Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the...

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Powerol Sales Guide Necessity And Advantages Of DG Set Energy is needed for every system. To cater the needs of Industry, Residential, Agriculture and other purpose, State Electricity Boards Generate, transport and distribute Electrical Energy. The prime sources of energy are Coal, fossil fuel, Water, Nuclear fuel and Natural Gas. All these Power Plants are Economic only if they are built on large capacity i.e. 200 MW and above. Also the capital cost of establishment is very high. Due to larger demand of power than the generated, State boards can not supply power continuously. Also, the power is not available where the area or plant is under development. To have alternate source of Power, Diesel Generating Set is the ideal solution. It is used mainly as Standby Source and sometimes as Continuous Duty. MAHINDRA & MAHINDRA are one of the large manufacturers of DG sets, under the name POWEROL The range of the DG set is from 2.5 kVA to 500 kVA Chapter 4 - Basics of Diesel Generator Features of Mahindra Powerol Products Main Features of POWEROL are as below l The DG Set is housed in an acoustic enclosure. l Weather proof enclosure provides protection against all environmental conditions. l Easy for lifting- shifting. l Easily detachable Diesel Tank, for cleaning purpose. l Easy access for emergency stop control l Size of control panel is adequately large to provide better cooling. l Inner volume of acoustic canopy is larger to provide more air for cooling and engine aspiration.

Transcript of Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the...

Page 1: Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

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Necessity And Advantages Of DG SetEnergy is needed for every system. To cater the needs of Industry, Residential, Agriculture and other purpose, State Electricity Boards Generate, transport and distribute Electrical Energy. The prime sources of energy are Coal, fossil fuel, Water, Nuclear fuel and Natural Gas.

All these Power Plants are Economic only if they are built on large capacity i.e. 200 MW and above. Also the capital cost of establishment is very high.

Due to larger demand of power than the generated, State boards can not supply power continuously. Also, the power is not available where the area or plant is under development.

To have alternate source of Power, Diesel Generating Set is the ideal solution.

It is used mainly as Standby Source and sometimes as Continuous Duty.

MAHINDRA & MAHINDRA are one of the large manufacturers of DG sets, under the name POWEROL

The range of the DG set is from 2.5 kVA to 500 kVA

Chapter 4 - Basics of Diesel Generator

Features of Mahindra Powerol ProductsMain Features of POWEROL are as below

lThe DG Set is housed in an acoustic enclosure.

lWeather proof enclosure provides protection against all environmental conditions.

lEasy for lifting- shifting.

lEasily detachable Diesel Tank, for cleaning purpose.

lEasy access for emergency stop control

lSize of control panel is adequately large to provide better cooling.

lInner volume of acoustic canopy is larger to provide more air for cooling and engine aspiration.

ABC
Text Box
Basics of Diesel Generator
Page 2: Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

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Main components of DG set are

lDiesel Engine

lAlternator

lBase frame for Mounting

lFuel Tank

lEngine Control Panel

lAlternator Control Panel

lSilencer

lSound reducing Canopy

Diesel Engine

Engine converts heat energy into mechanical energy in rotational form. Heat is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

Alternator

Alternator converts the rotational mechanical energy into Alternating Current – Voltage and Power . Rotating magnets in alternator, generate AC voltage.

Base frame for Mounting

Engine and Alternator are mounted on Steel Base frame.

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Fuel Tank of DG Set

Alternator

Battery

Inside of DG Set - Rear Face

DG Set Fuel Tank

Diesel Tank - Removable

Fuel Tank

lFuel tank is housed in base frame.

lFuel tank can be taken out easily from the base for the purpose of cleaning.

lNormally Diesel storage capacity of the tank is sufficient for continuous running for 8 hours.

Page 4: Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

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Engine Control Panel – Manual operation

lEngine is started manually, maintains constant speed, stopping of the engine is manual.

lThe engine stops immediately, in case of any abnormal condition or accident.

lThe control panel indicates the nature of fault.

Alternator Control Panel

lFunction of Alternator control panel is to develop voltage, maintain constant output voltage, within specified limits, switch ON or OFF, the power supply, switch of the supply in case of fault or accident, indicate power consumption and nature of fault.

Silencer

Is used to arrest the sound caused by Internal Burning of Fuel and generated at exhaust.

Sound reducing CanopyDuring running, Sound generated by, moving components, Fan and external components of any Diesel Engine. A silencer is used for the purpose. However even the reduced sound is harmful to human ears. Hence it is essential to restrict the audible sound surrounding the DG set upto distance of 1 meter. It is reduced by covering the entire DG set by Acoustic and mechanically strong enclosure.

Page 5: Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

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CPCB Norms and CircularCentral Pollution Control Board have set norms for limits of pollution due to sound and Smoke Emission. And it is compulsory to follow the norms.

The GSR says,

“Noise Limit for Generator Sets run with Diesel

1. Noise limit for diesel generator sets (upto 1000 KVA) manufactured on or after the 1st January, 2005

The maximum permissible sound pressure level for new diesel generator (DG) sets with rated capacity upto 1000 KVA, manufactured on or after the 1st January, 2005 shall be 75dB(A) at 1 meter from the enclosure surface.

The diesel generator sets should be provided with integral acoustic enclosure at the manufacturing stage itself.

POWEROL Gensets are approved as per the norms.

Sound Reducing Barrier

Inside Alternator

DG Set showing Acoustic enclosure

Page 6: Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

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Basics Of EngineIn 1892, Rudolf Diesel Invented the Engine run by Fossil Fuel. Further the Engine and the fuel was called by the name Diesel.

Main parts of the Engine are:

Cylinder Block, Piston, connecting rod, crank shaft, fly wheel.

A piston is placed in a cylinder and allowed to move up-down.

A small amount of air + fuel mixture is forced into the gap between over piston.

Due to very high pressure, the mixture gets ignited. The burnt gas creates very high pressure on the piston. The piston is forced down.

While piston moves down, it rotates the crank shaft.

Hence the linear motion of piston is transferred to crank shaft. Crank shaft converts the linear motion in rotation.

Radiator

Fuel Filter

Bell Housing

Fly Wheel

Air Filter

Engine Images

Exhaust Manifold

Oil Filter

Oil Sump

Starter

Fuel Pump

Page 7: Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

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Engine has 5 main systems

1. Fuel Injection System: Diesel and Air are mixed in a specific ratio and pumped in each cylinder with high pressure. The fuel is ignited with high pressure compression. Fuel is first passed through a filter and then pumped in cylinders. For burning of fuel adequate air must be available.

Fuel Injection System

2. Exhaust System: The burnt hot gases are carried out through common duct. They are directed away from the DG set and should be guided through a high duct, so that it is not harmful to the persons, around it.

3. Lubrication System: The moving parts and piston rings have a great friction. Oil is circulated in engine with pump for effective lubrication. Oil is passed through filter and then pumped in system.

4. Cooling System: Engine gets heated due to burning of gases inside. It needs cooling. The engines are cooled by Air with help of Fan or they are cooled by Water radiator. The DG set must have a sufficient space around it for better cooling.

5. Governing System: Engine speed is maintained constant at 1500 RPM, with tolerance within 4%. The unit for control of speed is called Governor. Governors are Mechanical or Digital type.

Page 8: Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

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The various Terms used in specifications of Engine:

lHP : [IP ] Indicated Horse Power. Power Developed by the engine

in its cylinders.

lBHP : Brake Horse Power . Power available at output shaft /

flywheel. IP – Friction losses.

lRPM : Revolutions Per Minute. Speed of the engine is measured in

RPM

lTYPE :

lSFC : Specific Fuel Consumption. Fuel consumed in Litres /

BHP / Hour

lAIR COOLED : Engine is cooled by air with help of fan.

lWATER COOLED : Cooling is done with Water Radiator. Radiator is

cooled by a fan mounted on engine.

lTURBO CHARGED : A Turbo charger is connected in air inlet

system to enhance output power of engine.

Filter Units : To ensure entry of clean fuel , clean air and clean oil, they

are filtered before entry into engine.

Filter Units are need to be replaced after a specific period or after

specific running hours of engine.

Engine Oil : Lubricating Oil is to be replaced after a specific period or

after specific running hours of engine.

Page 9: Chapter 4 - Basics of Diesel Generator - Mahindra … is generated by burning Diesel Fuel inside the cylinder block. Engine Fly wheel is coupled to alternator and alternator is rotated.

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Alternator

Principle Of Operation-Stator-Rotor-Excitation-Control

When Magnetic rotor is rotated in stator coils, A.C. voltage is generated in stator.

Rotor of alternator is coupled to Engine. Speed of the Engine is maintained

constant at 1500 RPM [Rotations Per Minute]

TerminologyVoltage : Voltage is level of Electrical pressure. e.g. 240 Volt; 440 volt;

6600 volt etc.

Current : unit of measurement is Ampere. It is flow of electric power in wire.

E.g. 5 Amp; 15 Amp; 100 amp. Etc.

Phase : e.g. Single phase; three phase. i.e. the number of windings in the

stator.

KW = Kilo- Watt = 1000 Watt = Useful Power supplied by Alternator

KVA = Kilo- Volt- Ampere = 1000 Volt x Ampere = Total Power Generated by

alternator

RPM = Rotations Per Minute = Revolutions of rotor per minute.

Power Factor = Useful Power of load ÷ Total Power Generated by

DG set

Alternator

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Alternators are available with output of Single phase – 240 Volt or 3

phase 415 Volt. Depending upon the load requirement, select 1 phase or

3 phase alternator. The terminal arrangement of terminal box is as shown

in fig.

Single phase alternator has 2 terminals in connection box. They are:

LINE and NEUTRAL.

Three phase alternator has 4 terminals in connection box. They are: RED – YELLOW – BLUE - NEUTRAL.

AVR

Single Phase Alternator - Terminal Box

Phase

Neutral

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AVR : Automatic Voltage Regulator is fixed in the connection box. The functions of AVR are:

lIt maintains constant voltage output at all the loads.

lVoltage setting can be done ±10% of rated voltage.

lOutput voltage is switched OFF, in case of overload of problem of lower speed of engine. Alternator can be saved from further damage.

Control Panel

Alternator Control Panels are of two types.

1. Standard Panel

2. AMF Panel [Automatic Mains Fail – controlled panel]

STANDARD Control Panel : It has following features

lEngine ON / OFF control - done manually.

lPower ON / OFF control – manual operation.

lIndicating meters – Voltmeter, Ammeter, Frequency Meter, Hour meter.

lIndicating lamps for DG ON / OFF, Power ON / OFF.

lProtection circuit – Power goes OFF, if there is overload.

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AMF Panel – FEATURES AND APLICATIONS

lAutomatic Sensing of Failure of supply of Mains Power.

lRelay for command to Start Engine.

lRelay to switch ON supply.

lSensing restoration of Mains.

lCommand to switch OFF DG Supply.

lCommand to Stop Engine.

lIndicating meters – Voltmeter, Ammeter, Frequency Meter, Hour meter.

lIndicating lamps for DG ON / OFF, Power ON / OFF.

lProtection circuit – Power goes OFF, in case of overload.

lSupply for DG and supply from Mains, can not be short circuited.

Voltage, current, frequency meter

Hour meter

Control unit

Auto/Manual/ Test switch

AMF Panel