Diesel Generator Set Commissioning Procedures
by Starlight Generator dieselgeneratortechDiesel
engine unsealing
In order to prevent the diesel
engine from rusting, when the product leaves the factory, both inside and
outside is sealed with oil. Therefore, after the new unit is installed and
meets the installation requirements, it must be unsealed before it can start.
Otherwise, it will cause the danger. So it should be taken seriously.
The steps to
remove the oil seal are as follows:
1) Heating the diesel above 45 ℃ to 56 ℃for cleaning
and removing the external anti-rust oil.
2) Heating water aover 90 ℃, then continuously pouring water through the
water jacket outlet, flowing out from the plug assy Irain (or water pump inlet)
on the side of the cylinder body, continuously for 2--3 hours, and rolling the
crankshaft discontinuously to make the anti-proof oil of piston top, cylinder
liner surface and elsewhere dissolves and flows out.
3) Clean the oil sump with clean
diesel oil and replace it with new oil.
Cooling and fuel system, fuel
injection speed regulation system, water pump and starting drive system should
be cleaned and checked in accordance with the requirements of the instructions,
and sufficient clean cooling water should be added, starting batteries should
be fully charged, and preparations should be made for the start up of the
machine.
Inspection
before the genset has a test
1. Inspection procedures
1) Check whether the surface of
the unit is clean. The anchor nut, flywheel screw and other moving parts are
not loosened. It must be fastened if any problems found.
2) Check whether the clearance of
each part is correct, especially check the intake & exhaust valve clearance
to make sure it meets the requirements.
3) Put each cylinder in the
pressure reducing position, rotate the crankshaft to check if there is any
abnormal sound in the operating sound of the cylinder parts, and whether the
crankshaft rotates freely. At the same time, pump the engine oil into the
friction surface. Then, close the pressure - reducing device, shake the
crankshaft, and check the cylinder for air leakage. If the crankshaft is very
difficult to shake, it indicates that the compression is normal.
4) Check fuel supply system,
steps are as follows:
① Check
whether the venthole on the fuel tank cover is smooth and clean if there is
dirt in the hole. Whether the diesel added meets the required brand number,
whetehr oil mass is adequate, and turn on the oil circuit switch.
② Open the
mechanism of decompressor to shake the crankshaft. If each cylinder has a clear
injection sound, it indicates that the injection is good. Whereas, there may be
air in the oil line. This moment, you should rotate the fuel filter and
injection pump air bleed screw to eliminate the air in the oil line.
③Check
whether there is oil leakage in the oil pipe and joint, and deal with the
problems in time if found.
5) Check water cooling system,
procedures are as follows:
①Check
whether the cooling water in the tank is sufficient. If the water is
insufficient, clean soft water should be added.
②Check
whether there is water leakage in the joint pipe and solve the problem in time.
③Check that
the impeller rotation of the cooling water pump is flexible and the belt is
tight and appropriate. When checking whether the belt is tight, push the middle of the driving
belt. It is suitable if the driving belt is pressed down 10-15mm.
6) Check lubricating system
①Check the
oil pipe and pipe joints for oil leakage and solve the problem in time
②Check the
oil mass of the oil pan, draw out the oil dipstick next to the crankcase,
observe whether the height of the oil surface is in accordance with the rules,
otherwise, add oil to the diesel engine, add No.8 or 11 engine oil in winter,
and add No.14 oil in summer. Check again, if found that the oil surface height
is above the normal, should be carefully analyzed the reasons for the increase
in oil, usually there are three reasons.
a. Add too much oil
b. Diesel oil leaks into the
crankcase and dilutes the oil.
c. The cooling water leaked into
the oil.
7) Check starting system
a. First, check whether the
specific gravity of starting system is within the range of 1.240 ~ 1.280. If
the specific gravity is less than 1.180, it indicates that the battery power is
insufficient.
b. Check whether the power line
is correct.
c. Check whether there is
contamination or oxidation on the battery terminal, it should be cleaned up.
d. Check whether the electric contact
of starting motor and electro-magnetic control is good.
Installation and inspection
procedures of ac generator are as follows:
Note: We can provide 15KW to
2000KW Starlight synchronous ac generator
1) The coupling between alternator
and diesel generator requires that the parallelism and concentricity of the
coupling are less than 0.05 mm. In actual use, the requirements may be slightly
lower, about within the 0.1mm, over the assembly affects the normal operation
of bearing, resulting in damage, good coupling should be fixed with positioning
pin. The coupling should be re-tested before installation.
2) When a sliding bearing
generator is coupled, the height of the generator center should be adjusted
slightly lower than the center of the diesel engine, so that the weight of the
flywheel on the diesel engine will not be transferred to the generator bearing.
Otherwise, the generator bearing will bear extra weight of the flywheel, which
is not conducive to the formation of oil film of the sliding bearing, resulting
in heat and even burning of the bearing. The couplings of such generator are
not allowed to carry any weight.
3) When installing the generator,
make sure that the cooling air is free from the entrance, and avoid the release
of hot air into the generator. If there is shutter on the ventilation
cover, the window should be down to meet
the protection level requirements.
4) The mechanical coupling of
single bearing generator should pay special attention to the uniform air gap
between stator and rotor.
5) According to the schematic
diagram or wiring diagram, select the appropriate power cable, use copper joint
to connect, copper joint and busbar, busbar and busbar after fastening, the
local gap is less than 0.05 mm, the distance between the conductors is less
than 10 mm, and the necessary ground wire should be installed.
6) The terminal head of the
generator outlet box is marked with U, V, W, N, which does not mean that the
actual phase sequence but depends on the direction of rotation. UVW is printed
on the certificate to indicate the actual phase sequence in clockwise rotation,
VUW represents the actual phase sequence in counterclockwise rotation.
7) If the neutral point of each
generator in the power supply system is connected with each other, or when the
neutral point of the generator is connected with the transformer and its load
neutral point, the neutral line current of 3 times the frequency of the neutral
line will be produced during the operation of the unit. Therefore, it is
necessary to measure the mid-line current of the generator under various load
conditions that may occur in operation. In order to keep the generator from
overheating, the midline current shall not exceed 50% of the rated current of
the alternator. If the midline power is too large, the central line reactor
should be installed.
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Created on Aug 28th 2018 02:31. Viewed 311 times.