INTERNAL

COMBUSTION (IC)
ENGINE
USED IN GENERATION
OF ELECTRICITY

PRESENTED BY:
MR. NATARAJAN IYER
 OBJECTIVE
• To understand difference between other uses of I C
Engine.
• Selection of optimum configuration.
• Erection of IC Engine with electrical generator.
• Pre-commissioning checkup.
• Load trial
• Over load specifications
• Maintenance of IC engine.

At end of the topic, students will understand the

fundamentals of the same and able to troubleshoot
simple problems.
I C Engines are used as mover for all kinds of rotating
equipment where grid power is not available and
primarily for transport systems
E.g.- Bore well system
- Crusher’s
- Sugar cane juicer etc.

“Never to mention about road transport equipments

without them we go back to bullock cart age”
Equipment run at fluctuating RPM
Chemical energy converted to one from of another
form of mechanical energy
I C Engine used for generation of electricity to run at
Constant RPM

Hunting is not desirable

Sound emission to be minimum

Why no hunting ?

Michael Friday’s 1st law -

EMF = n (  /  t)
During change in rpm the emf
generated will also vary and power
fluctuation will bring damage to the
equipments
In case of electricity generation IC Engine is
coupled with electrical generator

I.C generator

Base frame

Generation of electricity is due to laws of

electromagnetic Induction 1st and 2nd law of
Faraday.

Why Hunting ????

As you put electrical load speed will try to go down.
To keep RPM constant the fly weights of the governor
move outward and crosses equilibrium position.
Therefore hunting continues in case of mechanical
governors. To minimize this variation in speed they
use hydraulic or electronic governors. These governors
are sensitive by which the hunting is minimized.

Governor positions for different loads

By hunting what changes?

Speed droop and voltage droop changes

IC engine manufacturer specify normally half to 2% maximum

The speed droop and voltage droop are less, then the hunting will be
minimum.
 Engine coupling

altenator

AMF Panel

Base Frame
AVM Pads

D G SET AND THE ACCESSORIES

By hunting what changes e.g.

At 1500 RPM =440V - 50Hz

(a)Speed Droop.

(b)Voltage Droop.

IC Engine manufactures specify normally ½

+ 0.1% is taken for very good control less
Hunting.
 HOW TO SELECT A DG SET
S. No   Selection Running Starting

1 Load Detail KWA KVA

2 Pump 6 DDOL

3 Fan 3 5 TIME

4  Blower 4 3 TIME
RPM should not change with the load.
Unlike other applications, DG set run at
constant RPM

Check whether running KVA is larger

than starting KVA
Taking that future 20% extra i.e. the
capacity of IC Engine.
 Selection
• In case of IC Engine whether cooling has to be
with radiator or heat exchanger, depends upon --
Water availability. Remember!!!
• Heat exchanger with cooling tower is more efficient
compared to radiator cooling, in continuous running.
• In case of radiator cool engine the energy for fan is
compensated for the pumps which are required for
heat exchanger cooling.
• The radiator cooled engine occupies less space
compared to heat exchanger cooling system.
Turbo charged engines are always preferred to
naturally aspirated engine :
BECAUSE-
• Exhaust gases which are thrown out of engine are
utilized to operate blowers, which sucks fresh air
by which the efficiency of the turbo charged
engine is high.
• Turbo charger normally runs at 75000-80000 rpm.
• When the engine starts there is a high amount of
back pressure because of turbo charger not running
in the startup and give rise to a dense smoke.
Power availability depends upon :-
Altitude
• As you go higher O2 level goes down and
generator has to run at constant rpm to
deliver required power. i.e. the amount of
air requirement will rise, which is not
available. Hence, the DG set has to be
derated as the altitude increases.
 FUEL CONSUMPTION

Normally in a DG set the fuel consumption graph is

parabola, i.e. at 100% load the fuel consumption for
that particular load is minimum, but we cannot run at
100% always.
It is economical to run at 80% load, which gives you
maximum practical fuel efficiency.
Always have maximum fuel efficiency which
should be operated at 80% load factor.
I.C.Engines coupled to electrical
generator is called Diesel Generating unit
(D.G)
Now they come with Acoustic hood thereby
separate room requirement is eliminated.
Most of the units are factory assembled.
In factory assembly:
 Engine and alternator are aligned.
 Electrical panel are fixed.
 Fuel tank is placed inside.
 In case of Auto main system emergency
light is fixed inside.
 LOAD TRIAL REQUIREMENTS

Factory assembled units load trail is given for

24-48 hrs.
Intermittently over loading according IS Spec
(i.e. 1hr in every 12 hrs)
Load is given by using generated electricity to
heat up water.
 HANDLING OF DG SET WHILE
TRANSPORTATION

While transporting , loading and unloading

unit experiences shock, this can alter
alignment and hence checking of alignment
and all critical points are important before
commissisoning.
 ERECTION OF DG SET

Exhaust piping height is governed by local

government authority. Every State have
there Pollution Control Board which
formulate rules.
Diameter of exhaust pipes decided by design
of engine and allowed back presume.
Bellow of exhaust fixing is very important
because the load of piping should not be
transferred to engine.

A gap of 40-50mm is kept and cold

expansion is done which gets compensated
during operation
 Flooring should be done with concrete - oil
resistant coating
 As the D.G. Sets are mounted in AVM

(Anti Vibrational Mounting)

 Small upward curvature should be given in

civil construction, which prevents DG set

from moving.
EARTHING REQUIREMENT FOR DG SET

DG set requires atleast:-

 Three Independent earthings as follows:-
 Body of the IC engine
 Electrical generator
 Panel
 Incase of parallel running, earthing is
required for neutral also.
• When fixing earthing, removal of painting is very
important.
• Earth resistance should be <1ohm.
• Earthing requirement for instrumentation should be <5
ohm.
• Construction of earthing is done according to the water
level of that place.
• The conductivity of earthing needs to be checked at regular
intervals for proper working of DG set.
 STARTING OF DG SET
• Starting of DG Set is done by compressed air or
battery.
• In case of compressed air pressure is very important
(10-15kg/cm2)
• In case of battery start:
• Keeping battery in proper condition is very important.
• Non conducting material to be placed underneath the
battery thereby battery doesn’t get chained during non
operating time

Note: When an engine starts there is no lubrication and

it takes more energy to rotate because of inertia. In case
of engine above 500 KVA either a hand driven or
electrical driven lubricating oil pump is run before
running DG set.
Cable Termination for battery are:
• Important and maintained minimum length (D.
C .x Length of cable )
• Apply in habitation at terminals
(About cable terminals!)
Petroleum jelly has to applied on the terminals to
avoid galvanic corrosion.
Batteries has to be checked for distilled water level.
PRE-COMMISSIONING

• Check and fill raditor with proper pH of

water and additives if any.
• Check earthings.
• Check all cable terminal .
• Check lubricating oil level.
• Alignment detail.
• Exhaust piping to relive tension.
• Check All foundation bolt .
• And all other points mentioned in manual.
Put the start key start

STOP

“ Anything which starts should stop”

Operate at low Idle and
Check each injector for pattern of spray.

Drops
Normal One
Sided
• Increase the RPM to set the RPM
• see the voltage and set the voltage
• see the RPM with non contact method
• set the RPM 30-50 RPM higher and
frequency 50.5Hz
Load the D.G.Set by transferring greater load
one by one and watch the operation
• Check Water temperature
• Check lubricating oil temperature.
• Check whether the battery is getting
charged.
• Check lubricating oil pressure.
• Check water pressure
Check all safety sensor before starting the DG
set in following manners:-
• Connecting two terminal
• In case of temperature sensor, put hot water
and check for increase in temperature.
• In case of pressure sensor, check by
applying pneumatic pressure and check the
output.
While operation check the vibration at Engine
side and generator side which will become
reference for healthiness of DG Set

Mark all points where vibration is noted and as a

preventive measure the vibrations are noted at
the same point, which will provide us a clear
indication about the healthiness of the DG set.
Smoke emitted by D.G.Set will Indicate
efficiency of operation

*White Smoke – Lubricating oil is burning

*Black Smoke – Excess fuel is burning
* Hazy smoke - Normal operation
Radiator Mounted D.G.Set should have
opening in front of DG Set at lest 1 ½
times width and height of Radiator for
uninterrupted flow of air.
Back of DG set also opening to be of similar
size
Fuel consumption has become Very Important for
economical running i .e specific fuel consumption is
given as gms/bhp/hr

This value is set value for different models/make with that

calculation grams required is calculated and that when it is
multiplied by specific gravity and volume, the cost of
running the DG set is arrived. This plays a very important
role in running a DG set economically.
When DG set is new, it is important to carry
out periodic maintenance.

Always remember before dismantling check

the components, it will tell the hidden
stories.
Maintenance can be divided according to different
systems
• Lubricating System
• Water cooling system
• Fuel oil system
• Air System
• Electrical system
• Starting System
Lubricating oil system
check the lubricating system for black particle,
carbon, water, etc.

Lubricating oil can be send for analysis, thereby

we can arrive at optimum time between the
change over instead of changing the
lubrication oil at equal intervals.
• Check the level of water in radiator
• Check the pH
• Check the condition of fans in case of
radiator
• Radiator fan belts
• Thermostat
• Circulating pump and mechanical seal
• All Hose connection.
• Corrosion inhabitor
• Check PRE/POST FILTER
• Injectors for proper working
• Fuel Pump
• Quality of fuel
• Tappet setting
• Air Filters
• Inlet Manifold
• Turbo Charger
• Exhaust manifold
 ELECTRICAL SYSTEM MAINTENANCE

• Diode Rectifiers
• Megger of electrical generator
• Electrical panel
• Contactors cleaning
• Check Earthings
• Cooling Fan.
• Starter Circuit
• Electro mechanical switches
• gear teeth near the fly wheel
• High temp greasing for generator bearings
• Carbon brushes for starters
• Commutator surface of starters
 After completing the maintenance,
check whether all the systems are properly assembled and
No Load trial has to be taken.
ANY QUERY?