A4 Standby Generator

Institut Teknologi Petroleum PETRONAS
Department of Electrical
& Instrumentation
Standby Diesel Gen-Set
STANDBY GEN-SET
A4 Chargeman
ALL RIGHTS RESERVED:

This material may not be reproduced in whole or part without written
permission from PETRONAS Management Training Sdn. Bhd.
Prepared by : Anuar Ali

The Department of Electrical & Instrumentation
(Nov 2004)
Page 2 of 22
Contents :
1.0 Overview
2.0 Learning Objectives
3.0 Learning Coverage
3.1 Introduction/Basic Description
3.2 Diesel Engine Generator Set Assembly

3.2.1 Generator Principle and Component
3.2.1.1 Brushless AC Generator Assembly
3.2.1.2 The Generator Excitation
3.2.2 Local Control Panel
3.2.3 Generator Switch Board
3.2.3.1 Metering System
3.2.3.2 Control Scheme
3.2.3.3 Protection System
3.2.3.4 Shutdown system and Alarm Panel
3.2.4 Battery Charger and Battery Bank
3.2.5 Fuel System
3.2.6 Auto Main Failure Board (AMF)
3.3 System Operation

3.3.1 Start-up/Shutdown
3.3.1.1 Start-up Procedure
Glossary of Terms
References
A4 Chargeman
Page 3 of 22
1.0 Overview
This module is design to provide trainees with the understanding of Standby

Diesel Gen-Set assembly, construction, operation and a basic knowledge on the
control aspect of the set. A brief explanation on gen-set maintenance is also
discussed in this module.
2.0 Learning Objectives :
At the end of the session, trainees will be able to :

.
1. State the purpose/main function of Standby generator installation.
2. Describe the operating principle of an AC Generator
3. State, explain and identify the main component of AC Generator
4. State, explain and identify the standby generator set assembly.
5. Describe the operation of Brushless generator type.
6. Aware of the safety considerations inside the Genset Room or Area
7. Read and interpret layout drawing/diagram of Standby generator installation.
8. Describe the metering, protection and control system.
9. State the performance parameters of Standby generator installation.
10. Perform generator startup and shutdown according to standard procedure.
11. Perform running parameter’s checking and monitoring on Standby generator.
12. Perform physical inspection on Standby generator installation.
13. Describe basic Standby generator servicing and maintenance.
14. Identify various possible fault on Standby generator installation.
3.0 Learning Coverage
3.1 Introduction/Basic Description

The need for emergency and continuous electrical power is increasing rapidly.
Personnel safety, environment and production schedules are adversely affected by
lack of power supply. The Standby Diesel Engine Generator is installed to provide
immediate available of alternative power due to its “island operation”: self
contained, requiring no external assistance to start them.
The primary function of a standby generating set is to deliver power automatically

to essential and vital power switchboards in the event of power failure in order to
powered the critical equipment such as UPS systems, Plant shutdown system,
instrumentation, motors, DC battery chargers and emergency lighting.
To demonstrate and develop understanding of the standby gen-sets, a simple

in-house power supply system is used. It consists of two self excited (residual
magnetism exciter), brushless, diesel driven generators and the generator board as
well as the Auto-Main Failure board.
A4 Chargeman
Page 4 of 22
A typical generator set is shown in the Figure 1 below.

Figure 1 - Typical Standby Gen-Set
3.2 The Diesel Engine Generator Set Assembly
The engine and generator are mounted on a single skid base and an
instrumentation devices are provided for indicating engine speed, oil pressure and
water temperature, whilst safety devices are fitted to protect the engine against low
oil pressure, high cooling water temperature and over speeding. The main system
are:
a) Diesel Engine c/w Fuel System, Starting System, Lubrication System, Cooling
System, Air Intake System and Exhaust System (covers in Diesel
Engine-Prime Mover Course)
b) Generator Assembly
c) Local Control Panel/Gauges and Indicators
d) Generator Switch Board
e) Battery Charger and Battery Rack
f) Fuel System
g) Auto-Main Failure Board
The diesel engine construction and operation is not going to be discussed in

detail here. It is usually multi-cylinder, turbo charged and jacket cooled through a
water/air radiator, sometimes assisted by a cooling fan. It is usually battery started,
and some sets have an alternative hydraulic starter or air starter.
It is vitally for diesels which drive emergency generators which are automatically
started that the batteries are maintained fully charged ready for an instant start also
that practice starts should be exercised regularly.
A4 Chargeman
Page 5 of 22
3.2.1 The Generator Principle and Component

An AC Generator is a device or equipment which converts mechanical
energy to electrical energy in the form of Alternating Current (AC). The principle
simply stated, is that a voltage is induced in a conductor whenever the conductor is

moved through a magnetic field. It require mechanical energy for its operation
which supply by a prime mover, diesel engine as an example.
The basic operating principle of electrical generator is called Dynamic
Induction. The word dynamic is often associated with motion and the word
induction is often associated with generation. The dynamic induction is a process of
generating electricity which involves either motion of conductor and stationary
magnetic field or motion of magnetic field and stationary conductor. In whatever
relation there may be an electro- motive force (emf) is always induced into the
conductor. If the conductor forms a close circuit current will flow in that circuit and
such current is called induced current. Thus the simple process of generating
electricity is done and such arrangements constitute the basis for the generator
design and construction as in figure 2.
Relative-motion Relative-motion
Magnetic moving down Magnetic moving down
Conductor moving up Conductor moving up
Figure 2 - Process of Generating Electricity
The commonly installed generator is a Three phase, Self Excited, Rotating

Field, Stationary Coil, Brushless AC Generator which driven by a diesel engine as
a prime mover. This type of generator is used since it is rugged and less
maintenance required as compared to a Rotating Coil, Stationary Field type shown
in Figure 3 below.
Armature
Field
AC Output DC Input
a) Rotating Armature b) Rotating Field
Stationary Field Stationary Armature
Figure 3 - Generator (Conventional) Internal Assembly
A4 Chargeman
Page 6 of 22
The main component of a generator are:

a) The Stator and Rotor
A low-loss steel laminations fitted to frame or shaft respectively, blocked
axially by a welded ring. The coils/windings are inserted and blocked in the slots,
then impregnated with varnish, and polymerized to ensure maximum resistance to
mold, excellent dielectric rigidity and perfect mechanical linking.
b) The Armature winding
This winding will carry the load current when the generator is in operation. It
will be slotted/wound into the stator or rotor assembly ( depends on the type of
generator), connected either in STAR or DELTA (for 3-phase generator) and
insulated by Class F (Ultimate Temperature of 155oC) materials such as glass fibre,
asbestos and epoxy impregnated. The number of slots is generally based upon a
symmetrical polyphase winding where the coils of the windings are displace by 120o
electrical degrees.
c) The Field winding
This winding will carry a DC exciting current to provide the generator field
flux and field poles. The number of field poles will determine the speed of the
generator. It will be slotted/wound into the stator or rotor assembly ( depends on the
type of generator), insulated by Class F materials such as glass fibre, asbestos and
epoxy impregnated even though it only carries a DC voltage.
Other components are slip-ring and carbon brushes, bearing, cooling fan and space
heater.
3.2.1.1 Brushless AC Generator Assembly

This generator operates without any slip-ring and carbon brush, it is connected
directly to the exciter via a rotating rectifier which is mounted on the generator
shaft. The assembly is much depends on the capacity (KVA Rating). For lower
capacity set, it may consist only a main generator and AC exciter only whilst for
bigger capacity normally higher than 1MVA rating has the pilot exciter (PMG -
Permanent Magnet Generator) as an additional equipment. The overall assembly is
shown in Figure 4.
A4 Chargeman
Page 7 of 22
a) The Main Generator

It is a rotating field ac generator where the field winding is wound to the
projection poles (salient pole) of the rotor to provide the field pole of the generator.
It has 4 field poles (4-pole generator) which running at the speed of 1500rpm. The
generator output is tap from the stationary armature winding which being slotted at
the stator slots.
b) The AC Exciter
It is a brushless stationary field ac generator where the field winding is wound
to the projection poles of the stator to form the field poles which normally 8 or
higher in numbers. It has three-phase armature winding rotating with the exciter
rotor. The output of these windings will be rectified and converted to DC voltage by
a rotating rectifier to feed the field winding of the main generator. The field winding
of the ac exciter is feed with a DC voltage from the Automatic Voltage Regulator
(AVR) which powered by the main generator output via a potential transformer.
c) The Pilot Exciter

It is an AC generator with rotating permanent magnets as its filed, providing
the excitation. It has more than 12 field poles in order to produce a very high
frequency of its armature output. The armature output will feed the static rectifier of
the AVR and converted into DC to supply the field winding of the AC Exciter. It
provides constant power to the AVR under all conditions regardless of the main
generator output condition.
d) Automatic Voltage Regulator(AVR)

It is an automatic voltage control devices which going to compare an output
voltage with the reference voltage setting and supplies the field current required to
maintain the predetermined ratio between the generator voltage and the reference
voltage.
e) Rotating Rectifier
It is a three-phase full-wave bridge, requiring six diode elements, mounted on
a rotating steel plate, located at the exciter end for easy inspection, testing and
replacement. The output of ac exciter is rectified and converted to DC excitation
voltage here for main generator field excitation.
The connection as in Figure 5 below.
D.C.
A.C. Fuse +
Rectifier Generator field

A.C. Exciter winding
armature
Rotating rectifiers
Figure 5 - ‘Graetz Formation’ of Rotating Rectifier
A4 Chargeman
Page 8 of 22
The interconnection and operation of the brushless AC generator is explained

by the block diagrams below, refer to Figure 6 and Figure 7.
Figure 6 - Block Diagram of Brushless Generator without PMG
Figure 7 - Block Diagram of Brushless Generator with PMG Connected
The block diagrams show that the rotating and stationary parts of a brushless
ac generator. The rotating parts will rotate since they are installed on the shaft
whereas the stationary parts will not rotate because they are installed on the stator of
the machine.
The two parts are not electrically connected by using a hard wire instead they
are being connected through ‘magnetic connection’. This mean that the generator
action must take in place first then there will be a current flow in the rorating parts
of the machine.
A4 Chargeman
Page 9 of 22
3.2.1.2 The Generator Excitation
For generator set which block and schematic diagram shown in Figure 6 and
Figure 8, the rotation of the shaft caused the rotor of the exciter and main generator
rotate. Since the field poles of the exciter carries a residual magnetism (the remain
of magnetic flux in the pole pieces material), a minimum cutting process occurs
which induced a minimum current in its armature. This ac current then converted
into dc current by the rotating rectifier which later on used by the main generator
field winding to produces main magnetic flux.
AVR Set Voltage

Output Terminals
Amplifier RYBN
3
Comparator 3 CT
3
AC/DC PT
Stator
Field
W dg ArmatureW dg
Armature AC DC
W dg Field W dg
Rotor
Rotating
Rectifier
Prime Mover
AC Exciter Main Generator
Figure 8 -Brushless Alternator with AVR
At this moment, the cutting process also takes place and the main generator
produces its output but not at the rated value. The sample of the low generator
output terminal voltage is picked up by the AVR. The comparator analyses the
voltage sample (by comparing the voltage sample with the reference voltage) and as
a result produces feedback (positive or negative feedback) to the amplifier which
amplifies such error signal and feeds it to the logic controller. The logic controller
will then reduces the firing angle of the power thyristor in order to increase the
exciter field excitation. The exciter’s magnetic field is now strengthening to cause
increase in its output voltage which is fed to the rotating rectifiers and thereby
increases the field excitation of the generator. The generator’s magnetic field is now
strengthening which enables the generator to increase its output to rated voltage.
The generator control will monitor the running parameters of the generator as well
as the engine status. The generator control also through one of the relay will cut off
the supply to the starting motor and fuel control relay after a successful starting of
the engine.
A4 Chargeman
Page 10 of 22
3.2.2 The Local Control Panel
This steel panel normally with IP55 rating of ingress protection located nearby
the engine skid. The functions of this panel are as follows:
a) To start and stop the generator from the engine skid.

b) To provide general fault indicating lights.
c) To monitor engine speed
Figure 9 shows the devices installed on the panel which are:

a) Analog Tachometer - for engine speed indicator
b) Indication Light/LED - for fault indicating lights
c) DC control source light - for indicating the availability of DC source
d) Engine switch - for starting and stopping the engine
e) Running Hour Meter
f) Voltmeter
g) Lub oil pressure indicator meter
h) Water Jacket temperature indicator
i) Relays unit for enhancing protection switching capabilities.
Figure 9 - Local Control Panel
It is very seldom this panel is used to start and stop the engine operation unless if
the DC Control Unit (remote control) at the generator Board is malfunction or under
maintenance.
A4 Chargeman
Page 11 of 22
3.2.3 The Generator Board
This panel is also known as Generator Control Panel and installed together
with other low voltage switchboard in the substation. The functions of this panel are
as follows:
a) To remotely start and stop the generator set.

b) To provide continuous display and monitoring of the generated voltage,
frequency, current, power factor, true and reactive power as well as operating
hours.
c) To protect the generator during fault occurs at the engine/generator or the
electrical system e.g short circuit and earth fault.
d) To provide audible alarm signal and fault indication lights during faults or
malfunction of the control.
e) To connect/disconnect the generator to/from the generator common busbar by
generator circuit breaker.
f) To control engine speed, generator excitation/generator voltage.
g) To provide synchronization facilities.
i) To control the sharing of Real Power and Reactive Power.
The systems/devices installed on the board as in Figure 10 can be categories/

classified into four namely Metering, Control, Protection and Shutoff and Alarm
Panel systems.
Figure 10 - Generator Board
A4 Chargeman
Page 12 of 22
3.2.3.1 The Metering System
The metering system is for system performance monitoring purposes e.g line
voltage, line current, power factor, reactive power , true power , frequency and
power consumption rate. The circuit diagram of the meters installation as in Figure
11 below.
R Y B N
CB
VS
P.T
Hz
AS
C.T P.F
A
KWH KW VAR
Figure 11 - Generator Metering System
The system comprises of the measuring meters; Voltmeter, Ammeter, KW meter,

KWH meter, KVAR meter, Power Factor meter and Frequency meter. The supply
for these meters are taken from the instrument transformer (Current and Potential
Transformer).
3.2.3.2 The Control Scheme
As discussed earlier in section 3.2.1.2 The Generator Excitation, the primary

functions of a control system for a standby generator set is to control the generator
set operation and performance; ensure the smoothness of engine/generator
auto-start-up, regulates the speed and voltage output as well as synchronize the
generator during power failure. A simple control scheme of a generator is shown in
Figure 12.
Exciter Voltage Regulator
Prime
Mover Generator
Governor kW Controller
Auto Synchronizer
Figure 12 - Typical Generator Control Scheme
A4 Chargeman
Page 13 of 22
The two main parameters which to be controlled are the speed of the prime
mover and the generator output voltage. As in figure 12, the electronic governor is
used to control the prime mover generator speed which directly related to the
frequency as well as the output voltage, whereas the voltage regulator (AVR) is
used to control the output voltage by varying the exciting current to the generator
field.
There are two rheostats installed for this purpose, one for voltage adjustment
known as Voltage Trimmer, the other one is for speed/frequency adjustment known
as Speed Trimmer. By regulating these two knobs manually (Raise of Lower), the
frequency and the voltage of the generator output can be fine tuned to the rated
value.
This system used Woodward Electrical Actuator/Governor to control the flow

of fuel for engine operation. It measures engine speed constantly and makes
necessary corrections to the engine fuel setting through an actuator connected to the
fuel system. It provides two functions, exact engine speed and kilowatt load sharing
when synchronised. As in Figure 13, the sensor (Magnetic Pickup) is detecting the
speed of the shaft and send the signal to the processor to compare against the set
speed. The feedback will be use to control the fuel control valve by controlling the
amount of electrical current flows to the actuator. With this device the system is
consistent in its performance.
Figure 13 - Essential Elements of electronic Governor
A4 Chargeman
Page 14 of 22
3.2.3.3 The Protection System
The protection system is critical since it protects the generator against system
problems such as overload, loss of load, unbalanced loading, under/over frequency
and under/over voltage, and also protect from system fault e.g Insulation failure,
mechanical failure, excitation system failure etc. The overall protection scheme is
shown in Fig 14 .
Supply Authority
M
Prime Mover
Protection
Differential
Relay
EX G
Field Failure Relay
Rotor Earth Fault Relay
Reverse Power Relay
Overcurrent Relay
Stator Earth Fault Relay
Earthing Resistor
Figure 14 - Generator Protection Scheme
The common protection components/relays are:
1. Circuit Breaker (CB)

- Control current flow to the load or busbar. Break a current when internal or
external faults occur using a shunt trip coil.
2. Reverse Power Relay (RPR)
- Detect and break or open a circuit breaker automatically when a generator
receive supply from busbar ( reverse power ) to prevent generator “motoring”.
3. Over Current Relay (OCR)

- Detect and break or open circuit breaker when an internal or external
overcurrent fault occur.
4. Over Voltage Relay (OVR)

- Detect and break a circuit breaker when generated voltage is higher due to
overspeed or over exciting current.
5. Under Voltage Relay (UVR)

- Detect and open a circuit breaker when generated voltage is lower due to under
or loss of speed or exciting current.
A4 Chargeman
Page 15 of 22
6. Under Frequency Relay (UFR)

- Detect and open a circuit breaker when a frequency is lower due to under or
loss of speed.
7. Earth Fault Relay (EFR)

- Detect an internal or external fault leakage current and open a circuit breaker
automatically.
8. Restricted Earth Fault Relay (REF)
- Detect and break a circuit breaker when an internal earth fault occur.
The signal from these respective relay is going to energise a Master/Lock-Out

Relay installed (does not shown in the Figure 14), which in turn trips the circuit
breaker and sound the alarm buzzer. As a metering devices, the protection devices
also getting the supply by tapping to the main line through the CT and PT. In real
installation as in Figure 15, the two system will share the PTs but not the CTs since
there are in different class. This is to ensure that the operational integrity of the two
system is almost guaranteed.
R Y B N
CB Master Relay
RPR OC
CT
E/F
UVR OVR UFR
VS
P.T
Hz
AS
C.T P.F
A
KWH KW VAR
C.T
REF
Figure15 - Generator Metering& Protection System
A4 Chargeman
Page 16 of 22
3.2.3.4 Shutoff System and Alarm Panel
Emergency shutoff controls may be electrically, mechanically or hydraulically

operated. The operation of all electrical shutoff controls is similar where a critical
operating condition actuates a switch to stop the engine. The shutoff control may
require resetting before the engine can start.
Alarm switches are set at a less critical temperature, pressure, or level limit
than the shutoff controls. The purpose of the alarm switch is to warn the operator
that an unsafe operating condition is occurring. Corrective measures must be taken
to avoid possible damage to the engine.
These switches are electrically connected to their respective relays: LOP-Low

Oil Pressure, HWT-High Water Temperature which in turns deenergise the Fail
Control (FC) relay which going to shutdown the system by disconnecting the supply
to the DC Control Panel. Other relays such as Overspeed (OSR), Fail Start (FSR),
Earth fault (EFR) an so on, are installed in the system for the same purposes.
*Do not use an emergency shutoff control for a normal stopping procedure. Always
determine the cause of the shutdown and have the necessary repairs made before
restarting the engine. See the “Troubleshooting” section of set operating manual.*
When an alarm is activated, corrective measures must be taken before the

situation becomes an emergency. Each alarm switch is electrically connected to an
indicator light at the alarm panel, bell or horn. The alarm will continue until the
condition is corrected and alarm reset button is depressed. Then the light will turn
off and the bell or horn will be silenced.
In modern installation, Programmable Logic Control (PLC) is used to enhance the

monitoring as well as the protection of the system operation. The functions of PLC
are:
i) to monitor the operation as well as data storage
ii) to shutdown the system during abnormal running condition
3.2.4 Battery Charger and Battery Bank
A 24VDC 10AMP Automatic Battery Charger equipped with Trickle/Boost

facility together with DC Ammeter, DC Voltmeter and charger ' ON'lamp is
installed in one of the compartment of the generator board (In normal situation this
charger is installed as a unit by itself). A 240VAC supply is taken from the Main
Switch Board to power this charger unit.
The charger output is used for charging the two-ten-cell Nickel Cadmium
battery bank situated beside the engine skid during the engine stop, but will be
cut-off when the engine is running. During this time the battery bank is charged by
using the supply from the engine-driven alternator. This alternator in actual fact is
an AC generator with a built-in static rectifier for DC conversion.
A4 Chargeman
Page 17 of 22
3.2.5 FUEL STORAGE/SYSTEM
Fire regulations limit the amount of fuel that can be stored in the generator
room and the usual arrangement of fuel supply comprises a small service tank on or
near the set which is topped up from a bulk tank situated outside. Maximum fuel
storage should not exceed 700 litres. Thus for large installation, another outdoor
bulk storage tank will be necessary to feed the day tank inside the engine room in
order to provide for 6 hours or longer continuous operation.
For the system, fuel transfer pump is located on the right side of the engine. The
lower shaft of engine oil pump drives the gear type transfer pump. Fuel from the
supply tank is pulled through a primary fuel filter by the transfer pump and sent to
the fuel filter housing.
The transfer pump has a check valve and a bypass valve to prevents fuel flow back
through the transfer pump when priming pump is used and limits the maximum
pressure of the fuel. It will open the outlet side of the pump to the pump inlet if the
fuel pressure goes up above limit. This helps prevent damage to fuel system
components caused by too much pressure.
3.2.6 Auto-Main Failure Board (AMF)
It is a floor standing board, designed to be operated automatically or manually,

which functions are as follows:
a) provide permissive to start signal to the generator set via undervoltage relay
b) do ‘supply to the load’ switching either from mains or from generator.
c) connect/disconnect the generator to/from the essential/vital switchboard.
The main components/devices installed on the board are:

i) Electrical and Mechanical interlock.
ii) Change Over Contactor
iii) Change Over Isolator
iv) Under Voltage Relay.
In normal condition, when the ‘mains'is healthy the sensing relay which is an
Undervoltage Relay setting at 80 -90% rated, will sense the condition of the ' mains' .
If there is any fault in the mains the genset will start up automatically if the duty
selector switch is in Auto position and the load is transferred to the Generator set by
means of a Change-over Contactor. When the Mains return to healthy conditions,
the load will transfer back to the "Mains" supply through the reenergising of
changeover contactor and shutdown the genset. For manual operation, the operator
has to start the generator set and operate the Change-over Isolator manually. The
board/system also equipped with an M&E interlock to ensure the safety or the
operator as well as the operation.
A4 Chargeman
Page 18 of 22
3.3 System Operation

The system is designed to operate in automatic mode in accordance with
pre-programmed instructions/procedures. The sequences of the single generator
installation operation in automatic mode are as follows:

(a) The mains failure detection system normally under voltage relay which being
set at 80-90% of rated voltage, monitor the voltage on the individual phases on
the mains supply to detect loss (or abnormal reduction) of voltage. It is
customary to delay, the activation of the run-up of a mains failure set for two
to three seconds to prevent a momentary loss of mains voltage being
interpreted as a genuine power failure. This permissive to start signal is then
activates the starting of the engine .
(b) The next stage in the sequence is the starting of the standby generator set.
(i) The first stage comprises part energising of the starter motor system so
that at. say one second intervals, the starter pinion attempts to engage and
as soon as this has been achieved,
(ii) The second stage of starting, i.e. actual full power cranking, commences.
An engine speed detection circuit indicates when the engine has fired and
has started to run up to speed and at this point the starter motor is
de-energised and locked out.
(iii) Acceleration of the engine to full speed is comparatively rapid, typically
a few seconds, in which time the generator voltage. and engine oil
pressure build up and as soon as speed, voltage and oil pressure are
within acceptable limits the generating set is deemed to ready for load
transfer.
c) The load is fed from the mains supply system through one of a pair of
changeover contactors or motorised circuit-breakers interlocked so that they
cannot both be closed at the same time. When the generating set is ready the
load is transferred from the mains to the generating set which supplies the load
for the duration of the mains outage. The changeover system must ensure that
in no circumstances can the generator be inadvertently connected in parallel
with the mains, and four-pole contactors, isolating the neutral, are frequently
specified.
(d) Many standby generating sets are fitted with some form of mains return delay
circuit which ensures that mains voltage is within acceptable limits for a
prearranged period before actual transfer of load back to mains. Small sets are
then usually shut down immediately, but the larger engines maybe run for a
few minutes on a no-load cooling run which allows a degree of equalization of
heat in the engine parts and prevents thermal stresses after shut-down.
If the system is equipped with a synchronizing facilities and required to do so,

the synchronizing process has to take place before item c). The installed Auto
Synchroniser will synchronise (generator to generator synchronising) the two supply
before the system can take-up the loads. This process is covered in the Generator
Synchronizing Module.
A4 Chargeman
Page 19 of 22
The overall system interconnection is shown in Figure 16.

Figure 16 - Block Diagram of Overall System
The system is also equipped with the manual operation mode . This is
important to ensure that the gen-set can be operated even though the auto mode
operation is fail . In manual mode, the sequence of operation more or less the same;
manually pressed the start push button, set the generator output to the rated value,
operate the generator circuit breaker, synchronised and if required, operate the AMF
board for load transfer.
In general, the whole process can be subdivided into:
1. Engine Startup,
2. Generator output control and
3. Put generator output to the busbar by operating the generator circuit breaker.
4. Synchronizing process
5. Load sharing and Load Shading
6. Shutdown Process.
The whole process from engine starting until generator ready to load normally takes
about 20 second if it is done in auto mode. It may take a longer time to operate it in
manual which much rely on the competency of the operator.
Since the system has to work automatically, maintenance of the system is so crucial
to ensure smooth operation of the set. To do so the following inspection must be
carried out at regular intervals, e.g. weekly inspection:-
1) Check lubrication oil level.
2) Check engine coolant water level.
3) Check all control fuses
4) Check battery condition and the battery water level.
5) Test run the generator set to make sure the engine is in good condition by
operating is manually.
A4 Chargeman
Page 20 of 22
3.3.1Engine Start-up/Shutdown
To start manually, turn the DC control switch to ON position, duty selector

switch to manual position, release the *emergency push button and check the alarm
indicators for any faults on the starting system. Press the manual start pushbutton for
starting, and hold it for sometimes until the engine is securely start up. The manual
pushbutton contact energises the Starting Relay (SR) which in turn energises engine
starter motor for cranking. At the same time Fuel Solenoid Monitor relay also
energised an opened the fuel solenoid valve. During cranking also, the electrical
actuator is automatically controlled the operation of the engine governor. When the
engine run up to certain speed and the generator starts to supply voltage , an under
voltage known as Alternator Fail Relay (AFR) energise to deenergise the SR to
prevent over cranking even with the start button is still pressed. Refer to Starting
Procedure in the next section in this module for more detail activities.
*Emergency Pushbutton
This stop button is a latched-on type, to release it, turn the
mushroom head of the pushbutton according to the direction of the
arrow shown on the button.
A Nickel cadmium or stationary lead acid battery, suitable for high discharged,
is required for engine cranking. It is either 24 to 110 volt depending on engine size
and can cater for 6 starting attempts separated by not less than 30 sec rest periods.
Each starting attempt is assumed to begin with 1 sec locked rotor followed by 5 sec
cranking with terminal voltage not lower than 1 volt per cell and 1.4 volt per cell
respectively in the case. of lead acid battery. The corresponding figures for nickel
cadmium battery are 0.65V and 0.85V. However, if the engine fail to start up after a
certain period, the operator is advised not to proceed further, but to check fuel level
and battery condition. As prolonged cranking does not help if the battery is weak or
fuel level too low.
It is normally written in the starting procedure for the operator to confirm the
gen-set readiness prior to starting process by checking the followings:
1) lubrication oil level.
2) engine coolant water level.
3) battery condition and the battery water level for electric starting system .
4) air/gas pressure if using pneumatic starter
5) fuel level and fuel control valves
6) all control fuses
7) alarm panel for faults
8) position of the generator breaker-should be in OFF position.
To stop the engine manually, it can be done by pressing the emergency stop
pushbutton. When this happened, all supply to the starting and alarm circuits are
being cutoff to prevent from re-starting. If the system is running with some loads,
make sure the load shading, system desynchronising and generator circuit breaker
isolation process has to take place first before pressing the emergency push button.
If in real emergency situation where fast action is required then only the emergency
pushbutton can be operated straight away, by- passing other procedures.
A4 Chargeman
Page 21 of 22
3.3.1.1 Start-up Procedure
*This procedure is written to guide the operator to operate the in-house diesel
engine generator training set . It may not applicable to be used for any other
installation.
A4 Diesel Engine - Generator Sets Starting Procedure
A) Entering the Generator Room.

i) complete safety gears; coverall, hard hat, boot, ear plug/ear guard and
goggle.
ii) ensure that the room is safe to enter by referring to the room condition
indicating light (Green), open the main door, let the door open for a
while to ensure all the gas inside the room is purge out.
iii) ensure the light is enough, the availability of fire extinguisher, single line
drawing and rubber mate inside the room.
iv) sign and record the intended activities in the record/log book.
B). Before operating the generator

a) ensure fuel for diesel engine is at operating level and both valves for fuel
inlet and return line are in open position.
b) do inspect on Diesel Engine
- Battery bank voltage at minimum of 24VDC
- Radiator water level at operating level
- Lub oil at operating level and no leaking
- any loose items on top of the engine
C). Before operating the panel, ensure all breakers and switches are in OFF
position.
D) Follow the procedure and refer to attach DC Control single line drawing.
1. Put DC Control switch to ON position and DC Selector Switch to
manual position .
2. Release the Emergency Stop button.
3. Press START button .................. Prime Mover will start.
4. Monitor generator metering panel.
- Adjust value of voltage and frequency using voltage trimmer and
speed trimmer to a required Value ( V= 415V, f= 50 Hz ).
5. Put a circuit breaker switch to manual mode.
6. Release circuit breaker Emergency Trip button.
7. ON Neutral Contactor or Close Neutral Knife Switch.
8. Press circuit breaker ON Push Button...........Circuit breaker will close.
Gen A is now supplied power to the busbar and can take up in average about 75%
loads in comparison to its rating which is 100kVA. Further increases of load says
120kVA, then the incoming generator need to be put in parallel (Synchronize).
The shut down procedure is reverse the start-up

procedures unless emergency shutdown required by
pushing the emergency push button.
A4 Chargeman
Page 22 of 22
Glossary of Terms
Residual Magnetism - the remain of magnetic flux in the pole pieces magnetic
material.
Cutting Process - the process of the field flux of a generator cuts the armature
conductor to induce an ac output.
Positive feedback - a comparator signal indicates under rated generator output, send
to the AVR to inject more field current to the Ac exciter field.
Negative feedback - a comparator signal indicates over rated generator output, send
to the AVR to reduce the field current injected to the Ac exciter
field.
Synchronizing - a process of adding power to the existing supply due to

increasing of loads
References
1. B.L Theraja - A Book of Electrical Technology

2. John R. Duff, Stephen L. Herman - Alternating Current Fundamentals
3. Eugene C. Lister - Electric Circuits and Machines
4. Alan Symonds - Electric power Equipment and Measurements
5. Electrical Power System - Shell UK
A4 Chargeman

A4 Standby Generator

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

A4 Standby Generator

Uploaded by

Copyright:

Available Formats

Institut Teknologi Petroleum PETRONAS

ALL RIGHTS RESERVED:

Prepared by : Anuar Ali

2.0 Learning Objectives

3.0 Learning Coverage

3.1 Introduction/Basic Description

3.2 Diesel Engine Generator Set Assembly

3.3 System Operation

This module is design to provide trainees with the understanding of Standby

discussed in this module.

2.0 Learning Objectives :

At the end of the session, trainees will be able to :

3.0 Learning Coverage

3.1 Introduction/Basic Description

The primary function of a standby generating set is to deliver power automatically

To demonstrate and develop understanding of the standby gen-sets, a simple

A typical generator set is shown in the Figure 1 below.

Figure 1 - Typical Standby Gen-Set

3.2 The Diesel Engine Generator Set Assembly

The diesel engine construction and operation is not going to be discussed in

3.2.1 The Generator Principle and Component

simply stated, is that a voltage is induced in a conductor whenever the conductor is

Figure 2 - Process of Generating Electricity

The commonly installed generator is a Three phase, Self Excited, Rotating

Figure 3 - Generator (Conventional) Internal Assembly

The main component of a generator are:

3.2.1.1 Brushless AC Generator Assembly

a) The Main Generator

c) The Pilot Exciter

d) Automatic Voltage Regulator(AVR)

The connection as in Figure 5 below.

Rectifier Generator field

Figure 5 - ‘Graetz Formation’ of Rotating Rectifier

The interconnection and operation of the brushless AC generator is explained

Figure 6 - Block Diagram of Brushless Generator without PMG

Figure 7 - Block Diagram of Brushless Generator with PMG Connected

3.2.1.2 The Generator Excitation

AVR Set Voltage

Figure 8 -Brushless Alternator with AVR

3.2.2 The Local Control Panel

a) To start and stop the generator from the engine skid.

Figure 9 shows the devices installed on the panel which are:

Figure 9 - Local Control Panel

3.2.3 The Generator Board

a) To remotely start and stop the generator set.

The systems/devices installed on the board as in Figure 10 can be categories/

Figure 10 - Generator Board

3.2.3.1 The Metering System

Figure 11 - Generator Metering System

The system comprises of the measuring meters; Voltmeter, Ammeter, KW meter,

3.2.3.2 The Control Scheme

As discussed earlier in section 3.2.1.2 The Generator Excitation, the primary

Figure 12 - Typical Generator Control Scheme

This system used Woodward Electrical Actuator/Governor to control the flow

Figure 13 - Essential Elements of electronic Governor

3.2.3.3 The Protection System

Reverse Power Relay

Stator Earth Fault Relay

Figure 14 - Generator Protection Scheme

The common protection components/relays are:

1. Circuit Breaker (CB)

3. Over Current Relay (OCR)

4. Over Voltage Relay (OVR)