Generator, Part and How to Start

8/4/2019 Generator, Part and How to Start

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MECHANICAL SYSTEMS MAINTENANCE

COURSE WORK

SUBMITTED BY

IMASUEN EMMANUEL OSARETIN

F / HD / 09 / 3440451

DEPARTMENT

OF

INDUSTRIAL MAINTENANCE

ENGINGEERING

YABA COLLEGE OF TECHNOLOGY

SUBMITTED

TOEngr. UDOH

DATE: 12TH

AUGUST 2011.


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1.0 DEFINITION OF GENERATOR

Generator is

an engine or devices that convert mechanical energy into electrical energy by electromagnetic

induction. A generator forces electrons in the windings to flow through the external electrical

circuit. It is somewhat analogous to a water pump, which creates a flow of water but does not

create the water inside. The source of mechanical energy may be a reciprocating or turbine

steam engine, water falling through a turbine or waterwheel, an internal combustion engine, a

wind turbine, a hand crank, compressed air or any other source of mechanical energy.

The reverse conversion of electrical energy into mechanical energy is done by an electric motor,

and motors and generators have many similarities. In fact many motors can be mechanically

driven to generate electricity, and very frequently make acceptable generators.

Before the connection between magnetism and electricity was discovered, electrostatic

generators were invented that used electrostatic principles. These generated very high voltages

and low currents. They operated by using moving electrically charged belts, plates and disks to

carry charge to a high potential electrode. The charge was generated using either of two

mechanisms:

Electrostatic induction The triboelectric effect, where the contact between two insulators leaves them charged.

Because of their inefficiency and the difficulty of insulating machines producing very high

voltages, electrostatic generators had low power ratings and were never used for generation of

commercially significant quantities of electric power.
http://en.wikipedia.org/wiki/Electronshttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wiktionary.org/wiki/prime_moverhttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wikipedia.org/wiki/Hydropowerhttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Wind_turbinehttp://en.wikipedia.org/wiki/Crank_%28mechanism%29http://en.wikipedia.org/wiki/Compressed_airhttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Magnetismhttp://en.wikipedia.org/wiki/Electricityhttp://en.wikipedia.org/wiki/Electrostatic_generatorhttp://en.wikipedia.org/wiki/Electrostatic_generatorhttp://en.wikipedia.org/wiki/Electrostatichttp://en.wikipedia.org/wiki/Voltagehttp://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/Electric_chargehttp://en.wikipedia.org/wiki/Electrostatic_inductionhttp://en.wikipedia.org/wiki/Triboelectric_effecthttp://en.wikipedia.org/wiki/Electrical_insulationhttp://en.wikipedia.org/wiki/Electrical_insulationhttp://en.wikipedia.org/wiki/Triboelectric_effecthttp://en.wikipedia.org/wiki/Electrostatic_inductionhttp://en.wikipedia.org/wiki/Electric_chargehttp://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/Voltagehttp://en.wikipedia.org/wiki/Electrostatichttp://en.wikipedia.org/wiki/Electrostatic_generatorhttp://en.wikipedia.org/wiki/Electrostatic_generatorhttp://en.wikipedia.org/wiki/Electricityhttp://en.wikipedia.org/wiki/Magnetismhttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Compressed_airhttp://en.wikipedia.org/wiki/Crank_%28mechanism%29http://en.wikipedia.org/wiki/Wind_turbinehttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Hydropowerhttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wiktionary.org/wiki/prime_moverhttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wikipedia.org/wiki/Electrons


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Dynamo Electric Machine: A dynamo machine consists of a stationary structure, which provides

a constant magnetic field, and a set of rotating windings which turn within that field. On small

machines the constant magnetic field may be provided by one or more permanent magnets;

larger machines have the constant magnetic field provided by one or more electromagnets,

which are usually called field coils. Large power generation dynamos are now rarely seen due to

the now nearly universal use of alternating current for power distribution and solid state

electronic AC to DC power conversion. But before the principles of AC were discovered, very

large direct-current dynamos were the only means of power generation and distribution. Now

power generation dynamos are mostly a curiosity.

1.1 ALTERNATORWithout a commutator, a dynamo becomes an alternator, which is a synchronous singly-fed

generator. When used to feed an electric power grid, an alternator must always operate at a

constant speed that is precisely synchronized to the electrical frequency of the power grid. A DC

generator can operate at any speed within mechanical limits, but always outputs direct current.

The primary advantage of the alternator is that the field windings can be swapped from the

exterior non-rotating shell to the interior rotating shaft, and the current producing windings are

on the exterior shell. This allows for extremely thick current producing windings that stay in a

fixed position with permanent non-moving wiring.

The rotating field coil by contrast can operate at high voltage and low current so that only

small, simple, and low-cost slip rings are needed. For example, automotive alternators

commonly only use a single carbon brush to supply power to the field coil; the other end of the

coil is attached to the vehicle ground by way of the rotor bearings.

By using a rotary transformer to convey power to the rotating field coil, no rubbing physical

contacts are needed at all, and the alternator becomes an almost maintenance-free power

generation device.
http://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Solid_state_%28electronics%29http://en.wikipedia.org/wiki/Commutator_%28electric%29http://en.wikipedia.org/wiki/Alternatorhttp://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Grid_%28electricity%29http://en.wikipedia.org/wiki/Rotary_transformerhttp://en.wikipedia.org/wiki/Rotary_transformerhttp://en.wikipedia.org/wiki/Grid_%28electricity%29http://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Alternatorhttp://en.wikipedia.org/wiki/Commutator_%28electric%29http://en.wikipedia.org/wiki/Solid_state_%28electronics%29http://en.wikipedia.org/wiki/Alternating_current


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1.2 OTHER ROTATING ELECTROMAGNETIC GENERATORSOther types of generators, such as the asynchronous or induction singly-fed generator, the

doubly-fed generator, or the brushless wound-rotor doubly-fed generator, do not incorporate

permanent magnets or field windings (i.e., electromagnets) that establish a constant magnetic

field, and as a result, are seeing success in variable speed constant frequency applications, such

as wind turbines or other renewable energy technologies. The full output performance of any

generator can be optimized with electronic control but only the doubly-fed generators or the

brushless wound-rotor doubly-fed generator incorporate electronic control with power ratings

that are substantially less than the power output of the generator under control, a feature

which, by itself, offers cost, reliability and efficiency benefits.
http://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Doubly-fed_electric_machinehttp://en.wikipedia.org/wiki/Brushless_wound-rotor_doubly-fed_electric_machinehttp://en.wikipedia.org/wiki/Wind_turbinehttp://en.wikipedia.org/wiki/Renewable_energyhttp://en.wikipedia.org/wiki/Doubly-fed_electric_machinehttp://en.wikipedia.org/wiki/Brushless_wound-rotor_doubly-fed_electric_machinehttp://en.wikipedia.org/wiki/Brushless_wound-rotor_doubly-fed_electric_machinehttp://en.wikipedia.org/wiki/Doubly-fed_electric_machinehttp://en.wikipedia.org/wiki/Renewable_energyhttp://en.wikipedia.org/wiki/Wind_turbinehttp://en.wikipedia.org/wiki/Brushless_wound-rotor_doubly-fed_electric_machinehttp://en.wikipedia.org/wiki/Doubly-fed_electric_machinehttp://en.wikipedia.org/wiki/Singly-fed_electric_machine


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2.0 PARTS OF A GENERATOR


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1. ROTOR ASSY2. STATER ASSY3. HOLDER ASSY,BRUSH4. FRAME ASSY., DRIVE SIDE END5. B/BRG RAD N/COM6. ALTERNATOR7. INS,TERMINAL8. INS,TERMINAL9. FRAME ASSY., RECTIFIER SIDE END10.FRAME,SIDE END12.FELT,OIL13.WASHER,INSULATION15.RECTIFIRE ASSY16.COVER, FELT17.COLLAR,SPACE20.PLATE,RETAINER21.PULLEY22.BOLT,THROUGH23.NUT,PULLEY LOCK24.SCREW,PAN,5X1426. NUT,HEX.,6MM27.WASHER,PLAIN,5MM28.WASHER,SPRING 5MM29.SPG/WASHER,6MM30.

SPG-WASHER 14MM


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The two main parts of a generator or motor can be described in either mechanical or electrical

terms.

Mechanical:

Rotor: The rotating part of an electrical machine Stator: The stationary part of an electrical machine

Electrical:

Armature: The power-producing component of an electrical machine. In a generator,alternator, or dynamo the armature windings generate the electric current. The

armature can be on either the rotor or the stator.

Field: The magnetic field component of an electrical machine. The magnetic field of thedynamo or alternator can be provided by either electromagnets or permanent magnets

mounted on either the rotor or the stator.

Because power transferred into the field circuit is much less than in the armature circuit, AC

generators nearly always have the field winding on the rotor and the stator as the armature

winding. Only a small amount of field current must be transferred to the moving rotor, using
http://en.wikipedia.org/wiki/Rotor_%28electric%29http://en.wikipedia.org/wiki/Electrical_machinehttp://en.wikipedia.org/wiki/Statorhttp://en.wikipedia.org/wiki/Armature_%28electrical_engineering%29http://en.wikipedia.org/wiki/Field_coilhttp://en.wikipedia.org/wiki/Field_coilhttp://en.wikipedia.org/wiki/Armature_%28electrical_engineering%29http://en.wikipedia.org/wiki/Statorhttp://en.wikipedia.org/wiki/Electrical_machinehttp://en.wikipedia.org/wiki/Rotor_%28electric%29


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slip rings. Direct current machines (dynamos) require a commutator on the rotating shaft to

convert the alternating current produced by the armature to direct current, so the armature

winding is on the rotor of the machine.

2.1 Excitation

An electric generator or electric motor that uses field coils rather than permanent magnets

requires a current to be present in the field coils for the device to be able to work. If the field

coils are not powered, the rotor in a generator can spin without producing any usable electrical

energy, while the rotor of a motor may not spin at all.

Smaller generators are sometimesself-excited, which means the field coils are powered by the

current produced by the generator itself. The field coils are connected in series or parallel with

the armature winding. When the generator first starts to turn, the small amount of remanent

magnetism present in the iron core provides a magnetic field to get it started, generating a

small current in the armature. This flows through the field coils, creating a larger magnetic field

which generates a larger armature current. This "bootstrap" process continues until the

magnetic field in the core levels off due to saturation and the generator reaches a steady state

power output.
http://en.wikipedia.org/wiki/Slip_ringhttp://en.wikipedia.org/wiki/Commutator_%28electric%29http://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Direct_currenthttp://en.wikipedia.org/wiki/Self-excitationhttp://en.wikipedia.org/wiki/Self-excitationhttp://en.wikipedia.org/wiki/Self-excitationhttp://en.wikipedia.org/wiki/Remanent_magnetismhttp://en.wikipedia.org/wiki/Remanent_magnetismhttp://en.wikipedia.org/wiki/Saturation_%28magnetic%29http://en.wikipedia.org/wiki/Saturation_%28magnetic%29http://en.wikipedia.org/wiki/Remanent_magnetismhttp://en.wikipedia.org/wiki/Remanent_magnetismhttp://en.wikipedia.org/wiki/Self-excitationhttp://en.wikipedia.org/wiki/Direct_currenthttp://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Commutator_%28electric%29http://en.wikipedia.org/wiki/Slip_ring


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Very large power station generators often utilize a separate smaller generator to excite the

field coils of the larger. In the event of a severe widespread power outage where islanding of

power stations has occurred, the stations may need to perform a black start to excite the fields

of their largest generators, in order to restore customer power service.

2.2 DC EQUIVALENT CIRCUIT

Equivalent circuit of generator and load.

G = generator

VG=generator open-circuit voltage

RG=generator internal resistance

VL=generator on-load voltage

RL=load resistance

The equivalent circuit of a generator and load is shown in the diagram to the right. The

generator's VG and RG parameters can be determined by measuring the winding resistance

(corrected to operating temperature), and measuring the open-circuit and loaded voltage for a

defined current load.
http://en.wikipedia.org/wiki/Power_outagehttp://en.wikipedia.org/wiki/Islandinghttp://en.wikipedia.org/wiki/Black_starthttp://en.wikipedia.org/wiki/File:Generator-model.svghttp://en.wikipedia.org/wiki/Black_starthttp://en.wikipedia.org/wiki/Islandinghttp://en.wikipedia.org/wiki/Power_outage


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2.3 ENGINE-GENERATORAn engine-generator is the combination of an electrical generator and an engine (prime mover)

mounted together to form a single piece of self-contained equipment. The engines used are

usually piston engines, but gas turbines can also be used. Many different versions are available -

ranging from very small portable petrol powered sets to large turbine installations.

2.4 HUMAN POWERED ELECTRICAL GENERATORSA generator can also be driven by human muscle power (for instance, in field radio station

equipment). Human powered direct current generators are commercially available, and have

been the project of some DIY enthusiasts. Typically operated by means of pedal power, a

converted bicycle trainer, or a foot pump, such generators can be practically used to charge

batteries, and in some cases are designed with an integral inverter. The average adult could

generate about 125-200 watts on a pedal powered generator, but at a power of 200 W, a

typical healthy human will reach complete exhaustion and fail to produce any more power after

approximately 1.3 hours.[4]

Portable radio receivers with a crank are made to reduce battery

purchase requirements, see clockwork radio.

2.5 LINEAR ELECTRIC GENERATOR

In the simplest form of linear electric generator, a sliding magnet moves back and forth through

a solenoid - a spool of copper wire. An alternating current is induced in the loops of wire by

Faraday's law of induction each time the magnet slides through. This type of generator is used

in the Faraday flashlight. Larger linear electricity generators are used in wave power schemes.

2.6 TACHOGENERATORTachogenerators are frequently used to power tachometers to measure the speeds of electric

motors, engines, and the equipment they power. Generators generate voltage roughly

proportional to shaft speed. With precise construction and design, generators can be built to

produce very precise voltages for certain ranges of shaft speeds
http://en.wikipedia.org/wiki/Enginehttp://en.wikipedia.org/wiki/Prime_moverhttp://en.wikipedia.org/wiki/Petrolhttp://en.wikipedia.org/wiki/DIYhttp://c/Users/opeyemi/Desktop/electrical%20gen%20harrison%201.htm%23cite_note-3http://c/Users/opeyemi/Desktop/electrical%20gen%20harrison%201.htm%23cite_note-3http://c/Users/opeyemi/Desktop/electrical%20gen%20harrison%201.htm%23cite_note-3http://en.wikipedia.org/wiki/Clockwork_radiohttp://en.wikipedia.org/wiki/Magnethttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Faraday%27s_law_of_inductionhttp://en.wikipedia.org/wiki/Faraday_flashlighthttp://en.wikipedia.org/wiki/Wave_powerhttp://en.wikipedia.org/wiki/Tachometerhttp://en.wikipedia.org/wiki/Tachometerhttp://en.wikipedia.org/wiki/Wave_powerhttp://en.wikipedia.org/wiki/Faraday_flashlighthttp://en.wikipedia.org/wiki/Faraday%27s_law_of_inductionhttp://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Magnethttp://en.wikipedia.org/wiki/Clockwork_radiohttp://c/Users/opeyemi/Desktop/electrical%20gen%20harrison%201.htm%23cite_note-3http://en.wikipedia.org/wiki/DIYhttp://en.wikipedia.org/wiki/Petrolhttp://en.wikipedia.org/wiki/Prime_moverhttp://en.wikipedia.org/wiki/Engine


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3.0 COMMON FAULTS IN A GENERATORThe major faults in case of generator can be classified as:

(a)Failure of prime movers:

Whenever there is a fault on prime mover side the conversion of mechanical power to electrical

power stops. If this generator works in parallel with other generator sets it will start working as

a synchronous motor running at synchronous speed and the prime mover will act as load on it.

When generator starts running as a motor it is called as inverted operation. If the fault is

cleared the generator will automatically pick up generation.

(b)Failure of excitation:

The turbo generator set under consideration works in parallel with other sets. If the field of the

generator is interrupted it will continue to operate as an induction generator-delivering load at

very low power factor. So the other generators will be overloaded, as they will have to supply

the load of this faulty generator. This may lead to decrease the supply voltage and the stability

of the system will be affected.

The fault generator can be switched off but for an automatic operation an under current relay

in conjunction with time lagged tripping and time lagged reinforcing relay as shown in fig 1 can

be used.

The under current relay is a moving coil type instrument and is fed through a shunt in the field

circuit and its provided with a double trip circuit contact. When there is field circuit failure

under current relay is no longer energized and the action moves up the operating armature up

and in doing so it stops supply to time lagged reinforcing and trip relays, thus both of theses

relays are operated simultaneously.
http://electricalandelectronics.org/wp-content/uploads/2009/03/generator-faults.png


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(a)Failure of insulation in the stator or interconnecting cable can be further divided into:

i.Interphase short circuits These are accompanied by large fault currents, the values of

which are dependent upon the capacity of the system to which the alternator is

connected, the nature of inter connection to the system and the moment at which the

short circuit occurs.

ii.Single phase to earth fault This will lead top the burning of alternator winding when

leakage current exceeds even 5 amps. This current is dependent upon the nature of

neutral connection, i.e. whether its earthed or unearthed.

iii.Inter turn faults In this type of fault short circuit exists between the turns of the same

phase or between turns of parallel branches in the same phase. The magnitude of the

fault current depends on the number of turns shorted. This is a dangerous type of

fault

iv.Earth fault on the rotor Shorting of the rotor at one point to earth in itself does not

cause any damage. But the appearance of another fault to earth may sharply disturb

the magnetic flux distribution, which will lead to unequal voltages being induced in the

stator and increased vibration in the alternator.

3.1 FAULTS AND WARNINGSDiesel engine common fault location list

Fault phenomena

Fault Location Fault phenomena

Fault Location

Starting problem of

diesel engine

1Oil supply system

2Distribution

Mechanism

3Starting system

4Piston cylinder

liner

5Intake and exhaust

Black smoke 1Oil supply

system

2Distributio

n Mechanism

3Piston

cylinder

liner


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system

6Lubricating

system

7Superchargingsystem

8Crank-link

mechanism

9Environment factor

4Intake

system

5Superchargi

ng system6Equipment

factor

Diesel engine overheat

1Fan system

2Injection system

3Lubricating

system

4Distribution

Mechanism

5Cooling surface

6Environment factor

White smoke

1Oil supply

system

2Superchargi

ng system

3Piston

cylinder

liner

4Distributio

n Mechanism5Environment

factor

Diesel engine

underpowered

1Oil supply system

2Distribution

Mechanism3Piston cylinder

liner

4Supercharging

system

5Intake and exhaust

system

Blue smoke1Piston

cylinderliner

2Lubricating

system

3Superchargi

ng system
http://www.emacsz.com/catalogue/diesel-engine.htmhttp://www.emacsz.com/catalogue/diesel-engine.htmhttp://www.emacsz.com/catalogue/diesel-engine.htm


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6Environment

factor

7Fuel system

The oil pressure of

diesel engineis not

normal

1Lubricating

system

2Crank-link

mechanism

3Cooling system

Noise

1Distributio

n Mechanism

2Combustion

system

3Crank-link

mechanism4Other

factor

The fuel consumption

of diesel engineis

too high

1Oil supply system

2Distribution

Mechanism

3Piston cylinder

liner

4Supercharging

system

5Other factor

The speed is

not normal

1Governor of

injection

2Fuel

system

3Equipment

factor
http://www.emacsz.com/catalogue/diesel-engine.htmhttp://www.emacsz.com/catalogue/diesel-engine.htmhttp://www.emacsz.com/catalogue/diesel-engine.htmhttp://www.emacsz.com/catalogue/diesel-engine.htmhttp://www.emacsz.com/catalogue/diesel-engine.htmhttp://www.emacsz.com/catalogue/diesel-engine.htm


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Under certain conditions, the Auto Gen Start generates a fault or warning message. These messages

appear on the System Control Panel. This section describes how to respond to fault and warning

messages when they appear.

When a fault or warning message appears, you can acknowledge the message by pressing Enter on the

System Control Panel. This action removes the message from the screen. After acknowleding the

message, you can proceed configuring or operating the Auto Gen Start. This action does not clear the

condition that caused the fault or warning, Self-clearing warnings If unacknowledged, some warnings

may clear themselves if the condition that generated the message goes away. For example, if the Auto

Gen Start fails to start the generator, warning message W202 appears. However, if the generator starts

on the next start try, the message goes away. Clearing faults to clear active Auto Gen Start faults,

highlight Clear Faults on the Automatic Generator Start menu and press Enter . Multiple faults and

warnings if several fault or warning messages occur before you can acknowledge or clear them, they are

displayed together on a fault list or a warning list. These lists contain messages from every Xanbus-

enabled device, not just the Auto Gen Start. You can select a message and view its details from the fault

list or warning list.

To view a message from a fault list or warning list:

1. On the list, use the up arrow or down arrow button to highlight the message you want to view.

2. Press Enter. The complete message appears. After viewing the message, you can return to the fault

list or warning list by pressing Exit or continue to the menu for the device that caused the fault or

warning by pressing Enter. Each time you return to the list after viewing a complete message, the

viewed message is removed from the list. If you have left the fault list or warning list, you can view them

at any time from the System Settings menu.

To view a fault list or warning list:

1. On the Select Device menu, highlight System and press Enter.

2. On the System Settings menu, highlight View Fault List or View Warning Messages

Table provides details and suggests action for Auto Gen Start warnings.


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4.0 CALIBRATION OF GENERATORCalibration helps a power plant in maintaining or even improving safety, as well as in meeting

national and international standards. However, calibration is also a matter of profitability. By

using high-accuracy calibration equipment, the accuracy of vital measurements can be

maintained on a required level and the plant can increase its annual power production

capability.

4.1 POWER AND ENERGY OPERATIONSElectric, natural gas, oil, and other energy meters directly influence revenue. Because of rising energy costs, power

and energy operations carefully scrutinize these devices to ensure that they accurately account for their energy

and bill correctly. Calibration issues that arise in the power and energy industries are also similar to those faced in

power and energy consumer industries. Although not directly billable, internal energy consumption and its

allocation can make or break a seemingly viable product.

4.2CALIBRATION REQUIREMENTS FOR INCREASING PLANT PRODUCTIVITY AND SAFETYAccurate measurements can allow increased energy production. Therefore, high-accuracy calibrators

such as the Beamex MC5 Multifunction Calibrator, have a significant role in improving plant

productivity. For instance, reducing the measurement uncertainty in a nuclear power plant can

potentially increase electrical production up to nearly 2 percent.

The economic consequence of this seemingly small power increase typically increases revenues by many

millions of dollars because the total value of power and energy flows can easily be over a billion dollars

per year. Therefore, seemingly small measurement errors caused by poor calibration techniques can

potentially result in major revenue losses. With these improved measurements comes the additional

requirement of maintaining calibration equipment and techniques that are comparable with the

improved instrument performance with traceability to national and international standards, such as

NIST, ISO 9001 and ISO 17025Improving power plant performance through calibration

Safety is based upon never exceeding established operating limits such as reactor power and cooling

capacity. A byproduct of improved calibration is an improvement in safety and fewer problems because

instruments periodically calibrated to more accurate standards reduce the risk associated with these


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measurements. In addition, improved calibration standards can be used to detect instrument

degradation sooner.

4.3 POWER AND ENERGY INDUSTRY CALIBRATIONField calibration allows the in-situ calibration of instruments that measure electrical parameters such as

voltage, current

Increasing annual production with high-accuracy calibrators

Enhanced calibration equipment performance makes it possible to perform calibration operations with

better uncertainty levels, with which it is possible to improve production results. This is achieved by

using the Beamex MC5 high-accuracy multifunction calibrators for calibration in the power plant.

By improving the measurement of the parameters from 2 % to 0.4 % (parameters associated with thedetermination of reactor power), enabled the power in each unit to be increased by 1.6 %. This has a

very significant effect on the annual production.

The performance of natural gas and oil flow measurement systems can also influence billing. In

particular, the calibration of flow meters used to check the custody transfer flow meters is important.

Small variances between these flow meters can result large billing differences and could indicate a

problem with the custody transfer flow meter. Field calibrators allow these calibrations to be performed

accurately and more efficiently, especially when the instrument is installed with poor personnel access.

Many electricity, steam, cogeneration, ethanol, bio-diesel, refinery and other types of energy plants use

these measurements to develop process heat and material balances that describe their processes. Heat

and material balances can be instrumental in locating opportunities that can save millions of dollars of

energy. For example, increased steam flow to a heat exchanger indicates that either the steam trap on

the heat exchanger leaks (wasting steam), or that the process changed (wasting steam) and needs to be

investigated to reduce steam consumption. Field calibrators help ensure that these instruments operate

properly and accurately quantify energy savings. In addition, instruments that are regularly and

accurately calibrated often tend to improve plant safety and reduce the probability of equipment

damage.

Further, automated portable calibrators can improve the calibration process by automating the

generation of the transmitter inputs and the recording of the transmitter measurements. This makes the

calibration process much less time-consuming and improves the accuracy with which data is collected by

reducing the probability of human error.


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Expensive qualification requirements often preclude the opening of transmitters in nuclear power

plants. In these applications, the calibration process can be performed faster and more accurately with

an automated calibrator as compared to using existing manual calibration techniques.

The Beamex MC5 multifunction calibrators and the Beamex CMX calibration software form an

integrated, automated calibration system. Calibrations performed using automated field calibrators and

calibration software with electronic documentation, result in more uniform calibrations that are less

prone to human error. This automated calibration process is faster and more complete than the manual

process. Aside from being more accurate, it also frees up significant amounts of time for the technician

to perform other work. The integrated system with communicating calibrators and calibration software

allow also easy upload of calibrations to a PC and produce easy-to-read calibration certificates showing

the accuracy of the instrument. It also allows the ability to search for instruments that are due for

calibration.

SUMMARYONIMPROVING POWER PLANT PERFORMANCE THROUGH CALIBRATION.

An optimal calibration plan executed well can improve both safety and productivity of the plant.

CALIBRATION IMPROVES SAFETY

Calibration is carried out to compare the quality and reliability of the measurements by means of

traceability through national and international standards (e.g. NIST, ISO 9001, ISO 17025).

Plan safety is based on never exceeding the established operat ing parameters (e.g. reactor power,

cooling capacity).

Calibration improves efficiency

Enhanced calibration equipment performance results in better uncertainty levels, with which it is

possible to improve annual production levels.

With an integrated calibration solution, such as the Beamex

calibrators and calibration software, plant

can reduce the amount of paperwork and equipment that has to be taken out in the field


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5.0 STARTING AND STOP OF GENERATOR SET

START AND RUN THE GENERATOR SET1. According to the Check before running requirement, finish each check. Then turn the fuel tank

switch to ON.

2. Disconnect all the outer loads on the AC receptacle.

3. Turn the breaker to the OFF position, draw the chock handle, and turn off the choke.

4. Turn the starting switch key to the RUN, the generator is in the standby mode after the digital

control panel display initial interface.

5. Turn the starting switch key to the START, loose the key after generator started, and the key will

return to RUN automatically. In the first time, if start fails, restart it after 30seconds.

6. Run the generator set and Loose starter switch key after starting, push the throttle handle back to

it's position, then the generator will be in the automatic running state.

7. After making sure the generator voltage, frequency and other running state meet the using require,

close the main breaker, then it can supply output power to load. Preheat generator three minute

without load after the set starting, then running with load


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The new generator set have a running-in period, the period is the initial 20 hours, only with 50% load

during the running-in period, or it will shorten the set life.

8. Checks during the running

a) Whether there is abnormal sound or vibration;

b) Whether the engine misfires or runs rough;

c) Check the color of the exhaust. (Is it black or too white?) If you notice any of the above-mentioned

phenomenon happened, stop the engine and find out the fault cause or contact with our agents. If the

engine has been running, the muffler will be very hot. Be careful not to touch the muffler.

STOPPING OF GENERATORFirst disconnect the unit and load, then stop the generator.

1. Normal stop

1) Cut off the load from the generator.

2) Turn the breaker to OFF position.

3) Turn the starter switch to STOP position after running for 1-3 minutes with zero load.

4) Turn off the fuel switch after the generator stopped.

2. Emergence stop

a. When generator set is running, the operator should keep eyes on its running state. If there is anything

wrong, stop the generator according to the normal procedure.

b. If there is any emergency which may cause serious damage to the generator or person injuries, eg.

short circuit, electric shock and so on. The operator should immediately apply the emergency stop:

pressing hard the Emergency stop button could stop the generator at once. (Caution: there is no

emergency stop on the KGE12E/KGE12E3 generator, please turn the Starting switch to the stop

position.

c. When the problem has been solved after stopping the generator, you should reset the Emergency

stop button before restarting the machine, rotate the Emergency stop in the arrow direction and the

button will reset.Reset the pressed Emergency stop, then the generator will run again. And restart the generator

according to the normal procedure.

Do not use Emergency stop when in non-emergency situations. If that, Emergency stop may cause

some damage to the generator.


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6.0 GENERATOR MAINTENANCEDiesel generator sets used for either prime or backup (emergency) power must be regularly

maintained to ensure they provide quality power throughout their service life. Larger

companies who own many generators, or those who rely on generator sets extensively for

prime power, may require an in-house engineer to maintain their generator sets. Smaller

companies, or users who own a generator to provide backup power in the event of an outage,

may establish maintenance contracts with generator dealers and/or electrical contractors to

maintain their generator sets. In either instance, the life-cycle of power generators is well

established and documented making routine maintenance fairly straight-forward. Best

generator maintenance practice is following the maintenance schedule provided by the

manufacturer of the generator.

The long outstanding use of generators over time has provided the necessary knowledge to

predict when certain components will fail or be in need of service. A fairly reliable maintenance

schedule can usually be acquired from the manufacturer and can be employed by a local

generator dealer or other electrical contractors/engineers with experience in power

generation. Adhering to this schedule will ensure maximum service time for the generator and

proper operation when it is called upon to provide power. Large generator manufacturers have

established maintenance plans and will not only service their own generators, but many of the

other industries major brand names as well. Below are links to Caterpillar and Cummins

generator maintenance programs that most any generator owner can subscribe too: The main

responsibilities of the maintenance contractors would be to inspect systems, study the

technical data provided by the manufacturers, maintain records and take precautionary

measures for safety as suggested by the manufacturers.

Some of the steps taken to ensure smooth generator operation while carrying out scheduled

maintenance include:

Timely removal of worn out parts or upgrading of components Checking fluid level Battery inspection and cleaning of connections


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Load bank testing Verifying control panel readings and indicators Changing fuel and air filters

Small investments made in replacing components and maintaining generators on a regular basis

can save expensive and unnecessary upgrades or even replacement of the entire generator set

in the future.

When performing routine maintenance, each action taken should be logged, and the readings

and various parameters are recorded along with the date of inspection and hour meter reading

of the generator. These set of readings are compared with the next set of data collected. Anyabsurd variation of readings indicates faulty performance of the unit.

Load testing of automatic transfer switches in regular intervals keeps track of the components

electrical and mechanical integrity in the actual mechanical transfer operation. Other factors to

be checked periodically are starting and timing relays, start signal continuity, and utility phase

sensing.

Preventive maintenance thus ensures that you get uninterrupted power supply for all your

needs. You are assured of service on priority basis in case of dire emergency and discounted

service rate for additional support or work. Once a business enters into such contracts, the

facility can relax on this aspect as the maintenance provider keeps track of when the next

servicing is due and makes the visits in regular intervals. They ensure that the products

purchased through them receive consistent and reliable service.

6.1 SAFE OPERATION OF DIESEL GENERATORS (A) THE AUTOMATIC STATE

1. To keep starting the motor and the battery to start the voltage.

2. To maintain the normal water level in the radiator cooling, circulating valve is always open.
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3. Keep the crankcase oil level dipstick groove within 2cm.

4, the fuel tank more than half of oil in the fuel supply valve is always open.

5. The generator control panel's "Run - Stop - Automatic" switch on "auto" position.

6. unit distribution screen mode switch in the "automatic" position.

7, the radiator fan switch is in the "automatic" position.

8, the unit received the signal loss of pressure mains start to confirm the utility loss of pressure,

conversion counter cut electricity switch, close the conversion counter power switch, start the engine

room of the intake and exhaust fan.

(B) MANUAL START

1, the indoor temperature below 20C, open the electric heater on the machine to warm up.

2, check the functioning of the body and the surrounding debris without prejudice, if any, should be

promptly removed.

3, check the crankcase oil level, fuel tank oil level, radiator water level. If the water level below the value

of the oil level should be added to the normal position.

4 check the fuel supply valve and the cooling water valve is in open position.

5, check the voltage of batteries for electric starter is normal.

6, test power distribution panel of the test button, observe the warning light has switched on lights.

7, check the power distribution panel of the switch is OFF position, the instrument is in zero indication.

8, the start into the wind and exhaust fan.

9, press the engine start button, it starts running. Such as the failure of the first start, press the power

distribution panel on the corresponding reset button, wait until the alarm to eliminate the crew return

to normal conditions before the second start. Started, the sound operation of the machine properly, the

cooling water pump running indicator lights and instruments indicate normal way to start successful.
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(C) OF THE PARALLEL POWER SUPPLY MANUAL1, and the cars to be turbine oil, water temperature, oil pressure reaches normal operating condition.

2, etc. and the cars generator output voltage and frequency values and the values consistent with bus

bars.

3, to be car generator synchronizer and hit the handle of "closing" position

4, the observed synchronization indicator lights and pointers

5, observe the synchronization indicator light, completely extinguished or the pointer to the zero

rotation, and can be marked with electrical closing switches.

6, the crew and vehicle to run into, and then handle its synchronizer cycle "off" position

7, after closing if the synchronizer, synchronization, pointer rotating too fast or anti-clockwise rotation,

and the car is not allowed, otherwise, will result in closing failure.

8, manual and the car is successful, should immediately contact with the low-voltage power distribution

room, the implementation of the main distribution panel feeding the switch can switch on power

transmission lines after the operation.

(D) OPERATIONAL SAFETY MANAGEMENT1, in accordance with the instructions specified time checking instruments, pay attention to oil pressure,

water temperature have changed. Lubricating oil pressure shall not be less than 150kPa, cooling water

temperature not higher than 95C.

2, check the crankcase oil level, fuel tank oil level, radiator water level, lower than the normal position

should be added.

3 ground power distribution panel of the instrument and observe the warning lights are normal. Where

a red light there is a failure, the green light for the normal operation of the light

4, check the charger is properly charged.

5, listen to the sound operation of the various parts of the machine is normal.

6, Shoumo body shell, bearing housing parts, tubing, pipes, feel the temperature is normal.

7, pay attention to hair dryer or other electrical equipment if there char, rather than smell.


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8, found that adverse events should be processed immediately resolved; serious should stop treatment.

9, where downtime is required to eliminate the fault and then repeat the hand pressing the button on

the unit, the unit before further operation

10, on the operating parameters, a class record at least twice.

(E) PROTECTION1, generator of high / low voltage pre-alarm, stop

2, the generator of high / low frequency pre-alarm, stop

3, the engine high water temperature alarm, shutdown

4, the engine speed / speed pre-alarm and shutdown

5, engine low oil pressure alarm, shutdown

6, the battery voltage high / low alarm

7, over-current alarm, trip, stopping

8, short-circuit fault trip

9, the oil pressure sensor break alarm, shutdown.

10, engine speed sensor signal loss alarm, stop

11, the generator phase sequence error alarm stop

12, hair units down by ground fault alarm

13, emergency stop / start the alarm stop

14, low fuel oil level alarm

(F) Parking1, the total output control panel feed switch sub-gate, Off grid.

2, the generator no-load operation of 10 minutes parking 3, stop the engine room fans, cooling water

pump.


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THE ADVANTAGES AND CHARACTERISTICS OF DIESEL GENERATORS1, the advantages:

(1), fuel economy, high thermal efficiency, operating conditions change, the fuel consumption rate

curve changes relatively flat economy even under low load

(2), reliable, durable. Because there is no ignition system, low fault

(3), using a wide range

(4), less harmful emissions

(5) And good fire safety

Generator automatic voltage regulator in the form of: SCR, phase compound, TD1-type carbon

resistance automatic voltage regulator, the individual use of high-power tube

2, features:

(1), multi-level unit capacity. International unit from a few kilowatts of ~ tens of thousands of kilowatts,

thousands of kilowatts of the largest domestic unit

(2), supporting equipment, compact structure, flexible installation locations (water as long as 34 ~

82L/KW H turbine 's 1 / 10)

(3), high thermal efficiency, fuel consumption is low (30 ~ 46% thermal efficiency)

(4), starting quickly, and can soon reach full power only a few seconds, with a maturity of 1 minute

emergency full load (normal 5 ~ 30MIN) stop the process short, to frequent starts and stops.

(5), maintenance is simple, few, easy to maintain during standby

(6), diesel generators power the building with the lowest overall cost

The future direction ofgenerator sets

Generator for the national economy and people's shoulders to provide household electricity generation

equipment of the task, so it will be a very long time occupied an important position. And with the
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progress of the times and social development, the original is clearly the kind of generator is not suitable

for the needs of society. Heavy, fuel consumption, noise , pollution

So the future direction of the generating units should be energy saving, environmental protection, light,

small, nice. Generating units in order to play a potential advantage

Incorrect operation of diesel generators

Diesel generators operating error will seriously affect the service life of diesel generator sets, let's look

at the daily life, mode of operation of diesel generating sets which the error?

Faulty operation of a diesel generator: diesel engine oil run low.

At this point the oil supply shortage due to friction caused by the lack of surface oil, resulting in

abnormal wear or burns. Therefore, diesel generators and diesel engines running before starting the

process to ensure sufficient oil to prevent the cylinder caused by the lack of oil, bush-burning failure.

Error operating two diesel generators: acute down-load or shut down immediately after the load

dropped suddenly

Diesel generator cooling system after the flame to stop the water cycle, dramatically reduce the cooling

capacity, heating cooling parts lost, could easily lead to the cylinder head, cylinder cover, cylinder block

and other parts overheating, cracks, or excessive expansion of the piston in the cylinder stuck inside. On

the other hand, without the idle shutdown diesel generator cooling, make the oil less friction surface,when the engine starts again when the increased wear due to poor lubrication. Therefore, the flame of

diesel generator dropped before loading, and gradually reduce the speed , load running a few minutes.

Operate threediesel generators Error: cold, not warm to start with a load operation

Cooler diesel generator starts, the oil viscosity, poor mobility, lack of fuel supply is a machine, the

machine short of oil because of poor lubrication friction surface, resulting in rapid wear, or even

cylinder, bush-burning and other failures. Therefore, the diesel engine starts warming should be idle,

standby oil temperature above 40 C and then with a load operation; machines started to be linked to

low gear, and orderly travel for a distance in each gear until the oil temperature is normal, adequate

supply only after to normal traffic.

Operation of four diesel generator error: Meng diesel cold start after the throttle
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If Meng throttle, the sharp rise in diesel generator speed will cause some friction surface on the machine

produced by dry friction and severe wear. In addition, the H-throttle piston, connecting rod and

crankshaft receiving power changes, caused by heavy impact, and easily damaged parts.

Diesel generatorsoperating five errors: lack of cooling water or cooling water, oil under high

temperature operation

Diesel generator cooling water shortage will reduce its cooling effect, due to the lack of effective cooling

engine is hot; cooling water, oil, the oil temperature is too high, can cause engine overheating. At this

point diesel generator cylinder head, cylinder liner, piston components and valve and other major heat

load, the mechanical properties such as strength, toughness and so sharply, so that deformation of parts

increases, decreases with the gap between the parts to speed up parts wear, but also serious cracks,

engine stuck fault. Diesel engine combustion process heat will deteriorate, so that fuel injector

malfunction, poor atomization, coke increased.

6.2 PREVENTIVE MAINTENANCE PROGRAM GENERATOREvery Start

A. Check coolant level

B. Check batteries

C. Check engine oil level

D. Check instrument readings

E. Check battery charger

Every 10 hours

A. Air cleaner oil cup - check level

B. Air pre-cleaner - clean

C. Cooling system - check level and deposits

D. Oil speed control linkage and Flo-matic control

E. Check engine oil in crank case

Every 50 hours

A. Air cleaner element (dry) - clear

B. Fan and water pump belts - check tension and wear
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C. Flexible rubber connector between carburetor and air cleaner - inspect for loose fit or

damage

D. Flo-matic control linkage - 3 drops of oil

E. Alternator belt - check tension and wear

F. Power take-off clutch - check and adjust

G. Radiator core - clean spaces

Every 100 hours

A. Automatic dust unloader - empty

B. Battery - check electrolite level

C. Crank case - change oil

Every 150 Hours

A. Spark plugs - clean and gap

Every 200 hours

A. Crank case ventilator metering valve - clean

B. Fuel pump filter - clean and check sediment bowl

C. Change engine oil filter

D. Distributor - apply oil to arm pivot and felt wick under rotor

Every 500 hours

A. Carburetor fuel screen - remove and clean

B. Distributor cap - remove and clean

C. Distributor rubbing block - high temperature grease in back

D. Distributor housing - 8 to 10 drops of engine oil in cup

E. Distributor drive shaft - three strokes of hard lubricator

F. Governor control wire - two strokes of hard lubricator to each fitting

Periodic

A. Battery terminals - clean and grease

B. Oil pump screen - clean when pan is removed

C. Wiring - check for worn, cracked or corroded connections


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References

1. Augustus Heller (April 2, 1896),"Anianus Jedlik",Nature (Norman Lockyer)

2. Langdon Crane, Magnetohydrodynamic (MHD) Power Generator:

3. Horst Bauer Bosch Automotive

Handbook4th Edition Robert Bosch GmbH, Stuttgart

4. http://www.ohio.edu/mechanical/programming/hpv/hpv.html

5. Chapman, Stephen J. 2005. Electrical Machinery Fundamentals 4th Edition New York:

Mc Grawl Hill

6. Baran, J.,

Sroka, J. (2010). IEEE Trans. Electromagn52 (4), 797-803

7. Zaridze, R.,

Karkashadze,

D. Pommerenke,

D. Aidam, M. (1996)

8. Borsero, M., Sardi, A., Vizio, G. (2008).

9.Wang, K.,

Pommerenke, D.,

Chundru, R.,

Van Doren ,

T, Drewniak,

J.L., Shashindranath, A. (2003).

10.Caniggia, S.,

Maradei, F. (2007).
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Documents

Generator, Part and How to Start