DIESEL ENGINES Installation, Dismantle and Assembly

Principle and References

By
Er. Laxman Singh Sankhla
B.E.Mech., Chartered Engineer
Jodhpur, India
Mail ID: laxman9992001@yahoo.co.in
Installation, Dismantle and Assembly Principle and References
The equipment with its appurtenant piping lays out providing clearance, access way and hardroom for
dismantling or removing the equipment for maintenance.
The emergency generator in SR CPP has around it a clear space of about 20 m (in almost all directions) allowing
all the operations mentioned above.
Around the diesel pump the clearance is also sufficient (1020 m).
In Barik Gathering Station the emergency generator (package A-9420) is attached to the control building.
However for the other three sides the clearances are from 2 to 5 m.
The weight of the engines is in the range 510 tons.
Appropriate lifting equipment capable of handling the specified overloads without damages to part concerned
are disponible and can be used by the maintenance team either to replace part of the engine (if necessary) or to
replace the whole engine if repairs are not possible in the field.
Some general rules regarding the installation of the engines are narrated herebelow just in case that a
replacement of the equipment could be necessary in the future.
The generating set and its accessories must be installed so as to be protected from main and other atmospheric
agents.
The discharge of fuel gases has to be installed as far as possible from the air intake required for ventilation of
any building or the cooling system of the Gen. Set.
The electric cables, installed as far as possible from the above mentioned discharge have an appropriate
protection and support.
A concrete base is necessary for each engine. Its construction has to take into consideration not only the weight
and dimensions of the engines but also the type of ground its density and cohesion characteristics.
Although the dynamic stresses, caused by the rotation of the Gen Set, are negligible, it is advisable for the Gen
Set base to be constructed so that, in case of unbalance due to accidental causes, any vibrations will not be
propagated to the surface to which other equipment is fixed and to the structure of the building.
Therefore the base must be separated from the rest of the floor by means of panels of rock wool, cork or
polystyrene having a thickness of at least 20 mm.

Moreover the depth of the excavation for housing the concrete block should be 10-15 cm more than the
thickness of the block itself. This is so that the bottom of the pit can be filled with an adequately pressed layer of
the sand, again to avoid the transmission of any vibrations.
The main activities when installing an engine on the base are described in the next paragraphs:
Place the Gen Set on the base at least a month after casting and insert the foundation bolts in the holes made
in the base itself.
Lock the foundation bolts using a good cement grout consisting of one part of Portland cement and two
parts of sand made by crushing of well-washed rock and having a granulometric composition between 0.1
and 0.5 cm.
Care must be taken so that during this operation, dangerous air bubbles are not formed.
Once the fixing holes have been filled, the protruding part of the foundation bolts must be protected from all
stress until the concrete is well hardened.
When the concrete has hardened fix the Gen Set to the base by tightening the foundation bolts.
Make the ground connections of all the generating set components.
The main preliminary operations prior to the start-up of an engine are as follows:
Filling the lubrication sump of the engine with oil (the operation to be carried out according to the
instructions in the booklet Use and Maintenance of the engine).
Putting oil in the air filters in accordance with the instructions in the said booklet (when they are of the oil
bath type).
Filling the radiator with water as prescribed in the instruction booklet of the engine.
Filling the fuel tank with diesel oil and remove the air from the feed system following the instruction in the
booklet Use and Maintenance of the engine.
When the engine is started, it takes a while to get the lubricating oil film re-established between shafts and
bearings and between pistons and liners. The most favourable clearances between moving parts are obtained
only after all engine parts reach normal operating temperature. Avoid seizing pistons in liners and running dry
shafts in dry bearings by bringing the engine up to operating speed gradually as it warms up.
The alternator is supplied ready for use and does not require any preliminary operation.
The battery is supplied dry charged, therefore for the putting into operation of the Gen Set it will be necessary to
fill the elements with a solution of chemically pure sulphuric acid having a specific weight of 1.27 (31 B) until
the separators are covered by about 5 mm of liquid.