Installation Of Diesel Generator| The Best Procedure In 26

Table of Contents

Introduction to Diesel Generator Installation

Installing a diesel generator is a multifaceted process that demands attention to detail, an understanding of mechanical and electrical systems, and adherence to safety protocols. This blog post aims to guide you through the essential phases involved in setting up a diesel generator, ensuring it operates efficiently and safely, whether as a backup or a primary power source.

Key Steps in Diesel Generator Installation

Unloading and Storage: Begin with the careful unloading and proper storage of your diesel generator, ensuring it’s protected from environmental elements and ready for installation.
Leveling The Foundation Base Frame: A crucial step is to level the foundation base frame accurately, providing a stable and secure platform for the generator.
Documentation: Maintain thorough documentation throughout the installation process to ensure compliance and ease future maintenance or inspections.
Preparation and Safety Checks:
- Make necessary arrangements for the installation space and equipment.
- Conduct comprehensive safety checks to mitigate any potential hazards.
- Ensure all signaling protocols and work permits are in place for effective communication and authorization throughout the installation team.
Erection of Diesel Generator:
- Highlight the importance of having the right materials and tools before beginning pre-erection activities.
- Guide through the steps of proper leveling, positioning, and mounting of the DG set to ensure optimal operation.
Electrical and Control & Instrumentation (C&I) Installation: Delve into the specifics of electrical connections and control systems setup, emphasizing the roles of personnel involved in these procedures.
Final Steps Before Commissioning:
- Conduct post-installation checks to verify system integrity and readiness.
- Perform pre-commissioning assessments to ensure all systems function as expected.
- Describe the initial startup process, marking the culmination of the installation and the beginning of the diesel generator’s operational phase.

Installation of Diesel Generator

Unloading and storage procedure

Complete Procedure: Unloading, Transportation & Storage of EDG Sets

Purpose

This procedure defines the comprehensive methodology for the safe and quality-compliant material handling of Engine Generating sets upon arrival at the site, covering receipt, inspection, unloading from transport, and subsequent storage.

Scope

This procedure covers all quality-related activities for:

External inspection of Engine Generating sets upon receipt
Unloading the Engine Generating sets from the transport trailer
Shifting and temporary placement of the Engine Generating Set onto the foundation or a designated storage area

General Specifications

Engine Type/Configuration: Medium‑speed, 4‑stroke, V‑type diesel engine
Generator Type: Three‑phase, synchronous, brushless alternator
EDG Capacity: 2 × 5.22 MW (approximate)
Approximate Length: 11,000 mm
Approximate Width: 3,854 mm
Approximate Height: 5,227 mm
Approximate Dry Weight: 116,000 kg
Approximate Wet Weight: 122,000 kg

Prerequisites & Documentation

The following documents must be available and verified on-site before commencing any activities:

Valid work permit issued by the HSE department
Inspection report for the Engine Generating Set unloading and storage area
Inspection reports and Material Test Certificates (MTC) for all tools and tackles
Valid fitness certificate for the crane and its inspection report
Medical certificate and valid operating/driving license for the crane operator
Manufacturers (OEM) instruction manual
Detailed packing list for each package
OEM standard or approved drawings and procedures, including the Engine Generating Set Lifting Drawing

Major Material Handling Equipment

All lifting gear must be certified, with documentation available on-site:

Mobile Crane: Minimum 400 MT capacity (1 number)
Lifting Tools: Provided by the engine manufacturer (OEM)
Self-Propelled Modular Transporter (SPMT): Required for the Primary Unloading and Transportation Method

For Alternate Unloading Method (Skidding):

Chain Pulley Block: 50 tons – 2 Nos.
Steel Wire Rope Slings: Diameter 20 mm × 7 meters long – 4 Nos.; Diameter 12 mm × 10 meters long – 4 Nos.
Wooden Sleepers: Sufficient quantity as required
Steel Rails: 5–6 meters long – 4 Nos.
Hydraulic Jacks: 100 Tons capacity – 4 Nos.
Pipe Rollers (Solid): 1″ diameter – 4 Nos., 1-1/2″ diameter – 4 Nos., 2″ diameter – 4 Nos.

Safety Checks

Before starting unloading operations, the following must be confirmed:

a) Ground Assessment: The ground must be levelled, and its load-bearing capacity checked.

b) Access Route: A safe and clear route to the unloading point must be established.

c) Crane Setup Area: The area where the crane jacks will rest must be prepared and compacted.

d) Equipment Inspection: The crane, all lifting tools, wire ropes, and brake operations must be thoroughly inspected.

e) Lifting Point Security: Ensure lifting tools are correctly secured to the engine’s designated lifting points.

f) Tool Condition: Check the condition of all lifting tools and wire straps for any signs of damage or wear.

g) Access Control: Unauthorized personnel are strictly prohibited from the rigging and unloading vicinity.

h) Barricading: The area around the unloading point must be suitably cordoned off.

Unloading & Transportation Procedure

Receipt of Material & Initial Inspection

Upon Engine Generating Set arrival at the site:

Conduct a visual inspection for any damages or shortages that may have occurred during transit
If any damage is noted, promptly notify the transport agency, the owner, and the insurance company
Arrange for an inspection by insurance representatives to assess the damage
Obtain an endorsement from competent authorities on the delivery documents to facilitate insurance claims

Primary Method: Unloading by Crane with SPMT Transportation

This method involves using a crane to lift the Engine Generating Set from the transport trailer and directly place it onto a Self-Propelled Modular Transporter (SPMT) for all subsequent movements.

Part A: Unloading from Trailer to SPMT

Ground Preparation: Prepare and compact the ground at the trailer unloading point and along the entire planned route to the storage/foundation area. Ensure the path can support the combined weight of the SPMT and the EDG set (~116 MT).
SPMT & Trailer Positioning:
- Position the SPMT adjacent to the transport trailer, ensuring it is on a level, stable surface and aligned for straightforward loading
- Precisely position the trailer carrying the Engine Generating Set. Place wedges at the trailer wheels to prevent movement
Crane Positioning: Position the crane with clear access to both the trailer and the waiting SPMT deck.
Lifting Setup: Set the crane boom at approximately 75 degrees. Secure the lifting tools (supplied by the OEM) to the Engine Generating Set as per the manufacturer’s directions and connect them to the crane hooks.
Trial Lift: Tighten the wire slings and lift the EDG set about 1–2 inches above the trailer to check for balance. Lower it back to adjust the crane, tools, or slings if any imbalance is observed.
Full Lift & Trailer Removal: Once stable, lift the Engine Generating Set clear of the trailer (approx. 6 inches). Remove the wheel wedges and carefully move the trailer away from the area.
Placement onto SPMT: Slowly and carefully lower the Engine Generating Set onto the SPMT deck. The set must be centred and positioned according to the SPMT’s load distribution plan. Use wooden blocks or custom saddles on the SPMT deck to stabilize the load and prevent any movement during transport. Secure the Engine Generating Set to the SPMT using appropriate tie-downs.

Part B: Transportation to Storage/Foundation Using SPMT

a) Movement to Storage: Once securely loaded, the SPMT will transport the Engine Generating Set along the pre-approved route to the designated dry, covered storage area. The movement must be slow, controlled, and monitored by spotters.

b) Storage Placement: At the storage location, the SPMT will be positioned. The crane will then be used to lift the Engine Generating Set from the SPMT and place it onto the prepared wooden sleepers. Alternatively, for temporary storage (one week), if the ground is suitable and the duration is short, the Engine Generating Set may remain on the SPMT, which must be properly braked and blocked.

c) Final Movement to Foundation: When ready for installation, the SPMT will be positioned next to the stored Engine Generating Set. The crane will lift the set onto the SPMT. The SPMT will then transport the Engine Generating Set to the final foundation location, manoeuvring into the precise position for the final lift.

d) Final Placement on Foundation: The crane will lift the Engine Generating Set from the SPMT and perform the final lowering onto the base plate, ensuring it rests fully and aligns with the centre markings as per the erection procedure.

Alternate Method: Skidding

Initial Setup: Follow the initial steps for ground preparation, trailer positioning, and wedging from the Primary Method (Steps 1–3 from Part A).
Stabilization: Pack wooden sleepers under the truck chassis to prevent tilting.
Rail Placement: Lift the Engine Generating Set approximately 200–250 mm. Place steel rails (coated with general-purpose grease) under its base.
Rail Extension: Extend the rails sufficiently, supported by wooden sleepers, to guide the set off the trailer.
Skidding Setup: Strap the engine’s front end with a steel wire rope sling. Mount two chain pulley blocks 6–7 metres from the Engine Generating Set front, 3 metres apart, anchored to suitable points.
Skidding: Simultaneously apply load to both chain pulley blocks to slowly and smoothly skid the Engine Generating Set off the trailer and onto the foundation/unloading point.
Trailer Removal & Alignment: Once the Engine Generating Set is clear, remove the trailer. Reposition the pulley blocks to turn the set 90 degrees and align it parallel to the foundation base bars.
Final Positioning: Jack the Engine Generating Set to remove the rails and lower it slowly onto the sole plate without any impact or jerk.

Storage & Preservation

Objective

To ensure the equipment remains in an as-delivered, pristine condition, fully protected from environmental degradation, corrosion, and physical damage from the point of receipt until the moment of installation and commissioning.

Storage Conditions & Requirements

The following conditions are non-negotiable for the storage of Engine Generating Set assets:

a) Location & Environment:

The Engine Generating Set must be stored in a designated, secure location that is weatherproof, well-ventilated, and free from excessive humidity, dust, and airborne contaminants
The storage area must have a solid, level floor capable of supporting the point loads of the Engine Generating Set and their storage cribbing
The area shall be inaccessible to unauthorized personnel and protected from potential impacts from other site activities

b) Physical Protection & Covering:

Regardless of the original packaging, all Engine Generating Sets and major components must be protected under a heavy-duty, waterproof tarpaulin or an equivalent engineered cover system
The covering must be securely fastened to prevent wind displacement and must be configured to allow for air circulation, preventing condensation build-up underneath
Regular inspections of the cover integrity must be performed, especially after severe weather events

Storage Duration and Critical Timeline

a) Short-Term Storage (Up to 4 Months):

Storage under a tarpaulin or in an open container is classified as Short-Term Storage and is permissible for a maximum period of four (4) months from the date of arrival at the site
This period is contingent upon the initial preservation applied by the OEM remaining intact and the storage conditions being rigorously maintained

b) Long-Term Storage (Exceeding 4 Months):

If the EDG sets and their auxiliaries are not installed within the 4-month short-term storage window, the equipment automatically enters a Long-Term Storage regime
It is a mandatory requirement that the comprehensive OEM Standard Preservation Procedure be initiated and strictly followed
The transition to long-term preservation must be formally documented and reported

Long-Term Preservation Protocol (As per OEM)

Adherence to the OEM procedure is critical to maintain equipment warranties and ensure operational readiness. The long-term preservation process is a systematic and active program and includes:

a) Cooling Water System Preservation: Complete draining and flushing of the system. Injection of a Volatile Corrosion Inhibitor (VCI) and pressurization of the system with Nitrogen Gas to an internal pressure of 0.5 bar to create an inert, moisture-free environment.

b) Fuel Oil System Preservation: Full drainage of all fuel from filters, pumps, and piping to prevent gumming and varnish formation.

c) Lubricating Oil System Preservation: Draining of existing lubricating oil. Cleaning of the crankcase and sump tank. Application of a Lubricity Rust Preventative Oil to all internal moving parts, including crankshafts, cylinder liners, and camshafts.

d) Combustion Chamber Preservation: Injection of a Corrosion Preventing Fluid into each cylinder via the indicator valve ports, followed by manual rotation of the crankshaft to coat the liner walls and piston crowns.

e) External Machined Surfaces: Cleaning and coating of all unpainted, machined surfaces with a dedicated Protective Agent to prevent rust.

f) System Sealing: All open ports, flanges, and intake/exhaust openings shall be sealed with blind flanges, plastic caps, or appropriate covers to prevent the ingress of moisture, dust, and pests.

Monitoring & Documentation

A Preservation Log shall be maintained for each EDG set, recording all preservation activities, inspection dates, and the condition of the equipment
Monthly visual inspections shall be conducted to verify the integrity of covers, the presence of desiccants (if used), and the absence of corrosion or damage
For long-term storage, quarterly internal inspections and re-application of specific preservation agents, as stipulated in the OEM manual, are mandatory

Responsibility

The overall responsibility for implementing, monitoring, and documenting the storage and preservation procedures lies with the Erection Contractor, under the mandatory supervision of the Project Owner and Engineering Team, to ensure strict compliance with this procedure and the OEM specifications.

Note: Loading and unloading of EDG sets and its auxiliaries is critical work. Supervision by qualified technical personnel is mandatory at every stage.

Leveling The Foundation Base Frame ( Installation of Diesel Generator )

Complete this job before lowering the DG set on the foundation base frame as per the following method.

Thoroughly clean and wash the engine foundation.
Mark the centreline of the foundation as per the drawing.
Verify the concrete foundation level with the help of the cup level.
Bring the foundation level equivalent to equal level and height by adjustment with shims
Place the DG set suitably above the foundation and leveled platform with wooden slippers.
Lower the DG set appropriately onto the foundation with the help of jacks for final positioning.

Documentation

Stores receipt
Manufacturers instruction manual
Packing slip
Drawings
Test certificate of material handling tools
Maintenance reports
Work permit for unloading

Other arrangements

Safety brief before the commencement of work.
PPE and safety gear as required. (The persons engaged in unloading shall wear PPE).
Safe work method statement to be submitted to Engineer before the commencement of work

Safety checks

Ground leveling shall be checked before the unloading operation
Prepare the access road to the Point of unloading at the Site.
Prepare the area suitably for resting the crane jack on the ground..
Inspect the crane and wire ropes, brake operation of jack, etc.
Secure the lifting tool over the engine lifting point.
Check the condition of the lifting tools/wire strap.
Put a board at the site displaying that “Unauthorized persons are not permitted in the vicinity of the rigging and unloading area”.
Suitably cordoned off the area near the unloading point.

Signalling

Decided one person for signalling and coordinate with the crane operator.

Work permit

Obtain the work permit from the Site Head.

Important checks

Make a safe work method statement
Identify the hazards associated with each activity.

Erection ( Installation of Diesel Generator )

Important Activities for the DG set Erection

Activities (Pre-erection )on the DG set foundation and grouting of the DG set base plate
Positioning, mounting, and leveling of the DG set.
Adjustment of elastic mounting for Generating Set.

Pre-erection activities on the DG set foundation and grouting of the DG set base plate.

Require

Important Material and tools before the pre-erection activities

Latest approved drawings.
All the erection material like base plate, foundation bolts jacking bolts.
Foundation marking and leveling equipment.

Carry out the following activities for the pre-erection of the DG set on foundation

Check the elevation of the foundation is as per the drawing.
Clean the foundation surface and place the base plate as per drawing and maintain the specified dimensions.
Mark the coordinates ( x-x, y-y) to maintain the center distance between two base plates as per the specified dimensions in the approved drawing.
Maintain the elevation of all base plates as per the approved drawing.
Mark the foundation for drilling the hole for foundation bolts.
Remove all the base plates after correct marking prior to drilling.
Drill the foundation with the dimensions specified in the drawing.
Ensure the base plate is neat and clean, clean any rust particles.
Clean the foundation surface and replace the base plates maintaining the dimensions as per the drawing.
Carry out the leveling of the base plates with the help of leveling screws.
Mount all the foundation bolts tighten up to specified torque.
Prepare the grouting chemical and fill in the pockets.
The base plate should be above the foundation as per the specified dimensions.
Wait for the grouting chemical to get hard.
Loosen all the adjusting screws upon curing.
Apply the final specified torque on the foundation bolts.

Guide lines for proper Levelling, Positioning and mounting of the DG set.

DG set placing on position Procedure for the Erection and commissioning of a Diesel Generator

Keep the Filling Piece, Elastic Mounting, shims, Nut, and bolts ready at the site
Clean the filling piece and elastic mountings from both sides.
Keep the DG lifting tool, wire ropes, and crane ready in all respects
Ensure the crane location at an approachable distance from the foundation and DG set or follow the manual procedure for the placement of DG set at the foundation
Ensure the cleanliness of the base frame bottom at the location of elastic mounting.
Mount the elastic mounting and filling piece at the bottom of the base frame.
Mark the base plate’s exact position for the elastic mounting’s exact location.
Lower the DG set till it rests completely on the base plate with the centerline matching.
Ensure the elastic mounting dimensions as per the approved drawing.
Remove the engine hoisting tool
Follow the next procedure only after a waiting period of 48 hours as per the OEM recommendations.

ADJUSTMENT OF ELASTIC MOUNTINGS FOR GENERATING SET

Installation of Diesel Generator for the elastic height measurement.

Keep the height measuring tool Steel scale, Vernier calliper, Inside Micrometer ( 100 to 150mm) readily available.
After the settlement period of 48 hours, measure the height of the elements.

The variation in the mountings should not exceed ± 1mm and should be as near as possible

Example

Carry out the following activities in case the measured height exceed ± 1mm
Raise the DG set with the help of a lifting device or hydraulic jack and add the shims wherever height is greater than the others.
Put the Jack down the engine and repeat the readings after 48 hours.
Procedure to be repeated time and again till the specified limit has been achieved.
Initially adjust the mounting with the largest deviation (from the average value) by adding the steel shims.

Enter all the elastic mounting height measurement for the review by OEM.
Carry out the further welding of all the required parts after the receipt of approval.

PRE- COMMISSIONING & COMMISSIONING OF DG SETS

PLANNING BEFORE COMMISSIONING (Installation of Diesel Generator)

Mechanical– Erection and commissioning of a Diesel Generator

Auxiliaries Systems

Exhaust
- Air intake
- Cooling water
- Lube oil
- Air (start / control)

Tanks Fuel & Water and associated pipelines

Electrical / C & I-Installation of Diesel Generator

. DC System (24 V & 110 V)

2. Electrical

DGCP
Synchronization panel
The equipment for receiving the Power (MV
Switchboard, PCC, and MCC) should be ready to accept the power.

3. Completion of Engine & electrical safety checks in stop & running condition

4. Fire detection and monitoring

5. Civil and structural works associated with DG sets, auxiliaries, and systems mentioned above

6. Safety – fire fighting systems and equipment

Post-Erection, Pre-commissioning, Commissioning checks & procedure

General (Installation of Diesel Generator)

Availability of all the relevant Datasheets of the DG sets at the site, including P&IDs and safety appliances, and all these documents are to be inspected by respective engineers and need to be satisfied before starting work. The commissioning team is acquainted with the details of the system.
Inspection and arrangement of all the tools and tackles before starting work.
All people working at the DG set should wear PPE before starting work. (Should have ear defenders/earplugs for use when sets are started up and in operation)
The area of work should be cleaned from all obstructions and examined for easy movement and passage.
Depute the commissioning team assigned with an area of responsibility during pre-commissioning and commissioning Time to attend to various equipment.
Availability of Testbed record of Engine and Alternator ( FAT- factory acceptance test report)

Tools and tackles -Installation of Diesel Generator

A set of spanners & Hand tools.
Sufficient trays and containers for collecting drip and leak-off from joints, if any.
Communication arrangement from one point to other. (walkie – talkies)

A set of electrical measuring and inspection tools (Megger, Voltmeter, Ammeter, Tong-tester, etc.)

Equipment for inspection and testing of C & I component including
Pressure & temperature calibration tool.
Tool for deflection measurement, torch & mirror.
Vernier caliper, Micrometer, Feeler gauge for tappet.
Peak pressure gauge (P-Max)
Contact lass thermometer (infrared)
Dial gauge with magnetic stand

Personnel attending the procedures (Installation of Diesel Generator)

Commissioning Engineer
Quality control engineer
Mechanical Engineer
Instrument Engineer
Electrical Engineer
Mechanical & Electrical Technicians

Post Installation checks (Installation of Diesel Generator)

Ensure that the DG set is correctly installed on the concrete foundation block and ready in all respect.Approved Drawings and all mechanical installation work are complete before pre-commissioning to be kept ready for reference.
Ensure that all the piping/ducting (Fuel, oil, water HT&LT, start air, intake air, exhaust gas) of the DG sets are connected to the machine’s respective connection points expansion joints/ bellows are applied as per the norms. Pipes are well supported and secured. The silencer is installed and well supported. Silencer drain valves are fitted.
All the isolation valves, fittings that have been provided are inspected and free to open and close completely
Exhaust ducting has been installed, supported, and secured well, and connected to the main chimney.
DG set has been fitted with all the necessary indicating (pressure & temperature gauges and pressure and temperature switches)
Ensure no other work inside the DG Hall is being carried out during the pre-commissioning checks and commissioning work.
Inspect all the platform, ladders, and access points to DG set and auxiliaries for proper securing from the point of access to inspection and logging.
Clean the DG set engine and alternator accessible for pre-commissioning and commissioning checks.
Check and ensure that all the coupling guards, belt guards, and barriers against moving parts are fitted and secured well.
Check clean and inspect and close HT and LT water expansion tank.
Charge the Water system
Check, clean, inspect, and closes the Engine sump for charging lubricating oil.
All consumables such as water, lube oil, diesel, service air, and lubricants, etc., are to be provided by the customer at the site.
A sufficient amount of Lubricating oil is available for charging into the engine oil sump. (Engine oil sump shall be charged first Time directly from the drums)
Check that all the MV LV & Control cables on the alternator have been laid and cables have been terminated according to the cable schedule.

Pre-commissioning checks (Installation of Diesel Generator)

(A) Check and ensure that the following systems are ready and are available for service as and when required

Make the availability of the compressed air to the system.
DM/ soft water is available and connected to the plant and DG sets system.
Engine start air and instrument air is available and is connected to the system.
HT & LT radiators are operational and connected to the respective system and charged with water, and ready for use.
Fire fighting equipment is available.
Fuel system (Diesel oil) is prepared, ready, and fuel available at engine inlet after priming.
Charge engine sump with manufacturers’ recommended lubricating oil to an acceptable level.
Check and fill oil in governor sump to the mark/ level.

(B) Ensure that the following auxiliaries and equipment are made operational and be available for a startup as and when required for the Erection and commissioning of a Diesel Generator

) Fuel booster is operational.

(2) 24/110 V DC. Supply is made available.

(3) Engine control Panel is made operational.

(4) Pre-lube oil pump is operational.

(C) After the DG set is fully loaded with mass after fitting all mountings, the Anti-vibration pad (elastic mounting) measurement may be taken and recorded. Final adjustment, if any, may be carried out. Record the final readings.

(D) Open alternator front cover and check rotor-stator air gap record the measurement. Check and tighten rotating rectifier connections and put the cover back into position.

E. Check engine crankshaft deflection at cold condition, make adjustments if necessary, and bring the last throw to an acceptable Limit if the deviation is noticed. The record measurement of all cranks throws. Refer to the instruction manual for procedures. (The job shall be carried out by OEM Engineers and recorded at all stages.)

F. Check and prepare the following electrical system.

) Check and put 110/24 V DC system is operational.

(2) All the relevant MV VCB’s are inspected and in-service position.

(3) Megger MV cable from alternator end with the help of 5 VK Megger and record readings. (Discharge cable on completion)

(4) Measure insulation value of alternator windings and record. Ensure AVR connections are disconnected before meggaring.

(5) Inspect all the insulator conditions in the alternator cable terminal box for good condition.

(6) Connect the cable to the respective winding terminal and re-tighten properly.

(7) Check that Engine moving parts have no obstruction and the area around the DG set is clear and accessible for easy movement of people.

(8) Check inlet & exhaust valve clearance and adjust to the permitted value.

Commissioning checks (Installation of Diesel Generator)

Perform all the procedures mentioned in the procedure, and commission the engine with the listed below instructions.

Carry out the heating of engine cooling system to 50 deg. C

Carry out the heating of lube oil 40 deg. C.

(2) Warm-up engine lube oil system and sump oil to about 40 deg. C.

(3) Start engine priming pump and lubricate Engine and ensure that all parts are supplied with sufficient oil. Turn engine in the direction of rotation few revolutions with engine indicator cock in open position on all cylinders.

(4) Put radiator system into operation

(5) Put compressed air and ventilation system into operation

(6) Put diesel oil system into operation, vent air from the fuel system, and ensure that there is at least 2.5 kg /sqcm pressure in the system.

(7) Prepare the Engine for barring on Air motor. Turn the Engine with oil priming on at least by two complete revolutions and ensure no abnormalities, and the Engine is free to rotate. Check that oil supply reaches all the observable points, including rocker arm.

(8) Open the crankcase door on one side and observe that oil flow is normal following oil drain from piston cooling.

(9) Close the crankcase door and secure the Engine (fuel system and governor locked to stop fuel position) for blow through by start air system.

(10) Turn the Engine (with oil priming on) by start air and blow through the system once or twice.

(11) Recharge compressed air system and built upstart air pressure to about 30KG/cm2.

12)Close all indicator valves on the cylinder unit and keep the engine ready

(13) Ensure that voltage excitation switch is put to off position as a precaution

Initial Starting in of DG set (Erection and commissioning of a Diesel Generator)

Check Engine speeds (idle and rated). Idling speed should be 400-500 RPM and rated speed 750 RPM). Start priming oil pump and prim Engine to lubricate parts sufficiently. Start the engine immediately after the firing.

OBSERVE THE FOLLOWING during (Installation of Diesel Generator)

Engine lubricating oil pressure. Around 3-3.5 Kg/cm2 and that there is no abnormal noise

(2) Water system LT and HT is registering some pressure on the system, and water circulation is on

(3) Turbocharger lubrication system registers pressure above 1. 0 – 1.1 kg/.sq cm. Inspect oil flow to rocker arm system.

(4) Ensure that all cylinders are firing

(5) After few minutes (2-3 minutes), stop the Engine and feel over the main and crankpin bearing by hand feel for abnormality.

(6) Check oil flow through the piston cooling on all units.

(7) When the inspection is complete and satisfactory Engine can be started and put on at rated RPM.

Second start

Start DG set again this time slowly increase engine RPM to 750 and run at idle speed AND OBSERVE FOLLOWING.

1.Engine lubricating oil pressure. Around 4 – 4.5 Kg/sqcm.

2. Abnormal noise

Engine lubricating oil pressure. Around 4 – 4.5 Kg/sqcm. and that there is no abnormal noise

(2) Water system LT and HT register pressure on the system between 1-1.5 kg/cm2 minimum.

(3) Lubrication system of the Turbocharger, registers pressure above
1.2 to1.3 kg.cm2.

(4) Oil flow to rocker arm system is proper

(5) Ensure that all cylinders are firing.

(6) Lubricating oil pressure difference is below 1.5Kg/cm2

(7) Fuel oil pressure is around 2KG/cm2

(8) Thoroughly check the Engine and alternator for 5 minutes and stop Engine. (Low lube oil pressure trip (Engine shut down) may be reviewed this time). Next, open the crankcase and feel over the Engine main and crankpin bearing and check the oil flow from piston cooling and satisfy.

(9) Check the important trip setting /Shut down of Dg set in the subsequent start-stop operations

Third start

Prepare DG set for start, switch on excitation switch.

Start DG set and warm for 2-3 minutes to check that the voltage is built up. Adjust voltage in the MV side and set it at 6.6KV.

(2) Prepare electrical system for the loading of the Engine by auxiliary loads

(3) Warm-up Engine for 3-5 minutes and check engine alternator thoroughly before loading. Ensure that all the parameters like HT water temperature, lube oil temperature have reached 60C & 50C, respectively.

Check and satisfy electrical panels MV side for the loading of the DG set. When all the above checks are complete set can be put on load as follow.

Start the generator for step load change after completing the routine test as per HYUNDAI guidance and standard. Then, test the engine at available load at the site.

Compare all the readings and values recorded in the test period with the testbed reports of OEM. If there are no apparent/unexplained deviations, the test can be deemed complete and acceptable.

Records and commissioning reports after Installation of Diesel Generator

Operating manual for Engine.

(2) P&ID diagram for the fuel, water, oil, waste oil, and starting & instrument air.

(3) Instruction manual for the alternator.

(4) Electrical drawings for MV and LV system

(5) DG set Logbook

(6) Anti-vibration sandwich measurement sheet

Auto-Log/ Deflection reading datasheet

Blog Conclusion

We hope you enjoyed our blog post about how to install a diesel generator. We know that many people find it difficult to figure out how to install a diesel generator, but that’s no problem! We have provided some helpful information that will make it easy for you to install it yourself and save you a lot of time and money in the process. Check out our blog post for more information about how to install a diesel generator. This blog post is also great for those who are considering installing a diesel generator for their business establishment. Thank you for reading, we are always excited when one of our posts is able to provide informative information like this!