FM Techie

What is Diesel Generator? A diesel generator is a type of electrical generator that uses a diesel engine to convert fuel into mechanical energy, which is then transformed into electrical energy using an alternator. Diesel generators are widely used as a backup power source in case of power outages or in locations where a reliable power grid is unavailable. Why is Efficiency Important for Diesel Generators? 1. Cost Effectiveness Diesel generators are often used in areas with unreliable electricity supply. Fuel costs can be significant, so a more efficient generator consumes less fuel, making it more economical in the long run. 2. Environmental Concerns Diesel generators emit pollutants such as nitrogen oxides, particulate matter, and sulfur dioxide. Higher efficiency reduces fuel consumption, leading to lower emissions and making the generator more environmentally friendly. 3. Reliability Diesel generators are critical in applications like hospitals and data centers, where downtime is u...

Top Energy Saving Tips for Diesel Generators Diesel generators are an essential source of power for many industries and businesses, but they can also be costly to operate. Fortunately, there are several energy saving tips that can help reduce fuel consumption and lower operating costs. Here are some of the top energy saving tips for diesel generators: 1. Regular Maintenance Proper maintenance of your diesel generator is essential to ensure its efficient operation. Regular servicing can help identify and fix any potential problems that could reduce fuel efficiency. It's essential to clean the air filters and change the oil and fuel filters regularly. 2. Use High Quality Fuel Using high quality fuel for your diesel generator can help to improve fuel efficiency. It's recommended to use a high grade diesel fuel that contains low sulfur and ash content. These types of fuels have a higher energy content and burn cleaner, resulting in better fuel economy. 3. Right Sizing Selecting the...

A diesel generator is a reliable source of power commonly used as a backup or primary power source in various applications. To ensure smooth and efficient operation, regular checks and maintenance are essential. Below is a comprehensive checklist to guide you through the diesel generator check procedure: 1. Check the Oil Level Inspect the engine oil level and ensure it is within the recommended range. If the oil level is low, add oil as per the manufacturer's specifications. 2. Check the Fuel Level Ensure that there is enough fuel in the tank for operation. If necessary, refuel following the manufacturer’s guidelines. 3. Inspect the Fuel Filters Check the fuel filters for dirt and clogging. Replace dirty or clogged filters to maintain efficiency and prevent malfunction. 4. Check the Air Filters Inspect the air filters and clean or replace them if necessary. Dirty air filters can lead to overheating and reduced generator performance. 5. Inspect the Battery Ensure that the battery is...

Standard Operating Procedure (SOP) for Diesel Generator Daily Check Purpose: To ensure that the diesel generator is in good condition and ready for use. Scope: This SOP applies to all personnel responsible for operating the diesel generator. Procedure: Check the fuel level: Check the fuel level of the diesel generator and ensure it is above the minimum level required for operation. Check the oil level: Check the oil level using the dipstick and ensure it is within the safe range. Check the coolant level: Check the coolant level in the radiator or expansion tank and ensure it is within the safe range. Inspect the air filter: Check the air filter for any signs of damage or blockages. Replace or clean the filter as necessary. Check the battery: Check the battery terminals for corrosion and clean them if necessary. Check the battery voltage using a voltmeter and ensure it is within the acceptable range. Inspect the belts: Check the condition and tension of the belts. Replace or adjust them...

Important components of a Diesel Engine Turbocharger A turbocharger can significantly increase an engine’s horsepower without adding significant weight. It enhances engine performance by forcing more air into the combustion chamber, enabling better fuel combustion. A turbocharger is made up of two main sections: The turbine and the compressor.  The turbine consists of the turbine wheel and the turbine housing.  It is the job of the turbine housing to guide the exhaust gas into the turbine wheel. The energy from the exhaust gas turns the turbine wheel, and the gas then exits the turbine housing through an exhaust outlet area. The compressor also consists of two parts: the compressor wheel and the compressor housing.  The compressor’s mode of action is opposite that of the turbine. The compressor wheel is attached to the turbine by a forged steel shaft, and as the turbine turns the compressor wheel, the high-velocity spinning draws in air and c...

Diesel Generator Maintenance Checklist A-CHECK (DAILY MAINTENANCE) Cleaning - Clean engine and premises. Checking Engine Oil Level - Ensure oil is between H and L marks on the dipstick, top up if required. Checking Coolant System - Verify coolant level in radiator, top up with premix coolant if needed. Inspect belt condition. Checking Fuel System - Inspect fuel strainer, clean breather on fuel tank, drain sediments/water from fuel water separator, and refill fuel tank at end of the day. Checking Air System - Monitor vacuum indicator for air restriction (red band). Inspect air filter sealing and condition. Other Checks Check for leaks and rectify if needed. Run engine and record all parameters. Checking Battery System Voltage should be above 26V. Ensure battery terminal tightness (use an insulated spanner). Check specific gravity using a hydrometer (1.21-1.24 or 1220-1250). B-CHECK (EVERY 225-250 HRS. OR 6 MONTHS, WHICHEVER IS EARLIER) Changing Lubrication Oil - Warm up and sto...

Diesel Generator Question & Answer - 1 1. Why should a DG set not be run with full fuel in the tank? Answer: A full fuel tank creates improper pressure across fuel lines, leading to excessive black smoke emission. 2. Why is bleeding required? Answer: The fuel system requires air bleeding under the following circumstances: The engine has not been operated for a long time. A fuel element has been replaced. The engine was started without opening the fuel cock and has run for some time. The feed pump is not functioning properly. There is leakage from fuel pipes or fuel filters. 3. How to remove Air Lock? Answer: Air lock can be removed using an air primer as per the steps below: Loosen the bleeding screw of the primary fuel filter. Unscrew the priming knob of the fuel pump, move it 10 to 15 times, until fuel flows out without air bubbles. Tighten the air vent screw and repeat for the secondary fuel filter. Finally, loosen the air vent screw of the fuel injection pump and remove air b...

Diesel Generator – Dos & Don'ts Dos: Idle the Engine Before Shutdown Allow the engine to idle for 3 to 5 minutes before shutting down. This helps the lubricating oil and coolant carry heat away from critical components like the combustion chamber, bearings, and shafts. Monitor Oil Pressure Oil pressure must be indicated on the gauge within 15 seconds after starting. If oil pressure is not indicated, shut off the engine immediately. Maintain Proper Oil Temperature Oil temperature should range between 75°C to 105°C. Shut off the engine if there is any sudden increase in oil temperature. Ensure Correct Coolant Temperature Coolant temperature should be maintained between 75°C to 95°C. Monitor Engine Pressure At 105°C, normal engine pressure should be between: 3 to 7 kg/cm² at rated speed. 1 to 2 kg/cm² at idle. Don'ts: Avoid Long Periods of Idling Extended idling lowers combustion chamber temperature, leading to incomplete fuel burn. This can cause carbon buildup, clogging in...

Diesel Generator Smoke & Safety Tips Black Smoke – Caused by overload or lack of fuel air mixture in the combustion chamber. Blue Smoke – Occurs when lubrication oil mixes with fuel. Check the piston rings. White Smoke – Indicates water contamination in the fuel. Key Diesel Generator Parameters Diesel Density: 0.832 kg/L Energy Output: 3.6 kWh per liter Efficiency Range: 40% to 60% Safety Tips for Diesel Generator Operation Proper Earthing Ensure 2 neutral earthing and 2 body earthing for single DG. For multiple DGs, use 2 separate neutral earthings and 2 common body earthings. Fuel Safety Store generator fuel safely in a closed container with proper labeling. Never attempt to inject fuel into the tank while the generator is in operation as it is highly hazardous. Battery Handling Precautions Avoid using metallic objects to clean battery terminals to prevent electrical shorts. Keep batteries away from fuses or switches to prevent sparks and potential fire hazards. Ensure proper v...

Starting procedure for Diesel Generators in "AUTO" mode Ensure the Emergency Stop switch in the DG panel is in the released condition. Set the Selector switch in the DG panel to "Remote" mode. Keep the DG and EB ACB in "Remote" mode in the relevant Main Distribution Board (MDB). Verify that the lube oil level is within the allowable limit. Check the day tank diesel level (should be above 75%). Ensure the radiator water is filled up to the brim. Confirm that the batteries are in a fully charged condition. If the Transformer Circuit Breaker (CB) trips or if power fails, the DG will start automatically. Monitor and verify the following parameters: DG Output Voltage Load Current Frequency Water Temperature Lube Oil Pressure Battery Voltage Day Tank Diesel Level Stopping procedure for Diesel Generators "AUTO" mode. If the EB (Electric Board) voltage resumes, the ACB will close automatically. The DG load transfers to EB supply, and the DG br...

Alternator: Overview and Working Principle What is an Alternator? An alternator is an electromechanical device that converts mechanical energy into electrical energy in the form of alternating current (AC). Parts of an Alternator: Rotating Rectifier Diode (RRD) Converts AC to DC to be used in the excitation system. Automatic Voltage Regulator (AVR) Senses the output voltage and sends a signal to the engine for regulation. Working principle of an alternator: The engine and alternator are connected through a shaft. When the alternator rotates, residual magnetism in the stator induces an electromotive force (EMF), producing AC voltage. The Rotating Rectifier Diode (RRD) converts this AC into DC. The DC voltage is fed into the rotor, inducing an alternating current in the stator. This process generates 400V AC at the alternator stator. The three phase AC output is then regulated by the AVR to ensure stable voltage supply. An alternator plays a critical role in converting mechanical energ...

Turbocharger A turbocharger can significantly boost an engine's horsepower without significantly increasing its weight. It compresses the air flowing into the engine, allowing the engine to squeeze more air into a cylinder. More air means more fuel can be added, leading to increased power from each explosion in each cylinder. Crankcase The crankcase ventilation system is designed to maintain a balance between the engine crankcase air pressure and atmospheric pressure. Excessive pressure variations can negatively affect component life, the lubrication system, and overall engine emissions. Proper ventilation ensures optimal engine performance and longevity. Electronic Control Panel (ECP) The Electronic Control Panel (ECP) plays a crucial role in managing engine speed and fuel flow: A magnetic pickup sensor detects engine speed at the flywheel ring gear, generating an AC voltage proportional to the engine speed. The actuator controls fuel flow from the fuel pump to the inj...

What is a Diesel Generator? A Diesel Generator is a combination of a diesel engine and an electrical generator (alternator) designed to generate electrical energy. It is widely used for backup power and remote applications where grid electricity is unavailable. Key Components of a Diesel Generator 1. Diesel Engine The engine serves as the mechanical energy source for the generator. It operates using compression ignition, where fuel is ignited by the heat of compressed air. 2. Alternator (GenHead) The alternator converts mechanical energy from the diesel engine into electrical energy. It consists of a stator and rotor to facilitate power generation. Working Principle of a Diesel Engine A diesel engine operates on the Diesel Cycle, which consists of four strokes: Suction Stroke: Air enters the combustion chamber through the intake valve. Compression Stroke: The piston compresses the air, raising its temperature significantly. Power Stroke: Diesel fuel is injected into the heated a...