Swastik Power

Swastik Power

Manimajra, Chandigarh
GST No. 04BXZPS3653N1ZG
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SELECTION OF SITE

  • Proper space should be there for placement and opening of doors of the Silent DG set.
  • There should be atleast 1.5 meter free space around the DG set for proper operation and maintenance.
  • There should be cross ventilation of air to ensure proper cooling of DG set. Exhaust gases and hot air discharge should not re-circulate inside the acoustic enclosure (canopy).
  • There should be no restriction for fresh air suction and hot air discharge. If 2 DG sets are installed at the site, ensure that hot air outlet of the one DG set does not become the fresh air intake of the 2nd DG set.
  • A low height shelter for the Silent DG Set should be avoided. It should not obstruct the hot air outlet.
  • It is preferable to install the DG set in an open area. No shade (roof) is required over it. However, if the AMF Panel is outside the Acoustic Enclosure, then a shelter is recommended for the Panel.
  • For Roof Top Installation, ensure that the civil structure is capable to bear the static and dynamic load of DG set. The load of the Silent DG set should be borne by Columns and Beams of the building.
  • Proper space should be there for Earthing.
  • If there are no space constraints, the DG set should be placed near the distribution panel.
  • The DG set should be located away from polluted surroundings such as corrosive fumes, cement dust, fibres, cotton and toxic chemicals to avoid overheating of the D.G. Set.
  • The Foundation should be water leveled and atleast 3” above the Ground Level.
  • The Length and width of the Foundation should be atleast 200mm to 400 mm more than that of the DG set size.
  • Please refer to the foundation drawing attached herewith.
  • A rigid foundation ensures the least vibration. Sand Filling should be there around the foundation. Rubber matting can also be used over the foundation to minimize the vibration effect and noise leakage.
  • Please refer to the dimension of DG set for deciding the foundation length, width and depth.

EARTHING SYSTEM

  • An Earthing system is required for the protection of equipment and human being, as per Indian electricity Rules 1956.
  • Separate earth should be used for body and neutral earthing.
  • 4 Nos. earthing pits are required for 3 phase DG set, 2 each for neutral & body
  • 2 Nos. earthing pits are required for single phase DG set, 1 each for neutral & body
  • The min. distance between 2 earthing pits should be 2.0 meters.
  • An earth pit cover should be provided.
  • A watering pipe of 19mm with a funnel should be provided for each pit, wherever depth of the earthing pit is not at water level.
  • Earthing  system  should  be  checked  with  meagre  and  maximum  1.0 om resistance should be ensured.
  • The earthing plate/pipe and strip size should be selected as per the rating of the DG set.
Description Unit 15 KVA - 125 KVA
Copper Strip 25x3 mm  
GI Strip 25x6 mm  
Description Unit 140 KVA - 625 KVA
Copper Strip 25x6 mm  
GI Strip 50x6 mm  

EXHAUST PIPING

Air cooled




Description Unit 15 KVA – 35 KVA 40 KVA­ 62.5 KVA 75  KVA
Exhaust Pipe Dia mm 63 76 100






Water  Cooled R-Series Unit 15 KVA – 35 KVA 40 KVA­ 62.5 KVA 75  KVA 100 KVA ­ 125 KVA-
Description mm 63 76 100 125
Exhaust Pipe Dia










SL Series




Description Unit 140 KVA - 250 KVA


Exhaust Pipe Dia mm 125








K Series




Description Unit 275 KVA 320 KVA 400 KVA  - 625 KVA
Exhaust Pipe Dia mm 125 150 2 x 150

FUEL PIPING

  • A supply and return fuel pipe is required in each DG set.
  • SDGs up to 200 KVA are provided with fuel tanks inside the acoustic enclosure.
  • Above 200 KVA, the fuel tank is outside the acoustic enclosure.
  • For fuel tank inside the enclosure, fuel piping is done by the manufacturer/supplier.
  • However, for Fuel Tank outside the enclosure, fuel piping is to be done by the customer.
  • Size of the fuel piping should be 12mm upto 250 KVA DG set.
  • Class M.S. pipe (19 mm -25mm I.D.) is recommended For fuel piping above 250 KVA DG sets.
  • MS pipe should be used with proper welded joints.
  • Stop valve and flange should be used at supply line to engine near fuel tank (for Fuel Tank mounted outside).


PRECAUTIONS TO BE TAKEN FOR FUEL PIPING AND FUEL SYSTEM.


  • Never use GI pipes in fuel piping of DG set.
  • Joints should be welded and never threaded.
  • Pipe should be above ground level with proper MS support.
  • All joints should be tested for any seepage or leakage.
  • For 320 KVA and above DG sets, Fuel Tank height should be such that lowest level of Fuel Tank is above Diesel pre-filter height.

CABLING

  • It has been our experience that most electrical failures are caused by overheating due to loose thimbling or undersize cables.
  • Please use cable of correct size to carry full load current and thimble of correct size for cable termination.
  • At no time, loose wires should be tightened on to terminal/busher with bolts.
  • Crimping should be done with proper crimping tool.

BATTERY CHARGING PROCEDURE

Battery Charging Procedure:-

  • If dry battery is supplied along with the DG set then initial charging of the battery is required.
  • Please get initial charging of the battery done) 520 an authorized service dealer of the battery manufacturer.
  • The initial charging process is of 72 hours.
  • Specific gravity of acid inside the battery should be 1.23 to 1.28 kg/ltr.

Method to use Charged Battery:

  • If charged battery has been provided along with the DG set, and the DG set is not in use then ensure that at positive terminal battery lead is not connected. It should be connected at the time of the commissioning of the DG set.
  • Charged battery may be used for commissioning of DG set within 15-20 days, else re-charging of charged battery is required.
  • Always connect the battery with the proper battery charger. The battery should be connected to the battery charger, which is connected with 230V AC supply.
  • The Battery charger is provided with an AMF Panel (Auto Mains Failure Panel) under the standard scope of supply. 230V AC supply is essential for battery charger operation.

Note
: Battery charger is not supplied with a std. manual Panel. So, it is suggested that the DG set must run once a day for 15-20 minutes so that battery is charged by engine dynamo/charging alternator.

Precaution to be taken during handling of battery

  • Do not charge the battery at a wet a place.
  • Flame, Candle and matchbox should not be used near charged battery. Use hand gloves while handling the charged battery.
  • Electrolyte level should be below the neck
  • Always switch off the charger first before disconnecting the battery from the DG set.
  • Never put tools etc. on the battery.

SUMP CAPACITY (LITRES)

AIR COOLED
Engine Model Rating HA294 HA394 HA494 HA494TC HA694 HA694TC
Lts. 4.5 8 11 11 13.5 13.5


Water Cooled
Engine Model Rating RV22 RV3 RB 3R1040 4R1040/4R1040T 4R1040TA 6R1080T 6R!080TA
Lts. 5.4 7.6 7.6 7.5 9.5 9.5 13.5 13.5
Engine Model Rating SL9088TAI/TA SL1500TA SL8800TA 6K1080TAI/TA 6K12TA 8K15TA 10K18TA 12K22TA
Lts. 21 21 21 39 23 28 35 40
Engine Model Rating DV8 DV10 DV112          
Lts. 41 42 50


CHECK UP BEFORE STARTING THE DG SET

CHECK UP BEFORE STARTING THE DG SET
S. No. Description Status
1 Air cleaner mounting Fitted/Not fitted
2 Air cleaner cleanliness Clean/dirty/replaced (Dry or oil)
3 Air cleaner clamps 7 Hoses Cracked/normal/ not clamped
4 Grade & specs of oil used As per manufactures recommendation
5 Lub oil level & positioning of oil filter OK/Not OK OK/Not
6 Check lub oil safety OK
7 All Nuts & Bolts Proper/Tightened
8 Battery condition Charged/Discharged
9 Battery Terminal/Leans Proper/damaged/ replaced
10 Electrolyte level High/Medium/Low
11 Fuel Filter Proper/to be replaced
12 V Belt for charging alternator Proper/Tightened/not Proper
13 V Belt tension Proper/adjusted
14 Water level in the Radiator OK/filled
15 Check water temp. safety OK/not OK
16 Wiring (Engine/Panel) OK/not OK
17 Check all wires tightening OK/not OK
18 Alternator back cover Fitted/removed
19 Cable termination Canopy Proper/loose/Tightened
20 door alignment Canopy door proper/adjusted/not proper
21 hinge operation OK/not OK/Adjusted

PRE-COMMISSIONING CHECK

Whenever you want to call a Service Engineer for commissioning, kindly ensure that:

  • Installation work has been completed (i.e. exhaust pipe job has been completed with proper supports, if extended beyond the canopy)
  • Fuel pipe line job is completed, if Fuel Tank is outside the canopy.
  • Power cable laying, fitting and connection jobs are completed with proper glanding.
  • If panel is outside canopy, Power Cable Control cable laying, fitting
  • Connection jobs have been completed.
  • Most important - Battery is charged.
  • If the DG set is with AMF Panel, then 230 V AC supply is provided
  • AMF Panel to check its operation and for Battery Charger.
  • Diesel is available in the Diesel Tank.
  • Engine is duly filled with Lube Oil.
  • Load is available.

ROUTINE CHECK POINTS

Check Points:-

  • Check Fuel Level
  • Drain water from fuel Tank (Especially during winter Season.) Check coolant Level.
  • Check Water level in the Radiator
  • Check for any leakage
  • Check for any loose connections
  • Check Battery condition
  • Check Lube oil level and quality (lube oil should not be very thick with visible carbon and metal particles).
  • Sient DG and Genset with Radiator, Should be installed at a place where opening for hot air escape and intake of fresh air is available.

DO'S & DON'T'S

DO'S:-

  • Check Fuel Level
  • Check Lube Oil Level and quality, lube oil should not be very thick with visible carbon and metal particles
  • Check coolant Level.
  • Check for any leakage.
  • Check for any loose connections
  • Check Electrolyte Level in Battery.
  • Check the Battery terminals.
  • Check Fan Belt Tension.
  • Check Battery Charger working.
  • Drain the water from the fuel tank, weekly during winters.
  • Please check all the Nuts, Bolts, Engine/alternator foundation bolts and loose cable connections tightening at the time of commissioning and then monthly.
  • Purchase all spare parts from authorized Kirloskar Service Dealer.
  • Refer Engine Maintenance Manual for routine and daily maintenance check.

DONTS:-

  • If the DG set is with AMF panel please do not touch live wire as mains also flow from AMF panel even if DG SET IS OFF.
  • Do not check coolant level, while DG is running.
  • Do not change any wiring or modify wiring it may attract void of warranty
  • Please do not get the DG set repaired and serviced by any unauthorized person. It may attract void of warranty. It should be done by the manufacturer or Kirloskar authorized Service Dealer.

TROUBLE SHOOTING - ENGINE


Trouble Cause Cause Redress
Engine dose not start No fuel in tank./ Air in fuel system./In sufficient speed
of starter
Fill in fuel, vent fuel system. / Vent fuel system. / Charge batteries.
Engine does not start at
temperatures below 0 C
See above or the ready to start / signal lamp does not light Of above , or change lamp.

Defect of series resistor solenoid / valve, or flame
heater plug / Paraffin precipitation of fuel
Heat up fuel Pipings, change / Filter
Engine starts up but stops after brief time Fuel tank cock closed. /
Dirt in primary fuel cleaner or in fuel filter. / No fuel in tank, no conveyance of
fuel.
Open cock / Clean or change filter cartridge respectively / Fill in fuel , vent fuel system. of fuel. inspect correct operation
pump, replace if necessary, and check safe venting of tank.
No power and misfiring of engine Water or dirt in fuel system. / Interruption of air supply or heavy jamming of air filter. / Air in fuel system / Fuel filter jammed. Clean fuel tank, fill in clean fuel replace filter, and vent fuel system.
/ Inspect, replace if necessary or clean. / Vent fuel system /
Change filter

Starts of fuel supply missed
/ Defect of exhaust brake.
Reset start of fuel supply. / Inspect and repair
Engine emits white or bluish
fumes,
Retorted and start of fuel supply Set correct start of fuel supply

Engine is still cold. / Mis setting of fuel injection system. Permit engine to heat up in operation / Check start of fuel supply inspect injectors.
Engine emits black fumes. Engine is overloaded. Reset fuel injection system / consult workshop.

For More Details Refer PDF


TROUBLE SHOOTING CHART : ALTERNATOR

Fault Cause Rectification
No voltage build - up 1) Insufficient residual voltage.
2) Improper connection
3) Low speed
4) Faulty Winding
5) Rotating rectifier failure
6) Faulty AVR
1) Excite the rotor using a battery.
2) Correct the connection
3) Reset the speed to the nominal.
4) Check the winding resistance and rewind if required.
5) Replace the rotating required.
6) Replace the AVR
Low no-load voltage 1) Low Speed
2) Faulty Rotating rectifier
3) Faulty Winding
1) Reset the speed to the nominal
2) Replace the rotating rectifier.
3) Check the winding resistance and rewind if required.
Low voltage on load 1) Low speed at full load
2) AVR faulty
3) Faulty rotor winding
4) Over load on alternator
1) Set the rated speed of the prime mover.
2) Change AVR
3) Check the rotor winding resistance and if faulty, rewind it.
4) Operate on specified load.
High voltage on load 1) Capacitors on the load side
2) Faulty AVR setting or AVR is faulty
1) Disconnect the PF improvement capacitors
2) Correct the setting/Replace AVR
Too high no-load voltage 1) Excessive speed
2) Correct the setting Replace AVR
1) Adjust the revolving speed Correct the setting
Replace AVR
Fault Cause Rectification
Voltage oscillations 1) Incorrect AVR Setting
2) Thyristor load more that specified limits
3) Insufficient engine flywheel
1) Set the AVR stability pot
2) Reduce the Thyristor load
Unbalance Voltage 1) Unbalance load
2) Loose connections
3) Stator winding faulty
1) Correct the load
2) Tighten the loose connections
3) Check winding resistance
& rewind if required.

For More Details Refer PDF

TROUBLE SHOOTING GUIDE FOR MANUAL PANEL

Engine does not start from the AMF panel in any mode.

  • Check the DC supply control MCBs F10 and F11 for 3 phase Supply. These should be in ON position.
  • Check the battery voltage at terminal 1 and 2 in the AMF Panel. It should be at or above 24V/12V.
  • Check all control wires at control terminals in AMF Panel.
  • Check Battery terminals. They should be properly tightened and should not be corroded.
  • Check LLOP signal at AMF Panel control terminal No. 8, up to 125 KVA It should be properly connected on engine terminal.
  • It there is rattling should that the starter is engaged but it slips or cranks slowly.
  • The battery connection may be loose or corroded. Check and correct te problem.

Check if the battery voltage is at 24V/12V or above. If not get the battery charged before making further attempts as the battery is weak. If the main supply is available, set the battery charger to boost and wait till the battery voltage is as stated above.


The engine cranks but will not fire.

  • Check the fuel supply line.

Engine starts but there is no Voltage from the control Panel

  • Check that the HRC fuses/MCB below the alternator contactor are O. K.
  • Check that the setting at the Alt Voltage Monitor is not too high, set it to 360 V and try.
  • Check the overload Relay if it is tripped and press the reset lever.

The Main supply is restored, but the load does not transfer.

  • Check the control MCBs at F4, F6. It should be in 'ON' position.
  • Check if all three phases (RY, YB and BR) of Mains supply are available. These can be checked through selector switch and voltmeter provided on AMF Panel. All three phases should be available and voltage should be more that the setting of mains voltage monitor or AMF Relay.
  • If required, lower the voltage setting of mains voltage monitor and differential setting or setting in AMF relays. Increase the voltage setting gradually if Mains Voltage is not acceptable on load equipment.

TROUBLE SHOOTING GUIDE FOR AMF PANEL

Engine does not start from the AMF panel in any mode.

  • Check the DC supply control MCBs F10 and F11 for 3 phase Supply. These should be in ON position.
  • Check the battery voltage at terminal 1 and 2 in the AMF Panel. It should be at or above 24V/12V.
  • Check all control wires at control terminals in AMF Panel.
  • Check Battery terminals. They should be properly tightened and should not be corroded.
  • Check LLOP signal at AMF Panel control terminal No. 8, up to 125 KVA It should be properly connected on engine terminal.
  • It there is rattling should that the starter is engaged but it slips or cranks slowly.
  • The battery connection may be loose or corroded. Check and correct te problem.

Check if the battery voltage is at 24V/12V or above. If not get the battery charged before making further attempts as the battery is weak. If the main supply is available, set the battery charger to boost and wait till the battery voltage is as stated above


The engine cranks but will not fire.

  • Check the fuel supply line.

Engine starts but there is no Voltage from the control Panel


  • Check that the HRC fuses/MCB below the alternator contactor are O. K.
  • Check that the setting at the Alt Voltage Monitor is not too high, set it to 360 V and try.
  • Check the overload Relay if it is tripped and press the reset lever.

The Main supply is restored, but the load does not transfer.

  • Check the control MCBs at F4, F6. It should be in 'ON' position.
  • Check if all three phases (RY, YB and BR) of Mains supply are available. These can be checked through selector switch and voltmeter provided on AMF Panel. All three phases should be available and voltage should be more that the setting of mains voltage monitor or AMF Relay.
  • If required, lower the voltage setting of mains voltage monitor and differential setting or setting in AMF relays. Increase the voltage setting gradually if Mains Voltage is not acceptable on load equipment.
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Reach Us
Rajneesh Sharma (Managing Director)
S. C. O. 815, 2nd Floor, Cabin No. 10 N. A. C.
Manimajra, Chandigarh -160101,India



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