Presentation On

Power Generation System and

Troubleshooting of Gas and Diesel
Generator

----presented by---
----------

Date: 25thApril 2012

IUBAT-International University of Business Agriculture and Technology

 CONTENTS
 Introduction
 Objective
 About Bangla Trac Ltd. (Bangla CAT)
 Power System of BanglaTrac Ltd. (Bangla CAT)
 Common Layout of generator
 AC Synchronous Generator
 Generator Specification
 Gas and Diesel Generator
 Control System
 Troubleshooting
 Conclusion
 Remarks

2
Introduction

Electrical power is a little bit like the air one breathes. One doesn't really
think about it until it is missing. Power is just "there," meeting ones daily
needs, constantly. It is only during a power failure, when one walks into a
dark room and instinctively hits the useless light switch, that one realizes
how important power is in our daily life. Without it, life can get somewhat
cumbersome. Electric Energy is the most popular form of energy, because it
can be transported easily at high efficiency and reasonable cost. The power
system of today is a complex interconnected network.

3
Objective

The main objective is to extrovert my theoretical

knowledge to the practical field.

Study on Gas , and Diesel AC Synchronous generator

Identify the different types of problem which arise

during generation.

Troubleshooting the probable problems occurred in

power generation.

Suggest probable solution of the identified problem.

4
About Bangla Trac Limited (Bangla CAT)

Bangla Trac Limited (concluding business under the name ‘Bangla

CAT’) was appointed the dealership for Caterpillar engines and
equipments in the Bangladesh on the 11th of October 2004.

Now it is the largest Power Generation Equipments company in

Bangladesh in private sector.

The company has wide variety of Gas, Diesel, Marine generators,

Tractors, Excavators, Industrial vehicles under its production
range.

With the well spread service points across the country Bangla CAT
hold unparalleled service coverage, access and most importantly
customer satisfaction.

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 Vision & Mission
Mission
Using our expertise to understand their needs
Providing innovative solutions
Actively encouraging a culture of continuous
improvement
Developing and utilizing our people, technology and
capital efficiently and effectively.

Vision

The vision of Bangla CAT is to make progress

possible through excellence in technology integrity
and best in class customer service.
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Business Type

Trade, Service.

Products

Engines,
Marine Engines,
Gas and Diesel Generators,
Construction Equipments,
Mining Equipments,
Forestry Equipments,
Power Generation.
7
Power System of Bangla Trac Ltd. (Bangla CAT)

Power system of Bangla CAT can be divided into two major

parts:

1) Source.
2) Control System

Source is the CAT gen-set which is the combination of AC

synchronous generator or alternator (Kato SR4B and SR5B
model) and gas and diesel engine.

8
 Common Layout of Generator:

Our Interest
A C
B

Figure: Block diagram of Synchronous Generator.

A. Engine – mechanical motion, RPM

B. Synchronous generator - main rotor and stator, output
high voltage
C. Excitation – excitation for B
D. Panel – can be local control panel, AVR, breaker 9
housing, etc.
 AC Synchronous Generator
The synchronous generator (also called alternator) belongs to the family of
electric rotating machines. Other members of the family are the direct current
(DC) motor or generator, the induction motor or generator. Synchronous
generator is a set of power generator that generates alternating current (ac).

Figure :Caterpillar Alternator (SR4B) & Sectional view of Synchronous Generator

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Synchronous Generator Components
Armature (Main Stator)
 Constructed with copper cored insulation.
 The armature consists of the stator core and its own windings called
stator windings or armature windings.
 Generates high voltage and applied to the load line.
1 2 3

Figure : Stationary components.

(1- Armature (Main Stator), 2- Field Coil, 3- Exciter Field 11
Main Rotor
 Main rotor shaft covered with poles.
 Always rotating through armature field.
 The rotor is rotated by an engine.

Figure: Main Rotor (Main Field).

 Rotate the poles and permanent magnet for generate

voltage.
 Create ac voltage through armature.
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Pole
 Constructed with iron and copper cored
insulation.
 4 Poles, two are north poles and two are
south poles.
 The four poles are connected in series
connection to each other.

 The number of poles (north-south-

north-south) and the desired frequency
(cycles per second or hertz) determine
the synchronous or no-load speed in
revolutions per minute (rpm).
Figure: Pole.

13
Excitation Rotor
 Consists with iron and copper
cored insulation.
 Placed in between primary
exciter.
 Take ac voltage from primary
exciter.
 Produce the ac voltage to the
rectifier. Figure: Excitation Rotor.

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Permanent Magnet
 Object that produce a magnetic
field.
 Placed in between secondary
exciter for excite the magnet.
 Always rotating.
 Magnetized secondary exciter to
create ac current.
Figure: Permanent Magnet.

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Primary Exciter
 Constructed with iron and copper
cored insulation.
 Placed to cover the excitation rotor.
 Excites the excitation rotor.
 Produce ac voltage to excitation rotor.
 Take ac voltage from CDVR.
Figure: Primary Exciter.

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 Coupling
 Constructed with iron.
 It is a device used to connect
two shafts together at their ends
for the purpose of transmitting
power.
 Conduct the engine and
synchronous generator together.
 Reduced the transmission of
shock loads from one shaft to
Figure: Coupling.
another.
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Bearing

 Device to allow to constrain relative

motion between two parts, typically
rotation.
 Exploits magnetic field.
 Reduce friction of synchronous
generator.
Figure: Bearing.

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CDVR (Caterpillar Digital Voltage Regulator)

 Microprocessor based voltage

regulator.
 Produce ac voltage to primary
exciter.
 Regulate constant voltage in
synchronous generator and
constant voltage is not over and
not less than 400V/11KV.
Figure: CDVR.

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Bridge Rectifier
 Consists three positive diodes
and three negative diodes.
 Connected with excitation rotor.
 Take ac voltage from excitation
rotor.
 Produce the DC voltage to main
rotor
Figure: Bridge Rectifier and
2 show Varrister.
Varrister
 Placed beside the rectifier diodes.
 It’s resistance is over than 15000 ohms.

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 Working principle of Synchronous Generator
Generator

Figure: Principal of synchronous generator.

In case of AC synchronous generator, armature is stationary and the field is

rotating. When DC voltage is applied to the field then a constant magnetic
flux is produced. At the presence of this constant magnetic flux, rotor is
rotated through the prime mover. When field (rotor) rotates, armature
conductors are cut by the magnetic flux and hence an e.m.f. is induced in it.
Since, the magnetic poles are alternately N & S, therefore an alternating
e.m.f. is produced in the stator conductor.
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Generator Specification

Engine data
Engine Model #3516 B
Cylinder: 16
1714 KVA 1200KW 50 Hertz

Generator data:
Alternate Gen Rating 1900KVA
Phase: 3, 6 wire
Power factor: 0. 8
Generator 600 volts 1649 Amps
Excitation: 34 volts 7.38 Amps
RPM: 1500
Maximum ambient temp.: 40 o C
Cooling system: Radiator type
Insulation: Class H
Gen: S/N: 7TN03521
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ESO: DHGRW
Gas Engine
A gas engine means an engine running on a gas, which refers to a
heavy-duty, slow-revving industrial engine capable of running
continuously at full output for periods approaching a high fraction
of 8,760 hours per year.

Figure: Caterpillar G3520C Generator set. 23

Diesel Engine
A diesel engine (also known as a compression-ignition engine) is
an internal combustion engine that uses the heat of compression
to initiate ignition to burn the fuel, which is injected into the
combustion chamber.

Figure: Caterpillar Diesel Generator (D 3516B) Set

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Differences between gas and diesel engine
The main differences between the gasoline engine and the diesel engine are:

A gasoline engine intakes a mixture of gas A diesel engine takes in just air, compresses
and air, compresses it and ignites the mixture it and then injects fuel into the compressed
with a spark. air.
A gasoline engine compresses at a ratio of A diesel engine compresses at a ratio of 14:1
8:1 to 12:1 to as high as 25:1
Gasoline engines generally use either Diesel engines use direct fuel injection - the
carburetion, in which the air and fuel is diesel fuel is injected directly into the
mixed long before the air enters the cylinder, cylinder.
or port fuel injection, in which the fuel is
injected just prior to the intake stroke
Less expensive to maintain gas engine Require more oil than those on gas.
Gas engine makes less noise and vibrations Diesel engine makes more noise and
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vibrations
Engine main Parts
Cylinder
Cylinder Bloc
Cylinder Head
Piston
Piston Rings
Connecting Rod
Gudgeon Pin
Crank Pin
Crank Shaft
Cam Shaft
Crank-Case
Flywheel
Inlet Valve & Exhaust Valve
Governor
Carburettor
Fuel Pump
Spark Plug
Fuel Injector
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Sequence of Operation

Intake stroke:
the inlet valve opens and
the vaporized fuel mixture enters the combustion
chamber.
Compression stroke

both valves are closed and

the piston starts its movement to the minimum
volume position

Power stroke
 the spark plug ignites the fuel mixture Figure : Sequence of
and burns. Operation
Exhaust stroke

the exhaust valve opens

allows the exhaust gases to escape the cylinder. 27
Starter systems
All internal combustion engines require some form of system to
get them into operation. Most piston engines use a starter motor
Cooling System
There are mainly two types of cooling systems:
(a)Air cooled system
Cylinder will be conducted to the fins and the air flows over the
fins,
heat will be dissipated to air.

Water Cooling System

The water when circulated through the jackets, it absorbs heat
of combustion. 28
Control System
For Controlling the Gen-set, Bangla CAT uses various types of
Control system. They are as follows:

Woodward Control System

Enercon Control System

Unilib Singapore Control System

Terberg Control System

Figure: Speed, frequency
& running hour
inspection by me.
29
Woodward Control System
Equipped with a Caterpillar digital speed control with a pulse
width modulated (PWM) input.

Operation

Senses the power output of a generator and

provides a pulse-width modulated signal to the Caterpillar
digital speed control

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 Power Supply
24 V dc power source.

Power Sensor
 senses current amplitude, and produces a load signal

Define Troubleshooting
Troubleshooting is process discovering true cause by eliminating
other possibilities.

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Importance of Troubleshooting
must be familiar with the organization's safety rules and
procedures for working on electrical equipment.
need to gather information regarding the equipment and the
problem.
Be sure you understand how the equipment is designed to
operate

Some Basic Rules to Follow

RULE 1: Check out the complaint yourself
RULE 2: Don’t make a assumptions
RULE 3: Consider all the possibilities
RULE 4: Don’t guess
RULE 5: Be patient 32
MY EXPERENCE ON TROUBLESHOOTING

Problem no.1: Engine Fail to Start

Activities: After receiving the gen-set at stop position we have to perform

the following task

Checked the control cable

Checked the compressed air line
Checked the air starting motor

Observation: Found starting motor’s rotor

has damaged.

Solution: Repair the starting motor or

arrange a new one.
Figure: I’m checking
control cable

33
Problem no.2: RPM Variation

Activities: After receiving the gen-set at stop position we have to perform

the following task

Checked throttle valve and actuator gap

Checked air filter
Checked gas pressure by PRV

Observation: Found air filter is jam and gas pressure was changed.

Solution: Changed the air filter and adjust the gas pressure by PRV.

Problem no.3: Gen-set shutdown by under frequency.

Activities: After receiving the gen-set at stop position we have to

perform the following task

Checked CDVR (Caterpillar Digital Voltage Regulator)

Checked pireo meter power supply cable
Checked oil pressure sensor 34
Observation: Found oil pressure sensor is out
of order and CDVR program is changed.

Solution: Changed the oil pressure sensor and

adjust the CDVR program.

Problem no.4: Gen-Set suddenly shutdown

Activities: After receiving the gen-set at stop

position we have to perform the following task

Checked the cylinder exhaust temperature

Checked the spark plug

Observation: Exhaust temperature deviations Figure: I’m checking

low. CDVR
Solution: Change the spark plug with a new
one.
35
Problem no.5: Engine Vibration and Fail to Start

Activities: After receiving the gen-set at stop position we have to perform the
following task

Checked all the spark plug for ignition system

Clean the air filter
Checked the timing of engine
Checked the control cable

Observation: Found no ignition in cylinder because of closing the spark plug

gap.

Solution: Repair the spark plug gap within 0.3mm to 0.7mm by Toe

Problem no.6: Engine frequently shutdown due to over speed.

Activities: After receiving the gen-set at stop position we have to

perform the following task-

36
Checked alternator and VR-3 connection.
Checked power screw adjustment accordingly.
Checked exhaust bypass valve.

Observation: Found exhaust bypass valve is lose.

Solution: Exhaust bypass valve tightened with three turns.

Problem no.7: Engine didn’t carry more than 60% load.

Activities: After receiving the gen-set at stop position we have to perform
the following task

Checked all ignition transformer

Checked all spark plug
Observation: Found 3 no. spark plug and one no ignition transformer is
faulty.

Solution: Both are replaced by new one.

37
Problem no.8: Detonation Alarm.

Activities: After receiving the gen-set at stop position we have to perform

the following task

Connected D.D.T

Observation: found detonation alarm in cylinder

no 15,9,4,8,13.

Solution: Adjust the bypass regulator valve for

fuel control.
Problem no.9: Abnormal sound and engine
was vibrating.
Figure: I’m working
Activities: After receiving the gen-set at stop
with DDT
position we have to perform the following task
Checked the engine with DDT(Digital
Diagnostic Tools )
Checked the pro-act with handler
38
Checked the pro-act power supply
Observation: Found pro-act power supply cable
is loose and setting is changed.

Solution: Adjust the setting with handler and

replaced the pro-act power supply breaker and
connected the cable properly.

Problem no.10: Exhaust temperature of

cylinder is high.

Activities: After receiving the gen-set at stop

position we have to perform the following task Figure: I’m working
with handler
Removed the spark plug and ignition
transformer
Checked that spark plug and ignition
transformer

Checked the compression presser and bridge
adjustment of cylinder
39
Observation: Found bridge adjustment is corroded.

Solution: Change the bridge couple.

Problem no.11: Engine didn’t carry more load up to 450kw.

Activities: After receiving the gen-set at stop position we have to perform

the following task

Removed the spark plug and checked gap.

Both side air filter checked.
Both side Turbo-charger dissemble and checked.
Checked Throttle valve

Observation: All spark plug are damaged and Turbo charger

kitties is broken.

Solution: Change all spark plug and kitties.

40
Problem no. 12: Voltage is too low

Activities: After receiving the gen-set at stop position we have to perform

the following task

Checked CDVR
Checked rectifier
Check varistor

Observation: One connection of CDVR is open and varistor has burned

Solution: Connect the connection properly and change the varistor by

new one

Problem no.13: Load cannot carry at rated value .

Activities: After receiving the gen-set at stop position we have to

perform the following task

41
Checked taped bridge adjustment
Checked spark plug
Check transformer
Checked all cylinder compression

Observation: Crack bridge adjustment and cylinder compression is low.

Solution: Change the bridge adjustment and clean the cylinder transformer.

Problem no.14: Engine starts but doesn’t keep running.

Activities: After receiving the gen-set at stop position we have to perform

the following task

Checked throttle control cable

Checked cylinder head gaskets
Checked power control cable
Checked fuel pump

42
Observation: Found power control cable is lose and cylinder head gasket is
torn.

Solution: Properly connect the power cable and replace the cylinder head
gasket.

Problem no.15: Engine loses power.

Activities: After receiving the gen-set at stop position we have to perform

the following task

Checked compression
Checked engine load
Checked spark plug
Checked crankcase oil level

Observation: Found compression is low.

Solution: Adjust the compression with compression meter.

43
Necessity of Troubleshooting (TST) Expert

Expert troubleshooter recognizes how engine works and

recognizes symptoms different problems. He is able to quickly and
correctly diagnose engine problem, save time and expense. So
necessity of expert troubleshooter is badly needed.

How It is Performed
This is performed by following way:

Official Training
Web resources of Caterpillar
Latest technology
Modern Tools and Rapid Response. 44
Conclusion
Considering the current electricity crisis in Bangladesh it is very
much important that private investment in power takes place at a
rapid rate. In this regard the govt. has a lot to do to ensure smooth
running of the power sector in private sector. My experience
during the short stay at Bangla CAT has not only increased my
depth of knowledge but also has given me the feeling of
challenges faced in engineering profession. Thanks to Bangla trac
Ltd (Bangla CAT) . For providing me with the opportunity to
conduct my industrial attachment in their Companey. I’m also
thankful to all the engineers and employs of Bangla trac Ltd
(Bangla CAT) for their heartiest support and co-operation. 45
Remarks

Though in Bangladesh, approximately 45% power is produced

from different types of CAT generator. But during my practicum
period I noticed some mismanagement at Bangla CAT. There are
some feasibility study in this regard is recommended and
suggested.

More shift engineer should be increased.

Parts requisition problem should be removed to solve the
problem in time.
Replacement of faulty and frequent equipments should be done
with equipment of better performance and quality.
Transportation facility should be increased.
46
Thanks All
For Your Patient…

47
Question Session

???
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