DIESEL GENERATOR DETAILS

1. M. Murali Mohan
Dy. Suptd (O)

2. Dui line of denis
ENT

3. HISTORY OF DIESEL GENERATOR
* Dieses el actually begins with the invention of

st Otto” had invented and patented

a “Nikolaus

the Gasoline engine by 1876.

4 This invention used the four-stroke combustion principle,
also known as the "Otto Cycle”.

@ In 1878, “Rudolf Diesel” learned about the low efficiency of
gasoline and steam engines.

Hrs: nf.
sturbing inforn
oms

ion Power

a By 1892 “Diesel” had obtained a patent for what we now call
the diesel engine. Conti...

4. & 1892, Rudolf Diesel obtained a patent.
@ 1893, “Diesel” built his first working

@ 1899, Diesel licensed his engine to

builders Krupp and Sulzer, who quickly
became major manufacturers.

> Until 1910, MAN produced 82 copies

SPA > ee ee 2 about | Diesel Engine built
84,420 0 kW. By MAN - AG in 1906

5. Diesel Generator - What is it

LL

+ A Diesel Generator is the c

ine with electric generator

6. Ge

Transportation: Marine & Elevators for fire
Mechanical Sn: Smoke control a

7. process power Laboratories,

luction proce:

: Cooling for computer equipment rooms,
cooling and heating for vulnerable people, ventilation of
hazardous atmospheres, ventilation of pollutants or biological
contamination, etc.

tion: Fire 3 and jockey pumps etc.

ng: UPS and cooling to prevent data loss, memory
loss, eee corruption.
i rt: Hospitals, Nursing homes, and other Health care

8. 3
3
&
=
S
Y

D
© N

9. combustion of fue

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

§

Second ring
Oil (4 stroke)

Piston head
Top land

——— Ring groove
— Second land 09

10. & Bottom dead center (BDC): The lowest point of
piston travel in the engine cylinder.

@ Compression ratio: A measure of the cylinder
volume when the piston is at BDC versus the
cylinder volume when the piston is at TDC.

Compression ratios in diesel engines fall between
14:1 and 24:1.

11. Bore & Stroke

Compression Ratio - 17:1

\<—Bore —»|

.. Crankshaft

—

y

"TM

atTDC

\

Crankshaft
at BDC

Diesel engine
17101

HUIT

12. 2 Str The distance through which a piston travels from
BDC to TDC.

cylinders expressed in Cubic inches or Cubic cm or Liters.

t: Bore X Bore X Stroke X 0.7854 X Number

of cylinders.

Engine di:

6 - cylinder engin

wine a is

12,419,134 cubic mm OR 12.4 liters.

13. = How it works ?

Diesel Engine is mainly works on below strokes.

1) Suction Stroke:-

9 In this stroke, the piston moves down from the
top dead centre. As a result, inlet valve opens and
air is drawn into the cylinder. revers)

intake

14. 2) Compression Stroke:

2 In this stroke, piston moves up from the bottom dead
centre. During this stroke both inlet and exhaust valve
are closed.

compression

15. 3) Constant Pressure Stroke:-
2

ning, maintaining
or

fuel injec cto
\

J\(
2 When the piston moves to its top Nr
dead centre, the supply of fuel is cut-

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

16. = O

=

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

17. 4) Exhaust Stroke:-

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

18. Exhaust

working principle ci...

19. chamber

fresh air inlet———— +

y

exhaust out! | € "LEN fuel injec

valve litter 7 2 | starter s

camshatt : u — ~ starter motor
connecting r ¡Pa crankshaft

|
— oil pan
oil intake screen asse is
oil drain plug
© 2007 Encyclopaedia Britannica, Inc. = cran BUG

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

21. Diesel Generator = Its parts

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

(1) Engine.

(2)

(3) Fuel System.

(4) Governor.

(5) Voltage Regulator.

(6) Cooling and Exhaust Systems.
(7) Lubrication System.

(8) Battery and Battery Charger.
(9) Control Panel (Automatic Mains Failure

(10) Fly wheel.

!, 4
zZ
IS

22. Starter Motor Fuel Filter attery with Box

23. LE

24. NTPC:

Specification

Engine make

2300 - Displacement in Cubic Inch.
G -Engine for Generator Application

KTA - 50-G8-I

50 - Displacement in

liters

Engine rating

89) BHP

890 BHP

RPM

1500 RPM

1500 RPM

No. of Cylinders

12, 60° Vee

12, 60° Vee

25. Specification

Method of
starting

Time required

for starting from
cold

Interval between
starting impulse

No. of starting

impulses

3

Type of
Governor

Woodward hydraulic PSG with
motorized head

Guaranteed
limits of
Governing

As per class -A1 Governing limits
of BS 649/1958 (+/- 4.5%)

Full load thrown
off

-Do-

Full load put on

-Do-

load from no

load to full load

26. Sp: ation

Stage - II

Guaranteed fuel
consumption

At full load

158 lit / hr (150 gr/BHP/hr) 310 lit /hr
(150 * 890 / 1000 * 0.84 = 158 liy/hr)

Lubrication oil
consumption

(0.84 = Sp. Gravity of diesel)
0.534 h 0.35 lit/ hr

Method of
aspiration

Method of
cooling of engine

Method of
cooling of
lubricating oil

Water cooled

Air filter cum
silencer

Dry type with replaceable paper element

Diesel storage
tank capacity

990 liters

Turbo ed after cooled

27. A’V’ or Vee’ engine is a common configuration for
an internal combustion engine.

The cylinders and pistons are aligned, in two
separate planes or 'banks', so that they appear to be
in a "V" when viewed along the axis of

28. CAMSHAFT: pe = EXHUAST VALVE
pe ROCKER ARM
INJECTOR ROCKER,
ARM

EXHAUST VALYE
BRIDGF

INJECTOR RACK :
TUCL INICCTOR TER > S a PISTON

AIR INLET PORTS—_ d PISTON CARRIER

è \ i CRANKCASE
IR =

CYUNDCR LINCR
WATER INLET a BLADE CONNCCTING|
JUMPER 3 f ROD

WATER INLET
MANIFOLD:

Y
RO ee
i ACW. papa

LÉ";
\ {i SA
PISTON COOLING

Se y OIL MANIFOLD

YY ¢

FORK CONNECTING
ROD

CONNECTING
ROD BASKET
CRANKSHAFT.

CRANKSHATT.

COUHTERWCIGHT SILLAS

OIL LEWCL GAUGE
OIL PAN SUMP

29. 2 The engine burns air and fuel to create mechanical power,
the more air and fuel it can burn the more powerful it is.

30. 2 This allows the engine to burn more fuel producing
more power and improve the overall efficiency of the
combustion process.

32. your generator.

33. » The fuel tank usually has sufficient capacity to keep

the generator operational for 6 to 8 hours.

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

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

36. || Ball check

Rol. Fig. 4-2 Water separator

37. Combustion Air Intak:
> Air for engine combustion must be clean.

38. Diese gine - Governor

% Mechanical Governors:- As the name suggests,
controls engine fueling based on mechanical
sensing of engine RPM through flyweights or
similar mechanisms.

% These systems exhibit about 3-5% speed droop

from no load to full load inherent in the design.

39. % The governor is used to control

engines or turbines driving
alternators, DC generators, pumps, or
compressors.

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

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

41. A FC e)

wOovernor

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

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

A change in current in

42. # Accurate speed sensing & PID control achieves steady state
speed stability of +/-0.25 % at any constant load.

2 A1 class governing with transient response of 15 msec.

Hh is ~} © a orni are aci e
2 Both isochronous & droop governing are possible.

# Solid state potentiometer is available for faster synchronizing
& load sharing functions.

43. yOVernor
Over speed
solenoid

Cable from
Over speed pickup

44. ® Liquid-cooled engines are cooled by pumping a

coolant mixture through passages in the engine
cylinder block and head(s) by means of an engine-
driven pump.

45. Mixtures of either ethylene - or propylene-glycol
and high-quality water shall be used for proper

cooling and freeze / boil protection.

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

46. lant
coolant

s

ngine coo.

ming

Cc.
| Grill type of ventilation
is provided for proper

0

with e
3

q

d
maintai

©
Qa
a

>

ui
of

capable

temperature ata

>These engines are eq
heaters

47. re

48. Typical exhau:

PREVAILING WINDS

MUFFLER SUPPORTED APPROVED THIMBLE VERTICAL -
INDEPENDENTLY OF THE ENGINE TO PROTECT DISCHARGE WITH —.
BY NON-COMBUSTIBLE STRAPS = COMBUSTIBLE WALL RAIN CAP

Fir

i

h

| ÈS = E
SAA 2222 Poren

LONG-RADIUS

FLEXIBLE
TUBING DRAIN PIPE BEND

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

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

50. Dampening and cushioning of components that
operate under high stress, such as gears and push
tubes

» Protection from oxidation and corrosion.

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

52. Lube oil Sump

Priming Pump

54. “ Batteries must have enough capacity (CCA, Cold
Cranking Amps) to provide the cranking motor

STARTER POSTIVE (+) BATTERY
SOLENOID > CABLE CONNECTION

STARTER
MOTOR

24V Battery $ N (-IBATTERY

CABLE CONNECTION

55. The starter motor converts electrical energy to mechanical
energy.

It is mounted on the cylinder block in a position to engage a
ring gear on the engine flywheel.

The starter motor is powered by the battery. It is designed to
have ee mas effort at low speed.

Drive pinion

Overrunning clutch Starter motor

56. Engine Manufacturer &
Model.

Cubic Inch displacement
of Engine.

Battery System Voltage.

Number of 10 second

cranking cycles.

57. Fly wheel

The flywheel is located on one end of the crankshaft
and serves three purposes.

58. Exhaust
(30%)

A

4
©}
5

(

hs
>

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

33% is converted into useful
mechanical energy delivered
to the fly wheel.

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

59. Stage - A LE
specifications

60. ALTERNATOR

Make
Model -
Rated KVA 625 KVA
Rated Terminal
voltage
Rated over load
capacity
Excitation Power
rating
Type of exciter

Jyothi Ltd NGEF Ltd Stomford. UK

= PI734C2
750 KVA 1500 KVA
415 V

110% for 1 Hr. in every 12 Hrs

2.6A, 57VDC 10.3 KVA

Brushless Brushless

Type of voltage

Automatic Automatic
regulator

P=Power Generation, I= Industrial, 7= Frame size, 3= Excitation system
(series-3), 4 = No. of poles, C= Core length, 2 = No. of Bearings

61. » The choke is meant for adjusting the teriminal
voltage at no load.

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

Conti. ...

62. Diesel Engine - Alternator

The Alternator is self excited due to residual flux.

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

63. The advantage of a self-excited system:

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

ight be necessary to select a larger generator in order
rovide acceptable motor starting performance.

64. AUTOMATIC
VOLTAGE
REGULATOR

EXCITER
ROTOR
AND
STATOR

NoIN
AND POWER

ROTATING
RECTIFIERS

ELECTRICAL POWER OUTPUT

MAIN STATOR

MAIN ROTOR

ROTATING
MECHANICAL
POWER
INPUT

65. Alternator

66. +

220
@
@
$
=)

© A

©

£
o
g
o
oi
o

ely te

4 For these reasons, separately - excited generator
excitation systems are recommended for
applications where enhanced motor starting
capability, good performance with non-linear loads
or extended duration short circuit performance are
necessary.

67. AUTOMATIC
VOLTAGE
REGULATOR

EXCITER

| ROTOR F

AND
STATOR

SENSING

ROTATING
RECTIFIERS

ELECTRICAL

MAIN STA

MAIN RO

ROTATING
MECHANICAL
POWER
INPUT

68. Diesel = AMF (Automatic Mains
Fail) panel
E This is the user interface of the

generator and contains provisions
for

a) Electric start and shut-down.

b) Engine gauges.

) Generator gauges
c) Generator gauges.

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

70. Diesel Generator - Routine checks

oil, Go

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

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

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 poor
mechanical conditions.

72. over sp

® Coolant temperature is high (

® Low coolant level (Level belo

73. Diesel Generator - Do’s Y Don’t

Tie 5

# It is important to idle the engine m
before shutting it down to allow the Tubricalin ane
oil and water to carry heat away from the
combustion chamber, bearings, shaft sila This i is
especially important for Turbo cha es

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

e Y

75. elf the engine does not start after about three
repeated attempts, then the starter should not be

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

76. Note:- Continuous operation with low coolant temperature below 60 °C,
or high coolant Temperature above 100°C, can damage the engine.

78. + After DG starts, ensure the following parameters are within

the limit

Coolant
Temperature
Between
70 to 95%C

Engine oil
pressure
Between
3 to 7 Ksc

Stage 10

VOLTS
wr ec
‘OM kg/em?
RPM
HOURS

Should be
At 1500

Engine oil
Temperature
Between
75 to 105°C

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

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

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

80. x Battery failure.
x Battery charger failure.
x Low coolant levels.

uel orc
x Controls not in auto.
x Air in the fuel system.
x Run out of fuel.

x Restriction in air supply.

Maintenance

Daly Weakiy

Monthly 6 Months Yearly

x

x
x
x
x
a

r piping

cleaner

Drain fuel filter

Drain water from fuel tank.

Change fuel

Clean coc

81. A-CHECK
{SECTION 4, 5)

B-CHECK
{SECTION 6)

FIRST 1500 HRS.
CHECK

C-CHECK
(SECTION 7)

D-CHECK
(SECTION 8)

1500 HRS. AFTER
EVERY ‘D’ CHECK

I Dally/weokiy

EY Check Engine
Si Level

Fuel System
ES Drain Seaiments
from Fuel Tarıke

system
EA Clean Pro-Cioaner
Dust Pan Weekly

DD Check air Cleaner
Change Air
loaner Element
1 required

EI Check Coolant

E Drain Air Tank

I Check & Correct
Coake

E Drain Fuel Finer!
Water Separator
Baily

Check oil level of
Raw Water pump

Engine Interval
Soros

Hours
Calendar

Repeat ar

Lubriention
E Sango Ena

D Barrow ono

TI Change By-Pass

E Change Marine
Sear Gil

E pecera où

ful grater
HE
Eine)
E Este
Ueto
(hanger

Clean Fuel Tank
Greater

E neck Aneroid
or

I Check Air Piping

Cooling System
FT nor. Add
“required.

Check Hes
Saehanger Zinc
Er

E Check bet
gust it required

Every 200 hours
Every 6 months

ALL STEPS OF
SCHECK AND
ADDITIONAL
Srers

Adjust injectors

Replace rocker
cover gaskets

E Repeat “A” and

Fuel System
ES Change Hyd. Gov.
EH

E Change Aneroid

E cheek Anerola
Adjustment

O Replace Anar

I Gien Fuel Tank
from inside.

Cooling System

loan Radiator!
E argo Ar

Other Maintenance
inspect folowing

al parts & replace,
Gaunt
Stare ste)

Check air Cleaner
Evacuator valve,
Change it
required.

TI Bepoat“A, B and
=

Fuel System
O Ssibrate recto
if required

C2 Replace rocker
‘cover gaskets

a mo

= pages esas
Prods

Air System
Goan
Compressor
and Diffuser if

E Check

Turbocharger
Boanng Cioarance

E Tighten Manitoie

Cooling System,
ES Change contant

O Descate cooling

Other Maintenance
“Check Vibration
Samper

E Queck air
Compressor

DO Shock Satety

ALL STEPS OF
C-CHECK AND
ADDITIONAL
STEPS

Adjust Injectors
if required
Replace rocker
cover gaskets

‘To be done at first 1500
hours any

©

Every 1500 hours
Every 1 yor.

o

Every 6000 hours
Every 2 years

To be done at 1500
hours after every D
Check

82. x Battery capacity to low.
x Faulty in starter motor.

Starter motor turns engine too slowly.

Faulty in fuel control solenoid.
Faulty in fuel lift pump.

Air in fi

83. x Restriction air filter/cleaner or induction system.

x Fault in atomizers or atomizers of an incorrect type.
x Fault in cold start system.

is too low:

x Wrong grade of lubrication.
x Not enough lubrication oil in sump.
x Defective gauge.

x Dirty lubrication oil filter element.

84. Starter
Contactor

Impulse
Timer

ulse
Timer

Summation
Timer

Lube oil

solenoid

Fuel solenoid
4 =” Energisation

=
A
El
3

supply

E
5
E
9
9
e
E
q

+24VDC Control

85. High Water
_ Temperature

Over speed

Lack of fuel

ircuit

Engine stop
On fault

86. YC from WC from
415V DG Switchgear Unit Aux SWGR - 1A

Y/C from
415V DG Switchgear Unit Aux SWGR - 2A

Unit - 2 - 415V Emergency MCC

YC from YC from
415V DG Switchgear Unit Aux SWGR - 3A

Unit - 3-415V Emergency MCC

Y/C from
415V DG Switchgear

Stage - I Units -
Diesel Generator supply

87. SM 7 Engine out off service
y y Mechanical fault

F1

Window Annunciations( LA | 4

|
BE — Engine - Out / Off / In

24VDC - ON / Off

88. Stage - II Units — Die
From UAT # A

à

UST # Na 6.6KV/415V
J 1750KVA

USSSEC#A N ne USS SEC #B

STAND BY DG
1500 KVA

©

Rn WwW Xx

UNIT DIESEL Y y y
GENERATOR U#5 U#6 U#7

750 KVA U#4

89. B/C

ONIT SERVICE SY ECHAS ANT DA

STAND BY DG
1500 KVA

UNIT DI .
GENERATOR TVDDC BVDDC

1500 KVA

90. Recommendations of 110% Operation Meet

(Held at PMI from 21st Co 2:

1 DG Set was not available during gri

Availability of DG set to be ensured.

3.2 DG S ipped on t pe: righ due to cooling system problem.

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

bility of DG

4 Ven on of DG set room
DG Set tripped on temperature high as ventilation was poor.
S l type.
to be maintai i ny co .
Power supply source for ventilation fans are to be reviewed. Power supply is to
be taken from reliable source to take care of total black out condition.

e DG set room shall be c

91. 4.3.5 DG Set did not start on auto

o Protocol is to be maintained for all such trials.

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

4.3.6 Access to DG sets in the case of emergency:

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

92. 4.3.8 USS 1/C to EMCC breaker tion was not available

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

ing of EMCC

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

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

r pump auto lity

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

Auto staring of DG sets:

+ Asa part of regular testing, under voltage to be simulated to start DG sets