DG Installation Works

DG Installation (Lowside) works involved in erection and installation of diesel generator set.

Installation works can be mainly divided into three categories - Mechanical, Insulation and Electrical. Check out the detailed description of installation tasks of diesel generator set which are listed below

Exhaust System

Exhaust System is the piping connection done to turbo side of diesel generator to guide the smoke flow away through pipe outlet, erected in a concerned location. Works involved in Exhaust System are erection & fabrication of exhaust pipe and its related supports (structure/chimney if needed), and also fabrication of dust cleaner, pollution checking point, mesh/rain cap/weather cap to exhaust pipe.

If the provision for MS exhaust pipe is provided within the building (that is shaft or along building wall), then MS exhaust pipe can be directly erected with help of supports (MS channels, MS angles, MS plates and anchor fasteners etc), if the provision is provided outside the building than a self supported structure or chimney should be fabricated (using MS angles, MS channels, MS plates) and installed to the foundation bolts grouted in a strong concrete pedestal.

In case of structure/chimney necessity, a strong concrete pedestal should be constructed as per specification, a template along with foundation bolts matching the base of structure/chimney should be grouted inside concrete except foundation bolts threading area, to which actual structure/chimney base fitted using nuts (lock nut on top). Two coats metal primer and two coats of heat resistant paint is sufficient.

In case of vertical erection of exhaust pip a support at every 2.5 meters is recommended whereas for horizontal exhaust pipe erection - a support at every 2 meters is recommended. Care should be taken in the area where exhaust pipe is connected to expansion bellow as such weight of exhaust pipe doesn't fall on expansion bellow.

MS mesh should be welded to exhaust pipe outlet end, there by avoiding birds, dust as such falling into exhaust pipe.

As per norms, Exhaust pipe should be erected at least 3 meter height from top surface of the building. In case of self support structure, exhaust pipe should be 1 1/2 meter height from top surface of structure. Standard height of the self support structure/Chimney is 30 meters. This standards may be differ with every nation. A lightning arrestor and Aviation lamp should be provided to Structure/Chimney,

Exhaust Pipe Insulation (Referred to as Cladding works)

Exhaust pipe insulation involves surface of the pipe covered with aluminium cladding procedure. Material required for pipe insulation are Mineral/glass wool, aluminium sheet, GI chicken mesh, binding wire, SS Screws. Exhaust Pipe Insulation is done because of following reasons..

Where pipework is operating at extremely high temperatures, the potential exists for injury to occur when any person come into physical contact with the pipe surface. Pipe insulation can be used to bring surface touch temperatures into a safe range.

Pipework can also radiate mechanical noise. Acoustic insulation can prevent noise transfer by acting to damp the pipe wall and performing an acoustic decoupling function wherever the pipe passes through a fixed wall or floor and wherever the pipe is mechanically fixed

Above pipe surface, 50mm thick cladding is sufficient, proper care should be taken at the joints and near bends of aluminium sheets for long life of the job done.

Fuel System

It the mechanical set up of diesel tanks, pipe line and other related components, installed for the storage, supply of diesel required to operate Diesel Generator. Fuel system is very important aspect of installation in terms of DG set operation and surroundings safety, as it is involved with combustion. Components required for installation of fuel system are standard Pipe (as suggested in DG set instructions catalog) & related bends, pipe clamps, ball valves, butterfly valve, float valve, foot valve, open and dummy flanges, fuel gasket, nut bolt & washers, flange earthing clamps, flow meters, level sensors, diesel filteration unit, rotary pumps, pressure gauge, vent hood, diesel tanks (including HSD tank) etc.

Electrical System

An Electrical System is a network of electrical components used to supply electricity to desired locations. In simple terms total electrical set up broadly divided into the generators that supply the power, the cables that carries the power from the generator to DG incomer panel and finally, the DG outgoing panel that feeds the power to different units for actual consumption, this concept little varies with the type of DG set purchased HT/LT. Components used to set up electrical system are power cable/bus duct, control cables, single/double compression glands, lugs, copper cable, ladder/perforated type tray, cable ties/clamps, panels etc.

Earthing System

An earthing system or grounding system is circuitry which connects parts of the electric circuit with the ground, thus defining the electric potential of the conductors relative to the Earth's conductive surface.

In Simple terms, it is the method of connecting the metallic (conductive) parts of an electric appliances or installations to the earth (ground), hence it is called Earthing or Grounding. In other words, connecting the metallic parts of electrical devices and machinery to the earth rod or earth electrode (which is buried in the earth) through a thick conductor cable or flat as a medium between electrical device and earth rod/electrode. The main purpose of earthing is to avoid or minimize the danger of electrocution, fire due to earth leakage of current through undesired path.

Components involved in installation of earthing system are

Neutral Earthing - copper cable, copper flat as per standards, earth rod, coated nut bolt washers, PVC coated copper tape(black sleeve), insulators, earth-pit chamber cover

Body Earthing - GI flat as per standards, GI ipesh connector, coated nut bolt washers, earth rod, earth-pit chamber covers etc.

Commissioning and Approvals Certification

Final stage of installation finishes with proper cable connections at desired ends, proper physical check of the DG set before conducting engine crank tests, followed by commissioning and synchronization of DG Set as per necessity. Commissioning of the generator is done by our commissioning engineer along with extended co-operation from the buyer's side.

Important Points:

Ensure to get certified all the government approvals from related departments to avoid the interruption in usage of DG Set. Pollution board, CEIG and department of explosives (in case of HSD yard) etc are some approvals required from concerned government bodies. Certain norms & standards may differ with location.

Having finalized the planning and purchase of DG set, all other installation tasks can be initiated and done simultaneously to finish the installation process quickly. All the jobs should be done following certified drawings, to avoid re-works in the job done.