Proper installation, commissioning and use are the basis for ensuring long-term safe, reliable and stable operation of diesel generator sets. Whether the installation, commissioning and use of the unit are standardized, has a great impact on the operation of the unit, the interval between overhaul and the service life. The superior characteristics, service life and reliability of the unit can be exerted in use, depending to some extent on whether the installation, commissioning and use methods are correct or not.
First, the preparation of the standby generator set before installation
1. Handling of the unit
When transporting, care should be taken to tie the hoisting ropes in place and hang them lightly. When the unit is shipped to the destination, it should be placed in the warehouse as much as possible. If there is no warehouse to be stored in the open air, the fuel tank should be raised to prevent the rain from getting wet. The box should be covered with a rainproof tent to prevent sun and rain. Damage to the device.
Due to the large size and heavy weight of the unit, the handling route should be arranged before installation, and the handling port should be reserved in the equipment room. If the doors and windows are not large enough, a large carrying port can be reserved by using the position of the door and window. After the standby group is moved in, the wall is installed and the doors and windows are installed.
2, out of the box
Before unpacking, first remove dust and check the box for damage. Check the box number and quantity and do not damage the machine when unpacking. The order of unpacking is to first remove the top plate and then remove the side plate. After unpacking, you should do the following work:
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 the unit and accessories for damage and rust;
4 If the unit cannot be installed in time after inspection, the rust-proof oil should be re-applied on the finished surface of the disassembled machine for proper protection. Do not turn the transmission part and the sliding part of the unit until the anti-rust oil has not been removed. If the anti-rust oil has been removed after the inspection, it should be re-applied with anti-rust oil after the inspection;
5 The unit after unpacking should be kept in a safe place and must be placed horizontally. The flange and various interfaces must be covered, bandaged, and protected from rainwater and sand.
3, line positioning
According to the relationship between the unit and the wall or column center marked by the plane layout drawing of the unit and the relationship between the unit and the unit, the vertical and horizontal reference lines of the unit installation location are delineated. 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 unit and the unit is 10mm.
4, check the equipment ready to install
Inspect 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 order according to the construction plan.
If there is no design drawing, refer to the instruction manual, and according to the use and installation requirements of the equipment, consider the water source, power supply, maintenance and use, etc., determine the size and position of the civil construction plane, and draw a plan layout of the unit.
5. Prepare lifting equipment and installation tools
Second, the pre-installation inspection
Before the unit is installed, check whether the equipment room, foundation, etc. meet the requirements. Avoid the passive situation that the test machine or operation does not meet the requirements after the installation is implemented.
In terms of overall layout, it can be based on the equipment room, infrastructure conditions, and equipment room design requirements. The choice of equipment room needs to consider the following factors:
1 The surrounding environment is conducive to ventilation and exhaust, ensuring exhaust back pressure and avoiding heating backflow.
2 sufficient operation and maintenance space.
3 layout is reasonable. The air inlet area is ≥ 2 times the heat-dissipating water tank area, and the air outlet area is ≥ 1.5 times the heat-dissipating water tank area.
4 Do not place flammable or explosive materials.
The equipment room must have enough space for the air to circulate freely, which is very important to ensure the normal performance of the unit, reduce the power loss of the unit and ensure the normal service life of the unit.
Other flammable and explosive materials should not be placed inside the equipment room, and any objects that are easily caught in the unit's protective net cover or even directly into the body and may affect the normal use of the unit.
For the installation and construction of units that do not have special requirements, the design requirements for the equipment room are not high. It is only necessary to ensure that the air inlet and exhaust air outlet of the equipment room meet the requirements of technical specifications under the premise of ensuring that the exhaust back pressure does not exceed the specified value. And to avoid the return of the heating, and the inside of the machine room can reserve enough space for operation and maintenance.
For some parts that need to be made and placed in the engine room, you should pay attention to the isolation from the main space of the equipment room and meet the requirements of the local environmental protection fire department.
The equipment room should be able to arrange enough air inlets and outlets. If the cooling capacity of the intake and exhaust air is insufficient, it is necessary to increase the installation mode of the air intake fan or the remote water tank. When selecting the specific placement position of the diesel generator set in the equipment room, It is preferable to reserve sufficient operation and maintenance space and air circulation space around the unit and the upper part.
When the automatic load conversion system ATS or synchronous parallel system is installed in the equipment room, it should be noted that sufficient operation and maintenance space is reserved around it.
Third, the unit installation
1. Measure the foundation and the centerline of the unit. Before the unit is in place, find the vertical and horizontal center lines and installation positioning lines of the foundation and unit according to the drawing “release line”.
2. Lifting the unit. When lifting, use a steel wire rope of sufficient strength to lift the unit in the lifting part of the unit (not allowed to cover the oil pipe and the meter box on the shaft). Lift the unit according to the technical installation procedure of the lifting, align the basic center line and the mounting hole, and hang the unit. Set it up and level it. If the crane is not allowed on site, the unit can be placed on the roller bar, rolled to the selected position, and then the jack is used to raise the unit.
3. The unit is leveled. When installing, the level should be measured with a level gauge to fix the unit on a level basis. There should be a special shock pad or anchor bolt between the unit and the foundation (only for external shock absorbers).
List of materials installed under the cushion base:
Installing the backplane
Connecting angle steel
Rivet bolts
Rubber cushions
Angle steel connecting bolt
Damper connection bolt
Damper adjustment
Figure 1 Note: Grounding treatment
After the unit is installed in position, it must be reliably grounded. The grounding is usually carried out by flat steel and the grounding point of the equipment room and is led to the base of the unit and connected to the grounding point (net). And in line with safety regulations.
Fourth, the oil supply system
1, fuel
The composition of the fuel has a very important impact on the operation and service life of the diesel engine and the composition of the emissions. In order to achieve the specified power, fuel economy and emission standards set by the local environmental protection department, clean light fuel oil that meets international and national standards should be used. Most of the fuel will deteriorate if it is not used for a long time. For the standby unit, it is best to reserve only a few hours of fuel for the unit to run continuously. Therefore, the correct unit maintenance is to completely clean the tank once in 18 months.
2, fuel tank
The tank volume should be designed according to the unit's full load fuel consumption. When customers make fuel tanks, they should pay attention to the following aspects:
(1) The fuel discharge port should be located at the bottom of the fuel tank to facilitate the discharge of water and sediment and keep the fuel clean. The fuel tank outlet (into the body) is not less than 50mm from the bottom of the tank to ensure that the fuel entering the body is clean enough to prevent water or other impurities from entering the combustion chamber.
(2) The distance between the oil outlet and the oil return port is at least 300mm. This is to prevent the hot oil and air from the oil return pipe from directly entering the oil outlet and the diesel engine, reducing the combustion efficiency and detrimental to the normal working state of the diesel engine. And service life. The suction port should not be lower than 1000mm of the oil pump, or the return pipe is 2500mm higher than the oil pump (different diesel engines are different), so as to avoid excessive pressure difference, affecting the normal operation of the oil pump and the normal supply of fuel.
An oil pan with a slight angle of inclination should be added to the bottom of the tank to collect the spilled or leaking diesel.
There should be a snorkel at the top of the tank to release the dirt and balance atmospheric pressure in the tank.
The fuel tank is preferably made of steel plate. In order to avoid chemical reaction between the fuel and the fuel tank material, impurities and deterioration of fuel quality, do not paint or galvanize the inside of the fuel tank. Copper plates and galvanized plates are not suitable as materials for the fuel tank.
The size of the fuel tank is generally determined by the length of the working hours and the requirements of the local fire department. If the fuel tank is placed in the machine room, it is necessary to separate the wall and install the fire door.
The tank capacity is calculated as follows:
Fuel tank capacity (L) = engine rated power (KW) × engine fuel consumption rate × (L / KWh.) × fuel replenishment period (h) × 1.2
3, tubing installation
The tubing shall be a black iron seamless steel tube and shall not be a galvanized pipe. The direction of the tubing shall be as far as possible to avoid the fuel being excessively affected by the heat dissipation of the engine. The maximum allowable temperature of the fuel before the fuel injection pump is 60 ° C ~ 70 ° C, depending on the model. It is recommended to use a soft connection between the engine and the delivery line and to ensure that the fuel line between the engine and the tank does not leak.
Figure 2 Oil pipeline and soft connection
Figure 3 Laying of the oil pipeline
4. Typical oil supply system
The oil supply system generally consists of a storage tank, a daily fuel tank, an oil pump, a solenoid valve, and a connecting line. When the position of the oil storage tank is low (lower than the suction stroke of the unit pump) or high (higher than the pressure that the throttle can withstand) Must use a daily fuel tank. The liquid fuel tank has a liquid level display and a float switch (automatic fuel tank equipment). The installation requirements of the oil pump system refer to the installation specifications of the system equipment.
Figure 4 Schematic diagram of a typical oil supply system
Fifth, the installation of the exhaust system
1. The exhaust fumes emitted by the unit during operation must be directly led out from a properly designed and installed discharge system to the outside environment without affecting the surrounding environment and the normal working life of the residents. The diesel generator set exhaust system includes a muffler, bellows, flanges, elbows, gaskets, and machine room that are standard in the engine and are connected to exhaust ducts outside the machine room.
The exhaust system should reduce the number of elbows as much as possible and shorten the total length of the exhaust pipe. Otherwise, the exhaust back pressure of the unit will increase, which will cause excessive power loss and affect the normal operation and lowering of the unit. The normal service life of the unit. The exhaust pipe diameter specified in the technical data of the diesel generator set is generally based on the installation example of a total length of the exhaust pipe of 6 m and a maximum of one elbow and one muffler. When the exhaust system is actually installed, it has exceeded the specified length. As for the number of elbows, the exhaust pipe diameter should be appropriately increased, and the increase range depends on the total length of the exhaust pipe and the number of elbows.
The first section of the pipe from the unit supercharger exhaust manifold must contain a flexible corrugated pipe section that has been supplied to the customer at random. The second section of the exhaust pipe shall be elastically supported to avoid unreasonable installation of the exhaust pipe, or additional side stress and compressive stress caused by the relative displacement of the exhaust system due to thermal effects during operation of the unit are applied to the unit. All support mechanisms and suspensions of the exhaust duct should have a certain degree of flexibility.
When there is more than one unit in the equipment room, it is important to remember that the exhaust system of each unit should be designed and installed independently. It is absolutely not allowed to share the same exhaust pipe with different units to avoid the exhaust pressure of different units when the unit is running. Abnormal agitation caused by different, and increase exhaust back pressure and prevent waste fumes from flowing back through the common pipeline, affecting the normal power output of the unit and even causing damage to the unit.
2. Weld the random flange and the exhaust pipe (the length and quantity of the exhaust pipe according to the size of the machine room and the direction of the smoke exhaust), pay attention to the matching relationship between the flanges when welding;
3. According to the size and installation height of the muffler and the exhaust pipe, configure the corresponding ferrule;
4. Connect the muffler, elbow, vertical direction exhaust pipe and bellows according to the drawings with bolts to ensure good sealing everywhere;
5. Connect the horizontal exhaust pipe and the muffler outlet with bolts to ensure the sealing of the joint surface;
6. A layer of thermal insulation material is wrapped around the exhaust pipe; in order to avoid excessive temperature in the machine room, the normal working environment of the unit is deteriorated and the operator is burned, and the mechanical noise of the exhaust system and the supercharger of the unit is reduced. The gas system should be fully insulated and insulated.
When the outer surface temperature of the exhaust pipe is ≤450°C, the thermal insulation layer is made of a layer of rock wool felt (rockwool is generally used for the heat preservation part with temperature of 600 °C). When the outer surface temperature of the exhaust pipe is ≥500 °C, the insulation layer adopts two layers. That is, the layer of the contact tube wall is an aluminum silicate fiber felt, and a layer of rock wool felt is wrapped.
Figure 5 Muffler and exhaust pipe insulation profile
Figure 6 Stereo view of muffler and exhaust pipe insulation
7. The connection between the diesel generator set and the exhaust pipe is conventionally used with bellows. The pipe weight of all the exhaust pipes is not allowed to be pressed on the bellows, and the bellows should remain free.
8. The outermost end of the exhaust pipe should be treated as rainproof. For example, cut a proper angle of inclination under the nozzle or install a rain cap.
9. When the exhaust pipe needs to pass through the wall, it should be equipped with a flexible telescopic sleeve. Otherwise, the exhaust pipe will cause side stress and pressure due to thermal expansion and contraction, which will affect the stability of the exhaust system of the unit and accelerate the exhaust of the unit. Unusual wear and tear on the system and the booster system, and cracking of the wall due to long-term stress.
The exhaust pipe and the muffler shall be separately provided with support and shall not be directly supported on the diesel exhaust pipe or fixed to other parts of the diesel engine. The specific vibration isolation installation is shown in the following figure:
Figure 7 Vibration isolation installation diagram of muffler and exhaust pipe
Figure 8 A—Beam bottom embedded plate installation
Figure 9 B—Hook
Figure 10 Vibration isolation installation diagram of muffler and exhaust pipe
图 11 A—梁底预埋板安装
Figure 12 B—Hook
Sixth, ventilation system
When the diesel generator set is running, part of the fresh air is sucked into the combustion chamber on the one hand, so that it is evenly mixed with the fuel in the combustion chamber to drive the work, driving the whole unit to continue to operate; at the same time, the large amount of heat generated during the operation of the unit must be timely distributed. Out of the machine room, this will consume a lot of cool air. Therefore, the standard unit must have a good circulating water cooling or oil cooling structure. The cooling and ventilation system of the equipment room is also very important and necessary. It must be ensured that there is enough air flowing through the engine room to supplement the consumption of the engine. The air for combustion and the large amount of heat emitted by the unit are discharged out of the machine room through the radiator core, so that the temperature in the machine room is as close as possible to the ambient temperature and the temperature of the body is kept within the normal working range. When the conditions of the equipment room cannot meet the requirements for the net area of the air inlet and outlet as specified in this manual, the forced air intake and exhaust method must be considered to ensure the normal combustion and cooling of the unit.
In buildings, vents are usually equipped with blinds and metal protective mesh curtains. In the winter, the engine room should be kept at an appropriate temperature to avoid affecting the normal starting capacity of the unit or freezing the cooling water, resulting in damage to the unit. This requires that all vents in the equipment room must be adjustable so that the unit can be automatically or manually closed when the unit is deactivated. At the same time, it is recommended that the unit be equipped with a water jacket heater that is assembled and kept in normal working condition.
1. Air inlet
The air inlet should be located at a reasonable position where the dust concentration is as small as possible and ensure that no foreign matter is nearby. When conditions permit, it is recommended that the customer adopt the oblique upper air inlet method near the generator end, and add blinds and metal protective mesh curtains to avoid foreign objects. Enter and ensure normal air convection. In order to prevent the return of hot air, the air inlet of the unit should be as far as possible away from the air outlet, and the air in the equipment room should be DC as much as possible. The air inlet should be protected to prevent rain and other foreign matter from entering. For a conventional closed-cycle water-cooled diesel generator set, the net flow area of the air inlet is estimated to be no less than 1.5 to 1.8 times the windward area of the radiator.
The following engine room air intake schemes are available for reference:
Figure 13 Room reference air intake scheme
2, exhaust vents
The net flow area of the exhaust vent is 1.25 to 1.5 times larger than the windward area of the radiator. The center position of the exhaust vent should be as close as possible to the center position of the radiator core of the unit. The width to height ratio of the vent is also as wide as possible. The height is the same. In order to prevent the return of hot air and mechanical vibration, it is recommended to install an elastic damping horn type air guiding groove between the radiator and the exhaust vent.
Figure 14 Elastic shock absorbing horn type air duct 1
Figure 15 Elastic shock absorbing horn type air duct 2
Figure 16 Large sample of elastic damping horn type air duct
The elastic damping horn type air guiding groove is divided into two parts as shown in Figure 16. The soft connecting part is made of heat-insulating canvas, one end is connected with the end face of the unit water tank through the angle iron flange, and the other end is also connected by the angle iron flange and the wind guide. The tube is connected; the air guiding tube adopts a galvanized plate and an angle iron frame structure, and one end is connected to the exhaust louver through an angle iron flange. The connections between the components of the exhaust duct are bolted. The iron parts of the exhaust duct must be brushed with anti-rust paint twice, and then the same paint as the unit is painted. Rubber seals should be placed between the angle iron flanges to prevent hot air leakage.
Installation of ventilation system
The iron frame will be pre-embedded in the exhaust, pre-buried into the wall, and secured with cement, and assembled after drying;
Install the air inlet louvers or dampers with bolts;
If you need to install the exhaust fan, intermediate over-body, soft connection, exhaust vent, relevant technical standards, see related majors.
Figure 17
List of exhaust hoods and soft connection materials:
Angle steel frame
Galvanized steel sheet (δ=1)
Flat iron bead (δ=2)
Thick canvas strips (W=300-500)
Auxiliary materials such as aluminum rivets
The following engine room exhaust schemes are available for reference:
3, air circulation
A good room ventilation system must ensure adequate air inflow and outflow and free circulation in the machine room. Therefore, there should be enough space in the equipment room to ensure that the temperature in the equipment room is balanced and the air is flowing normally and smoothly. Ventilation systems should normally be straight-in and straight-out if not subject to special installation conditions. And absolutely avoid the hot air discharged by the unit to enter the machine room again through the air inlet of the machine room.
Seven, cooling system
Diesel generator sets can be divided into the following three system cooling methods according to customer's installation and use requirements:
Closed loop fan water cooling
Split heat dissipation system
Heat exchanger system
1. Closed circulation system
The standard configuration of the unit is self-contained water tank closed circulation cooling method except for special requirements. In general, the cooling system includes a cooling water system and a cooling air system.
When the radiator is installed at the end of the engine, the unit should be positioned so that the radiator core is as close as possible to the exhaust vent according to the above requirements (the recommended maximum size of the radiator core from the outlet is 150 mm). Otherwise, a return of hot air may occur.
If the unit cannot be positioned as described above, a separate canvas exhaust duct with a steel flange must be added to the system to connect the radiator and the exhaust louver.
The elbow of the wind trough must have a perfect radius of curvature. If a long process pipe is to be made, the cross-sectional area of the pipe must be enlarged to reduce the back pressure of the radiator.
2, split heat dissipation system
When the unit is installed in the basement, the actual space is likely to limit the use of the trough, in which case other cooling methods are generally available.
The cooling system of the remote cooling water tank is one of the ways customers can choose. In this system, the radiator is separated from the unit and is cooled by an electric fan. The system can be used as a fully enclosed unit for outdoor use or as an open unit for indoor installations. In order to ensure the synchronization of the electric fan and the unit work, it is recommended that the customer use the unit output power as the power supply for the electric fan.
When the radiator installation is higher than 3m or the horizontal distance exceeds 10m, most units require a separate water tank and electric water pump. The size of the separation tank depends on the capacity of the entire cooling system, that is, the total amount of piping required. Cooling water consumption.
The cooling water is driven by an electric circulation pump, which is circulated from the separation tank through the radiator and the unit. Generally, radiator fans and pump motors are powered by generators, and the power they consume should be included in the unit's output power. When the unit is in a deactivated state, water will flow from the radiator into the sub-tank, and when the unit is in operation, the sub-tank must maintain sufficient cooling water for a long time to ensure full circulation of the entire cooling system and cooling water. See Figure 18 for a separate radiator installation diagram.
Points to note about this system:
(1) To prevent foreign matter from contaminating the coolant;
(2) The turbulence of the split water tank can oxidize the coolant;
(3) to avoid air retention in the system, the pipeline should be provided with venting holes;
(4) Proper water treatment to meet unit requirements;
(5) To prevent condensation of condensation;
(6) The coolant is naturally maintained (without pressure) in the body;
(7) If the radiator is installed at the same level as the engine, there is no need to use a separate tank, but an expansion tank should be placed directly above the radiator to allow the cooling water to expand and replenish.
3. Heat exchanger system
Heat exchanger cooling is used. This method can be of two specific types: "standard heat exchanger cooling method" and "split water tank with heat exchanger cooling method". This system requires less space than a split-type water tank, and its closed water path can automatically replenish the evaporation water lost by evaporation using a spherical valve of the supplementary water tank to ensure that there is always enough cooling water in the cooling system.
The diesel generator set can be equipped with a heat exchanger according to the special requirements of the user. In the area where the water quality may be polluted or the cooling water can be supplied from the cooling tower or the large storage tank, the heat exchanger can be used as the cooling means of the unit, but the water passes through After the heat exchanger, it should be regarded as contaminated water and not for domestic use.
Since the used water must flow to the waste pipe, drinking water is not allowed for heat exchanger use in most places. The water pressure of the heat exchanger can be maintained at about 0.14 Mpa.
When using a cooling system for a remote radiator or heat exchanger, the engine room must maintain a certain amount of ventilation to provide sufficient air for the engine to burn and serve as a radiant heat for the ventilation and cooling units of the equipment room.
Eight, the installation of electrical systems
1. Cable laying method
Cable laying methods include direct burial, cable trenching and cable trays. Electrical connections must be reliably contacted to prevent loosening, twisting and insulation damage caused by vibration.
Cable area selection: The generator set output cable should not be too small. Please select the cable with the appropriate cross-sectional area according to the rated current of the generator set.
2. Selection of cable laying route
When choosing a cable routing path, the following principles should be considered:
The shortest power path and the least bend;
Minimize the cable by mechanical, chemical and ground currents and other factors;
Cooling conditions are better;
Try to avoid crossing other pipes;
Avoid the place to be excavated in the planning.
3. General requirements for cable laying
To lay cables, be sure to follow the planning and design requirements of the relevant technical regulations.
Under the conditions of laying conditions, the cable length can be considered as a margin of 1.5 to 2%, as a backup during maintenance, and the buried cable should be wavy.
For cables to be introduced or led out of buildings or structures, cables passing through the slabs and main walls, from the cable channel to the poles, or along the walls of the cable at a height of 2 m on the ground and buried in a section 0.25 m deep. The cable shall be protected by steel pipe. The inner diameter of the steel pipe shall not be less than 2 times the outer diameter of the cable.
When the cable and the different pipelines are buried in the first stage, it is not allowed to lay cables in the channels of the gas pipes, natural gas pipes and liquid fuel pipes; a few cables are allowed to be laid in or intersect with the open channels or tunnels of the water pipes or air ducts. In the open channel or tunnel of the heat pipe, it is generally not necessary to lay cables; in special cases, if the cable is not overheated, a few cables may be allowed to be laid in the channel of the heat pipe, but they should be separated on different sides, or the cable should be installed in the heat. Below the pipe.
The buried depth of the buried cable shall not be less than 0.7m, and the trench shall not be 0.6m away from the foundation of the building.
The structure of the cable trench should take into account the problems of fire and water.
The metal sheath of the cable, the metal cable head, the protective steel pipe and the metal bracket shall be reliably grounded.
For the sake of convenience and safety, it is recommended that the customer pre-lay the cable in the cable trough when the unit is connected to the ATS 尧 switchboard and the cabinet, and prevent leakage and leakage. The electrical connection must be reliable and prevent vibration. The resulting loose, broken and insulated damage.
中文版
English
