DIESEL GENERATOR DETAILS

NTPCNTPC-- RamagundamRamagundam
ByBy
M.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 ofDiesel's story actually begins with the invention of
thethe Gasoline EngineGasoline Engine..
““NikolausNikolaus August OttoAugust Otto”” had invented and patentedhad 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 oflearned about the low efficiency of
gasoline and steam engines.gasoline and steam engines.
This disturbing information inspired him to create an engineThis disturbing information inspired him to create an engine
with awith a higher efficiency, and he devoted much of his time tohigher 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 callfor what we now call
the diesel engine.the diesel engine. Conti….

1892,1892, Rudolf DieselRudolf Diesel obtained a patent.obtained a patent.
1893,1893, ““DieselDiesel”” built his first workingbuilt his first working
prototype.prototype.
1897,1897, ““AdolphusAdolphus BuschBusch”” licenses rights tolicenses rights to
the Diesel Engine for the USA and Canada.the Diesel Engine for the USA and Canada.
1899, Diesel licensed his engine to1899, 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 theproduced 82 copies of the
stationary diesel engine.stationary diesel engine.
1919, First diesel engine from1919, First diesel engine from CumminsCummins..
The world's largest diesel engine is currentlyThe world's largest diesel engine is currently
aa WWäärtsilrtsilää -- SulzerSulzer RTA96RTA96 -- CC of aboutof about
84,42084,420 kW.kW.
Rudolf DieselRudolf Diesel
A Diesel Engine builtA Diesel Engine built
By MANBy MAN –– AG in 1906AG in 1906

Diesel GeneratorDiesel Generator –– What is it ?What is it ?
AA Diesel GeneratorDiesel Generator is the combination of ais the combination of a dieseldiesel
engineengine with anwith an electric generatorelectric generator (often called as(often called as
alternatoralternator) to generate Electrical energy.) to generate Electrical energy.

Diesel generator sets are used in places without connectionDiesel generator sets are used in places without connection
to theto the power gridpower grid, as, as emergency power supplyemergency power supply if the gridif the grid
fails, as well as forfails, as well as for more complex applications such asmore 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 exitEgress lighting for evacuation, illuminated exit
signs, security lighting, warning lights, operating roomsigns, 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 forCritical 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 pressurizationSmoke control and pressurization
fans, waste water treatment, etc.fans, waste water treatment, etc.
Diesel GeneratorDiesel Generator –– Why ?Why ?
Conti….

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 ofcooling and heating for vulnerable people, ventilation of
hazardous atmospheres, ventilation of pollutants or biologicalhazardous 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, memoryUPS and cooling to prevent data loss, memory
loss, Program corruption.loss, Program corruption.
Life Support:Life Support: Hospitals, Nursing homes, and other Health careHospitals, Nursing homes, and other Health care
facilities.facilities.
Communications Systems:Communications Systems: Police and Fire stations, HiPolice and Fire stations, Hi--riserise
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 ““CompressionCompression
IgnitionIgnition””.. More specifically, the combustionMore specifically, the combustion
process in the diesel engine is initiated byprocess in the diesel engine is initiated by
spontaneous ignition of the fuel when it is injectedspontaneous ignition of the fuel when it is injected
into a highly compressed charge of air, which hasinto a highly compressed charge of air, which has
reached approximatelyreached approximately 750750 00CC..
Heat engine:Heat engine: An engine that converts the potentialAn engine that converts the potential
heat energy of a combustibleheat energy of a combustible fuel into mechanicalfuel 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 dieselfunctions by converting the heat energy of diesel
fuel into mechanical work.fuel into mechanical work.
Diesel EngineDiesel Engine –– How it works ?How it works ?
Conti….

Internal Combustion Engine:Internal Combustion Engine: A Heat engine in which theA 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 theAn internal combustion engine in which the
cylinder fuel air charge is ignited by the heat ofcylinder 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 isis
acted upon by the pressure of the expanding combustionacted upon by the pressure of the expanding combustion
gases in thegases in the combustion chambercombustion chamber space at the top of thespace at the top of the
cylinder. This force then acts downwards throughcylinder. This force then acts downwards through
thethe connecting rodconnecting rod and onto theand onto the crankshaftcrankshaft..
Conti….

Top dead center (TDC):Top dead center (TDC): The uppermost point of theThe 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 ofThe lowest point of
piston travel in the engine cylinder.piston travel in the engine cylinder.
Bore:Bore: The diameter of a cylinder. Bore is expressedThe diameter of a cylinder. Bore is expressed
as the piston sectional area over which cylinderas the piston sectional area over which cylinder
pressures act.pressures act.
Compression ratio:Compression ratio: A measure of the cylinderA measure of the cylinder
volume when the piston is atvolume when the piston is at BDCBDC versus theversus the
cylinder volume when the piston is atcylinder volume when the piston is at TDCTDC..
Compression ratios in diesel engines fall betweenCompression ratios in diesel engines fall between
14:1 and 24:1.14:1 and 24:1.
Conti….

Bore & StrokeBore & Stroke Compression RatioCompression Ratio –– 17:117:1
Conti….

Stroke:Stroke: The distance through which a piston travels fromThe distance through which a piston travels from
BDC to TDC.BDC to TDC.
Swept volume:Swept volume: The volume displaced by the piston in theThe volume displaced by the piston in the
cylinder as it moves from BDC to TDC. It can be calculatedcylinder 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 engineof 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 NumberBore X Bore X Stroke X 0.7854 X Number
of cylinders.of cylinders.
Engine displacement calculation dataEngine displacement calculation data
For 6For 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 OROR 12.4 liters.12.4 liters.
1 Liter = 60.010 Cubic inches1 Liter = 60.010 Cubic inches

Diesel Engine is mainly works onDiesel Engine is mainly works on below strokesbelow strokes..
1) Suction Stroke:1) Suction Stroke:--
In this stroke, the pistonIn this stroke, the piston moves downmoves down from thefrom the
top dead centre. As a result, inlet valve opens andtop dead centre. As a result, inlet valve opens and
air is drawnair is drawn into the cylinder.into the cylinder.
Conti….
Diesel EngineDiesel Engine –– How it works ?How it works ?
After sufficient quantity of airAfter sufficient quantity of air
with pressure is drawn, suctionwith pressure is drawn, suction
valve closes at the end of thevalve closes at the end of the
stroke. The exhaust valvestroke. The exhaust valve
remains closed during thisremains closed during this
stroke.stroke.

2) Compression Stroke:2) Compression Stroke:--
In this stroke, pistonIn this stroke, piston moves upmoves up from the bottom deadfrom the bottom dead
centre. During this stroke both inlet and exhaust valvecentre. During this stroke both inlet and exhaust valve
are closed.are closed.
The air drawn into the cylinder during suction stroke, isThe air drawn into the cylinder during suction stroke, is
entrapped inside the cylinder and compressed due toentrapped inside the cylinder and compressed due to
upward movement of the piston.upward movement of the piston.
Conti….
In diesel engine, the compressionIn diesel engine, the compression
ratio used is very high as a result, theratio used is very high as a result, the
air is finally compressed to a veryair is finally compressed to a very
high pressure up tohigh pressure up to 40 kg/cm40 kg/cm22
,, at thisat this
pressure, the temp of the air ispressure, the temp of the air is
reached to very high which is enoughreached 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 hotIn this stroke, the fuel is injected into the hot
compressed air where it starts burning, maintainingcompressed air where it starts burning, maintaining
the pressure constant.the pressure constant.
Conti….
When the pistonWhen 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 isoff. It is to be said that the fuel is
injected at the end of compressioninjected at the end of compression
stroke and injection continues till thestroke and injection continues till the
point of cutpoint of cut--off, but in actualoff, but in actual
practice, the ignition starts before thepractice, the ignition starts before the
end of compression stroke to takeend 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 remainIn this stroke, both inlet and exhaust valve remain
closed. The hot gases (which are produced due toclosed. The hot gases (which are produced due to
ignition of fuel during compression stroke) andignition of fuel during compression stroke) and
compressed air now expand adiabatically, in thecompressed air now expand adiabatically, in the
cylinder pushing the piston down and hence work iscylinder pushing the piston down and hence work is
done.done.
At the end of stroke, the piston finally reaches theAt the end of stroke, the piston finally reaches the
bottom dead centre.bottom dead centre.
Conti….
Diesel EngineDiesel Engine –– Working PrincipleWorking Principle

4) Exhaust Stroke:4) Exhaust Stroke:--
In this stroke, theIn this stroke, the piston again moves upwardpiston again moves upward. The. The
exhaust valve opens, while inlet and fuel valve areexhaust valve opens, while inlet and fuel valve are
closed.closed.
A greater part of the burnt fuel gases escape due toA greater part of the burnt fuel gases escape due to
their own expansion. The upward movement of thetheir own expansion. The upward movement of the
piston pushes the remaining gases out through thepiston pushes the remaining gases out through the
open exhaust valve.open exhaust valve.
Conti….
Only a small quantity of exhaust gasesOnly a small quantity of exhaust gases
stay in the combustion chamber. Atstay in the combustion chamber. At
the end of exhaust stroke, the exhaustthe end of exhaust stroke, the exhaust
valve closes and the cycle is thusvalve closes and the cycle is thus
completed.completed.

Diesel Generator working principleDiesel Generator working principle
Diesel EngineDiesel Engine –– 44 -- StrokesStrokes
IntakeIntake CompressionCompression PowerPower ExhaustExhaust
Conti….
Connecting rodConnecting rod
PistonPiston
CrankshaftCrankshaft

Parts of EngineParts of Engine -- DetailedDetailed
Conti….

Diesel engines require theDiesel 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 toDiesel engines use high cylinder compression to
press the mixture of fuel and air into as small of anpress the mixture of fuel and air into as small of an
area as possible.area as possible.
This compression causes heat in the cylinder, whichThis compression causes heat in the cylinder, which
causes thecauses the fuel to ignitefuel to ignite and push the piston backand push the piston back
down, causing the crankshaft, facilitating the easydown, causing the crankshaft, facilitating the easy
transfer of the motion produced by the diesel enginetransfer of the motion produced by the diesel engine
to the magnets of the generator assembly.to the magnets of the generator assembly.
Diesel EngineDiesel Engine –– Overall functionOverall function

The main components of an Diesel Generator canThe 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.
Diesel GeneratorDiesel Generator –– Its partsIts parts

NTPCNTPC--RamagundamRamagundam DG Set detailsDG Set details
SpecificationSpecification StageStage -- II StageStage -- IIII StageStage -- IIIIII
Engine makeEngine make KirloskarKirloskar
Cummins Ltd.Cummins Ltd.
KirloskarKirloskar
Cummins Ltd.Cummins Ltd.
Cummins IndiaCummins India
Ltd.Ltd.
TypeType KTAKTA –– 2300 G2300 G KTAKTA –– 2300 G2300 G KTAKTA--5050--G8G8--II
KK –– Engine SeriesEngine Series
TT –– Turbo ChargedTurbo Charged
AA –– After CooledAfter Cooled
23002300 –– Displacement in Cubic Inch.Displacement in Cubic Inch.
GG ––Engine for Generator ApplicationEngine for Generator Application
KTAKTA -- 5050 -- G8G8 -- II
5050 –– 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 BHP
RPMRPM 1500 RPM1500 RPM 1500 RPM1500 RPM 1500 RPM1500 RPM
No. of CylindersNo. of Cylinders 12, 6012, 6000
VeeVee 12, 6012, 6000
VeeVee 16, 6016, 6000
VeeVee
Conti….12, 6012, 6000 VeeVee

Method ofMethod of
startingstarting
24 V DC24 V DC 24 V DC24 V DC 24 V DC24 V DC
Time requiredTime required
for starting fromfor starting from
coldcold
30 sec30 sec 30 sec30 sec 30 sec30 sec
Interval betweenInterval between
starting impulsestarting impulse
10 sec10 sec 10 sec10 sec 10 sec10 sec
No. of startingNo. of starting
impulsesimpulses
33 33
Type ofType of
GovernorGovernor
Woodward hydraulic PSG withWoodward hydraulic PSG with
motorized headmotorized head
(EFC) Electronic(EFC) Electronic
fuel control / A1fuel control / A1
GuaranteedGuaranteed
limits oflimits of
GoverningGoverning
As per classAs per class ––A1 Governing limitsA1 Governing limits
of BS 649/1958of BS 649/1958 (+/(+/-- 4.5%)4.5%)
As per classAs per class ––A1A1
of BS 5514of BS 5514
Engine SpeedEngine Speed
withinwithin ±±1% for1% for
any steady stateany steady state
load from noload from no
load to full loadload to full load
Full load thrownFull load thrown
offoff
-- DoDo --
Full load put onFull load put on -- DoDo --

Guaranteed fuelGuaranteed fuel
consumptionconsumption
At full loadAt full load
158 lit / hr158 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 oilLubrication oil
consumptionconsumption
0.534 lit / hr0.534 lit / hr 0.35 lit / hr0.35 lit / hr
Method ofMethod of
aspirationaspiration
Turbo charged after cooledTurbo charged after cooled
Method ofMethod of
cooling of enginecooling of engine
Radiator cooled EngineRadiator cooled Engine
Method ofMethod of
cooling ofcooling of
lubricating oillubricating oil
Water cooledWater cooled
Air filter cumAir filter cum
silencersilencer
Dry type with replaceable paper elementDry type with replaceable paper element
Diesel storageDiesel storage
tank capacitytank capacity
990 liters990 liters
Turbo charged after cooledTurbo charged after cooled

606000
-- ‘‘VeeVee’’ EngineEngine
AA ’’VV’’ oror ’’VeeVee’’ engineengine is a commonis a common configurationconfiguration forfor
anan internal combustion engineinternal combustion engine..
TheThe cylinderscylinders andand pistonspistons are aligned, in twoare aligned, in two
separate planes or 'banks', so that they appear to beseparate planes or 'banks', so that they appear to be
in ain a "V""V" when viewed along the axis ofwhen viewed along the axis of
thethe crankshaftcrankshaft..
TheThe ‘‘VeeVee’’ configuration generally reduces theconfiguration generally reduces the
overall engine length, height and weight comparedoverall engine length, height and weight compared
to an equivalentto an equivalent inlineinline configuration.configuration.
The most efficient cylinder bank angle for aThe most efficient cylinder bank angle for a ‘‘VV’’
engine is 60engine is 6000, for minimizing size and vibration., for minimizing size and vibration.

What is Turbo Charged after cooledWhat is Turbo Charged after cooled
The purpose of a turbochargerThe purpose of a turbocharger is to compress the airis to compress the air
flowing into the diesel engine,flowing into the diesel engine, this lets the engine squeezethis lets the engine squeeze
more air into a cylinder and more air means that more fuelmore 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 andIn simple terms, a turbocharger comprises of a turbine and
a compressor connected by a common shaft supported on aa compressor connected by a common shaft supported on a
bearing system.bearing system.
The turbocharger convertsThe turbocharger converts waste energywaste energy from an engine'sfrom an engine's
exhaust gases into compressed air, which it pushes into theexhaust gases into compressed air, which it pushes into the
engine.engine.
Conti….

This allows the engine to burn more fuel producingThis allows the engine to burn more fuel producing
more power and improve themore power and improve the overall efficiencyoverall efficiency of theof the
combustion process.combustion process.
AnAn IntercoolerIntercooler removes the heat of compressionremoves the heat of compression
between the stages of a compressor whereas anbetween the stages of a compressor whereas an afterafter
coolercooler reduces the temperature of the air leaving thereduces the temperature of the air leaving the
compressor.compressor. Delivering cold air means that there isDelivering 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 theThe engine is the source of the
input mechanical energy to theinput mechanical energy to the
generator.generator.
The size of the engine isThe size of the engine is
directly proportional to thedirectly proportional to the
maximum power output of themaximum power output of the
generator can supply.generator can supply.
There are several factors thatThere are several factors that
you need to keep in mindyou need to keep in mind
while assessing the engine ofwhile assessing the engine of
your generator.your generator.
DG SetDG Set –– Function of partsFunction of parts
Conti….

The fuel tank usually has sufficient capacity to keepThe fuel tank usually has sufficient capacity to keep
the generator operational forthe 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 supplyThe supply
line directs fuel from the tank to the engine and theline 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 aThe fuel tank has a
ventilation pipe to prevent the buildventilation pipe to prevent the build--up of pressure orup 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 separatesThis separates
water and foreign matter from the liquid fuel towater and foreign matter from the liquid fuel to
protect other components of the engine from corrosionprotect other components of the engine from corrosion
and contamination.and contamination.
Diesel EngineDiesel Engine –– Fuel systemFuel system
Conti….

Fuel Injector:Fuel Injector:–– This atomizes the liquid fuel andThis atomizes the liquid fuel and
sprays the required amount of fuel into thesprays 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 usedFuel return lines take the hot excess fuel not used
in the engine cycle a way from the injectors andin the engine cycle a way from the injectors and
back to fuel storage tank. The heat from the excessback 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 backNever run a fuel return line directly back
to the engine fuel supply lines. The fuel willto the engine fuel supply lines. The fuel will
overheat and break down.overheat and break down.
The fuel return lines should always enter theThe fuel return lines should always enter the
storage tank above the highest fuel level.storage tank above the highest fuel level.

DIESEL TANK (StageDIESEL TANK (Stage –– I)I) DIESEL FILTERSDIESEL FILTERS

PT (PressurePT (Pressure –– Time), self adjusting direct injectionTime), self adjusting direct injection
type fuel pump is provided for fuel supply.type fuel pump is provided for fuel supply.
Clean fuel filterClean fuel filter –– 100 mmHg, Choked fuel filter100 mmHg, Choked fuel filter ––
203 mmHg203 mmHg..
Oil InjectorOil Injector PT Fuel pumpPT Fuel pump
BowlBowl
Drain valveDrain valve
FloatFloat
Ball checkBall check
Oil InjectionOil Injection

Combustion Air Intake systemCombustion Air Intake system
Air for engine combustion must be clean.Air for engine combustion must be clean.
Normally this air can be drawn from the area surroundingNormally 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 = 250Clean filter = 250 mmwclmmwcl,, Choked filter = 500Choked filter = 500 mmwclmmwcl
Dry type replaceable paper element air cleaner withDry 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 mechanicalcontrols engine fueling based on mechanical
sensing of engine RPM through flyweights orsensing of engine RPM through flyweights or
similar mechanisms.similar mechanisms.
These systems exhibit aboutThese 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 leastThis type of system is generally the least
expensive and is suitable for applications whereexpensive and is suitable for applications where
the frequency droop is not a problem for the loadsthe frequency droop is not a problem for the loads
being served.being served.
Diesel EngineDiesel Engine –– GovernorGovernor
Conti….

The Woodward PSG governor is aThe Woodward PSG governor is a
speed droop governor for controllingspeed droop governor for controlling
speed of small diesel, gas, andspeed of small diesel, gas, and
gasoline engines, or small steam orgasoline engines, or small steam or
industrial gas turbines.industrial gas turbines.
The governor is used to controlThe governor is used to control
engines or turbines drivingengines or turbines driving
alternators, DC generators, pumps, oralternators, DC generators, pumps, or
compressors.compressors.
Pressure compensation provides thePressure compensation provides the
PSG governor with the necessaryPSG governor with the necessary
stability to control isochronously.stability to control isochronously.
Diesel EngineDiesel Engine –– Woodward PSG GovernorWoodward PSG Governor
Conti….

Electronic Governors :Electronic Governors :–– Electronic governors are used forElectronic governors are used for
applications where isochronous (zero droop) governing isapplications where isochronous (zero droop) governing is
required or where active synchronizing and parallelingrequired or where active synchronizing and paralleling
equipment is specified.equipment is specified.
EFC Governor is used on PT fuel system. The governorEFC 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 theThe magnetic pick up senses the engine speed at the
flywheel ring gear and generates an AC voltage with itsflywheel 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 governorSignal 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 theThe 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.
Conti….

Actuator valve is normally closed. It opens depending onActuator 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 fromThe 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 controllerIf 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 enginesThis advanced governing system can be retrofitted engines
with hydraulic governors.with hydraulic governors.
A change in current in the actuator coil will make theA change in current in the actuator coil will make the
actuator shaft rotate. The fuel flow and the engine speed oractuator 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.
Diesel EngineDiesel Engine –– EFC GovernorEFC Governor

Features:Features:--
Accurate speed sensing & PID control achieves steady stateAccurate 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 15A1 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 synchronizingSolid state potentiometer is available for faster synchronizing
& load sharing functions.& load sharing functions.

Governing oilGoverning oil
Dip stickDip stick
Cable fromCable from
Over speed pickupOver speed pickup
Over speedOver speed
solenoidsolenoid
Fuel lineFuel line
Fuel Return lineFuel Return line
PT type fuelPT type fuel
pumppump
Woodward PSGWoodward PSG
GovernorGovernor

Continuous usage of the generator causes itsContinuous usage of the generator causes its
various components to get heated up. It isvarious components to get heated up. It is
essential to have a cooling and ventilation systemessential 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 acooled engines are cooled by pumping a
coolant mixture through passages in the enginecoolant 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 theto cool the
coolant and ventilate the generator room.coolant and ventilate the generator room.
Diesel EngineDiesel Engine –– Cooling systemCooling system
Conti….

Water for coolant should be clean and free fromWater 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 slightlysulphates and acids. It should be kept slightly
alkaline with a pH value in the rangealkaline with a pH value in the range 8.5 to 10.5.8.5 to 10.5.
Mixtures of eitherMixtures of either ethyleneethylene -- or propyleneor propylene--glycolglycol
and highand high--quality water shall be used for properquality water shall be used for proper
cooling and freeze / boil protection.cooling and freeze / boil protection.
Coolant should be replaced after 6000 hrs ofCoolant should be replaced after 6000 hrs of
operation or after Two years.operation or after Two years.
Conti….
CoolantCoolant
Level InspectionLevel Inspection
CapCap

Stand by Generator sets may be required to startStand 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 coolantThese engines are equipped with engine coolant
heaters capable of maintaining coolantheaters capable of maintaining coolant
temperature at atemperature at a minimum of 38minimum of 3800C.C.
Grill type of ventilationGrill type of ventilation
is provided for properis provided for proper
exhaustexhaust

Exhaust fumes emitted by a generator are just likeExhaust fumes emitted by a generator are just like
exhaust from any other diesel or gasoline engineexhaust from any other diesel or gasoline engine
and contain highly toxic chemicals that need to beand contain highly toxic chemicals that need to be
properly managed.properly managed.
Exhaust pipes are usually attached to the engineExhaust 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 exhausts exhaust
system.system.
An outdoor weather protective housing suppliedAn outdoor weather protective housing supplied
by a generator set manufacturer usually will haveby a generator set manufacturer usually will have
variousvarious ““mufflermuffler”” options and usually with theoptions and usually with the
muffler mounted on the roof.muffler mounted on the roof.
Diesel EngineDiesel Engine –– Exhaust systemExhaust system

Typical exhaust systemTypical exhaust system

The lubricating oil used in a engine must beThe 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 theLubrication 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 toCooling 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 theSealing by filling in the uneven surfaces in the
cylinder wall, valve stems and turbo charger oilcylinder wall, valve stems and turbo charger oil
seals.seals.
Diesel EngineDiesel Engine –– Lubrication systemLubrication system
Conti….

Cleaning by holding contaminants in suspension toCleaning 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 thatDampening and cushioning of components that
operate under high stress, such as gears and pushoperate 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 pressureLarge capacity gear pump provides pressure
lubrication to all bearing and oil supply for pistonlubrication to all bearing and oil supply for piston
cooling.cooling.
All pressure lines are internal drilled passages inAll pressure lines are internal drilled passages in
cylinder block and heads.cylinder block and heads.
Oil cooler, full flow filters and by pass filtersOil 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 level
Checking dip stickChecking dip stick
Priming PumpPriming Pump
DischargeDischarge

Starter Motor:Starter Motor:--
The starter motor is a necessity for internalThe starter motor is a necessity for internal--combustioncombustion
engines, because theengines, because the Otto cycle requiresOtto cycle requires the pistons alreadythe 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 anThis 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.
TheThe batterybattery is used for the starter motor.is used for the starter motor.
If you remove the battery while the engine is running, theIf 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 stopOnce 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.
Diesel EngineDiesel Engine –– Battery and ChargerBattery and Charger

Battery starting systems for generator sets areBattery starting systems for generator sets are
usuallyusually 24 volts24 volts..
Batteries must have enough capacityBatteries must have enough capacity (CCA, Cold(CCA, Cold
Cranking Amps)Cranking Amps) to provide the cranking motorto provide the cranking motor
current.current.
Diesel EngineDiesel Engine –– Battery and ChargerBattery and Charger
24V Battery

The starter motor converts electrical energy to mechanicalThe starter motor converts electrical energy to mechanical
energy.energy.
It is mounted on the cylinder block in a position to engage aIt 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 toThe 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 toDuring 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 displacementCubic Inch displacement
of Engine.of Engine.
Battery System Voltage.Battery System Voltage.
Min Battery electrolyteMin Battery electrolyte
temperature.temperature.
Number of 10 secondNumber 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 wheel
TheThe flywheelflywheel is located on one end of the crankshaftis located on one end of the crankshaft
and servesand serves threethree purposes.purposes.
First,First, through its inertia, it reduces vibrations bythrough its inertia, it reduces vibrations by
smoothing out the power stroke as each cylindersmoothing out the power stroke as each cylinder
fires.fires.
•• Second,Second, it is the mounting surfaceit is the mounting surface
used to bolt the engine up to itsused to bolt the engine up to its
load.load.
•• Third,Third, on some diesels, the flyon some diesels, the fly
wheel has gear teeth around itswheel has gear teeth around its
perimeter that allow the startingperimeter that allow the starting
motors to engage and crank themotors to engage and crank the
diesel.diesel.

A turbocharger makes use ofA turbocharger makes use of
rejected heat by compressingrejected heat by compressing
the intake air forced into thethe intake air forced into the
engine cylinders, therebyengine cylinders, thereby
increasing the thermalincreasing the thermal
efficiency of the engine.efficiency of the engine.
The potential energy of theThe potential energy of the
fuel (100%) is released in afuel (100%) is released in a
typical diesel engine:typical diesel engine:
33%33% is converted into usefulis converted into useful
mechanical energy deliveredmechanical energy delivered
to the fly wheel.to the fly wheel.
The rejected heat isThe rejected heat is
dispersed as radiated heatdispersed 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 dieselHow the potential energy of diesel
fuel is released in a diesel engine.fuel is released in a diesel engine.

ALTERNATORALTERNATOR
MakeMake JyothiJyothi LtdLtd NGEF LtdNGEF Ltd StomfordStomford. UK. UK
ModelModel ---- ------ PI734C2PI734C2
Rated KVARated KVA 625 KVA625 KVA 750 KVA750 KVA 1500 KVA1500 KVA
Rated TerminalRated Terminal
voltagevoltage
415 V415 V
Rated over loadRated over load
capacitycapacity
110% for 1 Hr. in every 12 Hrs110% for 1 Hr. in every 12 Hrs
Excitation PowerExcitation Power
ratingrating
38V, 169A38V, 169A 2.6A, 57VDC2.6A, 57VDC 10.3 KVA10.3 KVA
Type of exciterType of exciter With brushesWith brushes
and slip ringsand slip rings
BrushlessBrushless BrushlessBrushless
Type of voltageType of voltage
regulatorregulator
Manual voltageManual 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 Bearings2 = No. of Bearings

Alternator isAlternator 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, DiodesThe excitation unit consists of choke, CT, Diodes
and Condenser.and Condenser.
Voltage is adjustable to within +/Voltage is adjustable to within +/--2.5% of the2.5% of the
nominal voltage from no load to full load at ratednominal voltage from no load to full load at rated
PF.PF.
The choke is meant for adjusting theThe choke is meant for adjusting the teriminalteriminal
voltage at no load.voltage at no load.
The CT is meant for adjusting the terminal voltageThe CT is meant for adjusting the terminal voltage
at load conditions.at load conditions.
Diesel EngineDiesel Engine –– AlternatorAlternator (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 loadOnce the alternator is run to rated speed at no load
the residual voltage appearing the terminals, isthe residual voltage appearing the terminals, is
getting rectified by a 3getting rectified by a 3-- FW bridge rectifier and isFW bridge rectifier and is
fed to the field winding through brushes and slipfed to the field winding through brushes and slip
rings.rings.
Thus the alternator builds up voltage by itself andThus the alternator builds up voltage by itself and
reaches a steady value depending on the choke airreaches a steady value depending on the choke air
gap.gap.
With the help of MVR, the voltage can be adjustedWith the help of MVR, the voltage can be adjusted
when the machine is running with or withoutwhen the machine is running with or without
load.load.
Diesel EngineDiesel Engine –– AlternatorAlternator
Conti….

The advantage of a selfThe advantage of a self--excited system:excited system:
SelfSelf--excited system is inherently self protecting underexcited system is inherently self protecting under
symmetrical short circuit conditions because the fieldsymmetrical short circuit conditions because the field
““collapses".collapses".
Because of this, a main line circuit breaker for protectingBecause of this, a main line circuit breaker for protecting
the generator and the conductors to the first level ofthe generator and the conductors to the first level of
distribution may not be considered necessary, furtherdistribution 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 orderIt 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 toexcited 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 toit will be necessary to ““flash" the field with a DC powerflash" the field with a DC power
source.source.

Self Excited GeneratorSelf Excited Generator
Conti….

Alternator (StageAlternator (Stage –– II & III)II & III)
•• They areThey are ““Separately excitedSeparately excited”” by the Permanentby the Permanent
Magnet Generator (PMG).Magnet Generator (PMG).
•• This is a shaft mounted, high frequency, pilot exciterThis is a shaft mounted, high frequency, pilot exciter
which provides a constant supply of clean power viawhich provides a constant supply of clean power via
the Automatic Voltage Regulator (AVR) to the mainthe 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 bythrough a full wave bridge rectifier, protected by
surge suppression.surge suppression.
Conti….

The excitation system of a separatelyThe excitation system of a separately -- excitedexcited
generator is similar to that of a selfgenerator is similar to that of a self -- excitedexcited
generator except that a separate permanent magnetgenerator except that a separate permanent magnet
generator (PMG) located.generator (PMG) located.
Is a separate source of power, the excitation circuitIs a separate source of power, the excitation circuit
is not affected by the loads on the generator. Theis not affected by the loads on the generator. The
generator is capable of sustaininggenerator 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, separatelyFor these reasons, separately -- excited generatorexcited generator
excitation systemsexcitation systems are recommendedare recommended forfor
applications where enhanced motor startingapplications where enhanced motor starting
capability, good performance with noncapability, good performance with non--linear loadslinear loads
or extended duration short circuit performance areor extended duration short circuit performance are
necessary.necessary.

Separately Excited GeneratorsSeparately Excited Generators
Conti….

Diesel EngineDiesel Engine –– AMF (Automatic MainsAMF (Automatic Mains
Fail) panelFail) panel
This is the user interface of theThis is the user interface of the
generator and contains provisionsgenerator 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 selectorPhase selector
switch, frequency switch, andswitch, frequency switch, and
engine control switch (manualengine 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 anyCheck 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 afterfter
filter or oil replacement.filter or oil replacement.
After DG set is started, check for exhaust. A smoky exhaust mayAfter DG set is started, check for exhaust. A smoky exhaust may
be due to poor grade of oil, dirty air cleaner, over fueling orbe due to poor grade of oil, dirty air cleaner, over fueling or poorpoor
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.
Diesel GeneratorDiesel Generator –– 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.
Diesel GeneratorDiesel Generator –– Start PermissivesStart Permissives

Lube oil pressure lowLube oil pressure low ((< 1Ksc)< 1Ksc)..
Engine over speedEngine over speed (1650 rpm for 10 sec).(1650 rpm for 10 sec).
Coolant temperature is highCoolant temperature is high ((> 95> 9500
C)C)..
Low coolant levelLow 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.
Diesel GeneratorDiesel Generator –– Causes for TripCauses for Trip

Diesel GeneratorDiesel Generator –– 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 lubricatingbefore shutting it down to allow the lubricating
oil and water to carry heat away from theoil and water to carry heat away from the
combustion chamber, bearings, shaft etc., This iscombustion 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 enginefor an engine
because the combustion chamber temperaturesbecause 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 spraythe injector spray
holes and piston rings and can result in stuckholes and piston rings and can result in stuck
valves.valves.

All diesel engines have a priming pump, to allowAll diesel engines have a priming pump, to allow
for removing air from the fuel system. This isfor 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 wouldWithout a priming facility, the start motor would
have to crank the engine over, to bleed and primehave to crank the engine over, to bleed and prime
the system.the system. Excessive use of the starter motorExcessive use of the starter motor forfor
this purpose would damage it, and it would soonthis purpose would damage it, and it would soon
discharge the battery.discharge the battery.
Diesel GeneratorDiesel Generator –– Priming PumpPriming Pump
Conti….

CrankingCranking
To prevent permanent cranking motor damage, doTo prevent permanent cranking motor damage, do
not crank engine for more thannot crank engine for more than 10 sec10 sec
continuously.continuously.
If the engine does not start after aboutIf the engine does not start after about threethree
repeated attempts,repeated attempts, then the starter should not bethen the starter should not be
operated and the fuel system has to be checkedoperated and the fuel system has to be checked
for any faults.for any faults.
Engine oil pressure must be indicated on theEngine oil pressure must be indicated on the
gaugegauge within 15 sec after starting.within 15 sec after starting. If oil pressureIf oil pressure
is not registered within 15 sec, shut off the engineis not registered within 15 sec, shut off the engine
immediately to avoidimmediately to avoid engine damage.engine damage.

Oil / Coolant TemperaturesOil / Coolant Temperatures
The oil Temperature should be maintainedThe oil Temperature should be maintained
betweenbetween 7575 –– 10510500CC under loading conditions.under loading conditions.
Any sudden increase in oil temperature, is aAny sudden increase in oil temperature, is a
warning of mechanical failure. Immediatelywarning of mechanical failure. Immediately ShutShut
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 bestis the best
assurance that working parts of the engine theassurance that working parts of the engine the
expanded evenly to the most favorable oilexpanded evenly to the most favorable oil
clearances.clearances.
Note:Note:-- Continuous operation with low coolant temperature belowContinuous operation with low coolant temperature below 6060 00
C,C,
or high coolant Temperature aboveor high coolant Temperature above 10010000
CC, can damage the engine., can damage the engine.

Normal engine oil pressure atNormal engine oil pressure at
(105(10500C) should be betweenC) should be between 33--77
Kg/cmKg/cm22 at rated speed andat rated speed and 11--22
Kg/cmKg/cm22 at low idle speed.at low idle speed.
A dipstick oil gauge is locatedA dipstick oil gauge is located
on the side of the engine. Theon the side of the engine. The
dip stick has andip stick has an ““HH”” (High)(High)
andand ‘‘LL’’ (Low)(Low) level mark tolevel mark to
indicate lubricating oil supply.indicate lubricating oil supply.
The dip stick must be keptThe 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 withinAfter DG starts, ensure the following parameters are within
the limitthe limit
CoolantCoolant
TemperatureTemperature
BetweenBetween
70 to 9570 to 9500CC
Engine oilEngine oil
pressurepressure
BetweenBetween
3 to 73 to 7 KscKsc
Engine oilEngine oil
TemperatureTemperature
BetweenBetween
75 to 10575 to 10500CC
Engine RPMEngine RPM
Should beShould be
At 1500At 1500
StageStage --IIIIII

The generatorThe generator’’s engine is lubricated by oil storeds 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 ofEnsure the level of lubricating oil every 8 hours of
generator operation.generator operation.
Also check for any leakages of lubricant andAlso check for any leakages of lubricant and
change the lubricating oil every 500 hours ofchange the lubricating oil every 500 hours of
generator operation.generator operation.
Oil change periods, filter change periods, payingOil change periods, filter change periods, paying
attention about selecting the true type of oilattention about selecting the true type of oil
prolongs theprolongs 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 system
Restriction in fuel tank vent.Restriction in fuel tank vent. Restriction inRestriction 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.

Starter
Contactor
Impulse
Timer
Impulse
Timer
Summation
Timer
Lubeoil
Pr.Low
BKRContacts
Multiplication
Fuelsolenoid
Energisation
-24VDC Control
supply
+24VDC Control
supply
To fuel
solenoid

Electrical
fault
Lowlevel
Ofoilintank
HighWater
Temperature
Overspeed
Lackoffuel
DGsetfailed
Tostart
Resetcircuit
Stopcircuit
Enginestop
Onfault
To Engine
Starter

I/C fromI/C from
Unit Aux SWGRUnit Aux SWGR -- 1A1A
I/C fromI/C from
415V DG Switchgear415V DG Switchgear
UnitUnit –– 11 -- 415V Emergency MCC415V Emergency MCC
I/C fromI/C from
I/C fromI/C from
I/C fromI/C from
I/C fromI/C from
I/C fromI/C from
415 V SWYD SER SWGR415 V SWYD SER SWGR
SWYDSWYD
SERSER
TxfmrTxfmr--11
SWYDSWYD
SERSER
TxfmrTxfmr--22
SECSEC -- AA SECSEC -- BBB/CB/C
DGDG-- 11 DGDG-- 22
625 KVA625 KVA
415V DG Bus415V DG Bus
StageStage –– I UnitsI Units ––
Diesel Generator supplyDiesel Generator supply

StageStage –– II -- AMF PanelAMF Panel
GovernorGovernor –– Local / Off / RemoteLocal / Off / Remote
Gov speedGov speed –– Lower / Off / RiseLower / Off / Rise
EngineEngine –– Local / Off / RemoteLocal / Off / Remote
EngineEngine –– Out / Off / InOut / Off / In
24VDC24VDC –– ON / OffON / Off
AC I/P Change over SwitchAC I/P Change over Switch
Battery ChargerBattery Charger -- DCDC
Engine Emergency OffEngine Emergency Off
Eng three attempts circuit resetEng three attempts circuit reset
DG ACB Emergency offDG ACB Emergency off
ManMan VolVol RegulatorRegulator
Over current, EarthOver current, Earth
Fault, over load,Fault, over load,
Restriction E/F,Restriction E/F,
Over voltage, andOver voltage, and
Reverse power relaysReverse power relays
DG ACB ClosedDG ACB Closed
Engine out off serviceEngine out off service
Mechanical faultMechanical fault
Electrical faultElectrical fault
Window AnnunciationsWindow Annunciations
1)1) Low oil pressureLow oil pressure
2)2) Gen set fail to startGen set fail to start
3)3) Engine over speedEngine over speed
4)4) Oil level lowOil level low
5)5) Over loadOver load
6)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
TOTO
TVDCTVDC
UNIT DIESELUNIT DIESEL
GENERATORGENERATOR
750 KVA750 KVA
From UAT # AFrom UAT # A From UAT # BFrom UAT # B
StageStage –– II UnitsII Units –– Diesel Generator SupplyDiesel Generator Supply
EMCCEMCC
I/C FROMI/C FROM
STAND BYSTAND BY
DG MCCDG MCC
USS SEC # AUSS SEC # A USS SEC # BUSS SEC # B
6.6KV/415V6.6KV/415V
1750KVA1750KVA
B / CB / C
STAND BY DGSTAND BY DG
1500 KVA1500 KVA
ODGODG
U # 5U # 5 U # 6U # 6 U # 7U # 7
U # 4U # 4
TOTO
BVDCBVDC

UST # AUST # A UST # BUST # B
TOTO
TVDDCTVDDC
UNIT DIESELUNIT DIESEL
GENERATORGENERATOR
1500 KVA1500 KVA
From Unit BusFrom Unit Bus –– 7CA7CA From Unit BusFrom Unit Bus –– 7CB7CB
StageStage –– III UnitIII Unit –– Diesel Generator SupplyDiesel Generator Supply
EMCCEMCC
I/C FROMI/C FROM
MCCMCC
UNIT SERVICE SWITCHGEAR # 7DAUNIT SERVICE SWITCHGEAR # 7DA
6.6KV/415V6.6KV/415V
2MVA2MVA
B / CB / C
1500 KVA1500 KVA
ODGODG
U # 5U # 5 U # 6U # 6
U # 7U # 7
U # 4U # 4
TOTO
BVDDCBVDDC

Recommendations of 11th Operation MeetRecommendations 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 andted and
recorded once in a year.recorded once in a year.
4.3.4 Ventilation of DG set room4.3.4 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 toer 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 fromrt from
routine testing in the presence of Operation and Electrical mainroutine testing in the presence of Operation and Electrical maintenancetenance
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 avoidd
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 ton 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 anyet 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 (Walkred (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 energizedIn 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 exploredplored
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 beare 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 dieselor 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 setstart DG sets

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