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DIESEL POWER PLANT OPERATIONS LEARNING OBJECTIVES

TABLE OF CONTENT

4601: Diesel Engines for Power Generation

4602: Diesel Engine Support System

4603: Power Generation

4604: Diesel Plant Operation

4605: Diesel Plant Maintenance

4601: Diesel Engines for Power Generation

The objective of this videotape is to look at the applications for diesel driven generators and to examine the basic constructional features of the diesel engine itself. This includes a review of compression-ignition operating fundamentals, and a look at all of the major components of the diesel engine. Upon completion of this videotape and associated workbook, the participant should be familiar with:

  • The main applications for diesel power generators emergency stand-by generators, power supply to remote areas.
  • The typical multi-unit diesel generating station.
  • Diesel engine efficiency and sources of power loss.
  • The basic four-stroke cycle.
  • Compression ignition instead of spark ignition.
  • The need for precise timing of valves and fuel injection.
  • The two-stroke cycle.
  • Exhaust gas scavenging.
  • Diesel engine compression ratio compared with automobile engine.
  • Classification of diesel engines by cylinder arrangement, number of cylinders, speed, and fuel type.
  • The major blocks or housings of the diesel engine.
  • The major internal components.
  • Features of piston liners, and pistons.
  • Connecting rod and crankshaft bearings.
  • Features of the crankshaft, crank angle or "throw".
  • Calculation of firing angle. Significance of firing sequence.
  • Camshaft, camshaft drives and timing gears.
  • Features and adjustment of valve gear.
  • The major constituents of diesel fuels.
  • Combustion principles.
  • Undesirable constituents of fuels and their effects.
  • Types of combustion chamber and pre-combustion chambers.
  • Staged combustion. The effect on NOx emissions.
  • Gas burning diesels.
  • Multi-fuel engines.

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4602: Diesel Engine Support Systems

The objective of this videotape is to present and discuss typical examples of the various support systems which are needed for the diesel engine to function. Upon completion of this videotape and associated workbook, the participant should understand and be able to apply the following concepts:

  • Diesel engine support systems include:
      1.fuel handling and storage,
      2.fuel injection systems,
      3.air inlet and exhaust systems,
      4.lubrication systems,
      5.engine cooling systems.
  • Requirements for storage and pumping of distillate oil.
  • Requirements for storage and pumping of residual oil.
  • The effect of temperature on oil volume and density.
  • The need for removing foreign materials and water from fuel oil.
  • Fuel heating requirements.
  • The function of the fuel injection system; different types.
  • The importance of precise timing of injection.
  • Fuel atomisation.
  • Control of fuel quantity injected (to control engine output).
  • Pilot oil injection to provide ignition on gas burning engines.
  • The need for filtration of incoming air.
  • The effect of supercharging incoming air, i.e. effective scavenging and increase in engine output and efficiency.
  • Blowers and turbo-chargers.
  • Air temperature control, after coolers.
  • ypical exhaust systems.
  • Removal of moisture from air inlet and exhaust gas systems.
  • Exhaust gas temperature, heat lost in exhaust, heat recovery.
  • The effect of sulphur gases in the exhaust.
  • The function of the lube oil system.
  • Lubricating points on the engine.
  • Lube oil pressure and temperature control.
  • The need for continuous filtration of lube oil.
  • Engine cooling systems.
  • eat exchangers.
  • Air-cooling; radiators.
  • Control of coolant temperature.
  • The function of the coolant head tank

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4603: Power Generation

The objective of this videotape is to present and discuss power generators and how they function. Design and constructional features are demonstrated for typical power generations as used in diesel sets. The fundamentals of AC generation are also reviewed preparing the ground for a study in synchronous operations; that is load sharing of generators in parallel. Upon completion of this module and associated workbook, the participant should be able to understand and apply the following concepts:

  • The main construction features of power generators as used in conjunction with diesel engines.
  • The function of the stator, rotor, and excitation system.
  • Various types of excitation system.
  • Generator terminal arrangements, connection of neutral point, outgoing leads, PT's, and CTs.
  • Sources of heat and temperature rise in a generator; copper loss, iron loss, and windage loss.
  • Generator cooling systems.
  • The principles of AC power generation.
  • The relationship between frequency, machine speed, and the number of magnetic poles.
  • Three phase power generation, 3 phase connections, and three-phase system.
  • Generator switchgear.
  • Synchronizing and loading the generator.
  • The operation of generators in parallel; balancing power output to equal demand.
  • The function of the diesel generator governor and its controls: governor set-point, load limit, percentage speed droop.
  • Load sharing between generators in parallel, load angle (power angle).
  • The definition of active power (megawatts) and reactive power (megavars).
  • Generator voltage control and production of megavars. Power factor.
  • The generator capability curve.

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4604: Diesel Plant Operation

The objective of this videotape is to look at various aspects of diesel power plant operation, including monitoring, control, and protection systems. Upon completion of this module and accompanying workbook, the participant should understand and be able to apply the following concepts:

  • Preparing the unit for start-up.
  • Cancellation of "Permits to work" and clearances.
  • Energizing the station service supply AC and DC.
  • Typical start-up procedure including auxiliary equipment.
  • Methods of cranking the engine.
  • The need for crankcase breathers.
  • Typical shutdown procedure.
  • Monitoring on-load operations.
  • The significance of operating parameters such as exhaust temperature, lube oil pressure and temperature, coolant temperature, bearing metal temperature, boost air pressure and temperature, filter differential pressure, lube oil level, coolant level and machine vibration.
  • The operator contribution to assessing machine condition and deterioration and identifying impending problems.
  • Types of control systems.
  • The traditional mechanical and electrical panel layout.
  • The location of controls on the machine and on the panel.
  • Typical annunciator arrangements and alarm points.
  • Summation meters, i.e. KWH, KVARH, fuel consumption and total running hours.
  • Digital control systems, processing units and remote SCADA application.
  • The difference between analog and digital signals.
  • Operation of the lockout relay and subsequent action to shutdown the machine.
  • Function of protection devices including over speed, low bearing oil pressure, high coolant temperature, high bearing metal temperature, excessive vibration, generator electrical protection.
  • Electrical protection relays for generators, distribution feeders, station service supply, transformers and the bus.

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4605: Diesel Plant Maintenance

The objective of this videotape is to present the different types of maintenance, (running, predictive and planned), and to look at the tasks involved in performance. A typical maintenance schedule is demonstrated in detail and the subject of maintenance control is discussed including examples of documentation. Upon completion of this videotape and associated workbook, the participant should be familiar with and be able to apply the following concepts:

  • The need for different types of maintenance:
      1.running maintenance,
      2.predictive maintenance,
      3.planned maintenance,
      4.breakdown maintenance.
  • The role of operator and maintenance technician.
  • Isolation, clearance procedures and "Permit to Work".
  • Running maintenance activities.
  • Predictive maintenance activities, trending pressures and temperatures, unit performance, vibration, lube oil analysis.
  • Interpretation of trend curves.
  • The objective of planned maintenance, also called "preventive maintenance".
  • Typical activities performed during P.M. (planned maintenance) periods.
  • Conciliation of calendar dates with maintenance running hour periods, depending upon unit operating regime.
  • Master schedule for all planned maintenance activities on all items of plant.
  • Need for documentation to control and record all maintenance activities including individual equipment history.
  • Typical maintenance control documentation.
  • Computerized maintenance control documentation.
  • Trouble-shooting typical diesel generator problems.