GENERATOR MANUFACTURING UNIT [CODE NO.3656]
A diesel generator converts mechanical energy (movement) into electrical power, and channels it through power cables. It can be helpful to imagine electricity flowing through wires in much the same way water flows through pipes. A generator can be thought of as a kind of ‘electrical pump’ which causes the electricity to flow through the wires. It doesn’t actually create or destroy the electrons that flow through the wires any more than a water pump creates new water. It just causes it to move in a useful fashion.
Diesel Generator set is used to generate electricity for meeting the electricity requirement of small establishments such as commercial buildings, Hotels, Railway Stations, Telephone Exchange, Shops etc. when there is a power supply failure from the State Electricity Board or other power supply undertakings.
The Generating set consist of alternator and a prime mover working on fuel. These two are coupled together and mounted on strong base. When the prime maker is started the alternator is rotated and required energy is available in the form of electricity from the alternator which can be supplied to the main switch.
COST ESTIMATION
Plant Capacity 60 Nos/Month
Land & Building (5000 sq.mt.) US$ 3.75 Lac
Plant & Machinery US$ 87 Th.
Working Capital for 2 Months US$ 48.68 Lac
Total Capital Investment US$ 53.76 Lac
Rate of Return 76%
Break Even Point 20%
INTRODUCTION
DG SET AS A SYSTEM
SELECTION CONSIDERATIONS
DIESEL GENERATOR CAPTIVE POWER PLANTS
ADVANTAGES OF ADOPTING DIESEL POWER PLANTS ARE:
DIESEL ENGINE POWER PLANT DEVELOPMENTS
ENERGY SAVING MEASURES FOR DG SETS
THE MAIN COMPONENTS OF A DIESEL GENERATOR
THE ENGINE
THE ALTERNATOR
THE FUEL SYSTEM
THE VOLTAGE REGULATOR
THE COOLING SYSTEM
THE EXHAUST SYSTEM
THE LUBRICATION (OIL) SYSTEM
THE STARTER & BATTERY SYSTEM
THE CONTROL PANEL
THE FRAME/HOUSING
THE CANOPY
TYPES OF GENERATORS:
THEY CAN FURTHER BE CLASSIFIED INTO 3 MAIN TYPES.
USES AND APPLICATION
MINING
HEALTHCARE
COMMERCIAL
OIL & GAS
CONSTRUCTION
MANUFACTURING
TELECOMMUNICATIONS AND DATA CENTERS
UTILITIES
EDUCATION
MILITARY
B.I.S. SPECIFICATION
PROCESS FLOW CHART
MANUFACTURE PROCESS
FUEL TANKS
EXHAUST SYSTEM
TESTING OF DG SET
STANDARD REFERENCE CONDITIONS:
GENERATOR LOAD BANK TESTING
HOW DOES A LOAD BANK TEST WORK?
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
CAUTION:
WET-STACKING:
BENEFITS OF LOAD BANK TESTING:
INDIA DIESEL GENSET MARKET
INDIA DIESEL GENSETS MARKET TO CROSS $2.9 BILLION BY 2021
THE FUTURE OF DIESEL GENSETS IN A WORLD OF RENEWABLES
INCREASING DEMAND FOR POWER TO BOOST INDIA DIESEL GENSET
MARKET DURING 2016-22
MARKET OVERVIEW
DIESEL GENSETS – FIRING UP
PERIOD OF VOLUME DECLINE OVER; EXPECT 10% CAGR OVER FY17-20
DO LOWER POWER DEFICITS IMPLY LOWER DG DEMAND?
INDUSTRIAL PRODUCTION AND CAPACITY BUILDING KEY DRIVERS,
IN OUR VIEW
SO WHAT DRIVES THE REVIVAL IN DG DEMAND OVER FY18-20?
INFRASTRUCTURE SPENDING – ROADS, METRO RAIL, RAILWAYS
DATACENTERS – A HUGE OPPORTUNITY FOR DG SET MANUFACTURERS
HOTEL OCCUPANCY AT 9-YEAR HIGH – TO DRIVE NEW SUPPLY GROWTH
SHIFT FROM UNORGANIZED TO ORGANIZED SEGMENT – GST TO
HASTEN TRANSITION
DIESEL GENSET INDUSTRY BACK ON GROWTH TRACK
INFRASTRUCTURE SPENDING IS THE KEY DRIVER
CUMMINS INDIA
CUMMINS INDIA GOEM
MAHINDRA POWEROL
KIRLOSKAR OIL ENGINES GOEM
PERKINS INDIA
PERKINS INDIA DEALER
WHAT GOES INTO MAKING A DG SET?
THE ENGINE IS THE HEART OF THE MACHINE
PLANT LAYOUT
PRESENT MANUFACTURERS/SUPPLIERS OF DG SET
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF DISEL ENGINE
SUPPLIERS OF ALTERNATOR
SUPPLIERS OF COUPLING
SUPPLIERS OF M.S. CHANNELS AND ANGLES
SUPPLIERS OF M.S. FLAT
SUPPLIERS OF M.S. PLATE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF EOT CRANE
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
SUPPLIERS OF MIG WELDING MACHINE
SUPPLIERS OF POWER PRESS
SUPPLIERS OF SHEARING MACHINE
SUPPLIERS OF BENDING MACHINE
SUPPLIERS OF PUNCHING PRESS
SUPPLIERS OF GRINDING MACHINE
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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