What is a Diesel Generator?

Diesel Generator: is the combination of a diesel engine

with an electrical generator (often called an alternator)
to generate electric energy.
Working: The prime mover of the Generator set will be a
diesel engine, which is coupled to the shaft of an alternator
(single phase for small units).
The rotating shaft of the diesel engine rotates the rotor of
an alternator, and due to electromagnetic induction the
output of an alternator is electricity.
Primary part of a DG
 Diesel engine
 Alternator
Available sizes

 5kVA up to5MVA
 Use of Diesel Generator
 To protect the critical systems from power
failures caused by poweroutages.
 StandbyDiesel Generators are commonly used
by all major
 Hospitals

 Militaryforces

 Governmentbuildings

 Datacenters

 Corporateoffices

 ResidenceBuildings

 Factories

 Industrialsectors

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 Classification of Diesel Generator
 According to coolingsystem
 Air cooled Dieselgenerator
 Radiator type coolingsystem
 Water Cooled DieselGenerator
 Heat exchanger and cooling tower type cooling
system
Air CooledDieselGenerator Water Cooled DieselGenerator

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 Diesel Engine
PARTS OF ENGINE
 Radiator
 Waterpump
 Radiatorfan
 Fuel pump
 Injector
 Cylinder head
 Piston
 Cylinder liner
 Connectingrod
 Crankshaft
 Camshaft
 Flywheel
 Turbochargers
 ECP
 Governor
 Anti-vibration mountingpad
 Battery
 Anti-vibrationdamper
 Coolant
 Camfollower
 Safety (HWT / LLOP / over speedsafety)
 Air filter / lubricatingfilter
 Silencer
 Silentcanopy
 Fuel tank
 Lubricating oilpump
 Thermostat
 Water and oil temperaturemeter
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 Engine Strokes
 Working ofEngine
 Induction stroke : Piston move from
TDC to BDC, air inlet valve opens
and air enters into the low pressure
area.
 Compression stroke: Both air intake
and exhaust valve remain closed
and piston moves from BDC to TDC
and air is compressed . At the end of
stroke fuel isinjected.
 Ignition/Power stroke : Injected
fuel ignite and burnt fuel turn into
gases at high Pressure due to which
piston moves towardsBDC.
 Exhauststroke: Exhaust valve
opened piston moves from BDC to
TDC the burnt gasesout the
cylinder.

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 Fuel Pump & Governor

 FuelPump: supply fuel from the fuel tank to

the injector as per combustioncycle.

 Governor: It controls the speed of engine by

increasing or decreasing the fuelquantity.
 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-sensitivedevice,
designed to maintain a constant engine speed .

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 Engine Safeties
 EngineSafeties
 HWT (High watertemperature)
 Engine Coolant Temperature indicator. If the Engine
Coolant Temp is too high, then there is an indication or
alarm in the AMF (Auto main failure)annunciation.
 Max. temperature: 90 degreeC.
 LLOP (Low Lube OilPressure)
 Engine oil Pressure indicator. The pressure should not be
less than 2.5Kg/cm².
 LCWL (Low Coolant WaterLevel)
 Radiator coolant water indicator. The level should not be
less than 95 % of overallvolume.
 OS (OverSpeed)
 The speed should be in between 1490-1515RPM.

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Function of lubricating oil :-
 Controlsfriction
 Reduce wear
 Reduce corrosion
 Dampers mechanical shock in gears
 Forms a seal on the walls of the cylinders

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Charger Alternator

 It is coupled to the
engine shaft through a
grooved belt.

 It’s a type of a dynamo,

which chargee the
battery while running.

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Cranking Motors/Self Starter

A DC motor, which takes power from battery and automatically
couples and rotates the flywheel.

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 Coolant
 Coolant: is a fluid which flows through a device in order to prevent its
overheating, transferring the heat produced by the device to otherdevices
that utilize or dissipateit.
 CoolantReplacement
 At 6000 hrs. of operation or after two years, it is necessary to
replace the coolant.
 Turbocharger
 Turbocharger consists of a Turbine and a
compressor linked by a shared axle.
 The turbine inlet receives exhaust gases from
the engine exhaust manifold causing the
turbine wheel to rotate. This rotation drives
the compressor, compressing ambient air and
delivering it to the air intake of theengine.
 Alternator
 Electrical generator (alternator) is an electromechanical
device that converts kinetic energy to electrical energy,
generally using electromagneticinduction.

Generator / Alternator

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 Parts of an Alternator

 STATOR
 ROTOR
 EXCITERROTOR
 DIODE
 AVR
 TERMINALS

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AMF Panel

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 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 VoltageMonitor
(L.V.M.) and three starting pulses are given to Genset.
 IfGensetdoesnotstartwithinthreeattempts,then„STARTING
FAILURE‟alarmissoundedandstopsignalisgiventoGenset to
stop it fully & no start signals are givenfurther.
 When Gen set starts successfully, it builds up the rated voltage
and Gen set contactor/breaker is closed automatically. Theload
then is switched on / transferred to the Genset.

 When Mains restores, which is checked by L.V.M. for its

healthiness, the generator is then disconnected from theload
and automatic transfer back to the mains source takes place.
Load is now connected to themains.
 Gen set is then run for about 5 minutes time set, on no loadand
it is stopped automatically.
 Safeties like L.L.O.P., H.W.T. and Over speed are operativewhen
the Gen set is running. For any of the above faults, Gen set
stopsimmediately.

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

Maintenance Checks for DG set

 “A”check

 “B”check

 “C”check

 “D”check
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“A” MaintenanceChecks– Daily /Weekly

1. Check Engine Oil Level

2. Check Belts
3. Check Engine Coolant Level in radiator/Heat Exchanger
4. Check for leakage of coolant, fuel,& lubricating oil.
5. Check all instrument are functioning
6. Check all parameters.
7. Check battery
8. Check fuel level
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“B” Checks –300Hrs./ 6Month
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 Coolant Level
9. Check air cleaner element
10. Check connection of starter motor and
alternator.

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 “C‟ Maintenance Checks - 1500Hrs.
 First repeat A & B checks
 1. Check & adjustment Injectors and
Valves Setting.
 2. Check & Adjustment Injector
Plunger.
 3. Check & Adjustment Crosshead.
 11. Change air cleaner.

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 “D” Maintenance Checks - 6000 Hrs. / 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. De-scaling and cleaning of Radiator
10.Replace Hose (As Required).
 Daily Checks
When the gauge indicates locks in the Red range ,change or clean the
air cleaner
 Check the water Temp.
Check the oil Temp.
Check the all belt (fan , Charging Alternator)
Repair any leaks, make major adjustments, tighten loose bolts,etc.
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 ADDmark, Before starting, add oil to
the FULL mark.
Stopping the Engine
Remove the load.
Reduce engine speed to half speed. RUN FOR 5-10 MINUTES to cool engine
Stop the engine.