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DG SET
Diesel generator sets are a
combination of engine and
alternator, which converts
chemical (Fuel) energy into
electrical energy.


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DIESEL ENGINES
Diesel engines converts
chemical (Fuel) energy into
mechanical energy.
These are Compression
Ignition (CI) Engines.
Clean Air is compressed and
the fuel is then injected in
atomized form at the correct
timing.


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MAJOR COMPONENTS

CYLINDER BLOCK

It houses the pistons and
liners and should be stronger
enough to withstand pressure
developed inside combustion
chamber.


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CYLINDER HEAD

It houses the inlet and exhaust valves
and their operating systems. The all the
joints should be leak proof at valve
insert fillings.
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CYLINDER LINERS
These are fitted inside the cylinder
block.
The piston moves inside the liner.
Water cooling is provided for cooling
these.

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CRANK SHAFT
The crankshaft shall be supported on
main bearings at two ends and at
intermittent positions to ensure smooth
and safe operations. The crankshaft
journals shall be smoothly machined
and the crankshaft shall be hardened to
ensure minimum wear and tear during
operations at rated speed .
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CAM SHAFT
Cam shafts have lobes to operate
the different valves at different set
timings.

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VALVES
There are different inlet and exhaust valves
for taking the fresh air and escaping the
exhaust gases.

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PISTON
It moves up and down in side combustion
chamber.
It is connected to the crank shaft.
Pistons in each cylinder with the piston rings
should be able to handle the peak cylinder
pressure with minimum power loss.

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PISTON PIN

It connects the connecting rod to the piston.

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FUEL PUMP
Engine driven fuel pump is
provided to ensure
sufficient flow and pressure
of fuel inlet to the engine
from the day fuel tank
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FUEL INJECTORS
It supplies the fuel in the combustion
chamber in an atomized form to
ensure proper, fast and complete
combustion.
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FUEL FILTERS
Clean fuel is necessary for longer life
of liners and fuel pump.

The filters used are replaceable type.

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WATER RADIATOR
It stores water for circulating in the
system for cooling the various parts
of the engine where heat is being
developed.

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THERMOSTAT
It is meant to control the
temperature of coolant .
It helps engine gain the operating
temperature quickly by not
allowing the coolant to pass
through radiator but making it to
circulate through the system.
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FLYWHEEL
The engine shall be fitted with a
heavy, dynamically balanced
flywheel suitable for constant speed
generator duty to meet cyclic
variations as per the requirements
of BS 649.
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SPEED GOVERNOR
An efficient, approved, engine
speed governor maintain engine
speed at all conditions of load in
line with the requirements of BS
5514 and this specification.
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CONNECTING ROD
The connecting rod is heavy duty
and made of forged special steel
suitable for handling power transfer
from the piston and combustion
chamber to the crankshaft.
The connecting rod piston
crankshaft assembly shall ensure
efficient and smooth transfer of
power with minimum wear and tear.
Forced lubrication as required is
ensured.
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TURBOCHARGER
It is meant to supply sufficient air into
the combustion chamber under
pressure.
It is driven by exhaust gases.
The ultimate purpose of turbo charger
is to increase the engine power with
same size of engine.

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GOVERNOR
The range of manual adjustment shall
not be less than 5% of rated speed.
The governor control should be
isochronous type and thus maintain
constant speed of the engine at different
load up to the maximum rating of the
engine.
The governor shall be suitable for
isochronous paralleling and load sharing
with another generator.
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AFTER COOLER
The compressed air from the turbocharger shall be
after-cooled with water to air heat exchanger as in-
built engine component for efficient operations.
The outlet compressed air temperature from the after-
cooler shall preferably be monitored for control of fuel
injection system. This is to enhance engine
performance level and avoid pre-mature requirements
of maintenance.
The density of air is increased by cooling air.
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STARTER MOTOR
The starting system is suitable for
three successive start attempts with
time intervals between attempts.
In case of failure of the three start
attempts, a failed-to-start alarm shall
be energised and the engine shall be
stopped for a pre-determined time for
further starting attempts.
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DIFFERENT STROKES OF
ENGINES
Induction Stroke

Compression Stroke

Power Stroke

Exhaust Stroke
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INDUCTION STROKE
In this stroke the piston moves from
TDC to BDC.
Inlet valves remain opened.
Exhaust valve remain closed.
Air under force enters the combustion
chamber through turbocharger.
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COMPRESSION STROKE
In this stroke piston moves from BDC
to TDC.
Inlet and Exhaust valves are closed.
The air inside combustion chamber is
compressed.
The temperature and pressure of the
air start rising as the piston moves
from BDC to TDC.
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POWER STROKE
The fuel is sprayed through injectors in
atomized form.
The compressed and hot air ignites the fuel
and the power is developed.
The piston is moved down (TDC to BDC) by
the pressure created with this burning of
fuel and air mixture.
Inlet and Exhaust valves remain closed in
this stroke.
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EXHAUST STROKE
The burnt gases are pushed out from
the combustion chamber in this
stroke.
The Exhaust valve is opened in this
stroke.
The piston moves from BDC to TDC
and the gases are then pushed out.

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ENGINE SYSTEMS
AIR SYSTEM
LUBRICATION SYSTEM
COOLING SYSTEM
FUEL SYSTEM
EXHAUST SYSTEM
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AIR SYSTEM

The sufficient quantity of clean air is
necessary for engine operation at all
loads.
The air filters are used to clean the
air.
Vacuum indicators are used to
measure the cleanliness of filters,
which is measured in terms of
restriction to the air flow.
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The main components of
air system are

Air Filters
Turbo charger
After Coolers
Inlet Manifolds

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LUBRICATION SYSTEM
The main components of lubrication
system are
Oil Filters
Oil Sump
Oil Pump
Oil Coolers

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The flow and pressure is developed by
engine driven lubricating oil pump and is
sufficient to ensure required flow and
pressure of oil to all required points.
Engine lubrication is a closed circuit wet
sump, forced feed system supplied by an
engine driven pump through gear-train
arrangement and fitted with pressure
regulating and relief valves, sump suction
filter and changeover renewable full-flow
line filters.


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The oil system is used to
provide
Lubrication to moving parts
Removing the heat from
system,
Forming a film on the piston
to avoid corrosion and also
To clean the system
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At normal speed and loads the oil
pressure of engine should be between
50-70 psi depending upon condition
and load on engine.

The special lub oil is recommended to
be used in Cummins engines with
additives to increase the engine life.

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The oil should be changed on
running hours or period basis
which ever falls early.
The lub oil capacity is nearly 177
litres.
The oils recommended are
Valvoline power supreme SAE-15W
40 or any 15 W-40 multi grade oil
meeting the CF-4 OR CH -4, API
categories.
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FUEL SYSTEM
The fuel system is to :
To supply the clean fuel to the system.
To control the quantity of fuel to
cylinder.
To inject the fuel in atomized form.
To ensure the correct timing of fuel
injection.
To govern the engine speed at various
loads.
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The main components of fuel
system are

Fuel Tank.
Fuel filters.
Magnetic filters.
Fuel pump.
Electrical shut down valve.
Governor.
Injector.
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The injectors used in K-Series engines are
STC injectors with less drain flow
STC - Step Timing Control
STC allows the engine to operate in
advance timing while starting and light
load conditions and at normal timing
during high and medium engine loads.
STC during advance timings gives :
Reduced cold weather while start.
Improved light load fuel economy.
Reduced injector carbonizing.
STC during normal timing :
Controls cylinder pressure.
Reduced emission.

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Magnetic filters is used after the fuel pump
to avert any metallic parts, which can
damage the engine.
Fuel injection control is with electronic
actuators with fuel injection timing control
mechanism, which is fast acting to
respond to variable, jerk and step loads.
The cleaning /replacement of fuel filters at
recommended durations improves the
engine life.

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FUNCTIONS OF COOLING
SYSTEM ARE

To dissipate the waste heat
generated by the engine.
Around 1/3 rd of total heat
generated is converted into
useful work.
To regulate the engine temperature
so that engine operates at optimum
temperature at all loads and
ambient conditions.
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COMPONENTS OF COOLING
SYSTEM
Radiator
Thermostat
Water Pump
Cooling Fan
Cooling Media and Pipe Lines
Oil Coolers
After Coolers
Capacity of cooling system is 161 ltrs.
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The coolant is stored in radiators.
The coolant is made to flow with
water pump once the engine is
started. The coolant extracts the
heat from cylinder block and
cylinder head, liners, through
passages built in these.
The water is also used to cool the
intake air through turbocharger.
The system need to be topped up
with premixed coolant only.
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EXHAUST SYSTEM
Around 1/3 rd of discarded heat and all the
exhaust gases and unburnt fuel are given
out through exhaust system.
The back pressure in exhaust system
should not be more than 3 of Hg measured
with a manometer close to the ex-manifold ,
at maximum speed and load.
If excessive back pressure is there, low
power and high combustion temperature
may reduce engine life.

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PRECAUTION
The over cleaning and under cleaning of air
filters is not good for engine.
The dust and moisture in air system
reduces engine life.
The engine should be run idle for 5 minutes
while switching off to allow the
turbocharger to settle because it rotates at
very high speed and sudden stopping may
damage its bearings

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ALTERNATOR


Alternator is a machine which
converts mechanical energy into
electrical energy

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COMPONENTS

MAIN STATOR
MAIN ROTOR
AVR (AUTOMATIC VOLTAGE
REGULATOR)
ROTATING RECTIFIER ASSEMBLY
EXCITER STATOR
EXCITER ROTOR
PMG STATOR
PERMANENT MAGNET ROTOR
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FUNCTION OF PARTS
Main stator is stationary part with AC winding.
Main rotor is rotating part with DC winding.
Exciter stator is stationary part with DC
winding.
Exciter rotor is rotating part with AC winding.
PMG stator is stationary part with AC winding.
PMG rotor is rotating part with permanent
magnet.
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PMG rotor is a permanent magnet.
PMG output voltage is dependent on
speed only(approx.180V AC).
AVR rectifies this voltage into DC
which is fed to exciter stator.
The three phase AC voltage of exciter
rotor is given as input to rotating
rectifier assembly and this AC supply
is converted into DC.
This DC supply is given to main rotor
winding
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The three phase AC voltage of exciter
rotor is given as input to rotating
rectifier assembly and this AC supply is
converted into DC.
This DC supply is given to main rotor
winding.
The AVR controls the generator output
by comparing it with set reference
voltages.
The second control is done by
controlling speed by changing the fuel
quantity.


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THANK YOU


BY:
RK SRIVASTAVA
SE/E&M