30/08/2015FORMATION TECHNICO-COMMERCIALE (NIVEAU I)1 TECHNICAL TRAINING HANDBOOK (LEVEL I)

19/04/23 FORMATION TECHNICO-COMMERCIALE (NIVEAU I) 1

TECHNICAL TRAINING HANDBOOK

(LEVEL I)


CONTENTS

Introduction

First part : basic principles•Magnetic fields Page 11•Creation of one sinusoid Page 12•Frequency formula Page 13•Number of phases Page 14 to 15•Three phases alternators Page 16•Three phases sinusoides Page 17•A few formula to remember Page 18•Intensity Page 19•Power factor cos Page 20•Active power / Apparent power Page 21 to 22•Electric power / mechanic power Page 23•Mechanic power Page 24 to 25•Various types of power Page 26


CONTENTS

Second part : the engine•Various types of engine Page 28•Diesel engine Page 29 to 30•Air circuit Page 31•Cooling circuit Page 32 •Water cooling circuit Page 33•Various water cooling systems Page 34 to 36•Gasoil supply circuit Page 37 to 39•Various types of intake Page 40 to 44•Pre-heating Page 45•Suspensions Page 46•Speed regulation Page 47 to 48•Electronic speed regulation Page 49 to 51•Diesel engine lubrification Page 52 to 53•Engine securities Page 54•Engine output Page 55


CONTENTS

3rd Part : the alternator•Exploded view Page 57 •Voltage regulator Page 58•6 threads alternators coupling Page 59•12 threads alternators coupling Page 60•Electrical connections Page 61•Alternator protection Page 62 to 63

4th Part : control command•Introduction Page 65•Various types of panels Page 66•Manual panel Page 67•Automatic panel Page 68 to 69•ATS Page 70


CONTENTS

5th Part : Various notions•Installation Page 72 to 76 •Noise Page 77 to 78

Questions



WHAT IS A GENERATING SET ?

ENGINE ALTERNATOR CONTROL COMMAND

+ +


PRESTATIONS DE SDMO INDUSTRIES

Ventilation Engine safeties Amps

Cooling A lternator safeties KW

Speed regulation Circuit breaker control cos phi

or ATS

GAZOIL

GAZ

Customer

AIR FREQUENCY

VOLTAGE

EXHAUST

AIR

WATER

FUEL

EXHAUST

PETROL

ENTRIES OUTPUT

LOAD

S

P

E

E

D

INSTALLATION ENGINE ALTERNATOR CONTROL

Ventilation

FRAME POSITION

S.D.M.O.

Customer

normal/standby

Voltage regulation

Installator Manufacturer Manufacturer Manufacturer

CONNECTION


MAGNETIC FIELDS

The magnetic field created by the rotating magnet cuts the coils leading to induced current.

The flux direction changes (alternates) once per rotation thus creating ALTERNATIVE POWER.The number of times this is happening per second is called FREQUENCY.


MAIN FUNCTIONS

In case of mains failure

The generating set is an element of assistance replacing the faulty mains and ensuring operating of vital functions of one company, one store or one hospital…

When there is no network

It is used as the unique energy production source on one construction site, within one works or in the desert…



CREATION OF ONE SINUSOIDE

Rotor rotation degrees


FREQUENCY FORMULA

Unlike the continuous current (supplied by a battery), the ALTERNATIVE current reverses its polarities + and – 50 times / second, thus obtaining a frequency of 50 Hz (or 60 times in 60 Hz).

Formula to remember :

Frequency (Hz) = Number of poles pairs (P) x rotation speed (rp/s.)

F

= P n

If number of poles = 4 (2 pairs)Then :Engine speed = 1500 rp/mn

If number of poles = 2 (1 pair)Then :Engine speed = 3000 rp/mn

= 2 x 1500

60 sec.= 50 Hz F 1 x 3000

60 sec.50 Hz= =

F

The frequency is constant. The number of poles is constant.A genset must operate with a constant speed Importance of the frequency stability.


SHAPE OF ONE SINUSOÏDE

Positive maximum voltage

Negative maximum voltage

1 period50 ou 60 per second

1 Hz = one period / second

50 Hz = 50 periods / second


NUMBER OF PHASES

SINGLE PHASE ALTERNATORS :

Fitted with coils so that the output voltage is obtained in two terminal points.

THREE PHASES ALTERNATORS :

Fitted with 3 independent groups of coils un-phased by 120° between each others.

We can distinguish alternators according to the number of phases :


THREE PHASES ALTERNATORS


THREE PHASES SINUSOIDES

Dephased

1 period


A FEW FORMULAS TO REMEMBER

VOLTAGE:Potential difference between two threads. It is measured with a voltmeter.

INTENSITY :Current passing through one receiver within a given time period. It is measured with an anmeter in series.

Schéma Chute d’eau


INTENSITYContrary to the voltage that must remain stable, intensity varies depending on the requested load.

Intensity, in the case of some electrical engines supply, may at the start-up of these engines, become during some milliseconds from 6 to 8 times superior to the nominal intensity.

I (Amp.)I D

I N

I D = Release intensity

I N = Nominal intensity

t


POWER FACTOR In some cases of utilization (supply of electric engines), the current is « late » compared to the voltage. This « delay » is called the power factor « cos ” and its value is very important for the gensets dimensions.

The power factor cos of one electric engine is very different between the starting phase and the nominal phase.

Cos d = can reach 0,2

Cos n = 0,8 up to 0,9

π π /2 π 2 π /3 2 0 t

U θ θ U

i


ACTIVE POWER / APPARENT POWER

Electrical equipments supplied by the generating set (the « consumers ») do not give back the entire power supplied.One distinguishes then the active power from the apparent power.

Active power = Apparent power x Power factor Cos

P(kW) = V x I x cos S (kVA) = V x I

kWe = kVA x cos

a) SINGLE PHASED

b) THREE PHASED

Active power = Apparent power x Power factor Cos x 3 P (kW) = U x I x cos x 3

S (kVA) = U x I x 3 « U » = Voltage between phase

« V » = Voltage between phase and neutral.


ACTIVE POWER / APPARENT POWER

Active P.(kW) Apparent P.

(kVA)

Active power = Apparent power x Power factor Cos

P = U x I x cos

kWe = kVA x cos


ELECTRIC POWER / MECHANIC POWER

Alternators do not transform the entire power supplied. Their performance () is around 0,9.

Mechanic power = Electric power :

P engine = elec. P. :

(kW = kWe : )


MECHANIC POWER : UNITS

The engines power rating is expressed with various units depending on the countries.

•In CV (« horse power »)

•In « British horse power »

1 CV = 0,736 kW

1 BHP = 0,746 kW


MECHANICAL POWER RATING : CALCULATION OF DEMAND

We can determine the requested power for the engine from the demand in electric power

P eng. = U x I x cos :

Theoretical example : one installation requesting- 500 amps- 380 volts- Power factor 0,8- Performance 0,9

In Kilowatt : 168,9 kWIn HP : 229,5 Cv

In « British Horse Power » : 226,4 BHP


VARIOUS TYPES OF POWER RATINGS

Power ratings for the GENERATING SET application are defined in the ISO 8528 international standard.

VARIOUS TYPES OF POWER RATINGS

PRP (Prime Power) : formerly known as Continuous PowerAvailable power (under variable load) 24H/24 with possibility of an overload of 10 % every 12 hours.

ESP (Emergency Standby Power) : formerly known as Standby PowerPower available (under variable load) limited to one 500 hours operating duty per year without possibility of overload of 10% every 12 hours.

COP (Continuous Power) : power rating available (under constant load) 24H/24.

STANDARD



VARIOUS TYPES OF ENGINES

COMBUSTIBLE - Petrol- Diesel- Gaz (GPL, natural gaz , biogaz)- Domestic Diesel oil- Bunker C fuel

OPERATING CYCLES - 2 strokes (mix of petrol + oil) - 4 strokes (pure combustible)

SPEED- Fast engines 3000 / 3600 rp/mn (50/60 Hz) – standby duty- semifast engines1500 / 1800 rp/mn – continuous duty- Slow engines 750 / 1000 / 1200 rp/mn – energy production / high power ratings


DIESEL ENGINEEXHAUST OUTLET

HOT WATER OUTLET

FANTURBOCOMPRESSOR

ENGINE POWER OUTPUT

AIR INLET

FUEL FILTER

OIL FILTER

STARTER

CHARGING ALTERNATOR

WATER PUMP


DIESEL ENGINEEXHAUST OUTLET

HOT WATER OUTLET

FAN

TURBOCOMPRESSOR

AIR INTAKE

ENGINE POWER OUTPUT

COLD WATER INLET


AIR SYSTEM

AIR INTAKEEXHAUST OUTLET


COOLING SYSTEMS

There are various types of cooling systems (see drawings on next pages) :

• AIR COOLING

• WATER COOLING

SIMPLE CIRCUIT

DOUBLE CIRCUIT

TURBO NOT COOLED

TURBO COOLED

TURBO COOLED


WATER COOLING SYSTEM

RADIATOR

WATER PUMP

WATER TANK


VARIOUS TYPES OF WATER COOLING SYSTEMS

1) A single water system Turbocompressor John Deere « T » Turbo with water cooled overfeeding air supply (see B) Volvo « TWD »



2) Double circuit Turbo with water cooled overfeeding air supply (see B) NB : these engines are not advised for installations with separated air coolers John Deere « H »

Volvo « TAD » and MTU – Series 2000



3 ) Water double circuit HT and BT MTU : 4000 Series


FUEL SUPPLY CIRCUIT

Separated fuel tank Integrated fuel tank


FUEL SUPPLY CIRCUIT

Tuyauterie fuel retour

Ligne d’injection

Valve de fermeture

Vanne de vidangeCloisons de séparation

Orifice remplissage et

bouchon

Tuyauterie fuel aller

eventTrou d’homme

¼ du volume du réservoir

5% du volume du réservoir

Filtre fuel

Pompe à injection

Filtre fuel optionnel / séparateur

d’eau


FUEL SUPPLY CIRCUIT

Fuel filter

Mechanic fuel pump (JOHN DEERE)

Electric fuel pump (MITSUBISHI)


VARIOUS TYPES OF INTAKE

• One engine creates a mix air / combustible in proportions enabling the complete combustible combustion.

• Ideal mixture : 1 volume of fuel (combustible) implies 35 volumes of air.

• To increase the engine maximal power, one needs to increase both fuel and air quantity.


• The maximum air volume that can be assimilated by an engine equals its cylinder capacity.

• For one given cylinder capacity, the admitted air intake quantity is :- Proportional to its pressure- Conversely proportional to its temperature

• To increase the power, one has to increase the air admitting pressure to lower its temperature




• In the basic engine, plungers, suck the air getting down in the cylinders :

ENGINE « NATURAL SUCTION »


• To increase the intake air pressure one uses a turbocharger : exhaust gaz drive one turbine

« TURBO » ENGINE



• To lower the air temperature, an intercooler (air or water) is mounted in the intake circuit.

INTERCOOLER ENGINE



PRE-HEATING

Pre-heating of water cooled engines is ensured through a resistor mounted in the water system to maintain the water temperature to its nominal value (x°C).

The resistor is supplied in single phase or three phases (depending on the type). Its power is of 0,3 up to 9 kW.

The resistor is supplied by the mains.

In order to preserve its longevity, the resistor is in some cases equipped with a thermoregulator.


SUSPENSIONS

Suspensions (rubber blocks) are intended to reduce vibrations between two parts.

Usually used between :

- skeleton genset (engine + alternator) and the frame

- Radiator and frame

The measuring unit for suspensions is the shore.


SPEED REGULATION

The regulation is a device which purpose is to maintain or vary an operating element on a machine : current, voltage, frequency, speed, pressure, power rating, output, etc…

The speed control is the key to the thermal engine regulation.

The speed regulation will act on the quantity of energy injected to the engine (fuel, gaz, petrol) to adapt it to the load in order to maintain the engine speed within pre-determined limits.

As seen already , the engine speed must be constant. To achieve this it is necessary to adjust it.


SPEED REGULATION

- Mechanical : the regulator is composed of flyweights acting under the effect of the centrifugal force.

Precision is of +- 3%

- Electronics : see hereafter

Precision is of +- 1%

LEVIER DE COMMANDE CARBURANT

AXE MOBILE

MASSELOTTE REFERENCE MASSELOTTE

AJUSTAGE VITESSE

RESSORT DE REGULATION ET DE STATISME

The mechanical regulation

There are two types of speed regulations :


THE ELECTRONIC SPEED REGULATION

The pick-up sensor measures the engine speed and sends this information to the electronic regulation.

The actuator is a mechanical system acting on the injection pump. The actuator control is managed with the electronic governor.

Electricactuator

Pick-up

Speedcontrol unit


THE ELECTRONIC SPEED GOVERNOR

Actuator

Pick-up


THE ELECTRONIC SPEED GOVERNOR

Speed governor (panel opened)


LUBRIFICATION OF THE DIESEL ENGINE

Lubrification has 3 goals : lubrification of moving parts in friction- Bearings- Bearing surfaces- Gearing- Segmentation and liners Cooling of parts submitted to temperature- Turbo- Plungers cap- Injection mump Removal of impurities resulting from wear and combustion


DIESEL ENGINE LUBRIFICATION

Drain pump Oil filter


ENGINE SAFETIES

On modern engines, numerous securities are available . Amongst the most common let’s mention :- Oil pressure- Water temperature- Water level- Overspeed- Level of combustible But also :- Oil temperature, combustible pressure , combustible temperature, etc…

-Safeties can have one or two thresholds (alarm or fault)- 1 threshold : Alarm or fault = signals the fault to the user or stops the engine - 2 thresholds : Alarm and fault = signals the fault to the user and stops the engine


ENGINE PERFORMANCE

COMBUSTION HEAT DISTRIBUTION

3%

34%

23%40%

Effective power Exhaust gas

Cooling system Radiation and convection



THE ALTERNATOR : EXPLODED VIEW


VOLTAGE REGULATION

In order to supply the most stable voltage , the alternator is fitted with a voltage regulator.

Depending on the requested voltage precision, usually between +/- 5% up to +/- 1%, regulators are +/- complex.

For example, all gensets from the ranges MONTANA, NEVADA, ATLANTIC and EXEL are fitted with electronic voltage regulators with a precision of +/- 1%.


6 THREADS ALTERNATORS COUPLING

STAR CONNECTION DELTA CONNECTION

230 / 400 V 3 PHASES + NEUTRAL

230 V 3 PHASES


12 THREADS ALTERNATORS COUPLINGSERIES DELTA CONNECTIONS

PARALLEL STAR COUPLING

SERIE STAR COUPLING


ELECTRICAL CONNECTIONS

Each genset is fitted with one terminal box which purpose is to :

- Connect the genset circuit-breaker to the utilization- Connect the genset earth terminal to the installation earth- Connect the genset auxiliaries (battery charger, mains detection, pre-heating, etc…)- Connect the modules ( remote transfert, safety genset, etc…)

Manual

Auto


ALTERNATOR PROTECTION

The alternator protection is ensured with the CIRCUIT-BREAKER.

Definition : The circuit-breaker is an electric equipment which role is to : - Isolate the genset from its utilization (power cut device) - Ensure the magnetic protection (short-circuit) - Ensure the thermal protection (overcurrent)

Control :There are circuit breakers- with manual command- with electrical command.

MAGNETO-THERMAL PROTECTION


ALTERNATOR PROTECTIONThere are two types of MANUFACTURE :

-MODULARCasted casing, maximal intensity : 125 Amps

-COMPACTPossibility to adjust the magnetic and thermal threshold from 125 Amps up to several thousand of Amps.

NUMBER OF POLES :

-BIPOLAR ( 2 poles) single phase (1 phase + neutral)

-THREE POLAR (3 poles) three phases without neutral (3 phases)

-FOUR POLAR (4 poles) Three phases with neutral (3 phases + neutral)

Disjoncteur modulaire

Disjoncteur compact



INTRODUCTION

The generating set control command is ensured with the electric panel enabling :

CONTROLTo watch the various genset parameters

-Mechanical (pressure, temperatures, levels, etc…)-Electrical (voltage, intensity, power ratings, etc…)

COMMANDTo change the status of the genset (start-up, standstill, coupling, etc…)Command is ensured either through :

- Ignition key- Pushing-button- keyboard


VARIOUS TYPES OF PANEL

•MANUAL PANEL (M50 or M150) :To start-up the generating set manually with an ignition key.

•AUTOMATIC PANEL (TELYS) :The automatic panel enables to start the generating set without human intervention closing-up the external contact. It also enables to start-up the genset in manual mode.

•COUPLING (PROCESS) :To put in parallel 2 or several generating sets between each others or networkedInterest : In most cases, this enables to add their respective power

There are three types of panels :


MANUAL PANEL : M50 OR M150

M50

M150

Manual start panels fitted on the generating set side.

These panels include :

- Measuring / control equipments(ignition key, testing lights, emergency stop button, hours counter…)

- Operating lights(charging alternator fault, oil pressure failure, water temperature fault…)


AUTOMATIC PANEL : TELYS

This control command panel integrates all the genset’s controls, securities and status display.

With a very user-friendly man/machine interface , 150 configuration parameters available in reading mode to check the genset operating status or through access code for their modification.

All gensets from 16 kVA onwards can be equipped.


AUTOMATIC PANEL : TELYS

The display module is comonly called interface man/machine .It is the only visible contact between the user and the generating set.28 pulse keys diameter 10 and diametrer 13, finger-guided for a better centring

4 VISUALISATION keys for electrical values and engine parameters

8 VISUALISATION LEDsFor alarms, defects, status- oil pressure defect- water temperature defect- no-start fault- overspeed defect- genset ready to supply- charging alternator failure- general alarm - general failure

2 keys OPENING and CLOSING genset output with integrated LED 2 RESET keys

(FAILURE and TEST LEDs)

15 PROGRAMMING keys

1 POWER-ON key with integrated LED (after

automatic extinction)

4 selecting keys SELECTION for operating

modes with integrated LEDs integrated for selection

LCD screen with integrated back light , with 8 lines of 21 characters


ATS’s

Definition : The ATS enables to select one source of energy amongst 2 existing. It includes two contactors (2, 3 or 4 poles).The ATS is separated from the genset and is usually fitted the closest possible to the installation circuit-breaker.

Protection : -MechanicalA locking system avoids the locking or simultaneous opening of both contactors.-ElectricalEach contactor is protected with one thermal relay (overcurrent)

E le c tr ic i téd e F r an c e

ATS

NETWORK



INSTALLATION

Installation of one generating set must meet with certain rules which must be strictly followed to obtain a correct operating of the equipment

The non-respect of the fundamental principles exposes the whole installation to damages and abnormal wear and tear.


INSTALLATION : A FEW RULES TO RESPECT

INSTALLATION ROOMIt must be located nearby the electric panel. The choice of the local must take into account :- Noise disturbance- Combustible supply- Burnt gaz exhaust- Access to the genset for maintenance.

Doors opening impossible. Maintenance and repair

difficult

Exhaust and ventilation correct

Ground uneven : genset unstable position

Plan for example :- One anti-vibrations flagstone underneath the generating set, when located near sensitive premises.- sound traps fitted within the inlet and outlet air ducts.- Exhaust silencers adapted


INSTALLATION : A FEW RULES TO RESPECT

VENTILATION

The heat released by the generating set must be evacuated outside the local, in order to ensure a good operating.

These calories released from the generating set are from various origins : - Cylinders cooling- Dissipation of the engine block as well as the exhaust pipe- Dissipation of the alternator

It is necessary to equip the local with air inlets and outlets adapted to conditions of use and to the cooling system.

Insufficient ventilation would provoke an increase of the ambient temperature leading to at least a drop in power , indeed the genset shutdown.


THE GENERATING SET INSTALLATION

COMBUSTIBLEOne has to respect certain rules regarding distribution and storage.One usually fits a daily tank as well as a storage tank on fixed installations. Both these tanks can become one if the genset fuel consumption is low.

EXHAUST OF BURNT GAZ

Some constraints must be respected :-Load drops -Isolation-Suspensions-Noise level-Air pollutionOne must remember that the more winding a circuit is the more load drops it provokes.


THE GENERATING SET INSTALLATION

START-UPThe type of starting systems directly depends on the engine temperature conditions. Therefore for starts with very low temperatures one has to foresee start-up devices such as intake air pre-heating, gazoil pre-heating…In some cases, two starters are fitted on the generating set, the second one acting as the standby one.

COOLING

Three types of heat production must be evacuated or recovered :- engine cooling water- ventilating air from the local- exhaust gazSpecific systems are fitted in order to canalize this heat : radiator, air cooler, sewage water exchanger , ventilation…


NOISE LEVEL

Noise level is expressed in decibels (dB). Some examples :

Levels of acoustic

pressure in dB

Examples

120 Boiler worksEngine test benchAir hammer Pain threshold

100 Sales yarn spinningInside of a busCar hooter

80

4020

ConversationStreet with a poor traffic Radio of poor intensityQuiet countryside


NOISE LEVEL

The new noise level standard requested by the directive2000 / 14 CE is in force within the European Union and affiliated countries. It sets a limit regarding the acoustic power expressed in LWA (and no longer a noise level limit ) to every generating sets, the generating set operating at ¾ of its nominal power.The authorized acoustic power variates depending on the power rating portion of the equipment according to the following distribution :

GENSET Power rating

Noise level

From 0 up to 2 kW LWA 97

From 2.1 up to 3.1 kW LWA 98

From 3.2 up to 10 kW LWA 99

From 10.1 up to 31.9 kW

LWA 98

From 32 up to 316 kW LWA 99

From 317 up to 400 kW

LWA 100

Above 400 kW No limits

The acoustic power takes into account the noise level but also the equipment measuring surface.Limiting the acoustic power and no longer the pressure enables to set comparison equivalences between a portable genset and a soundproofed container.



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30/08/2015FORMATION TECHNICO-COMMERCIALE (NIVEAU I)1 TECHNICAL TRAINING HANDBOOK (LEVEL I)