Index 1. Assembly 2. Control panel unit 3. Testing 4. Operation 5. Maintenance
ASSEMBLY In assembly unit different parts of generators are assembled to make a generator. The main parts of a generator are :
Engine Alternator Power control
In assembly line these three parts of the generator are assembled together . Sudhir gensets use cummins
diesel engines engines :
Diesel powered generator sets remain the number – –one o ne choice for standby and emergency power systems, worldwide. Able to start and assume load in less than 10 seconds, and rated load in a single step, Cummins diesel generator sets are the epitome of rugged dependability and reliable mechanical and electrical performance. Diesel generators are also well suited to utility peaking plants, Distributed Generation (DG) facilities, peak shaving (or peak lopping), and power management at large commercial or industrial sites.
Features and Benefits: As a mature technology, Cummins clean and modern diesel – powered generators offer these key benefits:
Rapid product availability Proven reliability and low life– cycle costs High efficiency and operational flexibility High quality electrical performance Well –e stablished service and fuel supply infrastructure Optional factory –i ntegrated exhaust aftertreatments reduce emissions for high– hour use in environmentally sensitive locations.
Our 7.5 kW to 25 kW air – and liquid –c ooled diesel generator sets offer traditional rugged construction, durability, and reliability for applications range from nursing homes to wireless services, to prime power for remote or temporary sites. In the 35 kW to 500 kW range, our diesel – fueled generator sets with PowerCommand offer a wide array of system features that can be tailored to your specific application, whether for standby or prime power. In the 600 kW to 2.7 MW range, our diesel – fueled PowerCommand generator sets meet your most demanding standby or prime power applications.
Stamford alternator
Stamford Electric is the worldrenowned transnational Electric Group, one of the three. The use of advanced technology in the United States and Europe prod uces frequency AC alternator all over the world until the environment is the poorest region. Its strong manufacturing and service support capability and reliable q uality accesses to the widely recognization of the usersaround the wor ld. At th e sa me ti me , the co mpan y la un ch ed a ma ss iv e driv e prod uc t line , including AC electric motor, selfstarting synchronous motor and DC motor. Standardization of these components could be coordinated with the g ear box in order to receive proper torque, speed and braking. The company also manufactures electronic systems for the production of full control, manipulation and orientation. Stanford's electrical power generation equipment in the field also play ed an important role in the production of complete line of lowvoltage and medium voltage electrical alternator products.
Standard features: voltage regulator, the regulation of stability, adjustment of voltage / low frequency performance of the protecti on, three-phase RMS detection, running parallel, over-excitation protection, over-voltage protection,
EMI suppression functions. These generator are very heavy to lift up and to transport for this purpose a very special kind of lifting machines are used called EOT cranes or electric overhead travelling crane.
EOT cranes: The most adaptable and the most widely used type of power driven crane for indoor service is undoubtedly the three motion EOT crane. It serves a larger area of floor space within its own travelling restrictions than any other permanent type hoisting arrangement.
As the name implies, this type of crane is provided with movement above the floor level. Hence it occupies no floor space and this can never interface with any movement of the work being carried out at the floor of the building. The three motions of such crane are the hoisting motion and the cross travel motion. Each of the motions is provided by electric motors. The above characteristics have made this type of crane suitable for medium and heavy workshop and warehouses. No engineering erection shop, machine shop, foundry, heavy stores is complete without an EOT crane. In a steel plant, rolling mill, thermal power plant, hydraulic power plant, nuclear power plant, this type of crane is considered indispensable. In short in all industries, wherein heavy loads are to be handled, EOT crane find its application.
A EOT crane consists of two distinct parts
1. Bridge 2. Crab
The Bridge consists of two main girders fixed at their ends and connected to another structural components called the end carriages. In the two end carriages are mounted the main runners or wheels (four or more) which provide the longitudinal motion to the main bridge along the length of the workshop. The motion of the bridge is derived from an electric motor which is geared to a shaft running across the full span of the bridge and further geared to a wheel at each end. In some design separate motors may be fitted at each corner of the main bridge. The wheels run on two heavy rails fixed above the floor level along the length of the shop on two girders, called gantry girder.
The Crab consists of the hoisting machinery mounted on a frame, which is in turn mounted on at least four wheels and fitted with suitable machinery for traversing the crab to and fro across the main girders of the crane bridge. Needless to mention that the crab wheels run on two rail sections fixed on the top flange of the main bridge. Thus the load hook has three separate motions, these being the hoisting, cross traverse of the crab, and longitudinal travel of the whole crane. Each motion is controlled independently of the other motions by separate controllers situated in a control cage or in a suitable position for controlling from the floor by pendent chains. The essential parts are:
1.
End carriage – 2
No’s
2.
Wheel of Bridge – 2
3.
The bridge – At least 4
4.
Crab (without auxiliary hoist) – 1
5.
Hoisting machinery set – 1 No’s
6.
Wheels of crab – At
7.
Bottom Block (without auxiliary hoist) – 1
8. Lifting hook – 1 9.
No’s No’s No’s
least 4 No’s No’s
No’s
Rail on the gantry girder for crane movement – 2 10. Rail on the bridge for crab movement – 2 11.Operators cabin – 1 No’s
No’s
No’s
In sudhir gensets different diesel range of generators are manufactured ranges from 25 KVA to2250 KVA. The description of some siletnt diesel generator are given below:
Specification sheet 12-20 kWe, 15-25 kVA Prime Ready to use, silent, compact and light weight The ready to use Cummins ® 'DXP series' DG sets are smaller and lighter than any other DG set in it's class, thus giving you the advantage of optimising your valuable space. Environment friendly power The Cummins ® 'DXP series' base DG sets are available with the lowest noise levels in it's range and are CPCB certified for emissions compliance, thus offering you environment friendly power.
The genset powered by the reliable Cummins ® 'X series' diesel engine meets stringent exhaust emission tests as per MOEF norms without sacrificing fuel efficiency at normal operating loads. Unmatched warranty The Cummins ® ‘DXP series’ DG sets are backed by the industry aknowledged best-in-class comprehensive warranty on the entire package including rubber components. Lowest operating costs All elements of the Cummins ® ‘DXP series’ DG sets are designed from the start to work together to maximize efficiency, even at part loads, thus offering you the advantage of lowest operating costs. Alternator Stamford alternator from Newage, suitable for operation at 1500 RPM, 415 Volts, 0.8 pf (lag) suitable for 50 Hz, 3 phase, 4 wire system, conforming to BS 5000/IS 4722. The Alternator is brushless type, screen protected, revolving field, self excited, self regulated through an AVR. The alternator has the following features: + 1.0 % Voltage regulation (max.) in static conditions IP: 23 Enclosure
Permissible overload of 10% for one hour in 12 hours of operation Mounting arrangement Engine and alternator are mounted on a common MS fabricated base frame with AVM pads. Control panel The control panel is manufactured with 14/16 gauge CRCA sheet and is powder coated for a weather-proof, long lasting finish. The control panel consists of following parts: 1. Standard engine instrumentation Multi function meter which measures: 2. Individual phase current (Amps) Phase voltages (V) Generator output frequency (Hz) Engine water temperature (Deg.C) Lube oil pressure (kg/cm2) and equipped with hour counter MCB of suitable rating 3. Key switch 4. Push button (Starter) 5. 6. LED: Battery charging alternator fail indication Current transformers 7. Instrument fuses duly wired and ferruled 8. Others Fuel tank suitable for 8 hours of operation One dry and uncharged battery with battery leads
Single source power assurance The rugged and reliable Cummins ® ‘DXP series’ DG sets are unique, because all the major components – the engine, alternator, control system and canopy are designed, manufactured and tested by Cummins India/ Channel partners (Powerica Limited). This, complemented by the largest customer support network in India, capable of providing roundthe-clock service and spares support, offers you SINGLE SOURCE POWER ASSURANCE from the world leaders in power generation.
Standard scope: Engine: Cummins® ‘DXP series’ diesel generating sets, powered by Cummins® ‘X series’ engines, are rated at 1500 RPM and conform to ISO 8528 specifications. The engines are radiator cooled, four stroke and multi-cylinder, conforming to BS 5514/ISO 3046.
The scope of supply includes: Electrical starter motor 12V DC Battery charging alternator MICO fuel system with mechanical governor Dual spin-on fuel filter Spin-on full flow lub oil filter Residential silencer Dry type air cleaner Recovery bottle Shut-off coil with safeties for LLOP/HWT Flywheel and flywheel housing First fill of lube oil and coolant Acoustic enclosure The acoustic enclosure is made of 1.6/2 mm thick CRCA sheets and structural/ sheet metal base frame painted in Munsel green shade. The walls of the enclosure are insulated with fire retardant foam so as to comply with the 75 dBA at 1mtr sound levels specified by Ministry of Environment & Forest.
The enclosure has the following features: \Specially designed to meet stringent MOEF/ CPCB norms of 75 DBA @ 1mtr at 75% load under free field conditions Single point lifting for easy handling at customer site Designed to have optimum serviceability
Air inlet louvers specially designed to operate at rated load Made on special purpose CNC machines for consistency in quality and workmanship Powder coated for long lasting service life and superior finish With UV resistant powder coating, can withstand extreme environments Use of special hardware for longer life Insulation material meets exacting IS 8183 specifications for better sound attenuation Flush styling - no projections Fluid drains for lube oil and fuel Fuel filling point
Diesel generator set V28 series
Lowest life cycle cost V28 Series design features have made Cummins® diesel, the standard for comparison of operating economy, reliability and long life. When all cost factors like initial purchase, fuel, lube oil, maintenance and overhaul are considered, the bottom line will show that this Cummins ® ‘V28 series’ will deliver the lowest life cycle cost. Heavy duty, durable and emission compliant Cummins ® ‘V28 series’ diesel engine comes with heavy duty features, optimum size camshaft, optimized turbo-matching, premium injectors and is yet compact in size with optimum power to weight ratio making it the obvious choice for your long-term power needs.
The gen set powered by the reliable Cummins ® ‘V28 series’ diesel engine meets stringent exhaust emission tests as per MOEF norms without sacrificing fuel efficiency at normal operating loads. Silent Power Cummins ® 600-625 kVA enclosures are so designed as to have optimum performance and serviceability over the complete operating range. The enclosures are compact and are designed for ease in maintenance. The powder coated enclosures are manufactured on latest CNC machines to ensure superior finish and durability.
Alternator Stamford brushless alternator Self-excited, self regulated Class ‘H’ insulation Salient pole revolving field Single bearing Digital automatic voltage regulator
Accessories Silencer suitably optimized to meet stringent sound emission standards laid down by MOEF/CPCB Base rail with integral fuel tank (520 litres capacity) is provided with drain plug, air vent, inlet and outlet connection, level indicator, manhole etc. Integral fuel tank of 926 litres capacity 2 x 12 V dry, uncharged batteries with connecting leads and terminals Acoustic enclosure Specially designed to meet stringent MOEF/CPCB norms of 75 dBA @ 1mtr at 75% load under free field conditions Designed to have optimum serviceability Air inlet louvers specially designed to operate at rated load even at 50 deg C air inlet temp. Made on special purpose CNC machines for consistency in quality and workmanship Powder coated for long lasting service life and superior finish With UV resistant powder coating, can withstand extreme environments Use of stainless steel hardware Insulation material meets exacting IS 8183 specifications for better sound attenuation
Specification sheet 480-500 kWe, 600-625 kVA Prime Single source power assurance Design, manufacture and testing of engine, alternator, enclosure and other accessories is done by Cummins India/ Channel partners (Powerica Limited) for that optimum performance integrity and is backed by countrywide product support network with single source responsibility for the entire package.
Standard scope Engine: Cummins® ‘V28’ series direct injection, water cooled engine, 12 cylinder, Vee, 4 stroke, rated at 1500 RPM, conforming to ISO 3046/BS 5514 has the following specifications: The scope of supply includes: Cummins PT Fuel Pump Cummins heavy duty injectors
Holset turbocharger, pulse tuned exhaust manifold, stainless steel exhaust flexible connections Radiator or heat exchanger, coolant inhibitor, Shell and tube type lube oil cooler Full flow paper element filters - fuel, lube oil and by-pass Dry type replaceable paper element air cleaner with restriction indicator Flywheel housing & flywheel to suit single bearing alternator Starting motor – Electric, battery charging alternator Electronic control panel with Electronic Governor (ECPG) Engine protections (trip) High water temperature Low lube oil pressure Over speed Low coolant oil level (alarm) First fill lube oil
Control panel Powder coated control panel manufactured with 14/16 gauge CRCA sheet provides: MCCB/ACB of suitable rating with overload and short circuit protection Voltmeter and Ammeter with selector switch KW/PF meters Frequency meter KWh meter Indicating lamps for “Load On” and “Set Running” Current transformers Aluminium busbars of suitable capacity with incoming and outgoing terminations Instrument fuses duly wired and ferruled
Optionals Engine Heavy duty air cleaner, lube oil/coolant heater with thermostatic switch
Alternator Thermistors, PMG excitation, space heater Control panel: "Power Command ®” control panel for micro processor based metering, monitoring & auto synchronising control system, AMF control panel, battery charger, remote/auto start panel, auto/ manual synchronizing panel, audio/ visual annunciation for faults Control panel "Power Command ®” control panel for micro processor based metering, monitoring & auto synchronising control system, AMF control panel, battery charger, remote/auto start panel, auto/manual synchronizing panel, audio/ visual annunciation for faults Others Mobile sets with canopy
Reliable and durable Cummins® ‘K50 series’ diesel engine with strong regrindable crankshaft, high strength connecting rod, low pressure fuel lines, STC (Step Timing Controls) injectors and high volume coolant system make ‘K50 series’ generating sets, more reliable and durable. Engines have clocked millions of hours, operating on some of the world’s most demanding conditions. Current engines are upgraded with new technologies for more performance and economy. The ultimate proof of superior performance and reliability is the fact that Cummins® entities itself source these engines from Cummins India for their worldwide market. Unmatched warranty Cummins® ‘K50 series’ diesel engine generating sets are a truly cost effective solution to long term power need backed by industry best 2 years / 5000 hrs warranty for the entire generating set. Cummins advantage Special features of Cummins® ‘K50 series’ engines like STC (Step Timing Controls) injectors, low temperature aftercooler, square cumbustion chamber,
optimised turbocharging and precision heavy duty camshaft make these engines the ultimate in exceptional fuel efficiency all across the operating range. lternator Stamford brushless AC alternator › Seperately excited, self-regulated › Class ‘H’ insulation › Salient pole revolving field › Single/double bearing › Automatic voltage regulator › PMG standard ccessories › Silencer suitably optimized to reduce noise › Sturdy base rail › 990 ltrs. free standing fuel tank › 4 x 12 V dry, uncharged batteries with connecting leads and terminals Control panel Powder coated control panel manufactured with 14 / 16 gauge CRCA sheet and provides › ACB of suitable rating with overload and short circuit protection Voltmeter and ammeter with selector switch › KW PF meters › Frequency meter › KWh meter › Indicating lamps for “Load On” and “Set Running” › Current transformers › Aluminium busbars of suitable capacity with incoming and outgoing › terminations › Instrument fuses duly wired and ferruled Optionals Engine Heavy duty air cleaner, lube oil/coolant heater with thermostatic switch lternator Space heater, RTDs, BTDs
Control Panel AMF control panel, battery charger, remote/ auto start panel, auto/ manual synchronizing panel, audio/ visual annunciation for faults PowerCommand® Genset Controls The PowerCommand® Control, is a micro processor based generator set monitoring, metering, protection and control system. It offers advanced levels of functions for reliability and optimum genset performance. An extensive array of integrated standard control and digital display features eliminate the need for discrete component devices such as the voltage regulator, governor control and protective relays. The control system has easy servicing capabilities that allow system parameters to be interrogated, monitored and adjusted with a PC.
Specification sheet 1000-1200 kWe, 1250-1500 kVA Prime Single source power assurance Design, manufacture and testing of engine, alternator, enclosure and other accessories is done by Cummins India/ Channel partners (Powerica Limited) for that optimum performance integrity and is backed by countrywide product support network with single source responsibility for the entire package. Standard scope Engine Cummins® ‘K series’ direct injection, water cooled engine, 12 cylinder , 4 stroke, rated at 1500 RPM, conforming to ISO 3046 / BS 5514 has the following specifications: The scope of supply includes: › Cummins PT fuel pump › Cummins heavy duty STC injectors › › › › › › › ›
Holset turbocharger, pulse tuned exhaust manifold, stainless steel exhaust lexible connections Radiator or heat exchanger, coolant inhibitor, Plate type lube oil cooler Outboard aftercoolers Full flow paper element filters - fuel, lube oil and by-pass Dry type replaceable paper element air cleaner with restriction indicator Flywheel housing & flywheel to suit single / double bearing alternator Starting motor – Electric, battery charging alternator
› › › › › › › ›
Electronic control panel Cummins Electronic Governor (EFC) Engine protections (trip) High water temperature Low lube oil pressure Overspeed Low coolant oil level (alarm) First fill lube oil
Features › Digital governing › Digital voltage regulation › ›
›
›
›
›
› ›
AmpSentryTM protection for true alternator O/C protection on PCC 2100/ 3100 for solo/ paralleling applications Analog/ bargraph/ digital AC output metering Battery monitoring system to sense and warn against a weak battery condition Digital alarm and status message display Genset monitoring : Displays status of all critical engine and generator set unctions Smart starting control system : Integrated fuel ramping to limit black smoke and frequency overshoot Advanced serviceability PowerCommand® network capability (optional)
PowerCommand® Paralleling Genset Controls In addition to the features described above, the PowerCommand® control with digital paralleling features eliminates the need for separate paralleling control devices such as synchronizers and load sharing controls, and KVAR / power actor controls. Besides this, features like synchronizing*, including import/ export controls for paralleling with an infinite (utility/ mains) bus and the ability to control the load on the generator set when paralleled with utility or mains are also built into the PowerCommand® control. * For utility synchronizing applications, please contact your local Cummins® distributor.
Control panel unit Genset Controllers
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 paralleling control devices such as synchronizers and load sharing controls, and KVAR / Power factor controls.
TESTING : TESTS AT MANUFACTURER'S WORK The following tests shall be performed at manufacture’s works prior to packing and dispatch to site, in the presence of Project Manager/Consultant. A week’s notice shall be given. Nothing extra shall be payable. If witness is waived off the contractor shall have to submit test certificate. On DG Set a. Maximum power load capacity. b. Maximum motor starting capacity c. Endurance test. d. Fuel consumption at full load, 50% load, 75% load and 25% load. On The Alternator a. High voltage tests on stator and rotor windings. b. Insulation resistance of stator and rotor windings. c. Temperature rise test. d. Stator voltage and current tests. e. Stator phase sequence check. On The Exciter a. High voltage tests on stator and rotor winding. b. Insulation resistance of stator and rotor windings. c. Temperature rise test. d. Measurement of losses. On The Automatic Voltage Regulator a. Sensitivity test. b. Response time test.
