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GENERATOR
The two bearing type has one bearing supporting each end of its rotor,
properly centering the rotor within the stator. The rotor shaft is connected
to the engine flywheel by a flexible coupling.
The single bearing type has a bearing supporting the rear end of the rotor,
with the opposite end attached to the engine flywheel through a flexible
disc coupling. It is necessary for the engine and generator to be aligned
so that the generator rotor is properly centered within the stator.
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2. Generator Capacity
The total load connected to the generator set may be the complete load in
a building or complex, or it may be selected essential loads connected
into an emergency circuit separate from other load circuit.
4. Alternator
The field of the alternator is referred to as the rotor. Rotation of field flux
past the stationary coils generate a voltage under all operating loads,
there must be adequate and this is maintained by supplying DC current to
the field by means of an exciter. The exciter may be static, or it may be a
small rotating DC generator. The revolving magnetic field is designed for
standard DC voltages of 63V, 125V, 150V and on very large alternator,
375V.
The two magnetic elements, the fixed stator and the rotor, are linked by a
small air gap. A mutual flux developed across the gap, link these two
components and causes an interaction necessary to produce an EMF.
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6. Excitor
a. Brushless
b. Brush
c. Static
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The exciter with rotating rectifier does not require brushes to connect
exciter output to the generator field since the field, rectifier and exciter
armature rotate together as a unit. A generator equipped with this type of
exciter is called as a “Brushless Generator”. This system replaces
brushes, brush holders, commutators and slip ring, thus reducing
maintenance and noise while improving reliability.
Generator copper and iron core losses are converted into heat. Copper
losses are I2R losses and vary with load. Core losses vary with voltage,
but not with load. Winding temperature depends on the ambient
temperature plus the temperature rise caused by the copper and core
losses. To keep winding temperatures below a level that would shorten
insulation life, a generator is equipped with a fan that draws air into the
generator housing at one end and expels it at the other end.
The open-ventilated or open guarded types cost less and are easiest to
cool, but should only be used in a clean environment where there is little
chance that dust or liquid will enter the generator. The totally enclosed
type provide the maximum protection from water, dirt and foreign
materials, but it is most expensive to cool.
For most generator-regulator systems, the average voltage is not the same
at one steady load as at another. Usually voltage droops with load, being
higher at light loads and lower at heavy loads. However some regulator
increase voltage with load.
The most severe voltage dip condition usually occurs when a large
amount of low-power factor load is suddenly applied. An example would
be the starting of a large induction motor.
When a step load (large load) is applied, the voltage dip abruptly, rises
again under the influence of the voltage regulator, overshoots the
regulation band slightly, decreases and settles out within the band. Its
new average steady value may be slightly different from its original
value, depending on the regulation characteristic of the regulator.
where light flicker must not occur and where X-ray equipment would be
affected by voltage variations. If light flicker is merely an annoyance
rather than a critical condition, it may be ignored, especially for a
generator, which is connected to the load only a small percentage of the
time.
While this discussion has centered mainly on voltage dip, voltage rise or
overshoot could be equally objectionable if there is sensitive equipment
in the load circuit. Although a large rise would occur when all load is
suddently removed, this would not be of concern because the sensitive
equipment is removed from the line. A large, abrupt part-load removal,
with sensitive equipment remaining on the line, is a situation in which
severe voltage rise might be of concern.
To restore speed fast, the engine must have enough power for the KW
load plus a margin of power for acceleration. Since, for a given
impedance, KW is proportional to E2, quick restoration of voltage
increases load and leaves less power margin for acceleration. Therefore,
if the voltage regulator is too stiff respond too abruptly while speed is
falling off, a greater load is imposed on the engine during the time that its
speed is reduced, and thus, acceleration is delayed. On the other hand, if
the regulator responds at a rate to raise voltage as the governor is
restoring speed, both respond smoothly.
Typically, the voltage reference is a zener diode bridge, which has the
characteristic of maintaining an essentially constant voltage. The
difference between the reference and the sensed voltage constitutes an
error signal that controls the firing time of the SCR, enabling it to
conduct long enough during each cycle to supply the required exciter
field excitation. When the generator load changes, causing a voltage rise
or dip, the regulator changes the conducting time of the SCR to supply a
new level of exciting current to the exciter field.
and drive the exciter to high output until the governor voltage nears
normal. High-performance voltage regulators employ current
transformers to obtain this field-forcing effect.
The build-up device bypass regulator action until generator voltage has
reached a predetermined percentage of rated voltage. Then the build-up
device connects the regulator in its normal operating mode.
Manual control system are available as backup for the voltage regulator.
Maximum back-up reliability is afforded if the back-up control is
separate from the regulator. Thus, the manual control incorporates its
own rectifiers and power transformer, which is a variable-ratio
transformer. In case of regulator failure the transformer ratio is adjusted
manually to control excitation and compensate for load changes.
A manual backup is practical only if the loads will operate with low-
quality voltage regulation. Obviously, a manual control cannot be fast
enough to prevent large voltage dips or rises during abrupt load changes.
If the load varies continuously, it would be a full-time job for an operator
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Depending on the requirement of the load, the governor may hold the
same average frequency at all steady loads or may permit the frequency
to be higher at light loads than at heavy loads. At any steady load, there is
a slight, random frequency variation. When load is applied or removed,
there is a momentarily drop or rise in frequency, and the governor
responds to change the engine fuel rate and restore frequency.
The two types of governors commonly used for diesel generator set are
hydraulic and electric. A hydraulic governor senses speed with revolving
flyweights and employs a hydraulic actuator to operate the engine fuel
control linkage.
When load is removed and speed increases, the flyweights lean outward
and displace the pilot valve to permit some trapped oil to escape so that
the power piston moves in a direction that reduce fuel flow to the engine.
Displacement of the power piston moves a lever that compresses the
speeder spring to return the flyweights and pilot valve to their neutral
position, again trapping oil and holding the power piston in its new
position.
When load is added and speed decreases, the flyweights lean inward and
displace the pilot valve to admit oil pressure to the end of the power
piston. The power piston moves the fuel control linkage to increase fuel
flow. Displacement of the power piston lever decompresses the speeder
spring to permit the flyweights and pilot valve to return to their neutral
position, trapping oil to hold the power piston to its new position. An
adjustable stop limits maximum displacement of the power piston and
thereby limits fuel flow to the engine.
The power supply for the reference signal transforms power from the
alternator output and rectifies it. Zener diode circuitry in the power
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Sensing frequency from a magnetic pickup has the advantage that the
pickup generates a measurable voltage through the full speed range from
start-up to synchronous speed, whereas alternator excitation normally
does not take effect on start-up until the generator set reaches 85% of
rated speed. Therefore an electric governor that senses alternator
frequency normally must have a mechanical-hydraulic governor backup
that senses speed mechanically until the generator speed is high enough
to provide voltage for alternator frequency sensing. Otherwise the engine
might overspeed on accelerating from startup, and actuate the overspeed
trip, causing the engine to shut down.
Terminology