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The exhaust pipe of a diesel generator, as a core component of its backup power system, directly affects the equipment’s lifespan, operational safety, and environmental compliance. Many users overlook installation details, leading to exhaust backflow, excessive noise, or even fire hazards.

1. Preparation: Material Selection and Path Planning

Pipe Material Selection

  • Prefer 304 stainless steel or double-layer galvanized steel pipes with a wall thickness ≥1.5mm.
  • Avoid ordinary iron pipes, as they are prone to rust and perforation in humid environments.

Path Design Principles

  • Total length should not exceed the manufacturer’s recommended value (typically ≤6 meters), and the number of elbows should be ≤3.
  • Maintain a 0.5%-1% downward slope (5-10mm drop per meter) to prevent condensation backflow.
  • Avoid flammable materials (e.g., wooden structures) and personnel activity areas, ensuring a minimum clearance of 1.2 meters.

2. Key Installation Steps and Practical Considerations

Step 1: Fixing the Support Brackets

  • Install one stainless steel support bracket every 1.5 meters.
  • Use high-temperature-resistant rubber pads (≥3mm) between the bracket and the pipe.

⚠ Case Warning: A factory neglected rubber padding, causing welding points on the support brackets to crack after three months of operation due to vibration.

Step 2: Installing the Flexible Connection Section

  • Use a corrugated compensator between the generator’s exhaust outlet and the main pipe.
  • Secure both ends with V-type clamps (welding is strictly prohibited).
  • Function: Absorbs displacement and vibration caused by equipment operation.

Step 3: Sealing Treatment

  • Use graphite-metal gaskets (temperature resistance ≥650°C) at flange connections.
  • Apply high-temperature sealant (e.g., Permatex® 81878) to threaded joints.
  • Leakage test: Hold a lit cigarette near the connection points and observe if the smoke is drawn in.

3. Safety Protection System Configuration

Spark Arrestor

  • Install a metal mesh spark arrestor within 1 meter of the generator’s outlet.
  • Mesh density: ≥120 mesh, with regular carbon deposit cleaning (recommended monthly).

Thermal Insulation

  • Wrap the pipe with double-layer aluminum foil fiberglass insulation (thickness ≥25mm).
  • Temperature control:
    • Contact areas: ≤60°C
    • Non-contact areas: ≤80°C

Drain Valve Installation

  • Install an automatic drain valve at the lowest point of the pipe (316 stainless steel recommended).
  • In humid regions, use electric heating tape to prevent condensation blockage.

4. Acceptance Testing Standards

Air Tightness Test

  • Seal the pipe’s end, start the generator at 80% load, and check all joints with soapy water.
  • Requirement: No bubbles observed for 5 minutes.

Back Pressure Test

  • Use a U-tube manometer to measure exhaust pressure.
  • Requirement: Exhaust back pressure should be below the manufacturer’s specification (typically <5kPa).

Noise Evaluation

  • Measure noise 1 meter from the exhaust pipe outlet.
  • Requirement: After installing a silencer, noise level should be ≤75dB(A).

5. Maintenance Considerations

  • Quarterly inspect the insulation layer; replace if aging or peeling occurs.
  • Before the rainy season, clean the drain valve to prevent clogging and water backflow.
  • During cold starts, monitor exhaust smoke color; if white vapor lasts over 3 minutes, check the sealing system.

By following standardized installation and regular maintenance, the exhaust system can operate safely for 8-10 years. A data center that strictly adhered to these standards successfully ran its generator for 72 hours during a typhoon without issues, demonstrating the importance of proper installation.