Bts Generators 5z4p22
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SCHEME OF PRESENTATION • • • • • • • • • • • • • • •
Introduction to Genset Why Genset is required Advantages of Gensets Types of Gensets maintained by Mobiserve Genset Capacities General Technical Difference b/w Diesel Engine and Spark Ignition (Gasoline) Engine How a Diesel Engine works Engine Identification Views of an Engine Identification and basic function of Engine parts and components Maintenance requirement Types of maintenance Preventive maintenance Overhauling
•
GENSET stands for Generator Set
•
Combination of: – Engine – Electric Generator or Alternator
•
Engine is a prime mover
•
Electric Generator generates electricity
AVAILABLE POWER SOURCES AT SITE • Normal: WAPDA Power Supply • Emergency: Genset • Backup: UPS/Battery 1
3 2
• • • • • • • •
Independent Power Source Emergency Power Supply Ease of Mobility Power Supply at Remote Sites Rugged and robust Easy availability of fuel Efficient working even in worst environment Water-cooled Engines have 85% mechanical efficiency
Make
Perkins John Deere
Others TOTAL
Rating (KVA)
Quantity
Total
C-1
C-2
C-3
North
20, 27, 30, 31
913
580
585
666
2744
31
226
231
181
27
665
14, 17, 20, 24, 27, 30, 31, 100
91
1
5
146
243
1230
812
771
839
3652
•
Thermodynamic Cycle: – – – – –
• • • • • •
Air Intake Compression Ignition Combustion Exhaust
Top Dead Center (TDC) Bottom Dead Center (BDC) Piston Stroke 2-Stroke and 4-Stroke Cylinder Bore Swept Volume
Cylinder Bore
TDC Piston Stroke
BDC
Diesel Engine
Spark Ignition Engine
• Intake:
Just AIR
• Intake:
• Ignition:
Heat of compressed air
• Ignition: Spark Plug
• Compression ratio:
14:1 to 25:1
• Higher compression ratio leads to better efficiency
Mixture of PETROL and AIR
• Compression ratio: 8:1 to 12:1 • Less efficient
•
Intake:
•
Compression: Very high pressure
•
Fuel Injection: Fine fuel spray by Fuel Injectors
•
Combustion:
Spontaneous combustion
•
Expansion:
Gases expand
•
Exhaust:
Burnt gases rush out
Fresh Air
• • •
Downward piston travel Intake valve is opened Air, fuel mixture enters
• • • •
Intake valve is closed Piston travels back up Intake air is compressed Fuel is injected near TDC
Combustion:
• •
Ignition Piston is forced down
Exhaust:
• • •
Piston rises up Exhaust valve is opened Exhaust gases go out
Intake: Compression:
Camsh aft
Fuel Injector
Camsh aft Intake and Exhaust Valves
Jacket Cooling Water Ports
Completes the thermodynamic cycle in FOUR movements of the piston (TWO crankshaft revolutions).
Piston
Connecti ng Rod
Cranksha ft
Downward Piston Stroke: Upward Piston Stroke:
• • • •
Exhaust valve opens Exhaust gases rush out Intake port uncovers Fresh air is sucked in
• • • • •
Intake port is blocked Exhaust valve closes Compression of intake air Fuel injection Combustion
Completes the thermodynamic cycle in TWO movements of the piston (ONE crankshaft revolution).
• Engine Serial Number • Significance – Exact identification of Engine – Correct procurement and replacement of spare parts
• Make – Perkins – John Deere
• Serial Number • Model Number
PERKINS 4000 Series Engine DGB 06 0081 U 0017 B Stafford ……………………………………………..D Application Code (Genset)………………….G Engine Type…………………………………………B Number of Cylinders……………………………06 Fixed Bill Number (0000 means Configured Product) 0081 United Kingdom…………………………………..U 17th Engine This Year…………………………..0017 Year Letter (B=1996)…………………………….B
JOHN DEERE ENGINE CD3029D500000 CD ............... Producing factory CD= Saran- PE= Torreon-MEXICO PY= L & T - John Deere (PuneINDIA) 3029 ........... Engine model designation 3 = Number of cylinders 029 = Total displacement (029 = 2.9 liters) D ................. Aspiration code D= Naturally Aspirated T= Turbocharger
PERKINS ENGINE SERIAL NUMBER
DGB 06 0081 U 0017 B
PERKINS
MADE IN UNITED KINGDOM
• According to Engine Types and Models – – – –
Right side Left side Engine top Rear End (Drive End)
Left Side
Rear End
Right Side
Engine Top
Rocker Cover
Air Intake and Exhaust Valves
Rocker Arm Atomize r
Turbochar ger
Camshaft Pisto n Connecting Rod Crankshaft Pulley
Oil Filter
Cranksha ft Oil Sump
Main Parts and Components • • • • • • • • • • • •
Engine Block Crankshaft Main Bearings Connecting Rods Pistons Piston Rings Cylinder Liner Intake and Exhaust Valves Cylinder Head Engine Gaskets Oil Sump Flywheel
•
Lubricating Oil Pump
•
Fuel Injection Pump
•
Fuel Injectors
•
Governor
•
Cooling Water Pump
•
Radiator Fan
•
Radiator
•
Fuel Filter
•
Lubricating Oil Filter
•
Weather Proof Enclosure
•
Muffler
Basic Structure of an Engine CONTAINS: •Crankshaft •Pistons and Connecting Rods •Cylinder Head •All other ancillaries
CONVERTS Reciprocating Movement of PISTON and CONNECTING RODS to: Rotational Movement
Cranksh aft Pulley
Cranksh aft
Cranksh aft Gear
Flywhe el
• Minimize friction • Frictionless movement of crankshaft • Avoid metal to metal • Ease of maintenance • Reduced maintenance cost
• Connects: • Piston • Crankshaft
• Form Combustion Chamber • Power generation by combustion gases • Allow reciprocating movement of pistons
• Sealing between Combustion Chamber and Oil Sump • Maintain compression chamber pressure • Efficient compression • Types: • Compression Rings • Oil Scraper Rings
• Provide timed age to: • Intake air • Exhaust gases • Controlled opening and closing by Rocker Arms and Camshaft • Fitted in Cylinder Head • Types: • Air Intake Valves • Exhaust Valves
• Top of an engine • Fitted with: • • • •
Air Intake Valves Exhaust Valves Fuel Injectors Rocker Arm Assembly
• Air Intake and Exhaust Ports • Cooling Water ages
• Top Gasket or Cylinder Head Gasket: Provide sealing between Cylinder Head and Cylinder Block • Bottom Gasket or Oil Sump Gasket: Provide sealing between Cylinder Block and Engine Oil Sump
• Engine oil storage • Provides: • Oil suction to Oil Pump • Oil drain facility • Easy access for engine inspection and maintenance
•
Stores inertial force of movement
•
Absorbs engine jerks
•
Provides smooth engine rotational speed
•
Ring gear connected with Starter Motor for initial start
•
Gear type pump
• •
Driven by Crankshaft To supply lubricating oil to Engine moving parts:
•
•
Main and Big End Bearings
•
Camshaft
•
Rocker Arms
•
Cylinders and Pistons
•
Timing Gears etc
Take suction from Engine Oil Sump
•
Fuel Tank
•
Fuel Lift Pump
•
Fuel Filter
•
Fuel Injection Pump
•
Fuel Injectors
Fuel Tank
•
Gear type pump
•
Driven by Crankshaft
•
To supply accurate fuel quantity in a specific order and sequence to the Engine through Fuel Injectors
•
Take suction from Fuel Tank through: •
Primary Fuel Filter
•
Fuel Lift Pump
•
Secondary Fuel Filter Fuel Tank
•
Supply diesel fuel to the engine
•
Produce very fine fuel spray into the cylinder
•
Better Air/Fuel mixture, efficient combustion
•
Actuated by fuel pressure
•
Fuel is pressurized by Fuel Injection Pump
Fuel Tank
•
Regulates the Idling Speed and Maximum Speed
• •
Controls the rate of fuel delivery Without Governor engine can easily overspeed resulting
DESTRUCTION • •
Diesel Engine Spark Ignition Engine
•
Types: • Mechanical Governor • Electronic Governor (ECM, ECU)
Fuel Tank
Fuel is controlled Air is throttled Govern or
•
Water is used in Cooling System
•
NEVER use SALINE WATER in Engine Cooling System
•
Recommended: Distilled Water or Deionized Water
•
Ethylene Glycol
•
Propylene Glycol
•
Water/Glycol mixture provides protection against:
•
•
Boiling
•
Freezing
•
Water Pump cavitations
Water/Glycol mixture:
1:1
Ethylene Glycol Concentration
Freeze Protection Anti-Boil Protection
50 Percent
-36 C
106 C
60 Percent
-51 C
111 C
Coolant Temperature Gauge
•
Combustion process generates heat
•
Excessive heat can damage engine components
•
Cooling system removes heat
•
Coolant: Distilled Water, De-ionized Water
•
Water is circulated by Cooling Water Pump
•
Water is circulated through engine water jackets
•
Forced air for better heat transfer i-e Convectional Heat Transfer
•
Fitted on a belt driven pulley
•
Crankshaft pulley drives Radiator Fan
•
Normally V-Type Belts are used
•
Imbalanced, damaged or fan with loose belt may cause vibration
•
Important component of Cooling Water System
•
Water es through Fine Copper Tubes
•
Radiator fan blows air through fins
•
Heat is transferred: — Copper Tubes — Fins Convectional Heat Transfer
•
•
Engine needs fine fuel spray
•
Fuel spray by Fuel Injectors
•
To maintain fuel quality Fuel Filters
•
•
are used Filters separate: — Water Contamination — Particulate Contamination Types: — Primary Fuel Filter — Secondary Fuel Filter
•
Lubricating Oil es through fine orifices
•
L.O makes a very fine oil film between two metal
•
Prevents metal to metal
•
L.O quality is most important
•
To maintain L.O quality Oil Filters are
•
used Oil Filters remove Particulate Contamination
•
Used for initial starting of an Engine
•
Battery (DC Power) runs Starting Motor
•
Starting Motor turns the Crankshaft
•
Thermodynamic cycle completes and Engine starts
•
Protects Engine and Generator from: •
Harsh environment
•
Relative humidity
•
Dust/Dirt
•
Malicious damage
•
Theft
•
Sound attenuation
•
Fitted on Exhaust System
•
Sound attenuation
• We need uninterrupted Electrical Power Supply • Genset runs when WAPDA Power Supply is not available • Genset Running Conditions: — Harsh environment — Continuous operation • Maintenance improves: — Equipment/Machinery life — Service quality • Maintenance reduces unexpected downtime and major breakdowns
• Preventive Maintenance (PM) — To prevent a defect or damage
• Corrective Maintenance (CM) — Fault finding — Fault rectification
• Change Engine Oil • Change Oil Filter • Change Fuel Filter • Change Air Filter • Radiator inspection and cleaning (if chocked) • Battery inspection • General cleaning
• Cylinder Liners • Pistons • Piston Rings • Gudgeon Pin • Engine Valves • Valve Seats • Valve Springs • Valve Guides • Main Bearings • Big End Bearings • Con-rod Bush • Front & Rear Oil Seals • Engine Gaskets
Introduction to Genset Why Genset is required Advantages of Gensets Types of Gensets maintained by Mobiserve Genset Capacities General Technical Difference b/w Diesel Engine and Spark Ignition (Gasoline) Engine How a Diesel Engine works Engine Identification Views of an Engine Identification and basic function of Engine parts and components Maintenance requirement Types of maintenance Preventive maintenance Overhauling
•
GENSET stands for Generator Set
•
Combination of: – Engine – Electric Generator or Alternator
•
Engine is a prime mover
•
Electric Generator generates electricity
AVAILABLE POWER SOURCES AT SITE • Normal: WAPDA Power Supply • Emergency: Genset • Backup: UPS/Battery 1
3 2
• • • • • • • •
Independent Power Source Emergency Power Supply Ease of Mobility Power Supply at Remote Sites Rugged and robust Easy availability of fuel Efficient working even in worst environment Water-cooled Engines have 85% mechanical efficiency
Make
Perkins John Deere
Others TOTAL
Rating (KVA)
Quantity
Total
C-1
C-2
C-3
North
20, 27, 30, 31
913
580
585
666
2744
31
226
231
181
27
665
14, 17, 20, 24, 27, 30, 31, 100
91
1
5
146
243
1230
812
771
839
3652
•
Thermodynamic Cycle: – – – – –
• • • • • •
Air Intake Compression Ignition Combustion Exhaust
Top Dead Center (TDC) Bottom Dead Center (BDC) Piston Stroke 2-Stroke and 4-Stroke Cylinder Bore Swept Volume
Cylinder Bore
TDC Piston Stroke
BDC
Diesel Engine
Spark Ignition Engine
• Intake:
Just AIR
• Intake:
• Ignition:
Heat of compressed air
• Ignition: Spark Plug
• Compression ratio:
14:1 to 25:1
• Higher compression ratio leads to better efficiency
Mixture of PETROL and AIR
• Compression ratio: 8:1 to 12:1 • Less efficient
•
Intake:
•
Compression: Very high pressure
•
Fuel Injection: Fine fuel spray by Fuel Injectors
•
Combustion:
Spontaneous combustion
•
Expansion:
Gases expand
•
Exhaust:
Burnt gases rush out
Fresh Air
• • •
Downward piston travel Intake valve is opened Air, fuel mixture enters
• • • •
Intake valve is closed Piston travels back up Intake air is compressed Fuel is injected near TDC
Combustion:
• •
Ignition Piston is forced down
Exhaust:
• • •
Piston rises up Exhaust valve is opened Exhaust gases go out
Intake: Compression:
Camsh aft
Fuel Injector
Camsh aft Intake and Exhaust Valves
Jacket Cooling Water Ports
Completes the thermodynamic cycle in FOUR movements of the piston (TWO crankshaft revolutions).
Piston
Connecti ng Rod
Cranksha ft
Downward Piston Stroke: Upward Piston Stroke:
• • • •
Exhaust valve opens Exhaust gases rush out Intake port uncovers Fresh air is sucked in
• • • • •
Intake port is blocked Exhaust valve closes Compression of intake air Fuel injection Combustion
Completes the thermodynamic cycle in TWO movements of the piston (ONE crankshaft revolution).
• Engine Serial Number • Significance – Exact identification of Engine – Correct procurement and replacement of spare parts
• Make – Perkins – John Deere
• Serial Number • Model Number
PERKINS 4000 Series Engine DGB 06 0081 U 0017 B Stafford ……………………………………………..D Application Code (Genset)………………….G Engine Type…………………………………………B Number of Cylinders……………………………06 Fixed Bill Number (0000 means Configured Product) 0081 United Kingdom…………………………………..U 17th Engine This Year…………………………..0017 Year Letter (B=1996)…………………………….B
JOHN DEERE ENGINE CD3029D500000 CD ............... Producing factory CD= Saran- PE= Torreon-MEXICO PY= L & T - John Deere (PuneINDIA) 3029 ........... Engine model designation 3 = Number of cylinders 029 = Total displacement (029 = 2.9 liters) D ................. Aspiration code D= Naturally Aspirated T= Turbocharger
PERKINS ENGINE SERIAL NUMBER
DGB 06 0081 U 0017 B
PERKINS
MADE IN UNITED KINGDOM
• According to Engine Types and Models – – – –
Right side Left side Engine top Rear End (Drive End)
Left Side
Rear End
Right Side
Engine Top
Rocker Cover
Air Intake and Exhaust Valves
Rocker Arm Atomize r
Turbochar ger
Camshaft Pisto n Connecting Rod Crankshaft Pulley
Oil Filter
Cranksha ft Oil Sump
Main Parts and Components • • • • • • • • • • • •
Engine Block Crankshaft Main Bearings Connecting Rods Pistons Piston Rings Cylinder Liner Intake and Exhaust Valves Cylinder Head Engine Gaskets Oil Sump Flywheel
•
Lubricating Oil Pump
•
Fuel Injection Pump
•
Fuel Injectors
•
Governor
•
Cooling Water Pump
•
Radiator Fan
•
Radiator
•
Fuel Filter
•
Lubricating Oil Filter
•
Weather Proof Enclosure
•
Muffler
Basic Structure of an Engine CONTAINS: •Crankshaft •Pistons and Connecting Rods •Cylinder Head •All other ancillaries
CONVERTS Reciprocating Movement of PISTON and CONNECTING RODS to: Rotational Movement
Cranksh aft Pulley
Cranksh aft
Cranksh aft Gear
Flywhe el
• Minimize friction • Frictionless movement of crankshaft • Avoid metal to metal • Ease of maintenance • Reduced maintenance cost
• Connects: • Piston • Crankshaft
• Form Combustion Chamber • Power generation by combustion gases • Allow reciprocating movement of pistons
• Sealing between Combustion Chamber and Oil Sump • Maintain compression chamber pressure • Efficient compression • Types: • Compression Rings • Oil Scraper Rings
• Provide timed age to: • Intake air • Exhaust gases • Controlled opening and closing by Rocker Arms and Camshaft • Fitted in Cylinder Head • Types: • Air Intake Valves • Exhaust Valves
• Top of an engine • Fitted with: • • • •
Air Intake Valves Exhaust Valves Fuel Injectors Rocker Arm Assembly
• Air Intake and Exhaust Ports • Cooling Water ages
• Top Gasket or Cylinder Head Gasket: Provide sealing between Cylinder Head and Cylinder Block • Bottom Gasket or Oil Sump Gasket: Provide sealing between Cylinder Block and Engine Oil Sump
• Engine oil storage • Provides: • Oil suction to Oil Pump • Oil drain facility • Easy access for engine inspection and maintenance
•
Stores inertial force of movement
•
Absorbs engine jerks
•
Provides smooth engine rotational speed
•
Ring gear connected with Starter Motor for initial start
•
Gear type pump
• •
Driven by Crankshaft To supply lubricating oil to Engine moving parts:
•
•
Main and Big End Bearings
•
Camshaft
•
Rocker Arms
•
Cylinders and Pistons
•
Timing Gears etc
Take suction from Engine Oil Sump
•
Fuel Tank
•
Fuel Lift Pump
•
Fuel Filter
•
Fuel Injection Pump
•
Fuel Injectors
Fuel Tank
•
Gear type pump
•
Driven by Crankshaft
•
To supply accurate fuel quantity in a specific order and sequence to the Engine through Fuel Injectors
•
Take suction from Fuel Tank through: •
Primary Fuel Filter
•
Fuel Lift Pump
•
Secondary Fuel Filter Fuel Tank
•
Supply diesel fuel to the engine
•
Produce very fine fuel spray into the cylinder
•
Better Air/Fuel mixture, efficient combustion
•
Actuated by fuel pressure
•
Fuel is pressurized by Fuel Injection Pump
Fuel Tank
•
Regulates the Idling Speed and Maximum Speed
• •
Controls the rate of fuel delivery Without Governor engine can easily overspeed resulting
DESTRUCTION • •
Diesel Engine Spark Ignition Engine
•
Types: • Mechanical Governor • Electronic Governor (ECM, ECU)
Fuel Tank
Fuel is controlled Air is throttled Govern or
•
Water is used in Cooling System
•
NEVER use SALINE WATER in Engine Cooling System
•
Recommended: Distilled Water or Deionized Water
•
Ethylene Glycol
•
Propylene Glycol
•
Water/Glycol mixture provides protection against:
•
•
Boiling
•
Freezing
•
Water Pump cavitations
Water/Glycol mixture:
1:1
Ethylene Glycol Concentration
Freeze Protection Anti-Boil Protection
50 Percent
-36 C
106 C
60 Percent
-51 C
111 C
Coolant Temperature Gauge
•
Combustion process generates heat
•
Excessive heat can damage engine components
•
Cooling system removes heat
•
Coolant: Distilled Water, De-ionized Water
•
Water is circulated by Cooling Water Pump
•
Water is circulated through engine water jackets
•
Forced air for better heat transfer i-e Convectional Heat Transfer
•
Fitted on a belt driven pulley
•
Crankshaft pulley drives Radiator Fan
•
Normally V-Type Belts are used
•
Imbalanced, damaged or fan with loose belt may cause vibration
•
Important component of Cooling Water System
•
Water es through Fine Copper Tubes
•
Radiator fan blows air through fins
•
Heat is transferred: — Copper Tubes — Fins Convectional Heat Transfer
•
•
Engine needs fine fuel spray
•
Fuel spray by Fuel Injectors
•
To maintain fuel quality Fuel Filters
•
•
are used Filters separate: — Water Contamination — Particulate Contamination Types: — Primary Fuel Filter — Secondary Fuel Filter
•
Lubricating Oil es through fine orifices
•
L.O makes a very fine oil film between two metal
•
Prevents metal to metal
•
L.O quality is most important
•
To maintain L.O quality Oil Filters are
•
used Oil Filters remove Particulate Contamination
•
Used for initial starting of an Engine
•
Battery (DC Power) runs Starting Motor
•
Starting Motor turns the Crankshaft
•
Thermodynamic cycle completes and Engine starts
•
Protects Engine and Generator from: •
Harsh environment
•
Relative humidity
•
Dust/Dirt
•
Malicious damage
•
Theft
•
Sound attenuation
•
Fitted on Exhaust System
•
Sound attenuation
• We need uninterrupted Electrical Power Supply • Genset runs when WAPDA Power Supply is not available • Genset Running Conditions: — Harsh environment — Continuous operation • Maintenance improves: — Equipment/Machinery life — Service quality • Maintenance reduces unexpected downtime and major breakdowns
• Preventive Maintenance (PM) — To prevent a defect or damage
• Corrective Maintenance (CM) — Fault finding — Fault rectification
• Change Engine Oil • Change Oil Filter • Change Fuel Filter • Change Air Filter • Radiator inspection and cleaning (if chocked) • Battery inspection • General cleaning
• Cylinder Liners • Pistons • Piston Rings • Gudgeon Pin • Engine Valves • Valve Seats • Valve Springs • Valve Guides • Main Bearings • Big End Bearings • Con-rod Bush • Front & Rear Oil Seals • Engine Gaskets
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