Power Generation System

Power Generation System and
Troubleshooting of Diesel Generator

“Your Body is the Engine. Your Mind is the Engineer”
-Ritik Sharma
Eng. Mohamed I Hussein
BSc. EE, PSTG BM, MSc IM
Eng. Mohamed Ibrahim (Xoogsade)
Objectives
General Objective
❑ To explain general concept of the Electrical Power System.
❑ To identify and analysis the structure and all the parts related with a Diesel
Generator.
❑ To study working procedure of Diesel Generator.
❑ To determine the process of maintaining, operation and troubleshooting of
a Diesel Generator.
❑ Suggest probable solution of the identified problem.
Eng. Mohamed I. Hussein
Norms of Our Work

If you think it, say it
Ask questions
Take care of yourself and neighbour
What is said here stays here; what
you learned here, leaves here.
Be present
Electrical Power System

Heart ---- Generation
- heartbeat- pump
- Pressure-Voltage power
Large arteries --Transmission
Small arteries -- Distribution
Electrical Power System

2
1
3
4
Facts About Synchronise Machines

❑ 99+% of all world power is generated by synchronise generators
Power Generation
Diesel Generator-What is it?

A Diesel Generator is the combination of a diesel engine with an electric generator
(often called as alternator ) to generate Electrical energy.
Energy Source ?
Prime Mover?
Electric generator?
Engine
Generator
Diesel Generator-What is it?

An electric generator is a device that covers mechanical energy to electrical energy.
A generator forces electric current to flow through an external circuit.
The source of mechanical energy may be a reciprocating or turbine steam engine, water
falling through a turbine or waterwheel, an internal combustion engine, a wind turbine,
a hand crank, compressed air, or any other source of mechanical energy.
Generator provide nearly all of the power for electric power grids.
Please, visit the link below:

How a diesel generator works
Power rating
Common generator power rating and their application
Standby Rating Prime Rating Base Load Rating

Applicable for supplying emergency Used for varying load and Applicable for supplying power
power for the duration of normal unlimited time. continuously to a constant load up to
power interruption. Typical application - where the the full output rating for unlimited
No sustained overload capability is generator is the sole source of hours
available for this rating. No sustained overload capability is
power for say a remote mining or
Typical application - emergency power available for this rating. Consult
construction site, fairground,
plant in hospitals, offices, factories Authorized distributor for rating
festival etc.
etc. Not connected to grid. Typical application - a generator
running a continuous unvarying load,
or paralleled with the mains and
continuously feeding power
Diesel Generator - Why?

Diesel generator sets are used in places without connection to the power grid, as
emergency power supply if the grid fails, as well as for more complex applications such
as peak - lopping, grid support and export to the power grid.
Main Components of a Generation

An electric generator is a device that converts mechanical energy obtained from an
external source into electrical energy as the output.
The main components of an electric generator can be broadly classified as follows:
Engine
Alternator
Fuel System
Voltage Regulator
Cooling and Exhaust Systems
Lubrication System
Battery Charger
Control Panel
Main Assembly / Frame Figure: Main Component of Generator
Engine
Engine
Device transforms one form of energy to another form.
Heat engine: Engine which converts thermal energy in to mechanical energy.
Ex: steam engine
Classified as:
External Combustion Engines (EC Engines)
Internal Combustion Engines (IC Engines)
IC Engines
IC Engine
The engine is the source of the input mechanical energy to the generator. The size of the
engine is directly proportional to the maximum power output the generator can supply.
Generator engines operate on a variety of fuels such as diesel, gasoline, propane (in
liquefied or gaseous form), or natural gas.
Smaller engines usually operate on gasoline while larger engines run on diesel, liquid propane,
propane gas, or natural gas.
IC Engine Major Parts

Engine/Cylinder block, cylinder head, and crankcase

▪ Engine / Cylinder block
▪ Piston
▪ Piston rings
▪ Piston pin
▪ Connecting rod
▪ Crankshaft
▪ Engine bearing / crankshaft bearing
▪ Crank case
▪ Engine oil pan
▪ Cylinder head
▪ Cam shaft
▪ Suction & exhaust Valves
▪ Valve Timing gear / Timing belt and pulley
▪ Inlet manifold & exhaust manifold
▪ gaskets
▪ Tappet cover
▪ Spark plug (used in petrol / gasoline engine)
▪ Fuel injector (used in diesel engine)
▪ Fuel supply system
IC Engine/ Cylinder Block

❑ The function of the engine block is to
provides structural support to various
engine components and provide structural
support to cylinder liner.
❑ Engine block consists of a water jacket for

engine heat dissipation and it also
provides passage for engine oil circulation
(for lubrication of engine components).
❑ Engine block/cylinder block also provides

structural support to other engine auxiliary
components such as, Alternator, Starter,
etc.


❑ Engine blocks must provide support,
alignment, position tolerance for all
rotating, reciprocating, oscillating
components of the engine.
IC Engine Assembly
Please, visit the links below:
1.Engine Assembly parts animation
2. Engine Assembly animation
3. automobile engine parts
Diesel Engine, How it works?

The diesel engine is an internal combustion engine or precisely it can be called as a
compression ignition engine.
Four-stroke cycle
❑ Intake or Suction
❑ Compression
❑ Power or Working or expansion
❑ Exhaust

Diesel Engine, How it works?
Four Stroke

Four Stroke Engine
Note: There is a TWO stroke engine.

Alternator
The alternator, also known as the ‘genhead’, is the part of the generator that produces the
electrical output from the mechanical input supplied by the engine. It contains an
assembly of stationary and moving parts. The components work together to cause
relative movement between the magnetic and electric fields, which in turn generates
electricity.
(a) Stator – This is the stationary component. It contains a set of electrical conductors
wound in coils over an iron core.
(b) Rotor – This is the moving component that produces a rotating magnetic field in any
one of the following three ways:
(i) By induction – These are usually used in large generators.
(ii) By permanent magnets – This is common in small alternator units.
(iii) By using an exciter – An exciter is a small source of direct current (DC) that
energizes the rotor through an assembly of conducting slip rings and brushes.
Alternator
The rotor generates a moving magnetic field around the stator, which induces a voltage
difference between the windings of the stator. This produces the alternating current (AC)
output of the generator.

Diesel Generator working principle
Diesel Fuel Systems

The diesel engine is an internal combustion engine using either a two- or four-stroke
cycle.
Burning or combustion of fuel within the engine cylinders is the source of the power.
Diesel Fuel System

The fuel tank usually has sufficient capacity to keep the generator operational for 6 to 8
hours on an average.
Common features of the fuel system include the following:
1) Pipe connection from fuel tank to engine

2) Ventilation pipe for fuel tank
3) Overflow connection from fuel tank to the drain pipe
4) Fuel pump
5) Fuel Water Separator / Fuel Filter
6) Fuel Injector
Diesel Fuel System

Diesel Fuel System

Fuel Injectors
Injectors: Purpose of fuel injector is to supply the metered quantity of fuel at high
pressure in to the cylinder of CI engine/ MPFI engine
Fuel pump: Electrically or mechanically driven pump to supply fuel from the fuel tank
(reservoir) to the engine
ENGINE COOLING SYSTEM

ENGINE COOLING SYSTEM

Engine Cooling System

All internal combustion (IC) engines (four stroke
and two stroke) are required some form of
temperature control. Why?
To prevent overheating and seized. How?
Regulate the most efficient temperature

A system, which controls the engine temperature, is
known as a cooling system.

Engine cooling system

There are two types of cooling system:.
Air cooling and
Liquid cooling
Pressure cap
Fan
Please, visit the links below:
1. Engine cooling system, how it works?
2. Engine cooling system
Cooling System Construction


The cooling system has four primary functions:
Remove excess heat from the engine.
Maintain a constant engine operating temperature.
Increase the temperature of a cold engine as
quickly as possible
Provide a means for heater operation (warming the
passenger compartment
Lubricating System
The generator comprises moving parts in its engine, it requires lubrication to ensure
durability and smooth operations for a long period of time.
Internal combustions engines require lubrication in operation that moving parts slide
smoothly over each other.
Oil acts as a hydrodynamic barrier between moving parts, to friction and wear and
remove heat from the working surfaces.
Insufficient lubrication subjects the parts of the engine to metal-to-metal contact, friction,
heat build-up etc.
Lubricating System Components

Lubricating System

Lubrication system
Exhaust System
Exhaust system carries away the gases created when the fuel and air burned in the
engine. These gases are harmful to humans and our life.
The exhaust pipe terminates outdoors and leads away from doors, windows and other
openings to the house or building.
Exhaust System
Exhaust System
All engine systems have exhaust systems to facilitate:
Channel out the waste products of combustion out of the engine
Safe evacuations of gases

Sound attenuation- reduce the noise generated by the engine.
Engine performance

Exhaust system
Engine Starting Systems

Voltage Regulator
Engine Starting Systems

HMI
Engine Starting System

Starting system gives the engine initial momentum before combustion power takes over .
Push-start
Common method are used for starting systems Chamber
DC motor cracking Hand cranking Air starter
Needs battery Small gensets Big generators

Battery & Charger

Battery starting systems for generator sets are usually 24 volts .
Batteries must have enough capacity (CCA, Cold Cranking Amps) to provide the
cranking motor current.

How an Engine Startor Motor works?
Charging System
Inside the alternator
The rotating field winding induces AC voltage in the stator winding.

The rectifier converts AC to DC, and the regulator controls output voltage
The fans extract warm air and keep components cool.
Discussion
Automatic Voltage Regulator

A voltage regulator is an electrical regulator designed to automatically maintain a
constant voltage level.
❑ A "Reference" voltage has been preset into the Voltage Regulator.

❑ An "Actual" ("sensing") voltage is delivered to the Voltage Regulator via sensing leads from
the Stator AC power windings.
❑ The Regulator "compares" the actual (sensing) voltage to its pre-set reference voltage.
❑ If the actual (sensing) voltage is greater than the preset reference voltage, the Regulator will
decrease the regulated current flow to the Rotor.
❑ If the actual (sensing) voltage is less than the preset reference voltage, the Regulator will
increase the regulated current flow to the Rotor.
In this manner , the Regulator maintains an actual (sensing) voltage that is equal to the pre-
set reference voltage.
Automatic Voltage Regulator

AVR connection to 3 Phase DG

Human Machine Interface (HMI)
Digital control panel

The Control Panel

This is the user interface of the generator and contains provisions for electrical outlets
and controls.
❑ Electric start and shut-down – Auto start control panels
automatically start your generator during a power outage,
monitor the generator while in operation, and automatically
shut down the unit when no longer required.
❑ Engine gauges – Different gauges indicate important
parameters such as oil pressure, temperature of coolant,
battery voltage, engine rotation speed, and duration of
operation.
❑ Generator gauges – The control panel also has meters for the
measurement of output current and voltage, and operating
frequency.
❑ Other controls – Phase selector switch, frequency switch, and
engine control switch (manual mode, auto mode) among
others.
Main Assembly / Frame

All generators, portable or stationary, have customized housings that provide a structural
base support. The frame also allows for the generated to be earthed for safety.
How do we get power from genset to load?
By using ATS
Load
Automatic Transfer Switch (ATS)

An Automatic Transfer Switch (ATS) is often installed where a backup generator is located,
so that the generator may provide temporary electrical power if the utility source fails.
Automatic Transfer Switch (ATS)

An automatic transfer switch (ATS) transfers power
from a standard source, like utility, to emergency
power, such as a generator.
When the standard source fails, an ATS senses the
power interruption on the line and in turn signals
the engine panel to start.
When the standard source is restored to normal
power the ATS transfers power back to the standard
source and shuts the generator down.
Controlling Apparatus
Circuit Breakers
A circuit breaker is an automatically operated electrical switch designed to protect an
electrical circuit from damage caused by overload or short circuit.
A circuit breaker is so designed that it can be operated manually under normal condition and
automatically under fault condition.
Air Circuit Breaker (ACB) Molded Case Circuit Breaker (MCCB)
ACB is used as medium voltage circuit breaker. MCCB) is a low voltage circuit breaker.
The breakers employ a high pressure air- It is the most used circuit breaker.
blast as arc quenching medium.
Fuse
A fuse is a short piece of metal, inserted in the circuit,
which melts when excessive current flows through it and
thus break the circuit.
It is inserted in series with the circuit to be protected.
Under normal operating conditions the fuse element it at a
temperature below its melting point.
Magnetic Contactor
A magnetic contactor is an electrically controlled switch used
for switching a power circuit, similar to a relay except
with higher current ratings.
Relay
A relay is an electrically operated switch. Current flowing through the
coil of the relay creates a magnetic field which attracts a lever and
changes the switch contacts.
The relay's switch connections are usually labelled as
COM, NC and NO:
COM = Common
NC = Normally Closed
NO = Normally Open
Protection Systems
Troubleshooting
Troubleshooting is process discovering true cause by eliminating other possibilities.
Some basic rules to follow

RULE 1: Check out the complaint yourself
RULE 2: Don’t make an assumption
RULE 3: Consider all the possibilities
RULE 4: Don’t guess
RULE 5: Be patient
Troubleshooting
Problem no. 01: Engine Fail to Start
Activities: After receiving the gen-set at stop position we have to perform the following
task
✓ Checked the battery voltage

✓ Checked the fuel solenoid
✓ Checked the starting motor
Observation: Found starting motor does not work

Figure: Starting Motor
Solution: Repair the starting motor or arrange a new one.
We bring Staring motor for repair in RESL.
Troubleshooting
Problem no. 02: Fuel Supply hampered and engine fails to start
task
✓ Checked fuel pump

✓ Checked water separator filter and fuel filter
✓ Checked fuel line
Observation: Found diesel fuel filter is blocked due to contamination. It may

happen due to water that can enter the fuel tanks or the wrong fuel is put in your
diesel fuel tank at the filling time.
Solution: Changed the fuel filter and oil filter and also change lube oil as a part of schedule
service.
Troubleshooting
Problem no. 03: Gen-Set suddenly shutdown
task
✓ Checked the controller alarm
✓ Checked the cylinder exhaust temperature
✓ Checked the radiator
✓ Checked fuel level
Observation: Exhaust temperature deviations low and after 50 minutes

running high temperature alarm break out due to dirty radiator.
Solution: Radiator servicing needed, Engine is okay.

Figure: Radiator
Troubleshooting
Problem no. 04: Engine Vibration and Fail to Start
task
✓ Clean the air filter
✓ Checked the timing of engine
✓ Checked fuel solenoid
✓ Checked the fuel supply line
Observation: Found insufficient fuel supply in fuel injector

due to fuel solenoid was faulty. Figure: Fuel Solenoid
Solution: Fuel solenoid was bringing to RESL for repairing. Engine set to manual start..
Troubleshooting
Problem no. 05: Exhaust temperature of cylinder is high and Black smock out.
task
✓ Checked air filter

✓ Checked fuel filter & fuel line
✓ Checked diesel injector
Observation: Found air to fuel ratio imbalance. This occurs when the diesel Figure: Exhaust / Silencer
fuel system is delivering either too much fuel into the engine or there is not pipe
enough air. Find air filter jam.
Solution: Change air filter and advised to make better air circulation
facility to generator room.
Electric Motor Troubleshooting...

Question Session???
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Power Generation System

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Power Generation System and

Troubleshooting of Diesel Generator

Norms of Our Work

Electrical Power System

Electrical Power System

Facts About Synchronise Machines

Diesel Generator-What is it?

Diesel Generator-What is it?

Please, visit the link below:

Standby Rating Prime Rating Base Load Rating

Diesel Generator - Why?

Main Components of a Generation

IC Engine Major Parts

Engine/Cylinder block, cylinder head, and crankcase

IC Engine/ Cylinder Block

❑ Engine block consists of a water jacket for

❑ Engine block/cylinder block also provides

IC Engine/ Cylinder Block

IC Engine/ Cylinder Block

Diesel Engine, How it works?

Please, visit the link below:

Please, visit the link below:

Note: There is a TWO stroke engine.

Please, visit the link below:

Diesel Fuel Systems

Diesel Fuel System

1) Pipe connection from fuel tank to engine

Diesel Fuel System

Diesel Fuel System

ENGINE COOLING SYSTEM

ENGINE COOLING SYSTEM

Engine Cooling System

Regulate the most efficient temperature

Please, visit the link below:

Engine Cooling System

Cooling System Construction

Engine Cooling System

Lubricating System Components

Please, visit the link below:

Safe evacuations of gases

Please, visit the link below:

Engine Starting Systems

Engine Starting Systems

Engine Starting System

DC motor cracking Hand cranking Air starter

Needs battery Small gensets Big generators

Battery & Charger

Please, visit the link below:

The rotating field winding induces AC voltage in the stator winding.

Automatic Voltage Regulator

❑ A "Reference" voltage has been preset into the Voltage Regulator.

Automatic Voltage Regulator

AVR connection to 3 Phase DG

Human Machine Interface (HMI)

Digital control panel

The Control Panel

Main Assembly / Frame

How do we get power from genset to load?

Automatic Transfer Switch (ATS)

Automatic Transfer Switch (ATS)

Some basic rules to follow

✓ Checked the battery voltage

Observation: Found starting motor does not work