Rewinding And Installation Of 18Kva Diesel Engine Generator

Electrical Electronics Engineering | Mechanical Engineering | Engineering

The process of rewinding and installation of an 18Kva diesel engine generator involves several intricate steps aimed at restoring and integrating the generator into a functional power system. Rewinding, which refers to the replacement or repair of damaged coils in the generator’s stator or rotor, is crucial for maintaining optimal performance and efficiency. This intricate task requires skilled technicians to carefully disassemble the generator, assess the extent of damage, and meticulously rewind the coils to restore electrical conductivity and insulation. Following rewinding, the generator undergoes rigorous testing to ensure compliance with safety and performance standards. Once verified, the installation phase begins, involving the placement of the generator in its designated location, connection to the electrical grid, and integration with auxiliary systems such as fuel supply and cooling mechanisms. Attention to detail and adherence to manufacturer guidelines are paramount throughout the process to guarantee seamless operation and longevity of the diesel engine generator in various applications.

ABSTRACT

A diesel generator is the combination of a diesel engine with an electric generator (often an alternator) to generate electrical energy. When a diesel generator fails, the user must decide whether to repair or replace it. To make a proper decision, one must consider the cost of the repair, the availability of a replacement, the age of the diesel generator, the electrical design required for the application, any special mechanical features, and the urgency of returning the failed diesel generator to service. Placing the driven equipment back into service is frequently the highest priority, and users often make their decision based on this criterion alone. Plant managers tend to be less concerned if the rewound diesel generator is less efficient when their operation’s downtime is costing thousands

TABLE OF CONTENTS

COVER PAGE

TITLE PAGE

APPROVAL PAGE

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE PROJECT

AIM OF THE PROJECT
OBJECTIVE OF THE PROJECT
PURPOSE OF THE PROJECT
BENIFIT OF THE PROJECT
SCOPE OF THE PROJECT
PROBLEM OF THE PROJECT

CHAPTER TWO

LITERATURE REVIEW

THE ORIGIN OF ELECTRIC POWER GENERATOR
REVIEW OF AN ALTERNATOR
ORIGIN OF ALTERNATORS
GENERATOR SIZE
GENERATOR SIZING AND RATING
GENERATOR CONTROL SYSTEM
ALTERNATOR AND ROTOR

CHAPTER THREE

METHODOLOGY

GENERATOR PARTS AND THEIR WORKING FUNCTION
MATERIAL USED
TOOLS USED
WINDING CONSIDERATION
CONSTRUCTIONAL DETAILS
REWINDING PROCESS

CHAPTER FOUR

TESTING AND RESULTS

PROCEDURE AND TESTING ANALYSIS
ASSEMBLING OF SECTIONS
TESTING OF DIESEL ENGINE GENERATOR
MAINTENANCE OF GENERATOR
IMPORTANCE OF MAINTENACNCE
DEFINITION AND MAINTENACE OF PARTS OF A 18KVA GENEGRATOR
PRESTART CHECKLIST
GENERATORS – PROBLEMS AND REMEDIES

CHAPTER FIVE

CONCLUSION
RECOMMENDATION
REFERENCES

CHAPTER ONE

1.1 INTRODUCTION

Diesel generators are everywhere, which is used to power household appliances such as water pumps and refrigerators to industry equipment such conveyor belts etc.

A diesel generator is the combination of a diesel engine with an electric generator (often an alternator) to generate electrical energy. This is a specific case of engine-generator. A diesel compression-ignition engine is usually designed to run on diesel fuel, but some types are adapted for other liquid fuels or natural gas.

Diesel generating sets are used in places without connection to a power grid, or as emergency power-supply if the grid fails, as well as for more complex applications such as peak-lopping, grid support and export to the power grid.

Proper sizing of diesel generators is critical to avoid low-load or a shortage of power. Sizing is complicated by the characteristics of modern electronics, specifically non-linear loads. In size ranges around 50 MW and above, an open cycle gas turbine is more efficient at full load than an array of diesel engines, and far more compact, with comparable capital costs; but for regular part-loading, even at these power levels, diesel arrays are sometimes preferred to open cycle gas turbines, due to their superior efficiencies.

When faced with this problem, the user must decide between repairing, rewinding or replacing their motor. In this work we are focusing on the rewinding and installation of an 18kva diesel generator.

1.1 BACKGROUND OF THE PROJECT

The packaged combination of a diesel engine, a generator and various ancillary devices (such as base, canopy, sound attenuation, control systems, circuit breakers, jacket water heaters and starting system) is referred to as a “generating set” or a “genset” for short.

Set sizes range from 8 to 30 kW (also 8 to 30 kVA single phase) for homes, small shops and offices with the larger industrial generators from 8 kW (11 kVA) up to 2,000 kW (2,500 kVA three phase) used for large office complexes, factories. A 2,000 kW set can be housed in a 40 ft (12 m) ISO container with fuel tank, controls, power distribution equipment and all other equipment needed to operate as a standalone power station or as a standby backup to grid power. These units, referred to as power modules are gensets on large triple axle trailers weighing 85,000 pounds (38,555 kg) or more. A combination of these modules are used for small power stations and these may use from one to 20 units per power section and these sections can be combined to involve hundreds of power modules. In these larger sizes the power module (engine and generator) are brought to site on trailers separately and are connected together with large cables and a control cable to form a complete synchronized power plant. A number of options also exist to tailor specific needs, including control panels for autostart and mains paralleling, acoustic canopies for fixed or mobile applications, ventilation equipment, fuel supply systems, exhaust systems, etc.^[1] Diesel generators, sometimes as small as 200 kW (250 kVA) are widely used not only for emergency power, but also many have a secondary function of feeding power to utility grids either during peak periods, or periods when there is a shortage of large power generators.

Ships often also employ diesel generators, sometimes not only to provide auxiliary power for lights, fans, winches etc., but also indirectly for main propulsion. With electric propulsion the generators can be placed in a convenient position, to allow more cargo to be carried. Electric drives for ships were developed before World War I. Electric drives were specified in many warships built during World War II because manufacturing capacity for large reduction gears was in short supply, compared to capacity for manufacture of electrical equipment.^[2] Such a diesel-electric arrangement is also used in some very large land vehicles such as railroad locomotives.

The decision to rewind a generator begins with an assessment of its performance and condition. The tools include testing that combines electrical measurements, such as megger, polarization index, hi-pot, surge and partial discharge levels, with a comprehensive visual assessment. Repair specialists collect these results and take into account the required reliability the customer needs before making a recommendation.

1.2 AIM OF THE PROJECT

The aim of this project is to rewind and install an 18kw diesel generator.

OBJECTIVE OF THE PROJECT

At the end of this work student involved will:

Learn about mantling and dismantling of a burnt or spoilt diesel generator.
Learn how to count number of turns of coil
- PURPOSE OF THE PROJECT

The main purpose of this work is to expose students to the need of restoring a spoil or burnt diesel alternator instead of buying a new one.

1.5 BENEFIT OF THE PROJECT

The importance of rewinding a diesel generator is to reduce the cost of buying new generator, and in the course of rewinding the efficiency of the machine can be increased.

1.6 SCOPE OF THE PROJECT

The obvious best approach is to rewind the diesel generator. If the magnetic core of a failed generator is undamaged and appropriate procedures are followed, a rewound generator will retain its original efficiency. Properly repaired, a “standard” efficiency generator will have its original “standard” efficiency, and an energy-efficient (EE) generator will have its original high efficiency.

On the other hand, those times when a generator alternator has failed are also opportunities to upgrade alternator efficiency. Especially if the failed generator is 10 or more years old — perhaps with unknown efficiency, and possibly having been improperly rewound in the past — you will want to seriously consider all the options, and look into the economics of replacing it with a new alternator.

1.7 PROBLEM OF THE PROJECT

The problem or issues noticed in this work is that it is very difficult and time consuming to rewind a spoilt generator.