Department of Building Economics

University of Moratuwa
B.Sc. (Hons.) in Quantity Surveying
B.Sc. (Hons.) in Facilities Management
Level II Semester I
BE 2202–Services II
ASSESSED PROJECT WORK I

Student Name Index No

Perera R.A.B.U.N. 192657T
Sampath A.M.P. 192672J
Aberathna P.G.S.A. 192601T
Yapabandara Y.M.S.D. 192703H
Pathirana S.M.P.P.V. 192653D
Rathnayake R.D.P.M.K.G. 192668D

Date of Assignment -: 28h May 2021 Department of Building Economics

Date of Submission -: 3rd June 2021 University of Moratuwa
DIESEL BACKUP GENERATOR

2
WHAT TO BE DISCUSSED ??
Diesel Backup Generator
Major Components
System Layouts
Factors Affecting Designing of Generator
Safety Precautions- Installing
Operations & Maintenance
Hazards of Installing & Designing
How to Overcome Hazards?
Conclusions 3
 DIESEL BACKUP GENERATOR
• Diesel Backup Generator is used as electrical equipment to generate electrical energy by
using electrical power and diesel engine power. Generally, it is a combination of an electric
generator and a diesel engine with various axillary equipment (British Electricity
International, 1992).

• The generator capacity varies with homes, small

businesses, and offices range from 8 to 30 kW (also 8 to
30 kVA single phase), whereas large scale industrial
generators vary from 8 kW (11 kVA) to 2,000 kW (2,500
kVA three phase) for office complexes, industries, and
other industrial facilities.
4
COMPONENTS OF DIESEL
BACKUP GENERATOR

5
MAIN COMPONENTS OF DIESEL BACKUP GENERATOR

1 – Diesel Engine
2 – Alternator
3 – Voltage Regulator
4 – Fuel system
5 – Exhaust system
6 – Cooling system(Radiator)
7 – Lubrication system
8 – Control Panel 6

9 – Frame Base
Cooling System – Prevents the generator from overheating.
Freshwater is sometimes used as a coolant for generators

Exhaust System – Absorbs and exhaust the gases which are produced by the engine.

Lubrication – Keeps the parts of the engine works smoothly.

System Makes the system more durable and smooth operations for a long
period of time.

Control Panel – It is the user interface of the generator where the generator is
controlled and operated.
Consists with start button, a frequency switch, an engine fuel
indicator, temperature indicator of the coolant and much
more.

Main Assembly – It keeps the all the parts together and protects from
Frame external influences. 7
 Diesel -Generates the mechanical energy by burning the fuel.
Engine The size of the engine is directly proportional to the maximum output.

Alternator – Alternator having two parts

• Stator - Stationary component which contains a set of electrical
conductors wound in coils over iron ore.

• Rotor – Moving component that produces a rotating magnetic field.

Fuel system – Consists with fuel tank with a pipe that connects to the engine.
Supply diesel to the engine.

For commercial applications, it may be necessary to erect and install an

external fuel tank.

Voltage - It regulates the voltage output.

Regulator
8
SYSTEM LAYOUT

9
S E
I L
N E
G C
L
E ELECTRICAL LAYOUT L
A
L Y
I O
N U
E T

10
DESIGNING FACTORS OF
DIESEL GENERATORS

11
FACTORS AFFECTING
DESIGNING OF GENERATOR
“ The working room for generator set shall be
designed specifically to meet the expected functions
and maintenance operations, and at the same time
the design of generator set working room shall
conform to local government’s laws and regulations
on architecture, fire protection laws and other
applicable regulations”

(HYUNDAI ENGINE Series, 2014)

12
 Repair &
Maintenance
Costs
Fuel Initial
Costs Cost

Electrical Fuel
connection Storage

Physical &
Factors
Lubrican
Environmental
t system conditions

Indoor
Applicat
ions
Outdoor
Applicat
Cooling ions
Safety
system

Capacity
Switch
of the
model Efficiency 13
generator
of the
generator
(Power
factor)
 • While both diesel and • The upfront cost of • How much fuel the
Repair & Maintenance Costs

natural gas generators purchasing and generator consumes or

should be maintained installing a commercial how much fuel is
regularly, diesel generator. required to run for X

Initial Cost

Fuel Cost
generators are more number of days
attractive for determines the fuel
businesses, because cost.
they require very little
maintenance when
compared to their
counterparts. 14
 • Diesel generators • Diesel Fuel is • Cable Type, connection
bolt type, wiring design
require a tank that is flammable. Due to its and how many areas

Electrical Connection
usually attached to the liquidity and natural and parts of the
Fuel Storage

building needed to be
base of unit (diesel odor, it is unlikely a covered.
base tank). diesel leakage without • Only full qualified and

Safety
experienced electrical
• Depend on the size the noticed. technicians should carry
efficiency and the cost • But the impact and out electrical
installation, service and
is varied. effect of these kind of repair work
incidents should be • Grounding / Earthing R
equirements and
considered. Insulation Test also
should consider.15
 • Generators come in
• First, the power • Starting Wattage- How many either manual switch

Efficiency of the Generator

watts are required to power or automatic switch
Capacity of the Generator

requirement of the
on each tool or machine models.
building should be
considered. within setup?
• Manual model
• Running Wattage- How Must go outside to the

Switch Model
• Calculate the Collective generator to activate it.
much power is needed to
Power Needs (add up keep each item operating for
the collective power the time-periods in • Automatic model will
needs of all the question? detect when there is
machines and tools an outage and turn on
included in the system). • Power wastage during the without an interruption
operation and main energy in power.
• With the required consumable factors such as
capacity of the electricity, “Industrial tools, factory • Depend on the
machinery, remote convenience and the
the output rating (in kW)
operations” budget limit, one of
of the generator should
this model type can be
also be considered. chosen. 16
 • Diesel generators are • This system provides
cooled with cycling sustained tempered oil

Physical & Environmental

water chilling units with film between the parts Indoor Outdoor
fan and radiator. which are in motion.

Lubricant System
Cooling System

Sound
Ventilation
• Depending on the • It reduces friction, wear
considerations

Conditions
working hours, switch and draw off part of the
model and capacity of heat absorb by parts, Sound/Vibration
Potential for
environmental
the generator, the heat improve sealing effect. incidents

generation will vary.

• Should consider the Security Access Security Access

• Anti-freeze system, type of: Oil pan, oil

coolant type, air flow pump, strainer, oil pipe,
methods can be used. oil cooling unit and oil
Space

path.
17
 Potential For Environmental
Incidents
• To prevent • The generator • Only

Sound/Vibration
• Generators

Security/Access
• Potential for

Airflow
are large overheating, engine and authorized Flooding
and bulky, there must possibly the personnel
Space

• Severe
so cost, be adequate remote should Weather
logistics and airflow cooling have access Patterns
maximizing around the systems can to the area
generator be noisy. where the • Other
space for
and the Vibration generator natural
the building
installation isolators and plant is incidents
occupants
must meet other barriers located to (lightning,
must be
NEC may be ensure snowing,
considered
in requirement. needed to generator Cyclone)
determining prevent reliability
the location inconvenience and safety.
of the to building
generators. tenants.

18
INSTALLATION CONSIDERATIONS
&
SAFETY PROVISIONS

19

Single Building
Locate the generators within the
building or within a rooftop
penthouse structure.
Multiple Buildings
Locate the generators either at each
building or centrally and distributing
to each building.
Other Consideration for the Location
✓ Ease of access for refuelling
✓ Exhaust air transport
✓ Structural components
✓ Future maintenance
✓ Generator removal
LOCATION
The location should concentrate on compliance with local,
state and national regulations and ensure specific guidelines
required by the generator manufacturer. (Mahon, 1992)
Space should be allocated around the generator, for cooling,
and easy maintenance, at least 2 meters around
without other objects. (Mahon, 1992)
✓ Aesthetics
✓ Servicing 20
✓ Vibration
✓ Effects on ambient noise
✓ security
✓ servicing
 WEATHER CONDITIONS

Flood-prone • Avoid the basement.

• Install where the air vents will not become blocked with
Extremely windy debris such as leaves, grass, plants etc.
• Should use Cold Weather Kit options and accessories for
Cold weather locations the generator. (Generator Installation In Commercial
Buildings, 2018)
DIRECTION OF PREVAILING WIND FLOW

• Generator should be installed so that natural wind flow

and the generator fan wind flow direction are the same
in order to meet cooling and combustion air
requirements (Instruction for Diesel Generator Set
Installation, 2018).

• Avoid exhaust gases returned to the engine area or to 21

the fresh air intake vents of surrounding buildings.

 GENERATOR ROOM
• Room should be 10 to 25 feet in length, with three
feet of clearance on all sides.

• Natural ventilation must be supplied to provide the

radiator ventilation and combustion air
requirements.

• Place the generators close to the usable area.

• Extend the exhaust pipes to outside the room .

• If fuel oil tanks are not included in generator set, it 22

must be installed in a separate room.

• Generators should be mounted on a proper concrete foundation to resist dynamic
loading and minimize transmitted noise and vibration.

• Reduce vibration transfer to the building by providing a shock absorber between

the engine and a footing and the underframe.

• Generators are easy to install in new construction but restore or modification in a

old building is more difficult because of creating exhaust pathways, fuel lines and
incorporating the safety codes (Installation guideline for stationary industrial generators :
Residential & Commercial).

23
 SAFETY PROVISIONS

Lifting Installation
Generators should be lifted using the
properly sized and sufficient strength System should be installed, serviced, and
equipment. repaired by an Authorized Service
company or skilled electrician or installation
Use the hook provided in the unit or professional who is aware about all
spreader bars to carry the load without applicable standards, codes and
damage. regulations.

Placing
Place the generators in an easily accessible
location for maintenance, repair, and
firefighting.
Comply with the minimum distance from
walls specified by the code.
Ventilation
Sufficient and unobstructed air flow is
necessary to avoid accumulation of
explosive gasses and to guarantee safe
functioning of the generator.
24
 Earthing
There are two earthing pits for
body earthing and which are
• Earthing of Diesel
connected in grid Generator Plant guarantees immediate discharge of
electrical energy, without risking the lives of people operating within the
installation.

• Generator should be connected to earth in compliance with local regulations.

damage. Body and
Neutral Earth
Should never be
• Chemical earthing- Suitable for places where water levels is low, soil resistivity
is high especially on hilly areas. Rit Wik (2016) interconnected

Two neutral pits for Neutral

earthing and which are connected
25
in grid.
 Wiring Installation

• Keep the generator and system de-energized and disabled while installing the
generator set and connecting cables.
• De-energize the wires using safety gear and a meter.
• Disable the generator by placing the Auto/Manual switch.
• De-energize the battery charger.
• Disconnect the negative cable from the negative battery terminal.

Piping Connection

• Require proper vibration isolation and secure pipe networks (fuel,

coolant, etc) before installing the flexible connections otherwise
26
crack, leaks, fractures can develop.
 OPERATION
&
MAINTENANCE

27
 OPERATION PRACTICES FOR DIESEL GENERATOR
01. Pre-heat
• Operators must decide if preheating is necessary before the generator set to ambient
temperature is started. (Negese, 2021)

02. Connect To Power

• First, turn the air switch from "OFF" to "ON" on the control panel. After that, watch the

panel until the background light turn on.

28

• The fuel pipes should be opened by the operator at the same time.
03. Start the Generator
• When pressing the Power button, diesel generator engine will be started by the motor.
• But, with the aid of a contactor, the automated generator is activated automatically.

04. Running the Generator

• Operators shall often watch and check the parameters such as if the generator set is
running normally. 29
05. Emergency Stop
• Operator should Press emergency stop on the control panel to quickly shutdown the generator set.

06. When Normal Stop

• Before stopping the generator, first, detach the load from the set, then operate the set
without load for a particular length of time, so that the set of generators is totally cooled
after the set is shut down.

07. After Running

• The fuel valve should be shut down.
• Cut off air intake and air outlet in the working chamber of the
generator set. 30

• Air output switch of the generator set should be shutdown

 MAINTENANCE PRACTICES FOR DIESEL
GENERATOR

Preventive Maintenance Predictive Maintenance Breakdown Maintenance

Preventive maintenance is the
Predictive maintenance is the Breakdown maintenance is
regular and routine
methodology used to conducted on equipment that
maintenance of equipment
discover abnormalities and has failed, failed, or cannot be
and assets to prevent
prospective problems of operated in another manner.
unintended breakdown of the
equipment and processes via The purpose of failure
equipment and any costly
data analysis tools and maintenance is to correct
unintended downtimes.
procedures. anything wrong.
FasTrak SoftWorks, 2019).

31
 IMPORTANCE OF PREVENTIVE MAINTENANCE IN DIESEL GENERATOR

Increase the efficiency of the Diesel

Generator (DG)

Reducing the
Continuing the
operating cost of the
safety of the DG
Diesel Generator

Minimizing the unexpected operation

failures 32
 General Routine Inspection
• Proper maintenance is vital, in any internal combustion
engine.
• Changing the oil in the diesel generator at the end of
every hundred hours of operation is significant.

Lubrication Service
• Using a dipstick, test the engine oil at set intervals while turning
down the generator. (Classic Maintenance Services, 2020).
• Let's the oil leak back into the crankcase on the higher sections of
the engine.
• Oil and filters must also be replaced at predetermined intervals. 33
 Cooling System
• During shutdown times at the prescribed frequency, coolant
level should be maintained.

• In the opposite direction of a regular air flow, low-pressure

compressed air or a stream may be utilized to clean the
radiator.

• With cotton bud or cloth, all dirt or organic object should be

removed with carefully to prevent damage to the fins.
Fuel System
• The charge-air cooler piping and hoses should be inspected regularly for leaks, holes,
cracks, dirt and debris that may be blocking the fins or loose connections.

• The water vapor accumulating and condensing in the fuel tank should drain the fuel filters
at the specified period.
34
• Regular testing and purification of gasoline may be necessary if the fuel is not used in 3 -
6 months and is changed.
 Generators Batteries
• Weak or low-powered starting batteries are a major cause of power
failure.
• Batteries should be tested at least every 200hr of the operation.
• Electrolyte level should be checked at least 200hr of the operation
• Generator's batteries should be cleared and checked specific
gravity

Other Maintenances
• Generators should be cleaned properly.
• Regular exercise maintains the engine parts grained and prevents electric
connections from oxidizing, utilizes fuel before degradation and contributes
to ensuring a reliable start to engines (M.H. Al Mahroos, 2017).
35
HAZARDS OF INSTALLING
&
DESIGNING

36
 GENERAL HAZARDS
• Exhaust fumes emitted by generator sets contain poisonous
gases.
• Fire hazard due to any combustible material that could be
dangerous around the generator.
• Hazards caused by defective or damaged parts of the
generator.
• Towing risks when installation.
37
• Excessive Noise
 ELECTRICAL HAZARDS

• Possible Burns Or Electric Shock

• Hazards occur in wiring, cable, and cord sets.- The capacity of
cables, wirings, and cord sets may differ from what is advised.

38
 FIRE & EXPLOSION HAZARDS

• Fuel or oil spills around the generator

• Hot Engine Burns
• Risk of an explosion because of combustible materials around
the generator.

39
SAFETY MEASURES FOR
HAZARDS

40
SAFETY MEASURES FOR GENERAL HAZARDS
• Exhaust systems must be properly installed.

• The area around the generator must be clean and free.

• Adhering to the manufacturer’s instructions and recommendations

when installation, repair and maintenance.

• While working with the generator, the operational crew must

remain aware at all times.

41
SAFETY MEASURES FOR
ELECTRICAL HAZARDS
• All power voltage supplies should be turned off at
the source while installing or servicing the
generator.

• Wires, cables, and terminals must be properly

insulated and covered.

• The generator should be properly grounded.

• The recommended capacity for wiring, cable, and

cord sets must be met.

42
SAFETY MEASURES FOR FIRE
& EXPLOSION HAZARDS
• Avoid smoking near appliances and do not use
flammable materials.

• Regularly check for fuel or oil leaks around the

generator.

• A fire extinguisher should always be nearby.

43
CONCLUSIONS

44
REFERENCES
British Electricity International. (1992). Electrical Systems and Equipment (Third ed.). Pergamon: British Electricity
International. doi:https://doi.org/10.1016/B978-0-08-040514-8.50017-3.

Classic Maintenance Services. ( 2020). Classic Maintenance Services. Retrieved from DG Operation and
Maintenance: https://www.classicmaintenance.in/dg-operation-and-maintenance/

ESSENTIAL CONSIDERATIONS FOR STARTING LOAD CURRENT CALCULATIONS. (2021). Retrieved from
Woodstock Poweer Company: https://woodstockpower.com/blog/starting-load-current-calculations/

FasTrak SoftWorks. (2019, October 7). What is Preventive Maintenance? | Types, Examples, and Advantages of PM.
Retrieved from FT maintenance: https://ftmaintenance.com/maintenance-management/what-is-preventive-
maintenance/

Generator Installation In Commercial Buildings. (2018). Retrieved May 31, 2021, from Worldwide Power Products:
https://www.wpowerproducts.com/news/genset-install-commercial-buildings/ 45
HYUNDAI ENGINE Series. (2014). Diesel Generator Operation and Maintenance Manual.

Installation guideline for stationary industrial generators : Residential & Commercial. (n.d.). Norwall
PowerSystems Publication. GENERAC. Retrieved May 31, 2021, from Norwall PowerSystems:
https://www.norwall.com/product_pdfs/798_RD_instm.pdf

Instruction for Diesel Generator Set Installation. (2018). Retrieved May 30, 2021, from Jiangsu Starlight
Electricity Equipments Corporation Web site: https://www.dieselgeneratortech.com/diesel-
generators/Instruction-for-Diesel-Generator-Set-Installation.html

KEY FACTORS TO CONSIDER BEFORE INSTALLING A GENERATOR. (2021). Retrieved from Woodstock
power company: https://woodstockpower.com/blog/key-factors-to-consider-before-installing-a-
generator/

M.H. Al Mahroos. (2017, July 25). 7 steps to proper maintenance of diesel generator. Retrieved from
Almahroos: http://www.almahroos.com/index.php/tips-and-tricks/item/167-7-steps-to-proper-
maintenance-of-diesel-generator
46
Mahon, L. L. (1992). Diesel Generator Handbook. Burlington, MA: Butterworth-Heinemann.
Negese, S. (2021). Academia. Retrieved from Diesel Generator Operation and Maintenance Manual HYUNDAI
ENGINE Series:
https://www.academia.edu/31675754/Diesel_Generator_Operation_and_Maintenance_Manual_HYUNDAI_E
NGINE_Series

Rit Wik. (2016, August 3). Diesel Generator Installation Basics [Video]. Youtube.
https://youtu.be/6BuSE8Ot98E

Technical Guidelines for Standby Diesel Generators. (2010). Citi Realty Services. Retrieved May 30, 2021, from
https://www.academia.edu/28769626/TECHNICAL_GUIDELINES_FOR_STANDBY_DIESEL_GENERATOR
S Coupal, J. (2017, september 25). Factors to Consider When Installing Industrial Generators. Retrieved
from South Shore Generators sales and services: https://ssgen.com/generator-sales-service-wareham-
ma-blog/factors-to-consider-when-installing-industrial-generators

THE ULTIMATE GUIDE TO PROPER GENERATOR SIZING. (2021). Retrieved from Wood stock power company:
https://woodstockpower.com/about/resources/proper-generator-sizing/

Valley, S. (2014). 3 Factors to Consider with a New Generator. Retrieved from Design AIR inc.:
47
https://www.designairinc.com/blog/3-factors-to-consider-with-a-new-generator/
THANK YOU

48