DIESEL GENERATOR

How Does a Generator Create Electricity? How Generators Work

Generators are useful appliances that supply electrical power during a

power outage and prevent discontinuity of daily activities or disruption of
business operations. Generators are available in different electrical and
physical configurations for use in different applications.
How does a generator work?
An electric generator is a device that converts mechanical energy obtained
from an external source into electrical energy as the output.
The modern-day generator works on the principle of electromagnetic induction
discovered by Michael Faraday in 1831-32. Faraday discovered that the above flow of
electric charges could be induced by moving an electrical conductor, such as a wire that
contains electric charges, in a magnetic field. This movement creates a voltage
difference between the two ends of the wire or electrical conductor, which in turn
causes the electric charges to flow, thus generating electric current.
 The main components of an electric generator can be broadly classified as follows (refer
Main components to illustration above):
of a 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. There are
several factors that you need to
keep in mind while assessing the
engine of your generator. The
manufacturer of the engine should
be consulted to obtain full engine
operation specifications and
maintenance schedules.
(2) Alternator
The alternator, also known as the ‘genhead’, 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 a
housing. The components work together to cause
relative movement between the magnetic and
electric fields, which in turn generates electricity.

(a) Stator – This is the stationary component. It

contains a set of electrical conductors wound in
coils over an iron core.
(b) Rotor / Armature – This is the moving
component that produces a rotating magnetic.
( C) Connection Terminal
(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. All such installations are
subject to the approval of the City
Planning Division. Click the following
link for further details regarding fuel
tanks for generators.
Common features of the fuel system include the following:
(a) Pipe connection from fuel tank to engine – The supply line directs fuel from the tank to the engine and
the return line directs fuel from the engine to the tank.

(b) Ventilation pipe for fuel tank – The fuel tank has a ventilation pipe to prevent the build-up of pressure
or vacuum during refilling and drainage of the tank. When you refill the fuel tank, ensure metal-to-metal
contact between the filler nozzle and the fuel tank to avoid sparks.

(c) Overflow connection from fuel tank to the drain pipe – This is required so that any overflow during
refilling of the tank does not cause spillage of the liquid on the generator set.

(d) Fuel pump – This transfers fuel from the main storage tank to the day tank. The fuel pump is typically
electrically operated.

(e) Fuel Water Separator / Fuel Filter – This separates water and foreign matter from the liquid fuel to
protect other components of the generator from corrosion and contamination.

(f) Fuel Injector – This atomizes the liquid fuel and sprays the required amount of fuel into the combustion
chamber of the engine.
 (4) Voltage Regulator
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.
(1) Voltage Regulator: Conversion of AC Voltage to DC Current – The voltage regulator takes up a small portion of
the generator’s output of AC voltage and converts it into DC current. The voltage regulator then feeds this DC
current to a set of secondary windings in the stator, known as exciter windings.
(2) Exciter Windings: Conversion of DC Current to AC Current – The exciter windings now function similar to the
primary stator windings and generate a small AC current. The exciter windings are connected to units known as
rotating rectifiers.
(3) Rotating Rectifiers: Conversion of AC Current to DC Current – These rectify the AC current generated by the
exciter windings and convert it to DC current. This DC current is fed to the rotor / armature to create an
electromagnetic field in addition to the rotating magnetic field of the rotor / armature.
(4) Rotor / Armature: Conversion of DC Current to AC Voltage – The rotor / armature now induces a larger AC
voltage across the windings of the stator, which the generator now produces as a larger output AC voltage.

This cycle continues till the generator begins to produce output voltage equivalent to its full operating capacity. As
the output of the generator increases, the voltage regulator produces less DC current. Once the generator reaches
full operating capacity, the voltage regulator attains a state of equilibrium and produces just enough DC current to
maintain the generator’s output at full operating level.

When you add a load to a generator, its output voltage dips a little. This prompts the voltage regulator into action
and the above cycle begins. The cycle continues till the generator output ramps up to its original full operating
capacity.
(5) Cooling & Exhaust Systems
(a) Cooling System
Continuous usage of the generator causes its various
components to get heated up. It is essential to have a
cooling and ventilation system to withdraw heat
produced in the process.

Raw/fresh water is sometimes used as a coolant for

generators, but these are mostly limited to specific
situations like small generators in city applications or
very large units over 2250 kW and above.

Hydrogen is sometimes used as a coolant for the

stator windings of large generator units since it is
more efficient at absorbing heat than other coolants.

This is why very large generators and small power plants

often have large cooling towers next to them. For all other
common applications, both residential and industrial, a
standard radiator and fan is mounted on the generator and
works as the primary cooling system.
(b) Exhaust System
Exhaust fumes emitted by a generator are just like exhaust from
any other diesel or gasonline engine and contain highly toxic
chemicals that need to be properly managed. Hence, it is essential
to install an adequate exhaust system to dispose of the exhaust
gases

Exhaust pipes are usually made of cast iron, wrought iron, or steel.
These need to be freestanding and should not be supported by the
engine of the generator. Exhaust pipes are usually attached to the
engine using flexible connectors to minimize vibrations and
prevent damage to the generator’s exhaust system. The exhaust
pipe terminates outdoors and leads away from doors, windows
and other openings to the house or building. You must ensure that
the exhaust system of your generator is not connected to that of
any other equipment. You should also consult the local city
ordinances to determine whether your generator operation will
need to obtain an approval from the local authorities to ensure
you are conforming to local laws a protect against fines and other
penalties.
(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 start function of a generator is battery-
operated. 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.
They are also fully automatic and do not require
any adjustments to be made or any settings to
be changed. The DC output voltage of the
battery charger is set at 2.33 Volts per cell,
which is the precise float voltage for lead acid
batteries. The battery charger has an isolated
DC voltage output that does interfere with the
normal functioning of the generator.
8) Control Panel
This is the user interface of the generator and contains provisions for
electrical outlets and controls. The following article provides further details
regarding the generator control panel. Different manufacturers have varied
features to offer in the control panels of their units. Some of these are
mentioned below.

(a) Electric start and shut-down – Auto start control panels automatically
start your generator during a power outage, monitor the generator while in
operation, and automatically shut down the unit when no longer required.

(b) Engine gauges – Different gauges indicate important parameters such as

oil pressure, temperature of coolant, battery voltage, engine rotation speed,
and duration of operation. Constant measurement and monitoring of these
parameters enables built-in shut down of the generator when any of these
cross their respective threshold levels.

(c) Generator gauges – The control panel also has meters for the
measurement of output current and voltage, and operating frequency.

(d) Other controls – Phase selector switch, frequency switch, and engine
control switch (manual mode, auto mode) among others.
(9) 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.
Technical data
 DG System in Project Consist of :
1) DG Supply – Included with DG + AMF Panel + Oil Tank
2) DG Exhaust work –Rock wool insulation + Piping work+ Exhaust work
3) Allied Electrical System work – Cable , Cable Tray , Earthing + Misc like rubber
mate , fire extinguisher, First Aid etc.
4) HSD Tank – SITC of HSD Tank + obtain local approval and liasoing work
5) Obtain Permission from Govt.Auto.to run the DG./Obtaining Approvals of
statuary bodies like:
a. Electrical Inspectorate
b. MSEB/Supply Authorities.
b. Pollution Dept/Board.
c. Any other permission to run the D.G set.
All above are design build work on the basis of given BOQ , Specification etc.
 DG certification and installation
Supporting Documents Required for DG approval
For DG Set Commissioning Approval:
1. Diesel Generator Installation Layout with seal and stamp of Licensed contractor
2. Diesel Generator Makers Paper & Test reports For DG Set Registration at Head Office
(Mumbai)
3. Application Form A
4. Sanction letter issued by electrical inspector for commissioning of generator set.
5. Registration certificate issued by Industries Department
6. Electrical Bill
7. Test Reports of DG set.

These all will be done from specialized licence contractor .

 Essential to send the enquiry to vendor for offer
1) Tender Specification for DG – Complete SITC System including allied work.
2) Tender BOQ – with detailed designed quantity
3) Make list of component
4) Civil & DG Room Layout

Makes Given in Make List :

Power Generating Engine - Caterpillar / Cummins India / Perkins
Alternator Leroy Somer / Stamford / Caterpillar
HSD Fuel Pumps Rotadel, Willow, DP, Grundfos.
Synchronizing panel /
AMF panel, Auxiliary Panel
and Motor Control Centre ABB / Siemens / Schneider / L&T
 DG Manufacturers in India
1) Cummins – Powercia / Jackson/ Sudhir
2) Kirloskar – Goel Power
3) Perkins - Sterling Generatoer / Supernova / Gmmco
4) Mitshubishi – Raipower
5) Kolher – Raipower / Gmmco
6) Volvo – Supernova / Sterling Generator
7) Caterpiller - Gmmco
8) Escort - Sterling Generator
THANK YOU!