Installation Guidelines - OHMS System control (P) Ltd.- Thrissur

DG SET INSTALLATION GUIDELINES :

1. Space around DG Set
There shall be at least one meter free spare around BLISS DG Set to facilitate DG set door opening and maintenance.

2. Installation Surface
The installation surface must be flat, even, firm and without undulations.

3. Requirement of Platform
Concrete platforms should be foreseen to prevent water entry in situations of flooding.

4. Cross ventilation
If installed in an enclosed space, the room should have cross ventilation allowing fresh air to enter from alternator side of the canopy and hot air to move out of the room on the opposite side.

5. DG Set orientation
If installed in an enclosed space, the Radiator of the BLISS DG Set should face an opening in the wall for hot air to escape.

6. Hot Air evacuation
Silencer and associated pipes radiates heat. Hence the room must have provision to evacuate hot air accumulated at the top by ventilator or exhaust fan.

7. Multiple Set Orientations
Multiple DG sets should be installed one beside the other and not one facing the other or one behind the other.

8. Earthing
Regulations vary from place to place. Hence advice should be sought from the local supply utility about requirements. The frame of the alternator, engine and control panel are all connected. Hence earthing the frame of the BLISS DG set ensures earthing the body of all the components. The neutral of the alternator has to be earthed separately. The provision for the same is also made in BLISS DG set. Grounding should be done in accordance with applicable National, Local code/Regulation. Regulations normally require 4 earth pits, one pair for alternator neutral and the other pair for DG set body. The earth pits should be separated by not less than 1 meter.

9. Roof top installations
Experts in the respective field like Structural Engineers must be consulted for roof top installations.

10. Exhaust Connections
The exhaust system is used to direct exhaust gases to non-confined areas and reduce the noise to tolerable levels. When designing a system, the main objective is to minimize back pressure. Excessive back pressure in an exhaust system will create horsepower loss and increase the engine operating temperature and emissions.
When bends are required in exhaust system, always make the radius at least 150% of the inside diameter of the pipe. As most exhaust system designs are governed by the physical characteristics of the building or room in which they are located, it is of utmost importance that the exhaust pipe be routed in a path offering the least amount of turns or bends so as not to increase back pressure more than 50mm of Hg.
Bevel the end of the pipe at a 30-45 degree angle. Should the pipe end be horizontal, bevel the pipe from the top back to the bottom. This will not only reduce the noise levels at the outlet but will also minimize entrance of precipitation on horizontal pipes.
By locating the silencer as close to the engine as possible you will be able to minimize the noise level in the exhaust piping. Each DG Set installation should have its own exhaust system and should not be connected to a system accommodating more than one DG Set as the possibility of exhaust gas and condensation backflow may cause permanent damage to an idle engine.

11. Balancing the loads
While connecting the loads on BLISS DG set, care should be taken to distribute the single phase loads equally on all the three phases.

12. Power Factor
As per standard, BLISS DG set is capable of providing power at 0.8 power factor (lag).Hence the maximum kW BLISS DG Set can supply is obtained by multiplying kVA by pf (Which is 0.8).Power factor lower than 0.8 (lag) will stress the alternator, while pf more than 0.8(lag) will stress the engine. Hence it is advisable to check KW and kVA loading separately. Leading power factor loads, as presented by power factor improvement capacitors will cause voltage instability and hence should be avoided on BLISS DG .

UP KEEP

1. As a daily routine, clean the BLISS DG Set with dry cloth.

2. Keep the door of the DG Set closed.

3. Don’t fill the fuel without strainer.

4. Maintain log book for BLISS DG set.

WATCH KEEP

1. Verify battery charge, lube oil level, coolant level & fuel level in the daily routine checks.

2. Regularly check all the connections of air, oil, coolant, fuel and exhaust for leaks. Report if abnormal.

3. Observe loosening of parts, nuts & bolts. Report if abnormal.

4. Observe for unusual sound of set. Report if abnormal.

DO’S & DON’TS

Do’s.....

1. Ensure that keys for the locks are in proper custody.

2. Use proper & appropriate place for storage of BLISS DG set, Spares and associated items.

3. Understand information provided in DG operation & maintenance literature and as conveyed during training & follow them.

4. Ensure minimum 1 meter clear distance between BLISS DG set & all surrounding structures. Remove obstacles if any for easy access to DG set.

5. Ensure free flow of fresh air to inlet provided on DG set and hot air from radiator to move out to atmosphere without restriction / reflection.

6. As a daily routine, clean the DG set with dry cloth.

7. Include verification of battery charge, lube oil level, fuel level & water level in the daily routine checks.

8. Regularly check all connections of Air, Oil, Water, Exhaust & Diesel for leaks.

9. Release start push bottom when speed picks up to prevent damage to self-starter.

10. Allow sufficient gap between successive starts to prevent draining of battery.

11. While operation in manual mode, run for a while on No-load before loading. Disconnect the load first & run for a while on No-load before stopping the DG Set.

12. Be alert for any unusual sound of DG Set and report without delay.

13. Maintain DG Run log book, Fuel log book & Visit Register.

14. Ensure maintenance checks are carried out in specified time as suggested in BLISS user Manual.

Don'ts.....

1. Don't allow DG set to run in inclined position.

2. Don't allow unauthorized person/s to meddle with DG sets.

3. Don't commission the DG set in the absence of authorized Kirloskar Electric service person/s.

4. Don't fill the fuel without strainer.

5. Don't allow operation of the DG set without proper Earthing.

6. Don't fill the fuel when set is running.

7. Don't bring the naked flame near the battery when it is being charged.

8. Don't press start button when the set is running.

9. Don't disconnect the battery when the set is running.

10. Don't operate the DG with Engine Oil below ‘min’ mark on the Oil dip stick.

11. Don't start the DG set when there is any fault indication.

12. Don't run the DG set without Maintenance checks as in user manual.

13. Don't stop the set on LOAD.

14. Don't open the Radiator cap when the set is running / hot condition.

15. Do not over load the set.

INSTALLATION CHECK LIST

1. LOCATION RELEATED

1.1 Is the set at sufficient height to prevent water entry in rainy season? Yes / No

1.2 Is space surrounding the DG set sufficient to allow maintenance work? Yes / No

1.3 Is the space around is leveled without pits, slopes and other physical Obstruction (as otherwise it is a safety hazard to persons attending) Yes / No

1.4 Whether the DG room has adequate cross ventilation Yes / No

1.5 Whether hot air from radiator moves out without obstruction. Yes / No

1.6 Is care taken that the rain water falling from the adjoining building do not fall on the DG set? Yes / No

1.7 Is exhaust directed away from likely human injury or damage to other equipment or air inlet for acoustic? Yes / No

2. FOUNDATION AND PLATFORM RELATED

2.1 Is the foundation leveled properly so that there are no gaps between base frame and platform surface of the foundation? Yes / No

2.2 Is the area of the platform adequate to provide seating for the entire set? Yes / No

PRODUCT INTACTNESS RELATED

3.1 Is the base frame intact without damage and waviness at the bottom? Yes / No

3.2 Is the enclosure dented or damaged during handing leading to rusting? Yes / No

3.3 Is the door alignment OK? Yes / No

3.4 Is the lock for enclosure functioning properly? Yes / No

3.5 Whether bolts holding engine, alternator, control panel, silencer exhaust fan, fuel tank and bolts of acoustic enclosure tight? Yes / No

3.6 Whether control panel components mounting tight and not loose? Yes / No

3.7 Whether battery has any physical damage? Yes / No

3.8 Whether any wire hanging loose or connection loose? Yes / No

3.9 Whether all fuel connections and drain plug are tight? Yes / No

3.10 Whether AVMs are positioned & not displaced? Yes / No

4. EARTHING & CABLING

4.1 Whether enclosure earthed? Yes /No

4.2 Whether neutral earthed? Yes / No

4.3 Whether Alternator body earthed? Yes / No

4.4 Is cable of mains and load exerting pressure on terminals? Yes / No

4.5 Whether connection to mains, load and alternator are with proper phase sequence? Yes / No

5. LEAKAGE RELATED

5.1 Is the lube oil level at the acceptable level? Yes / No

5.2 Is the coolant level in the Radiator at the acceptable level? Yes / No

5.3 Whether diesel is available at the required level in the fuel tank? Yes / No

5.4 Whether any leakage of fuel, lube oil and coolant observed at drain plug, banjo point crimping or in the pipes or at the neck of the tank or in tank joints? Yes / No

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