Cummins Installation, Operations & Maintenance Manual PDF

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D‹ZEL MOTOR JENERATÖR DIESEL GENERATING SETS GRUBU MONTAJ, ÇALIfiTIRMA, INSTALLATION RECOMMENDATIONS KULLANIM ve BAKIM EL K‹TABI AND OPERATIONS MANUAL 55 - 2250 kVA DIESEL GENERATING SETS INSTALLATION RECOMMENDATIONS and OPERATIONS MANUAL Aksa Service & Spare Parts Aksa Head Office Murat Bey Bel...

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D‹ZEL MOTOR JENERATÖR GRUBU MONTAJ, ÇALIfiTIRMA, KULLANIM ve BAKIM EL K‹TABI

DIESEL GENERATING SETS INSTALLATION RECOMMENDATIONS AND OPERATIONS MANUAL

55 - 2250 kVA

DIESEL GENERATING SETS INSTALLATION RECOMMENDATIONS and OPERATIONS MANUAL

Aksa Service & Spare Parts Murat Bey Beldesi Güney Girifl Caddesi No: 8 Çatalca - ‹STANBUL / TURKEY T: + 90 212 887 11 11 F: + 90 212 887 10 20 e-mail: [email protected]

Aksa Head Office Gülbahar Caddesi 1. Sokak 34212 No: 2 Güneflli - ‹STANBUL / TURKEY T: + 90 212 478 66 66 F: +90 212 657 55 16 e-mail: [email protected]

Dear Aksa Generating Set Users; First of all, we would like to thank you for your choice of Aksa Generating Set. It is solid, safe and reliable machine, built according to the latest technology. This operating and maintenance manual is designed and developed to make you familiar with the generating system. Please read the following instructions carefully before starting to use your machine. This manual gives general information about mounting, operation and maintenance of the generating set. Tables and diagrams are also available outlining your generating set. Never operate, maintain or repair your generating set without taking general safety precautions. Aksa Jeneratör does not assume responsibility for possible errors. Aksa Jeneratör reserves to make changes without prior notice.

1. 2. 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 3. 3.1. 3.2. 3.3 3.4. 3.5. 3.6. 3.7. 3.8. 3.9. 3.10. 3.11. 4. 4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7. 5. 5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7. 5.8. 5.9. 5.10. 6. 6.1. 6.2. 7. 7.1. 7.2. 7.3. 8. 8.1. 8.2. 9.

INTRODUCTION.................................................................................................................................................... 1 GENERAL SAFETY PRECAUTIONS.................................................................................................................... 2 General................................................................................................................................................................................................................. 2 Installation Handling and Towing........................................................................................................................................................... 2 Fire and Explosion.......................................................................................................................................................................................... 2 Mechanical .......................................................................................................................................................................................................... 3 Chemical.............................................................................................................................................................................................................. 3 Noise ..................................................................................................................................................................................................................... 3 Electrical............................................................................................................................................................................................................... 4 First Aid for Electric Shock........................................................................................................................................................................ 4 GENERAL DESCRIPTION...................................................................................................................................................................... 5 Generating Set Description and Identification............................................................................................................................... 5 Generating Set Main Parts......................................................................................................................................................................... 6 Diesel engine..................................................................................................................................................................................................... 7 Engine Electrical System.............................................................................................................................................................................. 7 Cooling System................................................................................................................................................................................................ 7 Synchronous Alternator.............................................................................................................................................................................. 7 Coupling............................................................................................................................................................................................................... 7 Fuel Tank and Base Frame ........................................................................................................................................................................ 7 Vibration Isolation .......................................................................................................................................................................................... 7 Silencer and Exhaust System.................................................................................................................................................................... 7 Control System................................................................................................................................................................................................ 8 INSTALLATION HANDLING AND STORAGE .............................................................................................. 8 General................................................................................................................................................................................................................. 8 Canopies.............................................................................................................................................................................................................. 8 Moving the Generating Set....................................................................................................................................................................... 8 Location ............................................................................................................................................................................................................... 8 Modular Installation ....................................................................................................................................................................................... 9 Base and Foundation.................................................................................................................................................................................... 9 Room design guidance notes...................................................................................................................................................................10 FUEL SYSTEM ............................................................................................................................................................15 General.................................................................................................................................................................................................................15 Fuel oil Recommendation..........................................................................................................................................................................15 Use of jet A Fuel in Diesel Engines......................................................................................................................................................15 Base Fuel Tank .................................................................................................................................................................................................16 Without Intermediate Fuel Tank...........................................................................................................................................................16 With Intermediate Fuel Tank...................................................................................................................................................................16 Daily Service Fuel Tank...............................................................................................................................................................................16 Bulk Storage Tanks ........................................................................................................................................................................................17 Determining Pipe Sizes................................................................................................................................................................................17 Fuel Return Lines............................................................................................................................................................................................18 EXHAUST SYSTEM ..................................................................................................................................................20 Sizing ......................................................................................................................................................................................................................20 Routing .................................................................................................................................................................................................................20 WATER TREATMENT..............................................................................................................................................................................21 General.................................................................................................................................................................................................................21 Engine coolant..................................................................................................................................................................................................21 Engine Warming..............................................................................................................................................................................................21 LUBRICATING OIL....................................................................................................................................................................................21 Oil Performance Properties .....................................................................................................................................................................21 Lubrication Recommendation.................................................................................................................................................................21 ELECTRIC STARTING SYSTEM.........................................................................................................................................................24

9.1. 9.2. 9.3. 9.4. 9.5. 10. 11. 11.1. 11.1. 11.2. 12. 13. 14. 14.1. 14.2. 14.3. 14.4. 14.5. 14.6. 15. 15.1. 15.2. 15.3. 16. 16.1. 16.2. 16.3. 17. 17.1. 17.2. 17.3. 17.4. 17.5. 17.6. 18. 18.1. 18.2. 18.3. 19. 19.1. 19.2. 19.3. 20. 20.1. 21. 22.

Battery Systems ...............................................................................................................................................................................................24 Maintenance Batteries..................................................................................................................................................................................24 Battery Maintenance ...................................................................................................................................................................................24 Maintenance Free Batteries.....................................................................................................................................................................24 Starting Aids.....................................................................................................................................................................................................24 GENERAL PRECAUTIONS AND CONTROLS WHICH MUST BE DONE BEFORE STARTING UP THE GENERATING SET..............................................................................................................24 GENERATING SET CONTROL SYSTEM.........................................................................................................25 P72 Control System ....................................................................................................................................................................................25 P602 Control System .................................................................................................................................................................................25 P732 Control System................................................................................................................................................................................26 GENERAL PRECAUTIONS AND CONTROLS WHICH MUST BE DONE AFTER STARTING UP THE GENERATING SET.................................................................................................................................29 THE PLACEMENT AND INSTALLATION OF TRANSFER SWITCH ......................................................29 ELECTRICAL CONNECTION ............................................................................................................................29 Cabling ................................................................................................................................................................................................................30 Protection..........................................................................................................................................................................................................30 Loading................................................................................................................................................................................................................30 Power Factor...................................................................................................................................................................................................30 Insulation Test.................................................................................................................................................................................................31 Grounding / Earthing Requirements.................................................................................................................................................31 ACUSTIC SILENCING...........................................................................................................................................36 Exhaust Silencers...........................................................................................................................................................................................36 Canopies ............................................................................................................................................................................................................36 Other Sound Attenuation .......................................................................................................................................................................36 TOWING (Mobile Generating Sets)..................................................................................................................36 Preparing to tow ...........................................................................................................................................................................................36 Towing ................................................................................................................................................................................................................36 Parking .................................................................................................................................................................................................................36 HEALTY and SAFETY .............................................................................................................................................36 Fire Protection ................................................................................................................................................................................................36 Exhaust Gases..............................................................................................................................................................................................37 Moving Parts...................................................................................................................................................................................................37 Hazardous Voltages.....................................................................................................................................................................................37 Water ..................................................................................................................................................................................................................37 Coolant and Fuel...........................................................................................................................................................................................37 LOAD CHARACTERISTIC and APPLICATIONS ...........................................................................................38 Load Characteristics ....................................................................................................................................................................................38 Motor Starting.................................................................................................................................................................................................38 Unusual Loads.................................................................................................................................................................................................38 STORAGE..................................................................................................................................................................39 Engine Storage................................................................................................................................................................................................39 Alternator Storage .......................................................................................................................................................................................41 Battery Storage........................................................................................................