Project Report on Sudhir Generator Set

8/2/2019 Project Report on Sudhir Generator Set

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INDUSTRIAL TRAINING AND

PROJECT

REPORT

ON

FAULTY TRACING IN DG SETS

PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF

REQUIREMENT FOR THE AWARDS OF PROJECT YEAR DEGREE IN

MECHANICAL ENGG. OF THE PUNJAB TECHINCAL UNIVERSITY

SUBMITTED BY

CHETAN SUNDAN (80603514003)

SUBMITTED TO

DEPTT. OF MECHANICAL ENGG.


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BABA KUMA SINGH JI ENGINEERING COLLEGE

HOSHAIR NAGAR AMRITSAR

PREFACE

If you know the laws of buoyancy it doesnt mean that you know how to swim. It is only

through jumping in the water that you get the feel of the depth. This is applicable to every

aspect of life. Therefore practical training is of utmost importance.

The object of undergoing this training was to get familiar with the weary waters of the industry

and to learn how to put theory into practice. I have been greatly privileged to have undergone

training at SUDHIR GENSETS LTD., JAMMU.

This report contains the extract of things I have learned during my training period.

Chetan Sundan


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ACKNOWLEDGEMENT

Any endeavor cannot lead to success unless and until a proper platform is provided for the

same. This is the reason I find myself very fortunate to have undergone my industrial training

of six months at SUDHIR GENSETS LTD.,JAMMU. The persons of my department and allother departments have extended a warm and helping hand.

I am very fortunate to have had a chance to feel the gravity of what role mechanical

engineering plays in the industry. It was a golden opportunity for me to get a chance to

experience what it feels to be in a company wgere disciple, quality and hard work are the

motto. This training helped me a lot in bridging the gap between the theoretical and practical

aspects of my knowledge.

First of all I would like to thank Mr. Jangbir Singh for his valuable guidance and

encouragement as a teacher and a friend throughout my training period.

I am also thankful to Mr. Shami Sharma for giving me an opportunity to undergo training in

such a renowned company.

My heartily thanks to Er. Vinod Sharma who was my project manger and my guide through

the project works. They always went out their to help me at all times. Their experience andknowledge motivated me to bring out the best in times.

I am sure that the knowledge and information that I have gained during this period would be of

immense value for my growth in the field of Mechanical Engineering.


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Chetan Sundan

DECLERATION

I hereby certify that the project report submitted for the award of degree in Mechanical Engg. It

is the record of work carried out by me during the period Jan-2011 to June-2011 under the

guidance of Er. Vinod Sharma at SUDHIR GENSETS LIMITED, JAMMU.

Signature of Candidate


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CERTIFICATE

BABA KUMA SINGH JI ENGINEERING COLLEGE

HOSHAIR NAGAR AMRITSAR

(RECOGNIZED BY THE PUNJAB GOVT. ANDAFFILIATED TO THE PUNJAB TECHNICAL

UNIVERSITY APPROVED BY ALL INDIA COUNCIL OF

TECHNICAL EDUCATION)

This is to certify that project work entitled Industrial Training

And Project Report on FAULT TRACING IN DG SETS has

been carried out by :-

CHETAN SUNDAN (80603514003)

The student of 8th Sem. B. Tech in Mechanical Engineering

under our Supervision and guidance have submitted in the

partial fulfillment of the Requirement for the degree in

Mechanical Engineering during the Academic Session 2007-

2011.


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Principal Project Guide :

Dr. P. S. Sandhu Mrs. Meenakshi Madam

Examiner

INDEX

ABOUT SUDHIR GROUP

INFRASTRUCTURE

PLANTS

PRODUCTS RANGE

PARTNERS

WORK CULTURE

SERVICES

GENSETS OVERVIEW

SUDHIR GENSETS OVERVIEW

ENGINE OPERATIONS

TESTING

FAULT TRACING IN DG SETS

CONCLUSION OF TRAINING


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ABOUTSUDH IR

GROUP

ABOUT SUDHIR GROUP


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Sudhir is a name synonymous with Power. It stands tall in the Indian Power Generation Sector,

providing complete turnkey Electrical solutions from GENERATION, DISTRIBUTION TO

ELECTRIFICATION.

An Industry leader in the field of setting up Diesel base Captive Power Plants upto 20MW

having its corporate office in Gurgaon & revenue of over INR 1000 Crs, it has leveraged its

relationship with Cummins Ltd. To capture a majority market share.

The Company has a wide blue-chip customer base and operates through multiple

manufacturing facilities across India and focuses & Gas Generators,

HT & LT Switchboards, Transformers and Turnkey EPC contracts.

The product line includes the widest range of Diesel Gensets 15-3000 KVA with a fuel option

of Gas, Transformers, Packaged Substations, complete range of HT 11KV & 33KV Panels, LT

Switchboards, Turnkey EPC contracts covering electrical and mechanical services of

DISTRIBUTION TO ELECTRIFICATION.

Indeed, we have achieved and leapfrogged towards unprecedented growth. But to us this is just

another step in our ongoing journey to greater goals and broader horizons.


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INFRASTRUCTURE

INFRASTRUCTURE

All our manufacturing units are equipped with the very latest technological machineries. From

customized designing and computer aided design system to qualified team of experienced

engineers, these facilities add to credibility and superiority of our products and services.

DESIGN

Customized designing as per customer's requirement

Computer aided design system.

Qualified team of experienced engineers.

Customized to suit broad array of application


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FABRICATION

Amada CNC turret punch press (aries - 255)

Amada CNC press brake (rg 80)

SURFACE TREATMENT & PAINTING

11 tank metal pre-treatment for degreasing, derusting, phosphating, water rinsing and

passivation.

State of art modern powder coating plant

All shades possible as per customer requirements

Most suited for coastal areas and for alkaline environment.


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TESTING

ISO 9001:2000 certified by DNV

100% incoming inspection

All tests as per IS/IEC codesStringent quality test at every stage from inspection of inward material till despatch.

Equipped to carryout primary current engine up to 3000 Amp.


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PLANTS

PLANTS

a) Corporate office, Gurgaon b) Athal plant


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c) Jammu plant d) Gurgaon palnt


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PRODUCTS RANGE

PRODUCTS RANGE


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Cummins Powered

Diesel and Gas Gensets

Ranging from 15 - 3000 KVA

Our complete range of Generators are useful in providing Power in areaswhere conventional power supply infrastructure is unreliable. Our product

line includes the widest range of Gensets ranging from 15KVA to 3000

KVA, with a fuel option of Diesel or gas, a complete range of intelligent

switchboards, design & build end to end power solutions for your Captive

Power Plants.

All our manufacturing units are equipped with the very latest technologicalmachineries. From customized designing and computer aided design

system to qualified team of experienced engineers, these facilities add to

credibility and superiority of our products and services.

GensetControllers


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The Power Command Control, is a microprocessor based generator

set monitoring, metering, protection and control system. It offers

advanced levels of functions for reliability and optimum genset

performance. The power command control with digital parallelingcontrol devices such as synchronizers and load sharing controls,

and KVAR / Power factor controls.

DG SET SPECIFICATION


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KVA MODEL NO.

1) 30 S3.8G3

2) 35 S3.8G3

3) 40 S3.8G4

4) 50 S3.8G6

5) 62.50 S3.8G7

6) 82.50 6BT5.9-G1

7) 100 6BTA5.9-G1

8) 125 6BTAA5.9-G3

9) 160 6BTAA5.9-G5

10) 180 6CTA-8.3-G2

11) 200 6CTAA-8.3-G1

12) 250 6CTAA-8.3-G4

13) 320 NTA-855-G2-1

14) 380 NTA-14-G3

15) 500 KTA-19-G9


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16) 600 VTA-28-G3-1

17) 625 VTA-28-G5-1

18) 750 KTA-38-G2-1

19) 750 QSK QSK23-G3

20) 1010 KTA-38-G5

21) 1250 KTA-50-G3

22) 1500 KTA-50-G8-1


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PARTNERS

PARTNERS


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We serve some of the largest, most prestigious and demanding clients

across India, including many Fortune companies. Read further, for a

description of our clients and to understand what we do for.

Realty

DLF EMAAR MGF Unitech Uppal Housing VatikaBPTP Alpha G Corp Essel Housing Ansal

Mahindra Gescom

OmaxeRaheja Developers Aerens Bestech Eros

Vipul SMCC TDI Ashiana Advance IndiaJMD Ambiance ERA Infra V3S KLJ

BAANI Sahara Anant Raj Ind

Hotels

Taj Jaypee Palace Eros Bristol Bharat HotelsTrident Hotel Oberoi Hotel Hans Plaza Maurya Sheraton Qutab Hotel

The Claridge Radisson Lodhi Hotel Ashoka Hotel Hotel Imperial

IHHR Nehru Palace

Hotel

Hospitals

AIIMS Safdarjung Sir Gangaram Lady Harding FortisUmkal Max Columbia Asia Dr, B. L. Kapoor Jaipur Golden

ApolloRajiv Gandhi

Cancer Institute

Dharamshila

Cancer Hospital

Moolchand

Medicity

Ram Manohar

Lohia

LNJP Medicity Paras Batra PGI Chandigarh ArtimisEscorts

Educational

Modern School DPSSalwan Public

School

Manav Sthali

School

G.D. Goenka

Public SchoolDAV Public SchoolDelhi University


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ITeS

Convergys Wipro SpectramindDaksh e-Services HCL

IT

HP Wipro Genpact HCL NIIT

IBM Patni Computer TCS Flextronix

Food Chain/ Restaurants

Barista Caf Coffee Day Haldiram Bikanerwala Nirulas

Dominos MC-Donald

Pharmaceutical

Ranbaxy Nectar LifesciencesGlaxosmithklineTorrent

PharmaceuticalsCipla

Panacea Biotech Cadila Dabur

Telecom

Bharti Reliance VSNL MTNL Voda PhoneESSAR ZTE Alcatel

Insurance

Max Newyork Tata AigIDBI Fortis Life

Insurance

HDFC Standard

InsuranceICICI Prudencial

Retail Outlets

Vishal Retail Bharti RetailHariyali Kissan

Bazzar

Big Bazar Aditya Birla Retail

Reliance Fresh Pantaloon Raymonds Gokul Mega Mart

Institutional

DMRC IOCL NDMC CPWD PWD

IOCL BPCL PDD C-Dot


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Export Houses

Apparel Export

Promotion CouncilOrient Craft Modelama Export Shahi Export SPl Ind

Beverages/ Distilleries

Radico NV Distilleries Pepsi Coca Cola

Banks

ICICI HDFC Citi Bank Axis Kotak Mahindra

Automobile

Maruti Hero HondaHonda Motorcycle

& ScooterHero Cycle TVS

Yamha Motors MICO/ BOSCH General Motors Amtek Auto JCB

Imperial Auto Competent AG Industries Bajaj Motors Hema EngineeringLumax Hero Cycle Munjal Auto Hero Motors Rockman Cycle

Hyghway Cycle Munjal Showa Sunbeam Auto Satyam Auto RICO Auto

Minda Ind Omax Auto Hi-Tech Gear Subros TVS Motor Exide GE Motor Atlas Krishna Maruti

Others

Jaypee L&T ABB Parle Bhushan Steel

Lakhani Relaxo Amul Dairy Vardhman Group Chinab Textile

Adani GroupBennett &

ColemannHindustan Times GMR-DIAL MBD

Kajaria Surya Roshni Jindal Nahar Spinning T-Series


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WORK CULTURE


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WORK CULTURE

The SUDHIR GENSETS seeks to create a culture where each employee, vendor, and dealer

feels himself responsible and integral part of the enterprises. The work culture at SUDHIR

GENSETS is open and participative Learning is encouraged in the company. Every member

respects 5 F formulas

1. Fast

2. Fair

3. Focused

4. Friendly

5. Fun

This governs its approach to business and relationships within the organization. It has

designee: its management structure in response to the needs of quick decision-making and

operational flexibility even through hierarchies and designation does exit. It is highly informal


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organization where communication moves in all direction, decision-making is quick and to a

large extent delegated.

Every member respects 5 s formulas also:

1. Seiri

2. Seiton

3. Seiso

4. Seikets

5. Shitsuk

5s stands for the first five letters of the japenese words:

S.No. JAPANESE

WORD

MEANING

1s SEIRI Sorting out, clearing, segregation, proper selection,

remove the waste

2s SEITON Systematic arrangement, keeping things at a proper

place, a place for every thing and every thing in its

place

3s SEISO Cleaning (spick and span) quality by the cleaniless.

Keep clean all area, equipment and work place

4s SEIKETSU Standardizing, environment, cleanliness, light,

noise, punctuality


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5s SHITSUKE Maintain discipline and standards to maintain above

4s, respect of rules.

The 5s are also five operations to keep a good behaviour for every work place 5s program

started in SUDHIR GENSETS LTD. From feb 2002 achieving clean floor and organized racks

is not an end in itself. The ultimate goal of house keeping through 5s is to reduce the cost of

product by increasing productivity and contributing to total quality.

How to achieve 5 s:-

5s can be achieved very easily by every employee by having close look at his work-place, he

is ensure that:

By organizing of work place and surrounding area in a better way.

No rejected! Unwanted items are lying at his work place.

By keeping all items, equipments at identified place.

Everybody should co-operate with each other in keeping his and others area clean.

Follow and respect of rules and regulations and maintain required standards.

PLEASE CHECK:

Do you have any unwanted things around you?


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Are all the required things kept at their allocated places? Are you following

timings and set norms?

Are you following the operation standards?

Are you regularly reviewing 5s

5s objectives:-

Productivity high

Quality high

Cost down

Delivery on time

Safe work place

Moral high

FUTURE PLANS:

1. To provide superior quality gensets over all the country with new technology at

reasonable rates, and to become NO.1 in gensets industry within five years.

2. SUDHIR GENSETS LTD. Have plans to market 10000 gensets during financial

year.

ACHIEVEMENTS

Company, which has shown about 30% increase in turnover within a period of 1 year.

Company has increased its production of diesel gensets.

The company has obtained ISO 9001 certification.


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Company has also obtained ISO 14001:2004 certification.


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SERVICES

SERVICES

It is a part of our mission to provide solutions that create value for our customers. Product

support is an important of our mission. Valuable owners of SUDHIR GENSETS LTD. Gensets

rely on uninterrupted power 247.

The success of your business demands solution that minimize downtime, reduce costs and keep

your equipment running at peak performance.

Whether its helping you select the right equipment for your job or utilizing the latest

technology to monitor your equipment SUDHIR GENSETS LTD. Are always there for you.


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By offering a wide range of solutions, services and products, we help you in lower costs,

increase productivity and manage your business more effectively.

In addition, our expert techinicans have the experience, knowledge, training and tooling

necessary to handle all your maintenance and repair needs. We have around 100 nos. ofworkforce, which cater services in different parts of the country so as to reduce downtime.


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GENSETS OVERVIEW

GENSETS OVERVIEW


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Other DG sets while power cuts eats into your profits, an inefficient DG set will simply add to

your losses, the SUDHIR GENSETS DG have been designed to ensure you an efficient power

supply. This also assures you years of hassle free operations.

Generates peace of mind

Its recovery time, easily the best in its category, gurrantees a seamless switchover to the back-

up power. Moreover, its effective governing system controls the voltage fluctuations, thus

ensuring completely safety of your equipments.

Performance unmatched

Its got one of the most preferred engines fitted inside- the CUMMINS ENGINE. Compact and

low on vibration, this engine has the smallest footprint as compared to other engines of

identical ratings.

Silence certified

Each and every SUDHIR DG set compiles with the most stringent noise and emission norms

stipulated by the central pollution control board of India (CPCB)

No compromise technology

Its got the other advantage too. Like, its transported through the SUDHIR Transport

solutions, it is installed and commissioned through a SUDHIR authorized dealer. It even comes

with an annual maintenance contract. It is the most fuel efficient in its class. It offers zero-leak

engines.

Preferred by all

A SUDHIR DG set can be used in the Telecom, Defence and railway sectors. It can also be

installed at places like petrol pumps, hospitals, super markets and banks.


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GENERAL DESCRIPTION OF GENSET

The Genset package includes a diesel engine, Alternator, control system and Canopy.

Gensets components Systems/Parts Function

Canopy Fabricated structure

Noise suppressing

material

Control noise level of

generating set housing

Base Fabricated structure

Anti vibration

mountings

Mount Engine+Alternator

Fuel tank Fabricated tank and

accessories

Store fuel

Battery Battery

Leads

Cables

Support direct current

Engine-Direct injection Air system

Cooling system

Fuel system

Exhaust system

Electrical system

Up-fitting parts

Produce mechanical

power


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Alternator-Brushless Stator

Rotor

Exciter

Rectifiers

Voltage regulator

Ventilation fan

Mounting arrangements

Produce electrical power

Control panel Measuring instruments

Controlling safeties

Logic controller

Meter power

Control power

Provide safeties

BEST FEATURES OF YOUR GENSET

Sr.No. SPECIFICATIONS PROPERTIES/ADVANTAGES

1. Modular in construction Easy for dismantling & assembly.

Easy for

shipment/handlings/installations

2. Lowest sound level in the series Lowest sound level of the rugged

M & M engines. CPCB certified


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3. Compact in size with proper air

passage.

Advanced design with sufficient

breathing and air movement for

great performance. Techanically

advanced.

4. Low fuel consumption in the

series.

Rugged and high fuel economy

5. Rust proof- powder coated &

weather proof

Long life- durable and branded for

good appeal for out door usage

without any additional sheets/

infrastructures.

6. Fire retardant and high noise

absorbent insulations.

UL94 & HF1 Grade insulation

foam used for fire

retardation/noise absorption.

7. Easy accessibility for services All parts of the equipments

accessible for easy serviceability

with enclosure illumination for

lightning at night in DG.

8. Draw out type fuel tank of easy

serviceability

Easy maintenance type fuel tank

for both routine maintenance and

sludge removals.

9. Low vibration to ground Technically tested anti vibration

mountings to arrest unnecessary

vibrations of equipment to

ground/structures.

10. High safety features for operator and equipment

Emergency stop from outsidecanopy. High canopy temperatures

switch and low fuel level switch-

alarm as optional.


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SUDHIR GENSETS

OVERVIEW

SUDHIR GENSETS OVERVIEW

In Sudhir Gensets LTD., jammu, there are two units:-

1.) UNIT 1

2.) UNIT 2

In UNIT 1, Manufacturing of canopies and base frames whereas in UNIT 2,assembly of genset

is done and then it is sent to testing area where testing is done before packing and delivering it

to the customers


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UNIT 1

MANUFACTURING PROCESS FLOW CHART OF CANOPY

Raw Material

Inward inspection

Shearing

Punching


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Welding

Grinding/Sanding

Stage Inspection

Pre-treatment

Stage Inspection

Powder Coating

Stage Inspection

Stuffing

Stage Inspection

To Assembly

DESIGN OF CANOPY:-

A) Back View


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b) Front View:-


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c) L.H.Side View:-


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d) R.H.Side View:-


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MANUFACTURING PROCESS FLOW CHART OF BASE FRAME


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Raw Material

Inward inspection

Shearing

Punching

Bending

Welding

Grinding

Leakage test

Pre-treatment

Stage inspection

Painting

To assembly( UNIT 2)

BASE FAME FOR 1250 KVA


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SIZE OF BASE FRAME


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SIZE(mm) KVA

1) 250 250, 380

2) 300 500, 625, 750

250mm base frames are used for silent sets. For example, for gensts of 250 or 380 KVA.

UNIT 2

MANUFACTURING PROCESS FLOW CHART OF SILENT DG SET


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1) Base Frame 2) Engine 3) AT & Other

__________________________________________________________________

Placement of base frame

Assembly of DG set on frame

Assembly of AE components

Alignment of doorsAlignment of roofs

Assembly of control panel Exhaust connection

a) Power cable connection Silencer fitting

b) Electrification of acoustic Cladding control panel

c) Fittement of battery

_____________________________________________________________________

Fittment of lube oil, coolant, blow by drainagePreparation for testing

Checking of service accessibility

Checking of lube oil and coolant levelConnection for testing

Checking of aesthetic Test in gidle

Load test

Cleaning of silent DG set

aspects and stickering

Documentation

Dispatch

DRAWING OF 1010KVA GENSETS


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DRAWING OF 1010 KVA GENSET BASE FRAME


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DRAWING OF 1250 KVA GENSET


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DRAWING OF 1250 KVA GENSET BASE FRAME

DRAWING OF 1500 KVA GENSET

DRAWING OF 1500 KVA BASE FRAME


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DRAWING OF QSK GENSET


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DRAWING OF QSK BASE FRAME

DIFFERENT VIEWS OF BASE FRAMES

a) FRONT VIEW


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b) SIDE VIEW (Radiator Side)


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c) SIDE VIEW (Alternator Side)


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d) TOP VIEW


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INSTALLATION

1. Installation

Most gensets installations must be engineered so the generator will function at

optimum output under the expected load conditions

Importance of proper installation of DG set:

a) improved reliability and durability

b) Better fuel economy

c) Easy serviceability

d) Improved aesthetic of genset room

e) High up time of genset

f) Better working conditions

LOCATION

Selecting a location for genset is very important part of any installation procedure.

Always locate the genset in the area that will provide:

a) Adequate ventilation

b) Clean, dry and bgood drainage capabilites.

c) Physical protection

d) Space for carry out services and also major repairs

e) Doors must be seized to allow access in & out for the complete generator set

anmd major accessories

FOUNDATION


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An inadequate foundation may lead to excessive genset vibrations resulting in

radiator leaks, failure of the auto electrical and safety system or failure of gauge,

coupling or other engine parts.

a) Genset should be kept on leveled surface.

b) Use of anti vibration mountings are recommended to isolate vibrations or

transmitting to floor. These are placed in between engine/alternator and base

frame.

c) The length and breadth of foundation should be atleast 150-300mm more

than the base rail length and breadth respectively.

d) It is recommended to have foundation height about 100-150mm above

ground level.

3. LIFTING/ UNLIFTING OF DG SET

a) Provision for genset lifting is provided on base rails. Unload the genset

from base rail by lifting with proper lifting tackle or nylon sling/ steel

rope of suitable capacity and crane so as to ensure no damage to oil

sump, air cleaner, radiator pipes etc.

b) Do not lift the genset from the engine hook and alternator hook.

ROOF TOP INSTALLATION

a) Structure of the roof area should be suitable for the entire weight, size

and shape of the enclosure

b) Floating floor of the structural steel platform across the main building

main columns can be a one of the solution] Ensure usingc) AVMs and also other installation techniques so that vibrations are not

transmitted to the building.


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GENERAL MAINTENANCE

1. VENTILATION

Ventilation inside the enclosure is necessary to remove heat and fumes diddipated

by the engine, alternator and its accessories and to provide clean and fresh air for

combustion. Additional ventilation arrangements may be required for gensets

installed in rooms. Radiator cooled engines may create slight negative pressure

inside the genset room/ enclosure. Maximum static restriction should not increase

6mm water column. Maximum allowed temperature rise above ambient in genset

room/ enclosed is 5 degree Celsius.

2. EXHAUST SYSEM

The exhaust system is used to direct exhaust to non-confined areas and to reduce

the noise to tolerable levels.

a) Ensure joints for

Proper clamping at the joint of exhaust and below

Proper clamping at the joint of exhaust pipe and silencer elbow No exhaust gas leak from any joint

b) Ensure alignment for

Exhaust bellow must have its free length, when installed with exhaust

pipe

Proper alignment of bellow and pipe

Ensure that bellow is not installed tilted or compressed

Ensure proper support to piping and silencer

c) Ensure free movement of exhaust pipe and silencder

d) Exhaust pipe lagging is must

e) Ensure exhaust back pressure limit is not exceeded in any case.


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3. AIR SYSTEM

a) Engine inlet air must be adequate, clean and as cool as possible. This will

help to achieve best possible performance and expected life of the genset.

b) Heavy duty air cleaner should be used for dusty environment. Please note

that gensets are supplied with medium/heavy duty air cleaner

c) Negative pressure(vaccum) inside the enclosure is not advisable. If it

exists/created, thyen value should not exceed 6mm of water column.

4. FUEL SYSTEM

a) Ensure leak proof joints

b) Piping should not restrict fuel flow to engine, accessibility to service points

and ventilation air flow.

c) Fuel can be cleaned or diesel can be drained without obstruction.

d) Provide diesel filling capacity from outside enclosure.

e) Provide level indicator and trip for low fuel level.

5. FUEL TANKS AND PIPES

a) The fuel delivery line carrying fuel to the engine and fuel return line

for carrying excessive fuel back to the tank should be no smaller than the

fitting sizes on the engine. For longer runs or extremely low ambient

temperatures increase the size of these lines to ensure adequate flow

b) Size to suit at least one shift operations or maximum 990 ltrs.

c) Drain fittings to bleed water condensate at lowest point of tank.d) Fill neck to be provided to allow min 5% expansion space

e) Use pipe sealant LOCTITE-577 for all connections for sealing. No Teflon

tape to be used

f) Suction line and return line to be separated by atleast n300mm


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g) Galvanizing not recommended inside fuel tank. Copper and GI pipes react

with diesels cant be used.

h) Wire mesh filter at suction point.

i) The fuel return line should be designed with minimum amount of bends or

dips to prevent air lock in the system.

j) Flexible fuel pipes should be used at a point between the tank and engine to

avoid the potential damage that could be created by vibration.

k) All standard genset with acoustic enclosure are provided with tank fitted in

the base frame. This tank will produce a ready fuel supply.

6. ENGINE BREATHER VENTS

a) Crankcase gases should be piped outside the engine room so that oil dont

accumulate on the engine/radiator.

b) Vent tube / hose should continuously slope downwards to avoid oil

accumulation.

7. SERVICE ACCESSIBILITY

a) Engine control panel should be visible from outside the enclosure

b) Service check should be possible without dismantling acoustic enclosure

c) In case of any major repairs, it may be required to dismantle the enclosure

and sufficient space around the enclosure should be available to carry out

the work

d) To avoid recirculation of hot air, durable sealing between radiator and

canopy is must.e) There should be provision for oil and coolant drain. Fuel tank have

provision for cleaning.


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8. COOLING SYSTEM

a) Systems are designed for ambient temperature of 500 degree Celsius.

b) Water used in the cooling systems should have properties as mentioned in

below table. If properties are beyond the limits then it can result in

Scale formation

Over heating

Corrosion

c) radiator fan flow should be free from any obstructions.

9. BATTERY / ELECTRICAL SYSTAM

a) 12V electrical system is used in SUDHIR engines upto 62.5 KVA.

b) Battery provided with the genset is maintenance free charged battery.

c) Battery should be placed on stands.

d) For AMF applications, a static battery charger working on main supply is

recommended to keep the batteries charged at all times.

e) Ensure polarity of the battery connections are correct.

10.ELECTRICAL CONNECTIONS

a) Ensure that only qualified electricans carry out installtion work

b) Use flexible cable to avoid vibrations and possible damages to the

alternator or circuit breaker terminals.

c) Ensure that the cable is laid in a cable tray and minimum bending radius

reference is followed.

d) Use correct size and type of cable to suit applied voltage, maximum current

and allowance should be made from maximum temperature inside the

enclosure.


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e) All electrical work should be carried out in accordance with any applicable

national, local standards, codes or regulations.

f) Protect the generating set from overload / short circuit by using circuit

breaker.

g) Maintain the power factor to 0.8 lagging by using inductive load or

capactiors depending upon the load type.

h) Never attempt to work on the living wire

i) Ensure balanced load is applied on the genset.

11.CABLING

a) Use only recommended cable sizes.

b) Use flexible wires.

c) Avoid any tension on the bolts / bus bars while terminating the cables.

d) Maintain R Y B phase notation in the alternator and control panel for ease in

maintenance.

e) Crimped cables should be connected to alternator and contol panel through

cable gland.

f) Strictly avoid loose thumbing / undersize cables.

g) Use armoured copper cable of right size for control cabling.

h) Support the cables such that weight of the cable should not fall on alternator

/ base rail.

12.EARTHING

a) Generated set + associated control and switchgears panels must be earthedproperly.

b) Earthing must be done on engine / alternator and not on base rail.

c) Earthing should be checked with multi-meter and ensure resistance is

maintained in prescribed limit (1).


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d) Copper GI strips of suitable size may be used.

e) Generating set should be earthed two distinct points through a conductor

heavy enough to carry the short circuit current without burning out.

f) Earthing must be in accordance with applicable national, local code or

regulation.

13.FIRE PRECAUTION

a) Install recommended type fire extinguishers.

b) Keep the room / enclosure free from accumulated rubbish which cab be fire

hazardous.

14.GENEST WITH ACOUSTIC ENCLOSURE

a) Engine control panel should be visible from outside the enclosure.

b) Service check should be possible without dismantling acoustic enclosure.

c) For major repairs / overhaul it may be required to dismantle the acoustic

enclosure.

d) To avoid recirculation of hot air, durable sealing between radiator and

canopy is must.

e) Sufficient capacity ventilation fans are required if radiator fan flow is not

sufficient. Fan flows in acoustic enclosure will be less due to higher

restrictions.

f) Exhaust piping inside the enclosure must be lagged

g) Temperature rise inside the enclosure should not be more than 50 degree

Celsius.

h) Radiator cooled engines may create slight negative pressure inside the

enclosure.

i) There should be provision for oil and coolant drain.


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15.SUCCESS KEYS

a) Adhere to central pollution board (CPCB) and other applicable national and

local codes, norms and regulations.

b) During installation, for dismantling of the acoustic enclosure and generating

set components, and then reassembly, ensure that both the processes are

done strictly as per manufacturers recommendations and by the authorized

work force.

c) Use only authorized channels for supply, installation and commissioning

and operation and maintenance.

d) Use genuine spares only.

e) Do operation and maintenance as per manufacturers recommendations and

through authorized service network. Maintain log book and other related

records. This will be useful during troubleshooting.

f) Insure right quality and quantity of air, fuel, lubricating oil and coolant. This

is more critical in case of AMF operations.

g) When generating set stops because of a fault, rectify 100% before start.


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ENGINE OPERATIONS


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TESTING


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TESTING


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ROJECT REPORT

ON

FAULT TRACING

IN

DG set


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Sr.

No.

DEFECTS REMEDY

1. FAULTY STARTER SWITCH REPLACE

2. BATTERY TOO LOW TO TURN

ENGINE

CHARGE OR INSTALL NEW

BATTERY

3. ENGINE OIL TOO LOW DRAIN OIL AND REFILL WITH

CORRECT GRADE

4. STARTER MOTOR INOPERATIVE INSPECT CABLES AND

TERMINALS

CHECK FOR TIGHTENING OF

MOUNTING SCREW

INSPECT BRUSH GEAR FOR

WEAR OR DAMAGE AND

COMMENTATOR FOR DIRT OR

DRAINAGE

5. STOPPER KNOB PULLED OUT PUSH THE KNOB IN

6. FUEL SYSTEM CLOGGED DRAIN SYSTEM, CLEAN AND

REFILL WITH PROPER FUEL

7. BATTERIES DISCHARGED CHARGE OR REPLACE

8. LACK OF COMPRESSION CHECK PUMP FOR

RESTRICTION IN SYSTEM AND

CLEAN OUT

ALSO CHECK VALVES AND

SPRING*


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9. LUBRICATING OIL OF WRONG

VISCOSITY

DRAIN AND REFILL WITH

PROPER LUBRICANT

10. FUEL FEED PUMP INOPERATIVE *

11. FUEL INJECTION PUMP HAS LOST

ITS EFFICIENCY

*

12. FAULTY HEAT INDICATOR REPLACE

13. INSUFFICIENT WATER IN THE

COOLING SYSTEM

CHECK WATER LEVEL IN THE

RADIATOR AND ADD WATER IF

NECESSARY

14. COOLING SYSTEM CLOGGED CLEAN OUT RADIATOR AND

ENGINE

15. FAN AND WATER PUMP BELT

SLIPPING

CHECK TENSION AND MAKE

PROPER ADJUSTMENT

16. INSUFFICIENT OIL MAINTAIN PROPER OIL LEVEL

17. DEFECTIVE THERMOSTAT *


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18. WATER PUMP DEFECTIVE *

19. FUEL INJECTION TIMING

INCORRECT

*

20. VALVE CLEARANCE INCORRECT ADJUST CORRECTLY

21. CLUTCH PLATE SLIPPAGE *

22. DEFECTIVE OIL PRESSURE

INDICATOR

REPLACE

23. BROKEN, LOOSE PIPES REPLACE, CLEAN AND

TIGHTEN

24. LOW OIL LEVEL IN THE

CRANKCASE

ADD OIL AND CHECK FOR OIL

LEAKAGE

25. DEFECTIVE OR DIRTY OIL

PRESSURE REGULATING VALVE

*

26. OIL PUMP NOT WORKING *

27. WORN BEARINGS *


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28. CLOGGED OIL FILTER *

29. TOO MUCH OIL IN AIR CLEANER CORRECT THE OIL LEVEL

30. INMPROPER GRADE OF FUEL/OIL DRAIN OFF AND REPLACE

WITH CORRECT GRADE OF FUEL/OIL

31. AIR CLEANER PIPE CLOGGED REMOVE AND CLEAN

IF DEFECTIVE REPLACE

32. INCORRECT VALVE ADJUSTMENT SET VALVE CLEARANCE

33. FUEL INJECTION PUMP LOST ITS

EFFICIENCY

*

34. LOOSE WIRING OR IMPROPER

CONNECTIONS CAUSING MALFUNCTIONING

CHECK WIRING TO SEE THAT

ALL CONNECTIONS ARE CONNECTIONS ARE CLEAN AND

TIGHT

35. BATTERY DEFECTIVE, LOW

CHARGE OR LOOSE

CONNECTIONS

RECHARGE, CLEAN AND

TIGHTEN CABLE PLUGS OR

REPLACE WITH NEW, CHECK EARTH

CABLE

36. STARTER MOTOR INOPERATIVE CHECK BRUSH GEAR

37. ALTERNATOR INOPERATIVE CHECK REGULATOR


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CONCLUSION OF

TRAINING


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CONCLUSION OF TRAINING

My training was the most versatile experience. I had the pleasure to do the work with one of

the most reputed factory in their field-SUDHIR GENSETS LTD. I received the blend of

experience in private sector. It was a good learning time during my training as we were

fortunate to be placed in the department related to manufacturing. I feel training has given me

exposure to undergo projects in the Manufacturing field as well help me a lot to understand the

company work culture, working with teams and much more.

In the end I would like to thank all persons who helped me throughout my training to enhance

my experience. I also pay my regards to my lecturers for their guidance during my training and

my academics helped me to do a lot during my training.

Project Report on Sudhir Generator Set

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Transcript of Project Report on Sudhir Generator Set