Power Generator Operation & Maintenance

ICTD International Centre for Training and Development

How long?

  • 5 days
  • in person

What are the topics?

ICTD International Centre for Training and Development


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Who should attend

This course is designed for mechanical engineers, instrumentation and control engineers, electrical engineers, project engineers, maintenance engineers, power system protection and control engineers, building service designers, systems planners and managers, electrical and instrumentation technicians

About the course

The Power Plant Operations training series addresses the need of the power plant worker to understand basic and advanced principles of power generation and the safe, efficient operation and maintenance of the power plant itself. It also provides a foundation for learning more of the technical aspects of power plant operations and maintenance.

This course also introduces waste-to-energy energy conversion, including fuel, furnace design, and plant operations.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

  • Carryout maintenance and troubleshooting techniques on power plant performance and generators
  • Understand the principle, process and operations of combustion
  • Enumerate the requirements of fuel and lube oil
  • Identify the components and functions of engine
  • Discuss the principles of generators including generator auxiliary systems, generator construction and generator mechanical maintenance
  • Determine excitation systems, voltage and frequency control
  • Apply stator visual inspection and rotor visual inspection
  • Distinguish abnormal operations and apply protective actions and recommendations for generator faults
  • Perform testing and monitoring on pre-commissioning

Course Outline

Day 1

  • Introduction
  • Major components
  • Field Coils, commutator, DC output, Power Generation methods regulator, armature, rotating diodes
  • Diesel Technology and Classifications
  • Basic engine processes
  • Reciprocating engines
  • Spark ignition engines
  • Diesel engines
  • Dual fuel engines
  • Speed classifications
  • Service classifications
  • Basic Engine Design and Ratings
  • Design characteristics and formulas
  • Turbo charger
  • Ambient conditions
  • ISO ratings
  • Performance and efficiency
  • Efficiency enhancements
  • Engine speed
  • Fuel combustion methods
  • Fuel Oil Systems and Layouts
  • Crude oil
  • HSD, LDO and heavy fuels
  • Economics of fuel selection
  • Pressure and temperature characteristics
  • Viscosity
  • Specific heat and temperature
  • Specific fuel consumption
  • Fuel filters and heaters
  • Fuel nozzles and igniters
  • Emission control
  • Storage requirements
  • Typical fuel system layouts and components
  • Lube Oil Systems
  • Lube oil specification
  • Lube oil consumption in diesel engines
  • Typical lube oil system layouts
  • Viscosity and temperature
  • Lube oil filters and heaters

Day 2

  • Generator Theory/Generator Lite
  • Armature Reaction
  • Resistive Loads
  • Inductive Loads
  • Capacitive Loads
  • Power Transfer and Load Angle
  • Reactive Power
  • Net Air Gap
  • Developed Torque
  • Watt and VAR Control
  • Generator Capability
  • Stator Winding Heating
  • Field Heating
  • Core End Iron Heating
  • Power System
  • Power Transfer Between Generator Rotor and Stator
  • Short Circuit Ratio, etc.
  • System Operations
  • Structure of the Power System
  • Interconnections
  • Power Balance
  • Operation of the System
  • State of the Power System
  • Diesel Generating Sets
  • Coupling requirements
  • Skid mounting
  • Layout requirements
  • Paralleling of multiple DG sets
  • Standard control panels
  • Interconnections
  • Generator Construction
  • Stator Frame
  • Core, Windings
  • End Shield
  • Rotor Body
  • Field Windings
  • Retaining Rings
  • Collector Rings
  • Hydroelectric Differences

Day 3

  • Excitation Systems, Voltage & Frequency Control
  • Speed Governor Response to Frequency Deviations
  • Automatic Voltage Regulator Response to Voltage Deviations
  • Manual Regulator
  • URAL
  • Impedance Compensator
  • Volts/Hertz
  • Maximum Excitation Limit
  • Transfer & Tracking
  • PSS
  • De-Excitation, etc.
  • Generator Auxiliary Systems
  • Purpose and Operations of the Generator Hydrogen Control System
  • Generator Seal Oil System
  • Stator Liquid Cooling System (as required)
  • Abnormal Operations
  • Relationships Between Operations, Protection and Alarms; Alarms, Protection when Off-Line, Tripping Methods, Protective Actions for Generator Faults and Abnormal Operations & Protection Recommendations (System Steady and Dynamic Conditions, etc.)
  • Outage Planning & Scheduling
  • Why Maintenance
  • Preparation
  • Tooling
  • Documentation
  • Pre-Shutdown Maintenance
  • Decision Making

Day 4

  • Generator Mechanical Maintenance Activities
  • Why Generators Fail
  • Special Tools
  • Spare Parts
  • Safety Precautions
  • Disassembly/Reassembly Procedure
  • Cleaning and Checklists
  • Stator Visual Inspection
  • Loose Slot Wedges
  • Discoloration
  • Loose Punching
  • Bar Vibration
  • Girth Cracks
  • Corona, etc.
  • Rotor Visual Inspection
  • Collector Rings
  • Rotor Journal Surface
  • Terminal Studs
  • Hydrogen Seal Areas
  • Axial Flow Fans
  • End Turns
  • Field Slot Wedges
  • Retaining Rings
  • Purpose of Generator Electrical Tests
  • Safety Considerations

Day 5

  • Other Components
  • Starting methods
  • Starting characteristics
  • Battery sizing
  • Step load requirements
  • Standby requirements
  • Auto start and auto transfer schemes
  • Auto transfer switches
  • DG Plant Layouts
  • Industrial applications
  • Power generation plant applications
  • Single and multiple sets
  • Fuel storage requirements
  • Air intake system
  • Exhaust system
  • Auxiliary power requirements
  • Typical power schemes
  • Testing and Commissioning
  • Factory tests
  • Pre-commissioning checks and tests
  • Performance monitoring
  • Fuel and lube oil consumption checks
  • Operation and Maintenance
  • Safety requirements
  • Operation monitoring based on applications
  • Maintenance techniques
  • Spares and inventory management
  • Inspection
  • Engine overhaul and repair
  • Troubleshooting

Course Methodology

A variety of methodologies will be used during the course that includes:

  • (30%) Based on Case Studies
  • (30%) Techniques
  • (30%) Role Play
  • (10%) Concepts
  • Pre-test and Post-test
  • Variety of Learning Methods
  • Lectures
  • Case Studies and Self Questionaires
  • Group Work
  • Discussion
  • Presentation

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Power Generator Operation & Maintenance at ICTD International Centre for Training and Development

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