Generator and its Parts.

By Chief Engineer Riaz Marghoob's Lecture On

Generator and its parts

It was the Daihatsu Generator.


There are two sides of the generator.
Electrical Side. (part after the flywheel)
Mechanical Side.

MECHANICAL SIDE
Cylinder Head is the top cover of the cylinder and contains following parts.
Rocker Arm.
Cylinder Relief Valve.
Exhaust Valve.
Air Starting Valve.
Fule injector.
Indicator Cock. (Indicates the inside position of the cylinder)
Push Rod
Turbo Charger is attached with the generator and is responsible for removing the burnt gasses from the cylinder and filling it with the fresh air. The more the fresh air in the cylinder the more will be the generator's efficiency.


Sump at the lower part of the engine contains lube oil for lubrication of Crank Pin Bering, main Bearing, cross head and Piston and cylinder liner.


There are two types of lubrication methods:
Splash Lubrication.
Forced Lubrication.

Splash Lubrication:

Splash lubrication takes place by the splashing due to the movement of the crank shaft.



Forced Lubrication:

For forced lubrication lube oil pump is required which pumps the lube oil through the connecting rod into the gudgeon pin hole through which it is released and lubricates the area between the piston and cylinder liner.



In both cases lube oil filter is attached to remove any impurity from the lube oil.


Fule pump is placed on the right hand side of the governor and is used to pump the fuel in the pipe over the cylinder head


Like a lube oil filter there is also a fuel oil filter which is used to filter the fuel oil.


Lube oil cooler is present to maintain the temperature of lube oil.


Piston contains two different types of ring attached in differnt combination depending upon the construct.
Compression Ring.
Scrapper Ring Or Oil Ring

Compression Ring:

It is used to restrict the hot gasses from entering into the sump.



Scrapper Ring:

It is responsible for creating a film of lube oil and scrap the lube oil into the sump from the liner.



Before attaching the ring make sure of the correct side of the ring to be at the top. Some times it is written on the ring "This Side Top."


Camshaft is present above the crank shaft and operates the rocker arms above the valve via push rod. It operates the push rod which further operates the rocker arm which further operates the spring loaded valves on cylinder head.

FOR ELECTRICAL SIDE PLEASE REFFER TO DOC. 1 ATHER RIZVI's LECTURE.

Written by Ali Ahmed

Overhauling the two units of generator

Allah the most merciful, the beneficent

Following is the procedure for overhauling the two units of generator

1.       Arrange the tools as required from experience, visit the application (generator) and read instruction from the service manual.

2.       Planned the full work.

3.       Start with name of Allah who is governing this world, this generator and you

4.       Drain the particular unit or all the units as required

5.       Shut the fuel, Lubricating oil and pneumatic line valve (starting line) as required

6.        Open up all the required connection Jacket water outlet, exhaust manifold, scavenging manifold expansion bellow ( or nut bolt if it is present)

7.       Open the nut of stud by the help of hydraulic pressure device.

8.       Lift the unit and keep it in safe place.

9.       Remove the carbon deposits. Clean it with the help of wire brush pneumatic motor, emery paper (Sand paper).

10.   Now place the new furnished units on cylinder block.

11.   Tightened the stud

12.   Place the rocker arm assembly and take the tappet clearance ( by rotating the fly wheel to the firing order of that particular unit at top position)

13.   Yup the overhauling is now complete. Open the requisite valve and enjoy the electricity from your new overhauled generator.

14.   Take a trial and fix the abnormal condition as necessary.

Dated: 06 June 2012

Tools Required

1.       24(For rotating fly wheel), 17(For fuel injector), 27(For fuel rod of fuel injector) socket

2.       Extension

3.       Copa slip (Copper compound)

4.       19, 17 and 27 MM spanner (with fixed and open end at the other end)

5.       Electro clean slow for general cleaning

6.       Blade for cleaning

7.       Pneumatic wire brush for cleaning

8.       Fuel injector extractor device

9.       Portable hydraulic hand pump, hub, pipes, hydraulic jack

10.   Replace the gasket b/w head and cylinder block normally four cooling water, one scavenge, rocker arm oil and main cylinder gaskets, exhaust gas pipe gaskets, steam joints for cooling water o/l to main pipe.

11.   Torches

12.   Fan incase of severe heating

13.   Clothes for cleaning

14.    

Marine engineering Direct Current and Alternating Current Generators

Marine engineering dc and ac generators 

• 1.  
• 2. IT IS THE ALLAH WHO SUBJECTED THE SEA TO YOU.THAT SHIP MAY SAIL THROUGH IT BY HIS COMMAND ,THAT YE MAY SEEK OF HIS BOUNTY,AND THAT YE MAY BE GRATEFUL (Al-Quran)
• 3. Marine Engineering DC and AC Generators
• 4. DC Generator Direct current motors is generally divided into three categories Shunt wound Generator Series wound Generator Compound wound Generator balancer
• 5. Shunt Wound Generator The shunt is attach in parallel with the motors Speed drops but little with increasing load
• 6. Series wound Generator Series falls heavily with increasing load starting torque is high Speed falls heavily with increasing load starting torque is high
• 7. Compound wound motor Shunt and series both are attach in compound motor This motor can function of shunt as well as series motor.
• 8. Generator #01 Radiator Belt driven fan (plastic) Fresh water pump (coupled with Crankshaft) Oil filter (lub oil) Turbocharger Air filter 24VDC Battery Governor (for oil controlling) Mechanical Starter (Self) attach in the gearbox Lub oil filter (with bottom hole to check oil quantity)
• 9. Generator #01 (cont.) 11. Oil pump (lub) 12. Oil pan 13. Dip stick 14. Fuel filter (diesel) 15. Fuel pump 16. Exhaust manifold 17. Injector 18. Thermostat 19. Oil pressure 20. Exhaust valve
• 10. Generator #01 (cont.) Prime Mover side Manufacturer name: Detriot Engine combustion: Diesel Stroke: 4stroke Model: Manufacturer:
• 11. Generator #01 (cont.) Alternator side (Brushes) Model No. E7315 Serial no. 78A80 KW con : 100KW Apparent power: 125KVA Power factor : 80%pf Phase: 3 phase Frequency: 60Hz RPM: 1800rpm Excit field: 82A ; 43V Ins Cl: F Arm H field 45centigrade Max Amb. DELCO PRODUCTS DIV OF GM COP. DAVTOH USA
• 12. Author Introduction ZEESHAN AHMED , Marine Engineer . After doing FSc(pre-engineering) from PAF(fazaia) intermediate college Lahore cantt. I joined Pakistan Marine Academy and choose Marine engineering branch. Two years of training at academy (practical + theoretical) we learned a lot of thing like CNC (computerize numeric code), trained on various models (like control valve, solenoid valve, flow meter, refrigeration system, CPP propeller, Main engine model (TWO stroke), Boiler model (water tube) ……………………………….. in GEK (general engineering knowledge) lab, Mechanical and physics lab, Engineering workshop. ETC . After two years, we joined PNSC workshop for the training of ONE year Industrial training. That was also the golden time where we learnt a lot of things at different shops as well as onboard (repairing and watch keeping). I learn many thing on tankers E.g. MT Johar (learn how to dismantle turbine rotor from casing and what are the precautionary measurement while working on turbine, learn how to change the diaphragm(stationary blade) Plate type heat exchanger gasket change, shell and tube Cooler Anode replacement and (Cont.)
• 13. Introduction (cont.) cleaning of SALT WATER tubes etc.) , MT Swat (major thing which I learn in Swat is how to dismantle head of main unit and copper gasket replacement with a minor facing defect which is found during overhauling which is filled and faced by Belzona) , MT Lahore(About the DEAD MAN ALARM, Alpha lubricator for Cylinder Main Engine Unit, Pump operation and watch keeping), MT Quetta(Auto load sharing of Generator Set, MT Karachi (Dry washing of the main engine turbocharger with granules, water washing of IG Fan of Inert Gas system, sludge removal of from purifier(centrifuge) etc. Beside the learning routine I learn many thing also on Cargo ship. The total flooding system for Engine room and Flooding system for Cargo holds. MV Islamabad (working on monkey bridge welding of Fish plate, threshen plate, refrigeration system and air conditioning system, ) ; MV Multan (learn how to change the liner of Units of Main Engine and measurement and cleaning related to unit overhauling; change the Gauge glass of HOT WELL : boiler mountings (dismantle and overhauling, assembling, major thing what we will do incase of BLACK-OUT on ship, Purifier overhauling, etc. (Cont.)
• 14. Introduction (contd) One thing I want to added is that the trend in ship building is more toward based on electronic and electrical application. So a marine engineer must strong in automation, instrumentation and control system. PLC (programmable and logic control) and SCADA (supervisory central access and data acquisition) are the upcoming technology that are using on modern ship. The latest engine of MAN B&W is based on Camless technology. Chain is removed ; fuel pump and exhaust valve actuation is control by hydraulic servo(lub) oil which is driven by Axial piston pump mounted on the Fly wheel. Regards, Z.A.
• 15. Author contact information zeetec4@yahoo/gmail/hotmail.com zeetec4@yahoo/gmail/hotmail.com Social networking sites Facebook: mariner46 Website: zeetec4.googlepages.com Any question and suggestion are welcome

Marine engineering paralleling of generators

Marine engineering paralleling of generators

• 1.  
• 2. IT IS THE ALLAH WHO SUBJECTED THE SEA TO YOU.THAT SHIP MAY SAIL THROUGH IT BY HIS COMMAND ,THAT YE MAY SEEK OF HIS BOUNTY,AND THAT YE MAY BE GRATEFUL (Al-Quran)
• 3. Marine Engineering Paralleling/Synchornizing of generators
• 4. Synchronizing or paralleling of generators Start the incoming generator Check the voltage and frequency of the generator. When the synchroscope will between 12 o clock to 5 o clock And synchronizing lamp revolve slowly clockwise. Close the air circuit breaker (ACB).
• 5. Note The incoming generator voltage and frequency must be greater then busbar voltage and frequency to prevent reverse power relay trip. Always close the ACB when the synchroscope is between 12 to 5’o clock.clockwise.
• 6. Author Introduction ZEESHAN AHMED , Marine Engineer . After doing FSc(pre-engineering) from PAF(fazaia) intermediate college Lahore cantt. I joined Pakistan Marine Academy and choose Marine engineering branch. Two years of training at academy (practical + theoretical) we learned a lot of thing like CNC (computerize numeric code), trained on various models (like control valve, solenoid valve, flow meter, refrigeration system, CPP propeller, Main engine model (TWO stroke), Boiler model (water tube) ……………………………….. in GEK (general engineering knowledge) lab, Mechanical and physics lab, Engineering workshop. ETC . After two years, we joined PNSC workshop for the training of ONE year Industrial training. That was also the golden time where we learnt a lot of things at different shops as well as onboard (repairing and watch keeping). I learn many thing on tanker E.g. MT Johar (learn how to dismantle turbine rotor from casing and what are the precautionary measurement while working on turbine, learn how to change the diaphragm(stationary blade) Plate type heat exchanger gasket change, shell and tube Cooler Anode replacement and (Cont.)
• 7. Introduction (cont.) cleaning of SALT WATER tubes etc.) , MT Swat (major thing which I learn in Swat is how to dismantle head of main unit and copper gasket replacement with a minor facing defect which is found during overhauling which is filled and faced by Belzona) , MT Lahore(About the DEAD MAN ALARM, Alpha lubricator for Cylinder Main Engine Unit, Pump operation and watch keeping), MT Quetta(Auto load sharing of Generator Set, MT Karachi (Dry washing of the main engine turbocharger with granules, water washing of IG Fan of Inert Gas system, sludge removal of from purifier(centrifuge) etc., . One thing I want to added is that the trend in ship building is more toward based on electronic and electrical application. So a marine engineer must strong in automation, instrumentation and control system. PLC (programmable and logic control) and SCADA (supervisory central access and data acquisition) are the upcoming technology that are using on modern ship. The latest engine of MAN B&W is based on Camless technology. Chain is removed ; fuel pump and exhaust valve actuation is control by hydraulic servo(lub) oil which is driven by Axial piston pump mounted on the Fly wheel. Regards, Z.A.
• 8. Author contact information zeetec4@yahoo/gmail/hotmail.com Social networking sites. Facebook: mariner46 Website: zeetec4.googlepages.com Any question and suggestion are welcome

Electrical Static Automatic Voltage Regulator

Static Automatic Voltage Regulator
The carbon pile regulator uses a magnetic coil powered from the alternator output Strength of the field vanes with alternator voltage and this strength is tested against springs which are the voltage reference. The moving contact regulator employs a similar matching of alternator output effect through a magnetic coil against springs.
The availability of a small transformed, rectified and smoothed power supply from the alternator output makes possible the matching or it directly against an electronic reference in the static automatic voltage regulator. The direct current derived from the alternator output is applied to a bridge which has fixed resistances on two arms and variable resistances (zener diode voltage references) on the other two. The zeners operate in the reverse breakdown mode having been manufactured with a zener breakdown voltage of very low value. As can be seen from the earlier description of zener diodes, voltage remains constant once breakdown has occurred despite change in current. This implies, however, that changes in applied voltage while not affecting voltage across the diode will cause a change in resistance which permits change in current. .As with a Wheatstone bridge, imbalance of the resistances changes the flow pattern and produces in the voltage measuring bridge an error signal
The error signal can be amplified and used to control alternator excitation in a number of different ways. Thus it can control the firing angle of Thyristors (Fig. 3.14) through a triggering circuit to give the desired voltage in the brushless alternator described. It can be used in the statically excited alternator to correct small errors through a magnetic amplifier arrangement-The error signal has also been amplified through transistors in series, for Excitation control.