FAQs on Gensets : Installation, Sales & Services, Type of fuel used, Genset Devices

All places where electricity is required are suitable applications for using Gensets.

What does a Genset consist of?

A Basic Genset consists of an engine and an alternator coupled to each other and mounted on a common base frame along with batteries, fuel tank, manual control panel and silencer.

Which are the various types of fuels that can be used?

As a general rule, Gensets below 1500kVA can run only on HSD. Special 1500 RPM engines are available for alternate fuels like natural gas and also for dual fuel applications where a combination of diesel and gas can be used.
For heavy fuel application (LDO, furnace oil, LSHS) low RPM engines are available and these and generally of higher ratings, i..e 0.7 MW and above. These Genest installations are much more expensive than 1500 RPM sets. They are installed at locations where continuous power is required.
Bio gas, wood gas, gobar gas, etc., are not directly compatible for use with our engines.

What are the required approvals to run a Genset?

To install and run a Genset, permission is required from the following authorities:

	›	Local Electricity Board - In most States, it is necessary that the Genset capacity should be equal to or less than the sanctioned load for the location at which it is being installed.
	›	Electrical Inspectorate - This approval is required as it confirms that the installation, cabling, earthing, etc., have been carried out as per the Central Electricity Rules applicable to all electrical applications in India.
	›	Central Pollution Control Board - For obtaining this approval, the exhaust gases of the Genset have to be discharged at a particular height above the building housing the Genset, so that the exhaust does not cause pollution.

Which are the various types of panels available?

A standard Genset is usually supplied with a manual control panel. In this case, the engine is started from it own control panel and after the rated speed and voltage have been attained the switch in the manual panel is put on to connect the Genset to the load.

For special applications various other panels can be made to order and some of these are as follows:

	›	AMF application : In these panels, the mains/ Electricity Board supply is monitored and in case of failure the Genset will start automatically and the load will be transferred to the Genset. When the Mains supply is restored, the load will be transferred back and the Genest will be shut down after a short cooling down period. AMF panels can be relay operated or PLC operated and options of auto start, auto changeover, no break change over etc. are also available.
	›	Synchronising panels : In some cases it may be necessary to run two or more Gensets in synchronism with each other. This may be required due to various reasons like high start-up loads, major variations in load during peak / non-peak hours, limitation in capacity of gensets etc. For these kind of applications, synchronising panels can be provided. These can be simple or very sophisticated viz. fully automatic depending on customer needs.

Where are Acoustic Enclosures required?

Due to the increasing emphasis on pollution of various kinds affecting citizens it has become mandatory in most major cities for all new genset installations to be provided with some kind of noise reducing systems. This can be either achieved by providing acoustic treatment to the walls of the DG room or by installation of an Acoustic Enclosure over the Genset. Both options are available and the feasibility at each location has to be checked and the best option selected.

Who does the installation and what are the prerequisites?

Installation of Gensets can be carried out by end user / his contractor or by Powerica Limited. Necessary guidelines and drawings for the installation of various auxiliaries and accessories will be provided by us. Commissioning of the Genset after installation has to be carried out by Powerica engineers, to ensure that the installation meets the necessary engineering standards.

Who takes care of after sales service?

Powerica Limited has 18 offices where service engineers are available to attend to any problems that you may face with your genset. M/s.Cummins India Limited also has a network of 110 dealers and offices all over India and these offices will provide after sales service for both engine and alternators installed in their areas.

What is the applicable guarantee for the genset?

The engine and alternator are guaranteed for 24 months from the date of despatch from our Works. The other components; i.e. battery, control panel are warranteed for 12 months from date of despatch.

What spares should be stocked?

Since there is a large network of dealers and offices all over India, necessary routine maintenance spares do not need to be stocked by the end user, these are readily available. Failure of any major equipment will require the engine/alternator to be either repaired at site by qualified engineer /technicians or will have to be shifted to the closest authorised workshop. Even in this case no spares need to be stocked by the end user. Minor items like indicating lamps, fuses, top-up oil, grease, etc. are generally available with the maintenance team at factories or can be procured from the closest hardware store.

What is the general maintenance schedule?

All filters, fuel, lub oil, bypass, etc. along with lub oil have to be changed after every 300 hours of operation or six months, whichever is earlier. Besides this, the general daily, weekly, and monthly checks are to be carried out as per the attached sheet.

What are the guidelines for understanding the specific rating of the DG Sets?

Stanby Power Rating:

Applicable for supplying emergency power for the duration of the utility power outage. No overload capacity is available for this rating. Under no condition is an engine allowed to operate in parallel with the public utility at the Stanby Power Rating.

This rating should be applied where reliable utility power is available. A Standby rated engine should be sized for a maximum of an 80% average load factor and 200 hours of operation per year. This includes less than 25 hours per year at the Standby Power Rating. Standby Ratings should never be applied except in true emergency power outage. Negotiated power outages contracted with a utility company are not considered an emergency.

Prime Power Rating:

Applicable for supplying electric power in lieu of commercially purchased power. Prime Power Applications must be in the form of one of the following two categories :

Unlimited Time Running Prime Power:

	›	Prime power is available for an unlimited number of hours per year in a variable load application.
	›	Variable load should not exceed a 70% average of the Prime Power rating during any operation period of 250 hours.
	›	The total operating time at 100% Prime Power shall not exceed 500 hours per year.
	›	A 10% overload capability is available for a period of 1 hour within a 12 hour period of operation.
	›	Total operating time at the 10% overload power shall not exceed 25 hours per year.

Limited Time Running Prime Power:

	›	Limited time Prime Power is available for a limited number of hours in a non-variable load application. It is intended for use in situation where power outages are contracted, such as utility power curtailment.
	›	Engines may be operated in parallel to the public utility up to 750 hours per year at power levels never to exceed the Prime Power Rating.
	›	The customer should be aware, however, that the life of any engine will be reduced by this constant high load operation. Any operation exceeding 750 hours per year at the Limited time Prime Power rating should use the Continuous Power Rating.

Continuous Power Rating:

Applicable for supplying utility power at a constant 100% load for an unlimited number of hours per year. No overload capability is available for this rating.