© 2018 JETIR June 2018, Volume 5, Issue 6 www.jetir.org (ISSN-2349-5162) JETIRC006278 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org 1619 DEVELOPMENT, ASSEMBLY AND PERFORMANCE TESTS OF 2250 KVA OPEN DGSET Nidhi Theresa Jeevan, Dr.Priam Pillai, PCE, New Panvel Abstract—In this paper we have designed the Base Frame for 2250 kVA DG Set using CAD Software Auto-CAD (2-D) and PTC Creo Parametric 3.0(3-D) and the 3-D Model is further simulated in Creo Simulate 3.0 to analyze the rigidity. Hence Structural analysis is performed using FEA(Finite Element Analysis) tools in Creo Simulate 3.0.To evaluate the natural frequency of 2250 kVA DG set Base frame Modal Analysis is also performed . Base Frame is designed in such a way to maintain and carry the weights of components of the entire DG Set and also to maintain its alignment and to withstand all the dynamic loads which all DG set generates .Anti-Vibration Mounts are used for the 2250 kVA Diesel Generator Set to reduce the structure borne noise and vibrations. The 2250 kVA DG Set was further physically tested and the Performance Test result was found satisfactory. Vibration Testing was done using a vibration meter as per as ISO 8528 Part 9, vibration max limit less than or equal to 320 microns. Thus have successfully developed a well optimized and stable open DG Set of 2250 kVA Rating by reducing the thickness of the Base Frame Material(IS 2062) from 16 mm to 12 mmthick. Index Terms—Base frame, Diesel Generator,Deflections,Anti- Vibration Mount, stiffness etc. I. INTRODUCTION DIESELGeneratorsisveryimportantforanydevelopedordevelopingnation,capacityofsupplyingunhinderedenergynotonlyensure sasteadyindustrialgrowth,butalsogoesintoimprovethequalityoflifeinlongway.Themainsourceofthisenergyisobviouslyelectricityan d thisiswhattheDieselGeneratorSetgenerate.TheDGSetisoneofthemostimportantandcomplicatedsystemindesign,manufacturing and testing. The DieselGenerator assemblyanditsauxiliarieshaveahugeweightusuallyrangingfrom8000 kg to several tones[1]. Diesel Generatorsare widelyused in various industries like steel, sugar,cement,paper,textile,chemical,bio- massbasedapplication.ThereareISOstandards for Diesel Generator manufacturersandprovidesguidelines for the maximum allowabledeflection,stiffness,frequenciesandstresslevelsforvariouscomponents.However,forindustrialapplicationsISO8528isman datory[2].MostoftheindustrialDieselGeneratoraremountedonbaseframes.WhichisrigidfabricatedstructureisgenerallymadeupofI beams and standard plates, I beams are mainly usedatmajorloadactinglocationswhereasplatesaremountedforsupportingthestructure.Steamturbinesaremountedonthebaseframetoc arryitsweight, tomaintain its alignmentandtoassistincarryingthedynamicloadswhicheveryDGSets generates.Diesel Generator base frame needsaneffectivedesigntechnologytoensurethatthebaseframeasdesignedperformstherequiredfunctions,andmaintainsitsintegrity.T hereisalsoaneedtomaximizethelifeoftheDieselGeneratorbaseframeundertheloadstowhichitisexposed. II. THE SCOPE OF WORK: Find out the structure deflection, stiffness,Calculation no of AVM(Anti-Vibration Mount)required for thebase frame,vibration test according to ISO Standards, Performance Testisalsocheckedforthe2250kVADGSet. Approach: Modeling and assembly of base frame, which comprises I beams and plates is done using PTC Creo 3.0.and static analysis is done by using Creo Simulate 3.0[6]. The vibration test at 8 different points of the 2250 kVA DG set are been noted down at different loads using a vibration meter and the performance test of the whole DG Set is done and the readings are also noteddown Specifications: The most important factor in selecting a generator set is of course its size and capacity. A careful study should be made to determineexactlytowhatendusethegeneratorsetisbeingput to, and the total wattage[7].It is always advisable to consider in a long run and select slightly larger generators,for future expansion and to add on more equipment to the load infuture. TABLE I ALTERNATOR SPECIFICATION Diesel Generator Set Specification Prime Power 1800kW/2250KVA Frequency 50Hz/1500 rmp Power Factor 0.8lagging Output Power 230V/400V Output Current 3240/3564A Phases 3 phases 4 wires