CHAPTER 11: INSTALLATION, ERECTION, TESTING

AND COMMISIONING OF PLANT

INSTALLATION OF ENGINE PROCEDURE

A well-known method of engine installation is the “bootstrap method” using commercially

available equipment. During the installation process, all precautions and procedural steps are
strictly to be adhered.

The complete kit for removal/installation of the engine is commercially available. Such kit
contains bootstrap hoists (manually/electrically operated type), engine cradle, engine dolly, etc.
Other required in tools/materials are: Rig pins (to secure and rig engine control cable runs), lock
wires, cowl door supports, mount bolt torque wrench and wrench sets and spanners and so as
specified in maintenance manual. Cockpit preparation is to be completed, pulling and tagging
CBs, securing control levers in required positions, including deactivation of systems, isolating
fluid system from engine. At the same time ground preparation is to be completed taking care of
every cautions/warnings/protections.

1. Configure Engine cowls by support bars as suggested in MM. Secure control cables with
rig pins.
2. Position dolly or trailer with engine and cradle installed under pylon.
3. Operate manual hoists to extend load chains, and attach hoisting brackets to cradle.
4. Check that manual hoists and crossbeams are properly attached and lock pins and
safety pins are properly installed.
a. Unlock engine cradle from dolly or trailer.
b. Carefully operate hoists to assume weight of engine, checking again for proper
rigging and cable chafing.
c. Check running torque of forward and aft mount bolts and nuts for minimum
torque of 50 inch-pounds.
5. Operate hoists simultaneously and raise engine up to approximate position for
installation.
WARNING: Make certain hoists are operated to keep engine at level attitude care about
engine weights.
a. Clean engine mount interface surfaces and check that alignment shear pins and
engine mount surfaces are free of lubricant.
6. Lightly coat engine mount bolt threads and washers with oil, MIL-L-25681.
7. Install washers under heads of engine mount bolts.
8. Raise engine, and perform following:
a. Align forward mount alignment pin with mating hole in pylon mount support.
b. Align engine aft mount alignment pins with mating holes in pylon aft mount
support.
 c. Continue to raise engine until forward mount alignment pin and aft mount
alignment pins are engaged and a gap of approximately 1/4-inch exists between
engine mounts and pylon mount supports.

CAUTION: Use hoist with extreme care when raising engine to final position or damage
to mounts and supports could result. Never operate hoists to completely close gap
between engine mounts and pylon mount supports.

9. Install forward and aft mount bolts. Tighten bolts evenly on left and right sides of engine
until engine mounts are flush with pylon mount supports. Then release tension on hoist
units simultaneously.
10. Torque forward mount bolts to proper figure (e.g. 320 to 340 foot-pounds).
11. Torque aft mount bolts to proper figure (e.g. 320 to 340 foot-pounds).
NOTE: Correct torque must be calculated when using adapter with torque wrench.
a. Safety forward and aft engine mount bolts with .032 corrosion-resistant steel R
lock wire or with retainers as applicable
12. Remove lock pins and disconnect forward and aft cradle fittings from attach adapters.
13. Operate manual hoists simultaneously and lower engine cradle onto dolly or trailer.
Secure cradle to dolly or trailer.
a. Operate manual hoists to relieve tension on load chains and disconnect cradle
hoisting brackets from cradle.
b. Remove forward and aft attach adapters from engine and install on engine
cradle.
c. Roll dolly or trailer with engine cradle clear of aircraft.
14. Remove engine hoist as follows:
a. Remove manual hoists from forward and aft crossbeams.
b. Remove balance cable from aft crossbeam.
c. Remove left and right outer sections from aft crossbeam center section.
d. Remove aft crossbeam center section from pylon eyebolts.
e. Remove left and right outer sections from forward crossbeam center section.
f. Remove hangars from pylons
g. Remove cowl door supports.

PIPING

DETERMINING PIPE SIZES

Minimum pipe sizes are determined by the size of the inlet to the fuel transfer pump. The
pipe inner diameter must be a least as large as the transfer pump inlet. If the piping must carry
the fuel over long distances, the pipe size must be increased. An auxiliary transfer pump at the
tank outlet may also be needed to avoid high suction pressure within the piping. In all cases,
excessive fuel line suction pressures must be avoided.

At high suction pressures the fuel vaporizes in the piping and the fuel supply to the
engine will be decreased. When sizing piping, always remember to account for pressure drop
across filters, fittings and restriction valves. A flex connector must be added to isolate the
engine vibration from the fuel piping. If this vibration is not isolated, the piping could rupture and
leak. The flexible connector must be as close to the engine transfer pumps as possible. Any
expanse of exposed piping must be properly supported to prevent piping ruptures. Use pipe
hangers to isolate vibration from the system. Exposed fuel piping must never run near heating
pipes, furnaces, electrical wiring or exhaust manifolds. It the area around the piping is warm, the
fuel lines should be insulated to prevent the fuel and piping from picking up any excess heat. All
pipes should be inspected for leaks and general condition, including cleanliness before
installation. Back flush all lines to the tank before start-up to avoid pulling excess dirt into the
engine and fuel piping system. After installation, the air should be bled from the fuel system. A
petcock should include at some high point in the system to allow air removal.

Use plugged tees, not elbows, to make piping bends. This will allow for cleaning by
removing the plugs and flushing out the lines. All threaded pipe fittings must be sealed with a
suitable paste.

CAUTION: Do not use tape to seal fuel line fittings. Pieces of tape could shear off and jam in the
pump or injectors.

WIRING

ELECTRICAL CONNECTION

Only full qualified and experienced electrical technicians should carry out electrical
installation, service and repair work. Make electrical connections in compliance with relevant
Electrical Codes, Standards or other requirements.

CABLING

Due to movement of generating sets on their vibration mounts, the electrical connection
to the set should be made with flexible cable.

The cable must be suitable for the output voltage of the generating set and the rated
current of the set. In determining the size, allowances should be made for ambient temperature.
Method of installation, proximity of other cables, etc.

All connections should be carefully checked for integrity. Current carrying capacity of
power cables that will be given in table 10.1 and the cable cross sections which must be used
according to the generating set power has been given in table 10.2. On the other hand, there is
a one more important point while falling at the load side can be too much at the transient current
duration. The voltage drop across a cable can be determined as follows:

√3 𝑥 𝐿 𝑥 𝐼 𝑥 (𝑅𝑐𝑜𝑠∅ + 𝑠𝑖𝑛∅)
𝑒=
1000
 Where:

e = Voltage drop (V)

I = Rated current (A)

L = Length of conductors (m)

R = Resistance (Ω/km to VDE 0102)

X = Reactance (Ω/km to VDE 0102)

PROTECTION

The cables connecting the generating set with the distribution system are protected by
means of a circuit breaker to automatically disconnect the set in case of overload or short circuit
(Manual models only).

LOADING

When planning the electrical distribution system, it is important to ensure that a balanced
load is presented to the generating set. If loading on one phase is substantially higher than the
other phases it will cause over heating in the alternator windings, imbalance in the phase output
voltage and possible damage to sensitive 3 phase equipment connected to the system. Ensure
that no individual phase current exceeds the current rating of the generating set. For connection
to existing distribution system, it may be necessary to reorganize the distribution system to
ensure these loading factors are met.

INSULATION FOUNDATION AGAINST VIBRATION

Each generating set is built as a single module with the engine and alternator coupled
together through a coupling chamber with resilient mounting to form one unit of immense
strength and rigidity. This provides both accuracy of alignment between the engine and
alternator and damping of engine vibration. Thus, heavy concrete foundations normally used to
absorb engine vibration are not necessary and all the generator requires is a level concrete floor
that will take the distributed weight of the unit.

The generating set is fitted with vibration isolators which are designed to reduce engine
vibration being transmitted to the foundation on which the generating set is mounted. These
isolators are fitted between the engine /alternator feet and the base frame. Lubrication: forced
lubrication via gear pump, special paper cartridge -type filters, lubricant cooling via heat
exchanger on most versions.
VIBRATION INSULATION DEVICES

 FLEXIBLE COUPLING
 UNIVERAL CROSS JOINT
 AUTOMATIC BELT TENSIONER
 ROLLER BEARING
 FLEXIBLE PIPE
 SPRING OR RUBBER DAMPER
 CORK OR RUBBER INSULATION
 PROPER PROVISION OF FOUNDATION DESIGN
 PROPER SOIL BEARING CAPACITY

AIR INTAKE AND EXHAUST SYSTEM

AIR INTAKE

Air for engine combustion must be clean and as cool as possible. Normally this air can
be drawn from the area surrounding the generating set via the engine mounted air filter.
However, in some cases due to dust, dirt or heat the air around the set is unsuitable. In these
cases, an inlet duct should be fitted. This duct should run from the source of clean air (outside
the building, another room, etc.) to the engine mounted air filter. Do not remove the air filter and
mount it at a remote location as this can increase the possibility of dirt leaking

EXHAUST SYSTEM

The exhaust systems are supported from the ceiling. Should the building construction be
such that the roof supports were unable to support the exhaust system, a floor standing steel
exhaust stand will be needed. Exhaust pipes should terminate at least 2, 3 m above floor level
to make it reasonable safe for anyone passing or accidentally touching

It is recommended that stainless steel bellows be fitted to the engine exhaust manifold
followed by rigid pipe work to the silencer.

It is good installation practice for the exhaust system within the generator room to be
insulated with a minimum of 50 mm. of high density, high temperature mineral insulation
covered by aluminum over clad. This reduced the possibility of operator burn injury and reduces
the heat being radiated to the operating generator room.

PERFORMANCE TESTING OF DIESEL ENGINE POWER PLANT

The performance of the diesel engine focuses on the power and efficiency. The engine
varies with the parameters of the engine like piston speed, air-fuel ratio, compression ratio, inlet
air-pressure and temperature. The two usual conditions under which Internal Combustion
engines are operated are:

a. Constant Speed with Variable Load

b. Variable Speed with Variable Load
 Type testing of Diesel Engine Systems based on AS/NZS 3584.2:2003 Standards which
includes:

1. Flame propagation and pressure determination testing exhaust conditioner shutdown

water levels and hydrostatic testing
2. Dynamometer testing of diesel engines for performance, exhaust emissions, surface
temperatures, fuel and exhaust conditioner water consumption and safety shutdown
systems
3. Smoke testing 4. Exhaust filter testing

OPERATION AND MAINTENANCE

Diesel engines compromise the vast majority of prime mover for standby power
generators because of their reliability, durability and performance under load. Diesel powered
generators are depended on for back-up power system in the most critical location: hospitals,
airports, government buildings, telecommunication facilities, and even nuclear power plants.
Like any mechanical device, maintenance is critical for ensuring that a diesel powered standby
generator will start and run when needed.

PREVENTIVE MAINTENANCE

Because of the durability of diesel engines, most maintenance is preventive in nature.

Preventive diesel engine maintenance consists of the following operations:

 General inspection
 Lubrication service
 Cooling system service
 Fuel system service
 Servicing and testing starting batteries
 Regular engine exercise

It is generally a good idea to establish and follow a schedule of maintenance and service
based on the specific power application and the severity of the environment. Some of the
factors that can affect the maintenance schedule include:

 Using the diesel generator set for continuous duty (Prime Mover)
 Extreme ambient temperatures
 Exposure to weather
 Exposure to salt water
 Exposure to dust, sand and other airborne contaminates

GENERAL INSPECTION

When the generator set is running, operators need to be alert for mechanical problems
that could create unsafe or hazardous conditions. Following are several areas that should be
inspected frequently to maintain safe and reliable operation.
 EXHAUST SYSTEM: With the generator set operating, inspect the entire exhaust
system including the exhaust manifold, muffler and exhaust pipe. Check for leaks at all
connections, welds, gaskets and joints, and make sure that the exhaust pipes are not
heating surrounding areas excessively. Repair any leaks immediately.

FUEL SYSTEM: With the generator set operating, inspect the fuel supply lines, return
lines, filters and fittings for cracks or abrasions. Make sure the lines are not rubbing
against anything that could cause an eventual breakage. Repair any leaks or alter line
routing to eliminate wear immediately.

DC ELECTRICAL SYSTEM: Check the terminals on the starting batteries for clean and
tight connections. Loose or corroded connections create resistance which can hinder
starting.

ENGINE: Monitor fluid level, oil pressure and coolant temperatures frequently. Most
engine problems give an early warning. Look and listen for changes in engine
performance, sound, or appearance that will indicate that service or repair is needed. Be
alert for misfires, vibration, excessive exhaust smoke, and loss of power or increases in
oil or fuel consumption

LUBRICATION SERVICE

Check the engine oil level when the engine is shut down at the interval. 1. For accurate
readings on the engine’s dipstick, shut off the engine and wait approximately 10 minutes to
allow the oil in the upper portions of the engine to drain back into the crankcase. Follow the
engines manufacturer’s recommendations for API oil classification and oil viscosity. Keep the oil
level as near as possible to the full mark on the dipstick by adding the same quality and brand of
oil.

FUEL SYSTEM SERVICE

Diesel fuel is subjected to contamination and deterioration over time, and one reason for
regular generator set exercise is to use up stored fuel over the course of a year before it
degrades. In additional to other fuels system service recommended by the engine manufacturer,
the fuel filters should be drained at the interval.

GENERATOR SET EXERCISE

Generator sets on continuous standby must be able to go from a cold start to being fully
operational in a matter of seconds. This can impose a severe burden on engine parts. However,
regular exercising keeps engine parts lubricated, prevents oxidation of electrical contacts, uses
up fuel before it deteriorates, and in general, helps provide reliable engine starting. Exercise the
generator set at least once a month for a minimum of 30 minutes loaded to not less than one-
third of the nameplate rating. Periods of no-load operation should be held to a minimum,
because unburned fuel tends to accumulate exhaust system. If connecting to the normal load is
convenient for test purposes, the best engine performance and longevity will be obtained by
connecting it to a load bank of at least one-third the nameplate rating.