Practical No. 4.
Aim: Identify various components used in diesel generating set and
maintain it.
Program Outcomes (POs) mapped:
PO1 : Basic and Discipline specific Knowledge
PO4: Engineering Tools, Experimentation and Testing
PO 5 : Engineering Practice for society, sustainability and
environmentPO6: Project Management
PO7 : Life Long learning
Course Outcome (CO) : Identify various components of hydro, steam, gas, diesel power plants.
Relative Affective Domain:
1. Follow safety practices.
2. Practice good housekeeping.
3. Maintain tools and equipment.
4. Follow ethical Practices.
Practical Significance: The objective of this practical exercise is to enable students to identify and
perform basic maintenance on the various components of a diesel generating set. A well-maintained
generator ensures reliability during power outages.
Minimum Theoretical background:
A diesel genset, or generator set, is a portable power supply that consists of an engine and a
generator. Theengine converts the chemical energy of a fuel into mechanical energy. This
mechanical energy is used to spin the alternator rotor, which converts mechanical energy into
electrical energy. The electrical energy is then channeled through power cables.
The main components of a diesel generator are:
Diesel engine,
Alternator,
Fuel system,
Voltage regulator,
Cooling system,
Lubrication system,
Battery charger,
Control panel.
Diesel generators work based on air compression and the fuel. Liquid fuels or natural gas are
usually used asthe primary fuel.
Application
Diesel generators are mechanical-electrical machines that produce electricity from diesel fuel.
They can beused as a backup power supply for homes, shops, and offices. They can also be used
to power machinery and power tools at job sites where getting power from the grid is difficult.
Diesel generators are also used in the following industries:
Oil and gas operations, such as drilling, pumping, and loading
Mining, including surface and underground mining
Road construction
Offshore drilling
Outdoor filming
Event management
Maintenance of Diesel Generator set
1. Identification and Overview:
a. Provide an overview of the diesel generator set, highlighting the major
components such asthe engine, alternator, fuel system, cooling system,
electrical control panel, and exhaust system.
b. Identify the locations of key components.
2. Engine Inspection and Maintenance:
a. Open the engine housing or access panel.
b. Demonstrate how to check engine oil levels and inspect for any oil leaks.
c. Explain the importance of changing the engine oil and oil filter
according to themanufacturer's recommendations.
d. If needed, demonstrate how to replace the oil filter and add or change engine oil.
3. Fuel System Inspection and Maintenance:
a. Identify the fuel tank, fuel lines, and fuel filters.
b. Show how to check for fuel leaks and inspect the condition of fuel filters.
c. Demonstrate how to replace fuel filters if they are clogged or damaged.
4. Cooling System Inspection and Maintenance:
a. Locate the radiator or cooling system components.
b. Demonstrate how to check coolant levels and inspect for any coolant leaks.
c. Explain the importance of flushing and replacing coolant at recommended intervals.
d. If needed, demonstrate how to add or replace coolant.
5. Alternator Inspection and Maintenance:
a. Identify the alternator and its components.
b. Show how to inspect the alternator for loose connections and signs of overheating.
c. Demonstrate how to clean the alternator and tighten connections if necessary.
6. Exhaust System Inspection:
a. Explain the significance of the exhaust system for generator operation.
b. Inspect the exhaust system for leaks and damage.
c. Show how to replace exhaust components if needed.
7. Electrical Control Panel Inspection:
a. Open the electrical control panel.
b. Identify key components, such as circuit breakers, relays, and control switches.
c. Demonstrate how to check and reset circuit breakers and relays.
d. Ensure proper grounding and electrical safety measures.
8. Documentation:
a. Record all maintenance actions, including inspections and replacements.
b. Update maintenance logs or records with the date and details of the maintenance
performed.
9. Final Check:
a. Ensure that all components are properly reassembled and secured.
b. Verify that no tools or debris are left in or around the generator.
c. Confirm that safety protocols are followed.
d. Remove lockout/tagout devices and restore power to the generator,
following establishedprocedures.
Safety Precautions:
a) Always wear appropriate PPE when working with gas turbine components.
b) Ensure the gas turbine is properly shut down, locked out, and tagged out before
performing anymaintenance.
c) Be aware of potential hazards such as hot surfaces, rotating machinery, and high-pressure
systems.
Conclusion:
Regular inspections and maintenance are critical to ensuring the reliability and longevity
ofgenerators used for backup or continuous power supply.
Watch video :
https://www.youtube.com/watch?v=eAX_fK_c8Mc
https://www.youtube.com/watch?v=6gvMn3eu8Jw
Question for Evaluation:
1. Write the application of diesel generator set?
2. List the maintenance procedure perform on diesel engine
