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INDUSTRIAL TRAINING AND
PROJECT
REPORT
ON
FAULTY TRACING IN DG SETS
PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF
REQUIREMENT FOR THE AWARDS OF PROJECT YEAR DEGREE IN
MECHANICAL ENGG. OF THE PUNJAB TECHINCAL UNIVERSITY
SUBMITTED BY
CHETAN SUNDAN (80603514003)
SUBMITTED TO
DEPTT. OF MECHANICAL ENGG.
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BABA KUMA SINGH JI ENGINEERING COLLEGE
HOSHAIR NAGAR AMRITSAR
PREFACE
If you know the laws of buoyancy it doesnt mean that you know how to swim. It is only
through jumping in the water that you get the feel of the depth. This is applicable to every
aspect of life. Therefore practical training is of utmost importance.
The object of undergoing this training was to get familiar with the weary waters of the industry
and to learn how to put theory into practice. I have been greatly privileged to have undergone
training at SUDHIR GENSETS LTD., JAMMU.
This report contains the extract of things I have learned during my training period.
Chetan Sundan
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ACKNOWLEDGEMENT
Any endeavor cannot lead to success unless and until a proper platform is provided for the
same. This is the reason I find myself very fortunate to have undergone my industrial training
of six months at SUDHIR GENSETS LTD.,JAMMU. The persons of my department and allother departments have extended a warm and helping hand.
I am very fortunate to have had a chance to feel the gravity of what role mechanical
engineering plays in the industry. It was a golden opportunity for me to get a chance to
experience what it feels to be in a company wgere disciple, quality and hard work are the
motto. This training helped me a lot in bridging the gap between the theoretical and practical
aspects of my knowledge.
First of all I would like to thank Mr. Jangbir Singh for his valuable guidance and
encouragement as a teacher and a friend throughout my training period.
I am also thankful to Mr. Shami Sharma for giving me an opportunity to undergo training in
such a renowned company.
My heartily thanks to Er. Vinod Sharma who was my project manger and my guide through
the project works. They always went out their to help me at all times. Their experience andknowledge motivated me to bring out the best in times.
I am sure that the knowledge and information that I have gained during this period would be of
immense value for my growth in the field of Mechanical Engineering.
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Chetan Sundan
DECLERATION
I hereby certify that the project report submitted for the award of degree in Mechanical Engg. It
is the record of work carried out by me during the period Jan-2011 to June-2011 under the
guidance of Er. Vinod Sharma at SUDHIR GENSETS LIMITED, JAMMU.
Signature of Candidate
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CERTIFICATE
BABA KUMA SINGH JI ENGINEERING COLLEGE
HOSHAIR NAGAR AMRITSAR
(RECOGNIZED BY THE PUNJAB GOVT. ANDAFFILIATED TO THE PUNJAB TECHNICAL
UNIVERSITY APPROVED BY ALL INDIA COUNCIL OF
TECHNICAL EDUCATION)
This is to certify that project work entitled Industrial Training
And Project Report on FAULT TRACING IN DG SETS has
been carried out by :-
CHETAN SUNDAN (80603514003)
The student of 8th Sem. B. Tech in Mechanical Engineering
under our Supervision and guidance have submitted in the
partial fulfillment of the Requirement for the degree in
Mechanical Engineering during the Academic Session 2007-
2011.
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Principal Project Guide :
Dr. P. S. Sandhu Mrs. Meenakshi Madam
Examiner
INDEX
ABOUT SUDHIR GROUP
INFRASTRUCTURE
PLANTS
PRODUCTS RANGE
PARTNERS
WORK CULTURE
SERVICES
GENSETS OVERVIEW
SUDHIR GENSETS OVERVIEW
ENGINE OPERATIONS
TESTING
FAULT TRACING IN DG SETS
CONCLUSION OF TRAINING
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ABOUTSUDH IR
GROUP
ABOUT SUDHIR GROUP
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Sudhir is a name synonymous with Power. It stands tall in the Indian Power Generation Sector,
providing complete turnkey Electrical solutions from GENERATION, DISTRIBUTION TO
ELECTRIFICATION.
An Industry leader in the field of setting up Diesel base Captive Power Plants upto 20MW
having its corporate office in Gurgaon & revenue of over INR 1000 Crs, it has leveraged its
relationship with Cummins Ltd. To capture a majority market share.
The Company has a wide blue-chip customer base and operates through multiple
manufacturing facilities across India and focuses & Gas Generators,
HT & LT Switchboards, Transformers and Turnkey EPC contracts.
The product line includes the widest range of Diesel Gensets 15-3000 KVA with a fuel option
of Gas, Transformers, Packaged Substations, complete range of HT 11KV & 33KV Panels, LT
Switchboards, Turnkey EPC contracts covering electrical and mechanical services of
DISTRIBUTION TO ELECTRIFICATION.
Indeed, we have achieved and leapfrogged towards unprecedented growth. But to us this is just
another step in our ongoing journey to greater goals and broader horizons.
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INFRASTRUCTURE
INFRASTRUCTURE
All our manufacturing units are equipped with the very latest technological machineries. From
customized designing and computer aided design system to qualified team of experienced
engineers, these facilities add to credibility and superiority of our products and services.
DESIGN
Customized designing as per customer's requirement
Computer aided design system.
Qualified team of experienced engineers.
Customized to suit broad array of application
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FABRICATION
Amada CNC turret punch press (aries - 255)
Amada CNC press brake (rg 80)
SURFACE TREATMENT & PAINTING
11 tank metal pre-treatment for degreasing, derusting, phosphating, water rinsing and
passivation.
State of art modern powder coating plant
All shades possible as per customer requirements
Most suited for coastal areas and for alkaline environment.
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TESTING
ISO 9001:2000 certified by DNV
100% incoming inspection
All tests as per IS/IEC codesStringent quality test at every stage from inspection of inward material till despatch.
Equipped to carryout primary current engine up to 3000 Amp.
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PLANTS
PLANTS
a) Corporate office, Gurgaon b) Athal plant
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c) Jammu plant d) Gurgaon palnt
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PRODUCTS RANGE
PRODUCTS RANGE
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Cummins Powered
Diesel and Gas Gensets
Ranging from 15 - 3000 KVA
Our complete range of Generators are useful in providing Power in areaswhere conventional power supply infrastructure is unreliable. Our product
line includes the widest range of Gensets ranging from 15KVA to 3000
KVA, with a fuel option of Diesel or gas, a complete range of intelligent
switchboards, design & build end to end power solutions for your Captive
Power Plants.
All our manufacturing units are equipped with the very latest technologicalmachineries. From customized designing and computer aided design
system to qualified team of experienced engineers, these facilities add to
credibility and superiority of our products and services.
GensetControllers
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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 parallelingcontrol devices such as synchronizers and load sharing controls,
and KVAR / Power factor controls.
DG SET SPECIFICATION
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KVA MODEL NO.
1) 30 S3.8G3
2) 35 S3.8G3
3) 40 S3.8G4
4) 50 S3.8G6
5) 62.50 S3.8G7
6) 82.50 6BT5.9-G1
7) 100 6BTA5.9-G1
8) 125 6BTAA5.9-G3
9) 160 6BTAA5.9-G5
10) 180 6CTA-8.3-G2
11) 200 6CTAA-8.3-G1
12) 250 6CTAA-8.3-G4
13) 320 NTA-855-G2-1
14) 380 NTA-14-G3
15) 500 KTA-19-G9
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16) 600 VTA-28-G3-1
17) 625 VTA-28-G5-1
18) 750 KTA-38-G2-1
19) 750 QSK QSK23-G3
20) 1010 KTA-38-G5
21) 1250 KTA-50-G3
22) 1500 KTA-50-G8-1
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PARTNERS
PARTNERS
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We serve some of the largest, most prestigious and demanding clients
across India, including many Fortune companies. Read further, for a
description of our clients and to understand what we do for.
Realty
DLF EMAAR MGF Unitech Uppal Housing VatikaBPTP Alpha G Corp Essel Housing Ansal
Mahindra Gescom
OmaxeRaheja Developers Aerens Bestech Eros
Vipul SMCC TDI Ashiana Advance IndiaJMD Ambiance ERA Infra V3S KLJ
BAANI Sahara Anant Raj Ind
Hotels
Taj Jaypee Palace Eros Bristol Bharat HotelsTrident Hotel Oberoi Hotel Hans Plaza Maurya Sheraton Qutab Hotel
The Claridge Radisson Lodhi Hotel Ashoka Hotel Hotel Imperial
IHHR Nehru Palace
Hotel
Hospitals
AIIMS Safdarjung Sir Gangaram Lady Harding FortisUmkal Max Columbia Asia Dr, B. L. Kapoor Jaipur Golden
ApolloRajiv Gandhi
Cancer Institute
Dharamshila
Cancer Hospital
Moolchand
Medicity
Ram Manohar
Lohia
LNJP Medicity Paras Batra PGI Chandigarh ArtimisEscorts
Educational
Modern School DPSSalwan Public
School
Manav Sthali
School
G.D. Goenka
Public SchoolDAV Public SchoolDelhi University
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ITeS
Convergys Wipro SpectramindDaksh e-Services HCL
IT
HP Wipro Genpact HCL NIIT
IBM Patni Computer TCS Flextronix
Food Chain/ Restaurants
Barista Caf Coffee Day Haldiram Bikanerwala Nirulas
Dominos MC-Donald
Pharmaceutical
Ranbaxy Nectar LifesciencesGlaxosmithklineTorrent
PharmaceuticalsCipla
Panacea Biotech Cadila Dabur
Telecom
Bharti Reliance VSNL MTNL Voda PhoneESSAR ZTE Alcatel
Insurance
Max Newyork Tata AigIDBI Fortis Life
Insurance
HDFC Standard
InsuranceICICI Prudencial
Retail Outlets
Vishal Retail Bharti RetailHariyali Kissan
Bazzar
Big Bazar Aditya Birla Retail
Reliance Fresh Pantaloon Raymonds Gokul Mega Mart
Institutional
DMRC IOCL NDMC CPWD PWD
IOCL BPCL PDD C-Dot
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Export Houses
Apparel Export
Promotion CouncilOrient Craft Modelama Export Shahi Export SPl Ind
Beverages/ Distilleries
Radico NV Distilleries Pepsi Coca Cola
Banks
ICICI HDFC Citi Bank Axis Kotak Mahindra
Automobile
Maruti Hero HondaHonda Motorcycle
& ScooterHero Cycle TVS
Yamha Motors MICO/ BOSCH General Motors Amtek Auto JCB
Imperial Auto Competent AG Industries Bajaj Motors Hema EngineeringLumax Hero Cycle Munjal Auto Hero Motors Rockman Cycle
Hyghway Cycle Munjal Showa Sunbeam Auto Satyam Auto RICO Auto
Minda Ind Omax Auto Hi-Tech Gear Subros TVS Motor Exide GE Motor Atlas Krishna Maruti
Others
Jaypee L&T ABB Parle Bhushan Steel
Lakhani Relaxo Amul Dairy Vardhman Group Chinab Textile
Adani GroupBennett &
ColemannHindustan Times GMR-DIAL MBD
Kajaria Surya Roshni Jindal Nahar Spinning T-Series
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WORK CULTURE
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WORK CULTURE
The SUDHIR GENSETS seeks to create a culture where each employee, vendor, and dealer
feels himself responsible and integral part of the enterprises. The work culture at SUDHIR
GENSETS is open and participative Learning is encouraged in the company. Every member
respects 5 F formulas
1. Fast
2. Fair
3. Focused
4. Friendly
5. Fun
This governs its approach to business and relationships within the organization. It has
designee: its management structure in response to the needs of quick decision-making and
operational flexibility even through hierarchies and designation does exit. It is highly informal
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organization where communication moves in all direction, decision-making is quick and to a
large extent delegated.
Every member respects 5 s formulas also:
1. Seiri
2. Seiton
3. Seiso
4. Seikets
5. Shitsuk
5s stands for the first five letters of the japenese words:
S.No. JAPANESE
WORD
MEANING
1s SEIRI Sorting out, clearing, segregation, proper selection,
remove the waste
2s SEITON Systematic arrangement, keeping things at a proper
place, a place for every thing and every thing in its
place
3s SEISO Cleaning (spick and span) quality by the cleaniless.
Keep clean all area, equipment and work place
4s SEIKETSU Standardizing, environment, cleanliness, light,
noise, punctuality
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5s SHITSUKE Maintain discipline and standards to maintain above
4s, respect of rules.
The 5s are also five operations to keep a good behaviour for every work place 5s program
started in SUDHIR GENSETS LTD. From feb 2002 achieving clean floor and organized racks
is not an end in itself. The ultimate goal of house keeping through 5s is to reduce the cost of
product by increasing productivity and contributing to total quality.
How to achieve 5 s:-
5s can be achieved very easily by every employee by having close look at his work-place, he
is ensure that:
By organizing of work place and surrounding area in a better way.
No rejected! Unwanted items are lying at his work place.
By keeping all items, equipments at identified place.
Everybody should co-operate with each other in keeping his and others area clean.
Follow and respect of rules and regulations and maintain required standards.
PLEASE CHECK:
Do you have any unwanted things around you?
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Are all the required things kept at their allocated places? Are you following
timings and set norms?
Are you following the operation standards?
Are you regularly reviewing 5s
5s objectives:-
Productivity high
Quality high
Cost down
Delivery on time
Safe work place
Moral high
FUTURE PLANS:
1. To provide superior quality gensets over all the country with new technology at
reasonable rates, and to become NO.1 in gensets industry within five years.
2. SUDHIR GENSETS LTD. Have plans to market 10000 gensets during financial
year.
ACHIEVEMENTS
Company, which has shown about 30% increase in turnover within a period of 1 year.
Company has increased its production of diesel gensets.
The company has obtained ISO 9001 certification.
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Company has also obtained ISO 14001:2004 certification.
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SERVICES
SERVICES
It is a part of our mission to provide solutions that create value for our customers. Product
support is an important of our mission. Valuable owners of SUDHIR GENSETS LTD. Gensets
rely on uninterrupted power 247.
The success of your business demands solution that minimize downtime, reduce costs and keep
your equipment running at peak performance.
Whether its helping you select the right equipment for your job or utilizing the latest
technology to monitor your equipment SUDHIR GENSETS LTD. Are always there for you.
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By offering a wide range of solutions, services and products, we help you in lower costs,
increase productivity and manage your business more effectively.
In addition, our expert techinicans have the experience, knowledge, training and tooling
necessary to handle all your maintenance and repair needs. We have around 100 nos. ofworkforce, which cater services in different parts of the country so as to reduce downtime.
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GENSETS OVERVIEW
GENSETS OVERVIEW
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Other DG sets while power cuts eats into your profits, an inefficient DG set will simply add to
your losses, the SUDHIR GENSETS DG have been designed to ensure you an efficient power
supply. This also assures you years of hassle free operations.
Generates peace of mind
Its recovery time, easily the best in its category, gurrantees a seamless switchover to the back-
up power. Moreover, its effective governing system controls the voltage fluctuations, thus
ensuring completely safety of your equipments.
Performance unmatched
Its got one of the most preferred engines fitted inside- the CUMMINS ENGINE. Compact and
low on vibration, this engine has the smallest footprint as compared to other engines of
identical ratings.
Silence certified
Each and every SUDHIR DG set compiles with the most stringent noise and emission norms
stipulated by the central pollution control board of India (CPCB)
No compromise technology
Its got the other advantage too. Like, its transported through the SUDHIR Transport
solutions, it is installed and commissioned through a SUDHIR authorized dealer. It even comes
with an annual maintenance contract. It is the most fuel efficient in its class. It offers zero-leak
engines.
Preferred by all
A SUDHIR DG set can be used in the Telecom, Defence and railway sectors. It can also be
installed at places like petrol pumps, hospitals, super markets and banks.
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GENERAL DESCRIPTION OF GENSET
The Genset package includes a diesel engine, Alternator, control system and Canopy.
Gensets components Systems/Parts Function
Canopy Fabricated structure
Noise suppressing
material
Control noise level of
generating set housing
Base Fabricated structure
Anti vibration
mountings
Mount Engine+Alternator
Fuel tank Fabricated tank and
accessories
Store fuel
Battery Battery
Leads
Cables
Support direct current
Engine-Direct injection Air system
Cooling system
Fuel system
Exhaust system
Electrical system
Up-fitting parts
Produce mechanical
power
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Alternator-Brushless Stator
Rotor
Exciter
Rectifiers
Voltage regulator
Ventilation fan
Mounting arrangements
Produce electrical power
Control panel Measuring instruments
Controlling safeties
Logic controller
Meter power
Control power
Provide safeties
BEST FEATURES OF YOUR GENSET
Sr.No. SPECIFICATIONS PROPERTIES/ADVANTAGES
1. Modular in construction Easy for dismantling & assembly.
Easy for
shipment/handlings/installations
2. Lowest sound level in the series Lowest sound level of the rugged
M & M engines. CPCB certified
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3. Compact in size with proper air
passage.
Advanced design with sufficient
breathing and air movement for
great performance. Techanically
advanced.
4. Low fuel consumption in the
series.
Rugged and high fuel economy
5. Rust proof- powder coated &
weather proof
Long life- durable and branded for
good appeal for out door usage
without any additional sheets/
infrastructures.
6. Fire retardant and high noise
absorbent insulations.
UL94 & HF1 Grade insulation
foam used for fire
retardation/noise absorption.
7. Easy accessibility for services All parts of the equipments
accessible for easy serviceability
with enclosure illumination for
lightning at night in DG.
8. Draw out type fuel tank of easy
serviceability
Easy maintenance type fuel tank
for both routine maintenance and
sludge removals.
9. Low vibration to ground Technically tested anti vibration
mountings to arrest unnecessary
vibrations of equipment to
ground/structures.
10. High safety features for operator and equipment
Emergency stop from outsidecanopy. High canopy temperatures
switch and low fuel level switch-
alarm as optional.
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SUDHIR GENSETS
OVERVIEW
SUDHIR GENSETS OVERVIEW
In Sudhir Gensets LTD., jammu, there are two units:-
1.) UNIT 1
2.) UNIT 2
In UNIT 1, Manufacturing of canopies and base frames whereas in UNIT 2,assembly of genset
is done and then it is sent to testing area where testing is done before packing and delivering it
to the customers
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UNIT 1
MANUFACTURING PROCESS FLOW CHART OF CANOPY
Raw Material
Inward inspection
Shearing
Punching
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Welding
Grinding/Sanding
Stage Inspection
Pre-treatment
Stage Inspection
Powder Coating
Stage Inspection
Stuffing
Stage Inspection
To Assembly
DESIGN OF CANOPY:-
A) Back View
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b) Front View:-
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c) L.H.Side View:-
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d) R.H.Side View:-
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MANUFACTURING PROCESS FLOW CHART OF BASE FRAME
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Raw Material
Inward inspection
Shearing
Punching
Bending
Welding
Grinding
Leakage test
Pre-treatment
Stage inspection
Painting
To assembly( UNIT 2)
BASE FAME FOR 1250 KVA
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SIZE OF BASE FRAME
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SIZE(mm) KVA
1) 250 250, 380
2) 300 500, 625, 750
250mm base frames are used for silent sets. For example, for gensts of 250 or 380 KVA.
UNIT 2
MANUFACTURING PROCESS FLOW CHART OF SILENT DG SET
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1) Base Frame 2) Engine 3) AT & Other
__________________________________________________________________
Placement of base frame
Assembly of DG set on frame
Assembly of AE components
Alignment of doorsAlignment of roofs
Assembly of control panel Exhaust connection
a) Power cable connection Silencer fitting
b) Electrification of acoustic Cladding control panel
c) Fittement of battery
_____________________________________________________________________
Fittment of lube oil, coolant, blow by drainagePreparation for testing
Checking of service accessibility
Checking of lube oil and coolant levelConnection for testing
Checking of aesthetic Test in gidle
Load test
Cleaning of silent DG set
aspects and stickering
Documentation
Dispatch
DRAWING OF 1010KVA GENSETS
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DRAWING OF 1010 KVA GENSET BASE FRAME
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DRAWING OF 1250 KVA GENSET
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DRAWING OF 1250 KVA GENSET BASE FRAME
DRAWING OF 1500 KVA GENSET
DRAWING OF 1500 KVA BASE FRAME
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DRAWING OF QSK GENSET
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DRAWING OF QSK BASE FRAME
DIFFERENT VIEWS OF BASE FRAMES
a) FRONT VIEW
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b) SIDE VIEW (Radiator Side)
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c) SIDE VIEW (Alternator Side)
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d) TOP VIEW
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INSTALLATION
1. Installation
Most gensets installations must be engineered so the generator will function at
optimum output under the expected load conditions
Importance of proper installation of DG set:
a) improved reliability and durability
b) Better fuel economy
c) Easy serviceability
d) Improved aesthetic of genset room
e) High up time of genset
f) Better working conditions
LOCATION
Selecting a location for genset is very important part of any installation procedure.
Always locate the genset in the area that will provide:
a) Adequate ventilation
b) Clean, dry and bgood drainage capabilites.
c) Physical protection
d) Space for carry out services and also major repairs
e) Doors must be seized to allow access in & out for the complete generator set
anmd major accessories
FOUNDATION
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An inadequate foundation may lead to excessive genset vibrations resulting in
radiator leaks, failure of the auto electrical and safety system or failure of gauge,
coupling or other engine parts.
a) Genset should be kept on leveled surface.
b) Use of anti vibration mountings are recommended to isolate vibrations or
transmitting to floor. These are placed in between engine/alternator and base
frame.
c) The length and breadth of foundation should be atleast 150-300mm more
than the base rail length and breadth respectively.
d) It is recommended to have foundation height about 100-150mm above
ground level.
3. LIFTING/ UNLIFTING OF DG SET
a) Provision for genset lifting is provided on base rails. Unload the genset
from base rail by lifting with proper lifting tackle or nylon sling/ steel
rope of suitable capacity and crane so as to ensure no damage to oil
sump, air cleaner, radiator pipes etc.
b) Do not lift the genset from the engine hook and alternator hook.
ROOF TOP INSTALLATION
a) Structure of the roof area should be suitable for the entire weight, size
and shape of the enclosure
b) Floating floor of the structural steel platform across the main building
main columns can be a one of the solution] Ensure usingc) AVMs and also other installation techniques so that vibrations are not
transmitted to the building.
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GENERAL MAINTENANCE
1. VENTILATION
Ventilation inside the enclosure is necessary to remove heat and fumes diddipated
by the engine, alternator and its accessories and to provide clean and fresh air for
combustion. Additional ventilation arrangements may be required for gensets
installed in rooms. Radiator cooled engines may create slight negative pressure
inside the genset room/ enclosure. Maximum static restriction should not increase
6mm water column. Maximum allowed temperature rise above ambient in genset
room/ enclosed is 5 degree Celsius.
2. EXHAUST SYSEM
The exhaust system is used to direct exhaust to non-confined areas and to reduce
the noise to tolerable levels.
a) Ensure joints for
Proper clamping at the joint of exhaust and below
Proper clamping at the joint of exhaust pipe and silencer elbow No exhaust gas leak from any joint
b) Ensure alignment for
Exhaust bellow must have its free length, when installed with exhaust
pipe
Proper alignment of bellow and pipe
Ensure that bellow is not installed tilted or compressed
Ensure proper support to piping and silencer
c) Ensure free movement of exhaust pipe and silencder
d) Exhaust pipe lagging is must
e) Ensure exhaust back pressure limit is not exceeded in any case.
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3. AIR SYSTEM
a) Engine inlet air must be adequate, clean and as cool as possible. This will
help to achieve best possible performance and expected life of the genset.
b) Heavy duty air cleaner should be used for dusty environment. Please note
that gensets are supplied with medium/heavy duty air cleaner
c) Negative pressure(vaccum) inside the enclosure is not advisable. If it
exists/created, thyen value should not exceed 6mm of water column.
4. FUEL SYSTEM
a) Ensure leak proof joints
b) Piping should not restrict fuel flow to engine, accessibility to service points
and ventilation air flow.
c) Fuel can be cleaned or diesel can be drained without obstruction.
d) Provide diesel filling capacity from outside enclosure.
e) Provide level indicator and trip for low fuel level.
5. FUEL TANKS AND PIPES
a) The fuel delivery line carrying fuel to the engine and fuel return line
for carrying excessive fuel back to the tank should be no smaller than the
fitting sizes on the engine. For longer runs or extremely low ambient
temperatures increase the size of these lines to ensure adequate flow
b) Size to suit at least one shift operations or maximum 990 ltrs.
c) Drain fittings to bleed water condensate at lowest point of tank.d) Fill neck to be provided to allow min 5% expansion space
e) Use pipe sealant LOCTITE-577 for all connections for sealing. No Teflon
tape to be used
f) Suction line and return line to be separated by atleast n300mm
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g) Galvanizing not recommended inside fuel tank. Copper and GI pipes react
with diesels cant be used.
h) Wire mesh filter at suction point.
i) The fuel return line should be designed with minimum amount of bends or
dips to prevent air lock in the system.
j) Flexible fuel pipes should be used at a point between the tank and engine to
avoid the potential damage that could be created by vibration.
k) All standard genset with acoustic enclosure are provided with tank fitted in
the base frame. This tank will produce a ready fuel supply.
6. ENGINE BREATHER VENTS
a) Crankcase gases should be piped outside the engine room so that oil dont
accumulate on the engine/radiator.
b) Vent tube / hose should continuously slope downwards to avoid oil
accumulation.
7. SERVICE ACCESSIBILITY
a) Engine control panel should be visible from outside the enclosure
b) Service check should be possible without dismantling acoustic enclosure
c) In case of any major repairs, it may be required to dismantle the enclosure
and sufficient space around the enclosure should be available to carry out
the work
d) To avoid recirculation of hot air, durable sealing between radiator and
canopy is must.e) There should be provision for oil and coolant drain. Fuel tank have
provision for cleaning.
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8. COOLING SYSTEM
a) Systems are designed for ambient temperature of 500 degree Celsius.
b) Water used in the cooling systems should have properties as mentioned in
below table. If properties are beyond the limits then it can result in
Scale formation
Over heating
Corrosion
c) radiator fan flow should be free from any obstructions.
9. BATTERY / ELECTRICAL SYSTAM
a) 12V electrical system is used in SUDHIR engines upto 62.5 KVA.
b) Battery provided with the genset is maintenance free charged battery.
c) Battery should be placed on stands.
d) For AMF applications, a static battery charger working on main supply is
recommended to keep the batteries charged at all times.
e) Ensure polarity of the battery connections are correct.
10.ELECTRICAL CONNECTIONS
a) Ensure that only qualified electricans carry out installtion work
b) Use flexible cable to avoid vibrations and possible damages to the
alternator or circuit breaker terminals.
c) Ensure that the cable is laid in a cable tray and minimum bending radius
reference is followed.
d) Use correct size and type of cable to suit applied voltage, maximum current
and allowance should be made from maximum temperature inside the
enclosure.
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e) All electrical work should be carried out in accordance with any applicable
national, local standards, codes or regulations.
f) Protect the generating set from overload / short circuit by using circuit
breaker.
g) Maintain the power factor to 0.8 lagging by using inductive load or
capactiors depending upon the load type.
h) Never attempt to work on the living wire
i) Ensure balanced load is applied on the genset.
11.CABLING
a) Use only recommended cable sizes.
b) Use flexible wires.
c) Avoid any tension on the bolts / bus bars while terminating the cables.
d) Maintain R Y B phase notation in the alternator and control panel for ease in
maintenance.
e) Crimped cables should be connected to alternator and contol panel through
cable gland.
f) Strictly avoid loose thumbing / undersize cables.
g) Use armoured copper cable of right size for control cabling.
h) Support the cables such that weight of the cable should not fall on alternator
/ base rail.
12.EARTHING
a) Generated set + associated control and switchgears panels must be earthedproperly.
b) Earthing must be done on engine / alternator and not on base rail.
c) Earthing should be checked with multi-meter and ensure resistance is
maintained in prescribed limit (1).
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d) Copper GI strips of suitable size may be used.
e) Generating set should be earthed two distinct points through a conductor
heavy enough to carry the short circuit current without burning out.
f) Earthing must be in accordance with applicable national, local code or
regulation.
13.FIRE PRECAUTION
a) Install recommended type fire extinguishers.
b) Keep the room / enclosure free from accumulated rubbish which cab be fire
hazardous.
14.GENEST WITH ACOUSTIC ENCLOSURE
a) Engine control panel should be visible from outside the enclosure.
b) Service check should be possible without dismantling acoustic enclosure.
c) For major repairs / overhaul it may be required to dismantle the acoustic
enclosure.
d) To avoid recirculation of hot air, durable sealing between radiator and
canopy is must.
e) Sufficient capacity ventilation fans are required if radiator fan flow is not
sufficient. Fan flows in acoustic enclosure will be less due to higher
restrictions.
f) Exhaust piping inside the enclosure must be lagged
g) Temperature rise inside the enclosure should not be more than 50 degree
Celsius.
h) Radiator cooled engines may create slight negative pressure inside the
enclosure.
i) There should be provision for oil and coolant drain.
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15.SUCCESS KEYS
a) Adhere to central pollution board (CPCB) and other applicable national and
local codes, norms and regulations.
b) During installation, for dismantling of the acoustic enclosure and generating
set components, and then reassembly, ensure that both the processes are
done strictly as per manufacturers recommendations and by the authorized
work force.
c) Use only authorized channels for supply, installation and commissioning
and operation and maintenance.
d) Use genuine spares only.
e) Do operation and maintenance as per manufacturers recommendations and
through authorized service network. Maintain log book and other related
records. This will be useful during troubleshooting.
f) Insure right quality and quantity of air, fuel, lubricating oil and coolant. This
is more critical in case of AMF operations.
g) When generating set stops because of a fault, rectify 100% before start.
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ENGINE OPERATIONS
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TESTING
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TESTING
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ROJECT REPORT
ON
FAULT TRACING
IN
DG set
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Sr.
No.
DEFECTS REMEDY
1. FAULTY STARTER SWITCH REPLACE
2. BATTERY TOO LOW TO TURN
ENGINE
CHARGE OR INSTALL NEW
BATTERY
3. ENGINE OIL TOO LOW DRAIN OIL AND REFILL WITH
CORRECT GRADE
4. STARTER MOTOR INOPERATIVE INSPECT CABLES AND
TERMINALS
CHECK FOR TIGHTENING OF
MOUNTING SCREW
INSPECT BRUSH GEAR FOR
WEAR OR DAMAGE AND
COMMENTATOR FOR DIRT OR
DRAINAGE
5. STOPPER KNOB PULLED OUT PUSH THE KNOB IN
6. FUEL SYSTEM CLOGGED DRAIN SYSTEM, CLEAN AND
REFILL WITH PROPER FUEL
7. BATTERIES DISCHARGED CHARGE OR REPLACE
8. LACK OF COMPRESSION CHECK PUMP FOR
RESTRICTION IN SYSTEM AND
CLEAN OUT
ALSO CHECK VALVES AND
SPRING*
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9. LUBRICATING OIL OF WRONG
VISCOSITY
DRAIN AND REFILL WITH
PROPER LUBRICANT
10. FUEL FEED PUMP INOPERATIVE *
11. FUEL INJECTION PUMP HAS LOST
ITS EFFICIENCY
*
12. FAULTY HEAT INDICATOR REPLACE
13. INSUFFICIENT WATER IN THE
COOLING SYSTEM
CHECK WATER LEVEL IN THE
RADIATOR AND ADD WATER IF
NECESSARY
14. COOLING SYSTEM CLOGGED CLEAN OUT RADIATOR AND
ENGINE
15. FAN AND WATER PUMP BELT
SLIPPING
CHECK TENSION AND MAKE
PROPER ADJUSTMENT
16. INSUFFICIENT OIL MAINTAIN PROPER OIL LEVEL
17. DEFECTIVE THERMOSTAT *
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18. WATER PUMP DEFECTIVE *
19. FUEL INJECTION TIMING
INCORRECT
*
20. VALVE CLEARANCE INCORRECT ADJUST CORRECTLY
21. CLUTCH PLATE SLIPPAGE *
22. DEFECTIVE OIL PRESSURE
INDICATOR
REPLACE
23. BROKEN, LOOSE PIPES REPLACE, CLEAN AND
TIGHTEN
24. LOW OIL LEVEL IN THE
CRANKCASE
ADD OIL AND CHECK FOR OIL
LEAKAGE
25. DEFECTIVE OR DIRTY OIL
PRESSURE REGULATING VALVE
*
26. OIL PUMP NOT WORKING *
27. WORN BEARINGS *
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28. CLOGGED OIL FILTER *
29. TOO MUCH OIL IN AIR CLEANER CORRECT THE OIL LEVEL
30. INMPROPER GRADE OF FUEL/OIL DRAIN OFF AND REPLACE
WITH CORRECT GRADE OF FUEL/OIL
31. AIR CLEANER PIPE CLOGGED REMOVE AND CLEAN
IF DEFECTIVE REPLACE
32. INCORRECT VALVE ADJUSTMENT SET VALVE CLEARANCE
33. FUEL INJECTION PUMP LOST ITS
EFFICIENCY
*
34. LOOSE WIRING OR IMPROPER
CONNECTIONS CAUSING MALFUNCTIONING
CHECK WIRING TO SEE THAT
ALL CONNECTIONS ARE CONNECTIONS ARE CLEAN AND
TIGHT
35. BATTERY DEFECTIVE, LOW
CHARGE OR LOOSE
CONNECTIONS
RECHARGE, CLEAN AND
TIGHTEN CABLE PLUGS OR
REPLACE WITH NEW, CHECK EARTH
CABLE
36. STARTER MOTOR INOPERATIVE CHECK BRUSH GEAR
37. ALTERNATOR INOPERATIVE CHECK REGULATOR
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CONCLUSION OF
TRAINING
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CONCLUSION OF TRAINING
My training was the most versatile experience. I had the pleasure to do the work with one of
the most reputed factory in their field-SUDHIR GENSETS LTD. I received the blend of
experience in private sector. It was a good learning time during my training as we were
fortunate to be placed in the department related to manufacturing. I feel training has given me
exposure to undergo projects in the Manufacturing field as well help me a lot to understand the
company work culture, working with teams and much more.
In the end I would like to thank all persons who helped me throughout my training to enhance
my experience. I also pay my regards to my lecturers for their guidance during my training and
my academics helped me to do a lot during my training.