bts Generators

7/29/2019 bts Generators

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SCHEME OF PRESENTATION Introduction to Genset

Why Genset is required

Advantages of Gensets

Types of Gensets maintained by Mobiserve

Genset Capacities

General Technical Terms

Difference b/w Diesel Engine and Spark Ignition(Gasoline) Engine

How a Diesel Engine works

Engine Identification

Views of an Engine

Identification and basic function of Engine parts andcomponents

Maintenance requirement

Types of maintenance

Preventive maintenance

Overhauling


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GENSET stands for Generator Set

Combination of:

Engine

Electric Generator or Alternator

Engine is a prime mover

Electric Generator generates electricity


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AVAILABLE POWER SOURCES AT SITE Normal: WAPDA Power Supply

Emergency: Genset

Backup: UPS/Battery

1

2

3


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Independent Power Source

Emergency Power Supply

Ease of Mobility

Power Supply at Remote Sites

Rugged and robust

Easy availability of fuel

Efficient working even in worst environment Water-cooled Engines have 85% mechanical

efficiency


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Make Rating(KVA)

Quantity Total

C-1 C-2 C-3 North

Perkins 20, 27, 30, 31 913 580 585 666 2744

John Deere 31 226 231 181 27 665

Others 14, 17, 20,24, 27, 30,

31, 100

91 1 5 146 243

TOTAL 1230 812 771 839 3652


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Thermodynamic Cycle:

Air Intake

Compression

Ignition

Combustion

Exhaust

Top Dead Center (TDC)

Bottom Dead Center (BDC)

Piston Stroke

2-Stroke and 4-Stroke

Cylinder Bore

Swept Volume

TDC

BDC

Piston Stroke

Cylinder Bore


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Diesel Engine Spark Ignition Engine Intake: Just AIR Intake: Mixture of PETROL and

AIR

Ignition: Heat of compressed air Ignition: Spark Plug

Compression ratio: 14:1 to 25:1 Compression ratio: 8:1 to 12:1

Higher compression ratio leads tobetter efficiency

Less efficient


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Intake: Fresh Air

Compression: Very high pressure

Fuel Injection: Fine fuel spray by Fuel Injectors

Combustion: Spontaneous combustion

Expansion: Gases expand

Exhaust: Burnt gases rush out


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Intake: Downward piston travel Intake valve is opened Air, fuel mixture enters

Compression: Intake valve is closed

Piston travels back up Intake air is compressed Fuel is injected near TDC

Combustion: Ignition Piston is forced down

Exhaust:

Piston rises up Exhaust valve is opened Exhaust gases go out

Completes the thermodynamic cycle in FOURmovementsof the piston (TWO crankshaft revolutions).

Camshaft

Camshaft

FuelInjector

Intake

andExhaustValves

Piston

Connecti

ng Rod

Crankshaft

Jacket CoolingWater Ports


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Downward PistonStroke:

Exhaust valve opens Exhaust gases rush out Intake port uncovers Fresh air is sucked in

Upward PistonStroke:

Intake port is blocked Exhaust valve closes Compression of intake air Fuel injection Combustion

Completes the thermodynamic cycle in TWO movementsof the piston (ONE crankshaft revolution).


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Engine Serial Number Significance

Exact identification of Engine

Correct procurement and replacement of spare parts

Make Perkins

John Deere

Serial Number

Model Number


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PERKINS

ENGINE SERIAL NUMBER

DGB 06 0081 U 0017 B

PERKINS MADE IN UNITED KINGDOM

PERKINS 4000 Series EngineDGB 06 0081 U 0017 BStafford ..DApplication Code (Genset).GEngine TypeB

Number of Cylinders06Fixed Bill Number (0000 means ConfiguredProduct) 0081United Kingdom..U17th Engine This

Year..0017Year Letter (B=1996).B

JOHN DEERE ENGINECD3029D500000CD ............... Producing factory

CD= Saran-FRANCEPE= Torreon-MEXICO

PY= L & T - John Deere (Pune-INDIA)3029 ........... Engine modeldesignation

3 = Number of cylinders029 = Total displacement (029 =

2.9 liters)D ................. Aspiration code

D= Naturally AspiratedT= Turbocharger


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According to Engine Types and Models

Right side

Left side

Engine top Rear End (Drive End)

Left Side Right Side Engine TopRear End


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RockerArm

RockerCover

Air Intake and

ExhaustValves

Turbochar

ger

Camshaft

Atomizer

CrankshaftPulley

ConnectingRod

Piston

OilFilter

Oil Sump

Crankshaft


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Main Parts and Components

Engine Block Crankshaft

Main Bearings

Connecting Rods

Pistons

Piston Rings

Cylinder Liner

Intake and Exhaust Valves

Cylinder Head

Engine Gaskets Oil Sump

Flywheel

Lubricating Oil Pump Fuel Injection Pump

Fuel Injectors

Governor

Cooling Water Pump

Radiator Fan

Radiator

Fuel Filter

Lubricating Oil Filter

Weather Proof Enclosure

Muffler


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Basic Structure of an EngineCONTAINS:CrankshaftPistons and Connecting RodsCylinder Head

All other ancillaries


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CONVERTS

Reciprocating Movement of

PISTON and CONNECTING RODS to:

Rotational Movement


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FlywheelCranksh

aft

Cranksh

aft Gear

Crankshaft

Pulley


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Minimize friction

Frictionless movement of crankshaft

Avoid metal to metal contact

Ease of maintenance

Reduced maintenance cost


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Connects: Piston Crankshaft

Form Combustion Chamber

Power generation by

combustion gases

Allow reciprocating

movement of pistons
http://en.wikipedia.org/wiki/File:Piston_and_connecting_rod.jpg


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Sealing between CombustionChamber and Oil Sump

Maintain compression

chamber pressure

Efficient compression

Types:

Compression Rings Oil Scraper Rings


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Provide timed passage to: Intake air Exhaust gases

Controlled opening andclosing by Rocker Arms andCamshaft

Fitted in Cylinder Head

Types:

Air Intake Valves Exhaust Valves


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Top of an engine

Fitted with:

Air Intake Valves

Exhaust Valves Fuel Injectors Rocker Arm Assembly

Air Intake and Exhaust Ports

Cooling Water passages


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Top Gasket or Cylinder HeadGasket:

Provide sealing between

Cylinder Head and CylinderBlock

Bottom Gasket or Oil SumpGasket:

Provide sealing betweenCylinder Block and Engine OilSump


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Engine oil storage

Provides:

Oil suction to Oil Pump

Oil drain facility

Easy access for engineinspection andmaintenance


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Stores inertial forceof movement

Absorbs enginejerks

Provides smoothengine rotationalspeed

Ring gear connected

with Starter Motorfor initial start


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Gear type pump

Driven by Crankshaft To supply lubricating oil to

Engine moving parts:

Main and Big End Bearings

Camshaft

Rocker Arms

Cylinders and Pistons

Timing Gears etc

Take suction from EngineOil Sump


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Fuel Tank

Fuel Lift Pump

Fuel Filter

Fuel Injection Pump

Fuel Injectors

Fuel Tank


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Gear type pump

Driven by Crankshaft

To supply accurate fuel quantity in a

specific order and sequence to the

Engine through Fuel Injectors

Take suction from Fuel Tank

through:

Primary Fuel Filter

Fuel Lift Pump Secondary Fuel Filter

Fuel Tank


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Supply diesel fuel to the engine Produce very fine fuel spray into the

cylinder

Better Air/Fuel mixture, efficient

combustion

Actuated by fuel pressure

Fuel is pressurized by Fuel Injection Pump

Fuel Tank
http://en.wikipedia.org/wiki/File:Injector3.gif


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Regulates the Idling Speed and Maximum Speed

Controls the rate of fuel delivery Without Governor engine can easily overspeed resulting

DESTRUCTIONDESTRUCTION

Diesel Engine - Fuel is controlled

Spark Ignition Engine - Air is throttled Types:

Mechanical Governor Electronic Governor

(ECM, ECU)

Fuel Tank

Governor


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CoolantTemperature

Gauge

Water is used in Cooling System

NEVERuse SALINE WATERin Engine Cooling System

Recommended: Distilled Water or Deionized Water

Ethylene Glycol

Propylene Glycol

Water/Glycol mixture provides protection against:

Boiling

Freezing

Water Pump cavitations

Water/Glycol mixture: 1:1

Ethylene Glycol

Concentration Freeze Protection Anti-Boil Protection

50 Percent -36 C 106 C

60 Percent -51 C 111 C


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Combustion process generates heat

Excessive heat can damage engine

components

Cooling system removes heat Coolant: Distilled Water, De-ionized

Water

Water is circulated by Cooling Water Pump

Water is circulated through engine water

jackets


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Forced air for better heat transfer i-e

Convectional Heat Transfer

Fitted on a belt driven pulley

Crankshaft pulley drives Radiator Fan

Normally V-Type Belts are used

Imbalanced, damaged or fan withloose belt may cause vibration


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Important component of CoolingWater System

Water passes through Fine CopperTubes

Radiator fan blows air through fins

Heat is transferred: Copper Tubes

Fins Convectional Heat Transfer


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Engine needs fine fuel spray

Fuel spray by Fuel Injectors

To maintain fuel quality Fuel Filters

are used Filters separate:

Water Contamination Particulate Contamination

Types: Primary Fuel Filter

Secondary Fuel Filter


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Lubricating Oil passes through fine

orifices

L.O makes a very fine oil film between

two metal

Prevents metal to metal contact L.O quality is most important

To maintain L.O quality Oil Filters are

used

Oil Filters remove ParticulateContamination


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Used for initial starting of an

Engine

Battery (DC Power) runs Starting

Motor

Starting Motor turns the Crankshaft

Thermodynamic cycle completes

and Engine starts


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Protects Engine and Generator

from: Harsh environment

Relative humidity

Dust/Dirt

Malicious damage

Theft

Sound attenuation

Fitted on Exhaust System

Sound attenuation


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We need uninterrupted Electrical Power

Supply Genset runs when WAPDA Power Supply

is not available Genset Running Conditions:

Harsh environment Continuous operation

Maintenance improves: Equipment/Machinery life Service quality

Maintenance reduces unexpected

downtime and major breakdowns


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Preventive Maintenance (PM)

To prevent a defect or damage

Corrective Maintenance (CM) Fault finding Fault rectification


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Change Engine Oil

Change Oil Filter

Change Fuel Filter

Change Air Filter

Radiator inspection and cleaning (if chocked)

Battery inspection

General cleaning


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Cylinder Liners

Pistons

Piston Rings

Gudgeon Pin

Engine Valves

Valve Seats

Valve Springs

Valve Guides

Main Bearings

Big End Bearings

Con-rod Bush Front & Rear Oil Seals

Engine Gaskets


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