davis & shirtliff · overheating of the engine & coolant system oil viscosity breakdown...
TRANSCRIPT
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POWER PRODUCTS
UNICEF TRAINING
SCOPE
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GENERATORS, WELDING SETS, PANELS
PUMPS (SKID & MOBILE)
BARE SHAFT ENGINES
AFTER SALES:- Installation- Servicing- Maintenance- Warranty
SCOPE
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REMOTE MONITORINGCUSTOMERSTRAINING
CONTRACTS LOAD ASSESSMENT
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WHERE WE CAN PARTNER• Water pumping Projects
• Off grid - power
borehole/booster pumps
• Engine couple pumps – water
transfer from dams, rivers
• Genset Standby power application –
unreliable utility supply
• Genset prime power – off grid areas,
schools, hospitals, offices, camps etc.
• Generator/Solar Hybrid systems
ENGINE FUNCTION PROCESS
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•Flywheel
•Crankshaft
Air
Fuel
Mixing Combustion
Exhaust
Power
Useful
Work
•Carburetor •Ignition •Valves
THE WORKING – 4 STROKE
compressionIntake Power Exhaust
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ENGINE RATINGName plate rating (HP/kW), at a given
speed
Continuous & Intermittent ratings
Ratings based on some standard
reference conditions i.e. for NA EnginesAir inlet temp – 25oC
Relative Humidity – 30%
Altitude – 100m
Air pressure, temperature & humidity
affect the air density Engine Output
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DERATING CURVES
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Selection Example – Engine Driven Pump
Determine a suitable engine driven pump to
deliver 35m3/h @ 80m total head. Site Altitude is
1650m asl, ambient temp is 26oC.
Suitable bare shaft pump – DE40/26 (255mm)
@2900rpm
Pump requirement at duty point – 15kW
Pump requirement (maximum) – 18kW
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Example –Engine Driven Pump
Derating for altitude (1650–100) x 1% 15.5%
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Derating for Temp (26–20) x 2% 1.2%
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Total deration factor 16.7%
(synonymous to 83.3% engine efficiency)
Engine should be derated at 1% for every 100m higher than
100m,above sea level, and 2% for every 5°C temperature above 20°c.
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Example –Engine Driven Pump
Derated engine size ( 18 ) 21.6kW
(0.833)
Allow 15% safety margin 21.6 x 1.15 24.8kW
Kohler KD626.3
As guideline engine size not to exceed 21.6 x 2
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Over loading:
Overheating of the engine & coolant system
Oil viscosity breakdown causing rapid engine wear
Shortened working life of the Engine
Under loading:
Engine not heating up to normal working temp
Oil leakage caused by poor sealing by piston rings
Lacquer formation on the piston cylinder liners
Increased maintenance costs; reduction in power
OVERLOAD/UNDERLOAD
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UNDER LOAD – WET STACKING
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D&S ENGINE RANGE• Generally classified into:
–Governing - Fixed (G-build)/
Variable speed
–Fuel – Petrol or Diesel
–Cooling System – Air/ Water
–Starting method – Hand/ Electric
KOHLER ENGINES
• Rebranded Lombardini Engines
• Two models stocked – Fixed Speed - 1500rpm
– Variable Speed – 2000 – 3000rpm
• Air Cooled– Simplified design
– Simpler maintenance requirements
– Hand / electric start options
• Water Cooling– Efficient cooling and reduced noise operation
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– 6.5 to 27kW
– 1500 – 3000 RPM
Air Cooled
KOHLER ENGINESWater Cooled– 24.5 to 33kW
– 2000 – 2600RPM
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DAYLIFF LOV ENGINES
Engine Data 1004-4Z 1004-4TZ
Continuous
Power kW
1500 rpm 41 65
1800 rpm 46 72
2200 rpm 50 75
• Variable speed design
• Two model, NA and Turbo charged
• PTO on flywheel, fuel tank not incl.
DAYLIFF DLA ENGINES
• 1 & 2 Cylinder variable speed Engines
• Ideal for short term or low budget projects
• Compact air-cooled engines
• 10HP & 17HP power output
• 5.5 and 7lt engine mounted fuel tanks and
drive shaft
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DAYLIFF PETROL ENGINE
• 6HP 3600rpm bare shaft Engine
• Chaff Cutter Engine• Supplied in cylindrical shaft
with key way• 3.6l Fuel tank, recoil start
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SKID MOUNTED SETS
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1. HIGH FLOW PUMPS–For small scale irrigation
projects
D&S PORTABLE PUMP
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2. HIGH PRESSURE
• For long distance pumping
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GENERATOR SYSTEM
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GENERATOR SYSTEM
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•Suitable prime mover/ Diesel engine
•AC generator (Alternator)
•Control circuit & AuxiliariesControl Cubicle
Engine
AVM
Start battery
AlternatorBase fuel tank
OPERATION PRINCIPLE
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GENSET RATING• Usually expressed in kVA
• Prime power:
-Supply of continuous power ALL DAY
-Applies to utility power installations
• Standby power:
-Prime power plus overload of 10% for 1 of every 10hours
-Applies to standby power installations
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Load Capacity
Consideration for special loads
Wiring configuration of the load
Future expansion plans
Site conditions effects on performance (deration)
Cable sizing for current and voltage drop
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FACTS WHILE SIZING
GENERATOR LOADING
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• Current output is determined by the connected
load
• When a three phase generator is loaded with
single phase loads
a) The loading may be imbalanced (phase
imbalance)
b) The maximum single phase power between
any line and neutral is 1/3 of the total 3 phase
power.
• A 12 lead stator can be reconfigured for both single
or 3 phase outputs
CONDUCTING A SUCCESSFUL SITE SURVEY
Tools: Altimeter, Clamp meter, Tape
measure, Screw drivers, analysers
Site Details:
• Power supply– No. of incoming power points
– Transformer details i.e. one or multiple
• Meter system– No. of Utility Power meters & location
– Single or three phase? & quantity
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CONDUCTING SITE SURVEY• Load Balancing
– Use clamp meter
• ATS location– Identify where to mount taking into consideration
weather condition
– Cable management – saddle clips or cable tray
• Generator Installation location– Accessibility – crane truck, pallet truck
– Noise consideration
– Length of cable
– Earthing arrangements
– Cable routing
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CONDUCTING SITE SURVEY• Generator Plant Room
– Plant room dimension - door
– Ventilation requirement
– Need for hot air ducting
– Exhaust pipe routing
– Type of plant room – steel cage, block wall
• Type of load– Resistive, capacitive, inductive
– Starting sequence
– Starting method for motors
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GENERATOR SIZING1. List Of Appliances & Rating
• When sizing a generator it is not always
sufficient to simply add together the ratings of
all electrical equipment.
• This is because it is unlikely that all the
electrical equipment on a supply will be used
simultaneously.
• Diversity factor is applied to work out the load
which can simultaneously be in operation
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GENERATOR SIZINGNo. Load Qty Power
Rating
(Watts)
Total
Wattage
(Watts)
Diversity
Factor
Net
Wattage
(Watts)
Single Phase Load
1 Instant shower 50 4,500 225,000 30% 67,500
232'' LED TV 50 120 6,000 50% 3,000
34 ft Fluorescent Lights 50 36 1,800 80% 1,440
4Energy Saving bed lamps 100 18 1,800 80% 1,440
5TFT Computers 6 300 1,800 100% 1,800
6Printer 1 120 120 30% 36
7Photocopy 1 500 500 30% 150
8Cooker/Oven 1 3,000 3,000 40% 1,200
9Microwave 1 1,200 1,200 20% 240
10Fridge 1 250 250 70% 175
11Freezer 1 500 500 70% 350
Total Wattage (Watts) 241,970 77,331
Three Phase Load
12Grundfos SP 9-40 1 7,500 7,500 100% 7,500
Total Wattage (Watts) 84,831
Factor 80% Loading Level (Watts) 106,039
Add 20% for future Expansion (Watts) 127,247
Proposed Generator Size 159,058
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GENERATOR SIZING2. Clamp Meter Reading
• Clamp each line with equipment switched on.
• Base calculation on highest phase currentPower (VA) (1 phase) = VxI
Power (VA) (3 phase) = √3xVxI
• Take note of peak requirement for induction
load - motors
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GENERATOR SIZING3. Energy Analyser
• Recommended for complex installations with
varying load demand – hospitals, malls,
factories
• Most accurate approach
TYPE OF LOAD• Single-phase loads and load imbalance.
• Peak loads - Such as welding, medical imaging equipment
• Motor loads - Result is a high inrush current
• Variable frequency – induce distortion in generator output voltage (Harmonics).
• Uninterruptible power supply - non-linear load, require appropriate filters
• Lifts
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CABLE SIZING• Cables have internal resistance which
causes voltage drop (heat)
• Why size cables?:1. Ensure that you get adequate voltage at the end of the line2. Safety – to avoid cables melting due to heat
• Cable size is selected as follows:1. Cable is calculated on current capacity2. Voltage drop is calculated (and cable size increased if necessary)
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• Sized based on Load/Capacity of the generator
• Cables must be sized for both maximum current and max allowed voltage drop
Current (1 phase) = kVA x 1000V
Current (3 phase) = kVA x 10001.73 x V
Cable Sizing Example!
Cable Sizing
Cable Sizing Chart
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TRANSFER PANEL• Changeover switch – electrical switch that switches a
load between two sources
• Comprises: sensing (AMF) and switchgear (ATS)
• AMF – monitors utility & initiates automatically load
transfer
• ATS – Automatically connects the load to available
power
• Capacity must be matched to the rating of the service
equipment
• Two types: manual and automatic
Application
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Yanan Motorised ATS
• Offer with Yanan and
Jubaili Perkins generators
• Fitted with DSE 6020 with
AMF capability
• Motorised Changeover
with provision for manual
operation
• Match current output of
generator with ATS size
(125A, 250A,400A)
• Control cable – 2 runs of
2.5mm2 x 3 core
PVC/SWA)
Application
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Remote Start ATS• For generators without
AMF capability
• Lister Petter (DSE5110)
• Can also work with
Yanan and Perkin
generators
• Sensing/Control done by
ATS
• Contactor based
• Manual by-pass switch
recommended
• Control cable – 1 runs of
2.5mm2 x 4 core
PVC/SWA)
Application
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Manual Changeover Switch
• For key start generators
without AMF control
modules
• Dayliff key/recoil start
generators. Petrol,diesel,
Kohler
• Install with pilot lamps to
indicate mains availability
Application
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Dayliff DG AMF
• For automatic range of
DG portable generators
• DG6000DS,
DG11000PS,
DG12000DS
• Have AMF capability
• Control Cable supplied
with AMF approx. 2.5m
• Power cable – 1 run of 4
Core cable for single
phase and 2 runs of 4
core cable for three
phase
Application
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Multi-Tariff AMF
• For installations with
more than 1No. Utility
meter
• Avoid billing when load is
on mains supply
• Set of contactors for each
of the utility meters
• Generator distribution
boards for multiple
changeover switches
• Remote /potential free
start signal
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Multi-Tariff AMF
Application
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Manual By-Pass Switch
• Recommended for
contactor based transfer
switches
• By-passes the
changeover switch in
case of faulty or when
servicing
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ATS Set-Up
PLANT ROOM
The alternator must be protected from weather
Large enough size - ventilation & working space
Proper plant room layout
Level, flat & compact floor
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PLANT ROOM LAYOUT
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PLANT ROOM
GENSET SYNCHRONIZATION
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PARALLELINGParalleling is an operation in which multiple power sources, usually two or more generator sets, are connected and synchronized to a common bus.
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WHY SYNCHRONIZE– To allow the generating capacity of the
system to be expanded as site load increase
– When site load varies greatly multiple units
avoid a scenario of “light loading”, which will
damage the engine
– Physical constraints of the installation site
– Allows uninterrupted supply even during
servicing/maintenance
– In some cases, cost
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CONDITIONS• The number of phases and direction of
rotation
• The voltage amplitudes of the two\multi
systems
• The frequencies of the two\multi systems
• The phase angle of the voltage of the
two\multi systems
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PHASE ANGLE
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60kVA UNOPS
DSE REMOTE MONITORING
HARDWARE
• DSE890 Gateway
•GSM/GPRS Antenna
•DSE Control module
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What we can monitor?
-
What we can monitor?
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What we can monitor?
• Sourced from Jubaili Brothers
• 12.5 to 2250kVA prime power rating
• Perkins (UK/USA) engines
• High efficiency Mecc Alte/ Leroy Somer
alternator
• DeepSea control modules
• Assembly UK (Marapco) & UAE (JET)
DGJ PERKINS RANGE
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JET & MARAPCO BRANDDIESEL GENERATOR SETS
ARE POWERED BY PERKINS ENGINES
DGJ PERKINS RANGE
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• Based on Isuzu
Engine design
• Ind., Agric. &
Vehicles
• 20 – 30kVA
DGY YANAN RANGE
• Joint Sino – UK Venture
• Customized for ease of
maintenance Service
parts on one side
• Ind., Agric. & Vehicles
• 45 – 70kVA
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DGY YANAN RANGE• Powered by Cummins Engine
• Local Support – Many spare
parts distributors
• 56kVA - 400kVA available ex-
stock
• Wider range available–up to
2000kVA – special order
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OEM CERTIFICATES PERKINS
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OEM CERTIFICATES YANAN
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DEEP-SEA MODULES• Standard - DSE 6020 (AMF)
• DSE 7310/DSE 7320 & DSE 8610
• PC and front panel configurable
• Load Transfer Switch – Motorized
and Contactor Based
KOHLER GENERATORS• Air cooled Open Sets
• Yanan & Linz Alternators as options
• Fitted C/panel – MCB, on-off switch,
hour-meter, digital display
• Inbuilt Autostop protection
• Key Start
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• Premium Honda engine
• 2.2 to 6.5kVA 1 phase
power rating
• Large capacity fuel tank
for longer operation
• DC output for extra battery
charging
• Compact and light weight
design
ELEMAX HONDA
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DG-P PETROL
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• 0.6 to 10kVA 1 phase power rating
• Value for Money – Reliable, Efficient
• Auto start function for DG-PS series
• DC output for extra battery charging
• Warranty, Spares and after-sale service
DG-D DIESEL
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• 4.5 & 10kVA 1 phase
• 12.5kVA 3 Phase
• Auto start function for
DG-DS series
DAYLIFF DGW• Option for Petrol or Diesel
• Diesel - 4.2kVA AC output; 180A arching
current; 28-35VDC
• Petrol – 5kVA AC 200A welding current
• Complete with electrode holder, welding clamp
& output plugs
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SUCCESSFUL PROJECTS
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WHY D&S• We offer solutions
• Complete range of Generators, engines &
associated accessories – premium quality
• Professional installation
• After Sales Support
• Maintenance contracts
• Warranty
• Spare parts
• Innovative products/customized
• Wide Branch network – response time