DG

SET
OBJECTIVES
INTRODUCTION.
BASIC SAFETY TIPS FOR DG.
SPECIFICATION OF DG.
PARTS OF A DIESEL GENERATOR.
INTRODUCTION
A simple diesel generators operate as a mechanical & electrical machine that convert one
source of energy into another form of energy.
In this case, a power generator works by taking mechanical energy and converting it into
electrical energy.
SAFETY TIPS FOR DG
EFFECTS OF IGNORING INDUSTRIAL GENERATOR SAFETY
If a generator is not properly installed, maintained or handled, it can cause a fire, damage
electrical equipment or give off deadly levels of carbon monoxide (CO).
Here are the top reasons to practice generator safety.
1. CARBON MONOXIDE POISONING
2. ELECTROCUTION
3. FIRE AND BURNS
4. SOUND ATTENUATION
 CARBON MONOXIDE POISONING
CO is an odorless, colorless gas. Because it gives no warning with taste or smell, it’s referred to as the “silent
killer.”
A person exposed to dangerous CO levels may experience symptoms associated with the early stage of CO
poisoning. Common CO poisoning symptoms include:
oHeadache
oDizziness
oWeakness
oConfusion
oVomiting
oChest pain
Breathing in too much CO makes someone pass out or die in a matter of minutes.
ELECTROCUTION
Generators are often paired together with an Automatic Transfer Switch (ATS).
 An ATS will prompt the generator to kick in seconds within the event of power loss due to power outage.
Once power is restored from the main power grid, the generator will be prompted to shut off, as service
from the main grid will resume.
This is simply due to the fact that because the ATS is connected to the main grid, the ATS can detect an
outage and signal the control panel to start the generator without the need to manually start the generator.
Without an ATS (Automatic Transfer Switch), you will need staff on-site to manually flip the switch on the
generator controls to run the generator in the event of a power outage and must also manually turn off the
generator once power is restored.
Failure to turn off the generator after power to the main grid is restored can cause an effect called back
feeding, which can be lethal to any electricians or maintenance workers that are working on the power lines.
FIRE AND BURNS
Liquid fuels or natural gas are usually used as the primary fuel of the diesel generator.
Totally, a diesel generator works based on air compression and the fuel.
First, the air is blown into the generator until it is compressed. Subsequently, the proper fuel of
diesel generator is injected.
The combination of air compression and subsequent injection of the fuel will contribute to
generate the heat that triggers the inflammation of the fuel.
In this way the diesel generator starts combustion and causes the generator to start up.
Thus the generator starts to produce the necessary electrical energy to be distributed
according to the needs of the loads connected to the diesel generator.
FIRE AND BURNS
If you exceed the generator’s power rating, you could overload the generator.
This could damage the generator as well as appliances hooked up to the generator.
The generator could also overheat and catch on fire. the first step is to 
calculate power needs and requirements to avoid overloading your generator and ensure that
your generator is properly sized to provide adequate power.
Business owners also need to keep themselves and their employees safe from generator-
related burns.
 Generators get hot when they run, and they remain hot for a long time once they are shut
down. General workers should know not to touch generators.
SOUND ATTENUATION
Commercial generators are loud. Simply stated, these generators not only produce high
outputs of power, but can also generate noise at high frequencies.
The high frequencies result in noise that reaches high-decibel levels that can seriously damage
or rupture eardrums, or worse, can permanently deafen those that near the generator.
If the generator has an enclosure, make sure that the generator is properly sound-attenuated.
Sound-attenuated enclosures help reduce noise and decibel levels of a commercial generator,
which will help protect your employees that are working with/around the generator itself.
THE MAIN PARTS OF A DIESEL
GENERATOR
DIESEL ENGINE
This is simply a basic diesel engine, it varies very little from ones found in cars, vans or other
large vehicles.
This is the source of the mechanical energy, and the size of the engine matters.
If you want a larger electrical output, then you need a bigger engine.
The larger the generator engine, the more electrical output you are able to generate.
ALTERNATOR
This is essentially the component that's responsible for generating power output.
According to the principle of electromagnetic induction, if an electrical conductor remains
stationary and a magnetic field moves around it, then an electrical current is induced.
In summary, the alternator takes mechanical energy created by the diesel engine, which drives
the rotor to create a magnetic field that moves around the stator, which in turn generates an
alternating current.
FUEL SYSTEM
The fuel system mainly consists of a fuel tank, the fuel transfer pump, filter, the injection
pump & the injection nozzles that connects it to the engine.
Here, diesel can be supplied through all these items explained above to the engine, which
will then kick start the whole process explained above.
The size of the fuel tank ultimately dictates how long a generator can remain active for.
VOLTAGE REGULATOR
In simple terms, it ensures that the generator produces electricity at a nice steady voltage.
Without it, you would see massive fluctuations dependent on how fast the engine is working.
All the electrical equipment we use will not be able to handle such an unsteady power supply.
So, this part works its magic to keep everything smooth and steady.
COOLING SYSTEM & EXHAUST
SYSTEM
These two components both play very crucial roles in DG set.
A cooling system works to help prevent your generator from overheating.
There is coolant released in the generator which counters all the additional heat energy
produced by the engine and alternator.
The coolant then takes all this heat through a heat exchanger and gets rid of it outside of the
generator.
The exhaust system works in the same way as your car exhaust. It takes any gases produced by
the diesel engine, brings them through a piping system, and exhausts them away from the
generator.
LUBRICATION SYSTEM
The function of the lubrication system in a diesel engine is twofold.
First, it reduces wear and heat generation by placing a film of lubricating oil between the parts
of the engine
Second, it removes a portion of the heat generated as a normal part of engine operation.
The heat is then transferred out of the lubricating oil system through the lube oil heat
exchanger.
BATTERY CHARGER
All diesel engines need a tiny little electrical motor to help kick it into action.
This small motor requires a battery, which needs to be charged.
The battery charger keeps it nice and full of charge, either by an external source of the
generator itself.
CONTROL PANEL
The control panel is simply where the generator is controlled and operated.
On an electric start (or auto start) generator you will find a whole host of controls here that
allow you to do different things or check certain figures.
This could include anything from the start button and a frequency switch, to an engine fuel
indicator, coolant temperature indicator and much more.
MAIN ASSEMBLY FRAME
Every generator needs to be contained somehow, and this is what the main assembly frame is.
It houses the whole generator and all the different parts of DG set are built onto.
It keeps everything together, and it can be an open design - or closed (canopied) for added
protection and sound attenuation.
Outdoor generators are typically housed in a protective frame that's weatherproof to prevent
damages.