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Diesel Engines, Alternators U A

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and Synchronizing Panels M
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KRISTOFFER ADRIAN B. MEJIA, REE, ECE
SMEDD-Operations
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29 June 2015
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1 Diesel Engines, Alternators and Synchronizing Panels
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 Objectives
1. To give Resident Engineers and Technicians the basic knowledge on how
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the Diesel Engines, Alternators and Synchronizing Panels works.
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2. To give Resident Engineers and Technicians the technical skills in
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troubleshooting generator set faults. M
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 Diesel Engine – Defined
Diesel engine, an internal combustion engine in which the heat for igniting the fuel oil is
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produced by compressing air. The engine, invented by Rudolf Diesel in the 1890s, is also referred
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to as a compression-ignition engine. The fuel-air mixture burns rapidly and expands to drive the
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pistons.
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 Four-Cylinder, Four-Stroke Cycle Diesel Engine

Exhaust Valve Camshaft

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Combustion
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UIntake Valve
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Piston

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Crankshaft
Connecting Rod
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 Types Diesel Engines by Design
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 Diesel Engine Four-Stroke Cycle

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1.
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Intake stroke – intake valve opens to draw in air, exhaust valve is closed and the piston descends down.

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2. Compression stroke – intake and exhaust valves are closed and the piston ascends to compress air.
3. Power stroke – intake and exhaust valves are closed, fuel is injected through the highly compressed air, hence,
igniting the fuel-air mixture. The piston is pushed downwards to create motion on the crank shaft.
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4. Exhaust stroke – intake valve is closed, exhaust valve opens, piston ascends to release the exhaust gas.

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6 Diesel Engines, Alternators and Synchronizing Panels
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 Diesel Engine Two-Stroke Cycle

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Scavenging is the process whereby air at a pressure greater than that of atmospheric pressure is used to push the
exhaust gas out of the cylinder of an engine. Unlike the 4 stroke engine, a two stroke diesel engine does not use the

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piston to push out the exhaust gas, instead, air enters the cylinder around bottom dead centre and sweeps or
scavenges the exhaust gas from the cylinder. 2 stroke engines with an exhaust valve mounted in the cylinder head are
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known as uniflow scavenged engines. This is because the flow of scavenging air is in one direction.

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7 Diesel Engines, Alternators and Synchronizing Panels
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 Pros and Cons of 2-Stroke and 4-Stroke Engines
Advantage of two stroke design:
Due to the existence of only two strokes, the "Power Stroke" occurs every half cycle. One in every two strokes
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produces power (whereas in four stroke engines, only one in four strokes produces power). This gives two stroke
engines a significantly higher power-to-weight ratio than four strokes.
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Disadvantage of two stroke design:
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Very low fuel economy due to the combustion of exhaust gases and the escape of fuel. Since exhaust gases are re-
compressed and hydrocarbons (fuel) are expelled from the exhaust, the exhaust is rich with carbon (causing it's
characteristic white colour) and unusually high amounts of carbon monoxide.
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Advantage of four stroke design: NI
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Much higher fuel economy than two stroke engines because the intake and exhaust strokes are treated as two
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different steps.

Disadvantage of four stroke design:

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Their power-to-weight ratio is much smaller as compared to two stokes because only one in ever four strokes
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produces power.
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8 Diesel Engines, Alternators and Synchronizing Panels
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 Types Diesel Engines by Speed
Governing System
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9 Diesel Engines, Alternators and Synchronizing Panels
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 Conventional Diesel Engines
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The Speed Controller and Electric Governor
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Governor Definition: An attachment to a machine for automatic control or
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limitation of speed
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The function of governor, in all operating conditions, is to adjust the fuel
injection pump and ensure the stable operation of diesel engine at regulated

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speed when the load changes.

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10 Diesel Engines, Alternators and Synchronizing Panels
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 Electronic Diesel Engines
The Electronic Controller Module (ECM)

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The electronic controller module is the microprocessor that receives electronic inputs from the sensors and switches
and is calibrated to control fuel metering, injection timing, diagnostics and engine protection. The ECM receives
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power from the battery and ignition switch and provides a reference voltage for sensors. The software contained in
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the ECM determines how the electronic diesel engine control system operates. The ECM stores the calibration values
that define the rated power, torque curves and RPM specifications. It is mounted usually on the diesel engine.

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 Electronic Diesel Engines
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Cummins ECM – DG#6 SMCF
N S Caterpillar ECM – DG#7 SMCF

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 Rating Definitions - MHI
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 Rating Definitions - CAT
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 Rating Definitions - Cummins
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 Generator Set Parts - MHI

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 Generator Set Parts - MHI

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 Electronic Engine Fuel System

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Unit Injectors
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 The Unit Injectors

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Unit injector (UI) is an integrated direct fuel injection system for diesel engines, combining the injector nozzle and the
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injection pump in a single component..

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 The Unit Injectors - Parts

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Unit injector (UI) is an integrated direct fuel injection system for diesel engines, combining the injector nozzle and the
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injection pump in a single component..

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20 Diesel Engines, Alternators and Synchronizing Panels
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 The Conventional Fuel System

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The Fuel system is responsible for distributing diesel fuel from the storage tanks up to the injection nozzles of the
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diesel engine.

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21 Diesel Engines, Alternators and Synchronizing Panels
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 The Lubrication System

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The Lubrication system is responsible for distributing lube oil from the engine oil sump up to the various moving
parts of the diesel engine to lubricate the metal-to-metal contacts such as the rocker shafts, crankshaft, camshaft,
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turbochargers and other moving parts.
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 The Cooling Water System

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The Cooling water system is responsible for regulating the diesel engine’s temperature to operate at its optimal
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performance. Temperature ranges from 70 deg. C up to 95 deg. C.

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 The Air Intake and Exhaust System

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The Intake and Exhaust system is responsible for the induction of air inside and the removal of exhaust smoke out of

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the diesel engine. The turbochargers and charge air cooler are the equipment used to give boost to the engine which

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will be discussed separately.

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24 Diesel Engines, Alternators and Synchronizing Panels
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 The Turbocharger
One of the ways to get more power out of an engine is to increase the amount of air and fuel that it can burn. One

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a turbocharger can be a simpler, more compact way to add power, especially for an aftermarket accessory. S
way to do this is to add cylinders or make the current cylinders bigger. Sometimes these changes may not be feasible -

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The turbocharger is bolted to the exhaust manifold of the engine. The exhaust from the cylinders spins the turbine,
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which works like a gas turbine engine. The turbine is connected by a shaft to the compressor, which is located
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between the air filter and the intake manifold. The compressor pressurizes the air going into the pistons.

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The exhaust from the cylinders passes through the turbine blades, causing the turbine to spin. The more exhaust that

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goes through the blades, the faster they spin. On the other end of the shaft that the turbine is attached to, the
compressor pumps air into the cylinders. The compressor is a type of centrifugal pump -- it draws air in at the centre
of its blades and flings it outward as it spins.
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 The Alternator
An alternator is an electrical generator that converts mechanical energy to electrical energy in the form of alternating

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current. For reasons of cost and simplicity, most alternators use a rotating magnetic field with a stationary armature.
Occasionally, a linear alternator or a rotating armature with a stationary magnetic field is used. In principle, any AC

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electrical generator can be called an alternator, but usually the term refers to small rotating machines driven by
automotive and other internal combustion engines. An alternator that uses a permanent magnet for its magnetic
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field is called a magneto. Alternators in power stations driven by steam turbines are called turbo-alternators. Large 50
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or 60 Hz three phase alternators in power plants generate most of the world's electric power, which is distributed by
electric power grids.

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Basic Alternator

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26 Diesel Engines, Alternators and Synchronizing Panels
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 The Brushless – Type Alternator
This is the construction/connection/design of a brushless type alternator. Looking at the diagram, the main stator is
the armature winding, the rotor winding is the magnetic field, the main exciter rotor is also an armature winding, the

the armature winding is the stator. L S

field exciter is a stator (magnetic filed). In the Regulator portion, the permanent magnet generator is the rotor and
Main Exciter

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I O DC Voltage Output

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Voltage Sensing
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Feedback
Auxiliary Exciter

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 The Synchronizing Panel
Definition

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Synchronizing, in its simplest form, is the process of electrically connecting additional generators to an existing bus.
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Conditions prior to Synchronizing a Generator
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In order to synchronize a generator to the system bus, four conditions must be met:
1. Phase Sequence A N
2. Voltage Magnitude M
3. Frequency
4. Phase Angle
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The synchroscope is a multiple parameter information source. It tells you if there is a slip rate (a frequency difference
between generator and bus) and if the generator frequency is running slower or faster than the bus frequency by

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causing the pointer to rotate in a counter-clockwise or clockwise direction. As seen in in the figure, the twelve o'clock
position indicates 0 degrees phase angle difference. Any instantaneous position of the pointer indicates the phase
angle difference between the bus and generator voltage.
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 The Synchronizing Panel
The most primitive device used for synchronizing is a
pair of incandescent lamps connected to the same
phases on either side of the generator breaker as L S
shown in the figure. This demonstrates that if both the
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generator and bus voltages are "in phase", there is zero
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be illuminated, hence, the term "dark lamp method of M
synchronizing". Although simplistic in design, this is a
reliable method of phase angle verification when used N G
in conjunction with a synchroscope to verify that there
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is no malfunction of either the lamps or synchroscope.
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 The Synchronizing Check Relay (25)

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These relays are used to verify that the
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are synchronized, in the proper phase and
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Synchronizing check relay block diagram.
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 The Synchronizing Controllers

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 Basic Diesel Engine Maintenance

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Note: If there is an oil-water dilution, the colour of the lube oil becomes milky. Upon
verification of dilution, never attempt to start the diesel engine and get support from diesel
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 Basic Diesel Engine Maintenance

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 Basic Diesel Engine Maintenance

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 Basic Diesel Engine Maintenance

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 Basic Diesel Engine Maintenance

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 Basic Diesel Engine Maintenance

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 Basic Diesel Engine Maintenance

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 Basic Diesel Engine Troubleshooting

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 Basic Diesel Engine Troubleshooting

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 Basic Diesel Engine Troubleshooting

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 Basic Diesel Engine Troubleshooting

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 Appendix

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 Gasoline Engine Combustion Chamber

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 List of Lubricating Oils

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 Recommended Fuel Requirements

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 Recommended Cooling Water Quality

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 Complete Device Numbers (ANSI)

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 L S
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Thank YouING
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