Synchronising Panels: Adding seamless symphony to Power

Synchronising Panels are used to ensure seamless flow of power through the DG sets when the main source of power falters.

The act is critical as it prevents any chance of an interim shut down of a critical device during power failure. A power fluctuation can result in the device restarting or even turning faulty.

A modern synchronizer compares the frequency and phase of the two voltages, and sends a correction signal to the summing point of the governor controlling the prime mover of the oncoming generator. When the outputs of the two systems are matched in frequency and phase, the synchronizer issues a breaker-closing signal to the tie-breaker, paralleling the two systems.

These synchronizers may include voltage-matching circuits which send raise and lower signals to the voltage regulator of the oncoming generator. If the voltage of the oncoming generator does not match the bus within set limits, the synchronizer will not allow a circuit breaker closure.

The synchronising panels can perform the following tasks depending on the requirement:-

• Synchronous operation of multiple generator sets with each other.
•  Synchronous operation of a single generator set with network
•  Synchronous operation of multiple generator sets with network
•  Synchronous operation of multiple generator sets with multiple networks

In order for the diesel generator sets to be synchronized, enabling them to run parallel, certain conditions need to be met. They need to have the same voltage, phase rotation, frequency & angular phase relationship. They need to share the load with respect to their ratings.

Check out our range of fuel efficient and silent DG sets on www.mahindrapowerol.com

Mahindra Powerol Ultra Super Silent Diesel Generators

By the sheer nature of its functioning, there are certain rules and regulations that the DG Sets fall in. The fundamental functions of these regulations are to curb the noise pollution that DG Sets may cause.

For instance the noise standards for DG Sets (15-500 KVA) should be less than, 94+10 log10 (KVA), dB (A), at the manufacturing stage. This level should fall by 5 dB (A) every five years. These rules are not just for the manufacturer. There is a need for mandatory acoustic enclosure/acoustic treatment of room for stationary DG sets (of 5 KVA and above). The acoustic enclosure/acoustic treatment of the room should be designed for minimum 25 dB (A) Insertion Loss or for meeting the ambient noise standards, whichever is on the higher side. The measurement for Insertion Loss may be done at different points at 0.5m from the acoustic enclosure/room, and then averaged. The DG set should also be provided with proper exhaust muffler with Insertion Loss of minimum 25 dB (A).

For DG sets of 5 KVA and above, the manufacturer should offer to the user a standard acoustic enclosure of 25 dB(A) Insertion Loss and also a suitable exhaust muffler with Insertion Loss of 25 dB(A). Meanwhile the user should make efforts to bring down the noise levels due to the DG set, outside his premises, within the ambient noise requirements by proper sitting and control measures.

The total sound power level of a DG set, at the user's end, needs to be within 2 dB(A) of the total sound power level of the DG set, at the manufacturing stage. Installation of a DG set needs to be strictly in compliance with the recommendation of the DG set manufacturer. Users are expected to set and follow a proper routine and preventive maintenance procedure for the DG set, which would help prevent noise levels of the DG set from deteriorating with use.

Additionally the generator sets above 5KVA are not allowed to be operated in residential areas between the hours from 10.00 p.m. to 6.00 a.m. The only exceptions to this rule are the generator sets of Group Housing Societies and Multi-storey residential apartments". The diesel generator sets above the capacity of 5 KVA in all areas residential/commercial/industrial shall operate only with the mandatory acoustic enclosures and other standards prescribed in the Environment (Protection) Rules, 1986. Diesel generator sets used in social gatherings and public functions shall be permitted only if they have installed mandatory acoustic enclosures and adhere to the prescribed standards for noise and emission as laid down in the Environment (Protection) Rules, 1986. Flouting of these rules may land the user/manufacturer under trouble. It may be a punishment of imprisonment for a term which may extend to five years with fine which may extend to one lakh rupees, or with both.

So while we use DG Sets to ensure our comfort, we need to ensure compliance with various factors so that the experience is as pleasant for those living around. 

Development of Generic Checklist for Diesel Power Generator Maintenance.

The service department in Mahindra Powerol performs the role of foreseeing repairs and initiating activities that prevent mechanical failures. Effective preventive maintenance inspection ensures that diesel power gensets reach their optimum service life what we refer to as ‘Happiness Delivery Machines’ (HDMs).

Preventive maintenance program is very successful in improving equipment reliability while minimizing maintenance-related costs. Preventive maintenance is an action involving inspection, servicing, repairing or replacing physical components of the diesel generator by following the prescribed schedule. The primary goal of PM is to prevent the failure of equipment before it actually occurs.

Preventive Maintenance can be classified in various ways. It is broken down into the following fundamental elements : Inspections, Repairs, campaigns and replacements and Overhauls/refurbish.

At Mahindra Powerol ‘Happiness Delivery Preventive Maintenance’ (HDPM's) are carried out where a total of 54 points are taken into consideration including tightening of the belts and checking the diesel generators wiring. The four most common HDPM's that are conducted are:

1.       Replacement of oil and fuel filters

2.       Cleaning and replacement of air cleaner filters

3.       Top up/ replacement of lube oil

4.       Top up/ replacement of coolant.

Inspections form a critical part of PM at Mahindra Powerol.

Inspections are done to check vital fluid levels, to obtain information about the well-being of the diesel power industrial generating plant. Manual inspection procedures entail manually checking engine oil, transmission fluid, and coolant levels; visually checking the engine compartment for leaks, listening for unusual sounds and other abnormalities.

Early detection of problems allows agencies to plan and prioritize repair schedules, order needed parts, and accordingly plan staff allocation. The alternative is addressing failures when they occur in service, resulting in service delays and operational inconveniences.

We’ve compiled a generic checklist of the list of things you must consider doing and the frequency in order to maintain the healthy life of your diesel generator. We recommend that you contact a Mahindra Powerol service engineer for the same.

Mahindra Powerol adds Power to ‘Saudi Power’

The Saudi Power Exhibition gathers the biggies from the industry under one roof, all in search of the latest products to service their multi-million dollar projects in Saudi Arabia. Saudi Power showcases the latest in equipment, technology and innovative solutions for a variety of industrial applications.

The event that happened at the Riyadh International Convention & Exhibition Center, KSA from 11th to 13th May ’15, was aimed at creating awareness for business opportunities in the region. Saudi is not a stranger to people with business interests. Its increasing affluence, high traction on tourism and steady population growth has made the region a hub for prospective businesses.

Saudi has recently seen a massive surge of mega projects which includes projects in the space of education, hotels, commercial spaces, residential projects and even expansion of cities. This massive roll out has resulted in a massive increase in demand for power back up solutions. We at Mahindra Powerol believe that we could contribute to the growth story of this booming market.

Competing with the biggest in the world, Team Powerol displayed the 160 kVA genset at the ‘Saudi Power’. Not only did the genset impress key decision makers from top corporates and trading houses, it also left the competition in awe.

A virgin visit at the Saudi Power, key executive from the Powerol family ensured that the stall was well attended. Mr. Atalkar, Sr. Manager Customer Care IO, Mr. Shelke, Country Manager Middle East, Powerol’s local distributors from Jeddah along with the Indian partner GSP were present at the site for catering to the local queries.

The visits to the stall, the inquisitiveness and the interest, all together were a testament to the acceptance of the Mahindra Powerol products in yet another international market. With our products powering over 300,000 Diesel generating sets in India & in global markets, we will soon be seeing Saudi being powered by Powerol. The advantages on offer like fuel Efficiency, better load acceptance, minimal vibration, low noise levels and low maintenance costs is too big a lure for any business man worth his salt to ignore us. The recent awards won, the prestigious Deming Prize for 2014 instituted by the Union of Japanese Scientists & Engineers (JUSE), is a testament of our global standards.

Effective practices for maintaining your diesel generator.

Irrespective of the nature of the use of your diesel generator, good maintenance practices will increase the life of your dg set. Here are some of things that should perform and continue to maintain one’s dg set.

1. Check the level of your oil regularly

2. Inspect and replace the oil filter – once a year is a good general practice.

3. Check the belts & look for signs of wear & tear. Belts that are dry or cracking can lead to inefficiency in your generators performance. Replace them on time to avoid overheating of the motor.  

The above was for smaller portable dg sets. For large generators the level of scrutiny in maintenance has to move a notch up. The Maintenance Schedule should be strictly followed and documented, logging any actions taken and readings for future comparison.  The best way to extend the life of your generator is through preventive maintenance.  

While on your maintenance spree, the maintenance provider checks for aberrations in the following systems to insure there are no mechanical issues that can lead to safety problems:

Electrical System

Check the battery terminals to clean rust at points. Clean points are as necessary to maintain a strong connection.  Ineffective Batteries are usually the primary reason of standby failures.  Batteries that have been maintained to the highest level weaken in time and must be replaced.  The only way to prevent a failure lead by a weak battery is testing and inspections. 

Air Intake System – If your system has a turbocharger – replace Air Cleaner Filter elements as recommended by the Manufacturer. Your routine inspection should include the checking the charge-air cooler for any debris which could damage or block the fins. 

Fuel System – All lines and filters should be checked for splits or thinning. Work on any lines that show signs of wear due to abrasion. Otherwise it would lead to an eventual breakage at a critical time.  Repair all leaking lines immediately. Diesel fuels should be drained periodically.

Exhaust System – The entire system must be tested for connection problems, any leaks must be detected and repaired.

Engine – Check all fluid levels. Please note that oil levels needs to be checked after engine has cooled down.

Coolant Systems – Check level on cool engine.  If level is low add to approximately three-quarter inch below the cap lower seal.  

Maintain these habits and be assured to give your DG sets a larger life. Do visit our website www.mahindrapowerol.com to check the guidelines and specific timelines on maintenance for various products.