DG Set - Presentation

FMSG Tech
Quality Concepts Delivered

Diesel Generator
What we will cover..
What is a diesel generator?

Where it is used & why it is used?
Types of Diesel Generator/Special Types of diesel generator/manufacturer list
Working Principle of Diesel generator
What is the work of a diesel engine?
Working of diesel Engine
Different parts of diesel engine and its safeties
What is alternator?
Working principle of alternator/types of alternator/manufacture list
Different Parts of alternator and there function
Installation process overview
Operation of diesel generator.
What do you mean by Synchronization of DGSET and the use
How DGSET is synchronized.
What is a AMF panel? Basic function
Maintenance of diesel engine and alternator.
Troubleshooting of diesel generator

Types of Diesel Generator/Special Types of diesel generator.
What is alternator?
What is a Diesel Generator?
A diesel generator is the combination of a diesel engine with

an electrical generator (often called an alternator) to
generate electric energy.
What is Diesel Generator?
There are two primary part of a DG

Diesel engine
Alternator
Available sizes
5kVA up to 5MVA
Use of Diesel generator
To protect the critical systems from power failures caused

by power outages.
Standby Diesel Generators are commonly used by all
major
Hospitals
Military forces
Government buildings
Data centers
Corporate offices
Classification of Diesel Generator
Classification according to cooling system

Air cooled Diesel generator
Radiator type cooling system
Water Cooled Diesel Generator
Heat exchanger and cooling tower type cooling system
Air Cooled Diesel Generator Water Cooled Diesel Generator

Working of Diesel generator
The diesel engine as a prime mover of the Generator set is

coupled to the rotating shaft of an alternator, and due to
electromagnetic induction the output of an alternator is
electricity.
The air is drawn into the cylinder and is compressed
to a high ratio (14:1 to 25:1).
Here, the air is heated to a temperature of 700
900C.
A measured quantity of diesel fuel is injected, which
ignites spontaneously because of the high air
temperature. Hence, the diesel engine is also known
as compression ignition (CI) engine.
Questions
What is a DG set?
Where and why it is used?
What is the Available sizes of DG set?
Give the classification of DG Set and describe the types?

Types of Diesel Generator/Special Types of diesel generator.
What is alternator?
DIESEL ENGINE
A Diesel engine is an internal combustion engine which

operates using the Diesel cycle.
An engine whose purpose is to produce kinetic energy
output from a fuel source.
DIESEL ENGINE
Diesels Engine need only two things to run:

1. A fuel and air (at the right time and quantity)
2. Adequate Compression
Engine Strokes
Four Stroke Engine

1. Intake / induction stroke
2. Compression stroke
3. Power stroke
4. Exhaust stroke
Working of engine
1st : Induction stroke - The inlet valve is open
and the descending piston draws in fresh air.
2nd : Compression stroke -The valves are
closed, the air is compressed to a pressure of up
to 25 bar.
3rd : Power stroke The fuel is injected, while
the valves are closed, the fuel ignites and the
piston is forced downwards by the combustion
gases.
4th : Exhaust stroke - The exhaust valve is open
and the rising piston discharges the spent gases
from the cylinder.
PARTS OF ENGINE
Radiator Governor/actuator/magnetic
Water pump pickup
Radiator fan Anti-vibration mounting pad
Fuel pump Battery
Injector Anti-vibration damper
Cylinder head Coolant
Piston Cam follower
Cylinder liner Safety (HWT / LLOP / over
Connecting rod speed safety)
Crankshaft Air filter / lubricating filter
Cam shaft Silencer
Flywheel Silent canopy
Turbocharger Fuel tank
ECP Lubricating oil pump
Thermostat
Water and oil temperature
meter
RADIATOR
A radiator is the part of the engine cooling system

that excess combustion heat is lost to atmosphere
by means of forced convection using a circulating
liquid such as water or water / glycol to affect heat
transfer.
Radiator
pressure cap
Inlet from
engine
Air
fins
Coolant
tube
Outlet to
engine
FUEL PUMP
The fuel that is drawn from the A portion of the fuel that is
fuel tank by the feed pump is delivered to the nozzle
filtered through the fuel filter, lubricates the sliding portion of
and is delivered to the injection the nozzle and returns to the
pump. fuel tank via the overflow pipe.
The fuel that is delivered to the To prevent the fuel delivered to
injection pump is pressurized the injection pump from
into a highly compressed state, becoming excessively
and is delivered via the pressurized, an overflow valve
injection steel pipe to the is provided in the fuel filter or
nozzle. The fuel is then injected in the injection pump itself. If
in an atomized state into the the feed pressure from the feed
combustion chamber, where pump exceeds a prescribed
combustion takes place. value, the overflow valve opens
to allow excess fuel to return to
the fuel tank via the overflow
pipe.
ENGINE CONTROL PANEL (ECP)
The Electronic control panel (ECP) is used on engines for

Monitoring engine parameters and governing engine speed
with software to govern the engine speed.
GOVERNOR
GOVERNOR
Governor controls the engine speed solely by the amount of fuel
injected into the engine by the injector.
The governor provides the engine with the feedback mechanism to
change speed as needed and to maintain a speed .
The governor is essentially a speed-sensitive device, designed to
maintain a constant engine speed .
MAGNETIC PICK UP
The magnetic pickup senses the engine speed at the

flywheel ring gear and generates an AC voltage with its
frequency proportional to the engine speed.
The signal is sensed by the ECP and is used as a speed
feedback.
Engine Safeties
HWT (High water temperature)

Engine Coolant Temperature indicator. If the Engine
Coolant Temp is too high, then there is an indication or
alarm in the AMF annunciation.
Max. temperature: 90 degree C.
LLOP (Low Lub Oil Pressure)
Engine oil Pressure indicator. The pressure should not be
less than 2.5 Kg/cm.
LCWL (Low Coolant Water Level)
Radiator coolant water indicator. The level should not be
less than 95 % of overall volume.
OS (Over Speed)
The speed should be in between 1490-1515 rpm.
BATTERY
The purpose of a battery is to store chemical energy and to convert this chemical energy
into electrical energy during starting of DG SET.
Charger Alternator
It is coupled to the engine

shaft through a grooved
belt.
Its a type of a dynamo,
which charges the battery
while running.
Cranking Motors
A DC motor, which takes power from battery and automatically couples and rotates the flywheel.
COOLANT
A coolant is a fluid which flows through a device in order to prevent its overheating,
transferring the heat produced by the device to other devices that utilize or dissipate it.
Salient Features of CAC
Safe / environmental & user friendly
- Easy operation, time saving at B check.
- To be filled in through Radiator / make up (auxiliary) tank Cap
- Cost benefit to the customer at B check.
- Easy checking process.
Checking
pH of coolant
No special checking kit is required for this property. ( visual check)
Special colour indicator.
When colour of the coolant is pink the pH is within limit.
If coolant becomes colourless, then it indicates very low level of concentration.
Coolant Replacement
At 6000 hrs. of operation or after two years, it is necessary to replace the coolant.
Important Note :
Use of good quality water along with CAC is important for optimum cooling system performance.
Water used in cooling system must meet following specifications.
It is suggested to get Water quality checked from authorized laboratories if water quality is doubtful.
FUNCTIONS OF LUBRICATING OIL IN AN ENGINE
A lubricating oil with the necessary properties and characteristics will

Provide a film of proper thickness between the bearing surfaces.
It do not corrode metal surfaces.
In internal-combustion engines, lubricating oil serves six functions:
1. Controls friction
2. Reduces wear
3. Limits the temperature
4. Reduces corrosion
5. Dampers mechanical shock in gears
6. Forms a seal on the walls of the cylinders
ENGINE COOLING SYSTEM
HYDROMETER
A hydrometer is an instrument used for determining

the specific gravity of liquids.
DG CABLE
RATING IN AH SIZE IN
KVA MM2
20 120 50
30 150 50
40 180 50
50 180 70
62.5 180 70
125 360 70
Questions
What is the function of a diesel engine?

What is the meaning of four stroke engine?
Different parts of diesel engine and its safeties?
What is the minimum voltage of a battery to start a DG ?
12 volts for single and 24 volts for double battery.
What should be the limit of specific gravity of a battery to start a DG?
1270-1170
What is the function of cranking motor ?
What is the function of charger alternator?
What should be the water level in radiator?
Min. 95% of total volume of radiator.
How many filters are there in an air cleaner?
Two
What is the function of turbo charger?
In internal combustion engines a turbocharger is a turbine driven forced induction supercharger
powered by exhaust gases.
What is the ratio of coolant to water in the radiator?
1:15

What is alternator?
ALTERNATOR
Electrical generator (alternator) is an electromechanical device that converts

kinetic energy to electrical energy, generally using electromagnetic induction.
Generator / Alternator
TYPES OF ALTERNATOR
BRUSHLESS TYPE ALTERNATOR
A brushless alternator is composed of two alternators built end-to-end on one shaft.

Brush-type alternators
In brush-type alternators, the exciting (DC) current is

conventionally supplied to the rotor assembly, in part, by
brushes that are in physical, sliding contact with a portion of
the rotor shaft of the alternator.
PARTS OF ALTERNATOR
STATOR
ROTOR
EXCITER ROTOR
DIODE
AVR
SLIP RING
SURGE SUPPRESOR
RECTIFIER ASSEMBLY
TERMINALS
ROTOR / STATOR
The rotor is the non-stationary part of a rotary electric motor or alternator.

The stator is the stationary part of an electric motor or alternator.
EXCITER
AVR
AVR is a controlling device governing the level of excitation
provided to the exciter field. The AVR Responds to a
voltage- sensing derived from the stator winding.
U V W N
LOAD
A.V.R OUTPUT
Main Armature (stator)

EXCITER
STATOR
ROTATING
EXCITER
MAIN FIELD (ROTOR) RECTIFIER
ASSEMBLY ROTOR
BLOCK SCHEMATIC DIAGRAM

SURGE SUPPRESSOR
A surge suppressor is an appliance designed to protect

electrical devices from voltage spikes.
Surge suppressor attempt to regulate the voltage supplied
to an electric device by either blocking or shorting to ground
voltage above a safe threshold.
SLIP RING
A slip ring (in electrical engineering terms) is a method of

making an electrical connection through a rotating
assembly.
DIODE RECTIFIER BRIDGE
The Diode Rectifier Bridge is responsible for the conversion

or rectification of AC Voltage into DC voltage
Questions
What is the most common cause of alternator electrical failure?

The component that has the highest failure rate on most alternators is the Bridge Rectifier.
The Bridge Rectifier is the component that converts the Alternating Current (AC) that an
alternator makes to Direct Current (DC) for use by the vehicle. Over time or under high
demand situations the diodes in the bridge rectifier can become weak, they don't do as
good a job as they did when they were new. So, your bridge rectifier is going bad when
you first start a cold vehicle and it charges better at first compared to after it warms up. As
the diodes in the bridge rectifier heat up they don't work as well. In high demand situations
the more AC power the alternator makes, based on demand, the more power the rectifier
has to convert to DC leading to a greater chance of diode failure.
Will a higher amp alternator hurt battery or charging system?
No. A good rule of thumb is that more amps are not harmful, but more voltage is. If you
look at electrical power like water, amperage is equivalent to the volume of water, and
voltage is equivalent to water pressure.
I noticed the Proof of Performance tag rates the output at 2400 RPMs. Is this engine
RPMs?
No, this is alternator rotor speed. To determine the engine RPMs, calculate the pulley
ratio. The typical street pulley ratio is 3:1. Therfore, 2400 alternator RPMs is 800 engine
RPMs (2400/3=800).
What is the function of exciter ?
What is the damper winding in an alternator?

What is alternator?
Operation of diesel generator
Paralleling Operations /
Synchronizations
Topics
What is Synchronizing
Types of Switching Operation
Types of Synchronizing
Concept of Slip frequency and Advance angle
Load pick-up and Governor droop Characteristics
Synchronizing methods
Generator Synchronizing
General criteria for Generator Synchronisation
Manual Synchronizing
Components used for Synchronisation
Automatic Synchronizing
Auto Synchronizing & Auto Load Sharing
Choice of Synchronization
Sources of Errors in Synchronisation System
Pre-commissioning Checks for Synchronisation System
Mechanism of Wrong Synchronisation System
Possible out of Synchronisation
Effect of faulty Synchronisation on Generator System
Shortfall in the Conventional Synchronising Scheme
Improvement Suggested in the Synchronisation System
Technical specification
THEME
Sources of Errors in Synchronization System

Mechanism of Wrong Synchronization
Effect of Wrong Synchronization on Generator
Pre-commissioning Checks
Drawback in the Present Synchronization System
Improvements suggested in the Synchronization System
What is Synchronising ?
Overall operation of ensuring that the two power systems to

be interconnected THROUGH a Circuit Breaker.
To achieve the same the following shall be satisfied on
either side of the circuit breaker
Voltage Magnitudes are same
Voltages are in same Phase sequence
Frequencies are equal
Types of Synchronisation
1. System synchronising:
When two different parts of a system are connected
together i.e. both Voltage Magnitude, Phase and Frequency
cannot be controlled like generator circuits)
For example Closing of a Bus coupler CB fed by two
Transformer feeders, the voltage magnitude can only be
varied through Tap changing mechanism.
2. Generator synchronizing
Generator is connected to a Grid. The voltage magnitude,
Phase and frequency of the generator supply can be varied.
Synchronising methods
1) Manual synchronising
It is performed by the operator using following synchronizing devices.
This is generally used for both Generator synchronisation and System
synchronisation.
Synchroscope
Check Synchronising Relay
DV, DF Meters, Guard Relay
2) Automatic synchronising
It is performed through Automatic Synchronising Relay. This provides
closed loop control for adjusting Speed & Voltage of the Generator
during synchronization. This is used for Generator synchronisation
Criteria for Generator Synchronising
Generator synchronising is of two methods:
1) Super synchronously synchronising, with the incoming

frequency higher than the running frequency
2) Sub synchronously synchronising, with the incoming
frequency lower than the running frequency
Permissible Synchronising Criteria for Generators
Manual Synchronising for Generator Synchronisation
To synchronize generator to a Grid the following steps shall

be adopted:-
1. Voltage difference is brought within limits by adjusting the excitation.
2. Slip frequency and Phase difference are brought within the limits by
adjusting the Speed governor
3. CB closing is done at the correct Phase Advance Angle.
4. Check synchronising relay.
Manual Synchronising for System
Synchronisation
To synchronize two Grid feeders (I.e. Non-Generator feeders)

The following steps to be adopted
1. Voltage magnitude and Frequency are almost becoming same.
2. The Phase difference is continuously varying as the function of Slip
frequency.
3. Switch closing is done at the instant of the correct Phase advance
angle.
Check synchronising relay separately measures the voltage, phase and
slip frequency, inhibiting the breaker-closing signal unless supply
differences are within the preset limits.
Automatic Synchronising for Generator Synchronisation
Automatic synchronising relays monitor the voltages and

the frequencies.
It gives out signal.
The Governor Characteristic, Slip frequency and CB closing
time characteristic.
A pulse signal is sent out to energise the interposing relay.
AUTO SYNCHRONIZING AND AUTO LOAD SHARING
SINGLE LINE DIAGRAM
SYNCHRONIZATION
When mains are healthy, both the D.G remain in the

standby mode.
When mains fail, Line Voltage Monitor (L.V.M.) senses.

Starting pulses are given to the Master D.G. Set. (Master
D.G Set is automatically selected by programmer).
After satisfactory starting of the D.G Set 1, voltage is

sensed by Generator Voltage Monitor (G.V.M.). If voltage is
healthy, then closing signal is given to D.G.1 breaker and it
is closed.
Synchronizing Panel gives corresponding pulses to start
load automatically.
The load is then sensed by KW transducer in the panel &

continuously monitored by PLC.
Engine & Alternator parameters are also continuously

monitored by P.L.C. in the Panel. In case of any fault (e.g.
Low Lube Oil Pressure, High Cooling Water Temperature
etc.), breaker is tripped & engine is stopped.
If the load reaches & crosses 80 % of the rated capacity of
the D.G. 1, then starting pulses are given to the second D.G
set by P.L.C.
When D.G.2 starts, then again G.V.M. checks the voltage,

and if voltage is healthy, then breaker 2 is closed.
After closing of the second breaker, Auto load sharing

function starts sharing the load between the two D.G Sets.
The percentage of sharing is directly proportional to their
individual capacities
Since sharing is proportional to their respective capacities,
even D.G sets of different capacities can be synchronized
successfully.
D.G sets continue to run in Synchronization until the load is

above 80 % of any one D.G. set.
When load comes below 80 % of any one D.G. set, then the
automatic signal is given to that D.G. & then it starts taking
the full load.
After transferring the total load to one D.G. (on which 80 %
load is to be connected), the breaker of the second D.G is
opened. Now one D.G is taking the load
The second D.G. is then stopped after its cooling period.
When mains are resumed, then load is transferred to the

mains & both the D.G sets are stopped after their cooling
period.
ADVANTAGES OF AUTO SYNCHRONISING
& AUTOLOAD SHARING
Changing of logic is very easy because of changes are made through

software only. There is no changing of wires, adding of components like
relays, contactors, which is very time consuming, cumbersome &
requiring additional space.
For any type of load addition or reduction, manual intervention as

regards D.G set operation is not required. However, in case of
emergency manual override is possible.
Because of KW dependent load sharing, optimum utilization of D.G. sets

are possible. This increases D.G. sets efficiency & saves lot of fuel.
Use of PLC reduces no. of relays, contactors, wiring etc.
This reduces fault points.
All the future changes / modifications can be easily made

through software only.
AMF Panel
AMF Control panel is designed to monitor & to start Generator automatically when the mains source
fails partially or fully.
When mains fail, then it is sensed by Line Voltage Monitor (L.V.M.) and three starting pulses are given
to Gen set.
If Gen set does not start within three attempts, then STARTING FAILURE alarm is sounded and stop
signal is given to Gen set to stop it fully & no start signals are given further.
When Gen set starts successfully, it builds up the rated voltage and Gen set contactor/breaker is closed
automatically. The load then is switched on / transferred to the Gen set.
When Mains restores, which is checked by L.V.M. for its healthiness, the generator is then
disconnected from the load and automatic transfer back to the mains source takes place. Load is now
connected to the mains.
Gen set is then run for about 5 minutes time set, on no load and it is stopped automatically.
Safeties like L.L.O.P., H.W.T. and over speed are operative when the Gen set is running. For any of the
above faults, Gen set stops immediately.
Automatic function can be totally by-passed and Gen set can be started-stopped in manual mode also.
Fault Indication
Low oil press

High room temp.
Over speed
Fail to start
DC battery rev. polarity
Engine hours run counter
RPM
Frequency
Voltage
Current
Engine temperature
Shutdown Protections
Low oil pressure

High room temp.
Over speed
Fail to start
Under speed
Over current
V belt failure
Blower failure
Earth fault
Applications
Optimization of chillers, pumps and cooling

towers
Energy management & performance
contracting
Process control
Real time power monitoring
Sources of Errors in Synchronisation System
Voltage Transformer Ratio & Phase error Burdens

The total burden connected to the secondary of winding shall be within
25% to 100% of rated burden.
Lead Resistance
The Cable Lead interconnecting VT and Synchronising panel should not

make any significant voltage drop.
Usage of Interposing PT.
Error in connecting Instruments.
Inadvertent Error - Connecting wrong terminals of Instruments to the PT
supply. (Say PT Polarity Reversal)
Mechanism of Wrong Synchronisation in
Generator System
To Synchronize a Generator with GRID,a load pick-up of

1% - 5% shall be considered.
This results into a Slip frequency (i.e. fs = 0)
Pre-Commissioning Checks for Synchronising System
Thorough Phasing out operation to be carried out using

following:-
Check for the correct connections of the wires
Check the Phase sequence.
Measure Voltage across Terminal ( Rr Ri, Yr Yi, Br Bi ).
Check the Synchroscope by interchange of running /
incoming polarity.
Check the Synchronising Relay.
Questions
What is synchronisation?
Overall operation of ensuring that the two power systems to be interconnected THROUGH a
Circuit Breaker to share the load.
What are the essential factors required for synchronisation?

Voltage Magnitudes are same
Voltages are in Phase
Frequencies are equal

What is alternator?
MAINTENANCE CHECKS FOR ENGINE
A check
B check
C check
D check
A Maintenance Checks Daily / Weekly
1. Check Engine Oil Level

2. Check Belts
3. Check Engine Coolant Level in radiator
4. Check for leakage of coolant, fuel,& lubricating oil and rectify.
5. Check all instrument are functioning
6. Check all parameters.
4. Check battery
5. Check fuel level
REPORT TO THE MAINTENANCE DEPARTMENT ANY OF THE
FOLLOWING.
1. Low lubricating oil pressure.
2. Low power.
3. Abnormal water or oil temperature.
4. Unusual engine noise.
5. Excessive smoke.
6 Excessive use of coolant, fuel or lubricating oil.
7. Any fuel, coolant or lubricating oil leaks.
8.Idle Engine A Few Minutes Before Shut-Down .
B Maintenance Checks 300Hrs./ 6 Month
1. Change Super Lubrication Oil By-Pass Filter element

2. Change Fuel Filter Element
3. Change Lubricating Oil Filter Elements
4. Change Engine Oil
5. Check Coolant Additive Concentrate
6. Clean/Change Crankcase Breather
7. Clean fuel tank breather
8. Check Hydraulic Governor & Oil Level
9. Check Oil Levels
10. Clean and check battery terminals
11. Check air cleaner element
12. Check connection of starter motor and alternator.
C MAINTENACE CHECK- 1500 Hrs. Check
First repeat A & B checks

1. Check & adjustment Injectors and Valves
Setting.
2. Check & Adjustment Injector Plunger.
3. Check & Adjustment Crosshead.
4. Check fan hub, Idler and water pump
5. Change Hydraulic Governor Oil
6. Clean Radiator externally
7. Check water pump
8. Check end play for turbocharger
9. Check air ducting hoses
10. Check thermostat for proper functioning
and operating system.
11. Change air cleaner .
12. Drain sediment from fuel filter and from
water separator.
D MAINTENACE CHECK- 6000 Hrs. Check / 2Year
Repeat all A,B,C Checks
1. Clean and Calibrate Fuel Pump

2. Clean and Calibrate Injectors
3. Repair heads
4. Check Crankshaft End Clearance
5. Check Fan and Drive Pulley Mounting
6. Check water cooling system
7. Check all drives clearance .
8. Check camshaft end play.
9. Rescaling and cleaning of Radiator
10. Replace Hose (As Required)
11. Check Turbocharger Bearing Clearance
12. Clean Cooling System
13. Inspect Vibration Damper
Diesel maintenance schedule
DAILY CHECK
1.When the gauge indicates locks in the red range ,change or clean the air cleaner
2.check the water Temp.
2.Check the oil tem.
5.check the all belt (fan ,water pump)
Repair any leaks, make major adjustments, tighten loose bolts, etc.
Observe the Service Meter reading.
Drain the water from water separator / diesel tank.
Check the oil level. Oil level must be between the ADD and FULL marks on the side of the dipstick .
If the oil level is below the ADD mark, Before starting, add oil to the FULL mark.
Stopping the engine
1.Remove the load.

2.Reduce engine speed to half speed. RUN FOR 5-10 MINUTES to cool engine
3.stop the engine.
WARNING: DO NOT remove the pressure cap on an overheated engine. The coolant is under
pressure and relieving the pressure will cause the coolant to flash into steam.
High Water Temperature Checks-Engine Stopped and Cold
1. Check coolant level.
3. Check engine room vents and/or louvers. Be sure the engine is receiving sufficient air.
4. Be sure temperature regulators are operating at proper temperature range.
5. Inspect all water hoses carefully for collapsing, external and internal failures. Replace hoses as
required.
6. Have the cooling system cleaned.
Maintenance of Engines
MAINTENANCE RECOMMENDATIONS
CAUTION: Fill fuel tank at the end of each day of operation.

Do not fill the tank to the brim.
Drain fuel tank of moisture and sediment as required by prevailing conditions.
After changing fuel filters, always bleed fuel system to remove air bubbles from system.
Lubricating Grease
Use Multipurpose-type Grease (MPGM) which contains 3-

5% molybdenum disulfide conforming to MIL-M-7866, and
a suitable corrosion inhibitor.
NLGI No.2 Grade is suitable for most temperatures.
Use NLGI No. 0 or No. 1 Grade for extremely low
temperatures.
Diesel Engine And Engine Pumpset
Trouble Starting
Read all the steps before checking.

Correct fuel.
ALL the fuel valves open.
Is the fuel filter plugged.
Do we have enough oil.
Low oil pressure.
The key off position.
Fuel solenoid valve to cut off the fuel supply and shut down.
The fuel valve is opened by a magnetic field.
Remove the spring and plunger and let it operate as it is.
To turn off the engine without the magnetic fuel valve
Close the fuel tank valve.
A lobe on the cam shaft pushes on the plunger.
To remove the air we need to remove the supply line.
Use a can or glass jar to catch the fuel that will spill out.
Make sure the run/stop leaver is locked into the run position.
If we loosen the high-pressure fuel line we should notice fuel dripping out when cranking.
Trouble Starting
Note Point
If it can't get started.
The final step would be to remove the fuel injector.
Up to 3000 lbs of pressure is used and the fuel spray can
penetrate our skin or spray in our eyes resulting in injury.
Stalling or Surging Engine
Look at is oil pressure.
Check all fuel valves.
Questions
What is the purposes of DG maintenance?
To improve life of DG, reliability, durability, aesthetic, easy servicebility etc.
What are the types of checks?
A check
B check
C check
D check
What are A checks & when these are carried out?
A Maintenance Checks Daily / Weekly
1. Check Engine Oil Level
2. Check Belts
3. Check Engine Coolant Level in radiator
4. Check for leakage of coolant, fuel,& lubricating oil and rectify.
5. Check all instrument are functioning
6. Check all parameters.
4. Check battery
5. Check fuel level
REPORT TO THE MAINTENANCE DEPARTMENT ANY OF THE FOLLOWING.
1. Low lubricating oil pressure.
2. Low power.
3. Abnormal water or oil temperature.
4. Unusual engine noise.
5. Excessive smoke.
6 Excessive use of coolant, fuel or lubricating oil.
7. Any fuel, coolant or lubricating oil leaks.
8.Idle Engine A Few Minutes Before Shut-Down.

What is alternator?
Proper installation of DG set leads to
Improved reliability and durability
Improved aesthetic of DG set
Better working condition
Easy serviceability
High uptime of DG set
Location
Room Layout
Room layout is important for :

- Serviceability
- Ventilation
- Ease in operation
Genset room aesthetics
While making room layout provision should be made for :
- Cables
- Fuel lines
- Breather vent
- Coolant / lub oil drain
- Raw water lines
- Oil / spares storage
Future expansion plans should be considered while deciding room size.
Room Ventilation
Ventilation of the generator room is necessary to remove heat and

fumes.
Air should flow from alternator end to engine.
Total openings in two side walls should be at least 3 times radiator core.
Maximum static restriction should not increase 6-mm of water column.
Typically for heat exchanger cooled engines, forced ventilation is required.
Foundation
Do not install on loose sand or clay.

Foundation should be designed considering safe bearing
capacity of soil.
Unloading
Provision for genset lifting on

base-rails.
Do not lift the genset from
engine and alternator hooks.
Keep the genset covered with
polyethylene or tarpaulin
during installation.
Spreader bar / spacer plate of
suitable size may be
required.
Air System
Vacuum indicator is supplied with all engines to indicate

choked filter. Max air intake restriction with clean and
choked filter is as follows :
Higher restrictions leads to :
-Early choking of air filter
-Low power
Black smoke
Turbocharger failure
Heavy duty air cleaners should be used for dusty
environment.
For fibrous conditions provide air ducts, air curtains, nets
etc.
Fibre element shouldnt enter/ block the air flow of
alternator.
Exhaust System
Exhaust system should create minimum back pressure.

Higher back pressure leads to :
Lower fuel economy

High exhaust temperatures and related failures
Poor performance of the engine
Less durability of the engine
Second Stage Pressure Regulator
The second stage regulator is bigger in size than 1st stage (main line) regulator and is in blue colour.
This regulator should be mounted near the engine carburetor.
The outlet pressure can be adjusted by means of a 14 mm Allen key.
The gas pressure just before should be set as follows :
When engine is stopped, the gas pressure at 200 mm of
water column.
The gas pressure should be 75 mm of water column at
running condition.
Fluctuation free gas flow at inlet of regulator.
Care to be taken while installing the gas pipe line
components.
1 Arrow is in the direction of GAS FLOW

2 The entire line is flushed by air. After installation ensure no
leak.
Engine Breather Vents
Crankcase gases should be piped outside the engine room.
Vent tube / hose should continuously slope downwards to
avoid oil accumulation.
Cooling System
Ambient temperature of 50 degree C.
If properties are outside the limits then it can result in
Scale formation
Overheating
Corrosion
Water softening / demineralizing plants should be used.
Genset / Engine Controls
The generator set is controlled locally by a
dedicated Generator Control Panel.
Conventional and Power Command control.
Polarity of the battery connections are correct.
Do not test wire leads to see if they are live by
flashing.
Disconnect all connections to the control system on
engine / genset before doing any welding work on
set.
Turn off or remove AC power from the battery
charger and then remove ve battery cable from the
engine / genset battery.
Battery area is well ventilated before servicing the
battery.
AMF Operation :
There are three types of AMF operations as below :

A) Operational system is automatically restored to operation within 10 seconds after interruption of normal
power source - with sudden load on the engine. This operation exerts Thermal shock to the engine. For
example UPS.
B) Operational system is automatically restored to operation within 10 seconds after interruption of normal
power source - but with gradual load (in steps) on the engine with initial load. There is no Thermal shock
to the engine.
C) Operational system is manually restored to operation after interruption of normal power source - with
gradual load the engine. There is no - Thermal shock to the engine. No changes in engine are required
for AMF operations described in B and C above.
For A type of AMF operation :
No oil heaters are required, coolant heaters are required.
Cabling
Cabling
Flexible cables
Power cabling between alternator and control panel.
No tension on the bolts / busbars.
R.Y.B. phase notations should be maintained.
Crimped cables should be connected to alternator and control panel.
Overheating
For AMF application, use armoured copper cable for control cabling.
Weights of cables should not fall on alternator / base rail.
Earthing
The generating set and all associated equipment, control and switch gear panels must be
earthed.
4 numbers earth pits are required as per Indian Electricity rules or local electricity board.
- 2 earthing pits for genset / control panel body
- 2 earthing pits for neutral
Copper or GI strips
Earthing should be checked with multimeter
The earthing MUST be done at the engine / alternator and NOT at baserail.
Conductors should be heavy.
Alternator Termination Links
The following situations should also be avoided
Point contact arising out of improper positioning of links with switchgear terminals.
Gaps between bus bars / links and terminals being remedied by connecting bolt / stud.
In such cases the bolt will carry the load current.
Adequate clearance between bus bars / links at terminals should be maintained (IS:4232 may be referred to for
guidelines).
Improper termination will lead to local heat generation which may lead to failure.
Genset with Acoustic Enclosure Installation
Genset can be installed directly on the

leveled surface.
Ensure provision of rain cap.
Service Accessibility
Gen set / Engine control panel should be

visible.
A / B / C check on engine / alternator
(filter replacement and tappet setting)
should be without dismantling acoustic
enclosure.
For major repairs / overhaul, the acoustic
enclosure should be to dismantle.
Space should be available around the gen
set.
ROOF TOP INSTALLATION
What are the advantages of
roof top installation?
No air flow problems
No expensive duct work
No lengthy exhaust runs
No problems with exhaust fume
emissions
No noise problem
No space limitation problems
Questions
What should be the height of fuel tank above ground level?

Above fuel filter
What should be the min. clearance of exhaust pipe above roof top?
3 m above roof top
How many Earthings are required for DG set?
Four (2 for body and 2 for neutral)

What is alternator?
Questions and Case study
Case Study Reason

Piston Liner Seizure Material Investigation indicated no problem
Customer : ABC India Ltd.
Power Source : DG Set with quality of small end bearing or gudgeon
Accident : Seizure in Piston/Liner pin
Monetary Loss : 10 Lacs (components)
Power Outage : 72 hours Piston was seized in liner due to low lube oil Flow to
Production Loss: Unknown piston.
Observations: Seizure has happened gradually
All exhaust temperature and bearing Low lube oil flow caused overheating of
temp were o.k
Lube Oil temp was o.k. piston top
Lube oil pressure was o.k Lube oil flow was reduced due to ingress of
Operating Parameters were o.k dirt in piston oil drillings
However Crankcase Relief valve How the accident could have been
operated during Failure
Piston was seized in liner Avoided
Rings were not seized Engine was not equipped with
Small end Bearing was seized
Oil Mist detector

Big end Bearings were o.k.
Gudgeon Pin suffered multiple cracks due to Crankcase Pressure Transducer
seizure Engine Could have been stopped earlier if

Lube Oil Pump was o.k.
Connecting Rod was o.k.
the above safety were present.
Sketch map of the control panel:
Sketch map of the control panel:

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FMSG Tech

Quality Concepts Delivered

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