Generators

Nandun Madhusanka
What is a generator?
 An electricity generator is a device that converts mechanical energy into
electrical energy. The process involves electromagnetic induction, which is
the production of an electric current across a conductor moving through a
magnetic field.
What are the types of electricity
generators
•Diesel Generators: Use a diesel engine to drive an alternator, producing electricity.
•Gas Generators: Utilize natural gas or propane to fuel an engine that turns an alternator.
•Steam Turbine Generators: Use steam produced by boiling water (often from burning fossil fuels, nuclear
reactions, or geothermal sources) to turn a turbine connected to an alternator.
•Hydroelectric Generators: Harness the energy of flowing water to turn turbines that drive an alternator.
•Wind Turbines: Use the kinetic energy of wind to spin blades connected to an alternator.
•Solar Power Generators: Convert sunlight directly into electricity using photovoltaic (PV) cells.
•Biomass Generators: Burn organic materials to produce steam or gas that drives a turbine or engine
connected to an alternator.
•Nuclear Generators: Use nuclear reactions to produce heat, which generates steam that drives a turbine
connected to an alternator.
•Hand Crank Generators: Manually operated generators that convert mechanical energy from cranking into
electrical energy.
What is the primary working principle of an
electricity generator?
•Mechanical Energy Input: The generator uses an external mechanical
force to rotate a coil of wire (the rotor) within a magnetic field. This
mechanical force can come from various sources such as steam turbines,
water turbines, internal combustion engines, wind turbines, or hand cranks.
•Magnetic Field Interaction: The rotating coil cuts through the magnetic
lines of force. In an alternator, the rotor usually creates the magnetic field,
and the stator contains the wire coils where the electricity is induced. In other
types of generators, the magnetic field might be stationary while the wire
coils rotate.
•Induced Voltage: According to Faraday's Law of Electromagnetic Induction,
when the conductor (coil) moves through the magnetic field, a voltage is
induced across the conductor. This happens because the magnetic flux
linking the coil changes as it rotates, creating an electromotive force (EMF)
across the coil.
•Current Flow: If the coil is part of a closed circuit, the induced voltage
causes an electric current to flow. This current can then be harnessed and
directed to where it is needed, such as the electrical grid or storage batteries.
Different sources of mechanical energy input
to a generator?
•Steam Turbines: Steam produced by boiling water (using coal, natural gas,
nuclear energy, or geothermal energy) is used to turn turbines.
•Hydraulic Turbines: The kinetic energy of flowing or falling water (in
hydroelectric dams) is harnessed to spin turbines.
•Wind Turbines: The wind’s kinetic energy is used to rotate the blades of the
turbine, converting wind energy into mechanical energy.
•Internal Combustion Engines: Engines powered by fuels such as diesel,
gasoline, or natural gas produce mechanical energy that drives the generator.
Commonly used in portable generators and backup power systems.
•Gas Turbines: Combustion of natural gas or other fuels creates high-pressure
gas that spins a turbine.
•Human Power: Manual devices like hand-crank generators convert human
mechanical effort into electrical energy, useful in small-scale or emergency
applications.
•Ocean/Tidal Energy: The movement of tides and waves can drive turbines that
generate electricity.
•Geothermal Energy: Heat from the Earth’s core is used to produce steam that
drives turbines.
Steam turbine
What about steam powered locomotives?
(Additional learning)
Hydraulic turbines
Wind turbines
Steam powered power plant
Ocean/tidal energy turbines
Internal combustion engines
Internal combustion engines (ICEs) are engines in which the combustion of a fuel
(usually a fossil fuel) occurs with an oxidizer (typically air) in a combustion chamber
that is an integral part of the engine. In an ICE, the expansion of high-temperature and
high-pressure gases produced by combustion applies direct force to some component of
the engine, such as pistons, turbine blades, a rotor, or a nozzle. This force moves the
component over a distance, transforming chemical energy into mechanical energy.
What are the main 2 sections of a diesel
generator?
1. Diesel Engine: This is the mechanical component of the generator that burns
diesel fuel to produce mechanical energy. It functions as the prime mover,
converting the chemical energy of diesel fuel into mechanical energy by
rotating a crankshaft. The engine's size and capacity determine the generator's
overall power output.
2. Alternator: This is the electrical component of the generator that converts the
mechanical energy produced by the diesel engine into electrical energy. It
consists of a rotor (which rotates) and a stator (which remains stationary). The
interaction between the rotor's magnetic field and the stator's windings
generates an alternating current (AC).
 These two sections work together, with the diesel engine driving the alternator
to produce electricity.
What are the 3 things needed to burn
fuel?
•Fuel: A combustible material that serves as the source of energy. This can be in the
form of a solid (e.g., wood, coal), liquid (e.g., gasoline, diesel), or gas (e.g., natural gas,
propane).
•Oxygen: An oxidizing agent that reacts with the fuel. In most cases, the oxygen comes
from the air, which contains approximately 21% oxygen.
•Heat: Sufficient heat energy is required to raise the fuel to its ignition temperature, the
temperature at which it will start to burn

Internal Combustion Engines: In engines, fuel is mixed

with air (oxygen) and compressed, then ignited by a spark
(in gasoline engines) or by the heat generated from
compression (in diesel engines).
Diesel engine components
4 strokes
2 stroke engine (additional learning)
2- strokes (additional learning)
V6 engine? (additional
learning)
V8 engine?(additional learning)
Petrol engine (additional
learning)
 An engine of a diesel generator of a
large building
•Small to Medium Generators (50 kW to 500 kW): These generators typically have 4 to 12
cylinders (pistons).
•Large Generators (500 kW to 2 MW): These might have 12 to 16 cylinders.
•Very Large Generators (2 MW and above): These can have 16 to 20 or more cylinders. For
instance, some industrial diesel engines, like those used in large power plants or ships, can have up
to 20 cylinders or more.
Components of Generator set
Main components and their functions of
a diesel engine of a generator
 Engine Block
• Function: The foundation of the engine, housing the cylinders and many other
components.
• Components: Contains the cylinders, coolant passages, oil galleries, and
crankcase.
 Cylinders
• Function: Houses the pistons and is the site of fuel combustion.
• Components: Multiple cylinders arranged in a line or V configuration, where
the fuel is ignited and burned to produce power.

 Pistons
• Function: Moves up and down inside the cylinders, converting the energy from
combustion into mechanical work.
• Components: Connected to the crankshaft via connecting rods.
 Crankshaft
• Function: Converts the linear motion of the pistons into rotational motion to drive the
generator.
• Components: Supported by main bearings and connected to the pistons via connecting rods.
 Connecting Rods
• Function: Connects the pistons to the crankshaft and transmits the motion from the
pistons to the crankshaft.
• Components: Attached to the piston via the piston pin and to the crankshaft via the
crankpin.
 Camshaft
• Function: Controls the opening and closing of the intake and exhaust valves.
• Components: Timed with the crankshaft via a timing belt, chain, or gears.
 Valves (Intake and Exhaust)
• Function: Intake valves allow air (and fuel in some designs) into the cylinder,
and exhaust valves allow exhaust gases to exit after combustion.
• Components: Operated by the camshaft.
Difference between petrol (gasoline) and
diesel engines
Fuel injection system
• Function: Delivers the right amount of fuel into the cylinders at the correct time.
• Components: Includes fuel injectors, fuel pump, and fuel lines.

Types of fuel injection

•Direct Injection (DI):
•Common Rail Direct Injection (CRDI)- most common type
•Unit Injector (UI)
•Unit Pump (UP)
•Indirect Injection (IDI)
•Distributor/Rotary Pump Injection
•In-Line Pump Injection
•Electronic Unit Injection (EUI)
Common Rail Direct Injection (CRDI)
Air intake system and exhaust system
•Air intake system
•Function: Supplies clean air to the engine for
combustion.
•Main Components: Air filter, intake manifold, and
sometimes turbocharger

Exhaust System
•Function: Channels exhaust gases away from the engine
and reduces emissions.
•Components: Exhaust manifold, muffler, and exhaust
pipe.
Exhaust system
Exhaust system of a vehicle (additional
learning)
Cooling system of an engine
• Function: Keeps the engine from overheating by circulating coolant through
the engine block and radiator.
• Main Components: Includes a water pump, radiator, thermostat, and coolant.
What is intercooler turbo engine?
 An intercooler turbo engine in a generator is a type of internal combustion
engine that is equipped with both a turbocharger and an intercooler. This
combination is used to enhance the engine's performance, efficiency, and
longevity. Here’s a breakdown of how each component functions and its benefits:
 Turbocharger
• Function: A turbocharger is a device that uses the engine's exhaust gases to spin
a turbine, which in turn drives a compressor. This compressor forces more air
into the engine's cylinders than atmospheric pressure alone could provide.
• Benefit: By increasing the amount of air (and thus oxygen) entering the
combustion chamber, more fuel can be burned efficiently, leading to a significant
boost in power output.
 Intercooler
• Function: The intercooler cools the air that has been compressed by the
turbocharger before it enters the engine's combustion chamber.
• Benefit: Cooling the compressed air increases its density, allowing for a greater
mass of air to enter the engine. This improves combustion efficiency and power
output while also reducing the risk of engine knocking (pre-detonation).
Turbocharger
What is Intercooler?
 An intercooler in a generator is a device used to cool the air that has been
compressed by the turbocharger before it enters the engine's combustion chamber.
The process of compression increases the temperature of the air, reducing its
density and the amount of oxygen available for combustion. By cooling the air with
an intercooler, the air density is increased, allowing for a more efficient combustion
process, which can improve the engine's power output and efficiency.
 Here are the key functions and benefits of an intercooler in a generator:
1. Temperature Reduction: It cools the compressed air from the turbocharger,
reducing its temperature before it enters the engine.
2. Increased Air Density: Cooler air is denser, which means more oxygen is available
for combustion, leading to better engine performance.
3. Improved Combustion Efficiency: By providing cooler, denser air, the intercooler
helps in achieving more efficient and complete combustion of the fuel.
4. Enhanced Power Output: With better combustion efficiency, the engine can
produce more power.
5. Engine Protection: Lowering the air temperature reduces the thermal load on the
engine components, helping to prevent overheating and potential engine damage.
6. Fuel Efficiency: More efficient combustion can lead to better fuel economy.
Intercooler unit
Why intercooler turbo engines are
efficient?
 Intercooler turbo generators are more efficient because they enhance the performance
of the engine by cooling the compressed air from the turbocharger, leading to several
benefits:
1. Increased Air Density: Cooler air is denser and contains more oxygen, improving
combustion efficiency.
2. Improved Combustion: Efficient combustion means more power from the same amount
of fuel, reducing fuel consumption.
3. Reduced Thermal Stress: Lower intake air temperatures prevent engine knocking and
protect engine components.
4. Enhanced Turbo Performance: The intercooler allows the turbocharger to operate
optimally, delivering consistent power.
5. Higher Power Density: Turbocharging with intercooling allows for higher power output
from a smaller engine, making the generator more compact and powerful.
6. Adaptability: These generators respond efficiently to variable loads, maintaining high
efficiency across different operating conditions.
Lubrication system
Engine oil cooling system
The oil cooler specifically cools the engine oil to ensure it maintains the correct
viscosity and thermal properties, which are essential for proper lubrication and
cooling of engine components. This helps to prevent overheating and ensures the
efficient operation and longevity of the engine.

•Regulate Oil Temperature: The oil cooler helps maintain the oil at an
optimal temperature, preventing it from getting too hot during operation.
•Enhance Lubrication Efficiency: By keeping the oil at a stable
temperature, the oil cooler ensures that the oil maintains its proper
viscosity, which is crucial for effective lubrication of engine components.
•Prevent Overheating: It aids in dissipating the heat generated by the
engine, thereby reducing the overall operating temperature and
preventing overheating.
•Extend Oil and Engine Life: Proper cooling of the oil reduces thermal
degradation and oxidation, thereby extending the life of the oil and the
engine.
•Improve Engine Performance: Maintaining an optimal oil temperature
ensures that the engine performs efficiently and reliably, as overheating
can lead to reduced performance and potential engine damage.
Starter motor of diesel engine
 A starter (also self-starter, cranking motor, or starter motor) is a device used
to rotate (crank) an internal-combustion engine so as to initiate the engine's
operation under its own power.
•.

Battery
 Battery
• Functions
Starting the Engine: Provides initial power to the starter motor to crank the
engine.
Powering Control Systems: Supports electronic control systems for engine
management.
Emergency Backup: Acts as a backup power source during generator
startup and failures
• Components: Battery cells, terminals, and connecting cables.
Alternator
An alternator in a diesel generator set has a critical role in converting mechanical energy produced by the diesel
engine into electrical energy.
1.Electrical Power Generation: The alternator converts the mechanical energy from the diesel engine into
electrical energy in the form of alternating current (AC). This is done through electromagnetic induction, where
the rotation of the engine drives the alternator's rotor inside a stator winding.
2.Frequency Regulation: The alternator helps in maintaining a consistent frequency of the generated AC power
(typically 50 Hz or 60 Hz), which is crucial for the proper operation of electrical devices and systems.
3.Voltage Regulation: The alternator includes a voltage regulator that ensures the output voltage remains stable
and within the specified range, preventing damage to electrical equipment and ensuring efficient operation.
4.Load Handling: The alternator adapts to varying electrical loads by adjusting the output power. This ensures
that the generator set can handle different power demands without fluctuations or interruptions in the
electricity supply.
5.Protection and Monitoring: Modern alternators in generator sets come with various protection mechanisms,
such as over-voltage, under-voltage, over-current, and thermal protection, to safeguard both the alternator and
the connected load. They also often include monitoring systems to provide information about the performance
and status of the alternator.
Function of 3-phase motor (additional
knowledge)
 A 3-phase motor operates on the principle of electromagnetic induction using
alternating current (AC) to convert electrical energy into mechanical energy.
 Components:
• Stator: The stationary part of the motor, consisting of three sets of windings, each connected to one phase
of the AC supply.
• Rotor: The rotating part of the motor, located inside the stator.
 Operation:
1. AC Power Supply: A 3-phase AC power supply provides three alternating currents that are 120 degrees out
of phase with each other. These currents flow through the stator windings.
2. Rotating Magnetic Field: The 3-phase currents create a rotating magnetic field in the stator. This field
rotates at a speed proportional to the frequency of the AC supply (synchronous speed).
3. Induced Current in Rotor: The rotating magnetic field induces a current in the conductors of the rotor
(typically a squirrel cage rotor). According to Faraday's Law of Electromagnetic Induction, the changing
magnetic field induces an electromotive force (EMF) in the rotor conductors.
4. Torque Generation: The induced current in the rotor creates its own magnetic field, which interacts with
the stator's rotating magnetic field. This interaction produces a torque that causes the rotor to turn,
following the rotating magnetic field.
5. Mechanical Output: The rotor's rotation is converted to mechanical output, which can be used to drive
machinery or other mechanical systems.
Function of a 3-phase generator
 A 3-phase generator, also known as an alternator, operates on the principle of
electromagnetic induction to convert mechanical energy into electrical energy.
 Components:
• Stator: The stationary part of the generator, consisting of three sets of windings.
• Rotor: The rotating part of the generator, which can be an electromagnet or have permanent magnets.
 Operation:
1. Mechanical Input: A prime mover (such as a steam turbine, internal combustion engine, or wind
turbine) drives the rotor, causing it to rotate inside the stator.
2. Magnetic Field: The rotor is magnetized, either by direct current (DC) supplied to its windings (for an
electromagnet) or by permanent magnets.
3. Rotating Magnetic Field: As the rotor turns, its magnetic field rotates and cuts through the stator
windings.
4. Induced EMF: According to Faraday's Law, the rotating magnetic field induces an electromotive force
(EMF) in the stator windings. Because the rotor is rotating, the magnetic field is changing with respect
to the stator, inducing a voltage.
5. 3-Phase AC Output: The induced EMF in the stator windings produces three separate AC voltages that
are 120 degrees out of phase with each other, creating a 3-phase AC output. This output can be used to
supply electrical power to the grid or to electrical loads.
Alternator
Electromagnets
What is AVR in an alternator?
 The Automatic Voltage Regulator (AVR) in a generator alternator is
responsible for maintaining a consistent voltage level from the
generator.
1. Voltage Regulation: The primary function of the AVR is to regulate the output
voltage of the generator. It senses the output voltage and adjusts the excitation
current to the generator's field winding to maintain the desired voltage level.
2. Stabilization: The AVR helps to stabilize the generator's output by responding to
changes in load. When the load on the generator increases or decreases, the AVR
adjusts the excitation current to keep the output voltage stable.
3. Protection: The AVR provides protection against over-voltage and under-voltage
conditions. If the voltage goes beyond the set limits, the AVR can reduce the
excitation current or shut down the generator to prevent damage to the
electrical equipment and the generator itself.
4. Power Factor Correction: In some advanced AVRs, there is also functionality for
power factor correction, which optimizes the generator’s performance and
efficiency by adjusting the phase angle between the voltage and current.
5. Improved Performance: By maintaining a consistent voltage output, the AVR
helps ensure the smooth operation of electrical equipment and machinery
connected to the generator, improving overall performance and reliability.
Fleming’s rules (additional knowledge)

Fleming's Left-Hand Rule (for

Motors)
•Thumb: Force (motion)
•Forefinger: Magnetic Field (N to S)
•Middle Finger: Current
Fleming's Right-Hand Rule (for
Generators)
•Thumb: Motion
•Forefinger: Magnetic Field (N to S)
•Middle Finger: Induced Current
Governor of a diesel generator
 The governor of a diesel generator controls the engine
speed to maintain a constant RPM, which is crucial for
generating stable electrical output. It achieves this by
monitoring engine speed continuously and adjusting
the fuel supply accordingly. When the electrical load
on the generator changes, the governor detects these
variations and adjusts the fuel injection rate to
compensate. This ensures that the engine speed
remains steady, preventing fluctuations in voltage and
frequency in the electrical output.
 The governor plays a vital role in optimizing fuel
efficiency by supplying just enough fuel to meet the
current load demand, thereby reducing unnecessary
consumption and emissions. Additionally, it protects
the engine from potential damage by maintaining
speed within safe limits, ensuring smooth and reliable
operation of the generator system.
Diesel generator control panel
 A diesel generator control panel manages and monitors the
operation of the generator. The basic functions include:
1. Starting and Stopping: Automatically or manually starts and stops the generator.
2. Monitoring: Displays parameters like voltage, current, frequency, and running
hours.
3. Protection: Includes alarms and shutdown mechanisms for conditions like low oil
pressure, high coolant temperature, and over/under voltage.
4. Synchronization: Manages the synchronization of multiple generators for load
sharing.
5. Fault Diagnostics: Identifies and logs faults or errors for maintenance and
troubleshooting.
6. Battery Charging: Ensures the battery is charged for reliable starting.
7. Load Management: Balances the load on the generator to prevent overloading.
Thank you