Diesel Generator Sets

Umesh Gulati: You can never rely on grid supply, it an go off any time.
B B Gupta: We can not stop the production at the unit as we have to achieve the set
targets.
Kartikeya Dwivedi: During power cut, DG set is the only source which helps to run the
factory.
Umesh Gulati: Energy Efficiency in DG sets? How?
Narration: To reduce energy expenditure in DG sets, measures have been implemented
under the World Bank GEF Project - Financing Energy Efficiency at MSMEs.
Energy Efficiency Options in Diesel Generator Sets
1. SEGR
Kartikeya Dwivedi (Plant Head): While working on this project, I and my team
learned one very important thing which is SEGR, that is, Specific Energy Generation
Ratio. Through this SEGR we can come to know how much electricity is being
generated by a particular DG set in 1 liter diesel.
Energy auditor told us that it can be calculated very easily. If we divide the total
electricity energy generated by the DG set with the amount of diesel consumed in litres,
we get SEGR.
Our company has three DG sets which cater to different sections of the factory and now
we have SEGR record of every DG set and thus we give priority to the best DG set
always.
2. Frequency Optimization
B.B Gupta (Manager - Maintenance): During power cut, electricity is supplied
through DG set more unit. When a team of energy auditors visited us they found that
our DG set is running approximately at 52-53 HZ which was much above its average

frequency range.
Due to higher frequency the RPM of DG set increases which results in excess diesel
consumption. They suggested us to reduce the frequency working on the suggestion
given by the audit team, we set the frequency of our DG at 49.5 HZ. It didn't create any
problem in the working of our generator or any other equipment.
By taking this step, our company is saving Rs. 4 lakhs per year and that too without any
investment.
3. Modulation of DG Sets
Rahul Sharma (Sr. Engineer Electrical): We have 2 DG sets of 1300 KVA and 500
KVA respectively out of which 1300 KVA DG set was being used maximum number of
times.
Audit team found that in general 300 kilo watt load is running on 1300 KVA DG set.
We realized that if our requirement is being fulfilled by 500 KVA DG set only then why
should we run 1300 KVA DG set. Now the bigger DG set is used to use only when
required.
By this this change today our unit is saving Rs. 7 lakhs per year without any investment.

4. Replacement and Maintenance

Umesh Gulati (Managing Partner): We had rented a DG set to cater to our electricity
supply during power cut. When the team of energy auditors visited and audited our unit
they found that gen-set is of higher capacity than required by our unit. Because of
consumption of diesel, had reached. There was no maintenance, maintenance cost was
more and because there was no comopy, so there was more sound pollution.
Adopting the suggestion given by the experts, instead of rented DG set we bought a new
DG set. By taking this step, our unit is saving approximately 30% of fuel. With this new

DG Set our working environment has reduction in sound pollution as this new DG set
has a comopy. With regular increase in diesel prices such measures play an important
role in making more savings.

Narration: In today's modern world, technology is changing and developing day by day.
In a situation where
If your unit's load capacity has increased;
If DG set is of very old technique;
If SEGR has reduced;
Then it is advisable to replace old DG sets with new DG sets and save energy
expenditures.
Besides this, get maintenance check-ups of DG sets regularly.
Kartikeya Dwivedi Through this project we came to know about various methods of
energy saving which are now being implemented in our company.
B B Gupta This project made us realise that energy efficiency can be increased with
such small-small steps.
Umesh Gulati The good thing about this is that there is less investment and more
savings.
B B Gupta Now both fuel and money are being saved.
Umesh Gulati Taking into consideration market scenario, we cant control the sale
price but we can certainly reduce input costs by adopting energy efficiency measures.

Closing Narration: Energy efficiency is the need of the hour. Raw material, manpower
cost etc. is increasing continuously. So, adopt these solutions of energy efficiency and

help in the development of the nation by doing energy saving in your unit.