GENERATING SET INSTALLATION MANUAL
FOREWORD This installation manual will guide you to the factors to be considered in the installation of your diesel generator system. It discusses location and mounting of the generating set; size of room; ventilation and air flow; engine cooling water supply or radiator location; exhaust outlet; fuel tank and fuel transfer system.
TABLE OF CONTENTS PAGE 1. INSTALLATION FACTORS 1 2. MOVING THE GENERATING SET 1 3. GENERATING SET LOCATION 1 4. GENERATING SET MOUNTING 2 5. VENTILATION 3 6. ENGINE EXHAUST 6 7. EXHAUST SILENCING 9 8. SOUND ATTENUATION 10 9. ENGINE COOLING 10 10. FUEL SUPPLY 13 11. SELECTING FUELS FOR STANDBY DEPENDABILITY 18 12.
Never lift the generating set by attaching to the engine or alternator lifting lugs! 1. INSTALLATION FACTORS Once the size of the generating set and the required associated control panel and switchgear have been established, plans for installation can be prepared. Proper attention to mechanical and electrical engineering details will assure a satisfactory power system installation. For lifting the generating set, lift points are provided on the baseframe.
4. GENERATING SET MOUNTING discharge duct, conduit for control and power cables and other externally connected support systems. The generating set will be shipped assembled on a rigid base that precisely aligns the alternator and engine and needs merely to be set in place (on vibration isolation pads for larger sets) and levelled. See figure 4.1 4.2 Floor Loading Floor loading depends on the total generating set weight (including fuel and water) and the number and size of isolator pads.
In providing ventilation, the objective is to maintain the room air at a comfortable temperature that is cool enough for efficient operation and full available power, but it should not be so cold in winter that the room is uncomfortable or engine starting is difficult. Though providing adequate ventilation seldom poses serious problems, each installation should be analysed by both the distributor and the customer to make sure the ventilation provisions are satisfactory. 5.
Both the inlet and exit ventilators should have louvres for weather protection. These may be fixed but preferably should be movable in cold climates. For automatic starting generating sets, if the louvres are movable, they should be automatically operated and should be programmed to open immediately upon starting the engine. 5.
and silencer so that heat radiation from this source may be neglected in calculating air flow required for room cooling. 5.3 Inlet Ventilator Size Before calculating the inlet ventilator size, it is necessary to take into account the radiator cooling air flow requirements and the fan static pressure available when the generating set is operating at its rated load. In standard room installations, the radiated heat is already taken into account in the radiator air flow.
It is not normally recommended that the engine exhaust share a flue with a furnace or other equipment since there is danger that back pressure caused by one will adversely affect operation of the others. Such multiple use of a flue should be attempted only if it is not detrimental to performance of the engine or any other equipment sharing the common flue. 6.
and silencer and retained by a stainless steel or aluminium sheath may substantially reduce heat radiation to the room from the exhaust system. 6.2 Exhaust Pipe Flexible Section A flexible connection between the manifold and the exhaust piping system should be used to prevent transmitting engine vibration to the piping and the building, and to isolate the engine and piping from forces due to thermal expansion, motion or weight of piping. A well designed flex section will permit operation with ± 13 mm (0.
Excessive restriction in the exhaust system can be avoided by proper design and construction. To make sure you will avoid problems related to excessive restriction, ask The FG Wilson distributor to review your design. Flexible Sections: Length (ft): 0.
Silencers normally are available in two configurations - (a) end inlet, end outlet, or (b) side inlet, end outlet. Having the choice of these two configurations provides flexibility of installation, such as horizontal or vertical, above engine, on outside wall, etc. The side-inlet type permits 90° change of direction without using an elbow. Both silencer configurations should contain drain fittings in locations that assure draining the silencer in whatever attitude it is installed. 7.
8. SOUND ATTENUATION If noise level must be limited, it should be specified in terms of a sound pressure level at a given distance from the generator enclosure. Then the enclosure must be designed to attenuate the noise generated inside the enclosure to produce the required level outside. Don't attempt to make this noise level unnecessarily low, because the means of achieving it may be costly.
FIG 9.1 SET MOUNTED RADIATOR DISCHARGING THROUGH OUTSIDE WALL Set mounted radiators are of two types. One type is used with the cooling fan mounted on the engine. The fan is belt-driven by the crankshaft pulley in a two-point drive. The fan support bracket, fan spindle and drive pulley are adjustable with respect to the crankshaft pulley in order to maintain proper belt tension. The fan blades project into the radiator shroud, which has sufficient tip clearance for belt tension adjustment.
FIG 9.2 REMOTE RADIATOR CONNECTED DIRECTLY TO ENGINE COOLING SYSTEM 9.2 Remote Radiator A remote radiator with electric motor-driven can be installed in any convenient location away from the generating set. See figure 9.2. A well-designed remote radiator has many useful features and advantages that provide greater flexibility of generating set installations in buildings. FIG 9.
AUXILIARY PUMP HEAT EXCHANGER FIG 9.4 TYPICAL HEAT EXCHANGER INSTALLATION FIG 9.5 HEAT EXCHANGER COOLING SYSTEM 9.5 Antifreeze Protection 10. FUEL SUPPLY If the engine is to be exposed to low temperatures, the cooling water in the engine must be protected from freezing. In radiator-cooled installations, antifreeze may be added to the water to prevent freezing. Ethylene glycol permanent antifreeze is recommended for diesel engines.
10.2 Remote Fuel Systems Three types of remote fuel systems are recommended by the manufacturer: Fuel System 1: Installations where the bulk fuel tank is lower than the day tank. Fuel System 2: Installations where the bulk fuel tank is higher than the day tank. Fuel System 4: Installations where fuel must be pumped from a free standing bulk fuel tank to the day tank. Fuel System 1: The bulk fuel tank is lower than the day tank.
With this system, the basetank must include an overflow via the return line, sealed fuel level gauges and no manual fill facility. All other connections on top of the tank must be sealed to prevent leakage. Fuel System 2 is not compatible with the polyethylene fuel tanks standard on smaller generator sets. The optional metal tank is required. A 2001 Series control system (or above) is required. top of the tank must be sealed to prevent leakage.
Flexible piping should be used to connect to the engine to avoid damage or leaks caused by engine vibration. The fuel delivery line should pick up fuel from a point no lower than 50 mm (2”) from the bottom of tank at the high end, away from the drain plug. 10.5 Day Tank Capacity The capacity of the day tank is based on the fuel consumption and the expected number of hours of operation that is requested between refills.
11. SELECTING FUELS FOR STANDBY DEPENDABILITY Reliable operation of diesel engines may vary from one fuel to another, depending on many factors, including fuel characteristics and engine operating conditions. The types of fuels available for diesel engines, vary from highly volatile jet fuels and kerosene to the heavier fuel oils. Most diesel engines are capable of burning a wide range of fuels within these extremes.
Other solutions are to add inhibitors to the fuel or to obtain greater turnover by using the fuel for other purposes. A gum inhibitor added to diesel fuel will keep it in good condition up to two years. If the building furnace has an oil burner, it is possible to burn diesel fuel in the furnace, connecting both the engine and the furnace to the same tank.
12. TABLES AND FORMULAS FOR ENGINEERING STANDBY GENERATING SETS Table 1. Length Equivalents Unit Microns Meters Kilometres Inches Feet Yards Miles 1 Micron 1 1,000,000 -25,400 ---- 0.000001 1 1000 0.0254 0.3048 0.9144 1609 --1 ---1.609 0.00003937 39.37 39,370 1 12 36 63,360 -3.281 3281 0.0833 1 3 5280 -1.0936 1093.6 0.0278 0.3333 1 1760 --0.621 ---1 1 Meter 1 Kilometre 1 Inch 1 Foot 1 Yard 1 Mile One unit in the left-hand column equals the value of units under the top heading. Table 2.
Table 4. Volume and Capacity Equivalents Unit Inches 3 Feet3 Yards 3 1 Inch 3 1 1728 46656 61023 231 0.000579 1 27 35.31 0.1337 0.0000214 0.03704 1 1.308 0.00495 0.0000164 0.0283 0.765 1 0.003785 277.42 61.02 0.16 0.03531 0.00594 0.001308 0.004546 0.001 1 Ft.3 1 Yd.3 1 M3 1 U.S.Liq.Gal 1 Imp. Gal. 1 Litre Meters 3 US Liquid Gallons Imperial Gallons Litres 0.004329 7.481 202 264.2 1 0.00359 6.23 168.35 220.2 0.833 0.0164 28.32 764.6 1000 3.785 1.2 0.2642 1 0.22 4.
Table 7. Conversions for Measurements of Water Unit Feet3 Pounds Gal (U.S ) Gal Litres (IMP) Head (Ft) lb/in² Ton/Ft² Head (Meters ) Ft³/Min Gal.(U.S) /Hr Feet3 1 0.01602 -- 62.42 1 8.34 -0.12 1 -0.10 -- -0.4536 -- ---- ---- --- ---- ---- --- -- 10.0 -- 1 -- -- -- -- -- --- 2.2046 -- --- --- 1 -- -1 -4.335 --- ---- ---- ---- ---- ---- 2.3070 35.92 -- 1 -1.4221 0.02784 1 -- 0.7039 -1 --- --- --- --- --- --- --- --- --- Pounds Gal (U.
Table 9. Conversions of Units of Flow Unit U.S Gallons/Minute Million U.S Gallons/Day Feet3 /Second Meters 3 /Hour Litres/Second 1 U.S Gallon/Minute 1 Million U.S Gallons/Day 1 Foot3 /Second 1 0.001440 0.00223 0.2271 0.0630 694.4 1 1.547 157.73 43.8 448.86 4.403 15.85 0.646 0.00634 0.0228 1 0.00981 0.0353 101.9 1 3.60 28.32 0.2778 1 1 Meter3 /Hour 1 Litre/Second One unit in the left-hand column equals the value of units under the top heading. Table 10.
Table 12. Electrical formulae Desired Data Kilowatts (kW) Kilovolt-Amperes kVA Electric Motor Horsepower Output (HP) Amperes (I) When Horsepower is known Single Phase Three-Phase Direct Current I x V x PF 3 x I x V x PF IxV 1000 1000 1000 IxV 3 xVxE 1000 1000 I x V x Eff . x PF 3 x I x V x Eff . x PF 746 746 HP x 746 V x Eff . x PF HP x 746 3 x V x Eff . x PF I x V x Eff .
TABLE 13. kVA/kW AMPERAGE AT VARIOUS VOLTAGES (0.8 Power Factor) kVA 6.3 9.4 12.5 18.7 25 31.3 37.5 50 62.5 75 93.8 100 125 156 187 219 250 312 375 438 500 625 750 875 100 0 112 5 125 0 156 3 187 5 218 8 250 0 281 2 312 5 375 0 437 5 500 0 kW 208V 220V 400V 440V 460V 480V 600V 5 7.5 10 15 20 25 30 40 50 60 75 80 100 125 150 175 200 250 300 350 400 500 600 700 800 17.5 26.1 34.7 52 69.5 87 104 139 173 208 261 278 347 433 520 608 694 866 1040 1220 1390 1735 2080 2430 2780 16.5 24.7 33 49.5 66 82.
Conversions of Centigrade and Fahrenheit Water freezes at 0 ºC (32ºF) Water boils at 100 ºC (212ºF) ºF= ( 1.8 x ºC ) + 32 ºC = 0.5555 ( ºF - 32 ) Fuel Consumption Formulas Fuel Consumption(lb / hr) = Specific FuelCons.( lb / BHP / hr) xBHP Fuel Consumption(US gal / hr ) = Spec. Fuel Cons. (lb / BHP / hr) x BHP FuelSpecific Weight(lb / US gal ) FuelSpec.Weight( lb / US gal) = FuelSpecific Gravity x8.34 lb Specific FuelConsumption(lb / BHP / hr ) = FuelCons.( US gal / hr) x FuelSpec.
13. GLOSSARY OF TERMS ALTERNATING CURRENT (AC) - A current which periodically reverses in direction and changes its magnitude as it flows through a conductor or electrical circuit. The magnitude of an alternating current rises from zero to maximum value in one direction, returns to zero, and then follows the same variation in the opposite direction. One complete alternation is one cycle or 360 electrical degrees. In the case of 50 cycle alternating current the cycle is completed 50 times per second.
CURRENT (I) - The rate of flow of electricity. DC flows from negative to positive. AC alternates in direction. The current flow theory is used conventionally in power and the current direction is positive to negative. CYCLE - One complete reversal of an alternating current or voltage from zero to a positive maximum to zero to a negative maximum back to zero. The number of cycles per second is the frequency, expressed in Hertz (Hz). DECIBEL (dB) - Unit used to define noise level.
kW - 1,000 Watts (Real power). Equal to KVA multiplied by the power factor. POWER - Rate of performing work, or energy per unit of time. Mechanical power is often measured in horsepower, electrical power in kilowatts. POWER FACTOR - In AC circuits, the inductances and capacitances may cause the point at which the voltage wave passes through zero to differ from the point at which the current wave passes through zero.
TELEPHONE INFLUENCE FACTOR (TIF) - The telephone influence factor of a synchronous generator is a measure of the possible effect of harmonics in the generator voltage wave on telephone circuits. TIF is measured at the generator terminals on open circuit at rated voltage and frequency. THREE PHASE - Three complete voltage/current sine waves, each of 360 electrical degrees in length, occurring 120 degrees apart. A three phase system may be either 3 wire or 4 wire ( 3 wires and a neutral).
GROUP HEADQUARTERS Old Glenarm Road Larne, Co. Antrim BT40 1EJ Northern Ireland, United Kingdom Telephone: (44) 028 2826 1000 Fax: (44) 028 2826 1111 276-851 INSTALL.
