What should I pay attention to when installing an exhaust system for diesel generators?

Diesel generator sets must be installed properly before they can be loaded, such as the installation of the intake and exhaust system of diesel generator sets. Otherwise, it will not only affect the normal performance of the power of the unit, but also may lead to the existence of hidden faults. Today I would like to share with you the installation requirements of the intake and exhaust system of diesel generator sets.

1. Air intake system.

In order to ensure that sufficient fresh air is provided for the operation of the diesel generator set, the air inlet of the diesel engine should be arranged in a place with air circulation. The diesel engine inlet pipe of the diesel generator set should avoid using long pipes as much as possible, and reduce the number of elbows, or adopt a large arc transition; The inner diameter of the inlet pipe should not be less than 200mm, the inner wall of the pipe should be smooth and free of welding slag particles, and the dust and debris should be avoided from entering the intake pipe during installation.

It is recommended to adopt the oblique upper air intake method close to the side of the control screen of the diesel generator set, and add shutters and metal protective curtains to avoid the entry of foreign objects and ensure normal air convection. In order to prevent the backflow of hot air and to allow the air in the computer room to flow as much as possible, the air inlet should be protected from rainwater and other foreign objects.

In order to ensure the ventilation volume of the machine room, the minimum net area of the air inlet of the machine room is not less than the effective area of the radiator core of the diesel generator set.

2. Exhaust system.

It should be ensured that the minimum net area of the exhaust outlet is not less than the effective area of the radiator core, the center position of the exhaust outlet should be consistent with the center position of the radiator core of the unit as much as possible, and the width and height ratio of the exhaust outlet should be the same as the width and height ratio of the radiator core as much as possible. In order to prevent the backflow of hot air and the transmission of mechanical vibrations to the outside, the balloon training recommends the installation of an elastic shock-absorbing horn type air duct between the radiator and the exhaust outlet.

The external exhaust pipe is made of steel pipe, and the diesel engine supercharger of the unit must be flexibly connected, the inner diameter of the external intake pipe should be greater than the expansion joint, the external exhaust pipe should be firmly fixed, no vibration is allowed, and its weight should not be applied to the diesel engine expansion pipe; Expansion joints are not allowed to be used to eliminate inter-tube alignment errors.

The exhaust system should reduce the number of elbows and shorten the total length of the exhaust pipe as much as possible, otherwise it will lead to the increase of the exhaust pipe pressure of the unit, and cause excessive power loss of the unit, which will affect the normal operation of the unit and reduce the normal service life of the generator set.

The exhaust pipe diameter specified by the diesel generator set is generally based on the total length of the exhaust pipe of 6m and the installation of a maximum of one elbow and a muffler, when the exhaust system has exceeded all the specified length and the number of elbows when the actual installation, the exhaust pipe diameter should be appropriately increased, and the increase depends on the total length of the exhaust pipe and the number of elbows.

Daze Power Wang Gong will answer for you.

Attention should be paid to the installation of exhaust system of diesel generator: silencer device, exhaust connection, elbow welding, etc.; If the exhaust pipe is too long, pay attention to whether the power is compromised.

Diesel generator sets have their standard configurations, such as industrial mufflers, flexible exhaust connections, elbows. The user can install the exhaust system with the supporting facilities provided. But there are a few things you need to pay attention to when installing:

1.Make sure the back pressure is lower than the set maximum (usually, don't be lower than 5kPa)2Fix the exhaust system to avoid lateral and longitudinal pressures.

3.Leave room for contraction and expansion.

4.Leave room for vibration.

5.Reduced exhaust noise.

What should be paid attention to when installing the valve of the diesel generator set: The valve parts in the diesel generator set are insignificant small parts for the whole unit, but the valve plays a very important role in the whole power generation equipment. The quality of the valve directly affects the air tightness and power of the diesel engine, and the valve may have various problems under the strong mechanical load and high temperature corrosion, so the correct installation of the valve of the Shouxiao diesel generator set is an important prerequisite to ensure its use effect.

1. After the new conduit is installed in the cylinder head, the roundness and inner hole size of the conduit should be corrected with a reamer, so that the gap between the valve stem and the conduit hole meets the provisions of the diesel generator set manual, and the finished valve stem cannot be processed. In use, the gap between the valve stem and the duct hole shall not exceed the wear limit specified in the engine manual, generally as long as the gap between the valve stem and the guide reaches millimeters (valves with rod diameter equal to or less than 8 mm) or millimeters (valves with rod diameter greater than 8 mm), the valve or guide needs to be replaced, otherwise it will lead to early valve damage.

2. The valves of the same series of different types of diesel generator sets may be different, so do not mix them.

3. The deformed or burned valve seat ring must be reamed and ground corrected, and cannot be repaired only by the method of research with the valve, and the valve seat ring that cannot be repaired should be replaced with new parts, and the repaired or new seat ring mouth and the duct hole should be coaxial, the coaxiality tolerance is millimeters, the valve is loaded into the valve seat ring, and the sinking amount of the valve and the cylinder head should meet the requirements specified in the engine manual.

4. The valve and the valve seat are gently ground to ensure the valve tightness, no coarse abrasives can be used when grinding, the contact part between the valve seat and the valve cone should be in the middle and lower part of the valve cone, the valve and the seat ring must be sealed, and poor sealing will lead to the power drop of the generator set and the early damage of the valve.

5. After grinding, the abrasive should be cleaned with kerosene, and then the valve stem and catheter should be lubricated with clean oil.

In addition to the above-mentioned installation precautions, the valve should not collide in the process of unpacking and transportation, and overload should be avoided during use, otherwise it may cause the deformation of the valve to fail, resulting in early damage to the valve of the diesel generator set, which should be kept in mind.

The connection of each exhaust pipe of the diesel generator set must be well sealed to prevent gas leakage, and the connection between the flange and the gasket is the most ideal, and it is recommended to place a condensing aggregator with a socket at the bottom end of the pipe.

The connection between the exhaust outlet of the diesel generator set engine and the pipeline should use an elastic hose, which can alleviate the vibration of the diesel generator set engine and the thermal expansion of the pipeline and avoid damage to other components.

The exhaust pipe of the diesel generator set also needs to be flanged (not the flange on the unit), so the exhaust pipe must be fixed on the wall or the top of the machine room and have a strong support to prevent it from leaning on the diesel generator set engine (assembler, turbo blower), which can extend the length of the exhaust pipe of the diesel generator set.

When a long exhaust pipe is required, an expansion joint with an elastomeric sealing element is required.

When designing the exhaust pipeline, the designer of the diesel generator set manufacturer recommends that the installed exhaust pipe should be far away from the air filter of the diesel generator set engine to prevent the machine from absorbing hot air, or the exhaust pipe should be thermally insulated.

When using multiple diesel generator sets, it is recommended not to install all the exhaust pipes on the same pipe, because when some units are running and others are down, problems arise: the exhaust gas will enter the unused units and cause damage to the units.

The exhaust back pressure of the engine has a great influence on the power generated by the unit and the heat exchange. Excessive back pressure values (measured at the exhaust outlet of a naturally aspirated engine or at the turbine outlet of a turbocharged engine) can lead to a decrease in the power of the diesel generator set, excessive exhaust temperatures, thick smoke, increased fuel consumption, overheating of the cooling water, failure of lubricant function and damage to other engine components.

If you encounter other situations, please consult with the diesel generator manufacturer in time.

Because there are many places in the diesel generator in the form of pressure seals, such as cylinder liner - piston - piston ring, supercharger - supercharger rotor shaft, this seal is generally in the engine has about 1 3 load, only to play a full role, and the load hour may occur slight leakage. Therefore, foreign diesel engine manufacturers generally emphasize it in their manuals. If the unit is operating at a small load, the following faults will occur as the operation time continues:

1.For supercharged diesel engines, the boost pressure is low due to low load, no load. It is easy to cause the sealing effect of the supercharger oil seal (non-contact) to decrease, and the oil will enter the pressurized chamber and enter the cylinder with the intake air.

2.The piston-cylinder liner is not well sealed, the oil is channeled, enters the combustion chamber for combustion, and the exhaust emits blue smoke. 3.

Part of the oil that goes up to the cylinder participates in combustion, and part of the oil cannot be completely burned, forming carbon deposits in the valves, intake tracts, piston tops, piston rings, etc., and some parts are discharged with the exhaust. As a result, oil builds up in the cylinder liner exhaust duct and carbon deposits are formed. 4.

Oil in the booster chamber of the supercharger accumulates to a certain extent and leaks out of the joint surface of the supercharger. 5.Long-term low-load operation will lead to more serious consequences such as aggravated wear of moving parts and deterioration of the engine combustion environment, resulting in an early overhaul period.

Therefore, foreign diesel engine manufacturers emphasize that the use of naturally aspirated or supercharged models should minimize the low-load no-load running time, and stipulate that the minimum load can not be less than 25%-30% of the rated power of the unit.

1. The space around the diesel generator set should not be less than 1 meter, and the ventilation window should be left at the end of the water tank according to the size of the core of the water tank. This requirement is the minimum size of the unit room, and the user can increase it according to the need.

2. The foundation of the diesel generator set should be built on the hard ground, and after tamping, the concrete floor with a thickness of 200mm should be made and the ground should be flat.

3. When the user is building the machine room, the user should pre-embed the hoisting I-beam steel (below 250kw) on the roof above the unit for future maintenance.

4. The computer room should be well ventilated, and the ground should be smooth and non-slip.

5. The inner diameter of the exhaust pipe of the unit should not be less than the diameter of the exhaust port of the diesel engine, the elbow should not exceed 3, the angle of the elbow should be greater than 90 degrees, and the exhaust pipe should have a support or hoisting bracket to ensure that the silencer and supercharger of the unit are not forced.

6. Fire extinguishers and other fire-fighting tools should be equipped in the machine room.

Precautions for installing diesel generator sets:

a.If the diesel generator is used indoors, the smoke exhaust pipe must be channeled outdoors, the diameter of the smoke exhaust pipe must be greater than the diameter of the smoke outlet pipe of the silencer, and the elbow of the pipeline should not exceed 3 to ensure that the smoke exhaust is unobstructed, and the pipe should be tilted down by 5-10 degrees to avoid rainwater injection; If the exhaust pipe is installed vertically upward, a rain cover must be installed.

b.If it is an indoor machine room, the installation site should be well ventilated, the generator end should have enough air inlet, and the diesel engine end should have a good air outlet, and the air outlet area should be more than multiple times the area of the water tank.

c.Avoid placing items that can produce acidic, alkaline and other corrosive gases and steam near Weichai generators, and the machine room should be equipped with fire extinguishing devices.

d.When the foundation is made of concrete, the levelness must be measured with a level ruler during installation, so that the unit is fixed on the horizontal foundation. There should be a special anti-vibration pad or foot bolts between the unit and the foundation.

e.The two-way switch between the diesel generator and the mains must be very reliable to prevent the power from being reversed. The wiring reliability of the bidirectional switch needs to be inspected and approved by the local power supply department.

f.The shell of the unit must have reliable protective grounding, and for generators that need to have a neutral point direct grounding, it is strictly forbidden to use the grounding device of the mains power to carry out direct grounding at the neutral point, and the neutral grounding must be carried out by professionals, and the lightning protection device must be configured.

1. The rated voltage of the diesel generator at the construction site must be consistent with the voltage level of the external power line. 2. The stationary diesel generator set should be installed indoors on the basis of compliance with the regulations, and should be higher than the indoor ground. The mobile diesel generator set should be in a horizontal state, placed firmly, its trailer should be reliably grounded, and the front and rear wheels should be stuck.

Outdoor diesel generator sets should be equipped with protective sheds. 3. The setting of diesel generator sets and their control, power distribution, repair rooms, etc. should ensure the electrical safety distance and meet the fire protection requirements. The smoke exhaust pipe should extend outdoor, and it is strictly forbidden to store oil storage drums indoors and near the smoke exhaust pipe.

4. The installation environment of the diesel generator set at the construction site should be close to the load center, convenient access to and out lines, smooth surrounding roads, and avoid the downwind side of pollution sources and places prone to water accumulation. 5. The power supply of the diesel generator set must be interlocked with the power supply of the external power line, and it is strictly forbidden to run in parallel with the external power line. When two or more generator sets run in parallel, a synchronization device must be installed, and the power supply to the load should be supplied after the unit is synchronized.

What are the installation requirements for diesel generator sets? Today, Yanan Motor will take you to understand the installation requirements of diesel generator sets!

During installation, the foundation levelness must be measured with a spirit level to ensure that the unit is fixed on the basis of the horizontal position. (For reference only: Yanan Group: R&D and production of diesel generator sets and fuel cells).

Ensure that the inlet and exhaust air of the computer room is smooth, and ensure that the hot air discharged from the radiator is directed out of the equipment room and prevents its backflow.

Ensure that the operating noise and smoke emissions of the unit meet or exceed the national standards.

Ensure that the space distance around the unit is not less than 1 meter, the space distance of the upper part of the unit is not less than 2 meters, and no other objects are allowed in the space, so as to facilitate the cooling, operation and maintenance of the unit.

Make sure you have lighting that works at night.

Ensure that the exhaust pipe of the diesel engine is unblocked, and avoid excessive length of the pipe or sudden turns; When the exhaust pipe is connected to the outside, it is advisable to tilt the outer pipe down a little to make the condensation water flow out of the pipe.

Do not store flammable and explosive materials, acidic, alkaline and other corrosive gases around the unit, and the environment should be kept clean.