DIES E L G E N E R ATO R , OPE R

AT I O N S A ND
M A I N TA I N A N C E

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IMPORTENCE OF DIESEL GE
N E R AT O R

When a power outage occurs, there will be a disturbance in communication

systems, emergency lighting, smoke exhaust fans, fire fighting water pumping stations,

security, other critical electrical systems and equipment’s, which should be in running

condition.

To solve such problems common solution is ‘the installation of Diesel Generator Sets.
D I E S E L G E N E R AT O
R

A Diesel generator (DG) (also known as a Diesel Genset) is the combination of

a Diesel engine with an electric generator (an alternator) to generate electrical
energy. A Diesel compression-ignition engine is usually designed to run
on diesel fuel.

Diesel generating sets are used in places without connection to a power grid,
or as an emergency power supply if main source fails.

Diesel generator set sizes range from 8 to 30 kW (also 8 to 30 kVA single

phase) for homes, small shops, and offices, with the larger industrial
generators from 8 kW (11 kVA) up to 2,000 kW (2,500 kVA three phase) used
for office complexes, factories, and other industrial facilities.
PA R T
S

Main components of a generator set are :

•Engine
•Alternator
•Starting battery and charger.
•Lubrication system.
•Cooling and exhaust systems, including the radiator.
•Fuel system.
•Voltage regulator
•Exhaust piping and silencer.
•Control and monitoring panel.
PA R T
S
CONSTRUCTIO
N
W O R K I N GP R I N C I P L
E
 Diesel generators convert some of the chemical energy, contained by the diesel
fuel, to mechanical energy through combustion. This mechanical energy then
rotates a crank to produce electricity. Electric charges are induced in the wire by
moving it through a magnetic field

Engine-

 The engine is an internal combustion machine, four stroke cycle and usually
diesel fueled.

 The power of the engine must be suitable for the rated power of
the alternator.

 The engine must have electrical start-up, time shall not be higher than 10 sec.

 Engine cooling done by circulation of air or water, in a close circuit with

a radiator. To improve engine start-up, it must be with an oil.
W O R K I N GP R I N C I P L
E
Alternator

 The alternator is of synchronous type, single or three-phase, self excited, regulated and
ventilated.
 Rated voltage: 230 V (single-phase alternators); 400/230 V (three-phase
alternators).
 Rated frequency: 50 Hz or 60 Hz.
 Rated power (depending on the operation )
 Power factor: usually 0.8.
 Insulating class: usually H.
 Insulating class of alternators are designed considering the maximum
temperature that the windings can withstand, since temperature is
often main factor that contributes for insulating material ageing.

 The starting battery is lead-acid type and connected to a battery

charger that will assure
the maintenance charge of the battery and is normally installed in
C O N T R O LA N D M O N I T O R I N G PA N E L E
QUIPMENT

•Metering equipment (ammeters; voltmeters; frequency meter).

•Control and monitoring equipment: start and stop push-buttons; oil manifold;

water thermometer.

•Control switch with 3 positions: Automatic/Manual/off.

•Start and stop generator set automatic system.

•Circuit breaker for alternator protection.

•Monitoring lamps.

•Emergency shutdown system of the engine.

•Battery charger .
S A F E T Y F E AT U R E
S

• Over speed trip.

• L.O low pressure trip and alarm.

• F.O low pressure alarm.

• Water high temperature alarm.

• Water high temperature trip.

• Thermometer.

• Pressure gauge.

• L.O high temperature alarm.

• Dip stick.
M A I N TA I N A N
CE

Generator sets play a critical role in safety of people and goods of certain electrical installations and
for that reason, it is important to establish an accurate maintenance program that must include:

•Run monthly, or twice a month, with load for a period of an hour (to assure that it will run when

necessary).
•Healthiness of ‘Auto start up ‘ of the system to be ensured.
•Visual inspection.
•Verification of earthing connection of neutral and all metallic parts.
•Verification of oil level and
•Battery status (visual inspection; voltage measurement of the elements; situation of the electrolyte).
M A I N TA I N A N
CE

 Generator set start-up shall be automatic, when there is an undervoltage or a negative sequence

voltage in the power supply network and it is done through an automatism system installed in

the generator set control and monitoring panel. This automatism system will provide also

the disconnection and the stop of the generator set when the network voltage returns to normal.
P R E V E N T I V EM A I N TA I N A N C
E-
DG A Check this check is preventive maintenance of DG sets(1000-1500KVA).

1) A-check is done on daily basis:

a) Oil level.
b) Coolant level.
c) Gauge valve level.
d) Check for any leakage.
e) Cleanliness of DG set.
2) B-check (done after 300hrs of cycle or 6 months whichever is earlier. )
a) Check lube oil filter .
b) Fuel filter.
c) Air filter.
d) Bypass filter.
3) C-check (done after 1500hrs of cycle or 01 yrs whichever is earlier.)
a) All steps of B-check.
b) Check/change of air filter (if needed).
c) Check/change of other filters mentioned in b-check.
d) Change of gasket of chambers.
4) D-check - Done in 6000 hrs of cycle.

 DG Efficiency. “The generator efficiency is calculated by units generated/diesel consumed”.

CATEGORIES OF PERSONEL PROTECTIVE EQUIPMENT -

 Head protection

 Hearing protection

 Eye and Face protection

 Respiratory protection

 Hand protection

 Body protection

 Foot and Leg protection

PERSONEL PROTECTIVE EQUIPMENT -

 Head protection - Hard Helmet.

• Hearing protection- Ear muff/ Ear plug.

• Eye and Face protection -Safety goggle/ Face Shield.

• Respiratory protection -Dust mask.

• Hand protection - Hand gloves .

• Body protection - Full body safety harness.

• Foot and Leg protection -Safety shoes.

Note - Safety procedures to be followed

as per company policy
Questions &
Answers
THANK YOU