of power from the mains to the genset in case of a power outage. Checking the AMF panel's functionality and seamless transition is essential.

8.5 Alarms and Shutdown

All alarm systems, including low oil pressure (LOP), high water temperature (HWT), low fuel level (LFL), and reverse power (RWL), should be tested for proper functioning. The genset's automatic shutdown mechanisms should also be tested to ensure prompt response in case of any emergencies.

8.6 Final Checks and Shutdown

Before shutting down the genset, final checks should be conducted to ensure the proper functioning of all components. Power should be turned off, and the genset should be allowed to run on no load for a few minutes before shutting it down completely. This final step helps in eliminating any residual energy and allowing the genset to cool down gradually.

Highlights

• Proper installation and commissioning of gensets are crucial for uptime and safety.
• Government regulations mandate the use of canopies for gensets in India.
• Concrete foundation blocks of adequate size and earthing requirements are essential.
• Chemical earthing offers advantages over conventional methods.
• Ventilation, exhaust piping, and proper cabling are important considerations.
• Thorough testing and calibration of performance parameters are necessary.
• Sound level monitoring, load testing, and AMF panel operation are crucial.
• Alarms and shutdown systems should be tested for proper functionality.
• Final checks and a gradual shutdown ensure safe operation and longevity.

FAQ

Q: Why is proper installation and commissioning of gensets important? A: Proper installation and commissioning ensure safety, uptime, and reliability of gensets. It also helps comply with government regulations and maintain warranties.

Q: What are the requirements for installation and commissioning? A: The requirements include concrete foundation blocks, proper earthing, ventilation, exhaust piping, cabling, and testing and calibration procedures.

Q: What is chemical earthing, and why is it recommended? A: Chemical earthing is a maintenance-free method that offers better conductivity and has a longer lifespan compared to conventional salt or charcoal earthing methods.

Q: How should load testing be conducted? A: Load testing should be done in steps, avoiding starting with 100% load. Distribution of load on all phases should be balanced, and performance parameters should be monitored.

Q: What are the key parameters to monitor during genset testing and calibration? A: RPM, frequency, voltage, oil pressure, water temperature, and sound level are the key parameters to monitor during genset testing and calibration.