P1-GIPL-001

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PROCESS MANUALGIPL-OEM

Project and Operation & Maintenance

PROCEDURE

P1-GIPL-001

OPERATION AND MAINTENANCE PROCEDURE FOR

DIESEL GENERATOR SET

PROCEDURE NO.: P1-GIPL-001

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2.1 Purpose

This document provides instructions for carrying out Periodic Maintenance of

Diesel Generator set and its various components like diesel engine, alternator

with battery unit & AMF panel. Periodic maintenance and routines are necessary

to reduce/prevent plant outages which can affect network integrity and

therefore leading to loss of revenue and customer inconvenience.

2.2 Scope

This procedure will outline the maintenance routines and responsibilities for

Diesel Generator (DG) in BTS sites. The users of this procedure are advised to

refer the corresponding OEM (O&M) manual for carrying out all O&M activities.

This procedure provides general guidelines as applicable to DG Sets supplied by

different OEMs Supernova / M&M etc.

2.3 Responsibilities

2.3.1 National Head

The HOD National Head at Corporate office New Delhi is responsible for the

technical integrity of this procedure. He or his nominated Deputy shall be

authorised for any changes in this procedure.

2.3.2 Circle Manager

The Circle Manager is responsible for ensuring that all activities related to thisprocedure are complied with and recorded as described in this document.

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2.3.3 Maintenance Process

2.3.3.1 Background

Diesel Generator (DG) set acts a standby source of AC power supply. DG set can

also be referred as Emergency Power Plant (EPP). When the SEB supply fails the

DG set starts through the controller. DG set primarily consists of diesel engine,

alternator with battery unit and AMF panel.

The capacity of DG set may be different depend upon load at BTS location: 15KVAto 30 KVA. There are different suppliers (OEMs) for these DG Sets. All these

suppliers purchase Engine & Alternator from reputed manufacturers and

assemble them with their AMF Panel. For example 15 KVA DG set engine make is

Mahindra & Mahindra (M&M) & Alternator make is Crompton Greaves. For rest

of the engines alternator make is Stamford.

2.3.3.2 Operations

A diesel generator is a combination of a diesel engine and alternator that areconnected by way of a gearbox or direct coupling. The engine runs on diesel fuel

and provides the power required by the alternator in order to generate AC

electrical power.

The engine controls include a governor that controls fuel flow in order to control

the power output and the speed of the engine generator set. The generators

output frequency is fixed by the generator speed. A voltage regulator controls

voltage by controlling the current applied to the field windings of the generator.

AMF panel continuously monitors the SEB power supply and through AMF

controller and relays it sends command to the engine to provide emergencypower on SEB failure. The main components of the AMF panel are:

AMF controller like EC1, EC2, MCU etc

Mains & DG power contactors

Mains & DG MCBs

Control relays for logic buildings

Voltage monitoring relays like ALVD2, UVT etc.

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The AMF controller uses advanced single chip microcomputer for easy and

trouble free gen-set controls. During the running of the engine various

parameters like lube oil pressure, high water temperature of engine cooling

medium, fuel level, canopy temperature and speed of the engine & overload is

continuously monitored by suitable sensors provided on the engine and any

abnormality is detected i.e. indicated by a audio-visual alarm and alternator is

isolated with the engine being shut down. The controllers are normally

multifunctional and programmable. They operate in different modes like Test

mode, Auto mode, Manual mode, Reset mode, program mode & lock mode.

The AMF panel is provided with adequate controls to start and stop the DG set &

to extend the power to load in both manual and auto mode. Users of this

procedure are advised to refer the individual wiring and control drawings for the

different types of DG sets. The following indications / measurement are generally

provided on the front of the AMF panel:

1. Output voltage

2. Load current

3. Frequency

4. Engine RPM

5. Kilowatt

6. Power factor

7. Battery voltage

8. Engine running hours

9. Fuel level

10. Engine Oil pressure

11. Engine temperature

12. Lube oil temperature

When a power failure occurs, the controls energize the engine starter to start

than engine and fuel flow. Once the fuel ignites in the cylinders, the engine runs

under the control of the governor. If the engine does not start on more than first

cranking cycle, the control system will typically repeat the cycle three times

depending on the programmed commands.

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When the generator output stabilizes, a transfer switch/contactor or a set of

transfer breakers switches the load from the utility power feeders to the

generator output.

The output from the dynamo charges the engine starting battery. Separate

battery charger of constant voltage type is provided for all DG sets to keep the

battery in charged condition when DG set is idle. The DC voltmeter and ammeter

will indicate the charging voltage and current respectively when charging the

battery using static battery charger. The battery charger should be in ON position

during normal/regular operation.

The engine is tripped on various fault conditions like HWT, CHT, LFL, overload, etc.

the transfer switch/contactor drops and the engine runs in cool down mode for

normal faults. In case of severe faults like LLOP the fuel flow is cut off immediately

and the engine halts without cool down time. During emergency conditions the

Emergency push button can be used to trip the DG set. The Emergency push

button is of stay-put type and should be kept in pressed condition till DG set

reaches to zero speed.

If the maintenance of DG set is carried out in de-energised state then in case of

SEB power failure the network may be down due to battery discharge or due to

high shelter temperature, whichever occurs earlier. In order to avoid such a

scenario, it is proposed to arrange a portable DG or any other alternative for

backup power supply.

A Petrol Gen set is a combination of a petrol engine and alternator. The engine

runs on petrol fuel & provides rotating motion to alternator for generating single

phase AC power output.

The earthing for the DG set has great importance for the satisfactory performance

of DG set as for the safety:

As per IE Rules 1956, it is mandatory to provide two separate earth pits for

neutral connections of DG set. Check these connections during PM.

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Separate earth connections are provided for generator body, engine frame

and control panel. Check the connections and tighten if required.

2.3.3.3 AMC & CAMC with Vendors

Till the warranty period expires the sets would be maintained in coordination with

the OEMs/original manufacturers of engine basically. But may be after the

warranty period is completed one should plan for either Annual Maintenance

Contract or Comprehensive Annual Maintenance Contract (CAMC) with different

vendors.

AMC: Annual Maintenance Contract only services without spares and sparesarrangement is with owners scope

CAMC: Comprehensive Annual Maintenance Contract is complete servicecontract which includes services and spares.

If the routine instruction mentioned in the following paragraphs fails toadequately cover the functions of a given sites standby EPP, then a specific

routine for that site should be developed and implemented after approval by the

Corporate Maintenance Manager.

2.3.3.4 Maintenance Frequency and Records

Refer the DG maintenance check sheets and Process Manual for details.

The guidelines provide the general checks that need to be carried out during the

preventive maintenance checks. For the task lists please follow the formats asspecified.

The fortnightly inspection has to be done at all relevant sites and records to be

maintained as specified.

Contact the vendor for any manufacturing defects or discrepancies found during

the maintenance.

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For quarterly/Yearly maintenance of DG sets the vendor does the quarterly

checks and periodic maintenance. Vendor and Circle representative shall jointly

sign the necessary formats.

2.3.3.5 Safety Precautions

The following safety precautions need to be followed for carrying out any work on

the DG set:

2.3.3.5.1 Inspections of DG set in Auto Mode/running condition

Inform the concerned authority and take work permit for the job.

When the DG set is in Auto mode beware that the engine may start at any

time.

Always wear ear protection while engine is running.

Do not touch any rotating parts.

Maintain a safe distance from the rotating parts.

Do not touch any live conductors/cables.

Ensure that the DG house floor is free of oil.

Batteries in charging emit Hydrogen Gas, which may explode under some

circumstances. Therefore, do not smoke or bring naked flame near the

Battery.

Switch off the light inside the enclosure after inspection otherwise it may

raise the inside temperature and generate a faulty alarm.

2.3.3.5.2 Inspections of DG set in Manual mode/de-energised

condition

Select Manual mode.

Before working on any part of the electrical system disconnect the earthing

terminal of battery. This will prevent short-circuits and damage to electrical

units.

Access to working space and escape passages shall be kept clear and

unobstructed.

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Warning signs, if required shall be placed at appropriate places.

Follow all precautions while using hand held tools like blowers, drill

machines etc. Use hand held tools with ELCB boards only.

Switch off the light inside the enclosure after maintenance otherwise it may

raise the inside temperature and generate a faulty alarm.

While refueling the tank, always ensure that the engine is not running.

Ensure that the DG house floor is free of oil.

Keep away any fire accelerating substances from the fuel. Any spillage must

be wiped dry immediately.

Do not use hand to check for fuel leaks. Use piece of cardboard or paper to

search for leaks.

Do not use cloth for filtering diesel, as minute cloth threads might mix up in

fuel and effect the performance of engine. So use the fine filter mesh.

Relieve pressure before disconnecting fuel lines. Tighten all connections

before pressurising lines.

If diesel is injected into the skin then obtains medical attention immediately

or else, gangrene may result. Never add coolant to an overheated engine as engine damage can occur.

Allow the engine to cool first. Water is corrosive at engine operating

temperature.

Do not operate the engine while lubricating or cleaning.

Do not stop the engine suddenly from full load running. Initially remove the

load and let the engine run at high idle speed for 3 to 4 minutes before

stopping the engine.

Do not start the engine with load.

During starting do not crank the engine for more than 10 secondscontinuously.

Do not remove the radiator cap when the engine is hot. Always turn the

cap slowly to the first stop and allow pressure to escape before removing

the cap completely.

Paper element can be cleaned with low air pressure supply with gun at

comfortable distance from the element so as to avoid damage to paper

filter.

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Protect the turbocharger by running the engine for 5/10 minutes with load

before shut off.

Never run the engine without battery in the circuit.

Before carrying out any welding work on the engine, disconnect the battery

charger alternator from the electrical circuit or disconnect the battery

terminal.

Take welding current return path as close as possible to welding point.

Before washing the engine, the alternator should be wrapped with

polythene sheet to avoid direct water entry into the alternator (panel

board wiring should not be washed).

For cleaning engine do not use additives or cleaning agents.

If the clutch slip noise of starter motor is heard, do not try to start the

engine.

Ensure to lift the DG Set only from the hook provided on bottom base

frame. Guide nylon rope through rope guide provided on top frame. Do not

lift the DG Set from the rope guide.

2.3.3.5.3 Tools Required

Calibrated digital multimeter

Earth resistance meter

Ring spanner box spanner and open spanner set

Cloth, cotton rags

Nylon brush

Normal hand gloves

Megger (500V) First aid kit

Hand held single phase hot air blower

Distilled water

Battery tester and Hydrometer

Trays to drain oil, trays for keeping, removal parts/spare parts for engine.

Funnel for fuel and oil filling.

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2.3.3.5.4 Purpose of Inspection

The purpose of the fortnightly inspection is to assess the general condition of the

DG set including condition-monitoring check of its various parameters. This

fortnightly inspection is intended to be a general quick check for the more

conspicuous problems that can be encountered. In exceptional cases, the

fortnightly inspection schedule may be carried out on weekly basis. The following

types of DG set problems can be detected during the fortnightly inspection:

Abnormal loading of the DG set while running

Abnormal temperatures of water or oil.

Unusual engine noise

Excessive smoke

Any fuel, coolant, lubricating oil or exhaust leaks

Abnormality of the cables/conductors

High vibrations

Checking of auto transfer scheme

Checking of LLOP, LFL, HWT alarms

Oil level Radiator coolant level, Battery electrolyte level, battery condition,

battery charger condition.

2.3.4 Inspection Procedure

NOTE: Whenever performing maintenance inspections ensure that the

manufacturers operation and maintenance manual for the particular PG/DG set

is available for review.

2.3.4.1 Fortnightly maintenance procedure of DG sets

Inform the NOC/OMC about the work.

Ensure that a backup power supply in case of SEB power failure is arranged.

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Select both the DG sets (wherever applicable) on Manual mode.

Ensure that all power supplies to the DG are switched OFF and the

respective switch locked and red tags placed on them.

When carrying out any maintenance in engine, alternator or AMF panel

disconnect the starting battery. Failure to take this precaution may result in

very serious injuries.

Follow all safety precautions listed above in safety section.

Check the equipment for free of oil, water and dirt. Check for any loose or missing bolts and nuts. Check all bolts and nuts and

replace any broken or lost bolts or cap screws.

Check in the AMF panel the individual component like MCB, contactors,

relays and fuses for any abnormality like overheating, broken condition,

discoloration, loose termination, carbonized terminals, unusual noises etc.

Replace, if necessary.

Check the spark plug, if applicable.

Check all connections and hoses (i.e. fuel, lubricant, coolant etc.) for leaks,

looseness, damage, corrosion and paint condition. Repair or replace if

required.

Check the fuel systems, fuel pumps, fuel filters, high-pressure lines, fuel

transfer pump and fuel injection pump (if applicable) for leakage,

maladjustment or tampering.

Drain the sediment, if present from the fuel tanks, fuel filter and water

separator (if applicable).

Drain the water from fuel filter. Before draining close the fuel supply cock,

if fitted and after draining prime the filter.

Drain the condensate trap, if applicable.

Check leakage from fuel piping, coolant piping, lubricating piping and

injector high-pressure lines (if applicable). Repair or replace if required.

Check the fuel tank fuel level is minimum 3/4th of tank capacity filled.

Check that the engine oil level is up-to the operating level between L &

H mark on the dipstick.

In case of PG sets, change the engine oil after every 200 hours of operation.

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When the system is cool, check that the radiator is filled with coolant till

25mm below the filler cap seat.

Check that the oil level is up-to the Arrow level mark in the air filter.

Check the air filter condition and clean if necessary.

Check the air cleaner indicator (used for paper type air cleaner). Clean the

paper element when indicator shows RED. If RED mark persists after

cleaning also then replace the paper element.

Check air intake piping and connections for any leaks or damage. Replace, iftorn hose is found.

Check that the insulation of exhaust lines is not soaked with oil.

Check that there is no leakage at exhaust manifold, gaskets, bellow and

flange connections. Repair or replace, if required.

Clean and check radiator fins for chocking & clogging and tubes for leak or

damage. Repair or replace if required. Use only the hoses purchased from

the authorised dealers.

Tighten the jubilee clips properly after replacement of radiator hoses.

Check that all the belts (water pump/alternator drive) are tight i.e. 10 to

12mm when pressed on the belt between two pulleys. Adjust the belts to

appropriate tension. Check the belts for wear & tear too.

Check the radiator guard for tightness.

Check battery vent caps are fixed properly. Check by hand tightening.

Check rubber cap is placed properly on battery terminal, measure & record

the voltage by using multimeter.

Check the speed control lever and emergency stop lever/button, if

applicable.

Check the battery terminals for tightness.

Check the electrolyte level in the battery. If required fill it with distilled

water up-to 10mm above cell plates.

Check the specific gravity of the electrolyte. It should be at least 1.2

Check the static battery charging system.

Check the condition of battery charging alternator.

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Check the earthing connection of DG set and panel. Repair if found loose,

corroded or broken.

Select both the DG sets (wherever applicable) on Auto mode.

Conduct the engine trial test as per section 2.3.6.2.5 & record the

parameters as in Format No: OEM/0009

Carry out the simulation of alarms as mentioned in section 2.3.6.2.5.5

Check the oil pressure indicators, temperature indicators, warning lights

and other gauges to make sure they are operational. Check battery terminal voltage while charging with engine. Ammeter

should show readings on the positive side.

Check the working condition of the lamp in the control cubicle.

Check the exhaust smoke color, unusual vibration & noise.

Check for the smooth operation of starter motor and alternator.

Follow all maintenance steps as mentioned by the engine manufacturer.

Table: 2.1

Sr.

No.Item

Every 40-50

hrs

Every 140-

150 hrs

Every 200-

250 hrs

Every 250-

300 hrs

1 Engine oil level check & top up

2 Engine oil change

3 Air filter cleaning

4 Spark plug check

5 Decarbonising

6 Fuel Filter Cleaning

7 Battery fluid level check

8 Fuel level check & top up

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2.3.5 Quarterly/Periodic/Preventive Maintenance Tasks

2.3.5.1 Purpose of Inspection

The Quarterly/periodic/preventive maintenance provides the confirmation that

the DG set is being maintained within well operating conditions. These

maintenance activities shall be carried out as per the due time i.e. engine running

hours or the duration mentioned in the ESS task list, whichever occurs earlier. If

the due time is not mentioned then the frequency of maintenance should be

considered as quarterly.

Cleaning wire mesh gauze in oil bath air cleaner.

Replacing oil in air filter and engine

Replacing fuel filter, engine oil filter

Check the specific gravity of electrolyte in battery & record.

Check battery conditions & AMF panel switchgear components.

Replacement of all missing meters, gauges and indication lamps

Rectification of faults observed during the normal energised state

inspection.

Meggering of AMF panel components and alternator winding, alternator

cable, etc.

Calibration of the controller and LVM

AVR connections checks

Cleaning of diesel engine

Checking of all the trips and alarms

2.3.5.2 Inspection Procedure

NOTE: Whenever performing maintenance inspections ensure that the

manufacturers operation and maintenance manual for the particular DG set is

available for review.

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2.3.5.2.1 Quarterly/Periodic/Preventive maintenance procedure for

DG sets of rating 15KVA to 100KVA

Inform the NOC/OMC desk about the work.

Ensure that a backup power supply in case of SEB power failure is arranged.

Select both the DG sets (wherever applicable) on Manual mode.

Ensure that all power supplies to the DG are switched OFF and the

respective switch locked and red tags placed on them. When carrying out any maintenance in engine, alternator or AMF panel

disconnect the starting battery. Failure to take this precaution may result in

very serious injuries.

Follow all safety precautions listed in safety section.

Clean the Air cleaner element with air pressure in such a way that paper

element is not damaged.

If vacuum indicator shows Red after element cleaning then replace paper

type air cleaner element. In case of oil type, clean gauze and replace oil if

required.

Replace the paper type air cleaner element.

Check the vacuum indicator of paper type air cleaner. Replace, if required.

Clean the engine breather, if applicable. Replace if it is dirty or clogged.

Clean the pre-cleaner dustpan.

Check that all air hoses and clamps are tight and free from cracks. Replace

if required.

Remove and clean the air- ducting hoses.

Check Blow by of the engine visually.

Drain the condensate exhaust trap, if fitted.

Check exhaust manifold flange and connections for leakrectify if required.

Check the lubricating system hoses and connections for free of leakage and

damage. Replace, if required.

Check lubricating oil condition and level in FIP. If required change the oil.

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Replace lube oil, lube oil filter and bypass filter if fitted. Before replacement

of lube oil run the engine for about 5 to 10 minutes. Stop the engine and

wait for 15 minutes and then drain the old oil.

Clean the float tank breather, if fitted (Frequency: 3 months).

Check the fuel injection pump (FIP), drive coupling and its guard, if

applicable (Frequency: 3 months).

Check excessive mist from fuel tank breather, if applicable. Remove and

clean if required. Clean strainer in the fuel tank, if fitted.

Check the fuel level gauge. Repair or replace if required.

Clean fuel feed pump strainer/pre filter if fitted.

Drain the sediment or water, if present from the fuel tanks & clean the

water separator. Replace the fuel filter element. The O-rings of the

removed fuel filter should never be re-used. Always use a new O-ring

during the fuel filter replacement.

Check that the oil level in the governor is up-to the operating level.

Check the governor linkages.

Replace governor oil filter (wood ward)/Hydraulic governor oil if fitted.

Check the fuel system hoses and connections and high-pressure lines for

free of leakage and damage. Replace if required.

Check the fuel in the storage tanks for water.

Visually check the coolant condition. Check that the coolant level is 25mm

below the filler cap seat in radiator

Check the cooling system hoses and connections for free of leakage and

damage. Replace, if required. Check the pressure cap of the radiator. Replace, if required.

Check the radiator fan for free movement. Check that the bearings are not

damaged.

Check radiator cowl stay & gap between fan and cowl.

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Clean radiator core with compressed air. Blow air through the radiator core

in opposite direction to the normal flow of air, to remove dirt and dust.

Check the fan hub, drive pulley and water pump for any damage or

misalignment. Repair or replace if required.

Lubricate the water pump bearings with grease if grease cup or nipple is

provided.

Check all the belts condition and tension. Adjust the belt to appropriate

tension i.e. 10 to 12 mm when pressed on the belt between two pulleys. Check the battery terminals. Clean and apply petroleum jelly, place rubber

cap properly on terminals.

Check the electrolyte level in the battery. If required fill distilled water up

to 10 mm above cell plates.

Check the battery healthiness i.e. check the battery voltage and specific

gravity and record it.

Check static battery charger system.

Check that the battery-charging alternator is working.

Fill up the drive end shield reservoir of the starter motor with Multi-grade

20W40 oil, if applicable.

Clean & lubricate the stop solenoid stem with the engine oil.

ALTERNATOR

Check that all the electrical connections for the engine, alternator, and

battery charging alternator, stop solenoid, safety devices, starter motor and

battery are tight.

Remove commutator end (CE) cover of the starter motor and smear

molybdenum sulphide grease over CE bearing pin, (6M14, and BS5

starters). Lubricate pinion on shaft with MOS2 grease OKS 410 (SM 130 PE

Starter). Frequency: 3 months.

The commutator of the starter motor should be clean and have a polished

appearance. If it is dirty, remove the starter motor from the engine, hold a

fine dry or petrol moistened cloth against the commutator and revolve the

commutator by turning the pinion.

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Remove the cover band from the starter motor body. Remove the brush

dust inside the starter. Check that the brushes move freely in their holders

by holding back the brush springs and pulling gently on the flexible

connectors. If a brush is inclined to stick, remove it from the holder and

clean the sides with petroleum moistened cloth. Ensure that the brushed

are retained in their original positions. Replace badly worn out brushes.

Apply Elcoprin sealing compound around CE cover-Frequency: 3 months.

Check the alignment of engine to drive unit. Check that the couplingbetween the engine and the drive unit is tight.

Retighten the cylinder head bolt/nuts.

Tighten all engine mounting bolts and nuts. All 15 -100 KVA sets, 600hrs/6

months

Tighten the nuts, bolts and cap screws of delivery valve holder, injection

pressure lines, leak off lines, oil sump screws, heat exchanger bolts, oil

pressure connections on heat exchanger, water temperature transducer on

upper cooling line, exhaust manifold, muffler assembly, push rod cover,

timing gear cover, fuel filter, radiator hose connections, fan and mountingsof bracket, radiator, alternator, starter motor, battery charging alternator

and air filter. Frequency: 6 months.

Check the smoothness of battery charging alternator ball bearing.

Frequency: 6 months

Visually check that the alternator and terminal box are free of damage,

spare entries are plugged properly.

Check that there is no ingress of moisture, hot air or solid objects on

alternator winding.

Clean the alternator windings using hot air blower. Frequency: 3 months

Check bearing noise of alternator, Grease the bearings of alternator,

wherever applicable Check & reset injection pump timing. Leyland: 600

hrs/6 month Check & Adjust valve clearance. 600hrs/6 months 15 to 100

KVA

Adjust Injectors. 600 hrs/1 year, M&M 15KVA:

Clean diffuser and impeller of turbocharger. Check end float and radial

clearance of turbocharger. 5000 to 6000hrs/2 years

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Check vibration damper. Check crankshaft end play, corrective action must

be taken if it is beyond recommended limits. 6000hrs/2 years

Replace injector inlet screen and magnetic filter screen in fuel pump. 5000

to 6000hrs/2 years

Replace external rubber components like belts, hoses if required. 5000 to

6000hrs/2 years

Check the proper condition of all fuses.

Check the contacts of power contactors clean the contacts with carboncleaning solvent if found carbonised.

Check the relay connections/Relay base connections/Relay contacts/Timer

settings.

Check that all the electrical and mechanical connections inside control

panel, on connector strip, AMF controller and CT/PT connections are tight.

Check the parameter settings in the AMF controller as per OEM. Calibrate

the AMF controller and LVM.

Check the megger value of various components in AMF panel with 500V

megger. Frequency: 1 year.

Check the condition of the alternator winding by megger test. Record the

winding resistance. Note: Before meggering, alternator winding, please

ensure that the AVR connection is disconnected. Megger the field

winding, alternator stator winding and rotor winding separately,

Frequency: 1 year

Check alternator cable megger value & record

Check that the AVR connections as per circuit diagram are right and tight.

Check the working condition of all the indicating lamps, meters and gauges.

Replace, if required.

Check the functions of the safety devices.

Check the earthing connection of DG set and panel. Repair if found loose,

corroded or broken.

Measure the earth pit resistance of the DG neutral (covered in ESCS of

earthing). Value should be less than 1 ohm.

Check the condition of earth pits.

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Clean the diesel engine and check that there is no leakage.

Check canopy for corrosion, insulation & outside sheet damage, door locks,

and unwanted openings.

Lubricate door hinges & door locks.

Check the housekeeping of the DG set. Check that no tools, rags or oil is left

on the floor & all tools & tackles are removed.

Select both the DG sets (wherever applicable) on Auto mode.

Conduct the engine trial test as mentioned in section 2.3.5.2.5 All the maintenance jobs carried out shall be recorded.

Follow all the maintenance steps as mentioned by the engine

manufacturer.

PLEASE NOTE THAT THE ABOVE CHECK/DIRECTIONS POINTS ARE ONLY INDICATIVE

AND ALWAYS REFER THE MANUFACTURERS MANUAL WHENEVER WORKING ON

THE SET.

2.3.5.2.2 Fuel Tank cleaning procedure

Open the drain valve/drain plug for draining the fuel sediment.

Keep drain valve open till you get the fresh diesel, tighten the drain

valve/drain plug after fresh diesel starts coming.

Arrange the empty, clean container for storage of fuel tank diesel.

Ensure fuel tank is empty by opening the fuel-filling cap.

Use cotton rag for cleaning the fuel tank internally, by opening the fuel fill

cap or level/float gauge.

If the tank is detachable remove the tank from foundation & clean itinternally by taking it outside.

Clean fuel tank breather using air.

Check fuel level gauge & float for functioning.

Check fuel tank for any corrosion/leakage externally. Remove the corrosion

& seal the leakage if any.

Assemble the fuel gauge & float by replacing gasket.

Close the drain valve/drain plug.

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Fill fresh diesel.

2.3.5.2.3 Engine Health Check up

Engine health check up should be carried out after every 4000 hours of engine run

and very after 1000 Hrs, if engine is not recommended for top overhauling. These

shall be performed before and after engine top & major overhaul. Refer Annexure

I for the various activities to be carried out during the engine health check up andthe parameters to be recorded.

2.3.5.2.4Engine top Overhaul / Major Engine Overhaul

Operating conditions of the engine, normally dictate when the engine is in need

of a top overhaul or a major overhaul. Oil consumption, excessive drop of oil

pressure at idling, oil dilution, excessive blow-by, unusual noise, vibrations and

exhaust smoke should be analysed in determining the next course of action. Refer

Annexure II for the activities to be carried out during engine top overhaul. Refer

Annexure III for activities to be carried out during major overhaul.

2.3.5.2.5Engine trial test

The engine trial test shall be carried out after every maintenance check. Before

starting the engine take precautions and ensure that standby equipment like

battery, UPS are healthy and can take load, in case of SEB power failure.

2.3.5.2.6Start the Engine

Select the DG set on Auto mode.

Ensure that no person is near engine and equipment, to prevent accidents.

Check all the tools, tackles & used parts are removed.

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ANNEXURE I

D.G. SET HEALTH CHECK

ALWAYS REF THE MANUFACTURERS MANUAL AND TALK TO THE

MANUFACTURER /AUTHORISED VENDOR BEFORE ATTENDING AND ALSO SEE THE

POINTS MENTIONED IN THE FOLLOWING ANNEXURES ARE CHECKED / FOLLOWED

DURING THE ACTIVITY.

First Health check to be started at 4000 Hrs DG run. It is to continue at every 1000Hrs run.

Carry out the following activities and record the observations:

1) Date

2) Name of the City/site/Maintenance Point

3) Engine make and model

4) Engine number

5) Date of commission (to be procured from CIRCLE OFFICE)6) Hour meter readings

Intake Air System

1) Clean the air cleaner element if it is clogged or shows Red indication.

Replace if required.

2) Clean the oil type air cleaner if provided and replace oil if required.

3) Check the functioning of the vacuum indicator

4) Check the hose conditions for surface cracks and clamp tightness Replace

hose if required.

5) Check the condition and orientation of dust cap at bottom for dry type air

cleaner.

6) Open the intake manifold/suction line and clean if dust is observed inside

inlet manifold or suction hose.

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Cooling system

1) Check the coolant as recommended and coolant level.

2) Check the radiator and rectify other leakages.

3) Check all hose conditions and clamps Replace if required.

4) Visually check the radiator cap and rubber gasket. Replace if required.

5) Record the coolant gauge temperature.

6) Check the airflow across the radiator visually

7) Ensure that the radiator fins are free from dust & bends.8) Ensure proper venting.

9) Check the fan for cracks and bend. Replace if required.

10) Adjust the fan and cowl gap if required.

11)Check and tighten or replace the radiator mountings

Lubrication system

1) Change the lube oil and lube oil filter.

2) Check for leakages and rectify.3) Check & record the oil pressure at no load and at normal load (also refer

past data from site log book).

4) Lube oil consumed. (Oil top up between two immediate oil renewal)

Fuel system

1) Change the fuel filter.

2) Check the fuel hose conditions. Replace if required. Use fuel hoses of

correct length and size that are purchased from the Authorized Dealersonly. Do not reuse old copper/aluminium washers.

3) Clean the fuel strainer, breather and water collector if provided.

4) Drain fuel condensate from fuel tank drain plug.

5) Check the fuel injectors, if required.

6) Fuel consumed from B check to immediate B check. (Data SHOULD BE

available at site)

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ANNEXURE III

ENGINE MAJOR OVERHAUL

Engine health checks should be performed before and after engine major

overhaul. When the engine attains its normal running temperature, all the

parameters like temperature, speed, pressure etc. displayed on the panel board

shall be noted down. When vender recommends engine for Major overhaul

engine Health Check report shall be sent to H.O. for review and approval. In theengine major overhaul, completely dismantle the engine. Inspect and clean the

entire parts .Use chemical cleaning for engine parts cleaning. Check the

dimensions of the running parts such as piston, connecting rod, camshaft,

crankshaft, bearings etc. Check the clearances after assembling the engine and

note down the important torque values and clearances. Carry out the

overhauling, assembling and testing of the engine.

Inspect following major components.

1) Lubricating oil pump.

2) Oil cooler. Replace if required.

3) Accessory drive

4) Crankshaft and its journals.

5) Connecting rod.

6) Camshaft.

7) Cam followers if used.

8) Push rods.

9)

Rocker arm assembly.10) Injectors calibration

11) FIP calibration.

12) Compression pressure of the cylinder after assembly.

13) Starter motor overhaul

14) Battery charging alternator overhaul

15) Engine cylinder head hydro test. Cylinder block hydro test if required.

16) Servicing of the radiator.

17) Silencer and its line, internal cleaning.

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10)Check body earthing for connection tightness & record resistance value.

Automatic Voltage Regulator (AVR)

Check AVR for terminal tightness & PCB cleanliness.

AMF Panel

1) Serving and overhauling of power contactor/Air circuit breaker. Testing &

calibration of protection relay.

2) Check for control connection tightness.

3) Check for functioning of all indication & monitoring meters or panels.

4) Check power connection for tightness. Check power cable overheating,

discoloration, chafing marks.

5) Check fuses & fuse holders for contact surface & tightness.

6)

Check AMF panel earthing for tightness & record earth resistance reading.7) Check bus bar connection for tightness, overheating, chafing marks,

insulation peel off.

Documents

P1-GIPL-001