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Installation Guide for 150kW Diesel Generator

2025-12-15

1.1 Site Investigation and Foundation Construction

Site selection principle: The generator room should be located in an area with good ventilation, smooth drainage, easy operation and maintenance, and away from hazardous material storage areas and densely populated areas. The computer room space needs to meet the minimum size requirements for equipment heat dissipation, operation, and maintenance.

Foundation construction: Pour concrete foundation, whose strength (usually not lower than C25) and size must strictly follow the base diagram provided by the equipment manufacturer. The foundation should be level and able to withstand the full weight of the Generator Set and the dynamic load during operation. The top of the foundation usually needs to be about 100-150mm higher than the final ground level, and pre embedded with anchor bolts for fixing the unit.

1.2 Equipment and personnel preparation

Equipment inspection: After unpacking, carefully check whether the model and power (150kW) of the generator set are consistent with the contract, and inspect whether there is any obvious damage or missing components during transportation of the equipment.

Tool preparation: Prepare complete installation tools, including jacks, lifting equipment (such as gantry cranes or forklifts, whose lifting capacity needs to be greater than the weight of the unit), leveling instruments, torque wrenches, electrical tools, etc.

Personnel qualifications: Installation personnel must have received relevant safety and skills training, and electricians must hold valid special operation certificates.

2、 Core installation steps

2.1 Unit positioning and leveling

Lifting in place: Use professional lifting equipment to smoothly lift the generator set and slowly place it on the pre built concrete foundation. Special lifting points designed on the unit base must be used, and lifting through non load bearing components such as fans, fuel tanks, mufflers, etc. is strictly prohibited.

Leveling and fixing: Use a high-precision level to measure at multiple points on the base of the unit, and adjust the unit to absolute level by adding or removing shims (usually requiring a longitudinal and transverse levelness error of no more than 1mm/m). After confirming the level, use a torque wrench to tighten all the nuts of the anchor bolts according to the manufacturer's specified torque, and firmly fix the unit on the foundation.

2.2 Exhaust system installation

Pipeline layout: The exhaust pipeline should be as short as possible and have as few bends as possible to reduce exhaust back pressure. The pipeline should have a certain downward inclination to facilitate the smooth discharge of condensed water.

Flexible connection and insulation: A flexible corrugated pipe must be installed between the engine exhaust port and the fixed exhaust pipe to compensate for the vibration during engine operation. When passing through walls or roofs, insulated wall sleeves must be used. The surface temperature of the exhaust pipe is extremely high, and it is necessary to wrap it with professional high-temperature insulation materials and ensure sufficient safety distance from flammable materials.

2.3 Fuel System Installation

Daily fuel tank: For a 150kW level generator, an independent external daily fuel tank is usually required. The installation position, capacity, and structure of the fuel tank must comply with national fire safety regulations.

Pipeline connection: Use high-quality diesel dedicated pipelines. The diameter of the inlet and return pipes must meet the fuel flow requirements of the engine. All joints must be tightly sealed without leakage. Install a fuel filter/oil-water separator on the inlet pipeline.

2.4 Electrical System Installation

Warning: All electrical wiring work must be carried out in a power-off state and completed by a certified electrician.

Battery connection: Check the electrolyte level and battery capacity of the battery. First connect the positive pole (+), then connect the negative pole (-). The connection must be firm, and Vaseline or special grease should be applied to the terminal posts to prevent corrosion.

Generator output line connection:

According to local electrical regulations and national standards (such as GB standards), select copper core cables with sufficient cross-sectional area and qualified withstand voltage rating.

2.5 Installation of cooling and ventilation system

Ventilation of radiator: Ensure that there is sufficient fresh air intake at the front end of the generator radiator and unobstructed hot air exhaust at the rear end. The total effective area of the air inlet and exhaust outlet must meet the manufacturer's requirements to avoid overheating in the machine room, which may cause a decrease in unit power or shutdown.

Coolant filling: Fill the designated model of antifreeze coolant into the engine cooling system until the liquid level reaches the "FULL" mark on the expansion tank. After filling, the air in the system needs to be emptied.

2.6 Connection between control system and grid cabinet (if any)

Connect the signal and control lines between the control panel of the generator and the external ATS (Automatic Transfer Switch) cabinet or grid connected cabinet according to the design drawings. This part of the work is highly technical and must strictly follow the schematic diagram and be carried out by professionals.

3、 Post installation inspection and initial startup

3.1 Comprehensive Inspection

Mechanical inspection: Recheck the tightening of all bolts and pipe joints.

Fluid inspection: Check if the engine oil and coolant levels are normal.

Electrical inspection: Use a megohmmeter to measure the insulation resistance of the generator stator winding to ground, and the value should meet the standard (usually>1M Ω).

3.2 Initial start-up and trial operation

No load operation: After confirming that all checks are correct, start the engine. Observe whether it starts smoothly, monitor whether the running sound is normal, and check whether the various readings on the dashboard (oil pressure, water temperature, voltage, frequency) are within the normal range. Run for about 30 minutes.

Load testing: Gradually increase the load (dummy load can be used) and test the operation at 25%, 50%, 75%, and 100% rated load respectively. Record key parameters and verify performance indicators such as output voltage stability and frequency stability.