DIESEL GENERATOR DETAILS

NTPCNTPC--

RamagundamRamagundam

ByByM. M. MuraliMurali

MohanMohan

DyDy. . SuptdSuptd

(O)(O)

Diesel GeneratorDiesel Generator

What is it ?What is it ?

Why ?Why ?

How ?How ?

O & MO & M

PartsParts

FunctionsFunctions

RSTPSRSTPS

Diesel's story actually begins with the invention of Diesel's story actually begins with the invention of thethe

Gasoline EngineGasoline Engine..

““NikolausNikolaus

August OttoAugust Otto””

had invented and patented had invented and patented thethe

GGasolineasoline

engine by 1876.engine by 1876.

This invention used the fourThis invention used the four--stroke combustion principle, stroke combustion principle, also known as thealso known as the

"Otto Cycle"Otto Cycle““..

In 1878,In 1878,

““Rudolf DieselRudolf Diesel””

learned about the low efficiency of learned about the low efficiency of gasoline and steam engines.gasoline and steam engines.

This disturbing information inspired him to create an engine This disturbing information inspired him to create an engine with awith a

higher efficiency, and he devoted much of his time to higher efficiency, and he devoted much of his time to

developing adeveloping a

"Combustion Power Engine."Combustion Power Engine.““

By 1892By 1892

““DieselDiesel””

had obtained ahad obtained a

patentpatent

for what we now call for what we now call the diesel engine.the diesel engine. Conti….

http://science.howstuffworks.com/gasoline.htm

http://money.howstuffworks.com/patent.htm

1892,1892,

Rudolf DieselRudolf Diesel

obtained a patent.obtained a patent.

1893, 1893, ““DieselDiesel””

built his first working built his first working prototype.prototype.

1897, 1897, ““AdolphusAdolphus

BuschBusch””

licenses rights to licenses rights to the Diesel Engine for the USA and Canada.the Diesel Engine for the USA and Canada.

1899, Diesel licensed his engine to 1899, Diesel licensed his engine to buildersbuilders

KruppKrupp

andand

SulzerSulzer, who quickly , who quickly

became major manufacturers.became major manufacturers.

Until 1910,Until 1910,

MANMAN

produced 82 copies of the produced 82 copies of the stationary diesel engine.stationary diesel engine.

1919, First diesel engine from 1919, First diesel engine from CumminsCummins..

The world's largest diesel engine is currently The world's largest diesel engine is currently aa

WWäärtsilrtsilää

--

SulzerSulzer

RTA96 RTA96 --

CC

of about of about

84,42084,420

kW.kW.

Rudolf DieselRudolf Diesel

A Diesel Engine builtA Diesel Engine builtBy MAN By MAN ––

AG in 1906AG in 1906

https://en.wikipedia.org/wiki/Rudolf_Diesel

https://en.wikipedia.org/wiki/W%C3%A4rtsil%C3%A4-Sulzer_RTA96-C









Diesel Generator Diesel Generator ––

What is it ?What is it ?AA


is the combination of ais the combination of a

diesel diesel

engineengine

with anwith an

electric generatorelectric generator

(often called as (often called as alternatoralternator) to generate Electrical energy.) to generate Electrical energy.

https://en.wikipedia.org/wiki/Diesel_engine

https://en.wikipedia.org/wiki/Diesel_engine

https://en.wikipedia.org/wiki/Electric_generator

https://en.wikipedia.org/wiki/Alternator

Diesel generator sets are used in places without connection Diesel generator sets are used in places without connection to theto the

power gridpower grid, as, as

emergency power supplyemergency power supply

if the grid if the grid

fails, as well as for fails, as well as for more complex applications such as more complex applications such as peakpeak--lopping, grid support and export to the power grid.lopping, grid support and export to the power grid.

Specific Requirements:Specific Requirements:

Lighting:Lighting:

Egress lighting for evacuation, illuminated exit Egress lighting for evacuation, illuminated exit signs, security lighting, warning lights, operating room signs, security lighting, warning lights, operating room lighting, elevator car lighting etc.lighting, elevator car lighting etc.Control Power:Control Power:

Critical drives like oil pumps for Critical drives like oil pumps for

Generators, Turbines. Boiler and air compressors etc.Generators, Turbines. Boiler and air compressors etc.Transportation:Transportation:

Marine & Elevators for fire Dept use.Marine & Elevators for fire Dept use.

Mechanical Systems:Mechanical Systems:

Smoke control and pressurization Smoke control and pressurization fans, waste water treatment, etc.fans, waste water treatment, etc.


Why ?Why ?

Conti….

https://en.wikipedia.org/wiki/Electric_power_transmission

Heating:Heating:

Critical process heat.Critical process heat.Refrigeration:Refrigeration:

Blood banks, Food storage, etc.Blood banks, Food storage, etc.

Production:Production: Critical process power for Laboratories, Critical process power for Laboratories,

Pharmaceutical production processes, etc.Pharmaceutical production processes, etc.Space Conditioning:Space Conditioning:

Cooling for computer equipment rooms, Cooling for computer equipment rooms,

cooling and heating for vulnerable people, ventilation of cooling and heating for vulnerable people, ventilation of hazardous atmospheres, ventilation of pollutants or biological hazardous atmospheres, ventilation of pollutants or biological contamination, etc.contamination, etc.Fire Protection:Fire Protection:

Fire pumps and jockey pumps etc.Fire pumps and jockey pumps etc.

Data Processing:Data Processing:

UPS and cooling to prevent data loss, memory UPS and cooling to prevent data loss, memory loss, Program corruption.loss, Program corruption.Life Support:Life Support:

Hospitals, Nursing homes, and other Health care Hospitals, Nursing homes, and other Health care

facilities.facilities.Communications Systems:Communications Systems:

Police and Fire stations, HiPolice and Fire stations, Hi--rise rise

building PA systems, etc.building PA systems, etc.Signal Systems:Signal Systems:

Rail, Road, Ship and Air traffic control.Rail, Road, Ship and Air traffic control.

The Diesel Engine works onThe Diesel Engine works on ““Compression Compression

IgnitionIgnition””.. More specifically, the combustion More specifically, the combustion

process in the diesel engine is initiated by process in the diesel engine is initiated by spontaneous ignition of the fuel when it is injected spontaneous ignition of the fuel when it is injected into a highly compressed charge of air, which has into a highly compressed charge of air, which has reached approximately reached approximately 750 750 00CC..

Heat engine:Heat engine:

An engine that converts the potential An engine that converts the potential heat energy of a combustible heat energy of a combustible fuel into mechanical fuel into mechanical workwork. The diesel engine is a heat engine that . The diesel engine is a heat engine that functions by converting the heat energy of diesel functions by converting the heat energy of diesel fuel into mechanical work.fuel into mechanical work.

Diesel Engine Diesel Engine ––

How it works ?How it works ?

Conti….

Internal Combustion Engine:Internal Combustion Engine:

A Heat engine in which the A Heat engine in which the combustion of fuel is contained within a cylinder.combustion of fuel is contained within a cylinder.

Diesel Engine:Diesel Engine:

An internal combustion engine in which the An internal combustion engine in which the cylinder fuel air charge is ignited by the heat of cylinder fuel air charge is ignited by the heat of compression.compression.

Piston:Piston:

The piston of anThe piston of an

IInnternal Combustion Engineternal Combustion Engine

is is acted upon by the pressure of the expanding combustion acted upon by the pressure of the expanding combustion gases in thegases in the

combustion chambercombustion chamber

space at the top of the space at the top of the

cylinder. This force then acts downwards through cylinder. This force then acts downwards through thethe

connecting rodconnecting rod

and onto theand onto the

crankshaftcrankshaft..

Conti….

http://en.wikipedia.org/wiki/Internal_combustion_piston_engine

http://en.wikipedia.org/wiki/Internal_combustion_piston_engine

http://en.wikipedia.org/wiki/Combustion_chamber

http://en.wikipedia.org/wiki/Connecting_rod

http://en.wikipedia.org/wiki/Crankshaft

Top dead center (TDC):Top dead center (TDC):

The uppermost point of the The uppermost point of the piston travel in an engine cylinder.piston travel in an engine cylinder.

Bottom dead center (BDC):Bottom dead center (BDC):

The lowest point of The lowest point of piston travel in the engine cylinder.piston travel in the engine cylinder.

Bore:Bore:

The diameter of a cylinder. Bore is expressed The diameter of a cylinder. Bore is expressed as the piston sectional area over which cylinder as the piston sectional area over which cylinder pressures act.pressures act.

Compression ratio:Compression ratio:

A measure of the cylinder A measure of the cylinder volume when the piston is at volume when the piston is at BDCBDC

versus the versus the

cylinder volume when the piston is at cylinder volume when the piston is at TDCTDC. . Compression ratios in diesel engines fall between Compression ratios in diesel engines fall between 14:1 and 24:1.14:1 and 24:1.

Conti….

Bore & StrokeBore & Stroke Compression Ratio Compression Ratio ––

17:117:1

Conti….

Stroke:Stroke:

The distance through which a piston travels from The distance through which a piston travels from BDC to TDC.BDC to TDC.

Swept volume:Swept volume:

The volume displaced by the piston in the The volume displaced by the piston in the cylinder as it moves from BDC to TDC. It can be calculated cylinder as it moves from BDC to TDC. It can be calculated if both stroke and bore are known.if both stroke and bore are known.

Engine displacement:Engine displacement:

The swept volumeThe swept volume

of all the engine of all the engine cylinders expressed in Cubic inches or Cubic cm or Liters.cylinders expressed in Cubic inches or Cubic cm or Liters.

Displacement:Displacement:

Bore X Bore X Stroke X 0.7854 X Number Bore X Bore X Stroke X 0.7854 X Number of cylinders.of cylinders.

Engine displacement calculation dataEngine displacement calculation dataFor 6 For 6 --

cylinder engine, bore 126 mm, stroke 166 mm.cylinder engine, bore 126 mm, stroke 166 mm.

Engine displacementEngine displacement

isis

126 X 126 X 166 X 0.7854 X 6 =126 X 126 X 166 X 0.7854 X 6 = 12,419,134 cubic mm12,419,134 cubic mm

OR OR 12.4 liters.12.4 liters.

1 Liter = 60.010 Cubic inches1 Liter = 60.010 Cubic inches

Diesel Engine is mainly works on Diesel Engine is mainly works on below strokesbelow strokes..

1) Suction Stroke:1) Suction Stroke:--

In this stroke, the piston In this stroke, the piston moves downmoves down

from the from the top dead centre. As a result, inlet valve opens and top dead centre. As a result, inlet valve opens and air is drawnair is drawn

into the cylinder.into the cylinder.

Conti….


How it works ?How it works ?

After sufficient quantity of air After sufficient quantity of air with pressure is drawn, suction with pressure is drawn, suction valve closes at the end of the valve closes at the end of the stroke. The exhaust valve stroke. The exhaust valve remains closed during this remains closed during this stroke.stroke.

2) Compression Stroke:2) Compression Stroke:--

In this stroke, piston In this stroke, piston moves upmoves up

from the bottom dead from the bottom dead centre. During this stroke both inlet and exhaust valve centre. During this stroke both inlet and exhaust valve are closed.are closed.

The air drawn into the cylinder during suction stroke, is The air drawn into the cylinder during suction stroke, is entrapped inside the cylinder and compressed due to entrapped inside the cylinder and compressed due to upward movement of the piston.upward movement of the piston.

Conti….

In diesel engine, the compression In diesel engine, the compression ratio used is very high as a result, the ratio used is very high as a result, the air is finally compressed to a very air is finally compressed to a very high pressure up to high pressure up to 40 kg/cm40 kg/cm22,,

at this at this

pressure, the temp of the air is pressure, the temp of the air is reached to very high which is enough reached to very high which is enough to ignite the fuel.to ignite the fuel.

3) Constant Pressure Stroke:3) Constant Pressure Stroke:--

In this stroke, the fuel is injected into the hot In this stroke, the fuel is injected into the hot compressed air where it starts burning, maintaining compressed air where it starts burning, maintaining the pressure constant.the pressure constant.

Conti….

When the piston When the piston moves to its topmoves to its top dead centre, the supply of fuel is cutdead centre, the supply of fuel is cut-- off. It is to be said that the fuel is off. It is to be said that the fuel is

injected at the end of compression injected at the end of compression stroke and injection continues till the stroke and injection continues till the point of cutpoint of cut--off, but in actual off, but in actual practice, the ignition starts before the practice, the ignition starts before the end of compression stroke to take end of compression stroke to take care of ignition tag.care of ignition tag.

Working or Power Stroke:Working or Power Stroke:--

In this stroke, both inlet and exhaust valve remain In this stroke, both inlet and exhaust valve remain closed. The hot gases (which are produced due to closed. The hot gases (which are produced due to ignition of fuel during compression stroke) and ignition of fuel during compression stroke) and compressed air now expand adiabatically, in the compressed air now expand adiabatically, in the cylinder pushing the piston down and hence work is cylinder pushing the piston down and hence work is done. done.

At the end of stroke, the piston finally reaches the At the end of stroke, the piston finally reaches the bottom dead centre.bottom dead centre.

Conti….


Working PrincipleWorking Principle

4) Exhaust Stroke:4) Exhaust Stroke:--

In this stroke, the In this stroke, the piston again moves upwardpiston again moves upward. The . The exhaust valve opens, while inlet and fuel valve are exhaust valve opens, while inlet and fuel valve are closed. closed.

A greater part of the burnt fuel gases escape due to A greater part of the burnt fuel gases escape due to their own expansion. The upward movement of the their own expansion. The upward movement of the piston pushes the remaining gases out through the piston pushes the remaining gases out through the open exhaust valve.open exhaust valve.

Conti….

Only a small quantity of exhaust gases Only a small quantity of exhaust gases stay in the combustion chamber. At stay in the combustion chamber. At the end of exhaust stroke, the exhaust the end of exhaust stroke, the exhaust valve closes and the cycle is thus valve closes and the cycle is thus completed.completed.

Diesel Generator working principleDiesel Generator working principle


4 4 --

StrokesStrokes

IntakeIntake CompressionCompression PowerPower ExhaustExhaust

Conti….

Connecting rodConnecting rod

PistonPiston

CrankshaftCrankshaft

Parts of Engine Parts of Engine --

DetailedDetailed

Conti….

Diesel engines require the Diesel engines require the fourfour

things to run; things to run; fuel, fuel, air, ignition, and compression.air, ignition, and compression.

Diesel engines use high cylinder compression to Diesel engines use high cylinder compression to press the mixture of fuel and air into as small of an press the mixture of fuel and air into as small of an area as possible.area as possible.

This compression causes heat in the cylinder, which This compression causes heat in the cylinder, which causes the causes the fuel to ignitefuel to ignite

and push the piston back and push the piston back

down, causing the crankshaft, facilitating the easy down, causing the crankshaft, facilitating the easy transfer of the motion produced by the diesel engine transfer of the motion produced by the diesel engine to the magnets of the generator assembly.to the magnets of the generator assembly.


Overall functionOverall function

The main components of an Diesel Generator can The main components of an Diesel Generator can be broadly classified as:be broadly classified as:

(1) (1) Engine.Engine.(2) (2) Alternator.Alternator.(3) (3) Fuel System.Fuel System.(4) (4) Governor.Governor.(5) (5) Voltage Regulator.Voltage Regulator.(6) (6) Cooling and Exhaust Systems.Cooling and Exhaust Systems.(7) (7) Lubrication System.Lubrication System.(8) (8) Battery and Battery Charger.Battery and Battery Charger.(9) (9) Control Panel (Automatic Mains Failure panel).Control Panel (Automatic Mains Failure panel).(10) (10) Fly wheel.Fly wheel.


Its partsIts parts

Starter Motor

NTPCNTPC--RamagundamRamagundam

DG Set detailsDG Set detailsSpecificationSpecification Stage Stage --

II Stage Stage --

IIII Stage Stage --

IIIIII

Engine makeEngine make KirloskarKirloskarCummins Ltd.Cummins Ltd.

KirloskarKirloskarCummins Ltd.Cummins Ltd.

Cummins India Cummins India Ltd.Ltd.

Type Type KTA KTA ––

2300 G2300 G KTA KTA ––

2300 G2300 G KTAKTA--5050--G8G8--II

K K ––

Engine SeriesEngine SeriesT T ––

Turbo ChargedTurbo ChargedA A ––

After CooledAfter Cooled

2300 2300 ––

Displacement in Cubic Inch.Displacement in Cubic Inch.G G ––Engine for Generator ApplicationEngine for Generator Application

KTA KTA --

50 50 --

G8 G8 --

II

50 50 ––

Displacement in litersDisplacement in liters

1 Liter = 60.010 Cubic inches1 Liter = 60.010 Cubic inches

Engine ratingEngine rating 890 BHP890 BHP 890 BHP890 BHP 1735 BHP1735 BHPRPMRPM 1500 RPM1500 RPM 1500 RPM1500 RPM 1500 RPM1500 RPMNo. of CylindersNo. of Cylinders 12, 6012, 6000

VeeVee 12, 6012, 6000

VeeVee 16, 6016, 6000

VeeVee

Conti….12, 6012, 6000

VeeVee

SpecificationSpecification Stage Stage --

II Stage Stage --

IIII Stage Stage --

IIIIIIMethod of Method of startingstarting

24 V DC24 V DC 24 V DC24 V DC 24 V DC24 V DC

Time required Time required for starting from for starting from coldcold

30 sec30 sec 30 sec30 sec 30 sec30 sec

Interval between Interval between starting impulsestarting impulse

10 sec10 sec 10 sec10 sec 10 sec10 sec

No. of starting No. of starting impulsesimpulses

33 33

Type of Type of GovernorGovernor

Woodward hydraulic PSG with Woodward hydraulic PSG with motorized headmotorized head

(EFC) Electronic (EFC) Electronic fuel control / A1fuel control / A1

Guaranteed Guaranteed limits of limits of GoverningGoverning

As per class As per class ––A1 Governing limits A1 Governing limits of BS 649/1958 of BS 649/1958 (+/(+/--

4.5%)4.5%)As per class As per class ––A1 A1

of BS 5514of BS 5514Engine Speed Engine Speed

within within ±±1% for 1% for any steady state any steady state

load from no load from no load to full loadload to full load

Full load thrown Full load thrown offoff

--

Do Do --

Full load put on Full load put on --

Do Do --

SpecificationSpecification Stage Stage --

II Stage Stage --

IIII Stage Stage --

IIIIIIGuaranteed fuel Guaranteed fuel consumptionconsumptionAt full loadAt full load

158 lit / hr 158 lit / hr (150 (150 grgr

/BHP/hr)/BHP/hr)(150 * 890 / 1000 * 0.84 = 158 lit/hr)(150 * 890 / 1000 * 0.84 = 158 lit/hr)

(0.84 = Sp. Gravity of diesel)(0.84 = Sp. Gravity of diesel)

310 lit / hr310 lit / hr

Lubrication oil Lubrication oil consumptionconsumption

0.534 lit / hr0.534 lit / hr 0.35 lit / hr0.35 lit / hr

Method of Method of aspirationaspiration

Turbo charged after cooledTurbo charged after cooled

Method of Method of cooling of enginecooling of engine

Radiator cooled EngineRadiator cooled Engine

Method of Method of cooling of cooling of lubricating oillubricating oil

Water cooledWater cooled

Air filter cum Air filter cum silencersilencer

Dry type with replaceable paper elementDry type with replaceable paper element

Diesel storage Diesel storage tank capacitytank capacity

990 liters990 liters

Turbo charged after cooledTurbo charged after cooled

606000

--

‘‘VeeVee’’

EngineEngineAA

’’VV’’

oror

’’VeeVee’’

engineengine

is a commonis a common

configurationconfiguration

for for

anan

internal combustion engineinternal combustion engine..

TheThe

cylinderscylinders

andand

pistonspistons

are aligned, in two are aligned, in two separate planes or 'banks', so that they appear to be separate planes or 'banks', so that they appear to be in ain a

"V""V"

when viewed along the axis of when viewed along the axis of

thethe

crankshaftcrankshaft..

The The ‘‘VeeVee’’

configuration generally reduces the configuration generally reduces the overall engine length, height and weight compared overall engine length, height and weight compared to an equivalentto an equivalent

inlineinline

configuration.configuration.

The most efficient cylinder bank angle for a The most efficient cylinder bank angle for a ‘‘VV’’ engine is 60engine is 6000, for minimizing size and vibration., for minimizing size and vibration.

http://en.wikipedia.org/wiki/Engine_configuration

What is Turbo Charged after cooledWhat is Turbo Charged after cooledThe purpose of a turbochargerThe purpose of a turbocharger

is to compress the air is to compress the air

flowing into the diesel engine,flowing into the diesel engine,

this lets the engine squeeze this lets the engine squeeze more air into a cylinder and more air means that more fuel more air into a cylinder and more air means that more fuel can be added. can be added.

The engine burns air and fuel to create mechanical power, The engine burns air and fuel to create mechanical power, the more air and fuel it can burn the more powerful it is.the more air and fuel it can burn the more powerful it is.

In simple terms, a turbocharger comprises of a turbine and In simple terms, a turbocharger comprises of a turbine and a compressor connected by a common shaft supported on a a compressor connected by a common shaft supported on a bearing system.bearing system.

The turbocharger converts The turbocharger converts waste energywaste energy

from an engine's from an engine's exhaust gases into compressed air, which it pushes into the exhaust gases into compressed air, which it pushes into the engine.engine.

Conti….

This allows the engine to burn more fuel producing This allows the engine to burn more fuel producing more power and improve the more power and improve the overall efficiencyoverall efficiency

of the of the

combustion process.combustion process.An An IntercoolerIntercooler

removes the heat of compression removes the heat of compression

between the stages of a compressor whereas an between the stages of a compressor whereas an after after coolercooler

reduces the temperature of the air leaving the reduces the temperature of the air leaving the

compressor. compressor. Delivering cold air means that there is Delivering cold air means that there is more oxygenmore oxygen

per cylinder thus more engine power.per cylinder thus more engine power.

1)1)

Engine:Engine:

The engine is the source of the The engine is the source of the input mechanical energy to the input mechanical energy to the generator.generator.

The size of the engine is The size of the engine is directly proportional to the directly proportional to the maximum power output of the maximum power output of the generator can supply.generator can supply.

There are several factors that There are several factors that you need to keep in mind you need to keep in mind while assessing the engine of while assessing the engine of your generator.your generator.

DG Set DG Set ––

Function of partsFunction of parts

Conti….

The fuel tank usually has sufficient capacity to keep The fuel tank usually has sufficient capacity to keep the generator operational for the generator operational for 6 to 8 hours6 to 8 hours..

Pipe connection from fuel tank to engine:Pipe connection from fuel tank to engine:––

The supply The supply line directs fuel from the tank to the engine and the line directs fuel from the tank to the engine and the return line directs fuel from the engine to the tank.return line directs fuel from the engine to the tank.

Ventilation pipe for fuel tank:Ventilation pipe for fuel tank:––

The fuel tank has a The fuel tank has a ventilation pipe to prevent the buildventilation pipe to prevent the build--up of pressure or up of pressure or vacuum during refilling and drainage of the tank.vacuum during refilling and drainage of the tank.

Fuel Water Separator / Fuel Filter:Fuel Water Separator / Fuel Filter:––

This separates This separates water and foreign matter from the liquid fuel to water and foreign matter from the liquid fuel to protect other components of the engine from corrosion protect other components of the engine from corrosion and contamination.and contamination.


Fuel systemFuel system

Conti….

Fuel Injector:Fuel Injector:––

This atomizes the liquid fuel and This atomizes the liquid fuel and sprays the required amount of fuel into the sprays the required amount of fuel into the combustion chamber of the engine.combustion chamber of the engine.

Fuel return lines take the hot excess fuel not used Fuel return lines take the hot excess fuel not used in the engine cycle a way from the injectors and in the engine cycle a way from the injectors and back to fuel storage tank. The heat from the excess back to fuel storage tank. The heat from the excess fuel is dissipated in the tank.fuel is dissipated in the tank.

Caution:Caution:

Never run a fuel return line directly back Never run a fuel return line directly back to the engine fuel supply lines. The fuel will to the engine fuel supply lines. The fuel will overheat and break down.overheat and break down.

The fuel return lines should always enter the The fuel return lines should always enter the storage tank above the highest fuel level.storage tank above the highest fuel level.

DIESEL TANK (Stage DIESEL TANK (Stage ––

I)I) DIESEL FILTERSDIESEL FILTERS

PT (Pressure PT (Pressure ––

Time), self adjusting direct injection Time), self adjusting direct injection type fuel pump is provided for fuel supply.type fuel pump is provided for fuel supply.

Clean fuel filter Clean fuel filter ––

100 mmHg, Choked fuel filter 100 mmHg, Choked fuel filter –– 203 mmHg203 mmHg..

Oil InjectorOil Injector PT Fuel pumpPT Fuel pump

BowlBowl

Drain valveDrain valve

FloatFloatBall checkBall check

Oil InjectionOil Injection

Combustion Air Intake systemCombustion Air Intake systemAir for engine combustion must be clean.Air for engine combustion must be clean.

Normally this air can be drawn from the area surrounding Normally this air can be drawn from the area surrounding the generating set via the engine mounted air filter.the generating set via the engine mounted air filter.

Clean filter = 250 Clean filter = 250 mmwclmmwcl,,

Choked filter = 500 Choked filter = 500 mmwclmmwcl

Dry type replaceable paper element air cleaner with Dry type replaceable paper element air cleaner with Restriction IndicatorRestriction Indicator

Mechanical Governors:Mechanical Governors:––

AAs the name suggests, s the name suggests, controls engine fueling based on mechanical controls engine fueling based on mechanical sensing of engine RPM through flyweights or sensing of engine RPM through flyweights or similar mechanisms.similar mechanisms.

These systems exhibit about These systems exhibit about 33--5% speed droop5% speed droop from no load to full load inherent in the design.from no load to full load inherent in the design.

This type of system is generally the least This type of system is generally the least expensive and is suitable for applications where expensive and is suitable for applications where the frequency droop is not a problem for the loads the frequency droop is not a problem for the loads being served.being served.


GovernorGovernor

Conti….

The Woodward PSG governor is a The Woodward PSG governor is a speed droop governor for controlling speed droop governor for controlling speed of small diesel, gas, and speed of small diesel, gas, and gasoline engines, or small steam or gasoline engines, or small steam or industrial gas turbines.industrial gas turbines.

The governor is used to control The governor is used to control engines or turbines driving engines or turbines driving alternators, DC generators, pumps, or alternators, DC generators, pumps, or compressors.compressors.

Pressure compensation provides the Pressure compensation provides the PSG governor with the necessary PSG governor with the necessary stability to control isochronously.stability to control isochronously.


Woodward PSG GovernorWoodward PSG Governor

Conti….

Electronic Governors :Electronic Governors :––

Electronic governors are used for Electronic governors are used for applications where isochronous (zero droop) governing is applications where isochronous (zero droop) governing is required or where active synchronizing and paralleling required or where active synchronizing and paralleling equipment is specified.equipment is specified.

EFC Governor is used on PT fuel system. The governor EFC Governor is used on PT fuel system. The governor contains a magnetic pick up, actuator mounted in housing.contains a magnetic pick up, actuator mounted in housing.

The magnetic pick up senses the engine speed at the The magnetic pick up senses the engine speed at the flywheel ring gear and generates an AC voltage with its flywheel ring gear and generates an AC voltage with its frequency proportional to the engine speed. frequency proportional to the engine speed.

Signal from magnetic pick up is sensed by a governor Signal from magnetic pick up is sensed by a governor controller and is used as a speed feed back.controller and is used as a speed feed back.

The actuator mounted in the housing is used to control the The actuator mounted in the housing is used to control the fuel flow from the fuel pump to the injectors.fuel flow from the fuel pump to the injectors.


GovernorGovernor

Conti….

Actuator valve is normally closed. It opens depending on Actuator valve is normally closed. It opens depending on the amount of current through the actuator.the amount of current through the actuator.

The governor controller compares the electrical signal from The governor controller compares the electrical signal from the magnetic pickup with a preset speed reference point.the magnetic pickup with a preset speed reference point.

If there is a difference in the two signals, the controller If there is a difference in the two signals, the controller will change the current to the actuator.will change the current to the actuator.

This advanced governing system can be retrofitted engines This advanced governing system can be retrofitted engines with hydraulic governors.with hydraulic governors.

A change in current in the actuator coil will make the A change in current in the actuator coil will make the actuator shaft rotate. The fuel flow and the engine speed or actuator shaft rotate. The fuel flow and the engine speed or power will change, when the actuator shaft rotates.power will change, when the actuator shaft rotates.


EFC GovernorEFC Governor

Features:Features:--

Accurate speed sensing & PID control achieves steady state Accurate speed sensing & PID control achieves steady state speed stability of +/speed stability of +/--0.25 % at any constant load.0.25 % at any constant load.A1 class governing with transient response of 15 A1 class governing with transient response of 15 msecmsec..Both isochronous & droop governing are possible.Both isochronous & droop governing are possible.Solid state potentiometer is available for faster synchronizing Solid state potentiometer is available for faster synchronizing & load sharing functions.& load sharing functions.

Governing oilGoverning oilDip stickDip stick

Cable fromCable fromOver speed pickupOver speed pickup

Over speedOver speedsolenoidsolenoid

Fuel lineFuel line

Fuel Return lineFuel Return line


GovernorGovernor

PT type fuel PT type fuel pumppump

Woodward PSGWoodward PSGGovernorGovernor

Continuous usage of the generator causes its Continuous usage of the generator causes its various components to get heated up. It is various components to get heated up. It is essential to have a cooling and ventilation system essential to have a cooling and ventilation system to withdraw heat produced in the process.to withdraw heat produced in the process.

LiquidLiquid--cooled engines are cooled by pumping a cooled engines are cooled by pumping a coolant mixture through passages in the engine coolant mixture through passages in the engine cylinder block and head(s) by means of an enginecylinder block and head(s) by means of an engine--

driven pump.driven pump.

The Generator set configuration has a mountedThe Generator set configuration has a mounted radiator and an engineradiator and an engine--driven fandriven fan

to cool the to cool the

coolant and ventilate the generator room.coolant and ventilate the generator room.


Cooling systemCooling system

Conti….

Water for coolant should be clean and free from Water for coolant should be clean and free from any corrosive chemicals such as chlorides, any corrosive chemicals such as chlorides, sulphates and acids. It should be kept slightly sulphates and acids. It should be kept slightly alkaline with a pH value in the range alkaline with a pH value in the range 8.5 to 10.5.8.5 to 10.5.

Mixtures of either Mixtures of either ethylene ethylene --

or propyleneor propylene--glycolglycol and highand high--quality water shall be used for proper quality water shall be used for proper

cooling and freeze / boil protection.cooling and freeze / boil protection.

Coolant should be replaced after 6000 hrs of Coolant should be replaced after 6000 hrs of operation or after Two years.operation or after Two years.

Conti….

CoolantCoolantLevel InspectionLevel Inspection

CapCap

Stand by Generator sets may be required to start Stand by Generator sets may be required to start and come in service in 10 sec or lessand come in service in 10 sec or less..

These engines are equipped with engine coolant These engines are equipped with engine coolant heaters capable of maintaining coolant heaters capable of maintaining coolant temperature at a temperature at a minimum of 38minimum of 3800C.C.

Grill type of ventilation Grill type of ventilation is provided for proper is provided for proper

exhaustexhaust

Exhaust fumes emitted by a generator are just like Exhaust fumes emitted by a generator are just like exhaust from any other diesel or gasoline engine exhaust from any other diesel or gasoline engine and contain highly toxic chemicals that need to be and contain highly toxic chemicals that need to be properly managed.properly managed.

Exhaust pipes are usually attached to the engine Exhaust pipes are usually attached to the engine usingusing

flexible connectors to minimize vibrationsflexible connectors to minimize vibrations

and prevent damage to the generatorand prevent damage to the generator’’s exhaust s exhaust system.system.

An outdoor weather protective housing supplied An outdoor weather protective housing supplied by a generator set manufacturer usually will have by a generator set manufacturer usually will have variousvarious

““mufflermuffler””

options and usually with the options and usually with the

muffler mounted on the roof.muffler mounted on the roof.


Exhaust systemExhaust system

Typical exhaust systemTypical exhaust system

The lubricating oil used in a engine must be The lubricating oil used in a engine must be multifunctional. It will perform the following.multifunctional. It will perform the following.

Lubrication by providing a film between the Lubrication by providing a film between the moving parts to reduce wear and friction.moving parts to reduce wear and friction.

Cooling by serving as a heat transfer media to Cooling by serving as a heat transfer media to carry heat away from critical areas.carry heat away from critical areas.

Sealing by filling in the uneven surfaces in the Sealing by filling in the uneven surfaces in the cylinder wall, valve stems and turbo charger oil cylinder wall, valve stems and turbo charger oil seals.seals.


Lubrication systemLubrication system

Conti….

Cleaning by holding contaminants in suspension to Cleaning by holding contaminants in suspension to prevent a build up of deposits on the engine surfaces.prevent a build up of deposits on the engine surfaces.

Dampening and cushioning of components that Dampening and cushioning of components that operate under high stress, such as gears and push operate under high stress, such as gears and push tubestubes

Protection from oxidation and corrosion.Protection from oxidation and corrosion.

Lube Oil FiltersLube Oil Filters Lube Oil By pass FiltersLube Oil By pass Filters

Large capacity gear pump provides pressure Large capacity gear pump provides pressure lubrication to all bearing and oil supply for piston lubrication to all bearing and oil supply for piston cooling.cooling.

All pressure lines are internal drilled passages in All pressure lines are internal drilled passages in cylinder block and heads.cylinder block and heads.

Oil cooler, full flow filters and by pass filters Oil cooler, full flow filters and by pass filters maintain oil quality.maintain oil quality.

Priming PumpPriming Pump

Lube oil SumpLube oil Sump

Lube oil levelLube oil levelChecking dip stickChecking dip stick

Priming PumpPriming PumpDischargeDischarge



Starter Motor:Starter Motor:--

The starter motor is a necessity for internalThe starter motor is a necessity for internal--combustion combustion engines, because theengines, because the

Otto cycle requiresOtto cycle requires

the pistons already the pistons already

to be in motion before the ignition phase of the cycle.to be in motion before the ignition phase of the cycle.

This means that the engine must be started in motion by an This means that the engine must be started in motion by an outside force, before it can power itself.outside force, before it can power itself.

The The batterybattery

is used for the starter motor.is used for the starter motor.

If you remove the battery while the engine is running, the If you remove the battery while the engine is running, the engine continues to run.engine continues to run.

Once the diesel engine is started it will run until you stop Once the diesel engine is started it will run until you stop the fuel flow or block off the air intake.the fuel flow or block off the air intake.


Battery and ChargerBattery and Charger

Battery starting systems for generator sets are Battery starting systems for generator sets are usually usually 24 volts24 volts..

Batteries must have enough capacityBatteries must have enough capacity

(CCA, Cold (CCA, Cold Cranking Amps)Cranking Amps)

to provide the cranking motor to provide the cranking motor

current.current.


Battery and ChargerBattery and Charger

24V Battery

The starter motor converts electrical energy to mechanical The starter motor converts electrical energy to mechanical energy.energy.It is mounted on the cylinder block in a position to engage a It is mounted on the cylinder block in a position to engage a ring gear on the engine flywheel.ring gear on the engine flywheel.The starter motor is powered by the battery. It is designed to The starter motor is powered by the battery. It is designed to have high turning effort at low speeds.have high turning effort at low speeds.During engine cranking excessive current draw will lead to During engine cranking excessive current draw will lead to the cables becoming hot and a drop in battery voltage.the cables becoming hot and a drop in battery voltage.

Staring Motor (24V, 11 KW)Staring Motor (24V, 11 KW)

Battery sizing requirementsBattery sizing requirements

Engine Manufacturer & Engine Manufacturer & Model.Model.

Cubic Inch displacement Cubic Inch displacement of Engine.of Engine.

Battery System Voltage.Battery System Voltage.

Min Battery electrolyte Min Battery electrolyte temperature.temperature.

Number of 10 second Number of 10 second cranking cycles.cranking cycles.

The following information is required for sizing of the batteryThe following information is required for sizing of the battery

Fly wheelFly wheelThe The flywheelflywheel

is located on one end of the crankshaft is located on one end of the crankshaft

and serves and serves threethree

purposes.purposes.

First,First,

through its inertia, it reduces vibrations by through its inertia, it reduces vibrations by smoothing out the power stroke as each cylinder smoothing out the power stroke as each cylinder fires.fires.

••

Second,Second,

it is the mounting surface it is the mounting surface used to bolt the engine up to its used to bolt the engine up to its load.load.

••

Third,Third,

on some diesels, the fly on some diesels, the fly wheel has gear teeth around its wheel has gear teeth around its perimeter that allow the starting perimeter that allow the starting motors to engage and crank the motors to engage and crank the diesel.diesel.

A turbocharger makes use of A turbocharger makes use of rejected heat by compressing rejected heat by compressing the intake air forced into the the intake air forced into the engine cylinders, thereby engine cylinders, thereby increasing the thermal increasing the thermal efficiency of the engine.efficiency of the engine.

The potential energy of the The potential energy of the fuel (100%) is released in a fuel (100%) is released in a typical diesel engine:typical diesel engine:

33%33%

is converted into useful is converted into useful mechanical energy delivered mechanical energy delivered to the fly wheel.to the fly wheel.

The rejected heat is The rejected heat is dispersed as radiated heat dispersed as radiated heat (7%) to engine coolant (30%), (7%) to engine coolant (30%), and into the exhaust (30%).and into the exhaust (30%).

How the potential energy of diesel How the potential energy of diesel fuel is released in a diesel engine.fuel is released in a diesel engine.

ALTERNATORALTERNATORMakeMake JyothiJyothi

LtdLtd NGEF LtdNGEF Ltd StomfordStomford. UK. UKModelModel ---- ------ PI734C2PI734C2

Rated KVARated KVA 625 KVA625 KVA 750 KVA750 KVA 1500 KVA1500 KVARated Terminal Rated Terminal

voltagevoltage415 V415 V

Rated over load Rated over load capacitycapacity

110% for 1 Hr. in every 12 Hrs110% for 1 Hr. in every 12 Hrs

Excitation Power Excitation Power ratingrating

38V, 169A38V, 169A 2.6A, 57VDC2.6A, 57VDC 10.3 KVA10.3 KVA

Type of exciterType of exciter With brushes With brushes and slip ringsand slip rings

BrushlessBrushless BrushlessBrushless

Type of voltage Type of voltage regulatorregulator

Manual voltage Manual voltage regulatorregulator

AutomaticAutomatic AutomaticAutomatic

Conti….

P=Power Generation,P=Power Generation,

I= Industrial, I= Industrial, 7= Frame size,7= Frame size,

3= Excitation system3= Excitation system(series(series--3), 3), 4 = No. of poles,4 = No. of poles,

C= Core length, C= Core length, 2 = No. of Bearings 2 = No. of Bearings

Alternator is Alternator is salient pole typesalient pole type, self excited and self , self excited and self regulated by an excitation unit.regulated by an excitation unit.

The excitation unit consists of choke, CT, Diodes The excitation unit consists of choke, CT, Diodes and Condenser.and Condenser.

Voltage is adjustable to within +/Voltage is adjustable to within +/--2.5% of the 2.5% of the nominal voltage from no load to full load at rated nominal voltage from no load to full load at rated PF.PF.

The choke is meant for adjusting the The choke is meant for adjusting the teriminalteriminal voltage at no load.voltage at no load.

The CT is meant for adjusting the terminal voltage The CT is meant for adjusting the terminal voltage at load conditions.at load conditions.


Alternator Alternator (Stage (Stage ––I)I)

Conti….

The Alternator is self excited due to residual flux.The Alternator is self excited due to residual flux.

Once the alternator is run to rated speed at no load Once the alternator is run to rated speed at no load the residual voltage appearing the terminals, is the residual voltage appearing the terminals, is getting rectified by a 3getting rectified by a 3--

FW bridge rectifier and is FW bridge rectifier and is

fed to the field winding through brushes and slip fed to the field winding through brushes and slip rings.rings.

Thus the alternator builds up voltage by itself and Thus the alternator builds up voltage by itself and reaches a steady value depending on the choke air reaches a steady value depending on the choke air gap.gap.

With the help of MVR, the voltage can be adjusted With the help of MVR, the voltage can be adjusted when the machine is running with or without when the machine is running with or without load.load.


AlternatorAlternator

Conti….

The advantage of a selfThe advantage of a self--excited system:excited system:

SelfSelf--excited system is inherently self protecting under excited system is inherently self protecting under symmetrical short circuit conditions because the field symmetrical short circuit conditions because the field ““collapses". collapses".

Because of this, a main line circuit breaker for protecting Because of this, a main line circuit breaker for protecting the generator and the conductors to the first level of the generator and the conductors to the first level of distribution may not be considered necessary, further distribution may not be considered necessary, further reducing the installed cost of the system.reducing the installed cost of the system.

The disadvantages of a self excited system are:The disadvantages of a self excited system are:

••

It might be necessary to select a larger generator in order It might be necessary to select a larger generator in order to provide acceptable motor starting performance.to provide acceptable motor starting performance.

••

SelfSelf--excited machines rely on residual magnetism to excited machines rely on residual magnetism to energize the field. If residual magnetism is not sufficient, energize the field. If residual magnetism is not sufficient, it will be necessary to it will be necessary to ““flash" the field with a DC power flash" the field with a DC power source.source.

Self Excited GeneratorSelf Excited Generator

Conti….

Alternator (Stage Alternator (Stage ––

II & III)II & III)

••

They are They are ““Separately excitedSeparately excited””

by the Permanent by the Permanent Magnet Generator (PMG).Magnet Generator (PMG).

••

This is a shaft mounted, high frequency, pilot exciter This is a shaft mounted, high frequency, pilot exciter which provides a constant supply of clean power via which provides a constant supply of clean power via the Automatic Voltage Regulator (AVR) to the main the Automatic Voltage Regulator (AVR) to the main exciter.exciter.

••

The main exciter output is fed to the main rotor, The main exciter output is fed to the main rotor, through a full wave bridge rectifier, protected by through a full wave bridge rectifier, protected by surge suppression.surge suppression.

Conti….

The excitation system of a separately The excitation system of a separately --

excited excited generator is similar to that of a self generator is similar to that of a self --

excited excited

generator except that a separate permanent magnet generator except that a separate permanent magnet generator (PMG) located.generator (PMG) located.

Is a separate source of power, the excitation circuit Is a separate source of power, the excitation circuit is not affected by the loads on the generator. The is not affected by the loads on the generator. The generator is capable of sustaining generator is capable of sustaining two to three timestwo to three times

rated current for approximately ten seconds. rated current for approximately ten seconds.

For these reasons, separately For these reasons, separately --

excited generator excited generator excitation systems excitation systems are recommendedare recommended

for for

applications where enhanced motor starting applications where enhanced motor starting capability, good performance with noncapability, good performance with non--linear loads linear loads or extended duration short circuit performance are or extended duration short circuit performance are necessary.necessary.

Separately Excited GeneratorsSeparately Excited Generators

Conti….


AMF (Automatic Mains AMF (Automatic Mains Fail) panelFail) panel

This is the user interface of the This is the user interface of the generator and contains provisions generator and contains provisions forfor

a)a)

Electric start and shutElectric start and shut--down.down.b)b)

Engine gauges.Engine gauges.

c)c)

Generator gauges.Generator gauges.d)d)

Other controlsOther controls––Phase selector Phase selector switch, frequency switch, and switch, frequency switch, and engine control switch (manual engine control switch (manual mode, auto mode) among others.mode, auto mode) among others.

Ensure Engine oil, Governing oil and Coolant levels are normal.Ensure Engine oil, Governing oil and Coolant levels are normal.

Check for fuel oil, engine oil, coolant and exhaust for any Check for fuel oil, engine oil, coolant and exhaust for any leakages.leakages.

Lube oil priming to be done if engine is idle for long time or aLube oil priming to be done if engine is idle for long time or after fter filter or oil replacement.filter or oil replacement.

After DG set is started, check for exhaust. A smoky exhaust may After DG set is started, check for exhaust. A smoky exhaust may be due to poor grade of oil, dirty air cleaner, over fueling or be due to poor grade of oil, dirty air cleaner, over fueling or poor poor mechanical conditions.mechanical conditions.

Visually check for belts looseness.Visually check for belts looseness.

Check for battery and battery charger for any abnormality.Check for battery and battery charger for any abnormality.

Check the air filter gauge for proper air intake.Check the air filter gauge for proper air intake.


Routine checksRoutine checks

Conti….

No Electrical fault is persisting.No Electrical fault is persisting.Engine oil Temperature is not high.Engine oil Temperature is not high.No over speed relay is dropped. No over speed relay is dropped. Lube oil pressure is adequate.Lube oil pressure is adequate.EPB is in released condition.EPB is in released condition.Fail to start is not persisting.Fail to start is not persisting.Alternator breaker is in OFF condition.Alternator breaker is in OFF condition.


Start PermissivesStart Permissives

Lube oil pressure low Lube oil pressure low ((< 1Ksc)< 1Ksc)..Engine over speed Engine over speed (1650 rpm for 10 sec).(1650 rpm for 10 sec).Coolant temperature is high Coolant temperature is high ((> 95> 9500C)C)..Low coolant level Low coolant level (Level below sensor).(Level below sensor).Electrical fault.Electrical fault.Lack of fuel.Lack of fuel.From Emergency Push button.From Emergency Push button.


Causes for TripCauses for Trip


––

DoDo’’s & s & DonDon’’tsts

It is important to idle the engineIt is important to idle the engine

““33--5 minutes5 minutes”” before shutting it down to allow the lubricating before shutting it down to allow the lubricating

oil and water to carry heat away from the oil and water to carry heat away from the combustion chamber, bearings, shaft etc., This is combustion chamber, bearings, shaft etc., This is especially important forespecially important for

Turbo charger enginesTurbo charger engines..

Long periods ofLong periods of

idling are not goodidling are not good

for an engine for an engine because the combustion chamber temperatures because the combustion chamber temperatures drops to low and fuel will not burn completely. drops to low and fuel will not burn completely. This willThis will

cause carbon to clogcause carbon to clog

the injector spray the injector spray

holes and piston rings and can result in stuck holes and piston rings and can result in stuck valves.valves.

All diesel engines have a priming pump, to allow All diesel engines have a priming pump, to allow for removing air from the fuel system. This is for removing air from the fuel system. This is called bleeding, or priming.called bleeding, or priming.

Air can enter the system during filter replacement, Air can enter the system during filter replacement, or when a fuel line is disconnected.or when a fuel line is disconnected.

Without a priming facility, the start motor would Without a priming facility, the start motor would have to crank the engine over, to bleed and prime have to crank the engine over, to bleed and prime the system.the system.

Excessive use of the starter motorExcessive use of the starter motor

for for

this purpose would damage it, and it would soon this purpose would damage it, and it would soon discharge the battery.discharge the battery.


Priming PumpPriming Pump

Conti….

CrankingCranking

To prevent permanent cranking motor damage, do To prevent permanent cranking motor damage, do not crank engine for more thannot crank engine for more than

10 sec 10 sec

continuously.continuously.

If the engine does not start after aboutIf the engine does not start after about

three three repeated attempts,repeated attempts,

then the starter should not be then the starter should not be

operated and the fuel system has to be checked operated and the fuel system has to be checked for any faults.for any faults.

Engine oil pressure must be indicated on the Engine oil pressure must be indicated on the gaugegauge

within 15 sec after starting.within 15 sec after starting.

If oil pressure If oil pressure

is not registered within 15 sec, shut off the engine is not registered within 15 sec, shut off the engine immediately to avoid immediately to avoid engine damage.engine damage.

Oil / Coolant TemperaturesOil / Coolant TemperaturesThe oil Temperature should be maintained The oil Temperature should be maintained betweenbetween

75 75 ––

10510500CC

under loading conditions.under loading conditions.

Any sudden increase in oil temperature, is a Any sudden increase in oil temperature, is a warning of mechanical failure. Immediatelywarning of mechanical failure. Immediately

Shut Shut

off the engineoff the engine

to avoid engine damage.to avoid engine damage.

The coolant temperature ofThe coolant temperature of

75 to 9575 to 9500CC

is the best is the best assurance that working parts of the engine the assurance that working parts of the engine the expanded evenly to the most favorable oil expanded evenly to the most favorable oil clearances. clearances.

Note:Note:--

Continuous operation with low coolant temperature below Continuous operation with low coolant temperature below 60 60 00C,C,or high coolant Temperature above or high coolant Temperature above 10010000CC, can damage the engine., can damage the engine.

Normal engine oil pressure at Normal engine oil pressure at (105(10500C) should be betweenC) should be between

33--7 7

Kg/cmKg/cm22

at rated speed andat rated speed and

11--2 2

Kg/cmKg/cm22

at low idle speed.at low idle speed.

A dipstick oil gauge is located A dipstick oil gauge is located on the side of the engine. The on the side of the engine. The dip stick has andip stick has an

““HH””

(High) (High)

and and ‘‘LL’’

(Low)(Low)

level mark to level mark to indicate lubricating oil supply.indicate lubricating oil supply.

The dip stick must be kept The dip stick must be kept with the oil pan or engine.with the oil pan or engine.

••

After DG starts, ensure the following parameters are within After DG starts, ensure the following parameters are within the limit the limit

Coolant Coolant TemperatureTemperature

Between Between 70 to 9570 to 9500CC

Engine oil Engine oil pressurepressureBetween Between 3 to 7 3 to 7 KscKsc

Engine oil Engine oil TemperatureTemperature

Between Between 75 to 10575 to 10500CC

Engine RPMEngine RPMShould be Should be

At 1500At 1500

Stage Stage --IIIIII

The generatorThe generator’’s engine is lubricated by oil stored s engine is lubricated by oil stored in a sump (Approx. 200 liters).in a sump (Approx. 200 liters).

Ensure the level of lubricating oil every 8 hours of Ensure the level of lubricating oil every 8 hours of generator operation.generator operation.

Also check for any leakages of lubricant and Also check for any leakages of lubricant and change the lubricating oil every 500 hours of change the lubricating oil every 500 hours of generator operation.generator operation.

Oil change periods, filter change periods, paying Oil change periods, filter change periods, paying attention about selecting the true type of oil attention about selecting the true type of oil prolongs the prolongs the life cost of the engine.life cost of the engine.



Probable reasons for Generators Fail to StartProbable reasons for Generators Fail to Start

Battery failure.Battery failure.Battery charger failure.Battery charger failure.Low coolant levels.Low coolant levels.Oil, fuel or coolant leaks.Oil, fuel or coolant leaks.Controls not in auto.Controls not in auto.Air in the fuel system.Air in the fuel system.Run out of fuel.Run out of fuel.Restriction in air supply.Restriction in air supply.Restriction in fuel supply.Restriction in fuel supply.Starter motor failure.Starter motor failure.

The starter motor turns the engine too slowly:The starter motor turns the engine too slowly:

Battery capacity to low.Battery capacity to low.

Bad electrical connection.Bad electrical connection.Faulty in starter motor.Faulty in starter motor.

Wrong grade of lubricating oil.Wrong grade of lubricating oil.

The engine does not start or difficult to start:The engine does not start or difficult to start:

Starter motor turns engine too slowly.Starter motor turns engine too slowly.

Fuel tank empty.Fuel tank empty.Faulty in fuel control solenoid.Faulty in fuel control solenoid.

Restriction in a fuel pipe.Restriction in a fuel pipe.

Faulty in fuel lift pump.Faulty in fuel lift pump.

Dirty fuel filter element.Dirty fuel filter element.Air in fuel system.Air in fuel system.

Faulty in atomizers.Faulty in atomizers.

Cold start systems used incorrectly.Cold start systems used incorrectly.

Fault in cold start systemFault in cold start systemRestriction in fuel tank vent.Restriction in fuel tank vent.

Restriction in Restriction in exhexh. pipe.. pipe.

Wrong type or grade of fuel used.Wrong type or grade of fuel used.

Engine Trouble shootingEngine Trouble shooting

Conti….

The engine temperature is too high:The engine temperature is too high:

Restriction air filter/cleaner or induction system.Restriction air filter/cleaner or induction system.Fault in atomizers or atomizers of an incorrect type.Fault in atomizers or atomizers of an incorrect type.Fault in cold start system.Fault in cold start system.Restriction in exhaust pipe.Restriction in exhaust pipe.Fan damaged.Fan damaged.Restriction in air or water passage of radiator.Restriction in air or water passage of radiator.Insufficient coolant system.Insufficient coolant system.

The pressure of the lubrication oil is too low:The pressure of the lubrication oil is too low:

Wrong grade of lubrication.Wrong grade of lubrication.Not enough lubrication oil in sump.Not enough lubrication oil in sump.Defective gauge.Defective gauge.Dirty lubrication oil filter element.Dirty lubrication oil filter element.

StarterC

ontactor

Impulse

Timer

Impulse

Timer

Summ

ationTim

erLube oilPr. Low

BKR

Contacts

Multiplication

Fuel solenoidEnergisation

-24VDC Controlsupply

+24VDC Controlsupply

To fuelsolenoid

Electricalfault

Low level

Of oil in tank

High W

aterTem

perature

Over speed

Lack of fuel

DG

set failedTo start

Reset circuit

Stop circuit

Engine stopO

n fault

To EngineStarter

I/C fromI/C fromUnit Aux SWGR Unit Aux SWGR --

1A1AI/C fromI/C from

415V DG Switchgear415V DG Switchgear

Unit Unit ––

1 1 --

415V Emergency MCC415V Emergency MCC




Unit Unit ––

2 2 --





Unit Unit ––

3 3 --


I/C fromI/C from415V DG Switchgear415V DG Switchgear

415 V SWYD SER SWGR415 V SWYD SER SWGR

SWYDSWYDSER SER

TxfmrTxfmr--11

SWYDSWYDSER SER

TxfmrTxfmr--22

SEC SEC --

AA SEC SEC --

BBB/CB/C

DGDG--

11 DGDG--

22

625 KVA625 KVA

415V DG Bus415V DG Bus

Stage Stage ––

I Units I Units ––Diesel Generator supplyDiesel Generator supply

Stage Stage ––

I I --

AMF PanelAMF Panel

Governor Governor ––

Local / Off / RemoteLocal / Off / Remote

Gov speed Gov speed ––

Lower / Off / RiseLower / Off / Rise

Engine Engine ––

Local / Off / RemoteLocal / Off / Remote

Engine Engine ––

Out / Off / InOut / Off / In

24VDC 24VDC ––

ON / Off ON / Off

AC I/P Change over SwitchAC I/P Change over Switch

Battery Charger Battery Charger --

DCDC

Engine Emergency OffEngine Emergency Off

Eng three attempts circuit resetEng three attempts circuit reset

DG ACB Emergency offDG ACB Emergency off

Man Man VolVol

RegulatorRegulator

Over current, EarthOver current, EarthFault, over load,Fault, over load,Restriction E/F,Restriction E/F,

Over voltage, and Over voltage, and Reverse power relaysReverse power relays

DG ACB ClosedDG ACB ClosedEngine out off serviceEngine out off service

Mechanical faultMechanical faultElectrical faultElectrical fault

Window AnnunciationsWindow Annunciations1)1)

Low oil pressureLow oil pressure2)2)

Gen set fail to startGen set fail to start3)3)

Engine over speedEngine over speed4)4)

Oil level lowOil level low5)5)

Over loadOver load6)6)

Over voltageOver voltage

Battery charger AC ONBattery charger AC ON

Engine manual start PBEngine manual start PB

Fault circuit reset PBFault circuit reset PB

Lamp test PBLamp test PB

UST # AUST # A UST # BUST # B

TO TO TVDCTVDC

UNIT DIESEL UNIT DIESEL GENERATORGENERATOR

750 KVA750 KVA

From UAT # AFrom UAT # A From UAT # BFrom UAT # B

Stage Stage ––

II Units II Units ––

Diesel Generator SupplyDiesel Generator Supply

EMCCEMCC

I/C FROMI/C FROMSTAND BY STAND BY DG MCCDG MCC

USS SEC # AUSS SEC # A USS SEC # BUSS SEC # B

6.6KV/415V6.6KV/415V1750KVA1750KVA

B / CB / C

STAND BY DGSTAND BY DG1500 KVA 1500 KVA

ODGODG

U # 5U # 5 U # 6U # 6 U # 7U # 7U # 4U # 4

TO TO BVDCBVDC

UST # AUST # A UST # BUST # B

TO TO TVDDCTVDDC

UNIT DIESEL UNIT DIESEL GENERATORGENERATOR

1500 KVA1500 KVA

From Unit Bus From Unit Bus ––

7CA7CA From Unit Bus From Unit Bus ––

7CB7CB

Stage Stage ––

III Unit III Unit ––

Diesel Generator SupplyDiesel Generator Supply

EMCCEMCC

I/C FROMI/C FROMSTAND BY DG STAND BY DG

MCCMCC

UNIT SERVICE SWITCHGEAR # 7DAUNIT SERVICE SWITCHGEAR # 7DA

6.6KV/415V6.6KV/415V2MVA2MVA

B / CB / C

STAND BY DGSTAND BY DG1500 KVA 1500 KVA

ODGODG

U # 5U # 5 U # 6U # 6

U # 7U # 7U # 4U # 4

TO TO BVDDCBVDDC

Recommendations of 11th Operation Meet Recommendations of 11th Operation Meet (Held at PMI from 21st to 23(Held at PMI from 21st to 23rdrd Nov 2012)Nov 2012)

4.3.1 DG Set was not available during grid failure:4.3.1 DG Set was not available during grid failure:••

Availability of DG set to be ensured.Availability of DG set to be ensured.

4.3.2 DG Set tripped on temperature high due to cooling system p4.3.2 DG Set tripped on temperature high due to cooling system problem.roblem.••

DG sets to be run for a minimum of 15DG sets to be run for a minimum of 15--20 minutes during daily trial runs. 20 minutes during daily trial runs. ••

Capability of DG Set to run continuously on load to be demonstraCapability of DG Set to run continuously on load to be demonstrated and ted and recorded once in a year. recorded once in a year.

4.3.4 Ventilation of DG set room 4.3.4 Ventilation of DG set room ••

DG Set tripped on temperature high as ventilation was poor.DG Set tripped on temperature high as ventilation was poor.••

Shutter of the DG set room shall be changed to grill type. Shutter of the DG set room shall be changed to grill type. ••

All ventilation fans are to be maintained in healthy condition.All ventilation fans are to be maintained in healthy condition.••

Power supply source for ventilation fans are to be reviewed. PowPower supply source for ventilation fans are to be reviewed. Power supply is to er supply is to be taken from reliable source to take care of total black out cobe taken from reliable source to take care of total black out condition. ndition.

4.3.5 DG Set did not start on auto4.3.5 DG Set did not start on auto••

DG sets are to be started without chargers (only on battery) apaDG sets are to be started without chargers (only on battery) apart from rt from routine testing in the presence of Operation and Electrical mainroutine testing in the presence of Operation and Electrical maintenance tenance representatives. representatives.

••

Protocol is to be maintained for all such trials. Protocol is to be maintained for all such trials. ••

An alarm for "DG chargers failure" to be provided in UCB to avoiAn alarm for "DG chargers failure" to be provided in UCB to avoid d chance of charger remaining switched off. chance of charger remaining switched off.

4.3.6 Access to DG sets in the case of emergency:4.3.6 Access to DG sets in the case of emergency:••

Easy access to DG set room shall be ensured to curtail time takeEasy access to DG set room shall be ensured to curtail time taken to n to restore emergency power in case of any station blackout. restore emergency power in case of any station blackout.

••

Practice of locking DG set rooms to be reviewed. Practice of locking DG set rooms to be reviewed.

4.3.7 DG Set Diesel tank level:4.3.7 DG Set Diesel tank level:••

Adequate diesel level is to be ensured in DG Set fuel tank to meAdequate diesel level is to be ensured in DG Set fuel tank to meet any et any emergency situation.emergency situation.

4.3.8 USS I/C to EMCC breaker status indication was not availabl4.3.8 USS I/C to EMCC breaker status indication was not availablee••

Healthiness of all indications of breaker (On/Off) is to be ensuHealthiness of all indications of breaker (On/Off) is to be ensured (Walk red (Walk down checklist to be prepared).down checklist to be prepared).

4.3.9 Automatic charging of EMCC4.3.9 Automatic charging of EMCC••

In the event of total power failure, EMCC should get energized In the event of total power failure, EMCC should get energized

automatically. Auto changeover of DG breaker to EMCC is to be exautomatically. Auto changeover of DG breaker to EMCC is to be explored plored wherever it is not available. wherever it is not available.

4.3.10 DG Set load tests:4.3.10 DG Set load tests:••

DG Set Load tests to be carried out during overhauls. Such testsDG Set Load tests to be carried out during overhauls. Such tests

are to be are to be well documented and circulated as a controlled document.well documented and circulated as a controlled document.

4.7.3 Diesel fire water pump auto start facility4.7.3 Diesel fire water pump auto start facility••

Auto start (on header pressure low) facility is to be provided fAuto start (on header pressure low) facility is to be provided for diesel or diesel fire water pumps.fire water pumps.

4.3.3 Auto staring of DG sets:4.3.3 Auto staring of DG sets:••

As a part of regular testing, under voltage to be simulated to sAs a part of regular testing, under voltage to be simulated to start DG sets tart DG sets

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DIESEL GENERATOR DETAILS