Installing a Diesel Generator’s Exhaust Pipe

The purpose of the diesel generator set exhaust system is to release harmful smoke to a certain height outdoors and reduce noise. 

   A) Precautions: -

        I.            All indoor generator sets should use a non-leakage exhaust pipe and the installation should comply with relevant regulations. Most importantly, the pipe should not be in contact with flammable materials and should not become a public hazard.  

     II.            The most important factor that should be considered is that the back pressure should not exceed the allowable range, because excessive back pressure will greatly reduce the efficiency of the engine, durability, and greatly increase fuel consumption. To reduce the back pressure, the exhaust pipe should be as short as possible. 

B) Other Points to be looked at: 

•  Unwelded flat steel material or in some cases asbestos cement is used to manufacture exhaust pipes. 

•  The exhaust pipe should discharge gas to a safe area and there should be a protective cap at the end of the pipe to prevent entry of rainwater. 

•   If the exhaust pipe, passes through a wall, it should be thermally insulated to prevent heat escaping into the wall.
  
•    When the pipe is connected to the generator, it should be sealed to prevent leakage. It will be a good practice to place a condenser with a socket at the bottom of the pipe. 

•              To avoid damage to other components, the connection between the exhaust outlet and the pipeline should use elastic hoses. 

•     If there is a need for a longer exhaust pipe, an expansion joint of an elastic sealing element should be installed.

• Always use smooth bends and keep number of bends minimum.

•  Calculate the total equivalent length of the exhaust piping and accordingly increase the diameter of the pipe. (From 5 to 15 meters, increase inner diameter by 20%. From 15 to 25 meters, increase inner diameter by 40%).

• It is recommended that the exhaust pipe should be installed away from the air filter of the diesel generator engine to prevent the machine from absorbing hot air. 

•  When using multiple diesel generator sets, it is not advisable to install all the exhaust pipes on the same pipe - when some gensets are running and others are shut down, the exhaust gas will enter the unused units, damaging the units. 

•   If the size of the exhaust pipe exceeds the range specified by the unit, please consult the diesel generator set manufacturer.

•  The noise generated by the machine can be lowered by reducing the distance of the exhaust pipe connected to the engine.

For further guidance or information on diesel/gas gensets visit our website at www.mahindrapowerol.com/ or call us at 1-800-419-1999

Generator sizing

One of the most important decisions that needs to be made in a factory or unit is the determination of the diesel generator size. Will it be used for continuous power supply or will it serve as a standby source? While you will be consulting an expert, who will recommend a size, this article aims to give you a basic understanding about the factors you need to consider for generator sizing.

1)    Generator Ratings

Diesel generator ratings are either continuous, prime or standby.

Ø  Continuous Rating is when a dg set is expected to work 24 hours a day, 365 days a year.

Ø  Prime rating allows some fluctuation in the load, and

Ø  Standby means the backup running time is up to 200 hours per year.

2)    Performance Classes

Generators are divided into the below classes as per their performance: 

a)    Class G1 is for general purpose loads, example lighting.

b)    Class G2 is meant for public electricity supply, pumps and fans. 

c)    Class G3 is used for telecommunications and thyristor-controlled loads.

d)    Class G4 is used in data processing or computer systems where the demands are stringent. 

3)    Start-up times

You can also choose your diesel genset on start-up times. 

A.    Manual starting for generators without a specified start-up time.

B.    Automatic start-up – Long Break: - A generator started from stationary on grid failure.

C.   Automatic start-up – Short Break: - When power is disrupted for only a few milliseconds while the electrical transfer takes place. 

D.   Automatic start-up – No Break: - A continuously running electrical machine providing an uninterrupted supply in the event of power failure. 

4)    How much power do you need? 

It is a myth that smaller dg sets can be used for standby requirements since they will not be used all the time. This thinking can lead to generator damage and other assets connected to it and create unsafe situations. 

5)    Assess your needs 

While it may be tempting to visit your nearest dealer and pick up the cheapest generator available, it won’t make good business sense. You should study and understand your power requirements before you go shopping for a generator. 

6)    Make a list

ü  Start with listing all units that will need to be powered by the diesel generator.

ü  The next step is to list the starting and running wattage of items.

ü  Finally, you should calculate the total power requirements. 

To know more about Mahindra Powerol, visit www.mahindrapowerol.com or call

1-800-419-1999

Causes of Voltage Drop in Diesel Generators

Voltage drops can have an adverse effect on productivity and profit and to make sure that they don’t happen too often, we must understand what causes the drops. 

It is well known that a voltage drop in diesel generators is mainly caused by the speed and frequency of the generator system. However, there are many other reasons that can cause a dip in voltage. 

1.  A main reason is that the load applied to the generator is greater than the capacity. This slows the machine down, drops frequency and voltage and leads to exhaust black stacking. The machine could eventually stall. 
2. The Automatic Voltage Regulator (AVR) voltage gain is set too low to respond to load being applied which will put pressure on the genset affect the life of the machine.
3. Clogged fuel injectors and fuel filters will supply less than required fuel to handle the load - this can cause the machine to slow down which will result in the reduction of hertz and volts.
4. Sometimes the speed control setting is not accurately set, and this may cause the generator to trip. 
5. If Automatic Voltage Regulator (AVR) feedback is from generator bus voltage transformer and voltage dips too far, all excitation could be lost and would typically result in an under voltage and over current trip.
6. A loose cable connection in the output terminal can also lead to voltage drops. 

Mahindra Powerol offers 25 kVA & 125 kVA Gas gensets, apart from diesel generators ranging from 5 kVA to 625 kVA. To know more about genset maintenance visit us at www.mahindrapowerol.com/ or call us at 1-800-419-1999

Tips for Generator Maintenance

Mahindra Powerol gensets are engineered to require as little maintenance as possible. Below are some regular steps that will help improve your gensets’ life and efficiency. 

1. Routine General Inspection :-

When the diesel genset is being operated, several systems need to be closely monitored for leaks. These include exhaust, fuel and DC electrical systems. Since the diesel genset is similar to an internal combustion engine, it is important to check it periodically and ensure that oil is changed after every 100 hours of operation.

2. Lubrication Service :-  

It is essential to check the level of the engine oil. You may let the oil in the upper parts of the engine drain back into the crankcase. It is advisable to keep the oil as close to the full level as possible and follow Mahindra Powerol’s recommendations for API oil classification and viscosity. You should also use the same brand of oil as far as possible. 

Mahindra Powerol has a set of procedures for draining and disposing of the oil in an environment friendly way. 

3. Cooling System :- 

During regular shutdowns, make it a point to check the coolant level. (Remove the radiator cap only after allowing the engine to cool.) The coolant can be a mixture of water, antifreeze and coolant additives. The exterior should be examined for obstructions and all foreign material should be removed with a soft brush. You can also use low-pressure compressed air or a stream of water. 

4. Fuel System :- 

Since diesel is subject to contamination, it is not advisable to use diesel that has been stored for a long time. Water vapour accumulates and condenses in the fuel tank, hence fuel filters should be cleaned at regular intervals. Preventive maintenance should also be undertaken in the form of general inspections and checking of coolant level, oil, fuel and starting systems. 

5. Testing Batteries :- 

One of the most common reasons gensets fail are undercharged batteries, so make sure batteries are charged. It is also advisable to keep batteries clean by wiping them with a damp cloth. 

A battery hydrometer can be used to check the specific gravity of the electrolyte in each battery cell.  A fully charged battery will have a specific gravity of 1.260 and the battery should be charged if the specific gravity reading is below 1.215.

The level of electrolyte should be verified after every 200 hours of operation. If the level is low, distilled water should be filled to the bottom of the filler neck. 

6. Keep your Generator Clean :- 

It is highly recommended to check your genset periodically and ensure it is kept clean. Hoses and belts are subject to wear and tear - they should also be inspected thoroughly. Sometimes wasps can rest inside, regular checks will take care of such pests. 

Mahindra Powerol offers 25 kVA & 125 kVA Gas gensets, apart from diesel generators ranging from 5 kVA to 625 kVA. To know more about genset maintenance visit us at www.mahindrapowerol.com/ or call us at 1-800-419-1999

Benefits of Gas gensets

You have heard of the efficiency of gas generators and you may be wondering if it makes more sense to use a gas genset instead of a diesel genset for your business. The obvious and practical choice must be gas gensets.

Natural gas is known to be one of the most affordable and effective fuels and in terms of cost, except for coal which is cheaper. However, coal is a high pollutant.

Gas gensets are commonly used in areas where the supply of fuel is made readily available through pipelines. Let’s take a look at some of the advantages: -

Advantages:

The most apparent benefits of using natural gas generators are:

a) They are cleaner

b) They are less expensive than other non-renewable fuels

c) And is considerably efficient.

1.    When compared to oil and coal, the emissions of sulfur, nitrogen, and carbon dioxide (a greenhouse gas) are considerably lower. Therefore, natural gas is one of the cleanest fossil fuels.

2.    Natural gas generators are also effective in reducing costs when used to power homes. This is because electricity from the main utility source is a far more expensive alternative.

3.    Natural gas is also readily available in areas where it is delivered directly through pipelines. So, there is no need to store fuel - this makes gas generators very easy to install and use.

4.    Natural gas is safer when inhaled in small amounts. Natural gas does not produce soot or ash and any leakage can be detected immediately.

5.    Natural gas generators can be easily installed in confined or restricted spaces.

6.    Gas gensets do not produce a pungent odor, while generators powered by oil or diesel tend to do so.

Conclusion.

As you can see, gas gensets tend to have quite a few advantages. However, the choice of genset depends on your budget and the purpose you will be using it for.

Mahindra Powerol offers 25 kVA & 125 kVA Gas gensets and apart from gas gensets, they also manufacture diesel generators from 5 kVA to 625 kVA. Gensets from Mahindra Powerol are known for their fuel efficiency and reliability. To know more about, visit www.mahindrapowerol.com/ or call 1-800-419-1999