Generator Installation — From Planning to Commissioning
A properly installed generator runs reliably for decades. Poor installation is the #1 cause of premature failure. This guide covers every step.
Level 1: Site Selection
Consider: proximity to fuel supply, exhaust discharge path, noise sensitivity of neighbors, flood risk, accessibility for maintenance and fuel delivery. Outdoor installations require weatherproof enclosure. Indoor requires ventilation system.
Level 2: Foundation Design
The foundation must support 1.5x the generator wet weight. Concrete pad minimum 200mm thick, extending 300mm beyond the generator footprint on all sides. Use anti-vibration mounts between generator base and foundation.
Level 3: Ventilation Calculation
Required airflow (m3/min) = (Engine Heat Rejection kW x 0.06) + (Alternator Heat Loss kW x 0.06) + Combustion Air. Typically 50-60 m3/min per 100 kVA. Use powered exhaust fans for indoor installations. Inlet louver free area must be 1.5x radiator face area.
Level 4: Fuel System
Daily tank capacity (L) = kVA x Load% x PF x 0.26 x 24 x 1.1 (10% reserve). Bulk tanks require: secondary containment (110% of tank volume), vent with flame arrestor, fill port with overfill protection, fuel level gauge, water drain valve, and fuel polishing circuit.
Level 5: Commissioning Checklist
- Mechanical: alignment, mounting bolts torque, belt tension, coolant fill, oil fill, fuel system primed
- Electrical: cable sizing, circuit breaker rating, grounding resistance < 5 ohms, ATS wiring
- Testing: no-load run (15 min), 50% load step (voltage dip < 15%), 100% load acceptance (recovery < 2 sec), full-load endurance (4 hours), safety shutdown tests
- Documentation: test reports, as-built drawings, O&M manuals, warranty registration