CHAPTER FOUR

3.0 DIESEL GENERATORS

A diesel generator is the combination of a diesel engine with an electric generator (often an alternator)
to generate electrical energy. This is a specific case of engine-generator. A diesel compression-ignition
engine often is designed to run on fuel oil, but some types are adapted for other liquid fuels or natural
gas.

Diesel generating sets are used in places without connection to a power grid, or as emergency power-
supply if the grid fails, as well as for more complex applications such as peak-lopping, grid support and
export to the power grid.

4.1 HOW A DIESEL GENERATOR WORKS

An electric generator is a device that converts mechanical energy obtained from an external source into
electrical energy as the output.

It is important to understand that a generator does not actually ‘create’ electrical energy. Instead, it
uses the mechanical energy supplied to it to force the movement of electric charges present in the wire
of its windings through an external electric circuit. This flow of electric charges constitutes the output
electric current supplied by the generator.

4.2 MAIN COMPONENT OF A DIESEL GENERATOR

(1) Engine

(2) Alternator

(3) Fuel System

 (4) Voltage Regulator

(5) Cooling and Exhaust Systems

(6) Lubrication System

(7) Battery Charger

(8) Control Panel

(9) Main Assembly / Frame

1. Engine

The engine is the source of the input mechanical energy to the generator. The size of the engine is
directly proportional to the maximum power output the generator can supply.

(a) Type of Fuel Used

(b) Overhead Valve (OHV) Engines versus non-OHV Engines

© Cast Iron Sleeve (CIS) in Engine Cylinder

(2) Alternator
This is the part of the generator that produces the electrical output from the mechanical input supplied
by the engine. It contains an assembly of stationary and moving parts encased in housing. The
components work together to cause relative movement between the magnetic and electric fields, which
in turn generates electricity.

(a) Stator

(b) Rotor / Armature

(i) By induction – These are known as brushless alternators and are usually used in large
generators.

(ii) By permanent magnets – This is common in small alternator units.

(iii) By using an exciter – An exciter is a small source of direct current (DC) that energizes the rotor
through an assembly of conducting slip rings and brushes.

(3) Fuel System

The fuel tank usually has sufficient capacity to keep the generator operational for 6 to 8 hours on an
average. In the case of small generator units, the fuel tank is a part of the generator’s skid base or is
mounted on top of the generator frame. For commercial applications, it may be necessary to erect and
install an external fuel tank.

Also produces cleaner power.

Common features of the fuel system include the following:

(a) Pipe connection from fuel tank to engine

 (b) Ventilation pipe for fuel tank

© Overflow connection from fuel tank to the drain pipe

(c) Fuel pump

€ Fuel Water Separator / Fuel Filter.

(f) Fuel Injector

(4) Voltage Regulator

As the name implies, this component regulates the output voltage of the generator. The mechanism is
described below against each component that plays a part in the cyclical process of voltage regulation.

(i) Voltage Regulator:

(ii) Exciter Windings: Conversion of DC Current to AC Current

(iii) Rotating Rectifiers: Conversion of AC Current to DC Current

(iv) Rotor / Armature: Conversion of DC Current to AC Voltage

(5) Cooling & Exhaust Systems

(a) Cooling System

(b) Exhaust System

(6) Lubricating System

Since the generator comprises moving parts in its engine, it requires lubrication to ensure durability and
smooth operations for a long period of time. The generator’s engine is lubricated by oil stored in a
pump.

(7) Battery Charger

The battery charger keeps the generator battery charged by supplying it with a precise ‘float’ voltage. If
the float voltage is very low, the battery will remain undercharged. If the float voltage is very high, it will
shorten the life of the battery. Battery chargers are usually made of stainless steel to prevent corrosion.

(8) Control Panel

(a) Electric start and shut-down

(b) Engine gauges

© Generator gauges

(c) Other controls

(10)Main Assembly / Frame

All generators, portable or stationary, have customized housings that provide a structural base support.
The frame also allows for the generated to be earthed for safety.

4.3 A DIESEL ENGINE

A diesel engine (also known as a compression-ignition engine) is an internal combustion engine that uses
the heat of compression to initiate ignition to burn the fuel, which is injected into the combustion
chamber. A diesel engine is a type of heat engine that uses the internal combustion process to convert
energy stored in the chemical bonds of the fuel into useful mechanical energy. This occurs in the two
steps. First, the fuel reacts chemically (burns) and releases energy in the form of heat. Second the heat
causes the gases trapped in the cylinder to expand, and the expanding gases being confined by the
cylinder, must motion of the piston to expand. The reciprocating motion of the piston is then converted
into the rotational motion by the crankshaft.

4.3.1 FOUR STROKE DIESEL ENGINE

A four- stroke engine, also known as four –cycle, is an internal combustion engine in which the piston
completes four separate strokes- intake, compression, power and exhaust –during two separate
revolutions of the engine’s crankshaft, and one single thermodynamic cycle.

4.3.2 TWO STROKE DIESEL ENGINE

Two-stroke or four-stroke refers to the number of strokes the piston makes in the cylinder to complete
one power. A stroke is the movement of the piston in one direction, moving the piston from the top to
bottom of the cylinder is one stroke. In a two stroke engine the camshaft is geared so that it rotates at
the same speed as the crankshaft (1.1).

B. Down Stroke-Power and Exhaust:

On the down ’power’’ stroke the piston is the forced towards the crankcase reducing its volume and
creating a positive pressure. As it continues downwards travel it starts first to uncover the exhaust ports.

4.3.3 PARTS OF DIESEL GENERATOR ENGINE

I. CYLINDER HEAD:

II CAMSHAFT:
 II. PISTON AND PISTON RINGS

III. CYLINDER SLEEVE OR BORE:

IV. CONNECTING ROD:

V. CRANKSHAFT:

VI. CRANKCASE AND OIL PAN:

VII. FLYWHEEL

VIII. ALTERNATOR:

IX. RADIATOR (HEAT EXCHANGER):

4.4 MAINTENANCE INTERVALS SCHEDULE

Whenever require

• Battery-replace

• Battery or battery cable-Disconnect

• Engine-clean
• Engine air cleaner element (dual element)-Clean/Replace

• Fuel system-prime

• Severe service applicable-Check

DAILY

• Cooling system coolant level-check

• Driven equipment-check

• Engine air cleaner service indicator-inspect

• Engine air precleaner-check/clean

• Engine oil level-check

• Fuel system primary filter/Water separator-drain

• Walk around inspection

Every 50 service hours or weekly

• Fuel tank water and sediment-Drain

Every 250 service hours or 6 months

• Alternator or fan belts-Inspect/Adjust

Every 500 service hours or 1 year

• Battery electrolyte level-check

• Cooling system supplemental coolant additive (SCA)-Test/Add

• Engine air cleaner element (dual element)-Replace

• Engine air cleaner element (single element)-Inspect/Replace

• Engine oil and filter-change

• Hoses and clamps-Inspect/Replace

• Radiator-clean

Every 1000 service hours

• Alternator and fan belts-Replace

• Engine valve lash-Inspect and adjust

• Turbocharger-Inspect

Every 2000 service hours

• Alternator –Inspect
• Engine crankcase breather-Replace

• Engine mounts-Inspect

• Starting motor-Inspect

Every 3000 service hours

• Fuel injection pump-Test/Change

• Water pump-Inspect

Every 6000 service hours or 3 years

• Cooling system coolant (Commercial Heavy Duty)-Change

• Cooling system extender (ELC)-Add

Every 12000 service hours or 6 years

• Cooling system coolant-change

These maintenance techniques are carried out on an 1100KVA generating set.