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DG Maintenance Work List and Maintenance Track Record:-Ht DG Name Plate Details
DG Maintenance Work List and Maintenance Track Record:-Ht DG Name Plate Details
HT DG commissioned on 16th May 2014 and load trail with 605 KW load for 1
hour taken and all parameters were recorded.
Model Details:
Engine:
Make
Model
Sr. No.
Cooling system
Type of coupling
Governer type
CUMMINS
QSK-60-G4
25393722
Radiator
Direct
PCC 3201
Alternator:
Make
Frame
Sr.No.
KW/KVA
Full Load Amps
AVR type
STAMFORD
MVSI80451
PI3i026450
1600/2900
485.3
PCC 3201
Control Panel:
Make
Sr.No.
Type
Swithgear
C.T.Ratio
AMF unit
POWERICER
07 PCA-A1310/1049
AMF
ABB/VCB/conserve
400/1A
VSR
LT DG commissioned on 22th April 2014 and load trail with 70 KW load for 2 hour
taken and all parameters were recorded.
Model Details:
Engine:
Make
Model
Sr. No.
Cooling system
Type of coupling
Governer type
CUMMINS
KTA-50 G3
25395844
Radiator
Closed
Electrical
Alternator:
Make
Frame
Sr.No.
KW/KVA
Full Load Amps
AVR type
STAMFORD
P1734B1
N13B051462
1000/1250
1739
PCC 3.3
Control Panel:
Make
Type
Swithgear
C.T.Ratio
AMF unit
POWERICER
AMF
ACB ABB
2000/5
MFM
General Maintenance Work list to be carried out for different check up for
both LT and HT DG are as follows:A Maintenance Checks-Daily
The A-Check covers the daily monitoring parameters that are required for
the satisfactory operation of the Diesel engine for power production. It provides a
detailed report that helps us to analysis for the fault in the event of a failure.
Comparison and intelligent interpretation of the daily report from the
parameters along with a practical follow-up action will eliminate practically all
failures and emergency repairs.
The following conditions are to be noted with caution:
1.
2.
3.
4.
5.
6.
7.
The following steps listed can avoid unnecessary risk to the engine.
1. Remove the old element gently that dirty filter carefully, until you get it
clear of the housing. Accidentally bumping it whilw still inside drops the
containment inside the housing itself leaving contamination to enter
inside the engines.
2. Always clean the inside of the housing carefully dirt left in the air
cleaner housing. Use a clean, damp cloth to wipe every surface.
3. Always clean the gasket sealing surface of the housing. Improper
gasket seal is one of the most common causes of the engine
contamination.
4. Check for uneven dirt patterns. A pattern on the element clean side is
a sign that the filter element was not firmly sealed or that a dust leak
exists.
5. Press your fresh gasket to see that it springs back to ensure proper
sealing of the filter elements.
6. Make sure that the gasket seats evenly.
7. Ensure air-tight fit on all connections and ducts.
A Maintenance Check- Weekly:
The weekly check includes the visual check of belts for looseness. If there is
evidence of belt slippage or so appropriate measures to be taken to rectify it.
The belts systems available are as follows:
B-Maintenance Checks
At each B Maintenance check, perform all the A checks in addition to
the following. This check should be carried out at every 300 hour of operation or at
every six month.
B-check interval is a very important factor in preventing the integrity of an
engine. It involves the following steps for engine maintenance.
Cooling system:
Fuel System:
-Recommended oil.
Lub oil and filter change period can be determined by laboratory tests of used
oil.
It is recommended that new engine be operated through at least one oil change
interval of 300hrs/6months.
Oil sample should be taken from each of the engines in the sub-group at
every 48-operating hour interval. The sampling intervals can be varied according to
the operational frequencies.
The oil sample can be collected by
1. Sample valve method
2. Vacuum pump method
3. Oil drain method.
Oil contamination guidelines:
Property
Viscosity change @ 100C
Fuel Dilution
Total acid number
Total base number
Water content
Potential contaminants:
Silicon(si)
Sodium(Na)
Boron(B)
Potassium(k)
Soot
Guidelines
4 cSt from new oil
5 percent
2.5 numbers increased from new oil
maximum
2.5 minimum or half original value
0.2 percent maximum
15ppm increase from new oil
20 ppm increase from new oil
25 ppm increase from new oil
20 ppm increase from new oil
1.5 % mass of used oil maximum
Coolant Specifications:
Cooling system:
Cummins engines are provided with fleet cool XB coolant Additive
concentrate-CAC and premix coolant. To ensure adequate corrosion protection,
checking coolant at every B check is essential .
CAC is available in two forms,
a) Coolant Additive , which can be mixed with water of 1:16 portion and
b) Pre-mixer coolant, which can be directly added to cooling water
system.
Coolant checking:
In normal conditions coolant checking is suggested as audit check, at every
1500 hrs/6 months during operation. During checking two coolant properties
namely coolant concentration and pH value of coolant are to be checked.
Concentration:
Done with Test kit as follows
i.
ii.
iii.
iv.
v.
pH of coolant
170ppm max
40ppm max
100ppm max
5-9
Less than 400ppm
-----Every 300Hrs/6 months.
Cooling System:
Clean Radiator/Charge air cooler externally
Fan hub, idler and water pump cleaning.
Other maintenance:
Inspect for any damages in Alternator/starter and replace.
Check air cleaner and evacuator valves.
D-Check:
Repeat A, B & C maintenance works and additional works as follows.
Fuel system:
Air System:
Clean Turbo charger, compressor wheels and diffuser if required.
Turbocharger bearings cleaning.
Tighten manifold nuts or capscews.
Cooling system:
Complete draining of coolants.
Descaling of sludge from cooling water circuit.
Other Maintenance:
Vibration damper conditions to be checked.
Air compressor and safety controls to be checked.
-----Every 6000hrs or every 2 years.
1500hrs after every D check:
Repeat all C check maintenance work.
Adjust injectors and vales if required.
Replace rocker cover gaskets.
HT DG Maintenance track record:First Free A Check---16-04-2014.
Hours=8hrs.
Engine Running
Engine
B-Check ---14-11-2014
Hours=89hrs.
Engine Running
Engine Running
A-Maintenance Check---14-08-2015.
Running Hours=170hrs.
Engine
A check weekly work done- Fan pulley and sleeve distance checked and found
ok.
Panel Replacement---25-01-2016.
Hours=208hrs.
Engine Running
Engine
Engine
Engine Running
Engine
Engine
Engine
Engine
Engine running
B-check Maintenance23-02-2016.
Running hours=1153.7hrs.
Engine
B-check maintenance03-02-2016.
running hours=1495 hrs.
Engine
Engine