Introduction to Byrne Generators

Course Objectives

To become familiar and understand:

• Generator Concept and Operation

• Generator main parts.
• Electrical Measure Units (V, A, KW, KVA, HZ)
• Correct Generator sizing.
• Generator Synchronizing.
• Oil and gas Requirements.
• Remote monitoring .
 Generator Concept and Operation

• A Diesel Generator is the combination of an Engine, Alternator

(electrical head) and a Control Panel.
• Diesel generators are normally used at locations lacking power from
grid or as an emergency standby supply, if the grid fails for some
reason.
• Other more complex applications include supporting the grid when
shortages of grid power occurs during peak hours.
• The proper sizing of a generators is necessary to avoid power
shortage, or engine damage, when over sized machines are used and
to achieve max fuel efficiency.
• The size of a generators is usually measured in kVA (Kilo Volt
Ampere) or MVA (Mega Volt Ampere).
• Diesel generator sizes range between 2.5kVA up to 3000 kVA and
larger sizes are also available for special applications
Generator Parts
• Diesel Engines , Generators engines in Byrne fleet :
 Perkins up to 500KVA
 Yanmar up to 45KVA
 JCB up to 65KVA
 MTU 500KVA to 1.6MVA
 Komatsu 350KVA to1000KVA
 Caterpillar up to 800KVA
 Mitsubishi 1300kVA
• Power Alternator (Electrical Generating Device) usually :
 Stamford (UK).
 Leroy Somer (France).
 Mecc Alte (Italy) .
• Control panel and operators interface
• Enclosure or Canopy
 The Engine (Prime Mover)

The Diesel engine or prime mover, is

an internal combustion engine that
uses the heat of compression to
ignite the fuel and produce power
(Watts), the fuel is injected into the
combustion chamber during the final
stage of compression. The diesel
engine was developed by Rudolf
Diesel in 1897
• The engine output is measured in mechanical Watts or Horse
power (HP)
• Engines vary in sizes from small engines in KW (1000W) to
large engines in MWs (1 million W).
• There are different manufacturers, models and designs.
• Emission Standards are also an important factor in design.
• Engine maintenance, life and service intervals .
• 20kVA – 450kVA every 250/300 hours
• 500kVA – 1500kVA every 500/600 hours
• Engine fuel efficiency .
• Cooling types ( remote radiator , engine Fan )
• Load parameters and site conditions.
Engine Systems

• Fuel System (Diesel, Petrol, Gas, HFO)

• Lubrication System.
• Exhaust System and Turbo.
• Cooling System.
• Starting System. ( Air or Electrical )
• Control Panel and Operators interface
• Engine power and speed Control
o Electronic (fuel Injection) ECM or ECU
o Mechanical Governor .
 Fuel efficiency
Generators consume fuel, the fuel consumption depends mainly on the load, and fuel
efficiency ( Fuel consumed /W) depend on many factors :
• Engine Size , normally smaller engines are less efficient.
• Fuel Quality.
• Ambient temp. and altitude .
• load profile .
• Engine design and governor type (ECU or Conventional mechanical).

The following rule of thumb can be used to roughly estimate the fuel consumption of a diesel
generator :
• Small units up to 100kVA the estimated fuel consumption is around 0.35 - 0.38 L/KWh
• Units between 100kVA to 400 KVA, 0.30 - 0.33 L/KWh.
• Large generators above 500kVA consumption will be around 0.26 - 0.28 L/KWh.
L/KWh is the energy unit and means liters consumed by one a load of one KW in one hour .

Usually Generator manufacturers show less consumption figures than above, this is because
they test the machines under optimum operating conditions.
 Consumption Vs Load

l/h
0.2800

0.2700 0.2703
Best efficiency @
75%
0.2600

0.2500

0.2436
0.2400 0.2400
0.2376

0.2300

0.2200
25% 50% 75% 100%
 The Alternator

An electromechanical device that

converts mechanical energy to electrical
energy, in the form of alternating
voltage and current.
Most alternators use a rotating
magnetic field, in principle, any AC
electrical generator can be called an
alternator, but usually the word refers
to rotating machines driven by
automotive engines, internal
combustion engines or turbines driven
by Steam, Gas, Wind and Water flow .
 Alternator Principles
• Normally Driven By Prime Mover (Engine)
• Frequency of the electrical wave is related
to the speed of generator rotation and the
number of magnetic poles in a rotor.
• The output voltage is controlled by and
Auto Voltage regulator or (AVR)
• The output power of an alternator is
measured in KVA, which is (Voltage X
Amperes) .

Simple alternator with a rotating magnetic core (rotor) and stationary wire (stator),
the wave is the voltage induced in the stator by the rotating magnetic field produced by
2 pole rotor
3Ø and 1Ø systems
• Byrne generators use a 3Ø-4 wire system, three phases (L1, L2, L3) and the
Neutral N, an earth Lead E is also used to connected to the generator metal
body to an earthing system, usually the neutral and ground are linked at the
generator terminals.

    
V (L-n) = voltage between one phase and the neutral (1 phase voltage)
V (L-L) = is the voltage between two phases (3 phase voltage)
 Control Panel
• A control panel is mainly the MHI ( Machine /Human/ interface )
with the generator;
 Controls starting and stopping of machine .
 Displays mechanical and electrical parameters
 Contains the fault protection settings
 Controls synchronizing, load sharing and management.
 Generate alarms and warnings based on settings .
 Calculates the running hours, fuel consumption, KWh
 Can offer remote monitoring communications, data logging .
The controller is normally fitted in a separate enclosure bolted to
the generator skid base, for larger industrial generators it may be
located at a remote location such as a control room.

Modern electronic Controllers display parameters reading , alarms

and settings on LCD screens , and can be called by scrolling PBs.

Old control panels have separate physical gauges and switches for
each parameter and operation .
 Electronic Control Panels
Today’s control panels are normally electronic and offer the following:

• Continuous digital readouts of electrical and

mechanical parameters.
• Large LCD screens.
• Displays with running time.
• Accurate digital readings of electrical and Mechanical
parameters .
• Simple alarm and S/D setpoint settings and custom
message options.
• Remote and local start/stop capabilities
• Auto remote start and time scheduling programming.
• Automatic Synchronizing ,load sharing & load
management capabilities.
• Telemetry monitoring capabilities using Gateway and
SIM card .
Controller Connections

• Inputs to Control Panel (manual commands by operator or by sensors).

• Outputs such as ( Alarms, trip signals, measurement values, engine control
commands).
• Communication ports ( CAN , USB , RS485, RS232 , Ethernet .. ETC )
• MSC communication links in synchronizing controllers .
• Computer interface software and tools
• Remote control and monitoring ports ( RS485, RS232 , Ethernet )
• Extension Ports ( extra inputs or output PCB cards ) .
• Controller samples
 ComAp MRS- 15, 16, 25 ….
 Deep sea DSE- 8610 , 6110, 7320 ..
 Old conventional control Panels
 Enclosures (Canopies)
• A soundproof enclosure is widely used in generators where there is a requirement
to prevent stray noises produced by the engine to exit and produce noise
pollution, it will help to contain noises indoors.
• Byrne canopies usually include sockets and power lock connections, for easy and
quick Plug & Play event activities. Also we usually ask for standard sound
attenuation levels when ordering our machines
Enclosures Requirements

• Good sound attenuation level .

• Sufficient air flow characteristics .
• High corrosion resistance.
• Durable & lasting sound attenuation material inside.
• Easy to access during service , maintenance and cleaning .
• Good ridged Build .
• Secure and safe for operators during generator operation.
• Logistic compliant with Byrne standards .
• Has the required Sockets and Power locks as Per Byrne Standards .
• Proper and durable door locks and hinges .
• Proper and safe roof claiming facilities for operators in large machines .
• Canopy Emergency PB faculty .
 Sound Requirements

• db is the unit used to measuring

noise levels.

• Byrne standard noise levels are

around
• And average of 80db at a 3m
distance from 4 generator corners .

• Super silent generators have noise

levels as low as 72db at 1m
distances .
 KVA and KW

• Real power (KW) is the capacity of performing real

work in particular time, this is produced by the engine
(engine mechanical power)
• Apparent power (kVA) is product by the alternator
called the Electrical power, (kVA) is made out of two
component the real power (KW) and the (kVAr) or
VARS, VARs are due to stored energy in the electrical
network, produced by inductive loads, they circulate
around the system as currents doing nothing except
over loading the cables
• The power factor (P.F) is the portion of KW (real power)
to that of the total power kVA, alternators are
designed to operate safely at (0.8) PF, so a 500kVA
generator can handle up to 400KW real power, ie
(500kVA X 0.8=400KW)
 Calculating KVA and KW
Useful formulas : 
KW= V (L-n) X A (L) X P.F ÷ 1000 ( for 1 phase ).
KW= V (L-L) X A (L) X √3 X P.F ÷ 1000 ( for 3 phase ).
KW= KVA X 0.8
V = Volts (Voltage), A=Amps (current), P.F.=Power factor (usually 0.8).

Example : -
A client is asking for 650A at 415V to feed a 3Ph load, what generator we suggest ,
and what is the load in KW at 0.8 Power Factor and Fuel consumption in one hour .

KVA =V (L-L) X A (L) X √3 ÷ 1000 for (3Phase )=(415X650X1.732)/1000=467.2KVA

Assuming the machine we offer should run at 75% of its full load , then we offer
467.2/0.75= 623KVA , nearest we have is 630KVA .
KW= KVAXPF = 467.2X0.8 =373.76KW
Fuel consumption in One hour = 373.76X0.28 = 104.65 L/H and
 Synchronizing of Generators

• Synchronizing is the process of connecting two or

more generators in parallel, as one source of power, it
is a crucial concept in electrical power generation
• Generators can also synchronize to and support main
utility supply
• Synchronization of generators is achieved by adjusting
and matching voltage and frequency parameters of
generators involved
• Linking them together as one single source, the
matching of these parameters can either be done
manually by operators, who will close the generators
breakers once matched, or automatically using
modern controllers which carry out the required
matching automatically then link the generators
without the need of human intervention.
 Synchronizing Advantages

• Improve the electrical system Redundancy

• Reduction in fuel consumption (through load management)

• Adding more power capacity to setups (load sharing)

• Extra flexibility in utilizing our generators

• May help in logistic issue and space availability issues

 Remote Monitoring

Remote Monitoring is accomplished

through GSM towers, gateways with
SIM Cards are connected to the
generator control panels, Monitored
Parameters Include:
o Start and Stop
o KW & KWH
o Voltages & Current
o Alarms & Shutdown
o Faults
o Doors open
o Fuel level , theft
o Running hours
o Engine Temperature
Information required to offer
a generator rental solution
• Size of generator in kva or KW – based on the connected load.
• Estimated running hours per day, eg 8, 12 or 24.
• Frequency, and voltage required for the setup.
• Cable requirements and distances involved.
• Distribution boards requirements, if any.
• Change over switch requirements, if any.
• Oil and gas requirements, eg zone ii fittings, gas detectors, alarm beacons.
• Lifting requirements, specific certification.
• Available space available for the full setup.
• Diesel tank requirement, such as how many days for refilling.
• Possible fuel supply by Byrne .
• Standby operator needed or not.
• Remote monitoring requirements .
• Site access.
• Other
Questions
Chalwyne Valves and Spark Aristos

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ComAp MRS 15,16 & 25
Deepsea DSE-8610 MKII
Caterpillar old Panel Board
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