INSTALLATION / General

INSTALLATION / General

REMARKS

 In the installation process, all basic rules must be applied.

 The purpose of this training is to give general information.
 Specifications of the products which is going to be installed, must
be considered during installation process.
 The basic information is included in the operation and
maintenance handbook of the products.
 Use engine oil, fuel, additives and spare parts suggested by
manufacturer.
 All these subjects are related to product performance, operating
and economical life and warranty coverage.
 INSTALLATION / General

 Safety
 Determination of the power
Place/Ground
Ventilation
 Exhaust System
 Fuel System
 Noise
 Electrical System
 Commissioning
 safety

• Install and operate the gensets proper to rules,

regulations and standards.

• Gensets should be installed, operate and conform to

safety rules as stated in operation and maintenance
handbook, diesel engine service and maintenance
handbook and alternator service and maintenance
handbook.

• Responsibility of safe operation of the genset belongs

to whom installed, use and maintain the genset.

• In case of respect to safety rules, the risk of accident

will decrease.
 safety

 The main risks during the installation and operation

process of the genset are; heavy load accidents, hot
liquid burns, contact with hot surfaces, turning part
accidents, contact with acid, poisonous gases and
electric shock.
 Breaking the safety rules, may increase the chance of
breakdown, accident and injury.
 Genset should be only used by staff who trained on this
subject or authorized, read and understand the
maintenance and operation handbook.
 Turn off the genset before maintenance, repair or
setting-up process and isolate from interfere of
unauthorized people.
safety
 ! Important

 To select a suitable place for genset is the most important phase of the
genset installation.

 The point to consider when you select a suitable place is to pay

attention for all topics that we will issue in this presentation.

 As a result of all evaluations, the place that is the closest to ideal

conditions is to be selected.

 This selection is regarging to;

performance of the product,
operational and economical lifetime,
warranty coverage.
 ground

Engine
Alternator

Baseframe

Vibration absorber wedges

 ground

Engine
Alternator

Baseframe

Vibration absorber wedges

ground
 location

• To select a suitable location for genset is another important phase

of the installation process.

• Install the genset on a place where it will be protected from rain,

snow, hail, flood water, high humidity, direct sun light, frosty or
very high temperature, dust, soil or the harmful materials carried
by wind.

• Install the genset on clean, dry, well illuminated and ventilated,

warm places which will also protect the genset from mohair,
smoke, oil vapor, engine exhaust smoke or other pollutives carried
by wind.
 location

• In purpose of making easy the maintenance and control of the

genset there should be enough space around it.

• The ground should be clean, dry and have a good drainage

system.

• If the conditions mentioned above are not satisfied, do not install

and operate the genset.

• Place the genset away from vehicle and caterpillar ways or place
it if only protective barriers are available around genset. Make
necessary protections to avoid genset interfere of unauthorized
people.
location
 location

If the genset is going to be installed at outdoor;

• Protect the genset against to open air conditions.

(Protection cabins may be used.
• Cabin doors should be opening easily in order to access
the genset and main parts.
• There should be no block in front of exhaust, air inlet and
outlet vents. If there will be an addition, the rules should
be applied.
• In order to protect from unfavorable effects, build a
platform under the genset. Platform may be concrete or
steel.
location
location
 ventilation

• The main purpose of the ventilation is discharging the

heat that arise by engine and alternator, outside the
cabin or room.

• In this way, damage or performance loss of the

alternator and engine is prevented.

• Generally, fresh air intake is from the alternator side,

hot air is discharged from radiator side.
 ventilation

Genset room ventilation

 ventilation

Genset room ventilation – WRONG!

 ventilation

Genset room ventilation – RIGHT!

 ventilation

Air temperature change in the genset room

(52C)

(43C)

(32C)
 ventilation

• Windows’ area should be at least the area of radiator

comb. If possible the air inlet and outlet area should be
%150 of the radiator area.

• To protect air vents, windows should have jalouise.

These may be moving or fixed.
ventilation
 ventilation

• Make sure that hot air is completely discharged from

the room by flexible connection which is set up
between radiator and window.

• If the air flow is made via canals, then canals must be

wide enough and the bends must be circular.

DOĞRU YANLIŞ
 ventilation

• Some times wind may blow through air outlet window.

This will prevent the hot air discharging. This will cause
high temperature problems.
DEFLECTOR

Wind

Radiator
 exhaust system

• Exhaust system is used to decrease the noise from

exhaust manifold and redirecting the poisonous
exhaust gas to suitable areas.
• Breathing the exhaust gas may result in death. To be
exposed engine exhaust noise for a long time may
cause hearing problems.

• Exhaust system consist of steel pipe, bend, muffler,

assembly parts and compensator which absorbs
vibration and expansions.
• Exhaust system must be leak proof until the suitable
outlet point.
 exhaust system

Exhaust Connection (Blade, Chain)

Exhaust Silencer
Pipe Connection Isolation Part

Flexible Steel Pipe

Cover

Drain plug
 exhaust system

• Main objective should be not to create back pressure

while designing exhaust system.

• Exhaust systems are designed according to physical

characteristics of building or room which genset is
placed. So shortest and minimum curved way should
be selected for exhaust pipes.

• It is recommended that flammable materials should be

placed at least 250mm away from the all exhaust
pipes because of they dissipates heat.

• To wrap up exhaust pipes with high temperature

isolators or to mount suitable isolator parts may
prevent possible injuries.
 exhaust system

• For vertical exhaust pipes, a rain cap acts with exhaust

pressure should be used.

• There should be a drainage hole at the lowermost point

of the exhaust pipe extension. Thus, water will not reach to
muffler or engine.

• Exhaust gas, smoke, soot and condensations may

damage the inactive genset. So, all gensets should be
connected to separate exhaust pipes.

• Exhaust system should be connected to engine exhaust

outlet with a flexible connector.
exhaust system
 exhaust system

• The exhaust system’s exit points to external ambient

should be selected in a way that does not cause the
retraction of poisonous exhaust smokes from clean air
canals.
• While selecting exit points, the blowing direction of
continuous winds should be cared.

• The exhaust system should be at a secure distance

from the fuel tank, filters, radiator, alternator, electrical
installation and components.
exhaust system
 exhaust system

• Excessive back pressure in the exhaust system decreases

the engine power, increases the fuel consumption,
increases the exhaust system temperature and engine
working temperature.
• The exhaust system max. back pressure is changing
according to the engine models, it should not be exceed
600mmWc in average.
• 1kPA=100mmWc

1- Transparent plastic hose

2- Back pressure mmWc
3- Manometer
4- Connection plug
 Fuel system

• The fuel system should be in an attribution that

supplies clean and continuous fuel to the engine.
• There should not be water, dregs, ruts, dirt, foreign
substances in the fuel.
• The fuel supply pressure should be adequate.
• The correct fuel filters should be used.
• It is advised that a fuel pre-filter should be used before
the engine fuel filters and fuel transfer pump.
 Fuel system

yakıt sistemi
Ventilation pipe

DAILY TANK Fuel return pump –from engine

Panel
Panel

Overflow pipe-to
main tank

Fuel level
Pump control float
Transparent level hose
Cleaning cap

Water and
dregs
collecting part

Pump Pouring valve

Valve

Engine fuel supply

Line from main tank
 Fuel system

• Main fuel tank can be placed under or on the ground..

• A ventilation pipe should exist to prevent vacuum.
• There should be a relief valve at the lowermost point of
the tank to relieve the accumulated water and dregs.
• Height difference between the main tank and daily tank
is important.
• Long horizontal distances cause the pressure loss.
• The fuel lines can be made of steel pipe or any
materials adaptable to petroleum. Do not use
galvanized pipe.
• The fuel return line should enter the tank from the top
part and should not contain any block valves.
Fuel system
 Fuel system

 Temperature of fuel used should not be greater than 40ºC

 noise

• The factors causing the noise in the

generator set:
– Cooling fans
– Exhaust system
– Air induction system
– Vibration
 noise

 Main solution: Isolation and Absorption

1. Sound isolation cabin
2. Sound isolation to the inside of the room
3. Constructing sound absorber canal to air throw
and induction ways
4. Placing sound directing panel
5. Coating exhaust silencer isolation material
6. Montage of additional exhaust silencer
7. Montage of vibration absorber wedge
8. Construction of vibration absorber platform
 noise

 Sound diffusions in the diesel generator sets are

between 100 dB and 110 dB. The least sound pressure
level that is economically reached is the one that is
between 65 dB and 75 dB.
 The precautions that are taken regarding the
decreasing of the noise should affect the generator
performance as low as possible.
 Being in the ambient where the sound pressure is
more than 85dB for long period can cause hearing
problems.
 The measurement standard of diffused noise is
mentioned in TS ISO 8528-10
electrical system
 electrical system

 The connections or repair operations of electrical

installation should only be made by the trained,
qualified electricians.
 Ensure that your body does not contact with the parts
on which the electrical energy exists directly or with
any non-isolated conducting objects.
 Stand on the dry grounds or non-conducting surfaces.
 Do not connect or disconnect busbar, cable,
equipment, etc. on which the energy exists.
 All electrical connections should be made in
accordance with the schemes that are given by the
Teksan Jeneratör.
electrical system
 electrical system

• The cables should be selected in accordance with the

value of the voltage used, table values to carry the
current which will flow on them, ambient temperature
and drawn method.
• The generator set should not be connected to the load
distribution panel directly. There should be power
switch, circuit breaker, contactor, etc. to cut the
generator set connection.
• During the planning of your distribution system it is
important to sustain the connection of a balanced load
to the generator set.
• Be sure that no drawn phase current exceeds the
calculated current amount that the generator set can
give.
• It should be controlled that the phase sequence
direction is appropriate.
electrical system
 electrical system

 The generator set will work in 0,8 power factor value in

a secure way.
 It should be cared that the system should not pass to
the capacitive. Otherwise, this condition will cause the
voltage instabilities in the generator output and will
cause the formation of dangerous excessive voltages.
 The compensation and fixed capacitor should be
connected in a form that it only will be fed from the
mains.
 electrical system

Kalıcı rejim (steady state) alternatör reaktif güç kapasite eğrisi

 electrical system

 The connection of parts which are not active in

electrical facilities with the earth with the help of a
conductor and a electrode is called earthing.
 The parts under the electrical tension in the electrical
systems are isolated to secure the continuity of
electrical systems and human life.
 The resistance between the equipment or part to be
earthed and reference earth should be sustained to be
as small as possible.
 The placing of electrode to a earth surface
considerably distant (at least 20 mt) from the earthed
object is required.
 electrical system

m s 10000
5000
2000
1000

t 500
AC -1 AC -2 AC -3 AC -4
200
100
50
20
10
0 ,1 0 ,2 0 ,5 1 2 5 1 0 2 0 5 0 1 0 0 2 0 0 5 0 01 0 0 02 0 0 0 1 0 0 0 0
IV mA
İnsana Etkisi
AC-1 : Genellikle tepki yoktur.
AC-2 : Zararlı bir fizyolojik etki yoktur.
AC-3 : Kalp atışlarında aksaklıklar görülür.
AC-4 : Tehlikeli fizyolojik etkiler, ağır yanıklar.
 electrical system

 The batteries should be as near as possible to the

generator set, make sure that the connections are right
and not loose.
• Pay attention that the diesel electrical control
installation are away from the parts which are
moveable and on which the heat is formed, that the
connections are tight.
 general layout / sample-1

Exhaust outlet Flapper to

protect from water, snow, etc.
Approved thimble to
protect combustible Access to fresh cool
Silencer Supports
Wind/Noise wall inlet Air
Barrier

Silencer

Drain Flexible Exhaust

Connectors

Outlet Air Flexible GenSet

Deflector Duct Foundation
 general layout / sample-2

System Vent Exhaust Pipe with

Head to Top Tank Rain/Snow
Flapper
Tank

Air Flow
Fresh cool Approved
Intake, away thimble to Room Ventilating Fan
from coolant protect
Remote Radiators combustible
radiators and
wall
exhaust.

Coolant System Vent

Silencer

Water pipes should be

Room Hot Air
insulated to prevent Drain
personal injury. X
Valves to isolate
Air Flow engine for servicing

X
general layout / sample-3
 commissioning

 Start-up operation contains the following

stages:
1. General situation and ambient conditions
(product, building, air, damage, etc)
2. Mechanical connection and ground control
3. Ventilation, exhaust, fuel system control
4. Engine oil, fuel, antifreeze control
5. Electrical system and connection control
6. Function and load test
7. Measurement and settings
8. Training of user
9. Documentation
commissioning
 commissioning

Why is it important?
• You can eliminate any wrong or fault situation if
there any.
• Eliminating any problems in the beginning is easier
than trying to solve them later.
• The installation is controlled in every aspects and
it is approved.
• The fault and missed points are recorded and
reported.
• The user is trained and becomes exempted from
the unnecessary calls.
• Your responsibility is considered as executed, the
responsibilities of customers are explained to
them.
 commissioning

• General state and environment conditions (product, building, air, damage, etc.)
 commissioning

• Product control
 commissioning

• Installation is controlled from all aspects and all mistakes are corrected
 commissioning

Engine Oil
• Use engine oils appropriate with API norms and
having a quality at least CF in your diesel engines.
• Use engine oils which are suitable with ambient
temperature.
 commissioning

Fuel
• Use fuel which are having specifications determined by diesel
engine manufacturers.
• Main standards which are accepted are:
• JIS K-2204 TYPE1, TYPE2, TYPE3
• ASTM, D975 No.1-D, No.2-D
• BS2869 CLASS-A1, CLASS-A2
• DIN51601 DIESEL-FUEL
• ISO8217 DMX-CLASS
• If sulphure ratio is more than 0.5 %, interval for oil change should
be more frequent.
• Biodiesel or kerosene based JP4 and JP8 should not be used.
• The basic properties for fuel are sulphure ratio, viscosity, sediment
ratio, cetane number, water ratio, dregs ratio, freezing point,
evaporization point.
 commissioning

Cooling Liquid

• Use antifreeze or additives specified by

specifications which are determined by diesel
engine manufacturers.
• The cooling liquid is obtained by mixing water
and additives with certain ratios, and protects
engine cooling system against freezing and
corrosion.
• In the cooling fluid use the mixture of %50 antifreeze (glycol ) and
%50 clean and pure water. This will protect your engine against -
40oC freezing. This mixture should be used all over the year.
• Using too much antifreeze, effects liquid’s heat transfer character
negatively.
• There should be no air in cooling Liquid system. Local boiling,
abrasion, overheating of metal, engine malfunctions)
 commissioning

• Electrical system and control of connections.

 commissioning

• Function and load test, measurements, settings

 commissioning

• User training, instructions.

commissioning
 commissioning

Documentation
 Invoice

 Maintenance and Operation Books

 Genset Book
 Engine Book
 Alternator Book

 Service Registration / Commissioning Forms

 Genset Info
 Customer Info
 Used Materials
 Important Points / Warnings

 Warranty Starting
 INSTALLATION / General

Thank you
for
your interest!