OVERVIEW OF A DIESEL GENERATOR SET

The main components of an diesel generator are

(1) Engine
(2) Alternator
(3) Fuel System
(4) Cooling & Air Intake System
(7) Exhaust System
(6) Lubrication System
(7) Starting System
(8) Control System
(9) Main Assembly

(1) Engine
The engine is the source of the mechanical energy to the alternator.
The power output of the engine is directly proportional to the maximum power output the generator can supply.
The engine power of engine is defined in kW or HP.
All engines are rated by manufacturer at NTP conditions. (Temperature = 25degC, Altitude = 100m , Humidity = 30%)

Selection of Engine:

- Site conditions
- Ambient
- Altitude
- Humidity

- Load Charateristics
(2) Alternator
The alternator, is the part of the generator that produces the electrical output from the mechanical input supplied by
the engine.
It contains Rotor , Stator , Exciter and AVR.
The alternator output is usually defined in kVA or kWe.
Alternator usually confroms to IEC60034-1, and is rated at 40degC , <1000m.

Selection of Alternator:

- Site conditions
- Ambient
- Altitude

- Load Charateristics

(3) Fuel System

The fuel System consists of Day fuel tank (suitable for 6 to 8 hours of operation).
The fuel tank is a part of the generator’s skid base for ratings upto 650kVA
For larger rating of DG set, an external fuel tank of capacity 990L is provided.

(4) Cooling & Air Intake System

The standard DG set engine is Radiator cooled.
The cooling medium is Coolant as per engine manufacturer recommendations.
The radiator fan provides sufficient cooling for the engine and the alternator.

The engine air intake is either Naturally aspirated or Turbocharged.

The engine is provided with Air intake filters, mounted on the engine.
(5) Exhaust System
The engine exhaust is fumes are disposed into atmosphere through a silencer.
The engines to be used in India are Emission compliant to CPCB2 norms.

(6) Lubricating System

The engine comprises of moving parts, it requires lubrication to ensure durability and smooth operations for a long
period of time.
The engine is provided with a Lub Oil sump, Engine driven lub oil pump and Filters.

(7) Starting System

The engine starting system comprises of Starter Motor, Lead Acid
Battery.
The batteries provided are suitable for 3-4 cranks.

(8) Control System

This is the user interface of the generator.
It comprises of Genset Controller, Indication lamps and Protection
relays.

(9) Main Assembly

As per CPCB norms all generators, upto 1000kVA are provided with an
Acoustic enclosure.
DG set ratings 1010kVA and above can be either in an Acoustic enclosure or Open type.
Relation between KWm and kWe

Engine Power = kWm

Engine kWe = kWm x Alternator efficiency

Genset kVA = kWe / Rated Power factor

Ex:

Engine Power = 88 kW
Alternator Efficiency = 91%
Rated power factor = 0.8

Genset rating (kVA) = (100 x 0.91) / 0.8

= 100 kVA

Genset rating (kWe) = 100.1 x 0.8

= 80 kWe