MANUFACTURING PROCESS dme MFG GUIDE 01

OF SILENCED GENERATING SET

MANUFACTURING PROCESS OF
SILENCED GENERATING SET
The process is composed of following major aspects:

1 - CAD DESIGN & ENGINEERING

2 - IMPORT OVERSEAS COMPONENTS FOR ASSEMBLY

3 - PURCHASE LOCAL MATERIALS FOR FABRICATION

4 - FABRICATION OF CANOPY

5 - INSTALLATION OF MECHANICAL COMPONENTS

6 - WELDING AND PAINTING

7 - ASSEMBLY OF ENCLOSURE

8 - PURCHASE/ WELDING AND ASSEMBLY OF PANEL

9 - ELECTRICAL WIRING

10 - SOUNDPROOFING

11 - TESTING OF GENERATOR FUNCTIONALITY, LOAD TESTS, WEIGHT BALANCING,

12 - QUALITY CHECK OF CANOPY AND ELECTRICAL WORK

13 - PACKAGING & TRANSPORTATION

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 CAD DEISGN AND ENGINEERING
For special client requirements, before any work is initiated, documentation is prepared after reviewing
their specifications for exact design and engineering standards of the DG set. This is a planning stage in
which all materials are calculated and listed by estimation engineers.

Preliminary meeting

Drafting of design

Preliminary meeting

General arrangement layout for generator enclosure and installation

Afterwards drawings are created in CAD software for arrangement at site of DG sets, Fuel tanks, Panels,
power cables etc, component layouts internal and outer with all descriptions, wiring/schematics then
reviewed by ITTS engineers of respective field for approval and then forwarded to client approval.

Fuel Tank P&ID

ACO Panel SLD

Synchronization Panel

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 IMPORT OVERSEAS COMPONENTS

The main product line is consisting of Perkins engines from the UK.
Other engine brands include Volvo, Cummins, Doosan.
Engine & Alternator are imported and kept in fairly good
stock in our main warehouse. Various capacities are maintained from
9 - 2000 kVA either direct from the UK or from official Middle East
dealers for Perkins.

Perkins Electric Power Diesel Engine

Lerorsomer Alternator - France

Alternator Stock

Engine stock
Brushless excitation - Alternator

CKD Stock
Linz Alternator

Engine Stock
Class H insulated Alternator

We are using IP23 alternators, brand are mainly Leroysomer from France
and Linz/ Meccalte from Italy. They come with AVR R220-R250 or SX440
etc of which we keep extra stock. Voltage level can be adjusted by
terminal arrangement

Our control panel consists of digital controller from Deep Sea Electronics UK.
They area coming with feature such AMF, Configurable timers and
alarms, compatible with a wide range of CAN engines, uses DSE
Configuration Suite PC software, IP65 rating (with supplied
gasket) offers increased resistance to water ingress, etc
Alternator Terminal Wiring for different voltage

AVR - R230

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 PURCHASE LOCAL MATERIALS FOR FABRICATION

We are using GI steel sheets for fabrication of Canopy of 1.5 – 2 mm and MS sheets 4mm – 6mm – 10 mm
for the Base Frame.

For soundproofing there are two options of either Rockwool or Black Foam or a mixtures of both to be
placed inside the canopy walls, doors, radiator sides, roof, etc

Various materials are used depending on client specification

Battery Isolator Fuel Valve

Air-Intake Shutdown Valve Tinned copper bars Anti-Condensation Heater
Chalwyn Valve
For oil and gas, in case of After bending and Heater for panel
emergency shutdown shaping the bars are enclosure to reduce
failure tinned for protection moisture
against rust
E1FW Brass Glands
Standard materials used in every generator

Residential Silencers PVC cables Circuit Polyamide Control and instrumentation materials
breakers Glands

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 FABRICATION OF CANOPY
For enclosed units, we use punching & laser CNC to cut and bend locally purchased GI sheets normally 2+ mm thick
for canopy and 4 mm+ thick for base skid with built in fuel tank;

GI sheets are generally shaped by CNC punching machines and bending machines

And for more detailed work a CNC laser machine is used ____

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 INSTALLATION OF MECHANICAL COMPONENTS

Majority of parts are fixed into their places either on engine or canopy parts while
assembly team waits for base frame completion

Lifting Lug
Rain Cap

Spark Arrestor

Nameplate

Coolant filling funnel Door Gasket

Door
Stoppers

Exhaust pipes

Chalwyn Valve

Fuel Inlet

Fuel Drain
Oil Drain

Drip Tray Drain

Fire extinguisher
Coupling plate is fixed after careful balancing
Expansion bellows from both ends to ensure proper lineup

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 WELDING AND PAINTING
MIG Welding Base Frame 4-6-10 mm + fuel tank and trolley welding

Automatic Welding Machine for high

quality works s

Powder Coating

Final Buffing

Powder coating is done with

standard cream white
RAL 9001 and base
jet black RAL 9005.
But from each trader we design
and assign unique colors also.
Trolley Mounting

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 ASSEMBLY OF ENCLOSURE
Hoist crane is used to lift and place engine & alternator in place
over base frame for fixing over anti-vibration mountings. Then
canopy parts are brought around to their fixing location and
assemblers start to weld and screw all the parts as per design.

For smaller units, the finished

but open top canopy is
lowered by hoist onto base
frame and welding work is
started. Silencer is placed as well as IP55 Control panel are fabricated
and fixed in this time. After enclosure is found to be sturdy and
properly connected, the engine + alternator coupling is
lowered into the enclosure with attached to anti-vibration mounting after which top cover is placed and then bolted
and welded. For larger units the canopy is constructed around the engine and alternator part by part.

. Cable entry is designed for The modular design allows

proper gland size and gasket for fabrication and welding
is placed behind for extra piece by piece which can
sealing. Drainage is provided later be removed for
in a manner such that oil, maintenance purposes. Our
coolant from leakage or from canopies are normally IP23
maintenance will flow where we provide 4 access
downward to base frame and doors, with one door cut out
exit below. Fuel inlet and
for control panel glass. We
can design it specifically to
outlet are provided at a
client requirements with.
distance to avoid high fuel
intake temp. Lifting eyes are
provided on top of the DG set
and at the base skid forklift
pockets

PURCHASE/ WELDING AND ASSEMBLY OF PANEL

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Different form types are purchased as per project requirement Flush or Free standing type

ELECTRICAL WIRING
Wiring of control panel and connection to DG ECU and sensors/ switches. Control panel is
normally consisting of DSE 4610 or DSE 7110 controller along with Schneider MCB’s,
Schneider mini plug-in relays for controlling fuel and starter motor, Schneider main breaker – 3P with phase
separator, ESD button, indication lights for phases. Earthing for generator body and internally in panel.

Control Panel wiring

Synchro Panel

All electrical connections are
ensured to be fitted with spring
lock washers and torque
tightening to prevent loosening
during vibration of generator.
After bending and making holes, all copper bars
are tinned properly.
Project specific glands are used as well as gland
plates of aluminum coated with epoxy layer.
Each wire is marked by ferrules and fixed facing
properly for ease of the site personnel.

Relays fixed with lock to prevent loosening during

gen. operation

TESTING OF GENERATOR FUNCTIONALITY, LOAD TESTS, WEIGHT BALANCING,

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 Internal inspection check
list is used to maintain a
standard of quality.

Resistive/Reactive Load test

at different load
percentages for various
time periods.

Check oil pressure, water

temperature, voltage,
current, active power,
apparent power, reactive
power, oil temperature, etc

Functional tests to check the operation

features such as synchronizing or
switching between mains or another
generator and protection of DG.

Abnormal
Temperature
check

DFT testing
Welding test NDT Vibration testing

SOUNDPROOFING
Page 110
Final filling of silicone and open area to seal the generator as much as feasible to reduce noise and any
forgotten openings for protection from weather. A Final check up is done on the generator by measuring
the sound level from all sides at 1 meter distance

QUALITY CHECK OF CANOPY AND ELECTRICAL WORK

This is last stage in which the generator final checkup is done to fix loose
components, check documentation such as manuals or maintenance
routine, and small quality points to be noted and fixed on the spot such as
loose wiring or unsupported components hanging loose.

Wiring number check

Panel meters tightening Ferrules front face fixing

Labeling of all components readable at least a distance of 1 meter. PVC stickers are used for outer safety
and guidance labeling to stay long life and all labels used for ease of site personnel. Operation manual,
generator guide, and software rechecked for correct versions.

Page 111
 PACKAGING & TRANSPORTATION

Other items that go along with generators are

prepared in similar fashion with hooks or
opening below for lifting.

Finished set, ready for ATS panel, ready for

operation shipment

Normally a lifting hook is

provided at the center point
of the generator for balanced
lifting along with forklift
pockets at the base.

Genset wrapped
completely to prevent
any scratches or dent
during transport
The finished genset is wrapped
in heatshrink wrapping from all
ends and fixed with thick wood
logs at the base by bolting.

Another option is there for

smaller sets, a trolley with 2
wheels and front side with small
wheel with towing hook. Jacks to
Stocked units wrapped and kept stop the generator
safe in warehouse waiting delivery

Spare parts and other loose

materials such as exhaust
pipes, spark arrestors, etc are
also packaged securely for
installation later at site