Generator Installation Manual
Diesel Generator Setup & Commissioning
Step-by-step procedures for installing and commissioning diesel generators from 20kVA to 2000kVA capacity.
Disclaimer
Chapter 1: Introduction
This manual provides comprehensive procedures for diesel generator installation, from site preparation through commissioning and handover. Following these guidelines ensures safe, reliable, and code-compliant installations.
Scope of Work
- Civil foundation and equipment pad construction
- Generator set positioning and leveling
- Fuel system installation and testing
- Exhaust system and silencer installation
- Electrical connections to ATS and distribution
- Control panel wiring and configuration
- Commissioning tests and performance verification
- Operator training and documentation handover
Chapter 2: Site Preparation
Proper site preparation is critical for generator longevity and performance. The foundation must support the generator weight and vibration loads.
Foundation Requirements
| Generator Size | Foundation Size | Concrete Grade | Reinforcement |
|---|---|---|---|
| Up to 30 kVA | 1.5m × 1m × 0.3m | M20 | 10mm @ 150mm c/c |
| 30-100 kVA | 2.5m × 1.5m × 0.4m | M25 | 12mm @ 150mm c/c |
| 100-250 kVA | 3.5m × 2m × 0.5m | M25 | 16mm @ 150mm c/c |
| 250-500 kVA | 4.5m × 2.5m × 0.6m | M30 | 16mm @ 125mm c/c |
| 500+ kVA | Custom design | M30 | Structural engineer |
Chapter 3: Fuel System Installation
The fuel system must provide reliable diesel supply while meeting environmental and safety regulations.
Fuel Tank Sizing
Tank Capacity Calculation
Generator Consumption: Liters/hour at 75% load
Required Runtime: 8-24 hours typical
Reserve Margin: 20% additional capacity
Day Tank (if applicable): 4-8 hours supply
Installation Requirements
- Double-wall tanks for environmental protection
- Leak detection systems for underground tanks
- Proper venting to prevent vacuum during consumption
- Fuel return line for excess fuel from injectors
- Water separator and primary filter installation
- Lockable fill point with spill containment
Chapter 4: Electrical Connections
Electrical installation must comply with local regulations and ensure proper coordination between generator, ATS, and distribution systems.
Cable Sizing Guide
| Generator Output | Cable Size | Breaker Rating | Neutral Size |
|---|---|---|---|
| 30 kVA / 40A | 16mm² Cu | 63A | 16mm² |
| 60 kVA / 80A | 25mm² Cu | 100A | 16mm² |
| 100 kVA / 140A | 50mm² Cu | 160A | 25mm² |
| 200 kVA / 280A | 95mm² Cu | 315A | 50mm² |
| 500 kVA / 700A | 2×150mm² Cu | 800A | 95mm² |
Chapter 5: Exhaust System
Proper exhaust system design prevents dangerous gas buildup and noise pollution.
Installation Guidelines
- Use corrosion-resistant piping (e.g., stainless steel)
- Ensure adequate slope away from the generator
- Install silencers to meet local noise regulations
- Provide expansion joints for thermal movement
- Secure piping with appropriate supports to prevent vibration
Chapter 6: Commissioning
Commissioning validates that the installed generator operates correctly and safely.
Pre-Start Checks
- Verify all fluid levels (oil, coolant, fuel)
- Check battery voltage and connections
- Confirm emergency stop button functionality
- Inspect all electrical connections
Chapter 7: Load Testing
Load testing verifies the generator's ability to meet its rated capacity.
| Load Level | Duration | Parameters to Monitor |
|---|---|---|
| No Load | 30 minutes | Voltage, frequency, temperature |
| 30% Load | 1 hour | Voltage, frequency, fuel consumption |
| 75% Load | 2 hours | Voltage, frequency, fuel consumption, exhaust temp |
| 100% Load (if required) | 1 hour | Voltage, frequency, exhaust temp, vibration |
Chapter 8: Safety Guidelines
Adherence to safety protocols is paramount during generator installation and operation.
Chapter 11: Installation Checklists
Generator Installation Checklist
Installation Engineer
Date
Document Information
Document: Generator Installation Manual
Version: 3.1
Last Updated: December 2024
Author: HNL Engineering Team
Category: Energy & Power Systems
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