SELECTION OF D.G.

SETS

INTRODUCTION
Diesel Generating sets are used extensively in our department as standby source of
power. Thus selection of the same depends upon different types of load and their nature,
site conditions, capacity requirement of the engine and the alternator keeping
departmental instructions in our mind. About the nature of different types of load we
have already seen. Here, we shall study about the interpretation and application of
various standards (B.I.S/B.S./I.S.O.) in selecting our E.A. sets.

METHODOLOGY :
Declaration of power, efficiency, fuel consumption and lubricating oil consumption has
been laid down under I.S: 10000 (part iv) 1980. This deals with non-turbo charged
engines. B.S. 5514 : part 1: 1982 deals comprehensively the diesel engines under our
use. It may not be out of place to mention that both these standards are in conformity to
I.S.O. 3046 (all the relevant parts).

In this context it is remarked that B.S. 5514 supersedes B.S. 649 and I.S. 10000, I.S.
10001 and I.S. 10002 supersedes I.S. 1600, I.S. 1601 and I.S. 1602 respectively ; and
so, older standards are required to be withdrawn

Requirement for turbo-charged engines are dealt under I.S. 13018.

Requirement for an alternator is dealt under I.S. 4722.

In this section we shall deal with various terminologies of the standards and their
applications for interpreting I.S. 10000/B.S. 5514.

So far as this part is concerned we shall follow B.S. 5514 (since it covers both turbo-
charged and non-turbocharged engines) because I.S. 10000 part-iv gets covered under
this in sec. A’ and I.S. 13018 in Sec. B.

SECTION A :

DISCUSSION ON DECLARATION OF POWER :

A formula is evolved here to calculate the brake power under the conditions being
considered to that of the reference conditions. The following standard reference
conditions shall be used :

Total barometric pressure :

pr = 100 KPa
Air temperature :
Tr = 300 K (270 C)
Relative humidity :
φr = 60%
R. Sharma (BSNL Electrical Zone Patna) 2

Charge air coolant temperature :

Tcr = 300 K (270 C)
(If other reference conditions are chosen, these shall be stated).

POWER ADJUSTMENT FACTOR ‘D’ :

It is the ratio of power output under the ambient site conditions to the power output
under standard reference conditions.

ADJUSTMENT OF NET BRAKE POWER FOR AMBIENT CONDITIONS :

When it is essential to operate the engine under conditions different from the standard
reference conditions the net brake power output shall be adjusted as per the following
formulae :

Px = α Pr .......................... (I)
where,
α = K - 0.7 (1-K) (1/ηm-1) .................... (ii)

− aφ
m
 p p   Tr 
n
 Tcr 
q

K = 
x sx 
x
    .......................... (iii)

 p − aφ p   Tx   Tcx 
r r sr 

where the symbols have their meaning as explained below :

α = power adjustment factor

pr = Standard reference total barometric pressure
φr = Standard reference relative humidity
psr = Saturation vapor pressure under standard reference conditions.
px = Total barometric pressure conditions being considered
psx = Saturation vapour pressure under the conditions being considered.
φx = Relative humidity condition being considered
Tr = Standard reference absolute air temperature.
Tx = Absolute air temperature being considered.
Tcr = Standard reference absolute charge air coolant temperature
Tcx = Absolute charge air coolant temperature at charge air cooler inlet being
considered.
K = Ratio of indicated power
ηm = Mechanical efficiency
Pr = The brake power under reference condition
Px = The brake power under the conditions being considered
m, n, q = Various constants
a = a constant [either 1 (when power limited by air excess) or 0].

It may be noted that putting q = 0 gives the same equation (3) of I.S. 10000 (part iv) -
1980; and so we can follow the B.S. 5514.
R. Sharma (BSNL Electrical Zone Patna) 3

φxpsx = Water vapour pressure (depending upon air temperature and relative
humidity)

 p − aφ p 
 x x sx  = The dry air pressure ratio.

 p − aφ p 
r r sr 

In the case of turbo charged engines in which the limits of turbocharger speed and
turbocharger turbine inlet temperature have not been reached at the declared power
under standard reference conditions, the manufacturer may declare substitute reference
conditions to or from which power adjustment is to be made.

The following formulae will then be used

m
 p   Tra 
n
 Tcr 
q

K =  x 
    .......................... (iv)
 p   Tx   Tcx 
 ra 

p = p π r
...................................... (v)
ra
π r
max
where,

px = total barometric pressure conditions being considered.

pra = Substitute reference total barometric pressure.
πr = Boost pressure ratio at declared power under reference conditions to be
tested by the manufacturer.
πmax = Maximum available boost pressure ratio to be stated by the
manufacturer.
Tra = Substitute reference absolute air temperature to be stated by the
manufacturer
Tx = Absolute air temperature being considered.
Tcr = Standard reference absolute charge air coolant temperature
Tcx = Absolute charge air coolant temperature at charge air cooler inlet being
considered.
m,n,q = Constants.

Till new there is no difference. But I.S. rating of the engine has been classified as two
types - I.S. rating A (with overload) and I.S. rating B (without over load). But BS covers
only with overload. In any case our departmental requirement is for I.S. rating A.
R. Sharma (BSNL Electrical Zone Patna) 4

To find out the value of different constants the following table may be followed :

Engine type Condition Factor Exponents

a m n q
Compression Non- Power limited 1 1 0.75 0
ignition oil turbocharged by air excess
engine and duel Power limited 0 1 1 0
fuel engines by thermal
reasons
Turbocharge Low and 0 0.7 2 0
d without medium
charge air speed four-
cooling stroke
engines.
Turbocharge 0 0.7 1.2 1
d with charge
air cooling.
Spark ignition Non turbo 1 0.85 0.55 0
engines using charged
gaseous fuel Turbocharge Low and 0 0.57 0.55 1.75
d with charge medium
air cooling speed 4
stroke
engines
Spane ignition Naturally 1 1 0.5 0
engines using aspirated
liquid fuel

STEPS TO BE FOLLOWED FOR CALCULATION :

Step 1 : Obtain site conditions i.e. px., tx, & φx.

Guidelines for site conditions :

(a) Site barometric pressure (highest and lowest readings available : In absence of
these data take altitude above mean sea level.

(b) The monthly mean minimum and maximum air temperatures during the hottest
and the coldest months of the year.

(c) The highest and lowest ambient air temperatures around the engine.

(d) The R.H. (or alternatively the water vapour pressure or the wet and dry bulb
(temperature) ruling at the maximum temperature conditions.

(e) The maximum and minimum temperatures of the cooling water available (for
water cooled engine).

Step 2 : Note down the standard reference conditions.

R. Sharma (BSNL Electrical Zone Patna) 5

Step 3 : Obtain mech. efficiency ηm of the engine (assume 0.80, if not given).

Step 4 : Note the Engine type and from the previous table obtain the value of a, m, n and q.

Step 5 : Obtain the value of φxpsx at given tx and φx (use Annexure F).

Step 6 : Obtain the value of dry air pressure ratio at given px and φxpsx (use Annexure E).
n
 
Step 7 : Obtain the value of  Tcr  using Annexure D.
 Tcx 
q
 
Step 8 : Obtain the value of  Tcr  using Annexure D.
 Tcx 

Step 9 : Obtain the value of K from the values obtain above.

Step 10 : For given values of K & ηm obtain value of α and β using Annexure B & C
respectively.

Step 11 : Obtain px = αpr

& bx = βbr
where b is the specific fuel consumption
k
β = , called fuel consumption adjustment factor.
α

Exercise 1 : A non-turbocharged engine with its power limited by air excess has an ISO
standard power of 500 KW with a mechanical efficiency of 0.5%, and an I.S.O
Specific fuel consumption of 220g/KWh.

What is the expected continuous net brake power, and fuel consumption at a site
with a total barometric pressure of 650 mm Hg, air temperature 450 C and
relative humidity 80% ?
(750 mm Hg = 100 KPa)

Answer : Here px = 650 mm Hg

tx = 450C ∴ Tx = 318 K
φx = 0.8

Standard reference conditions are

pr = 750 mm Hg
Tr = 300 K,
Also ηm = 0.95

here a = 1, m = 1, n = 0.75 and q = 0

R. Sharma (BSNL Electrical Zone Patna) 6

From Annexure F at tx = 450 C & φx = 0.8 we get (by interpolation)

φxpsx = 58 mm Hg.

From Annexure E, at px = 650 mm Hg. φxpsx = 58 mm Hg,

 p − aφ p 
We get  x x sx 
= 0.807
 p − aφ p 
 r r sr 

From Annexure D at T r
=
300
=0.943 and n = 0.75
T x
318
n
 
We have  Tr  = 0.957
 Tx 

∴ K = 0.807 x 0.957 0.772 (formula 3)

From Annexure C, at K = 0.772 and ηm=0.85 we get β = 1.038

From Annexure B at K = 0.772 and ηm = 0.85 we get α 0.744.

∴ Site continuous new brake power = 500 x 0.744 = 372 KW

Site specific fuel consumption = 220 x 1.038 = 228.4 g/KWh

Exercise 2 : A turbocharger and charge cooled medium speed four stroke engine has a
declared power of 1000 KW at standard reference conditions with a mechanical
efficiency of 90%, the chosen reference charge air coolant temperature being
300K ;and the boost pressure ratio 2.0.

The manufacturer declares that the limits of temperature and turbocharger speed
have not been reached under standard reference condition and gives a substitute
reference temperature of 313K and a maximum available boost pressure ratio of
2.36.

What power will be available at an altitude of 4000 m with an ambient

temperature of 323K and a charge air coolant temperature of 310K ?
(750 mm Hg = 100 KPa)

Answer : From the table we get a = 0, m = 0.7, n = 1.2 and q = 1.0.

Also pr = 750 mm Hg ; πr = 2.0 & πmax = 2.36

750 x 2.0
∴ pra = = 636 mm Hg. [Formula V]
2.36

From Annexure E, at 4000 m altitude, p = 4.62 mm Hg.

∴ pra = 636 mm Hg
Tra = 313 K
R. Sharma (BSNL Electrical Zone Patna) 7

Tcr = 300 K
px = 462 mm Hg
Tx = 323 K
Tcx = 310 K
ηm = 0.90

p x 462
Hence = = 0.726
p ra
636

T ra
=
313
= 0.969 & T cr
=
300
= 0.968
T x
323 T cx
310

From Annexure D,

(0.726)0.7 = 0.800, (0.969)1.2 = 0.963

0. 7
 p   Tra 
1. 2
 Tcr 
1. 0

∴K=  
x
   
 p   Tx   Tcx 
 ra 

= 0.800 x 0.963 x 0.968

= 0.746

∴ From Annexure 8 at K = 0.746 & ηm = 0.90 ;

α = 0.726

Hence Site power = 0.726 x 1000 = 726 KW at 236 boost pressure ratio.

Also from Annexure C at K = 0.746 & ηm = 0.90

β = 1.030

SECTION B :

This section deals with turbocharged engines as dealt under I.S. 13018 : 1990. Most of
the definition discussed above remains the same. However, the reference conditions in
this standard are as follows :

pr = Total barometric pressure = 100 kPa

Tr = Air intake temperature = 298 K (250C)
Tcr = Charged air coolant temp. = 298 K (250C)
φr = Relative humidity = 30%
R. Sharma (BSNL Electrical Zone Patna) 8

POWER ADJUSTMENT, SPECIFIC FUEL CONSUMPTION ADJUSTMENT

AND POWER CORRECTION :

The adjustment procedures are carried out when required to determine :

(a) Whether the values of power and fuel consumption attained under engine test
ambient conditions correspond to the declared results.

(b) The permissible maximum power under test ambient conditions to prevent the
engine overloading which excess air allows.

Here the possible cases could be as under :

(i) Adjusted engines, where the power is adjusted to control limiting performance
parameters when the ambient conditions differ from the standard reference
conditions (for example, to maintain for an approximately constant thermal
and/or mechanical load on critical engine components.

(ii) Non-adjusted engines where the fuel settings are pre-set so that power and
performance parameters may vary as a function of ambient condition.

In general, the power and specific fuel consumption shall be adjusted or

corrected if any of the ambient conditions under which the engine operated
during test or on site differ from the standard reference conditions. The
manufacturer shall specify which method (power adjustment or power
correction) is applicable to his engine.

Power adjustment is the calculation procedure by which power at the set of

ambient conditions is modified to represent the power expected under another
set of ambient conditions. Power adjustment may result in engine adjustment, a
procedure of modifying an engine to adopt to a different set of ambient
conditions. This may be by moving the limiting fuel stop, rematching the turbo-
charger, changing the fuel injection timing or other mechanical charger.
However, the calculation procedure by which power determined under engine
test conditions is modified so that it represents the power expected under other
operational or reference conditions without any engine adjustment is called
power correction.

THUS WE FIND THAT THERE ARE SOME DIFFERENCES IN TREATING

THE ENGINES AS PER THEIR CLASS :

(i) Engines with pre-set fuel settings and as such we have to calculate power
correction factor (Non-adjusted engines).

(ii) Adjusted engines with adjusted fuel settings for which we have to calculate the
power adjustment factor etc.
R. Sharma (BSNL Electrical Zone Patna) 9

For the latter case, i.e. case (ii) the method and formula to be followed is exactly
as discussed in section ‘A’ and so needs no discussion. We shall discuss only
case (i) and its methodology.

POWER CORRECTION FOR NON-ADJUSTED ENGINES :

Step 1 : Calculate the corrected fuel delivery per cycle (mg/litre) using the
formula

qc = q/π
where qc = corrected fueled delivery per cycle (mg/litre)
q = fuel delivery per cycle in mg per litre of total
swept volume ; mg/litre
π = Absolute pressure of compressor outlet to that of
compressor inlet.

Step 2 : Calculate the Engine factor fm by the formula

fm = 0.036 qc - 114.
(This formula shall be used only if 40 ≤ qc ≤ 65.

If qc < 40 take fm = 0.3 and for qc > 65, fm = 1.2).

Step 3 : Determine the type of the engine i.e. whether it is mechanically pressure
charged or turbocharged with or without charge air cooling and in each
case calculate the atmospheric factor fa.

For mechanically pressure charged engine

 p −φ p   Ty 
0. 7

f a =  p r − φ r psx   
 Tr 
 y y sy 

and for turbocharged engines

0. 7
 p −φ p   Ty 
1.5
 sx 
f a =  p − φ p   
r r

 y y sy  Tr
where the suffix y denotes the test condition.

Step 4 : The power correction factor αd can be given by

αd = (fa)fm

Step 5 : Use the equation

Px = αd x Py

to get power at site ambient condition (Px) from that of the power at test
condition (Px).
R. Sharma (BSNL Electrical Zone Patna) 10

Example 1 : A four stroke turbocharged compression ignition engine with charge air
cooling will develop 896 kW at test ambient conditions. What is the
corrected power expected at the listed site ambient conditions. The engine
speed is 1500 r.p.m, total swept volume is 51.8 litre and fuel delivery is
45.42 gm/sec. The turbocharger pressure ratio of compressor outlet to
compressor inlet is 2.6.

Test ambient conditions : Site ambient conditions : ,

py = 96 Kpa px = 98kpa
Ty = 302 K Tx = 315 K
φy = 0.2 φx = 0.4.

Answer : ∴ q =
(1000 x 60 x 2) x 5.42 = 80 x
45.42
= 70.15 mg / litre
51.9 x 1500 51.9

70.15
∴ q
2. c
≅ 27.
=

New fm = 0.3 ( q < 40)

c

Since it is turbocharged engine,

0.7
 p −φ p   Ty 
1.5

f =  r r sx 
 
a 
 p −φ p
y y

sy 
 Tr 

0.7
 p −φ p   Ty 
1.5
 sx 
∴ f a =  p − φ p   
r r

 y y sy  Tr
[Note we can take site conditions in place of reference condition for cases
where 80 < px < 110 KPa, 0.9 < αd < 1.1 and the ambient temperature of
the air inlet of the engine is T+150 C. If these limits are exceeded then we
have to first correct from test conditions to standard reference conditions
and then from standard reference conditions to the site condition. In fact,
this is the correct approach in general. To correct the engine power
directly from test condition to site condition introduces bearable
inaccuracy in the calculation provided the limit are observed.]

0. 7 1.5
 98 - 3.3   303
∴ fa =     (use Annexure F)
 96 - 0.93  315
= 0.997 x 0.939 = 0.934
Now αd = (0.934)0.3 ≅ 0.98.

∴ Power in KW = 0.98 x 896 = 878 KW (Site power)

R. Sharma (BSNL Electrical Zone Patna) 11

Exercise 2 : A four stroke trubocharged compression-ignition engine without charge

air cooling with a mechanical efficiency of 0.85 will develop 700 KW at
test ambient conditions. What is the corrected power expected at the
listed site ambient condition ? The engine speed is 1500 per min. total
swept volume is 45 litres and fuel delivery is 64.1 gm/sec. The
turbocharger pressure ratio of compressor outlet to compressor inlet is
2.0.

Test ambient conditions : Site ambient conditions :

py = 96 Kpa px = 69 Kpa
Ty = 302 K Tx = 283 K
φy = 0.2 φx = 0.4

Standard ref. conditions :

pr = 100 Kpa
Tr = 298 K
φr = 0.3

Answer : q =
(64.1 x 1000) = 80 x
64.1
≅ 114 mg / litre
 1500  45
45 x  
 2 x 60 

114
Hence qc = = 57
2

∴ fm = (0.036 x 57) - 1.14 = 0.912

Since px < 80 KPa therefore power correction cannot be applied directly

from test condition to site condition.

∴ Expected power shall be calculated at reference standard condition and

then from that we shall calculate power developed at site condition.

0. 7 1.5
 100 - 0.95  302 
Now f a
=  
 96 − 0.83 
 
 298 

= 1.028 x 1.020 ≅ 1.049 ≅ 1.05.

∴ αd = (1.05)0.912 = 1.044

⇒ Pr = αd Py = 1.044 x 700 = 731 KW

Now Px = αdPr

where α = K - 0.7(1-K) (1/ηm -1)

R. Sharma (BSNL Electrical Zone Patna) 12

m
 p  n
 Tr   Tcx 
q

and K =  x
   
 p   Tx   Tcr 
 r

where m = 0.7, n = 2 and q = 0

0 .7 2
 69   298 
∴K=     = 0.7712 x 1.1088 ≅ 0.855
 100   283 

∴ α = 0.855 - 0.7 (0.145 x 0.18) = 0.837

∴ Px = 0.837 x 737 = 611.84 ≅ 612 KW

RATING AND SPECIFIC FUEL CONSUMPTION :

A problem is faced while mentioning the engine capacity in our

specification I.S. 10001 & 10002 deals with it. The power of the engine is
to be rated in KW and the recommended preferred ratings are as follows :

0.8 2.5 7.1 12.5 35.5 100 280

1.0 2.8 5.0 14.0 40.0 112 315
1.12 3.15 5.6 16.0 45.0 125 355
1.25 3.55 6.3 18.0 50.0 140 400
1.4 4.0 7.1 20.0 56.0 160 450
1.6 4.5 8.0 22.4 63.0 180 500
1.8 5.0 9.0 25.0 71.0 200 etc.
2.0 5.6 10.0 28.0 80.0 224
2.24 6.3 11.2 31.5 90.0 250

The specific fuel consumption of the Engine varies with the speed of the
Engine and shall have the following value as maximum

--------------------------------------------------------------------
Rated Engine Speed SFC, Max
(rev/min.) (g/kWh)
--------------------------------------------------------------------
Up to 500 332.5
Above 500 u to 100 275.5
Above 1000 up to 2000 241.75
Above 2000 308.75
--------------------------------------------------------------------