DG SET SYSTEM

Operation principle of 4 -stroke diesel engine

 Operation principle of 4 -stroke diesel engine
• Induction stroke - while the inlet valve is open, the descending
piston draws in fresh air.

• Compression stroke - while the valves are closed, the air is

compressed to a to a high ratio (14:1 to 25:1). During this
compression, the air is heated to a temperature of 700–900°C. A
metered quantity of diesel fuel is then injected into the cylinder.

• Ignition and power stroke - the fuel ignites spontaneously due to

high temperature and the piston is forced downwards by the
combustion gases.

• Exhaust stroke - the exhaust valve is open and the rising piston
discharges the spent gases from the cylinder.
 Diesel Engine Power Plant Developments
• The specific fuel consumption has come down
from a value of 220 g/kWh in the 1970s to a
value around 160 g/kWh in present times.

• Slow speed diesel engine, with its flat fuel

consumption curve over a wide load range
(50%–100%), compares very favourably over
other prime movers such as medium speed
diesel engine, steam turbines and gas turbines.

• Development of turbocharger
High Speed or Slow/Medium Speed Engine

The normal accepted definition of high speed engine is 1500 rpm

 Turbochargers

• They are part of the air system

• They are centrifugal blowers driven by exhaust gas.

• Thus they run on power which otherwise is wasted

• The net result is lower fuel consumption per kWh and

further increase in overall efficiency (43 – 45 % ).

• The purpose of turbochargers are to stuff more air

into the cylinder so more fuel can be burned thus
boosting power or to compensate for less air pressure
at higher altitudes so the engine does not lose power
as quickly.
Engine Selection Considerations
• Speed of the engine - Engines should be run as closely
as possible to their rated speed.

• Power of the engine - The engine power rating should

be 10 -20 % more than the power demand by the end
use.

• The engine are usually rated on continuous basis

against standard reference conditions at 1000 kN / Sq
mtr , 32 deg C and 60 % relative humidity.
Advantages of DG captive Power Plants

• The diesel engine is able to burn the poorest

quality fuel oils.
• Short delivery period .
• Low installation period & cost
• Short start up time
• More efficient performance under part loads
• Minimum cooling water requirements
• Adopted with air cooled heat exchanger in
areas where water is not available
 Components of DG system

• The diesel engine and its accessories.

• The AC Generator.
• The control systems and switchgear.
• The foundation and power house civil
works.
• The connected load
 Sizing of a Genset:
• Size of generator = 2x+y
Where x is total non linear load
Where y is total linear load
• In nonlinear load current is non sinusoidal even if
voltage is sinusoidal
• Due to non sinusoidal load current the internal
reactance drop in the generator winding is non
sinusoidal. Hence the terminal voltage of
generator will become non sinusoidal
• By oversizing the generator we reduce the per
unit reactane in same proportion and hence
voltage distortation can be minimized.
 Capacity Combinations
Advantage of one large
DG set than two or more
DG sets in parallel
- It is economical
• due to space requirement ,
• operation, maintenance
expenditure
• initial capital investment.
Advantage of two or
more DG sets running in
parallel
• One DG set can become
100% standby during low
power-cut periods.
• D.G. sets can be run at
optimum operating points
for optimum fuel
consumption.
 Air Cooling V s. Water Cooling
• In the lower capacities it may be possible
to have air cooled engines but it will be
necessary to go in for water cooled
engines in larger capacities to ensure that
the engine does not get over-heated.
 Safety Features
• High cylinder temperature
• low lube oil pressure
• High speed
• 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.
• When DG sets are to run in parallel reverse
power relay should be provided to avoid back
feeding from one alternator to another.
 Earthing
• Neutral Earthing - Two independent earths
to the neutral should be provided to give
adequate protection to the equipment in
case of an earth fault.
• Body Earthing - Two independent earths
to the body should be provided to drain
away any leakage of potential from the
equipment to the earth for safe working
Load Characteristics are entirely load
dependent and cannot be controlled by the
D.G.set.
 Maximum Single Load on DG Set
• The starting current of squirrel cage induction motors is
as much as six times the rated current for a few seconds
with direct-on-line starters. In practice, it has been found
that the starting current value should not exceed 200 %
of the full load capacity of the alternator.

• In general, the HP of the largest motor that can be

started with direct on line starting is about 50 % of the
kVA rating of the generating set.

• If the type of starting is changed over to star delta or to

auto transformer starter, then HP of the largest motor
can be upto 75 % of the kVA of Genset.
 Loading
• In alternators highest efficiency attainable is at a loading of around 70% and
more. Manufacturers curves can be referred to for best efficiency point and
corresponding kW and kVA loading values.

• Engine manufacturers offer curves indicating % Engine Loading vs fuel

Consumption in grams/BHP. Optimal engine loading corresponding to best
operating point is desirable for energy efficiency.

• Ideally, the engine and alternator loading conditions are both to be achieved
towards high efficiency.

• Alongside alternator loading, the engine loading needs to be maintained

above 50%.
 Overload
• Diesel engines are designed for 10%
overload for 1 hour in every 12 hours of
operation.
• The A.C. generators are designed to meet
50% overload for 15 seconds as specified
by standards.
• The D.G.set/s selection should be such
that the overloads are within the above
specified limits.
 Sequencing of Loads
• It is advisable to start the load with highest
transient kVA first followed by other loads
in the descending order of the starting
kVA.
• This will lead to optimum sizing and better
utilisation of transient load handling
capacity of D.G.set.
 Transient Loading
Specially designed generator are selected to

1. control transient voltage dip arising due

to transient load
2. to ensures that Prime mover is not over
sized which results in reduced capital
and running cost.
 Special Loads
• Loads, which are sensitive to voltage,
frequency , voltage wave form , should be
segregated and fed by a dedicated power
supply which usually assumes the form of DG
motor driven generator set.
• Such an alternative ensures that special
design of AC generator is restricted to that
portion of the load which requires high purity
rather than increasing the price of the D.G. set
by specially designed AC generator for complete
load.
 Unbalanced Load
• Cause heating of the alternator, which may
result in unbalanced output voltages.
• Maximum unbalanced load between phases
should not exceed 10 % of the capacity of the
generating sets.
• Where single phase loads are predominant,
consideration should be given for procuring
single phase A.C. generator.
 Power Factor
• The A.C. generator is designed for the power
factor of 0.8 lag as specified by standards.
• Lower power factor demands higher excitation
currents and results in increased losses , lower
operating efficiency, over sizing DG set and
higher costs.
• The economical alternative is to provide power
factor improvement capacitors.
 Energy balance in a DG set
• Input : 100% Thermal Energy

• Outputs :
35% Electrical Output
33% Stack Loss through exhaust Flue Gases
24% Coolant Losses
4% Radiation Losses
4% Alternator Losses
Waste Heat Recovery in DG Sets
• Potential WHR ( in kcals /Hour) = Q x 8 x .25 x (tg -180°C)

Where Q = kWh Output/Hour = actual average unit generation from

the
set per hour.
8 = Exhaust gases in Kg / kWh Output

0.25 = Specific heat of flue gases

tg = the gas temperature after turbocharger ( the criteria being

that limiting exit gas temperature cannot be less than
180°C,
to avoid acid dew point corrosion).
 Factors on which actual realisable
WHR in DG Sets depends
• Consistent DG set loading (to over 60% of
rating) would ensure a reasonable exit flue
gas quantity and temperature.
• Number of hours of operation of the DG
Set
• Maximum back pressure in the gas path
allowed is around 250-300 mm WC and
the waste heat recovery unit should have
a pressure drop lower than that.
 Energy Saving Measures for DG Sets

• Ensure compliance with maintenance checklist

• Provide cold, dust free air at intake & improve air filtration.
• Ensure fuel oil storage, handling and preparation as per
manufacturers' guidelines / oil company data.
• Consider fuel oil additives in case they benefit fuel oil properties
for DG set usage.
• Calibrate fuel injection pumps frequently.
• Ensure steady load conditions, avoiding unbalanced Load &
harmonic loads.
• Consider parallel operation among the DG sets for improved
loading and fuel economy thereof.
• In case of a base load operation, consider waste heat recovery
system adoption for steam generation. Even the Jacket Cooling
Water is amenable for heat recovery for vapour absorption
system.
• carryout regular field trials to monitor DG set performance.
• The compression ratio in diesel engines is in the range of
a) 5:1 to 10:1 b) 10:1 to 13:1
c) 14:1 to 25:1 d) none of the above

• The rated efficiency of a diesel generator captive power plant

has a range of
a) 43% – 45% b) 50% – 60%
c) 60% – 70% d) above 70%

• The maximum unbalanced load between phases should not

exceed …… % of the capacity of the DG set
a) 1 b) 5
c) 10 d) none of the above
• The operating efficiency of a DG set also depends on
a) turbo charger performance b) inlet air temperature
c) % loading d) all of the above

• Diesel Engine is normally over designed for power rating of DG sets.

( a) 10 - 20% (b) 20 – 30% ( c ) 30 – 40% (d) 40 – 50%

• The main precaution to be taken care by the waste heat recovery device
manufacturer to prevent the problem in a DG set during operation is:
a) temperature rise b) back pressure
c) over loading of waste heat recovery tubes d) turbulence of exhaust gases
• How many revolutions take place for every power stroke in a single
cylinder 4 strokes engine?
( a) 1 b) 2 c) 3 d) 4

• The capacity of largest motor that can be started in the given DG set is
(a) 25% (b) 50% ( c) 75% ( d) 100% KVA rating of DG set

• The starting current value should not exceed the----% of full load
capacity of alternator
(a)110% (b) 120% ( c )150% (d) 200%
• The factors affecting Waste Heat Recovery from exhaust flue gases of DG set are:
a) Temperature of exhaust flue gases after turbo charger
b) Back pressure on the DG set
c) DG set loading
d) all of the above

• The maximum back pressure drop (mmWC) allowed in a DG set is

100-150 b) 150-200 c) 250-300 d) none of the above

• Which of the following losses is the least in DG sets:

a) cooling water loss b) exhaust loss
c) frictional loss d) alternator loss

• Lower power factor of a DG set demands_____

a) lower excitation currents b) higher excitation currents
c) no change in excitation currents d) none of the above

• Which combination of readings as indicated by the panel mounted instruments of a

DG Set would give the indications of proper capacity utilisation of diesel engine and
generator
a) kW & Voltage b) kVA & kVAr c) kW & KVA d) none of the above
• In a DG set, the generator is generating 1000 kVA, at 0.7 PF. If the specific
fuel consumption of this DG set is 0.25 lts/ kWh at that load, then how much
fuel is consumed while delivering generated power for one hour.
a) 230 litre b) 250 litre c) 175 litre d) none of the
above

• The jacket cooling water in a diesel engine flows at 12.9 m3/hr with a range of 10oC
and accounts for 30% of the engine input energy. The power output of the engine will
be
500 kW b) 387 kW c) 430 kW d) none of the above

• In a DG set, the generator is consuming 150 litre per hour diesel oil. If the specific
fuel consumption of this DG set is 0.25 litres/ kWh at that load, then what is the kVA
loading of the set at 0.6 PF?
600 kVA b) 1000 kVA c) 300 kVA d) none of the above

•
• A 1100 kVA DG set is delivering 800 kW output. If the flue gas generated is 8
kgs/kWh then the total flue gas flow rate in kg/hr is
a) 8800 b) 6400 c) 100 d) 137

• The exhaust gas waste heat recovery potential of a turbo charged genset at 500 kW
loading and 480 C exhaust gas is closest to …… (Assume exit gas temperature of
180 C and 8 kg gas/ kWh generated)

1.6 lakh kCal/hr b) 2.2 lakh kCal/hr c) 3.0 lakh kCal/hr d) 3.5 lakh kCal/hr
• A 180 kVA, 0.80 PF rated DG set has diesel engine rating of
220 BHP. What is the maximum power factor which can be
maintained at full load on the alternator without overloading the
DG set? (Assume alternator losses and exciter power
requirement as 5.60 kW and there is no derating of DG set)

Ans:

Engine rated Power = 220 x 0.746 = 164 kW

Rated power available for alternator = 164 – 5.6
= 158.4 kW
Maximum power factor possible = 158.4 /180
= 0.88
Question :
Find DG set capacity for
Connected Load = 650 kW
Diversity Factor = 0.54
(Demand / connected load)
% Loading = 70

Solution :

Max. Demand = 650 x 0.54 = 350 kW

Set rating = 350/0.7 = 500 kW

At 0.8 PF, rating = 625 kVA