DIESEL GENERATOR:
A diesel generating set should be considered as a system
A Diesel generator is the combination of a diesel
engine with an electric generator to generate
electrical energy.
DG SET AS A SYSTEM
since its successful operation depends on the well-
matched performance of the components, namely:
a) The diesel engine and its accessories.
b) The AC Generator.
c) The control systems and switchgear.
d) The foundation and power house civil works.
e) The connected load with its own components like
heating, motor drives, lighting etc.
It is necessary to select the components with highest
efficiency and operate them at their
optimum efficiency levels to conserve energy in this
system.
DG Set System
SELECTION AND INSTALLATION FACTORS
Sizing of a Genset:
a) If the DG set is required for 100% standby, then
the entire connected load in HP / kVA should be
added.
b) After finding out the diversity factor, the correct
capacity of a DG set can be found out.
Capacity Combinations
From the point of view of space, operation,
maintenance and initial capital investment, it is
certainly economical to go in for one large DG set than
two or more DG sets in parallel.
Two or more DG sets running in parallel can be a
advantage as only the short-fall in power–depending
upon the extent of power cut prevailing - needs to
filled up. Also, flexibility of operation is increased since
one DG set can be stopped, while the other DG set is
generating at least 50% of the power requirement.
Another advantage is that one DG set can become
100% standby during lean and low power-cut periods.
Parallel Operation with Grid
Running the DG set in parallel with the mains from the supply
undertakings can be done in consultation with concerned
electricity authorities. However, some supply undertakings ask
the consumer to give an undertaking that the DG set will not
be run in parallel with their supply.
The reasons stated are that the grid is an infinite bus and
paralleling a small capacity DG set would involve operational
risks despite normal protections like reverse power relay,
voltage and frequency relays.
Unbalanced Load Effects
It is always recommended to have the load as much balanced
as possible, since unbalanced loads can cause heating of the
alternator, which may result in unbalanced output voltages.
The maximum unbalanced load between phases should not
exceed 10 % of the capacity of the generating sets.
Neutral Earthing
The electricity rules clearly specify that two independent
earths to the body and neutral should be provided to give
adequate protection to the equipment in case of an earth
fault,and also to drain away any leakage of potential from the
equipment to the earth for safe working.
Air Cooling Vs. Water Cooling

The general feeling has been that a water cooled DG set is better than an air cooled set, as most users are worried
about the overheating of engines during summer months. This is to some extent true and precautions have to be taken
to ensure that the cooling water temperature does not exceed the prescribed limits.

However, from performance and maintenance point of view, water and air cooled sets are equally good except that
proper care should be taken to ensure cross ventilation so that as much cool air as possible is circulated through the
radiator to keep its cooling water temperature within limits.

While, it may be possible to have air cooled engines in the lower capacities, it will be necessary to go in for water
cooled engines in larger capacities to ensure that the engine does not get over-heated during summer months.

Safety Features

It is advisable to have short circuit, over load and earth fault protection on all the DG sets.

However, in case of smaller capacity DG sets, this may become uneconomical. Hence, it is strongly recommended to
install a circuit protection.

Other safety equipment like high temperature, low lube oil pressure cut-outs should be provided, so that in the event of
any of these abnormalities, the engine would stop and prevent damage.

It is also essential to provide reverse power relay when DG sets are to run in parallel to avoid back feeding from one
alternator to another.
Energy Saving Measures for DG Sets
a) Ensure steady load conditions on the DG set, and provide cold, dust free air at intake (use of air washers for large
sets, in case of dry, hot weather, can be considered).
b) Improve air filtration.
c) Ensure fuel oil storage, handling and preparation as per manufacturers' guidelines/oil company data.
d) Consider fuel oil additives in case they benefit fuel oil properties for DG set usage.
e) Calibrate fuel injection pumps frequently.
f) Ensure compliance with maintenance checklist.
g) Ensure steady load conditions, avoiding fluctuations, imbalance in phases, harmonic loads.
h) In case of a base load operation, consider waste heat recovery system adoption for steam generation or refrigeration
chiller unit incorporation. Even the Jacket Cooling Water is amenable for heat recovery, vapour absorption system
adoption.
i) In terms of fuel cost economy, consider partial use of biomass gas for generation. Ensure tar removal from the gas for
improving availability of the engine in the long run.
j) Consider parallel operation among the DG sets for improved loading and fuel economy thereof.
k) Carryout regular field trials to monitor DG set performance, and maintenance planning as per requirements.
TYPES – EG. TOYO BRUSHLESS DIESEL GENERATORS
BOILERS
Boilers are special-purpose water heaters. While furnaces carry heat in warm air, boiler systems distribute the heat in
hot water, which gives up heat as it passes through radiators or other devices in rooms throughout the house. The
cooler water then returns to the boiler to be reheated. Hot water systems are often called hydronic systems. Residential
boilers generally use natural gas or heating oil for fuel.

Two general categories of boilers are hot water and steam boilers.

Most smaller commercial buildings use hot water boilers where water is heated to appropriate distribution
temperatures (typically 140 - 180°F). These systems are often "closed" with virtually no fresh water makeup. Hot water
boilers are often preferred because they normally do not need an operator or special water chemistry, and they run at
higher fuel conversion efficiencies than steam boilers.

In steam boilers, which are much less common in homes today, the water is boiled and steam carries heat through the
house, condensing to water in the radiators as it cools. Oil and natural gas are commonly used.

Steam boilers are found in many different configurations, but all serve one purpose: to contain water and transform it
into steam by the application of heat. The two basic boiler designs for buildings are fire-tube and water-tube. In fire
tube boilers, hot combustion gases pass through tubes submerged in water.
Hot Water Boiler

Water boiler heating systems rely on pressure, volume and temperature to provide efficient and safe heating to the
radiators in your home. It uses one or a series of pumps to circulate heated water through your home. Here's how water
boilers work:

• The thermostat calls for heat.

• An oil or gas burner is activated, heating the water in the boiler.
• The pumps will either begin pumping water through the system, or wait for the water to pre-heat to the desired
temperature.
• The heated water expands. Extra volume is sent into an expansion tank.
• The heat radiates from the hot water in the radiator(s).
• The water cools.
• Cooled water returns to the boiler via gravity or a separate pump.
• The cooled water flows back to the boiler to be reheated.

It should be noted that hot water boilers are not the same as hot water heaters. Water heaters heat the water for your
shower, dishwasher or tap water. Hot water boilers can be used to heat tap water in a separate tank, but the water for
heating the radiators and for heating tap water are kept separate.
 TYPES OF BOILERS

• Firetube
• Firebox
• Vertical
• Watertube
• Cast Iron
• Copper finned
• Condensing
• Electric Firetube Boilers
Firetube Boilers

In fire-tube boilers, combustion gases pass through the inside of the tubes with water surrounding the outside of the
tubes.
Advantages of a fire-tube boiler are its simple construction and less rigid water treatment requirements.
The disadvantages are the excessive weight-per-pound of steam generated, excessive time required to raise steam press
because of the relatively large volume of water, and inability to respond quickly to load changes, again, due to the large
volume.
The most common fire-tube boilers used in facility heating applications are often referred to as ''scotch'' or ''scotch
marine as this boiler type was commonly used for marine service because of its compact size
Firebox Boiler

In a steam engine, the firebox is the area where the fuel is burned, producing heat to boil the water in
the boiler.
The firebox in a boiler is a chamber where fuel, typically gas or oil, is burned to heat the boiler’s water to the
boiling point for use as hot water or steam.
A firebox is designed for burning a particular type of fuel. Conversion to a different type of fuel requires a
different type of burner and could require changes to the firebox size and shape.

Firebox Boiler
Vertical Boiler

• Hot Water or Steam

• It does not require heavy foundation and requires very small floor
area.
• Good high pressure, low
capacity steam boiler
• Marginal steam quality
• Minimal heating surface,
average efficiency

Cylindrical shell:
The shell is vertical and it attached to the bottom of the furnace.
Greater portion of the shell is full of water which surrounds the
furnace also. Remaining portion is steam space. The shell may be of
about 1.25 metres diameter and 2.0 meters height.

Cross-tubes:
One or more cross tubes are either riveted or flanged to the furnace
to increase the heating surface and to improve the water circulation.

Furnace (or fire box):

Combustion of coal takes place in the furnace (fire box).

Grate: Vertical Boiler

It is placed at the bottom of fire box and coal is fed on it for burning.
Fire door:
Coal is fed to the grate through the fire door.

Chimney (or stack):

The chimney (stack) passes from the top of the firebox through the top of the shell.

Manhole:
It is provided on the top of the shell to enable a man to enter into it and inspect and repair the boiler from inside it. It is
also, meant for cleaning the interior of the boiler shell and exterior of the compbustion chamber and stack (chimney).

Hand holes:
These are provided in the shell opposite to the ends of each cross tube for cleaning the cross tube.

Ashipt:
It is provide for collecting the ash deposit, which can be removed away at intervals.

Working:
The fuel (coal) is fed into the grate through the fire hole and is burnt. The ashpit placed below the grate collect the
ashes of the burning fuel.

The combustion gas flows from the furnace, passes around the cross tubes and escapes to the atmosphere through the
chimney.

Water goes by natural circulation due to convection currents, from the lower end of the cross tube and comes out from
the higher end.

The working pressure of the simple vertical boiler does not exceed 70 N/cm^2.
Water tube Boilers

A water-tube design is the exact opposite of a fire-tube. Here, the water flows through the tubes and is encased in a furnace
which the burner fires. These tubes are connected to a steam drum and a mud drum. The water is heated and steam is
passed in the upper drum.
Large steam users are better suited for the water-tube design. The industrial water-tube boiler typically produces steam or
primarily for industrial process applications, and is used less frequently for heating applications.

Advantages of the water-tube design include:

• Are available in sizes far greater than a fire-tube design , up to
several million pounds-per-hour of steam
• Are able to handle higher pressures up to 5,000 psig
• Recover faster than their fire-tube cousin
• Have the ability to reach very high temperatures

Disadvantages of the water-tube design include:

• High initial capital cost
• Cleaning is more difficult due to the design
• No commonality between tubes
• Physical size may be an issue

Water tube Boilers

Cast-iron boilers
Cast-iron boilers can be constructed in different configurations. The three most common designs found in use are:

Vertical Sectional – made up of individual cast iron sections assembled so the sections resemble slices in a loaf of bread.
This is probably the most common configuration.

Horizontal Sectional – made up of individual cast-iron sections assembled so the sections resemble a stack of pancakes.

One Piece – a single casting with no assembly joints. Another term used to describe this design is monobloc. This type of
cast-iron boiler is usually small in size.

Cast-iron boilers can be found in almost any application where heating boilers are used. They are popular replacements for
large welded steel boilers which may have been installed as the building was being constructed. Cast-iron sectional boilers
can usually be installed in existing boiler rooms by moving the individual sections through doors or window openings. A
very large boiler can be assembled in this manner without modifications to the building structure. Build in place makes this
a good choice for retrofits

• Construction cost is Low.

• Very prone to thermal shock
• Poor steam quality

Cast – Iron Sectional Boilers

Copper Finned Boilers
High Efficiency – 85%+
• Small Footprint
• Section IV, hot water only
• Domestic water compatible
• Low capacity - may require many units
to meet requirements
Copper Finned Boilers
Condensing Boiler
ALL boilers can condense. Condensing recaptures the latent heat in the
waste flue gases
• Acid is a byproduct, SS or AL heat exchange required.
Condensing boilers use heat from exhaust gases that would normally be
released into the atmosphere through the flue. To use this latent heat, the
water vapour from the exhaust gas is turned into liquid condensate.
In order to make the most of the latent heat within the condensate,
condensing boilers use a larger heat exchanger, or sometimes a secondary
heat exchanger.
Due to this process, a condensing boiler is able to extract more heat from
the fuel it uses than a standard efficiency boiler. It also means that less heat
is lost through the flue gases.
Condensing Boiler
Electric Boilers

Electric boilers work under a similar principle as traditional gas boilers; however instead of requiring fuel to heat the
water in a central heating system it uses electricity. Also available as an electric combi boiler, these heating systems offer
great space economy as they combine the water heater and central heating boiler into one unit.

Installation is simple and cost effective due to their compact and light construction, and because they are powered by
electricity they don’t require a flue or fuel supply. An electric boiler can therefore be sited anywhere within the property
which makes them ideal for homes that don’t have the extra space for storing an oil tank. The electric central heating
boiler is also suitable for properties which have no access to mains gas supply or experience gas boiler restrictions.
The size of the property and the heating requirements will determine what kilowatt output is needed. The lower kW
boilers are cheaper to buy and have considerably lower running costs, however these may not be as efficient as larger
models. Electric boilers are not suitable for homes of a larger size or properties with high demands for hot water. This is
due to the limitations in the amount of water that can be heated at any one time.

Electric Boilers