Annexure -II

Micro-Project Report
To Study Diesel Electric Power Plant

1.0 Rationale

Diesel Electric Power Plant

A generating station in which diesel engine is used as the prime mover for the generation of
electrical energy is known as diesel power station. In a diesel power station, diesel engine is used as
the prime mover. The diesel burns inside the engine and the products of this combustion act as the
working fluid to produce mechanical energy. As the generation cost is considerable due to high
price of diesel, therefore, such power stations are only used to produce small power. Although
steam power stations and hydro-electric plants are invariably used to generate bulk power at
cheaper costs, yet diesel power stations are finding favor at places where demand of power is less,
sufficient quantity of coal and water is not available and the transportation facilities are inadequate.
These plants are also standby sets for continuity of supply to important points such as hospitals,
radio stations, cinema houses and telephone exchanges.

2.0 Aims/Benefits of the Micro-Project.

To study Diesel Electric Power Plant with specifications and its working is the main aim of the
micro project. It is very easy to know about it. The basic concepts related to the topic can be
getting easily. We come to know about the construction, working, specifications with different
dimensions and so on. We can easily implement its application and can be learn it by using
model because of knowing its much more information.

3.0 Course Outcomes Achieved.

a. Identify various component of Diesel Power Plant.

f. Estimate economic parameter of power plant.
4.0 Actual Methodology Followed.

4.1Brief Information about Micro-project / Brief Description.

• Diesel Electric Power Plant:

Diesel engine plant in the range of 2 to 50 MW capacity are used is central station for small supply.
The diesel units used for electric generation are more reliable and long lived piece equipment
compared with other type of plant. It is used as stand by plant in hydro-electrical plant and steam
power plant. Diesel engine unit are installed side by side room left for extension in the future . the
repairs and maintenance works require some space around the units. The air intakes and filters are
exhaust mufflers are located outside. Adequate space for oil storage, and bulk storage of oil are
placed outdoors.

Fig.1 Layout Of Diesel Electric Power Plant

• Working Principle Of Diesel Power Plant:

The working principle of diesel power plant is when air is compress in a cylinder to raise the
temperature, then diesel is injected inside cylinder of the engine and burn. The combustion
produces the working fluid at high temperature and high pressure to convert the heat energy into
mechanical energy which converted into electrical energy by generator.
• Different Components (System) Of Diesel Power Plant :
Diesel Power Plant consists of following components:

 Engine

 Alternator

 Air-filter and Supercharger

 Exhaust System

 Fuel System

 Cooling System

 Lubrication System

 Starting System

 Governing System

Fig.2 Schematic Layout Of Diesel Generator.

Engine:

This is the main component of the plant which develop required power. This engine is
generally directly coupled to the generator.

The Alternator:

It is one of the most fascinating part parts of a generator this is the part which turns the
mechanical energy into electrical power through induction. This works on prin ciple of
Faraday law of electro magnetic induction that if a wire moves or any electrical conductor
through a magnetic field, an electric current is induced. The stronger the field, and the
longer the wire the greater the amount of current induced. Modern generators work by
placing several large, powerful magnets in a cluster around a central rotating shaft. This
is called the rotor or armature. The permanent magnets or electromagnets produce a
magnets field which the engine causes to turn and sub-component of the alternator is the
stator which is essentially a series of tightly bundled coils of wire all packed closely
around the rotor. When an outside force turns the central shaft, the rotor constantly moves
the north and south poles of its magnetic field across the bundles of wire called coil that
surround them. This causes a electrical current to flow back mains forth through coil alternating
current or AC mains power

Air-filter and Supercharger:

The function of the air filter is to remove the dust from the air which is taken by the engine.
The use of the supercharger is to increase the pressure of the air provided to the engine to increase
the power of the engine.

Exhaust System:
This includes the silencers and connecting ducts. The temperature of the exhaust gases is
sufficiently high therefore; the heat of the exhaust gases may be used for heating oil or air supplied
to the engine.

Fuel System:
It includes a storage tank, fuel transfer pump, strainers, and heaters. The fuel is supplied to
the engine depends upon the load on the engine.
Cooling System:
This includes water circulating pumps, cooling towers, and water filtration plants. The purpose of
the cooling system is to carry the heat from the engine cylinder and to keep the temperature of the
cylinder in the safe range and extend its life.

Lubrication System:
It includes oil pumps, oil tanks, filters, coolers, and connecting pipes. The function of
the lubricating system is to reduce the friction of moving parts and reduce the wear and tear of the
engine parts.

Starting System:
This includes compressed air tanks. The function of this system is to start the engine from the cold
by supplying compressed air.

Governing System:
This consists of the governor and its function is to maintain the speed of the engine constant
irrespective of load on the plant by controlling the fuel supply to the engine according to the load.

Fig. Cooling Tower

 4.2 Data Collected

Fig.3 Diesel Electric Power Plant Diagram

Diesel power plants are divided into two main classes:

 Stationary diesel power plants.

 Mobile diesel power plants.

 Stationary diesel power plant:

Stationary diesel plants are known for their high or fast availability and flexibility; however, they
typically have lower MW unit capacity than steam‚ gas‚ hydro or combined cycle power plants.
Because of their high or fast availability‚ it is common for these facilities to be utilized in support of
renewable power plants‚ such as wind. Stationary diesel plants can come on line quickly and ramp up
to full output in less than 10 minutes. Moreover‚ diesel engines that operate in this market are flexible
- burning a wide range of commercially available liquid or gaseous fuel which gives them a wide
range of opportunity in the power generation portfolio.

Stationary diesel engines play a critical role supporting the operation of a nation’s most important
businesses. They serve as emergency back-up power for‚ hospitals‚ large manufacturing facilities‚ and
government facilities. Also‚ stationary diesel engine systems provide back-up power to nuclear power
plants due in large part to their reliability and ability to maintain plat safety in emergencies. Coal-fired
power plants also rely on diesels for material handling.
 Mobile Diesel Power Plant:

Mobile diesel power plants are widely used in agriculture and forestry and by expeditions involved wit
h geological exploration. In these applications, diesel power plants can be used as a source of electricit
y for energy or lighting networks; they can be used as the main, auxiliary, or standby power source. In
transportation, diesel power plants are a basic power source (for instance, in dieselelectric locomotives
and in diesel ships). In mobile diesel power plants, the highspeed diesels serve as prime movers. A m
obile diesel power plant includes the dieselelectric unit itself, spare parts, instruments and accessories,
a set of cables for making connections to the load, and firefighting equipment. Automated diesel powe
r plants with a power rating up to 10 kW are often mounted on a singleaxle truck trailer; power plants
rated 20 kW or more are usually installed on twoaxle, covered trailers. Such a mobile station comprise
s not only the dieselelectric unit but also the power distribution cabinet (or panel), a cabinet containing
the automatic controls, the remotecontrol console, heatig and ventilation equipment, rectifiers, and the
storage batteries that feed the automatic controls or auted systems.

The first mobile diesel power plants in the USSR were built in 1934 and were known as diesel trains.
Such diesel trains have all the power plant equipment installed on platforms or in cars. The power rati
ngs of diesel trains are 1, 2.5, 4.5, and 10 megawatts.

The electric part of the power plant of a diesel train consists of a synchronous generator delivering a v
oltage of 310 kilovolts, assembled or unitized compartments containing highvoltage leads (overhead le
ads or cables), distribution equipment for voltages of 23380 volts (required for lighting and for auxilia
ry motors of the power plant), the storage battery, and operating power circuits and the battery charge.

 Diesel Generating Set:

The packaged combination of a diesel engine, a generator and various ancillary devices (such as
base, canopy, sound attenuation, control systems, circuit breakers, jacket water heaters and starting
system) is referred to as a "generating set" or a "genset" for short.

Set sizes range from 8 to 30 kW (also 8 to 30 kVA single phase) for homes, small shops and offices
with the larger industrial generators from 8 kW (11 kVA) up to 2,000 kW (2,500 kVA three phase)
used for large office complexes, factories, and other industrial facilities. A 2,000-kW set can be
housed in a 40 ft (12 m) ISO container with fuel tank, controls, power distribution equipment and all
other equipment needed to operate as a standalone power station or as a standby backup to grid
power. These units, referred to as power modules, are gensets on large triple axle trailers weighing
85,000 pounds (38,555 kg) or more. A combination of these modules are used for small power
 stations and these may use from one to 20 units per power section and these sections can be
combined to involve hundreds of power modules. In these larger sizes the power module (engine and
generator) are brought to site on trailers separately and are connected together with large cables and
a control cable to form a complete synchronized power plant. A number of options also exist to tailor
specific needs, including control panels for auto start and mains paralleling, acoustic canopies for
fixed or mobile applications, ventilation equipment, fuel supply systems, exhaust systems, etc.

Diesel generators are not only for emergency power, but may also have a secondary function of
feeding power to utility grids either during peak periods, or periods when there is a shortage of large
power generators. In the UK, this program is run by the national grid and is called STOR.

 Generator sets size:

Generating sets are selected based on the electrical load they are intended to supply, the electrical
load's characteristics such as kW, kVA, var, harmonic content, surge currents (e.g., motor starting
current) and non-linear loads. The expected duty (such as emergency, prime or continuous power) as
well as environmental conditions (such as altitude, temperature and exhaust emissions regulations)
must also be considered.

Most of the larger generator set manufacturers offer software that will perform the complicated sizing
calculations by simply inputting site conditions and connected electrical load characteristics.

Ships often also employ diesel generators, sometimes not only to provide auxiliary power for lights,
fans, winches etc., but also indirectly for main propulsion. With electric propulsion the generators can
be placed in a convenient position, to allow more cargo to be carried. Electric drives for ships were
developed before World War I. Electric drives were specified in many warships built during World
War II because manufacturing capacity for large reduction gears was in short supply, compared to
capacity for manufacture of electrical equipment. Such a diesel-electric arrangement is also used in
some very large land vehicles such as railroad locomotives.

• The Diesel Engine consists following main parts:

1. Piston:

piston cylinder has two function: To compress the air and To release the pressure of the gases
while they are burning.

2. Cylinder Head:

A cylinder head closes the top end of the cylinder. It makes a confined space for compress air
and the gases.
3. Connecting Rod:

To transmit forces in either direction between the piston and the crank on the crankshaft.

4. Main Bearing:

Support the crank shaft and permit it to rotate.

5. Supporting structure:

It holds the cylinder crankshaft and main bearing in firm relation to each other. This structure
is made up of two parts, the frame and the bed plane.

6. Fuel Injection Pump:

It forces the oil into cylinder and fuel injection nozzle breaks up the oil into fine spray.

7. Crank shaft:

To operate the fuel injection pump and valve.

8. Fly wheel:

To store the surplus energy of the power stroke & to return that energy when the piston is
being pushed upward on the compression stroke.

9. Blower:

To force air in to cylinder.

10. Miscellaneous Parts:

Miscellaneous parts such as piping to supply air and remove exhaust gases, lubrication
system etc.

11. Alternator: The alternator has following main part:

I. Rotor: Rotor are of two types: Salient pole type and smooth cylinder type.

II. Stator: The stator is equipped with seal type bearing and its required no lubrication. Stator
is insulated on one side with paper or vanish and housed in frame.
III. Exciter: The exciter is generally a DC shunt motor or compound generator whose
voltages is 250 V. In small alternator, the exciter is mounted on the same alternator the
Exciter is mounted on the same shaft of the alternator.
 Site Selection for Diesel Power Plant:

Fig 4. Diesel Electric Power Plant

1) Nearness to load centres:

To reduces the cost and loss of transmission of electricity the power plant must situated near to
the load centre.

2) Availability of water:
Large amount of water in required for diesel engine power plant for colling of the engines and
in cooling tower here it should be near to river or lake.

3) Transportation facilities:
The site should be near to the fuel supply so the transportation cost of fuel is low also oilier
facilities like transportation of machinery.

4) Space requirement:
Soil required for foundation it have good strength to bear the load.

5) Away From inhabited area:

The site selected should be away from town so that the exhaust gases of plant do not pollute the
atmosphere.
• Fuels Used in Diesel Engine Power plant:

Diesel fuel is named after diesel engines, and not vice versa; diesel engines are simply compression-
ignition engines, and can operate on a variety of different fuels, depending on configuration and
location. Where a gas grid connection is available, gas is often used, as the gas grid will remain
pressurized during almost all power cuts. This is implemented by introducing gas with the intake air
and using a small amount of diesel fuel for ignition. Conversion to 100% diesel fuel operation can be
achieved instantaneously.

In more rural situations, or for low load factor plant, diesel fuel derived from crude oil is a common
fuel; it is less likely to freeze than heavier oils. Endurance will be limited by tank size. Diesel engines
can work with the full spectrum of crude oil distillates, from natural gas, alcohols, gasoline, wood
gas to the fuel oils from diesel oil to cheaper residual fuels that are like lard at room temperature, and
must be heated to enable them to flow down a fuel line.

Larger engines (from about 3 MWe to 30 MWe) sometimes use heavy oils, essentially tars, derived
from the end of the refining process. The slight added complexity of keeping the fuel oil heated to
enable it to flow, whilst mitigating the fire risks that come from over-heating fuel, make these fuels
unpopular for smaller, often unmanned, generating stations.

Other possible fuels include: biodiesel, straight vegetable oil, animal fats and tallows, glycerine,
and coal-water slurry. These should be used with caution: because of their composition, they normally
have a detrimental effect on engine life.

• Typical operating costs Diesel Power Plant:

Fuel consumption is the major portion of diesel plant owning and operating cost for power
applications, whereas capital cost is the primary concern for backup generators. Specific consumption
varies, but a modern diesel plant will, at its near-optimal 65-70% loading, generate at least 3 kWh per
litre (ca. 30% fuel efficiency ratio).

• Maintenance of a Diesel power plant:

A diesel generator is the combination of a diesel engine with an electric generator (alternator) to
generate electrical energy. They require less maintenance due to their durability, reliability and the
sturdiness characteristic also they are considered cheaper to operate due to the low fuels costs as
compared to the other types of fuels such as gasoline and propane. They can withstand heavy load
for long hours and start off the power supply on full load within minutes and must be regularly
maintained so as to provide of quality power throughout their service life.

Diesel Generator Routine General Inspection.

During the running of the diesel generator, the exhaust system, fuel system, DC electrical system
and engine require close monitoring for any leaks that can cause hazardous occurrences.
, 1. Lubrication Service:

The engine oil must be checked while shutting down the generator at regular intervals using a
dipstick and keep oil level as near as possible to the full mark on the dipstick in the upper
portions of the engine to drain back into the crankcase. Use best quality oils, lubricants and
coolants.

The oil and filter must also be changed at proper time intervals also draining the oil and
replacing the oil filter and their disposal is to be done appropriately to avoid environmental
damage or liability.

2. Cooling System

Check the coolant level during shutdown periods at the specified interval. Remove the radiator
cap after allowing the engine to cool, and, add coolant until the level is about 3/4 in if necessary.
Heavy-duty diesel engines require a balanced coolant mixture of water, antifreeze, and coolant
additives. Inspect the exterior of the radiator for obstructions, and remove all dirt or foreign
material with a soft brush or cloth with caution to avoid damaging the fins.

3. Fuel System:

Diesel is subject to contamination and corrosion within period of one year, and therefore use
stored fuel before it degrades. The fuel filters should be drained at the specified intervals due to
the water vapor that accumulates and condenses in the fuel tank.

The charge-air cooler piping and hoses should be inspected regularly for leaks, holes, cracks,
dirt and debris that may be blocking the fins or loose connections.

4. Testing Batteries

Weak or undercharged starting batteries are a common cause of standby power system failures.
The battery must be kept fully charged and well-maintained to avoid dwindling by regular
testing and inspection to know the current status. Of the battery and avoid any start-up hitches
of the generator. They must also be cleaned and check the specific gravity, electrolyte levels
frequently. Battery must be clean by wiping them with a damp cloth whenever dirt appears
excessive. If corrosion is present around the terminals, remove the battery cables and wash the
terminals with a solution of baking soda and water.

Check electrolyte level if low, fill the battery cells to the bottom of the filler neck with
distilled water. Tight the connections if required.
 5. Engine starting

Start the engine and note the oil pressure both at idling 1.e. 15 psi (1.09 kg/cm*) minimum,
and rated speed 50-70 psi (3.63 to 5.08 kg/cm) minimum. In case in change of oil pressure,
then stop the engine and check through trouble shooting techniques the cause and correct if
necessary. Lubricated engine parts lubricated and remove oxidation of electrical contacts, uses
up fuel before it deteriorates. Engine should be started at least once a month for a minimum of
30 min. loaded to no less than one-third of the rating. Engine oil should be checked at least 20
minutes after stopping the engine and top up if necessary.

6. Exhaust system inspection:

In case there are leaks along the exhaust line which usually occurs at the connection points, the
welds and the gaskets; they should be repaired immediately.

7. Switch Gear:

Check automatic starting switch for its proper functioning. Check any abnormality if
visualized. Check phase indications and working of panel meters.

8. Alternator:

Check any abnormality, if visualized and check the air-in and out restrictions.

4.3 Advantages:
Diesel Power Plant:

• Design and installation are very simple.

• Can respond to varying loads without any difficulty.
• The standby losses are less.
• Occupy less space.
• Can be started and put on load quickly.
• No problem with ash handling.
• Requires less quantity of water for cooling purpose.
• Low capital investment
• Requires less operating and maintenance staff.
• More economical lubrication system.
• Can burn a fairly wide range of fuel.
• These plants can be located very nearer to the load centres,
• The cost of the building becomes very low.
 • More efficient than the steam power plant.

4.4 Disadvantages:

Diesel Power Plant:

• High operating cost.

• High maintenance and lubrication cost.
• Diesel units’ capacity is limited.
• Noise is a serious problem.
• It cannot supply overloads continuously.
• Overload is not possible.
• Releases unwanted emissions.
• Life is quite small (7 to 10 years).
4.5. Design / Actual Procedure Followed

Planned Name of
S. Start Planned Responsible
No. Details of activity
date Finish date Team Members
1 Search micro project topics related 09/10/2021 16/10/2021 Bhushan
To subject. Pokharkar
2 Selection of micro project title 16/10/2021 23/10/2021 Zameer Shaikh
3 Search & collect information 23/10/2021 30/10/2021 Swayam Jadhav
related to selected topic
4 Completion of micro project topic 30/10/2021 13/11/2021 Bhushan
Proposal Pokharkar
5 Analyze & finalize collected data 13/11/2021 20/11/2021 All Members
For micro-Project report.
6 Checked the data from teacher 20/11/2021 27/11/2021 All Members
7 Implementation of micro project 27/11/2021 04/12/2021 All Members
8 Report preparation, finalization, 04/12/2021 11/12/2021 All Members
Submission

4.6 Result & Analysis

 We have learnt information about Diesel Electric Power Plant.

 We have implemented the Diesel Electric Power Plant in various ways.

 We have created the jobs related to Diesel Electric Power Plant.

 We can handle the machine and tools independently

5.0Actual Resources Used

Name of Resource
S. No. /Material Specifications Qty. Remarks
1 Internet Wikipedia, Google -

2 Printer Desktop
1
Author- S .D.
Power Plant
Ambetkar
3 Engineering
1
6.0 Output of Micro-Projects
 We have learnt the types of Diesel Electric power plant.

 We have understood that the construction and working of the Diesel electric
power plant.
 We have learnt that it is useful in industry.

7.0 Skill Developed/ Learning outcome of this Micro-Project

 We have implemented the work on Diesel electric power plant.

 We have learned that how to use the Diesel electric power plant for different Purposes.

 We have learned the working of Diesel electric power plant.

8.0 Application of Micro-Project.

 The diesel power plant are mainly used as:

1. Peak Load Plant: It is used in combination with thermal or hydropower plant as peak load
plant. It is particularly preferable as peak load plain as it can be started quickly and it has
no stand by losses.
2. Mobile Plant: It can be used as mobile plant for temporary or emergency purpose where
no other power is available. telephone exchangers, industries, radio station.
3. Stand by units: It can be used as stand by unit to supply part load when required. E.g.
railways and ships.
4. Central Station: It can be used as central power station where the capacity required is
small. Small supply unit for commercial purpose and public utilities, eg. Cinema hall,
Hospital etc.
5. Emergency Plant: It can be used as emergency plant where power interruption would
cause financial loss or danger in key industrial process.

(Mr. Abuj D. K.)