DIESEL GENERATING SET

dimanche 30 décembre 2018

INTRODUCTION:

A generator is a machine that converts mechanical energy into electrical energy. A generator
needs a prime mover for rotating it. The prime mover may be a diesel engine, a steam turbine, a
gas turbine, or a water turbine. A diesel engine driven generator is called a diesel generating set
Diesel Generators are commonly available with outputs from 5 KVA up to 2500 KVA.

Purpose of Generator:
In general generators are used for two main purposes.
*) to provide power as a regular source of electricity
*) to act as an emergency power supply when there is no normal supply
available.

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Stand by duty:
A stand-by DG set is a backup to normal utility power. This designation is for generators that
will be used less than 500 hours per year and typically for short periods of time when the utility
power fails.
Prime Power duty:
Any generator that is used everyday or on a fixed schedule to provide power for long
duration is considered a prime power generator. These generators can operate continuously for
24-hour in a day and 7-days in a week.

Generator Phases:
Generator sets produce either single or three phase power. Choose a single phase set if you
do not have any motors above 5HP.

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Components of Diesel Generator:
The two main components of the diesel generator are
*) Diesel Engine as prime mover
*) Alternator or AC generator(brushless type)
*) DC shunt generator as exciter
*) Rotating Rectifier
*) AVR- Automatic Voltage Regulator

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ALTERNATOR:

An alternator is an electromechanical device that converts mechanical energy to

alternating current electrical energy.

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WORKING OF ALTERNATOR:

When the Engine cranks the alternator ,owing to the residual magnetism present in the exciter-
stator pole, a magnetic field is produced and it induces alternating current in its rotor armature
and is rectified into DC through its rotating rectifier.

The DC voltage is fed into the rotating field of the alternator and thus induces alternating
current in its stator armature. This AC voltage (3ph) is taken to AVR and this AVR, converts this
AC voltage into DC and supplies variable DC voltage (No Load 10V DC, Full load 60V DC) to the
exciter field depending upon the load on the alternator.

Accordingly the exciter generates DC voltage in its armature and supplies to the alternator rotor
field, thereby generating always 400V at the stator of the alternator.

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TYPES OF GENERATOR:

Diesel Engine can be classified according to cycle type as:

• Two stroke and four stroke.

• Naturally aspirated.
• Turbocharged.
• Turbocharged and after cooled (Intercooled).

*) In the diesel engine, air is drawn into the cylinder and is compressed to a high ratio (14:1 to
25:1). During this compression, the air is heated to a temperature of 700–900°C.

*) A metered quantity of diesel fuel is then injected into the cylinder, which ignites
spontaneously because of the high temperature.

Hence, the diesel engine is also known as compression ignition (CI) engine.

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PARTS OF ENGINE:
Electronic Control Module Crankcase Air/Oil Separator
Turbocharger

Engine Lube Oil Filter

Charge Air
Cooler
Valve Cover

High Pressure Fuel Pump

Fuel Filter
Flywheel
Air intake Manifold

Starter Motor
Oil Filler Neck Engine Bracket Engine Oil Pan

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Operation of Engine:

To know the operation of the Engine Fully ,the whole engine process can be classified as the
following subsystems
1.Starting system
2.Fuel injection system
3.Lubrication system
4.Cooling system
5.Air Inlet & Exhaust system

1. STARTING SYSTEM:
The purpose of the electrical system is to supply power to the Diesel Engine Control (ECU)
system and to provide the energy to start the engine if the engine is equipped with electric
starters.

COMPONENTS: Starter Motor, Battery Charging Alternator, Batteries, Control Panel, Starting
Motor Relay, Key Switch

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STARTING SYSTEM:

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BATTERY UP-KEEP:

Normally on commercial DG set applications, we use 12 volts, 25 plates, 180 AH batteries for
starting purpose.

*) The batteries on DG set application are likely to last for 30 months. To play safe , it is
suggested to replace the batteries at the end of 30 months. To enable this the date of
installation of the batteries is written on the sides of the batteries.

*) During the life of these batteries, only distilled water needs to be added to make –up the
electrolyte level. No fresh electrolyte needs to be added unless the original quantity of
electrolyte is removed.

*) One good battery maintenance practice is to measure the cell voltage at least twice a week
and ensure that each cell voltage is more than 1.5 volts at the end of 3 or 4 seconds of
application of the cell-tester.

*) Apply petroleum jelly on to the battery terminals and ensure the cable lugs are tight on the
battery terminals.

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FUEL INJECTION SYSTEM:

In Diesel Engine, the fuel has to be supplied when the air inside the cylinder is compressed to a
very high pressure.

*) Therefore the fuel must be injected at a high pressure than that developed in the cylinder at
the end of compression stroke.

*) Only air is compressed to a pressure of about 35 kilogram per centimetre square and the
temperature after this compression is reach near to 600 degree centigrade.

*) The time for which the fuel is injected into the engine cylinder must be very small, since high
injection velocities give a good atomization of fuel and the fuel has to be burnt at top dead
centre position of the piston.

*) In compression ignition engine (diesel engine),a pressure as high as 100 to 300 kilogram per
centimetre square are required to be developed for fuel injection systems.

*) The main advantage of diesel engine is, the maintenance cost of fuel injection equipments
are less than that those of the carburettor and spark plug of petrol engine
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FUEL INJECTION SYSTEM:

Requirements Of Fuel Injection System:-

The fuel injection system in diesel engine must satisfy the following requirements,

1) At beginning as well as the end of injection of fuel should take place sharply.
2) The injection of fuel must occur at the correct moment, correct rate and in correct quantity
as required by the various load conditions of engine. This is achieved by the Tune up
Process.
3) The fuel must be injected in a fine atomised condition and must be distributed uniformly in
the combustion chamber of engine.

Methods Of Fuel Injection:-

1)Air Blast Injection:-
In this, air is compressed to a very high pressure by means of compressor and the blast
of air the injected carrying fuel along with it into the cylinder. This method is obsolete
now.

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FUEL INJECTION SYSTEM:

2)Solid Injection:-
In this, the fuel under pressure is directly injected into the combustion chamber in
atomised state. It requires pump to deliver the fuel at very high pressure and used in all
big and small diesel engines.
Solid injection system is also subdivided in,
a) Individual Pump System:-
b) Common Rail System:-
a) Individual Pump System:-
In this system, each cylinder has its own individual high pressure pump and metering unit.
The cost of this system is very high.
b) Common Rail System:-
In this system, the fuel is pumped by multi-cylinder pump into a common rail, the pressure
in which is controlled by a relief valve. A metered quantity of fuel is supplied to each cylinder
from the rail. It requires higher accuracy during manufacturing.

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FUEL INJECTION SYSTEM:

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LUBRICATION SYSTEM:

*) An internal combustion engine would not run for even a few minutes if the moving parts
were allowed to make metal-to-metal contact.

*) The heat generated due to the tremendous amounts of friction would melt the metals,
leading to the destruction of the engine.

*) To prevent this, all moving parts ride on a thin film of oil that is pumped between all the
moving parts of the engine.

*) Once between the moving parts, the oil serves two purposes.
a) One purpose is to lubricate the bearing surfaces.
b)The other purpose is to cool the bearings by absorbing the friction-generated heat.

*) The flow of oil to the moving parts is accomplished by the engine's internal lubricating
system.

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*) Oil is accumulated and stored in the engine's oil pan where one or more oil pumps take a
suction and pump the oil through one or more oil filters as shown .

*) The filters clean the oil and remove any metal that the oil has picked up due to wear.

*) The cleaned oil then flows up into the engine's oil galleries.

*) A pressure relief valve(s) maintains oil pressure in the galleries and returns oil to the oil pan
upon high pressure.

*) The oil galleries distribute the oil to all the bearing surfaces in the engine.

*) Once the oil has cooled and lubricated the bearing surfaces it flows out of the bearing and
gravity-flows back into the oil pan.

*) In medium to large diesel engines, the oil is also cooled before being distributed into the
block. This is accomplished by either an internal or external oil cooler.

*) The lubrication system also supplies oil to the engine's governor.

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AIR INLET & EXHAUST SYSTEM:

TURBO CHARGER IN DIESEL ENGINE

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*) On the other end of the shaft that the turbine is attached to, the compressor pumps air into
the cylinders.

*) The compressor is a type of centrifugal pump it draws air in at the center of its blades and
flings it outward as it spins.

*) In order to handle speeds of up to 150,000 rpm, the turbine shaft has to be supported very
carefully.

*) Most bearings would explode at speeds like this, so most turbochargers use a fluid bearing.

*) This type of bearing supports the shaft on a thin layer of oil that is constantly pumped around
the shaft.

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*) This serves two purposes:
a) It cools the shaft and some of the other turbocharger parts,
b) It allows the shaft to spin without much friction.

*) A well-engineered, turbo-charged diesel engine offers better fuel efficiency (at times by 15
per cent), better overall performance (better torque and high-end power), reduced noise
(compared to normally aspirated diesel engines) and minimum engine maintenance (owing to
better combustion of diesel fuel).
The exhaust from the cylinders passes through the turbine blades, causing the turbine to spin.
The more exhaust that goes through the blades, the faster they spin.

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A CHECK: (Daily Activity)
1.Battery terminals
2.Battery Voltage
3.Distilled water level
4.Fuel level
5.Lube oil level
6.Lube oil Temperature
7.Lube oil Pressure
8.Water temperature
9. Fan belt Tension

B – CHECK: ( Every 250 Hrs or Every 6 months)

1.Replace lube oil
2. Replace oil filter, Fuel filter( Both Primary & Secondary)
3. Air Filter cleaning with air blower.

C- Check ( Every 1500 Hrs or 1 Year)

1.Replace Air filter
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2. Clean the Entire DG Parts.
Engine mounted safeties:
• High jacket water temperature( Max 96 Degree Celcius),
• low lub oil pressure cut-outs ( Minimum 20 PSI)
• over speed protection should be provided
• Lub oil temperature Maximum 50 Degree Celcius.

Precautions:
• Do not stop the engine with load . Run at No load for minimum of 5 mins before
shut down of the engine.
• It is also essential to provide reverse power relay when DG sets are to run in
parallel to avoid back feeding from one alternator to another.

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 THANK YOU

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