Gas Generator, Purpose:
Gas Generator, The purpose of this SOP is to define the operation and maintenance of the 1500 KW gas generator of XX Pharmaceuticals Ltd.
Gas Generator, Scope:
This SOP applies to the Cummins generator of capacity 1500 KW (Model: QST30-G4) which is located at General block of XX Pharmaceuticals Ltd.
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.
Head of Engineering
[][]To ensure that the operation and maintenance of generator are done properly.
[][]To approve any maintenance/plans related to the generator.
Head of Quality Assurance
[][]To approve this SOP
[][]To ensure overall implementation of this SOP.
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.
[][]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.
[][]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.
[][]Check whether the Gas pressure is 10 psi or not.
[][]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.
[][]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
[][]Reduce the load gradually to the range of 0 – 50 kW.
[][]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.
Maintenance Interval with Maintenance action to be taken
Daily Maintenance
[][]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 leaks.
[][]Check the amount of lubricating oil in the sump.
[][]Check the lubricating oil pressure at the panel display.
[][]Check the battery charge level.
[][]Check the air inlet filters.
[][]Drain air tank moisture and sediment.
[][]Inspect the engine fan blades.
[][]Inspect the drive belt.
[][]Check the intercooler and the coolant radiator for debris.
[][]Inspect and check the generator load and power factor.
[][]Check the voltage and frequency frequently
Weekly Maintenance
[][]Repeat Daily Check.
[][]Check Fuel lines and connections.
[][]Check for adequate fresh air to engine.
[][]Check hose and connections.
[][]Check 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.
[][]Inspect operation under load.
[][]Check for any unusual sounds.
[][]Terminals and connections normal color.
[][]Check if doors closed securely.
Monthly Maintenance
[][]Repeat weekly check.
[][]Clean the air filters.
[][]Check All fittings, Clamps, fasteners etc.
[][]Check generator air outlet.
After every 2500 Hours
[][]Tapped adjustment.
[][]Change lubricating oil.
[][]Change the lubricating oil filters.
[][]Change spin on filter.
[][]Change Air filter.
After every 16000 hours
[][]Change lubricating oil.
[][]Change the lubricating oil filters.
[][]Change spark plug cables.
[][]Clean/replace Gas filters and check/replace fuel hoses.
[][]Clean/replace air filter elements.
[][]Check for any leakage on engine, line and drains.
[][]Check crankcase venting valve and the crankcase pressure.
[][]Check/replace of all engine compensators.
[][]Check pumps and heat exchangers/radiator/cooling tower.
[][]Check engine starting battery, starting motor/starting system.
[][]Check/adjust valve clearances.
[][]Check engine safety controls, protection.
[][]Visually check turbocharger.
[][]Check push roads, cylinder head valve springs and valve heights.
[][]Check engine support, base rail level and anti-vibration pads
[][]Check air intake/exhaust system.
[][]Check engine governor.
[][]Check for any vibration or noise of engine
[][]Check cable termination.
[][]Check Genset control panel and instruments.
[][]Check performance and parameters of Genset during operation.
After every 32000 Hours
[][]Overhauling of engine
[][]Ensure that the turbocharger impeller and the turbocharger compressor casing are cleaned
[][]Ensure that the alternator, the starter and the turbocharger are checked
[][]Check the turbocharger bearing clearance.
[][]Check the exhaust restriction.
[][]Check the valves settings.
[][]Check, adjust and replace the ignition system spark plugs.
[][]Check vibration damper.
[][]Clean Turbocharger compressor wheel and diffuser.
After every 64000 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 1500 KW gas generator
Annexure-II: Log sheet for 1500 KW gas generator