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India - Member - Electrical Saving

Join Date: May 2007
Location: Tamilnadu
Posts: 56

DG Set Fuel Consumption Testing

10/22/2007 10:06 AM

We would like to test the 500kVA DG set fuel consumption at full load & half load apart from alternator test. Please advice me for correct test procedure to check the diesel consumption to ensure the specification.Also indicate the equipment requirements for this testing. Generally what are all the test to be carriedout for new DG set?

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Guru
United Kingdom - Member - Indeterminate Engineering Fields - Control Engineering - New Member

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#1

Re: DG set fuel consumption testing

10/22/2007 10:52 AM

In the absence of any plant-mounted measuring equipment to assess the fuel volume at the start and the end of a test run period,

  • a dipstick,
  • a tape measure, and
  • a first-principles volume calculation

is suitable.

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Guru
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#2

Re: DG Set Fuel Consumption Testing

10/22/2007 3:04 PM

If you can separate the engine from the generator, hook it up to a dynamometer at half and full loads. You'll need to calculate torque at rated speed (for generator) to determine horsepower to drive generator at full and half loads so that you'll know how much mechanical load to apply on dynamometer test.

If you can't separate them, then find 500 kVA worth of heaters . . .

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Guru

Join Date: Jan 2007
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#3

Re: DG Set Fuel Consumption Testing

10/22/2007 10:58 PM

Use fuel weight ONLY, not volume. The supplier will give you the fuel consumption in grams per kilowatt hour. The volume will change drastically with temperature, but the weight will not. Do not disconnect the generator (alternator) as your consumption is based on engine claims and generator efficiency. Use a purely resistive load bank and a calibrated ammeter. Get a 20-30 liter bucket and place it on a precise weighing device. Calibrate the weighing device and have the fuel circulated back to the same bucket. You only need 5 minutes at each load to see the weight difference if the weighing device is very sensitive (that's why to use a small bucket not a 500 liter tank). Warm up the unit on the 500 liter tank and disconnect both suction and return hoses and drop them into your test bucket and weigh the fuel, bucket and hoses all together then start your 1/2 load test for 5 minutes. Don't let the supplier tell you that the engine will cool off too much during the hose swap as it will stay warm enough for full load even if you take 30 minutes to change over.

Stop and refuel the bucket with ambient temp fuel (the fuel will be bloody hot from the 1/2 load test if you run longer than 5 minutes). Then go again at full load for 5 minutes.

Fuel consumption should be around 0.33 pounds per horsepower per hour (sorry . . . you convert to metric as I'm too tired tonight).

If it is a big contract for 20 units then you will need to get very precise and after the test have your fuel analyzed for calorific heat content and compare it to ISO 3046 fuel specifications and compare your test to ISO ambient temperature, altitude, humidity, etc etc.

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Power-User
Engineering Fields - Piping Design Engineering - New Member Technical Fields - Architecture - New Member

Join Date: Apr 2006
Location: Bangalore India
Posts: 290
Good Answers: 3
#4
In reply to #3

Re: DG Set Fuel Consumption Testing

10/29/2007 12:41 AM

I fully agree with Petropower.Follow relevent ISO specified for fuel consumption for generators .practically its not possible to test the fuel consumption at site.Its an exersise conducted at Generator test bed at factory.

crm

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Anonymous Poster
#5

Re: DG Set Fuel Consumption Testing

04/08/2008 4:36 PM

If you have not find a way to measure fuel consumption (total and instantaneous) on site at better than 1% accuracy I suggest you to contact company Reicon LLC (www.reicon.us) in the US. They have 25 years experience with testing and measuring fuel consumption in Lab or on site. The accuracy is comparable than the portable tank method (J1321) and much more easy to use. Many Engine and vehicle manufacturers use them for collecting consumption data points.

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Anonymous Poster
#6

Re: DG Set Fuel Consumption Testing

08/06/2008 6:16 AM

How to calculate consumption of fuel for 1500 KVA DG set

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Power-User
Engineering Fields - Piping Design Engineering - New Member Technical Fields - Architecture - New Member

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#7

Re: DG Set Fuel Consumption Testing

08/06/2008 6:50 AM

its too complicated to take a fuel consumption test at site for DG set At factory set is load tested with resistive load bank and fuel consumption is checked by weight best option for you is to pay little extra Rs and witness the fuel consumption test at manufacturer's factory but you need to gothrough ISO 3046 and understand the tests conducted on a DG set.

crm

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Anonymous Poster
#8

Re: DG Set Fuel Consumption Testing

08/17/2008 7:12 AM

there is a professional agency for testing dg sets m/s dolar systems and services pvt ltd ,#1,anjeneya temple cross,new bel road,banaglore 560058 contact its director mr p prkash mob 09448288562 or mail dolar@sify.com

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Anonymous Poster
#9

Re: DG Set Fuel Consumption Testing

06/22/2009 6:30 PM

Use volumetric fuel measurement system from REICON LLC. you will get current GPH and total consumption at an garanteed accuracy better than 1% of the reading. This system is used worldwide by testing and devolpment engineers.

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Anonymous Poster #1
#10

Re: DG Set Fuel Consumption Testing

12/27/2012 1:43 AM

if u want to calculate then i can suggest an approx approach as mentioned below:

Take DG's KVa and multiply it with 0.15 ltr/kwh like

500*0.15=75 ltrs for 75% load approximatly

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Users who posted comments:

Anonymous Poster (5); Bill (1); crm (2); PetroPower (1); PWSlack (1)

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