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8/4/2019 Generator, Part and How to Start
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MECHANICAL SYSTEMS MAINTENANCE
COURSE WORK
SUBMITTED BY
IMASUEN EMMANUEL OSARETIN
F / HD / 09 / 3440451
DEPARTMENT
OF
INDUSTRIAL MAINTENANCE
ENGINGEERING
YABA COLLEGE OF TECHNOLOGY
SUBMITTED
TOEngr. UDOH
DATE: 12TH
AUGUST 2011.
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1.0 DEFINITION OF GENERATOR
Generator is
an engine or devices that convert mechanical energy into electrical energy by electromagnetic
induction. A generator forces electrons in the windings to flow through the external electrical
circuit. It is somewhat analogous to a water pump, which creates a flow of water but does not
create the water inside. The source of mechanical energy may be a reciprocating or turbine
steam engine, water falling through a turbine or waterwheel, an internal combustion engine, a
wind turbine, a hand crank, compressed air or any other source of mechanical energy.
The reverse conversion of electrical energy into mechanical energy is done by an electric motor,
and motors and generators have many similarities. In fact many motors can be mechanically
driven to generate electricity, and very frequently make acceptable generators.
Before the connection between magnetism and electricity was discovered, electrostatic
generators were invented that used electrostatic principles. These generated very high voltages
and low currents. They operated by using moving electrically charged belts, plates and disks to
carry charge to a high potential electrode. The charge was generated using either of two
mechanisms:
Electrostatic induction The triboelectric effect, where the contact between two insulators leaves them charged.
Because of their inefficiency and the difficulty of insulating machines producing very high
voltages, electrostatic generators had low power ratings and were never used for generation of
commercially significant quantities of electric power.
http://en.wikipedia.org/wiki/Electronshttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wiktionary.org/wiki/prime_moverhttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wikipedia.org/wiki/Hydropowerhttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Wind_turbinehttp://en.wikipedia.org/wiki/Crank_%28mechanism%29http://en.wikipedia.org/wiki/Compressed_airhttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Magnetismhttp://en.wikipedia.org/wiki/Electricityhttp://en.wikipedia.org/wiki/Electrostatic_generatorhttp://en.wikipedia.org/wiki/Electrostatic_generatorhttp://en.wikipedia.org/wiki/Electrostatichttp://en.wikipedia.org/wiki/Voltagehttp://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/Electric_chargehttp://en.wikipedia.org/wiki/Electrostatic_inductionhttp://en.wikipedia.org/wiki/Triboelectric_effecthttp://en.wikipedia.org/wiki/Electrical_insulationhttp://en.wikipedia.org/wiki/Electrical_insulationhttp://en.wikipedia.org/wiki/Triboelectric_effecthttp://en.wikipedia.org/wiki/Electrostatic_inductionhttp://en.wikipedia.org/wiki/Electric_chargehttp://en.wikipedia.org/wiki/Electric_currenthttp://en.wikipedia.org/wiki/Voltagehttp://en.wikipedia.org/wiki/Electrostatichttp://en.wikipedia.org/wiki/Electrostatic_generatorhttp://en.wikipedia.org/wiki/Electrostatic_generatorhttp://en.wikipedia.org/wiki/Electricityhttp://en.wikipedia.org/wiki/Magnetismhttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Compressed_airhttp://en.wikipedia.org/wiki/Crank_%28mechanism%29http://en.wikipedia.org/wiki/Wind_turbinehttp://en.wikipedia.org/wiki/Internal_combustion_enginehttp://en.wikipedia.org/wiki/Hydropowerhttp://en.wikipedia.org/wiki/Steam_enginehttp://en.wiktionary.org/wiki/prime_moverhttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wikipedia.org/wiki/Electrical_circuithttp://en.wikipedia.org/wiki/Electrons8/4/2019 Generator, Part and How to Start
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Dynamo Electric Machine: A dynamo machine consists of a stationary structure, which provides
a constant magnetic field, and a set of rotating windings which turn within that field. On small
machines the constant magnetic field may be provided by one or more permanent magnets;
larger machines have the constant magnetic field provided by one or more electromagnets,
which are usually called field coils. Large power generation dynamos are now rarely seen due to
the now nearly universal use of alternating current for power distribution and solid state
electronic AC to DC power conversion. But before the principles of AC were discovered, very
large direct-current dynamos were the only means of power generation and distribution. Now
power generation dynamos are mostly a curiosity.
1.1 ALTERNATORWithout a commutator, a dynamo becomes an alternator, which is a synchronous singly-fed
generator. When used to feed an electric power grid, an alternator must always operate at a
constant speed that is precisely synchronized to the electrical frequency of the power grid. A DC
generator can operate at any speed within mechanical limits, but always outputs direct current.
The primary advantage of the alternator is that the field windings can be swapped from the
exterior non-rotating shell to the interior rotating shaft, and the current producing windings are
on the exterior shell. This allows for extremely thick current producing windings that stay in a
fixed position with permanent non-moving wiring.
The rotating field coil by contrast can operate at high voltage and low current so that only
small, simple, and low-cost slip rings are needed. For example, automotive alternators
commonly only use a single carbon brush to supply power to the field coil; the other end of the
coil is attached to the vehicle ground by way of the rotor bearings.
By using a rotary transformer to convey power to the rotating field coil, no rubbing physical
contacts are needed at all, and the alternator becomes an almost maintenance-free power
generation device.
http://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Solid_state_%28electronics%29http://en.wikipedia.org/wiki/Commutator_%28electric%29http://en.wikipedia.org/wiki/Alternatorhttp://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Grid_%28electricity%29http://en.wikipedia.org/wiki/Rotary_transformerhttp://en.wikipedia.org/wiki/Rotary_transformerhttp://en.wikipedia.org/wiki/Grid_%28electricity%29http://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Singly-fed_electric_machinehttp://en.wikipedia.org/wiki/Alternatorhttp://en.wikipedia.org/wiki/Commutator_%28electric%29http://en.wikipedia.org/wiki/Solid_state_%28electronics%29http://en.wikipedia.org/wiki/Alternating_current8/4/2019 Generator, Part and How to Start
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1.2 OTHER ROTATING ELECTROMAGNETIC GENERATORSOther types of generators, such as the asynchronous or induction singly-fed generator, the
doubly-fed generator, or the brushless wound-rotor doubly-fed generator, do not incorporate
permanent magnets or field windings (i.e., electromagnets) that establish a constant magnetic
field, and as a result, are seeing success in variable speed constant frequency applications, such
as wind turbines or other renewable energy technologies. The full output performance of any
generator can be optimized with electronic control but only the doubly-fed generators or the
brushless wound-rotor doubly-fed generator incorporate electronic control with power ratings
that are substantially less than the power output of the generator under control, a feature
which, by itself, offers cost, reliability and efficiency benefits.
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2.0 PARTS OF A GENERATOR
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1. ROTOR ASSY2. STATER ASSY3. HOLDER ASSY,BRUSH4. FRAME ASSY., DRIVE SIDE END5. B/BRG RAD N/COM6. ALTERNATOR7. INS,TERMINAL8. INS,TERMINAL9. FRAME ASSY., RECTIFIER SIDE END10.FRAME,SIDE END12.FELT,OIL13.WASHER,INSULATION15.RECTIFIRE ASSY16.COVER, FELT17.COLLAR,SPACE20.PLATE,RETAINER21.PULLEY22.BOLT,THROUGH23.NUT,PULLEY LOCK24.SCREW,PAN,5X1426. NUT,HEX.,6MM27.WASHER,PLAIN,5MM28.WASHER,SPRING 5MM29.SPG/WASHER,6MM30.
SPG-WASHER 14MM
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The two main parts of a generator or motor can be described in either mechanical or electrical
terms.
Mechanical:
Rotor: The rotating part of an electrical machine Stator: The stationary part of an electrical machine
Electrical:
Armature: The power-producing component of an electrical machine. In a generator,alternator, or dynamo the armature windings generate the electric current. The
armature can be on either the rotor or the stator.
Field: The magnetic field component of an electrical machine. The magnetic field of thedynamo or alternator can be provided by either electromagnets or permanent magnets
mounted on either the rotor or the stator.
Because power transferred into the field circuit is much less than in the armature circuit, AC
generators nearly always have the field winding on the rotor and the stator as the armature
winding. Only a small amount of field current must be transferred to the moving rotor, using
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slip rings. Direct current machines (dynamos) require a commutator on the rotating shaft to
convert the alternating current produced by the armature to direct current, so the armature
winding is on the rotor of the machine.
2.1 Excitation
An electric generator or electric motor that uses field coils rather than permanent magnets
requires a current to be present in the field coils for the device to be able to work. If the field
coils are not powered, the rotor in a generator can spin without producing any usable electrical
energy, while the rotor of a motor may not spin at all.
Smaller generators are sometimesself-excited, which means the field coils are powered by the
current produced by the generator itself. The field coils are connected in series or parallel with
the armature winding. When the generator first starts to turn, the small amount of remanent
magnetism present in the iron core provides a magnetic field to get it started, generating a
small current in the armature. This flows through the field coils, creating a larger magnetic field
which generates a larger armature current. This "bootstrap" process continues until the
magnetic field in the core levels off due to saturation and the generator reaches a steady state
power output.
http://en.wikipedia.org/wiki/Slip_ringhttp://en.wikipedia.org/wiki/Commutator_%28electric%29http://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Direct_currenthttp://en.wikipedia.org/wiki/Self-excitationhttp://en.wikipedia.org/wiki/Self-excitationhttp://en.wikipedia.org/wiki/Self-excitationhttp://en.wikipedia.org/wiki/Remanent_magnetismhttp://en.wikipedia.org/wiki/Remanent_magnetismhttp://en.wikipedia.org/wiki/Saturation_%28magnetic%29http://en.wikipedia.org/wiki/Saturation_%28magnetic%29http://en.wikipedia.org/wiki/Remanent_magnetismhttp://en.wikipedia.org/wiki/Remanent_magnetismhttp://en.wikipedia.org/wiki/Self-excitationhttp://en.wikipedia.org/wiki/Direct_currenthttp://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Commutator_%28electric%29http://en.wikipedia.org/wiki/Slip_ring8/4/2019 Generator, Part and How to Start
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Very large power station generators often utilize a separate smaller generator to excite the
field coils of the larger. In the event of a severe widespread power outage where islanding of
power stations has occurred, the stations may need to perform a black start to excite the fields
of their largest generators, in order to restore customer power service.
2.2 DC EQUIVALENT CIRCUIT
Equivalent circuit of generator and load.
G = generator
VG=generator open-circuit voltage
RG=generator internal resistance
VL=generator on-load voltage
RL=load resistance
The equivalent circuit of a generator and load is shown in the diagram to the right. The
generator's VG and RG parameters can be determined by measuring the winding resistance
(corrected to operating temperature), and measuring the open-circuit and loaded voltage for a
defined current load.
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2.3 ENGINE-GENERATORAn engine-generator is the combination of an electrical generator and an engine (prime mover)
mounted together to form a single piece of self-contained equipment. The engines used are
usually piston engines, but gas turbines can also be used. Many different versions are available -
ranging from very small portable petrol powered sets to large turbine installations.
2.4 HUMAN POWERED ELECTRICAL GENERATORSA generator can also be driven by human muscle power (for instance, in field radio station
equipment). Human powered direct current generators are commercially available, and have
been the project of some DIY enthusiasts. Typically operated by means of pedal power, a
converted bicycle trainer, or a foot pump, such generators can be practically used to charge
batteries, and in some cases are designed with an integral inverter. The average adult could
generate about 125-200 watts on a pedal powered generator, but at a power of 200 W, a
typical healthy human will reach complete exhaustion and fail to produce any more power after
approximately 1.3 hours.[4]
Portable radio receivers with a crank are made to reduce battery
purchase requirements, see clockwork radio.
2.5 LINEAR ELECTRIC GENERATOR
In the simplest form of linear electric generator, a sliding magnet moves back and forth through
a solenoid - a spool of copper wire. An alternating current is induced in the loops of wire by
Faraday's law of induction each time the magnet slides through. This type of generator is used
in the Faraday flashlight. Larger linear electricity generators are used in wave power schemes.
2.6 TACHOGENERATORTachogenerators are frequently used to power tachometers to measure the speeds of electric
motors, engines, and the equipment they power. Generators generate voltage roughly
proportional to shaft speed. With precise construction and design, generators can be built to
produce very precise voltages for certain ranges of shaft speeds
http://en.wikipedia.org/wiki/Enginehttp://en.wikipedia.org/wiki/Prime_moverhttp://en.wikipedia.org/wiki/Petrolhttp://en.wikipedia.org/wiki/DIYhttp://c/Users/opeyemi/Desktop/electrical%20gen%20harrison%201.htm%23cite_note-3http://c/Users/opeyemi/Desktop/electrical%20gen%20harrison%201.htm%23cite_note-3http://c/Users/opeyemi/Desktop/electrical%20gen%20harrison%201.htm%23cite_note-3http://en.wikipedia.org/wiki/Clockwork_radiohttp://en.wikipedia.org/wiki/Magnethttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Faraday%27s_law_of_inductionhttp://en.wikipedia.org/wiki/Faraday_flashlighthttp://en.wikipedia.org/wiki/Wave_powerhttp://en.wikipedia.org/wiki/Tachometerhttp://en.wikipedia.org/wiki/Tachometerhttp://en.wikipedia.org/wiki/Wave_powerhttp://en.wikipedia.org/wiki/Faraday_flashlighthttp://en.wikipedia.org/wiki/Faraday%27s_law_of_inductionhttp://en.wikipedia.org/wiki/Alternating_currenthttp://en.wikipedia.org/wiki/Solenoidhttp://en.wikipedia.org/wiki/Magnethttp://en.wikipedia.org/wiki/Clockwork_radiohttp://c/Users/opeyemi/Desktop/electrical%20gen%20harrison%201.htm%23cite_note-3http://en.wikipedia.org/wiki/DIYhttp://en.wikipedia.org/wiki/Petrolhttp://en.wikipedia.org/wiki/Prime_moverhttp://en.wikipedia.org/wiki/Engine8/4/2019 Generator, Part and How to Start
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3.0 COMMON FAULTS IN A GENERATORThe major faults in case of generator can be classified as:
(a)Failure of prime movers:
Whenever there is a fault on prime mover side the conversion of mechanical power to electrical
power stops. If this generator works in parallel with other generator sets it will start working as
a synchronous motor running at synchronous speed and the prime mover will act as load on it.
When generator starts running as a motor it is called as inverted operation. If the fault is
cleared the generator will automatically pick up generation.
(b)Failure of excitation:
The turbo generator set under consideration works in parallel with other sets. If the field of the
generator is interrupted it will continue to operate as an induction generator-delivering load at
very low power factor. So the other generators will be overloaded, as they will have to supply
the load of this faulty generator. This may lead to decrease the supply voltage and the stability
of the system will be affected.
The fault generator can be switched off but for an automatic operation an under current relay
in conjunction with time lagged tripping and time lagged reinforcing relay as shown in fig 1 can
be used.
The under current relay is a moving coil type instrument and is fed through a shunt in the field
circuit and its provided with a double trip circuit contact. When there is field circuit failure
under current relay is no longer energized and the action moves up the operating armature up
and in doing so it stops supply to time lagged reinforcing and trip relays, thus both of theses
relays are operated simultaneously.
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(a)Failure of insulation in the stator or interconnecting cable can be further divided into:
i.Interphase short circuits These are accompanied by large fault currents, the values of
which are dependent upon the capacity of the system to which the alternator is
connected, the nature of inter connection to the system and the moment at which the
short circuit occurs.
ii.Single phase to earth fault This will lead top the burning of alternator winding when
leakage current exceeds even 5 amps. This current is dependent upon the nature of
neutral connection, i.e. whether its earthed or unearthed.
iii.Inter turn faults In this type of fault short circuit exists between the turns of the same
phase or between turns of parallel branches in the same phase. The magnitude of the
fault current depends on the number of turns shorted. This is a dangerous type of
fault
iv.Earth fault on the rotor Shorting of the rotor at one point to earth in itself does not
cause any damage. But the appearance of another fault to earth may sharply disturb
the magnetic flux distribution, which will lead to unequal voltages being induced in the
stator and increased vibration in the alternator.
3.1 FAULTS AND WARNINGSDiesel engine common fault location list
Fault phenomena
Fault Location Fault phenomena
Fault Location
Starting problem of
diesel engine
1Oil supply system
2Distribution
Mechanism
3Starting system
4Piston cylinder
liner
5Intake and exhaust
Black smoke 1Oil supply
system
2Distributio
n Mechanism
3Piston
cylinder
liner
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system
6Lubricating
system
7Superchargingsystem
8Crank-link
mechanism
9Environment factor
4Intake
system
5Superchargi
ng system6Equipment
factor
Diesel engine overheat
1Fan system
2Injection system
3Lubricating
system
4Distribution
Mechanism
5Cooling surface
6Environment factor
White smoke
1Oil supply
system
2Superchargi
ng system
3Piston
cylinder
liner
4Distributio
n Mechanism5Environment
factor
Diesel engine
underpowered
1Oil supply system
2Distribution
Mechanism3Piston cylinder
liner
4Supercharging
system
5Intake and exhaust
system
Blue smoke1Piston
cylinderliner
2Lubricating
system
3Superchargi
ng system
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6Environment
factor
7Fuel system
The oil pressure of
diesel engineis not
normal
1Lubricating
system
2Crank-link
mechanism
3Cooling system
Noise
1Distributio
n Mechanism
2Combustion
system
3Crank-link
mechanism4Other
factor
The fuel consumption
of diesel engineis
too high
1Oil supply system
2Distribution
Mechanism
3Piston cylinder
liner
4Supercharging
system
5Other factor
The speed is
not normal
1Governor of
injection
2Fuel
system
3Equipment
factor
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Under certain conditions, the Auto Gen Start generates a fault or warning message. These messages
appear on the System Control Panel. This section describes how to respond to fault and warning
messages when they appear.
When a fault or warning message appears, you can acknowledge the message by pressing Enter on the
System Control Panel. This action removes the message from the screen. After acknowleding the
message, you can proceed configuring or operating the Auto Gen Start. This action does not clear the
condition that caused the fault or warning, Self-clearing warnings If unacknowledged, some warnings
may clear themselves if the condition that generated the message goes away. For example, if the Auto
Gen Start fails to start the generator, warning message W202 appears. However, if the generator starts
on the next start try, the message goes away. Clearing faults to clear active Auto Gen Start faults,
highlight Clear Faults on the Automatic Generator Start menu and press Enter . Multiple faults and
warnings if several fault or warning messages occur before you can acknowledge or clear them, they are
displayed together on a fault list or a warning list. These lists contain messages from every Xanbus-
enabled device, not just the Auto Gen Start. You can select a message and view its details from the fault
list or warning list.
To view a message from a fault list or warning list:
1. On the list, use the up arrow or down arrow button to highlight the message you want to view.
2. Press Enter. The complete message appears. After viewing the message, you can return to the fault
list or warning list by pressing Exit or continue to the menu for the device that caused the fault or
warning by pressing Enter. Each time you return to the list after viewing a complete message, the
viewed message is removed from the list. If you have left the fault list or warning list, you can view them
at any time from the System Settings menu.
To view a fault list or warning list:
1. On the Select Device menu, highlight System and press Enter.
2. On the System Settings menu, highlight View Fault List or View Warning Messages
Table provides details and suggests action for Auto Gen Start warnings.
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4.0 CALIBRATION OF GENERATORCalibration helps a power plant in maintaining or even improving safety, as well as in meeting
national and international standards. However, calibration is also a matter of profitability. By
using high-accuracy calibration equipment, the accuracy of vital measurements can be
maintained on a required level and the plant can increase its annual power production
capability.
4.1 POWER AND ENERGY OPERATIONSElectric, natural gas, oil, and other energy meters directly influence revenue. Because of rising energy costs, power
and energy operations carefully scrutinize these devices to ensure that they accurately account for their energy
and bill correctly. Calibration issues that arise in the power and energy industries are also similar to those faced in
power and energy consumer industries. Although not directly billable, internal energy consumption and its
allocation can make or break a seemingly viable product.
4.2CALIBRATION REQUIREMENTS FOR INCREASING PLANT PRODUCTIVITY AND SAFETYAccurate measurements can allow increased energy production. Therefore, high-accuracy calibrators
such as the Beamex MC5 Multifunction Calibrator, have a significant role in improving plant
productivity. For instance, reducing the measurement uncertainty in a nuclear power plant can
potentially increase electrical production up to nearly 2 percent.
The economic consequence of this seemingly small power increase typically increases revenues by many
millions of dollars because the total value of power and energy flows can easily be over a billion dollars
per year. Therefore, seemingly small measurement errors caused by poor calibration techniques can
potentially result in major revenue losses. With these improved measurements comes the additional
requirement of maintaining calibration equipment and techniques that are comparable with the
improved instrument performance with traceability to national and international standards, such as
NIST, ISO 9001 and ISO 17025Improving power plant performance through calibration
Safety is based upon never exceeding established operating limits such as reactor power and cooling
capacity. A byproduct of improved calibration is an improvement in safety and fewer problems because
instruments periodically calibrated to more accurate standards reduce the risk associated with these
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measurements. In addition, improved calibration standards can be used to detect instrument
degradation sooner.
4.3 POWER AND ENERGY INDUSTRY CALIBRATIONField calibration allows the in-situ calibration of instruments that measure electrical parameters such as
voltage, current
Increasing annual production with high-accuracy calibrators
Enhanced calibration equipment performance makes it possible to perform calibration operations with
better uncertainty levels, with which it is possible to improve production results. This is achieved by
using the Beamex MC5 high-accuracy multifunction calibrators for calibration in the power plant.
By improving the measurement of the parameters from 2 % to 0.4 % (parameters associated with thedetermination of reactor power), enabled the power in each unit to be increased by 1.6 %. This has a
very significant effect on the annual production.
The performance of natural gas and oil flow measurement systems can also influence billing. In
particular, the calibration of flow meters used to check the custody transfer flow meters is important.
Small variances between these flow meters can result large billing differences and could indicate a
problem with the custody transfer flow meter. Field calibrators allow these calibrations to be performed
accurately and more efficiently, especially when the instrument is installed with poor personnel access.
Many electricity, steam, cogeneration, ethanol, bio-diesel, refinery and other types of energy plants use
these measurements to develop process heat and material balances that describe their processes. Heat
and material balances can be instrumental in locating opportunities that can save millions of dollars of
energy. For example, increased steam flow to a heat exchanger indicates that either the steam trap on
the heat exchanger leaks (wasting steam), or that the process changed (wasting steam) and needs to be
investigated to reduce steam consumption. Field calibrators help ensure that these instruments operate
properly and accurately quantify energy savings. In addition, instruments that are regularly and
accurately calibrated often tend to improve plant safety and reduce the probability of equipment
damage.
Further, automated portable calibrators can improve the calibration process by automating the
generation of the transmitter inputs and the recording of the transmitter measurements. This makes the
calibration process much less time-consuming and improves the accuracy with which data is collected by
reducing the probability of human error.
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Expensive qualification requirements often preclude the opening of transmitters in nuclear power
plants. In these applications, the calibration process can be performed faster and more accurately with
an automated calibrator as compared to using existing manual calibration techniques.
The Beamex MC5 multifunction calibrators and the Beamex CMX calibration software form an
integrated, automated calibration system. Calibrations performed using automated field calibrators and
calibration software with electronic documentation, result in more uniform calibrations that are less
prone to human error. This automated calibration process is faster and more complete than the manual
process. Aside from being more accurate, it also frees up significant amounts of time for the technician
to perform other work. The integrated system with communicating calibrators and calibration software
allow also easy upload of calibrations to a PC and produce easy-to-read calibration certificates showing
the accuracy of the instrument. It also allows the ability to search for instruments that are due for
calibration.
SUMMARYONIMPROVING POWER PLANT PERFORMANCE THROUGH CALIBRATION.
An optimal calibration plan executed well can improve both safety and productivity of the plant.
CALIBRATION IMPROVES SAFETY
Calibration is carried out to compare the quality and reliability of the measurements by means of
traceability through national and international standards (e.g. NIST, ISO 9001, ISO 17025).
Plan safety is based on never exceeding the established operat ing parameters (e.g. reactor power,
cooling capacity).
Calibration improves efficiency
Enhanced calibration equipment performance results in better uncertainty levels, with which it is
possible to improve annual production levels.
With an integrated calibration solution, such as the Beamex
calibrators and calibration software, plant
can reduce the amount of paperwork and equipment that has to be taken out in the field
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5.0 STARTING AND STOP OF GENERATOR SET
START AND RUN THE GENERATOR SET1. According to the Check before running requirement, finish each check. Then turn the fuel tank
switch to ON.
2. Disconnect all the outer loads on the AC receptacle.
3. Turn the breaker to the OFF position, draw the chock handle, and turn off the choke.
4. Turn the starting switch key to the RUN, the generator is in the standby mode after the digital
control panel display initial interface.
5. Turn the starting switch key to the START, loose the key after generator started, and the key will
return to RUN automatically. In the first time, if start fails, restart it after 30seconds.
6. Run the generator set and Loose starter switch key after starting, push the throttle handle back to
it's position, then the generator will be in the automatic running state.
7. After making sure the generator voltage, frequency and other running state meet the using require,
close the main breaker, then it can supply output power to load. Preheat generator three minute
without load after the set starting, then running with load
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The new generator set have a running-in period, the period is the initial 20 hours, only with 50% load
during the running-in period, or it will shorten the set life.
8. Checks during the running
a) Whether there is abnormal sound or vibration;
b) Whether the engine misfires or runs rough;
c) Check the color of the exhaust. (Is it black or too white?) If you notice any of the above-mentioned
phenomenon happened, stop the engine and find out the fault cause or contact with our agents. If the
engine has been running, the muffler will be very hot. Be careful not to touch the muffler.
STOPPING OF GENERATORFirst disconnect the unit and load, then stop the generator.
1. Normal stop
1) Cut off the load from the generator.
2) Turn the breaker to OFF position.
3) Turn the starter switch to STOP position after running for 1-3 minutes with zero load.
4) Turn off the fuel switch after the generator stopped.
2. Emergence stop
a. When generator set is running, the operator should keep eyes on its running state. If there is anything
wrong, stop the generator according to the normal procedure.
b. If there is any emergency which may cause serious damage to the generator or person injuries, eg.
short circuit, electric shock and so on. The operator should immediately apply the emergency stop:
pressing hard the Emergency stop button could stop the generator at once. (Caution: there is no
emergency stop on the KGE12E/KGE12E3 generator, please turn the Starting switch to the stop
position.
c. When the problem has been solved after stopping the generator, you should reset the Emergency
stop button before restarting the machine, rotate the Emergency stop in the arrow direction and the
button will reset.Reset the pressed Emergency stop, then the generator will run again. And restart the generator
according to the normal procedure.
Do not use Emergency stop when in non-emergency situations. If that, Emergency stop may cause
some damage to the generator.
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6.0 GENERATOR MAINTENANCEDiesel generator sets used for either prime or backup (emergency) power must be regularly
maintained to ensure they provide quality power throughout their service life. Larger
companies who own many generators, or those who rely on generator sets extensively for
prime power, may require an in-house engineer to maintain their generator sets. Smaller
companies, or users who own a generator to provide backup power in the event of an outage,
may establish maintenance contracts with generator dealers and/or electrical contractors to
maintain their generator sets. In either instance, the life-cycle of power generators is well
established and documented making routine maintenance fairly straight-forward. Best
generator maintenance practice is following the maintenance schedule provided by the
manufacturer of the generator.
The long outstanding use of generators over time has provided the necessary knowledge to
predict when certain components will fail or be in need of service. A fairly reliable maintenance
schedule can usually be acquired from the manufacturer and can be employed by a local
generator dealer or other electrical contractors/engineers with experience in power
generation. Adhering to this schedule will ensure maximum service time for the generator and
proper operation when it is called upon to provide power. Large generator manufacturers have
established maintenance plans and will not only service their own generators, but many of the
other industries major brand names as well. Below are links to Caterpillar and Cummins
generator maintenance programs that most any generator owner can subscribe too: The main
responsibilities of the maintenance contractors would be to inspect systems, study the
technical data provided by the manufacturers, maintain records and take precautionary
measures for safety as suggested by the manufacturers.
Some of the steps taken to ensure smooth generator operation while carrying out scheduled
maintenance include:
Timely removal of worn out parts or upgrading of components Checking fluid level Battery inspection and cleaning of connections
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Load bank testing Verifying control panel readings and indicators Changing fuel and air filters
Small investments made in replacing components and maintaining generators on a regular basis
can save expensive and unnecessary upgrades or even replacement of the entire generator set
in the future.
When performing routine maintenance, each action taken should be logged, and the readings
and various parameters are recorded along with the date of inspection and hour meter reading
of the generator. These set of readings are compared with the next set of data collected. Anyabsurd variation of readings indicates faulty performance of the unit.
Load testing of automatic transfer switches in regular intervals keeps track of the components
electrical and mechanical integrity in the actual mechanical transfer operation. Other factors to
be checked periodically are starting and timing relays, start signal continuity, and utility phase
sensing.
Preventive maintenance thus ensures that you get uninterrupted power supply for all your
needs. You are assured of service on priority basis in case of dire emergency and discounted
service rate for additional support or work. Once a business enters into such contracts, the
facility can relax on this aspect as the maintenance provider keeps track of when the next
servicing is due and makes the visits in regular intervals. They ensure that the products
purchased through them receive consistent and reliable service.
6.1 SAFE OPERATION OF DIESEL GENERATORS (A) THE AUTOMATIC STATE
1. To keep starting the motor and the battery to start the voltage.
2. To maintain the normal water level in the radiator cooling, circulating valve is always open.
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3. Keep the crankcase oil level dipstick groove within 2cm.
4, the fuel tank more than half of oil in the fuel supply valve is always open.
5. The generator control panel's "Run - Stop - Automatic" switch on "auto" position.
6. unit distribution screen mode switch in the "automatic" position.
7, the radiator fan switch is in the "automatic" position.
8, the unit received the signal loss of pressure mains start to confirm the utility loss of pressure,
conversion counter cut electricity switch, close the conversion counter power switch, start the engine
room of the intake and exhaust fan.
(B) MANUAL START
1, the indoor temperature below 20C, open the electric heater on the machine to warm up.
2, check the functioning of the body and the surrounding debris without prejudice, if any, should be
promptly removed.
3, check the crankcase oil level, fuel tank oil level, radiator water level. If the water level below the value
of the oil level should be added to the normal position.
4 check the fuel supply valve and the cooling water valve is in open position.
5, check the voltage of batteries for electric starter is normal.
6, test power distribution panel of the test button, observe the warning light has switched on lights.
7, check the power distribution panel of the switch is OFF position, the instrument is in zero indication.
8, the start into the wind and exhaust fan.
9, press the engine start button, it starts running. Such as the failure of the first start, press the power
distribution panel on the corresponding reset button, wait until the alarm to eliminate the crew return
to normal conditions before the second start. Started, the sound operation of the machine properly, the
cooling water pump running indicator lights and instruments indicate normal way to start successful.
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(C) OF THE PARALLEL POWER SUPPLY MANUAL1, and the cars to be turbine oil, water temperature, oil pressure reaches normal operating condition.
2, etc. and the cars generator output voltage and frequency values and the values consistent with bus
bars.
3, to be car generator synchronizer and hit the handle of "closing" position
4, the observed synchronization indicator lights and pointers
5, observe the synchronization indicator light, completely extinguished or the pointer to the zero
rotation, and can be marked with electrical closing switches.
6, the crew and vehicle to run into, and then handle its synchronizer cycle "off" position
7, after closing if the synchronizer, synchronization, pointer rotating too fast or anti-clockwise rotation,
and the car is not allowed, otherwise, will result in closing failure.
8, manual and the car is successful, should immediately contact with the low-voltage power distribution
room, the implementation of the main distribution panel feeding the switch can switch on power
transmission lines after the operation.
(D) OPERATIONAL SAFETY MANAGEMENT1, in accordance with the instructions specified time checking instruments, pay attention to oil pressure,
water temperature have changed. Lubricating oil pressure shall not be less than 150kPa, cooling water
temperature not higher than 95C.
2, check the crankcase oil level, fuel tank oil level, radiator water level, lower than the normal position
should be added.
3 ground power distribution panel of the instrument and observe the warning lights are normal. Where
a red light there is a failure, the green light for the normal operation of the light
4, check the charger is properly charged.
5, listen to the sound operation of the various parts of the machine is normal.
6, Shoumo body shell, bearing housing parts, tubing, pipes, feel the temperature is normal.
7, pay attention to hair dryer or other electrical equipment if there char, rather than smell.
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8, found that adverse events should be processed immediately resolved; serious should stop treatment.
9, where downtime is required to eliminate the fault and then repeat the hand pressing the button on
the unit, the unit before further operation
10, on the operating parameters, a class record at least twice.
(E) PROTECTION1, generator of high / low voltage pre-alarm, stop
2, the generator of high / low frequency pre-alarm, stop
3, the engine high water temperature alarm, shutdown
4, the engine speed / speed pre-alarm and shutdown
5, engine low oil pressure alarm, shutdown
6, the battery voltage high / low alarm
7, over-current alarm, trip, stopping
8, short-circuit fault trip
9, the oil pressure sensor break alarm, shutdown.
10, engine speed sensor signal loss alarm, stop
11, the generator phase sequence error alarm stop
12, hair units down by ground fault alarm
13, emergency stop / start the alarm stop
14, low fuel oil level alarm
(F) Parking1, the total output control panel feed switch sub-gate, Off grid.
2, the generator no-load operation of 10 minutes parking 3, stop the engine room fans, cooling water
pump.
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THE ADVANTAGES AND CHARACTERISTICS OF DIESEL GENERATORS1, the advantages:
(1), fuel economy, high thermal efficiency, operating conditions change, the fuel consumption rate
curve changes relatively flat economy even under low load
(2), reliable, durable. Because there is no ignition system, low fault
(3), using a wide range
(4), less harmful emissions
(5) And good fire safety
Generator automatic voltage regulator in the form of: SCR, phase compound, TD1-type carbon
resistance automatic voltage regulator, the individual use of high-power tube
2, features:
(1), multi-level unit capacity. International unit from a few kilowatts of ~ tens of thousands of kilowatts,
thousands of kilowatts of the largest domestic unit
(2), supporting equipment, compact structure, flexible installation locations (water as long as 34 ~
82L/KW H turbine 's 1 / 10)
(3), high thermal efficiency, fuel consumption is low (30 ~ 46% thermal efficiency)
(4), starting quickly, and can soon reach full power only a few seconds, with a maturity of 1 minute
emergency full load (normal 5 ~ 30MIN) stop the process short, to frequent starts and stops.
(5), maintenance is simple, few, easy to maintain during standby
(6), diesel generators power the building with the lowest overall cost
The future direction ofgenerator sets
Generator for the national economy and people's shoulders to provide household electricity generation
equipment of the task, so it will be a very long time occupied an important position. And with the
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progress of the times and social development, the original is clearly the kind of generator is not suitable
for the needs of society. Heavy, fuel consumption, noise , pollution
So the future direction of the generating units should be energy saving, environmental protection, light,
small, nice. Generating units in order to play a potential advantage
Incorrect operation of diesel generators
Diesel generators operating error will seriously affect the service life of diesel generator sets, let's look
at the daily life, mode of operation of diesel generating sets which the error?
Faulty operation of a diesel generator: diesel engine oil run low.
At this point the oil supply shortage due to friction caused by the lack of surface oil, resulting in
abnormal wear or burns. Therefore, diesel generators and diesel engines running before starting the
process to ensure sufficient oil to prevent the cylinder caused by the lack of oil, bush-burning failure.
Error operating two diesel generators: acute down-load or shut down immediately after the load
dropped suddenly
Diesel generator cooling system after the flame to stop the water cycle, dramatically reduce the cooling
capacity, heating cooling parts lost, could easily lead to the cylinder head, cylinder cover, cylinder block
and other parts overheating, cracks, or excessive expansion of the piston in the cylinder stuck inside. On
the other hand, without the idle shutdown diesel generator cooling, make the oil less friction surface,when the engine starts again when the increased wear due to poor lubrication. Therefore, the flame of
diesel generator dropped before loading, and gradually reduce the speed , load running a few minutes.
Operate threediesel generators Error: cold, not warm to start with a load operation
Cooler diesel generator starts, the oil viscosity, poor mobility, lack of fuel supply is a machine, the
machine short of oil because of poor lubrication friction surface, resulting in rapid wear, or even
cylinder, bush-burning and other failures. Therefore, the diesel engine starts warming should be idle,
standby oil temperature above 40 C and then with a load operation; machines started to be linked to
low gear, and orderly travel for a distance in each gear until the oil temperature is normal, adequate
supply only after to normal traffic.
Operation of four diesel generator error: Meng diesel cold start after the throttle
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If Meng throttle, the sharp rise in diesel generator speed will cause some friction surface on the machine
produced by dry friction and severe wear. In addition, the H-throttle piston, connecting rod and
crankshaft receiving power changes, caused by heavy impact, and easily damaged parts.
Diesel generatorsoperating five errors: lack of cooling water or cooling water, oil under high
temperature operation
Diesel generator cooling water shortage will reduce its cooling effect, due to the lack of effective cooling
engine is hot; cooling water, oil, the oil temperature is too high, can cause engine overheating. At this
point diesel generator cylinder head, cylinder liner, piston components and valve and other major heat
load, the mechanical properties such as strength, toughness and so sharply, so that deformation of parts
increases, decreases with the gap between the parts to speed up parts wear, but also serious cracks,
engine stuck fault. Diesel engine combustion process heat will deteriorate, so that fuel injector
malfunction, poor atomization, coke increased.
6.2 PREVENTIVE MAINTENANCE PROGRAM GENERATOREvery Start
A. Check coolant level
B. Check batteries
C. Check engine oil level
D. Check instrument readings
E. Check battery charger
Every 10 hours
A. Air cleaner oil cup - check level
B. Air pre-cleaner - clean
C. Cooling system - check level and deposits
D. Oil speed control linkage and Flo-matic control
E. Check engine oil in crank case
Every 50 hours
A. Air cleaner element (dry) - clear
B. Fan and water pump belts - check tension and wear
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C. Flexible rubber connector between carburetor and air cleaner - inspect for loose fit or
damage
D. Flo-matic control linkage - 3 drops of oil
E. Alternator belt - check tension and wear
F. Power take-off clutch - check and adjust
G. Radiator core - clean spaces
Every 100 hours
A. Automatic dust unloader - empty
B. Battery - check electrolite level
C. Crank case - change oil
Every 150 Hours
A. Spark plugs - clean and gap
Every 200 hours
A. Crank case ventilator metering valve - clean
B. Fuel pump filter - clean and check sediment bowl
C. Change engine oil filter
D. Distributor - apply oil to arm pivot and felt wick under rotor
Every 500 hours
A. Carburetor fuel screen - remove and clean
B. Distributor cap - remove and clean
C. Distributor rubbing block - high temperature grease in back
D. Distributor housing - 8 to 10 drops of engine oil in cup
E. Distributor drive shaft - three strokes of hard lubricator
F. Governor control wire - two strokes of hard lubricator to each fitting
Periodic
A. Battery terminals - clean and grease
B. Oil pump screen - clean when pan is removed
C. Wiring - check for worn, cracked or corroded connections
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References
1. Augustus Heller (April 2, 1896),"Anianus Jedlik",Nature (Norman Lockyer)
2. Langdon Crane, Magnetohydrodynamic (MHD) Power Generator:
3. Horst Bauer Bosch Automotive
Handbook4th Edition Robert Bosch GmbH, Stuttgart
4. http://www.ohio.edu/mechanical/programming/hpv/hpv.html
5. Chapman, Stephen J. 2005. Electrical Machinery Fundamentals 4th Edition New York:
Mc Grawl Hill
6. Baran, J.,
Sroka, J. (2010). IEEE Trans. Electromagn52 (4), 797-803
7. Zaridze, R.,
Karkashadze,
D. Pommerenke,
D. Aidam, M. (1996)
8. Borsero, M., Sardi, A., Vizio, G. (2008).
9.Wang, K.,
Pommerenke, D.,
Chundru, R.,
Van Doren ,
T, Drewniak,
J.L., Shashindranath, A. (2003).
10.Caniggia, S.,
Maradei, F. (2007).
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