Industry Overview
A diesel generator (DG) converts mechanical energy into electrical power and supplies it through power cables. It functions by using a prime mover to drive an alternator, producing electrical energy that can be supplied to an electrical distribution system. DG sets are widely used as a source of backup or captive power when electricity supply from the State Electricity Board or other power supply undertakings is interrupted.
A typical diesel generator set consists of an alternator and a diesel-fuelled prime mover coupled together and mounted on a strong base. When the engine is started, it rotates the alternator, generating electrical energy that can be supplied through the main switch. DG sets are used in commercial buildings, hotels, railway stations, telephone exchanges, shops, industrial facilities and other establishments requiring reliable power availability. The report covers DG set components, selection considerations, manufacturing processes, testing and load-bank testing, energy-saving measures, applications, plant layout, market developments, and suppliers of major raw materials and equipment.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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
- 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)
Frequently Asked Questions
A diesel generator set is a power-generating system that uses a diesel engine to drive an alternator and produce electricity. The engine acts as the prime mover, while the alternator converts the mechanical energy into electrical energy. DG sets are commonly used for backup power when the normal electricity supply is interrupted. They can also be used for captive power applications in establishments where a dependable electricity source is required for continuous or critical operations.
The main components of a diesel generator include the diesel engine, alternator, fuel system, voltage regulator, cooling system, exhaust system, lubrication system, starter and battery system, control panel, frame or housing, and canopy. Each component performs a specific function in converting fuel energy into electrical power and controlling the generator. Proper integration and maintenance of these components are important for dependable operation, safe performance, efficient fuel use, and suitable power quality.
Diesel generator sets are commonly used in commercial, industrial and infrastructure applications where reliable electrical power is required. The report identifies applications including mining, healthcare, commercial facilities, oil and gas, construction, manufacturing, telecommunications and data centers, utilities, education, and military facilities. DG sets are particularly useful where interruption of the main electricity supply could affect essential services, production processes, communications, equipment operation, or other critical activities.
Diesel generator selection should be based on the electrical load, operating conditions, required duty, installation environment, fuel requirements, and applicable specifications. The expected load profile and starting characteristics of connected equipment are important considerations because generator sizing affects performance and efficiency. Other factors include the engine and alternator configuration, cooling and exhaust arrangements, control system, enclosure or canopy requirements, maintenance access, noise considerations, and testing requirements.
Load bank testing verifies the performance of a generator by applying a controlled electrical load to the generating set. The test allows operators to assess the engine, alternator, cooling system, fuel system, voltage regulation, and other operating parameters under defined load conditions. Regular testing can help identify performance problems that may not become apparent during lightly loaded operation. It is also useful for confirming that a standby generator can respond appropriately when it is required to supply its intended electrical load.
Wet-stacking is a condition associated with prolonged operation of a diesel engine at light loads, where unburned fuel and combustion-related deposits can accumulate in the exhaust system. It can affect engine and exhaust-system performance if the condition persists. Appropriate generator sizing, suitable loading, proper maintenance, and periodic controlled load operation can help reduce the risk. Load-bank testing is one method used to operate a generator under a controlled load and assess its performance.
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