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POWER PRODUCTS

UNICEF TRAINING

SCOPE

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GENERATORS, WELDING SETS, PANELS

PUMPS (SKID & MOBILE)

BARE SHAFT ENGINES

AFTER SALES:- Installation- Servicing- Maintenance- Warranty

SCOPE

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REMOTE MONITORINGCUSTOMERSTRAINING

CONTRACTS LOAD ASSESSMENT

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WHERE WE CAN PARTNER• Water pumping Projects

• Off grid - power

borehole/booster pumps

• Engine couple pumps – water

transfer from dams, rivers

• Genset Standby power application –

unreliable utility supply

• Genset prime power – off grid areas,

schools, hospitals, offices, camps etc.

• Generator/Solar Hybrid systems

ENGINE FUNCTION PROCESS

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•Flywheel

•Crankshaft

Air

Fuel

Mixing Combustion

Exhaust

Power

Useful

Work

•Carburetor •Ignition •Valves

THE WORKING – 4 STROKE

compressionIntake Power Exhaust

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ENGINE RATINGName plate rating (HP/kW), at a given

speed

Continuous & Intermittent ratings

Ratings based on some standard

reference conditions i.e. for NA EnginesAir inlet temp – 25oC

Relative Humidity – 30%

Altitude – 100m

Air pressure, temperature & humidity

affect the air density Engine Output

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DERATING CURVES

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Selection Example – Engine Driven Pump

Determine a suitable engine driven pump to

deliver 35m3/h @ 80m total head. Site Altitude is

1650m asl, ambient temp is 26oC.

Suitable bare shaft pump – DE40/26 (255mm)

@2900rpm

Pump requirement at duty point – 15kW

Pump requirement (maximum) – 18kW

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Example –Engine Driven Pump

Derating for altitude (1650–100) x 1% 15.5%

100

Derating for Temp (26–20) x 2% 1.2%

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Total deration factor 16.7%

(synonymous to 83.3% engine efficiency)

Engine should be derated at 1% for every 100m higher than

100m,above sea level, and 2% for every 5°C temperature above 20°c.

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Example –Engine Driven Pump

Derated engine size ( 18 ) 21.6kW

(0.833)

Allow 15% safety margin 21.6 x 1.15 24.8kW

Kohler KD626.3

As guideline engine size not to exceed 21.6 x 2

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Over loading:

Overheating of the engine & coolant system

Oil viscosity breakdown causing rapid engine wear

Shortened working life of the Engine

Under loading:

Engine not heating up to normal working temp

Oil leakage caused by poor sealing by piston rings

Lacquer formation on the piston cylinder liners

Increased maintenance costs; reduction in power

OVERLOAD/UNDERLOAD

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UNDER LOAD – WET STACKING

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D&S ENGINE RANGE• Generally classified into:

–Governing - Fixed (G-build)/

Variable speed

–Fuel – Petrol or Diesel

–Cooling System – Air/ Water

–Starting method – Hand/ Electric

KOHLER ENGINES

• Rebranded Lombardini Engines

• Two models stocked – Fixed Speed - 1500rpm

– Variable Speed – 2000 – 3000rpm

• Air Cooled– Simplified design

– Simpler maintenance requirements

– Hand / electric start options

• Water Cooling– Efficient cooling and reduced noise operation

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– 6.5 to 27kW

– 1500 – 3000 RPM

Air Cooled

KOHLER ENGINESWater Cooled– 24.5 to 33kW

– 2000 – 2600RPM

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DAYLIFF LOV ENGINES

Engine Data 1004-4Z 1004-4TZ

Continuous

Power kW

1500 rpm 41 65

1800 rpm 46 72

2200 rpm 50 75

• Variable speed design

• Two model, NA and Turbo charged

• PTO on flywheel, fuel tank not incl.

DAYLIFF DLA ENGINES

• 1 & 2 Cylinder variable speed Engines

• Ideal for short term or low budget projects

• Compact air-cooled engines

• 10HP & 17HP power output

• 5.5 and 7lt engine mounted fuel tanks and

drive shaft

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DAYLIFF PETROL ENGINE

• 6HP 3600rpm bare shaft Engine

• Chaff Cutter Engine• Supplied in cylindrical shaft

with key way• 3.6l Fuel tank, recoil start

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SKID MOUNTED SETS

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1. HIGH FLOW PUMPS–For small scale irrigation

projects

D&S PORTABLE PUMP

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2. HIGH PRESSURE

• For long distance pumping

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GENERATOR SYSTEM

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GENERATOR SYSTEM

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•Suitable prime mover/ Diesel engine

•AC generator (Alternator)

•Control circuit & AuxiliariesControl Cubicle

Engine

AVM

Start battery

AlternatorBase fuel tank

OPERATION PRINCIPLE

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GENSET RATING• Usually expressed in kVA

• Prime power:

-Supply of continuous power ALL DAY

-Applies to utility power installations

• Standby power:

-Prime power plus overload of 10% for 1 of every 10hours

-Applies to standby power installations

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Load Capacity

Consideration for special loads

Wiring configuration of the load

Future expansion plans

Site conditions effects on performance (deration)

Cable sizing for current and voltage drop

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FACTS WHILE SIZING

GENERATOR LOADING

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• Current output is determined by the connected

load

• When a three phase generator is loaded with

single phase loads

a) The loading may be imbalanced (phase

imbalance)

b) The maximum single phase power between

any line and neutral is 1/3 of the total 3 phase

power.

• A 12 lead stator can be reconfigured for both single

or 3 phase outputs

CONDUCTING A SUCCESSFUL SITE SURVEY

Tools: Altimeter, Clamp meter, Tape

measure, Screw drivers, analysers

Site Details:

• Power supply– No. of incoming power points

– Transformer details i.e. one or multiple

• Meter system– No. of Utility Power meters & location

– Single or three phase? & quantity

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CONDUCTING SITE SURVEY• Load Balancing

– Use clamp meter

• ATS location– Identify where to mount taking into consideration

weather condition

– Cable management – saddle clips or cable tray

• Generator Installation location– Accessibility – crane truck, pallet truck

– Noise consideration

– Length of cable

– Earthing arrangements

– Cable routing

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CONDUCTING SITE SURVEY• Generator Plant Room

– Plant room dimension - door

– Ventilation requirement

– Need for hot air ducting

– Exhaust pipe routing

– Type of plant room – steel cage, block wall

• Type of load– Resistive, capacitive, inductive

– Starting sequence

– Starting method for motors

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GENERATOR SIZING1. List Of Appliances & Rating

• When sizing a generator it is not always

sufficient to simply add together the ratings of

all electrical equipment.

• This is because it is unlikely that all the

electrical equipment on a supply will be used

simultaneously.

• Diversity factor is applied to work out the load

which can simultaneously be in operation

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GENERATOR SIZINGNo. Load Qty Power

Rating

(Watts)

Total

Wattage

(Watts)

Diversity

Factor

Net

Wattage

(Watts)

Single Phase Load

1 Instant shower 50 4,500 225,000 30% 67,500

232'' LED TV 50 120 6,000 50% 3,000

34 ft Fluorescent Lights 50 36 1,800 80% 1,440

4Energy Saving bed lamps 100 18 1,800 80% 1,440

5TFT Computers 6 300 1,800 100% 1,800

6Printer 1 120 120 30% 36

7Photocopy 1 500 500 30% 150

8Cooker/Oven 1 3,000 3,000 40% 1,200

9Microwave 1 1,200 1,200 20% 240

10Fridge 1 250 250 70% 175

11Freezer 1 500 500 70% 350

Total Wattage (Watts) 241,970 77,331

Three Phase Load

12Grundfos SP 9-40 1 7,500 7,500 100% 7,500

Total Wattage (Watts) 84,831

Factor 80% Loading Level (Watts) 106,039

Add 20% for future Expansion (Watts) 127,247

Proposed Generator Size 159,058

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GENERATOR SIZING2. Clamp Meter Reading

• Clamp each line with equipment switched on.

• Base calculation on highest phase currentPower (VA) (1 phase) = VxI

Power (VA) (3 phase) = √3xVxI

• Take note of peak requirement for induction

load - motors

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GENERATOR SIZING3. Energy Analyser

• Recommended for complex installations with

varying load demand – hospitals, malls,

factories

• Most accurate approach

TYPE OF LOAD• Single-phase loads and load imbalance.

• Peak loads - Such as welding, medical imaging equipment

• Motor loads - Result is a high inrush current

• Variable frequency – induce distortion in generator output voltage (Harmonics).

• Uninterruptible power supply - non-linear load, require appropriate filters

• Lifts

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CABLE SIZING• Cables have internal resistance which

causes voltage drop (heat)

• Why size cables?:1. Ensure that you get adequate voltage at the end of the line2. Safety – to avoid cables melting due to heat

• Cable size is selected as follows:1. Cable is calculated on current capacity2. Voltage drop is calculated (and cable size increased if necessary)

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• Sized based on Load/Capacity of the generator

• Cables must be sized for both maximum current and max allowed voltage drop

Current (1 phase) = kVA x 1000V

Current (3 phase) = kVA x 10001.73 x V

Cable Sizing Example!

Cable Sizing

Cable Sizing Chart

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TRANSFER PANEL• Changeover switch – electrical switch that switches a

load between two sources

• Comprises: sensing (AMF) and switchgear (ATS)

• AMF – monitors utility & initiates automatically load

transfer

• ATS – Automatically connects the load to available

power

• Capacity must be matched to the rating of the service

equipment

• Two types: manual and automatic

Application

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Yanan Motorised ATS

• Offer with Yanan and

Jubaili Perkins generators

• Fitted with DSE 6020 with

AMF capability

• Motorised Changeover

with provision for manual

operation

• Match current output of

generator with ATS size

(125A, 250A,400A)

• Control cable – 2 runs of

2.5mm2 x 3 core

PVC/SWA)

Application

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Remote Start ATS• For generators without

AMF capability

• Lister Petter (DSE5110)

• Can also work with

Yanan and Perkin

generators

• Sensing/Control done by

ATS

• Contactor based

• Manual by-pass switch

recommended

• Control cable – 1 runs of

2.5mm2 x 4 core

PVC/SWA)

Application

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Manual Changeover Switch

• For key start generators

without AMF control

modules

• Dayliff key/recoil start

generators. Petrol,diesel,

Kohler

• Install with pilot lamps to

indicate mains availability

Application

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Dayliff DG AMF

• For automatic range of

DG portable generators

• DG6000DS,

DG11000PS,

DG12000DS

• Have AMF capability

• Control Cable supplied

with AMF approx. 2.5m

• Power cable – 1 run of 4

Core cable for single

phase and 2 runs of 4

core cable for three

phase

Application

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Multi-Tariff AMF

• For installations with

more than 1No. Utility

meter

• Avoid billing when load is

on mains supply

• Set of contactors for each

of the utility meters

• Generator distribution

boards for multiple

changeover switches

• Remote /potential free

start signal

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Multi-Tariff AMF

Application

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Manual By-Pass Switch

• Recommended for

contactor based transfer

switches

• By-passes the

changeover switch in

case of faulty or when

servicing

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ATS Set-Up

PLANT ROOM

The alternator must be protected from weather

Large enough size - ventilation & working space

Proper plant room layout

Level, flat & compact floor

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PLANT ROOM LAYOUT

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PLANT ROOM

GENSET SYNCHRONIZATION

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PARALLELINGParalleling is an operation in which multiple power sources, usually two or more generator sets, are connected and synchronized to a common bus.

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WHY SYNCHRONIZE– To allow the generating capacity of the

system to be expanded as site load increase

– When site load varies greatly multiple units

avoid a scenario of “light loading”, which will

damage the engine

– Physical constraints of the installation site

– Allows uninterrupted supply even during

servicing/maintenance

– In some cases, cost

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CONDITIONS• The number of phases and direction of

rotation

• The voltage amplitudes of the two\multi

systems

• The frequencies of the two\multi systems

• The phase angle of the voltage of the

two\multi systems

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PHASE ANGLE

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60kVA UNOPS

DSE REMOTE MONITORING

HARDWARE

• DSE890 Gateway

•GSM/GPRS Antenna

•DSE Control module

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What we can monitor?

-

What we can monitor?

-

What we can monitor?

• Sourced from Jubaili Brothers

• 12.5 to 2250kVA prime power rating

• Perkins (UK/USA) engines

• High efficiency Mecc Alte/ Leroy Somer

alternator

• DeepSea control modules

• Assembly UK (Marapco) & UAE (JET)

DGJ PERKINS RANGE

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JET & MARAPCO BRANDDIESEL GENERATOR SETS

ARE POWERED BY PERKINS ENGINES

DGJ PERKINS RANGE

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• Based on Isuzu

Engine design

• Ind., Agric. &

Vehicles

• 20 – 30kVA

DGY YANAN RANGE

• Joint Sino – UK Venture

• Customized for ease of

maintenance Service

parts on one side

• Ind., Agric. & Vehicles

• 45 – 70kVA

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DGY YANAN RANGE• Powered by Cummins Engine

• Local Support – Many spare

parts distributors

• 56kVA - 400kVA available ex-

stock

• Wider range available–up to

2000kVA – special order

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OEM CERTIFICATES PERKINS

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OEM CERTIFICATES YANAN

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DEEP-SEA MODULES• Standard - DSE 6020 (AMF)

• DSE 7310/DSE 7320 & DSE 8610

• PC and front panel configurable

• Load Transfer Switch – Motorized

and Contactor Based

KOHLER GENERATORS• Air cooled Open Sets

• Yanan & Linz Alternators as options

• Fitted C/panel – MCB, on-off switch,

hour-meter, digital display

• Inbuilt Autostop protection

• Key Start

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• Premium Honda engine

• 2.2 to 6.5kVA 1 phase

power rating

• Large capacity fuel tank

for longer operation

• DC output for extra battery

charging

• Compact and light weight

design

ELEMAX HONDA

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DG-P PETROL

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• 0.6 to 10kVA 1 phase power rating

• Value for Money – Reliable, Efficient

• Auto start function for DG-PS series

• DC output for extra battery charging

• Warranty, Spares and after-sale service

DG-D DIESEL

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• 4.5 & 10kVA 1 phase

• 12.5kVA 3 Phase

• Auto start function for

DG-DS series

DAYLIFF DGW• Option for Petrol or Diesel

• Diesel - 4.2kVA AC output; 180A arching

current; 28-35VDC

• Petrol – 5kVA AC 200A welding current

• Complete with electrode holder, welding clamp

& output plugs

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SUCCESSFUL PROJECTS

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WHY D&S• We offer solutions

• Complete range of Generators, engines &

associated accessories – premium quality

• Professional installation

• After Sales Support

• Maintenance contracts

• Warranty

• Spare parts

• Innovative products/customized

• Wide Branch network – response time

Thank You

powerdesk@dayliff.com

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