Diesel Generator, Purpose
Diesel Generator, The purpose of this SOP is to describe the procedure of operation and maintenance of the 1000 KVA diesel generator which is installed in the Generator room of Solid Block of XX Pharmaceuticals Ltd.
Diesel Generator, Scope
This SOP applies to the Cummins generator of Model No.: QST30-G4 and capacity 1000 KVA which is located at General block of XX Pharmaceuticals.
Definitions / Abbreviation:
[][]EHS : Environment Health and Safety
[][]PPE : Personal Protective Equipment
[][]SOP : Standard Operating Procedure
Responsibilities:
[][]The roles and responsibilities are as follows
Engineering ( Validation) Department
[][]To prepare the SOP & revise it when necessary.
Engineering (Maintenance) Department
[][]To provide necessary support for smooth operation & maintenance of the system.
[][]To ensure that the operators are responsible to carry out the operation and maintenance work and regular checking of the critical components and logbooks.
[][]To develop a list of spare parts based on the manufacturer’s recommendations and to forward the list to the Planning and Procurement department with a request to place order as required
[][]Engage technician/mechanic/operator/supplier in repair and maintenance work
Operators
[][]To operate the generator according to the SOP.
[][]To fill up the logbooks related to the Generator.
[][]To do the maintenance according to the check list.
Procedure
Precautions:
[][]All maintenance work must be carried out safely in accordance with the requirements of the Plant Safety Requirements and the EHS safety notices must be displayed around the plant. Specific attention must be paid to the following:
[][]Personal protective equipment (PPE) and clothing appropriate to the job must be worn.
[][]Hearing protection must be used.
[][]Equipment must be electrically isolated and locked out where possible.
[][]Ensure the control panel is switched off before carrying out any check.
[][]Do not smoke when put fuel in the tank.
[][]Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place.
[][]Do not make adjustment that doesn’t understand.
[][]Do not remove the filler cap or any component of the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged.
[][]Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
[][]Use extreme care if emergency repairs must be made in adverse conditions.
[][]The fuel injector units are actuated by high pressure engine lubricating oil. Do not remove any component of the high pressure system while the engine oil is under pressure, because dangerous oil can be discharged.
[][]Maintenance activity must be carried out by trained technician/operators.
“Under Maintenance” be displayed in a prominent position on a machine, equipment or facility undergoing maintenance work.
Engine Starting Procedure
Pre-Start Check
[][]Before the engine is started the operator should understand fully the reason for the controls and their use. The following check should be done before engine start.
[][]Make a general visual inspection on the engine and alternator. Check if there is any breakage, crack, leakage or looseness.
[][]Check the battery electrolyte level-fill with distilled water as necessary.
[][]Check that there is sufficient coolant level and if necessary, add the correct coolant
[][]Check that there is sufficient lubricating oil in the sump & Viscosity and, if necessary add lubricating oil.
[][]Fill the fuel tank with fuel of the correct specification.
[][]Check the air filter and its connection.
[][]Check the all electrical connections are tight.
[][]Check the condition and tension of the fan end engine alternator belts-tighten as necessary.
[][]Check all hoses for loose connections or deterioration tighten or replace as necessary.
[][]Check the battery connection cables. Take care to tighten the loosened battery terminals with spanner and, cover with special substance and keep clean in order to avoid oxidation
[][]Take out foreign materials such as keys, tools, cleaning wool, papers etc. on the engine and the Alternator.
Engine Start
[][]Reset the emergency stop.
[][]Press the reset button.
[][]Start key turn to the “ON” Position.
[][]After start key turn to “ON” position following are checked:
[][]Check for any abnormal noise or vibration.
[][]Check for fluid leakage or leaks in the exhaust system.
[][]Check the control panel for indications of abnormal operations, particularly abnormally high temperature or low oil pressure. The oil pressure should be in the normal range within about 10 seconds of starting.
[][]Switch the alternator circuit breaker to “ON” (Handle Up).
Caution:
[][]Load can now be applied to the generating set (Normally 2-3 minutes wait from pressing the start button).
[][]The maximum step load can be 70%-100% of rated power depending on the generating set model. Typically we run 80% of rated load.
[][]Do not operate the engine at high speeds without a load.
[][]Do not overload the engine.
Engine Stopping Procedure
[][]Turn off the load by switching output circuit breaker to “OFF” (Handle Down).
[][]Allow the generating set to run without load.
[][]After 2-3 minutes the key turn to the “OFF” position.
[][]In case of an emergency where immediate shutdown is necessary, the emergency stop push button should be pushed immediately without discounting the load.
Preventive Maintenance Planning
[][]The preventive maintenance periods apply to average conditions of operation. The schedule which follows must be applied at the Interval (hours or months) which occur first.
Daily or every 20 Hours after
[][]Visually inspect engine, generator, transfer switch and Control panel.
[][]Clean the machine exterior and its surroundings.
[][]Ensure that the coolant is at the correct level.
[][]Check Oil, Water and fuel leaks.
[][]Check the amount of lubricating oil in the sump.
[][]Check the fuel level in the fuel tank.
[][]Check the lubricating oil pressure at the panel display.
[][]Battery charge level.
[][]Drain Fuel/Water separator.
[][]Inspect the engine fan blades.
[][]Inspect the drive belt.
[][]Drain water from the fuel pre-filter.
[][]Check the intercooler and the coolant radiator for debris.
Weekly Maintenance
[][]Repeat Daily Check.
[][]Fuel level in main tank.
[][]Fuel lines and connections.
[][]Adequate fresh air to engine.
[][]Check hose and connections.
[][]Battery charging alternator belts.
[][]Inspect the engine fan blades.
[][]Inspect the fan belt.
[][]Check oil level (Governor Housing).
[][]Check exhausts leakage.
[][]Tighten connections.
[][]Check Panel display.
[][]Tighten covers.
[][]Check output voltage and frequency
[][]Operation under load.
[][]No unusual sounds.
[][]Terminals and connections normal color.
[][]Doors closed securely.
Monthly Maintenance
[][]Repeat weekly check
[][]Clean the air filters.
[][]Check All fittings, Clamps, fasteners etc
[][]Check generator air outlet
After 6 Months or every 200 Hours
[][]Repeat weekly check
[][]Clean air filters
[][]Change, lubricating oil
[][]Change the lubricating oil filters.
[][]Change, lubricating oil filters
[][]Change, fuel filters
[][]Drain sediment from main tank
[][]Change, lubricating oil
[][]Check, antifreeze
[][]Governor lubricate with grease, bearing of the fan hub.
[][]Check operating alarms and safeties
After 12 Months or 800 Hours
[][]Repeat Maintenance after 200 Hours.
[][]Check and adjust if necessary, the antifreeze.
[][]Test the level of coolant conditioner and adjust if necessary.
[][]Check the condition of the drive belt.
[][]Change the engine lubricating oil.
[][]Change the canister of the lubricating oil filter.
[][]Change the air filter (or earlier if in extremely dusty conditions).
[][]Clean or renew the air filter element Check for damaged wiring or loose connections.
[][]Check radiator hoses for wear and cracks.
[][]Check exterior of radiator for obstructions.
[][]Clean engine.
[][]Generator rotor and stator with compressed air.
[][]Check water circulating pump.
[][]Check Circuit breakers and fuse holders.
[][]After 24 Months or 2,000 Hours
[][]Check the turbocharger bearing clearance
[][]Check the exhaust restriction
[][]Check the valves settings
[][]Check the injectors settings
[][]Check vibration damper
[][]Clean Turbocharger compressor wheel and diffuser.
After every 10000 hours
[][]Overhauling of full generator.
[][]Ensure that the turbocharger impeller and the turbocharger compressor casing are cleaned.
[][]Ensure that the alternator, the starter and the turbocharger are checked.
Annexure
Annexure-I: Maintenance logbook of 1000 KVA diesel generator
Annexure-II : Log sheet for 1000 KVA diesel generator