Guide to Pre-installation Commissioning of Diesel Generator Sets

 
Diesel generator sets, as critical backup power equipment, rely heavily on reliability and stability to ensure a consistent power supply. Proper installation and commissioning are essential to ensuring the unit operates smoothly and maximizes its lifespan. This article provides a detailed guide on the preparation before installation, pre-test checks, commissioning steps, and key operations during testing and running to help users efficiently and accurately complete the installation and commissioning of the diesel generator set.

Pre-Installation Preparation

 
Before beginning the installation of the diesel generator set, several key preparation steps are required to ensure the unit starts smoothly and runs reliably over the long term. These preparations mainly include rust prevention and oil changes.

1. Rust Prevention

 
Preheating and Cleaning Diesel: New units come with rust protection from the factory. Prior to installation, heat the diesel to 45–56°C to effectively remove the external rust-proof oil. This step helps prevent residual rust-proof oil from affecting subsequent operations inside the unit.
Water Jacket Flushing: Heat water to above 90°C and continuously flush through the water jacket until it flows out from the drain valve on the cylinder block side. This process should last 2–3 hours, with intermittent turning of the crankshaft to ensure complete removal of rust-proof oil and impurities from the piston top, cylinder liner surface, and other areas. This step aids in eliminating internal residues and contaminants.

2. Oil Change

 
Clean the oil pan and replace with fresh engine oil. This ensures proper lubrication during the first start and removes any contaminants that might have entered the oil pan during production and transport.

Pre-Test Inspection

 
After installing and initially preparing the diesel generator set, the pre-test inspection is crucial for ensuring the equipment operates correctly. This phase helps identify and correct potential issues to avoid failures during actual operation. Pre-test checks include appearance inspection, component checks, crankshaft inspection, leak tests, and preparation for the break-in process.

1. Appearance Inspection

 
Ensure the unit's exterior is clean and check for any damage caused during transport or installation, such as scratches or loose components.

2. Component Checks

 
Verify that the bolts on all components are tightened to prevent loosening during operation.
Check the clearances of intake and exhaust valves and the pressure relief mechanism to ensure they meet manufacturer specifications. Proper valve clearances ensure smooth gas flow and optimal engine performance.

3. Crankshaft Inspection

 
Place each cylinder in the decompression position and check the smoothness of crankshaft rotation to ensure there are no sticking issues. Difficult rotation may lead to starting problems or uneven operation.
Listen for unusual noises from each cylinder's components to identify potential mechanical faults or lubrication issues.

4. Leak Test

 
Close the pressure relief mechanism and rotate the crankshaft to check for any leakage from the cylinders. This ensures that cylinder seals are intact and prevents leakage issues during operation.

5. Break-In Process

 
Before full operation, conduct a break-in period to smooth out moving parts and extend the engine's lifespan. Follow a gradual increase in load and speed to ensure proper break-in and avoid premature wear or damage.

Commissioning Steps

 
The commissioning of the diesel generator set is crucial for ensuring stable and efficient operation under real conditions. Commissioning involves the diesel engine, generator, and control panel, each requiring careful adjustment to ensure proper component integration and overall system performance.

1. Diesel Engine Commissioning

 
Fuel Supply System Check: Inspect and adjust components such as the fuel pump, injection pump, regulator, and fuel quantity to ensure proper operation and combustion efficiency.
Valve Mechanism Check: Check valve clearances and the operating status of the valve mechanism to ensure proper adjustment, which is essential for engine performance and efficiency.

2. Generator Commissioning

 
Insulation Resistance Measurement: Measure the generator's insulation resistance to ensure good insulation performance. Proper insulation prevents electrical faults and leakage.
Generator Heating Check: Perform heating or test checks to ensure the generator does not overheat during operation and to avoid potential overload risks.
Excitation Device Adjustment: Adjust the excitation device to ensure proper excitation of the generator, which helps stabilize voltage output and ensures normal operation.
Regulator Adjustment: Check and adjust the regulator to ensure stable generator output, which is crucial for the reliability of the power system.
Air Filter and Anti-Condensation Heater Check: Inspect the air filter for cleanliness to ensure smooth air flow; check the anti-condensation heater to ensure proper operation in low-temperature environments.

3. Control Panel Commissioning

 
Switches and Buttons Check: Ensure that all switches and buttons operate smoothly and that connections are secure. Verify that all control panel functions are working correctly.
Wiring Check: Verify the correct wiring of primary and secondary circuits in the control panel to avoid faults caused by wiring errors.
Cable Connections: Connect the output lines of the AC generator, disconnect the isolator switch of the auxiliary control panel, and connect the power lines from the grid to the auxiliary control panel. Ensure correct cable connections to maintain system stability.
Heater Connection: Connect the diesel engine heater to the main control panel to ensure proper starting in low temperatures.

Testing and Operation

 
After completing the installation and commissioning of the diesel generator set, the testing and running phase is essential for verifying the unit's performance and reliability. This phase ensures that the generator set operates correctly under actual working conditions and helps identify and resolve potential issues.

1. Alarm Circuit Check

 
When pressing the "Test Alarm" button, the alarm bell should ring, the "Fault Alarm" light should illuminate, and a sound and light alarm signal should be emitted. The signal should disappear immediately when the button is released. This ensures the alarm system can issue warnings promptly in case of a fault.

2. Automatic Start Test

 
When the unit starts automatically, if the generator experiences overload or overcurrent, the diesel engine should automatically idle and emit a sound and light alarm. This protects the unit from overload or overcurrent damage.
After manually troubleshooting the fault within 3 minutes, switch the control from "Auto" to "Manual" and then back to "Auto" to allow the unit to automatically restore normal power supply. If the fault is not resolved after 3 minutes of idling, the unit will automatically shut down to prevent further damage.

3. Emergency Shutdown and Alarm

 
During testing, if there is a low oil pressure or high water temperature, the unit will automatically shut down and emit a sound and light alarm. This responds to abnormal conditions in a timely manner to prevent further damage.
 
By following detailed installation and commissioning procedures, the diesel generator set can achieve excellent stability and efficient performance when put into use. Accurate rust prevention, thorough pre-test checks, comprehensive commissioning, and rigorous testing are all key to ensuring long-term reliable operation. Understanding and adhering to these steps not only reduces the risk of faults but also significantly extends the unit's lifespan and operational efficiency. Whether for daily use or in emergencies, a well-commissioned diesel generator set provides stable and reliable power, ensuring continuity and safety in industrial production and emergency power supply.