Diesel Generator Training, Parts and components and working principle explain Power learning part 1

Summary

This video explains the basic components and systems of a diesel generator. It covers the engine's role in producing mechanical power, while the alternator converts it into electrical power. Key systems like the air intake, turbocharging, and cooling systems are discussed, alongside their specific functions to keep the engine running efficiently. The control panel, which manages and protects the generator, is also detailed, emphasizing automatic and manual control features. Additionally, the video touches on safety mechanisms, battery systems, and the function of the DC alternator for battery charging. Overall, it provides a comprehensive guide to the operation and protection of diesel generators.

Takeaways

• ⚙️ A generator has two main components: the engine (produces mechanical power) and the alternator (converts mechanical power into electrical power).
• 💨 The air system draws in fresh air through an air filter, cleans it, compresses it with a turbocharger, cools it in an aftercooler, and then sends it into the combustion chamber.
• 🔥 The turbocharger has two sides—one uses exhaust gases to spin a turbine, while the other compresses fresh air for engine combustion, improving efficiency.
• 🛢️ The turbocharger shaft is cooled with engine oil to prevent overheating during high-speed operation.
• 🧠 The generator control panel (AMF controller) automatically manages and protects the generator, monitoring voltage, temperature, and oil pressure.
• 🔌 The control panel can start or stop the generator manually or automatically when connected to an Automatic Transfer Switch (ATS) system during power failure.
• 💧 The engine uses a closed-loop water cooling system, where a circulation pump and thermostat regulate water flow and maintain engine temperature.
• 🚨 Built-in safety mechanisms automatically shut down the engine in case of overvoltage, overload, low oil pressure, or high coolant temperature.
• 🔋 The generator includes a DC Dynamo (charging alternator) that produces DC power to recharge the starter batteries while the generator is running.
• 🔧 Two 12V batteries connected in series provide 24V to power the starter motor, initiating engine operation.
• 🧱 Anti-vibration rubber mountings and flexible bellows are installed to absorb vibrations and protect exhaust and other connected parts from damage.
• 🔒 The main circuit breaker (MCCB) protects the generator and connected systems from short circuits and overcurrent situations.

Q & A

What are the two main components of a diesel generator that produce electrical power?

The two main components are the engine and the alternator. The engine produces mechanical power, and the alternator converts this mechanical power into electrical power.

How does the engine of the diesel generator work to produce mechanical power?

The engine generates mechanical power through its flywheel, which is coupled with the alternator's coupling plate. The engine's mechanical power is transferred to the alternator for conversion into electrical power.

What role does the air system play in the operation of the engine?

The air system ensures that fresh air is drawn from the environment, cleaned by the air filter, and pressurized by the turbocharger before being cooled in the aftercooler and sent into the engine’s combustion chamber.

What is the function of the turbocharger in the air system?

The turbocharger pressurizes the intake air, making it faster and more efficient for combustion. It uses exhaust gases to power a turbine, which drives the intake air fan.

Why is the aftercooler necessary in the air intake system?

The aftercooler cools the compressed air from the turbocharger. Since pressurizing air increases its temperature, the aftercooler reduces this heat to prevent the engine from overheating.

How does the cooling system of the engine work?

The engine uses a water-cooled system, where water circulates in a closed loop. The circulation pump sends water through the engine to absorb heat, then through the radiator to be cooled by airflow before returning to the engine.

What is the function of the thermostat in the engine's cooling system?

The thermostat acts as a mechanical switch that controls the flow of coolant based on the engine's temperature. It ensures that the engine operates within the ideal temperature range by allowing coolant to flow into the radiator when the engine gets too hot.

How does the control panel protect the engine from damage?

The control panel monitors critical parameters such as voltage, oil pressure, and coolant temperature. If these values exceed or fall below preset thresholds, the panel automatically shuts down the engine to prevent damage.

What is the role of the AMF controller in a diesel generator?

The AMF (Auto Mains Failure) controller automatically starts the generator when there is a power failure. It can also be manually controlled by the operator to start or stop the engine based on customer needs.

How do the batteries work in the diesel generator system?

The generator uses two 12V batteries connected in series to create 24V, which powers the starter motor. Once the engine is running, the DC Dynamo charges the batteries, ensuring they remain ready for the next start.