Standby Diesel Generator Set

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 Standby Diesel Generator Set

Objectives
1. State the purpose/main function of standby generator installation.
2. State, explain and identify the standby generator set assembly.
3. State, explain and identify the main component of AC Generator.
4. Describe the operation of Brushless Generator type.
5. Describe the metering, protection and control system.
6. State and explain the controlled parameters of Standby generator
installation.
7. Read and interpret layout drawing/diagram of Standby generator
installation.
8. Perform pre-start up inspection on Standby generator installation.
9. Perform Standby generator startup and shutdown according to
standard procedure.
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 Standby Diesel Generator Set

Coverage

System function and Assembly

Generator Principle and Components
Brushless AC Generator Construction
The Generator Excitation
Generator Control Panel System
Starting System and Component
System Operation
Start-up/Shutdown
Start-up Procedure
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 Standby Diesel Generator Set

Function
to deliver power automatically to essential and vital
switchboards in the event of power failure in order to powered
the critical equipment such as UPS systems, Plant shutdown
system, DCS, instrumentation,main motors, DC battery chargers
and emergency lighting.

Power Flow
Neutral Switch

/SYNCHRONIZING
Generator/
Synchronizing
Lightning
Arrestor
Lightning
Arrestor Switch Board
Main Switch
Board
AMF BOARD

AMF Board
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- Overhead System
- Street Lighting

Sub Switch
Board Lightning
Arrestor

Essential Switch
Board Vital Switch
- Overhead System
Board VITAL SWITCH BOARD

- Street Lighting

Lightning
Arrestor - DCS
- Fire and Gas Detection System
 Standby Diesel Generator Set
Assembly

Generator Switch Board

Prime Mover - Diesel Engine

Generator Control Panel

Fuel Storage

AC Generator
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Battery Bank and Starting System

 AC Generator (Basic)

Function

converts mechanical energy to electrical energy.

Prime mover Generator/Alternator

provides mechanical converts mechanical
power in term of rotation. power into electrical power
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 AC Generator (Basic)

Principle
"Whenever a conductor or coil cuts a magnetic field or
vise-versa, an induced current will flow in a conductor or an
induced voltage will exist across the conductor"
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 AC Generator (Basic)

Construction / Main components

AC Output
Armature Winding
DC input from
Stator Exciter

N
S Rotor
Rotation
N
S Frame of Yoke
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Field Winding
 AC Generator (Basic)
Requirements

1 Magnetic Fluxes
- produce by a copper conductors known as Field winding
when receives a DC supply from exciter.

2 Conductor or Coil
- a copper conductors known as Armature winding, carry
induced current when cutting process occurs.

3 Cutting Process
- is a process where a conductor cuts the magnetic field or a
magnetic field cuts the conductor which results and induce
current flow in the conductor.
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 AC Generator (Basic)
Performance

1. Generated Voltage or Output Voltage ( E )

E = B l v sin q in volt (V)

Where , E = output voltage

B = Magnetic field strength
l = Length of conductor under magnetic flux
v = speed of generator
q = cutting angle

E  Exciting Current and speed

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 AC Generator (Basic)
Performance
2. Frequency ( f )

pN
f = in Hertz ( Hz )
120

Where, p = number of poles

N = speed in rpm

f  generator speed
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 AC Generator (Basic)
Performance
3. Generator Speed ( N )

120f
N = in Hertz ( Hz )
p

Where, p = number of poles

f = frequency
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 AC Generator (Basic)
Performance
4. Output power ( P )

For a Single phase

P = V I cos q - Watt or Kilowatt ( kW ) or

P = VI - VA or Kilovoltamp ( kVA )

For a Three phase

P = 3 V I cos q - Watt or Kilowatt ( kW ) or

P = 3V I - VA or Kilovoltamp ( kVA )
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where V = line voltage

I = line current
cos q = power factor
 AC Generator (Basic)
Performance
5. Generator Efficiency ( h )

Output Wattage
h = x 100
Input Wattage

Output Wattage = kVA x cos q

Input Wattage = kVA x cos q + Copper loss + Stray loss

Copper loss = P losses in the armature winding +

P losses in the separately excited field winding
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Stray loss = Bearing and brushes friction losses +

Windage losses + Iron losses ( eddy current
+ hysteresis losses )
 AC Generator (Basic)
Overall Performance
Fuel (Chemical Energy)

KVA h h
Mechanical Energy Input
(Engine Power)

(Mechanical Energy Output)

p.fGen + Load

KWinput
h h
KWout
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(Mechanical Energy Input)

Motor Hp rating
 Brushless AC Generator
Main Parts and Function
No slipring and carbon Brush required
Less Maintenance
has PMG for high KVA rating as
an additional components
AVR
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AC Exciter

Rotating Rectifier

Main Generator
 Brushless AC Generator

Parts and Function

1 The Main Generator
4-pole, rotating field ac generator
The field winding is wound to the salient pole of the rotor
Speed at 1500 rpm
415VAC, 50Hz output is tap from the stationary
armature winding.

Inter-connector
Pole Shoe

Field Winding
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Rotor Body

Salient Pole Cylindrical Pole

 Brushless AC Generator

Parts and Function

2 The AC Exciter
> 8-pole brushless stationary field ac generator
provide high armature output @ >100Hz frequency to be rectified
and converted to DC voltage by a rotating rectifier for main
generator field excitation.
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 Brushless AC Generator
Parts and Function
3 The Pilot Exciter
an AC generator with rotating permanent magnets as its field.
provides constant power to the AVR/MVR under all conditions
regardless of the main generator output condition.
For high KVA rating only >1MVA

Permanent Magnet
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AC Exciter Armature
 Brushless AC Generator
Parts and Function
4 Automatic Voltage Regulator (AVR)
to control and regulate DC excitting current to the Exciter Field
consist of Rectifier circuit, Voltage regulator/adjuster/comparator
and Amplifier

Ac Exciter
Rotating rectifier
Armature

Ac Exciter Main
Field Generator
winding
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AVR
Main Generator
Field
 Brushless AC Generator
Parts and Function
5 Rotating Rectifier
a three-phase full-wave bridge, having six diode elements, mounted
on a rotating steel plate, located at the exciter end for easy
inspection, testing and replacement.
output of ac exciter is rectified and converted to DC excitation
voltage here for main generator field excitation.
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 Brushless AC Generator
Generator Excitation
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Self excited,Brushless
Rotating coil stationary field
Three phase generator
 Brushless AC Generator
Generator Excitation
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 Brushless AC Generator
Generator Excitation (with Pilot Exciter)
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Self excited,Brushless
Rotating coil stationary field
Three phase generator
 Brushless AC Generator
Generator Excitation (with Pilot Exciter)

Exciter Rotating rectifier

Permanent Magnet Assembly
Rotor
Rotor
Main field

Shaft Axis

Main Stator

Exciter
Stator Output
Permanent Magnet
Stator Terminals

AVR
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 Local Control Panel
Function

start and stop the engine from the engine skid.

provide general fault indicating lights.
monitor engine speed
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 Generator Board
Function

for start and stop the generator set.

continuous display and monitoring of the generated output.
provide generator protection facilities with audible alarm signal
and fault indication lights.
provide generator circuit breaker control .
provide control engine speed, generator excitation/generator voltage.
provide provide synchronization facilities.
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 Generator Board
Parts A B D D A B C E

F F
G G
H I

K Q P P K Q L O
M N N M

A - Generator Metering Panel G - Circuit Breaker Control Panel M - Neutral Contactor Panel

B - Busbar Metering Panel H - Synchronizing Panel N - Engine DC Control Panel

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C - Generator Protection Panel I - Load Metering Panel O - Lightning Arrestor Panel

D - Synchronizing Metering Panel J - Power Factor Correction Panel P - Battery Charger Panel

E - Power Factor Circuit Breaker K - Generator Circuit Breaker Q - SpecialTool Compartment

F - Neutral Isolator Panel L - Load Circuit Breaker

 Generator Board
The 3 Systems

 VITAL in ensuring the integrity and continuity of a supply.

Protection System
Busbar

PM G
Metering System

Control System
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 Generator Board
1. Metering System
 to monitor system performance
line voltage, line current,
power factor,reactive power , true power ,
frequency and
power consumption rate.

 tap to the main line through Potential transformer (P.T)

or/and through Current transformer (C.T).

 links together with indication devices: indicating lights

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 Generator Board
1. Metering System Connection
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 Generator Board
2. Control System

 to control the generator operation and performance

smooth start-up (auto and manual)
regulates the speed and voltage output (Governor and AVR)
synchronizing if possible
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 Generator Board
2. Control System (Electronic Governor)

 provides two functions, indicate exact engine speed and

kilowatt load sharing when synchronised

Input from Auto Synchronizer

Electronic
Processor
Actuator
Input from manual and
Speed Trimmer
Amplifier Fuel Control Valve

Magnetic Pickup

Engine Generator
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Engine Flywheel

Fuel line
 Generator Board
2. Protection System
 protects the generator against system problems/faults
overload, loss of load, unbalanced loading,
under/over frequency and under/over voltage,
Insulation failure,
mechanical failure,
excitation system failure
reverse power
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 Generator Board
2. Protection System Connection
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 Generator Board
2. Protection System (Alarm & Shutoff)
DC CONTROL SWITCH

EMERGENCY STOP START P/B

MANUAL

to warn the operator that an

AFR-3
SR
SR-4

unsafe operating condition is

AST
FSM-4 SDT-1
FSM

occurring. FC-4

FSR-1 EFR-1
AFR-4

OCR-1 RPTR-1 LOP-1 HWT-1 OSR-1

OPT

FC

ALARM CANCEL P/B

ACR

Remote switches deenergise

ACR-1

FC relay cause the engine

FC-2 ACR-2
AR
FSR-2 RESET P/B

shutdown
FST-1

FSR
EFR-2

EF-1
EFR

Alarm Bell continually sound

OCR-2

OC-1
OCR

until reset button is pressed. RPTR-2

RPR-1
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RPTR
LOP-2 Alt-Relay No Contact

OPT-1

LOP ive

HWT-2

HWT
OSR-2

OSR
 Charger and Battery Bank
Function
provide a DC supply to Starter Motor for engine cranking.

Starter Motor Governor Actuator

Rotary Charger

Static Charger
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Battery Bank
 Fuel Storage
Function (Bulk Storage)

to ensure continuous and clean supply of diesel fuel.

intake line
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 Auto Main Failure Board (AMF)
Function
provide permissive to start signal to the generator set via
undervoltage relay
to do 'supply to the load' switching either from mains or from
generator.
connect/disconnect the generator to/from the essential/vital
switchboard. From Generator
From Board
MSB
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To Ups and Vital

Switch Board
 Standby Diesel Generator Set
Sequences of Operation
Under Voltage Relay (set at 80-90% of rated voltage) detects loss (or
abnormal reduction) of voltage.
Permissive to start signal activates the starting of the engine (after 2-3
sec delay to confirm real power lost ).
Energising of the starter motor system (take about 1-2 second
intervals for the starter pinion to engage).
Full power cranking, an engine speed detection circuit indicates when
the engine has fired and has started to run up to speed and at this
point the starter motor is de-energised and locked out.
Acceleration of the engine/stable generator output. A few seconds is
needed for the generating set is deemed ready for load transfer.
(Synchronized if possible the system can take-up the loads.)
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Energising of Neutral Contactor and closing of generator CB.

In Auto-mode, it normally take ± 20 sec to complete the whole process.

 Standby Diesel Generator Set
to AMF Board

Overall Interconnection P.F

Correction
Unit

CB1 Synchronizer CB2

Control & Control
CB1 Unit Load Sharing Unit CB2
Module

Metering & Metering &

Protection Protection

Gen.1 Gen.2
AVR AVR

Governor Gen.1 Gen.2 Governor

& Speed Auto Start & Speed
Remote Remote
Sensor & Sensor
Control Control
Gen.1 Synch Gen.2
Unit Unit
Starter Local Local Starter
Motor Control Control Prime
Motor
Unit Built-in Built-in Unit Mover
Rectifier Rectifier
Prime Prime
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Mover Mover
Main Healthy
Rotary Battery Gen.1 Static Gen.1 Static Battery Rotary
Charger Bank Charger Charger Bank Charger

MUVR@AMF

240V Supply from MSB

 Standby Diesel Generator Set
Manual Start-up/Shutdown
DC CONTROL SWITCH

AT
AT-1
AUTO SCR-1 AFR-2

EMERGENCY STOP ATR

NC
NO
GR1a-1

SDT

FST
TEST AFR-4 AST-1
SR-3
ST
ST-1 SYNCHRONIZING
SR-4 MODE
SELECTOR SWITCH
START P/B S7
MASTER
MANUAL MASTER
START P/B
AUTO STOP P/B
MAN OFF

AFR-3 MSR
SR MSR-1

SR-4

AST MUVR-1
FSM-4 SDT-1 ASR
FSM
FC-4 AFR-4 GENSET
START_UP
OPT
SELECTOR
SWITCH
FSR-1 EFR-1 OCR-1 RPTR-1 LOP-1 HWT-1 OSR-1
S9
FC MSR
GEN.1OFF
GEN.2

ALARM CANCEL P/B

SCR1

ACR ASR

ACR-1

GR1a CON2

FC-2 ACR-2
AR GR2a CON1

FSR-2 RESET P/B

SNC2
FST-1

FSR SNC1
EFR-2
SCR2

EF-1
GR1b
EFR
OCR-2 GR1a

OC-1 GR2a
OCR
GR2b
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RPTR-2 GR1a

RPR-1

RPTR GR2a

LOP-2 Alt-Relay No Contact

OPT-1 OPT1
RR RY RY
ive
LOP
DBT1
HWT-2 OPT2
AR1
DBT2

HWT AR2
OSR-2

OSR
 Standby Diesel Generator Set
Manual Start-up Procedure

A) Entering the Generator Room.

wear complete safety gears; coverall, hard hat, boot, ear

plug/ear guard and goggle.

ensure that the room is safe to enter by referring to the room

condition indicating light (Green), open the main door, let the
door open for a while to ensure all the gas inside the room is
purge out.

ensure the light is enough, the availability of fire extinguisher,

single line drawing and rubber mate inside the room.
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sign and record the intended activities in the record/log book.

 Standby Diesel Generator Set
Manual Start-up Procedure

B) Before operating the generator

ensure fuel for diesel engine is at operating level and both valves
for fuel inlet and return line are in open position.
do inspect on Diesel Engine
Battery bank voltage at minimum of 24VDC
Radiator water level at operating level
Lub oil at operating level and no leaking
Any loose items on top of the engine

C) Before operating the panel, ensure all breakers and switches are
in OFF position.
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 Standby Diesel Generator Set
Manual Start-up Procedure
D) Follow the procedure and refer to attach DC Control single line drawing.
Put DC Control switch to ON position and DC Selector Switch to manual
position .
Release the Emergency Stop button.
Press START button .................. Prime Mover will start.
Monitor generator metering panel.
- Adjust voltage and frequency using voltage trimmer and
speed trimmer to a required Value ( V= 415V, f= 50 Hz ).
Put a circuit breaker switch to manual mode.
Release circuit breaker Emergency Trip button.
ON Neutral Contactor or Close Neutral Knife Switch.
Press circuit breaker ON Push Button...........Circuit breaker will close.
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 Standby Diesel Generator Set
Manual Shutdown Procedure
E) Follow the procedure and refer to attach DC Control single line drawing.
Open generator circuit breaker by pressing 'OFF' push button
Press generator circuit breaker Emergency Trip Push Button to disable
closing of the circuit breaker electrically
Switch 'OFF' generator Neutral Contactor Switch of 'Open' Neutral Knife
switch
Turn the generator circuit breaker Mode Switch to 'OFF'
Press 'Emergency Stop' push button to disable starting the generator
prime mover electrically
Turn Duty Selector Switch to 'OFF'
Turn DC Control Switch to 'OFF'
Instep

In general, shut down procedure is reverse the start-up procedures unless

emergency shutdown required by pushing the emergency push button