Powerlink GXE250-BG User manual

GXE250-BG

OPERATION MANUAL

Biogas Unit

Product No.：1000321484

01-2018

Engine Model：GX13k-LE01G

Biogas Unit

1 Liftingequipment for gensets

WARNING!

Warning! Lifting equipment should be used by trained personnel only. Genset must be lifted

using the lifting lugs on the base frame and a lifting plate or spreader lifting beam.

Preparations before hoisting genset:

When lifting genset, special lifting equipment is required. It is recommended that a lifting

plateor spreader lifting beam of the correct lifting load capacity is used and that chains, hooks,

shackles and eyebolts etc. are checked that they are well within their safe working loads (swl).

The load should be secure, stable and balanced when lifting, therefore an assessment of the

position of its Centre of gravity must be determined to ensure that the lifting point is over it, see

(A, B and C).

Note: When chains are used to lift an engine at an angle, the load on the lifting eye is

increased. An angle of 45° is equal to a 40% increase in load.

The lifting chains etc. must be firmly secured to the load by means of hooks etc. on to the

purpose-designed lifting points, and that the rated included angle is not exceeded.

2 Installation

When install genset the utmost consideration must be given to the type of engine foundation

which must be strong enough to support the weight of the genset and the stresses produced

when the genset is operating.

Undebased/foundation:

The simplest form of mounting is to rigidly bolt and driven the genset directly to an undebased

or bearers. It is essential that all mounting pads on the undebased or bearers are flat, square

and parallel to each other. Undebased or bearers should be designed so that the mounting

pads will not distort in any way and have sufficient rigidity to prevent deflection due to the

weight of the genset, vibrations and various stresses when the genset is running.

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Type of foundations:

The genset room floor/foundation where the undebased/bearers are fixed is of great

importance as it must:

Never use rigid connection between the foundation and genset room.

The surface of the foundation should be oil-water proof, and equipped with drainage

If the genset is set on the floor, the load carrying capacity of floor should be fitted to the static load

and dynamic load of genset.

Using shims between the genset mounting feet and the undebased/bearers. The dimensions

of the shims (or packing pieces) should not be less than the mating area of the genset

mounting feet. At least four fitted bolts (minimum quality 8.8 steel) must be used in the genset

mounting feet. Where it is not possible to use a fitted bolt, the mounting feet should be

dowelled to the undebased/bearers using one dowel in each foot at diagonal corners.

The surface of the foundation should be flat. The safe loading capability of the geological

material should be carefully evaluated when selecting the foundation for installing. We advise

adopting concrete as the material of foundation.

SBL=9.81 



SB--Weight of the load on the foundation (kg)

TW--Weight of the genset and foundation (kg)

L--Length of the foundation (m)

W—Width of the foundation (m)

Subsoil-site：

The site subsoil must have a bearing strength capable of supporting the weight of the

complete genset plus the concrete foundation on which it will stand.

If the bearing strength of the subsoil is in doubt advice should be taken from a qualified civil

engineer to enable the type and size of concrete foundations to be determined.

Geological Material Max Load(kg/m²)

Granite 244000-977000

Oil shale 98000-146000

Rock 78000-98000

Soft Rock 49000-98000

Tamped gravel 49000-59000

Pebble and gravel 39000-49000

Tamped sandy clay 28900-39000

Sandy clay 20000-39000

Sand 10000-20000

Soft clay 10000

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Concrete block/foundation:

Block/Foundation

Length(mm) Width(mm) Depth(m) Height(mm)

Genset Length+300 Genset Width+300 B ≥150

B= 2



B--Depth of foundation (m)

M--Weight of genset (kg)

Ρ--Density of concrete (kg/m³)

L--Length of foundation (m)

W--Width of foundation (m)

After determining the depth of concrete required for the weight and stability of the running

genset, the subsoil has to be checked to see if it will carry the total weight (genset plus

concrete block) and withstand the forces involved.

Fixed concrete block/foundation:

The concrete block/foundation is a proven method and preferred in some circumstances. In

this case the genset set bedplate is tightly bolted to the concrete block. See (A, and B).

Biogas

Floating concrete block/foundation:

The floating block is an effective alternative to the fixed concrete block. The concrete mix,

holding down bolt pockets, surface finish and installation of the set is the same. The block is

pre-cast using a wooden mound.

To isolate and float the block a matting of water resistant cork-like material or similar

proprietary material is placed on the surface of the sub-soil at the bottom of the pit and the

concrete block lowered on to it. The matting should be adequate to support the weight of set

plus concrete block

An air gap of approximately 25 mm should be maintained along all four sides of the block. The

gap at floor level must be sealed with a-non setting mastic or similar material to keep dirt and

water but still allow flexibility, see (A).

All services to the engine, fuel air and water pipes, exhaust system and electric cables must be

fitted with a flexible connection to prevent fractures and possible transmission of harmful

vibrations. Transmission of vibration may culminate as noise at a point remote from the

engine.

Genset Fixation:

The genset mounted on the steel base frame. In order to reduce vibration transmitted to the

foundation while running, the genset is equipped with isolators between the genset and the

base frame.Fix the base frame of the genset with foundation bolts before using the machine.

Each foundation bolts needs to use a hexagonal nut, flat washer and spring washer. The

amount and dimension of foundation bolts should be decided by the installation hole of the

base frame.

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Check that the bedplate is level without sag or twist. If necessary add shims between the

bedplate and packing plate.Pour and pack the concrete into the bolt hole pockets to within 50

mm of the top. This is to allow for the final grout.

Two typical fixation, see (A and B)

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Installation procedure for concrete block:

When the concrete block is being poured pockets must be incorporated for the ‘holding down

bolts’ see “Fixed concrete block/foundation (A)”, i.e. See“Two typical fixation (A and B)

hook type or equivalent. At each holding down bolt position removable wooden boxes are

placed. The size of box is to match the size of the bolt used in the installation. When the

concrete is reasonably firm the boxes are removed.

Ensure that the top surface of the concrete block is level and reasonably smooth and free from

blemishes.

Note: After removing the ‘holding down bolt boxes’ leave for 5/7 days to dry out before

positioning the set, see “Two typical fixation (B)” for the method to use the common ‘hook

bolt’.The depth ‘d’ should be a little more than the length of the bolt ‘L’. This is so that the bolt

can be dropped into the hole for the concrete and allow the set to be rolled into position without

obstruction from the bolts.

WARNING!

Use correct lifting equipment. Do not work alone. Always wear protective gear.

When lifting the genset into position it is essential that correct lifting equipment is used having

a tested safe working load well above the weight of the complete set to be lifted. Use the lifting

facilities provided where possible and observe safety precautions regarding suspended loads

Biogas Unit

etc. When the genset is in position pull the bolts up through the holes in the main bedplate. Fit

the washers and nut until approximately a thread length, equivalent, to the nut thickness,

stands proud of the nut.

At each holding down position fit a steel packing plate across the hole and on each side of the

bolt.

Grouting:

The recommended grout mixture is as follows:

Part best quality cement.

2- Parts clean sharp sand.

Grouting mixture is packed into the top of the holding down bolt pockets, around the bolts and

packing pieces, etc., and between the underside flange of the bedplate and the top of the

concrete block, see “Two typical fixation (B).”

Note:Leave for 5/7 days to dry out and set. Check holding bolts and tighten if necessary.

When the set has run for 50/75 hours after the completion of the installation the holding down bolts

should be checked and tightened as necessary.

Trenches:

When designing the foundation block various other areas should be taken into account. Trenches,

particularly for heavy duty electrical cables need to be considered, bearing in mind provision for drainage

to prevent the trench filling up with water.

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On the larger generating sets these cables have a large bending radius. It may be necessary to cut away

part of the concrete block so that a smooth sweep can be made, see (A).

Concrete raft:

This type of foundation distributes the weight of the genset plus the weight of the concrete raft

over a larger floor area than the fixed concrete block. The unit loading on the subsoil is

minimized and a reduced depth of concrete can be used.

Biogas Unit

3 Summary

A genset consists mainly of power system, lubricating system, gas intake system, heat

exchange system

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