Diesel Generators Annual Maintenance Contract

OBJECTIVS

1. The objective of your AMC programme is:
2. a) To obtain high equivalent availability and minimize down time.
3. b) To lower operating costs.

DG SET RESTORATION TIME

Minor breakdowns will be attended & rectified within 24 hours.

Major jobs like overhauling , rewinding of alternator will take a week or more depends

on nature of work & parts availability.

SCOPE OF WORK

The Service Engineers calling on your during the contract period will carry out.

1. All routine maintenance service, as and when it becomes due.
2. Visual inspection of the engine.
3. Inspection of the engine operation.
4. Regular maintenance checks on engine including ‘B’ & ‘C’ checks whenever these checks are due, for B and C checks, customer will ensure that necessary kits, oil and any other spares recommended, are available for use to carry out the required checks.
5. Training for your staff on operation and maintenance of the engine /DG set during Visits.
6. To carry out inspection of the said D.G. Set, to carry out minor adjustment & repairs if (any) required. To give expert advice guidance to operator for the proper maintenance & efficient working of D.G. Set.
7. Following will be checked during AMC Visit

• • a) Engine will be checked as per our standard format.
  • b) Alternator and D.G. Control Panel:

i) Insulation resistance of all the windings of the alternator twice in a year.
ii) Healthiness of the connection of AVR Assly.
iii) Cell conditions/capacity of the battery
iv) Connections and setting of the instruments such as Relays, timer etc, of the panel.
v) All relevant parameters connected with the performance of the alternator will be checked in both load and no load conditions.

8. We undertake to maintain and give you a copy of the Fields Service Reports (FSR) made by the calling service engineer, which will be a complete record of maintenance, failures / breakdowns are attended along with the effective action taken. We shall also provide recommendations for improved performance of the engine. It is the onuses of the customer comply with the recommendations as these will be based on the engine manufacture’s (Cummins) recommendations.

9. Our service engineer are equipped with all Cummins Special tools as and when required for the routine servicing or repair of the engine.
10. Battery charger & battery checking in each AMC visit.

What we do during Annual Maintenance of Diesel engine.

Engine Operating / Engine Cooling System:-

• Checking of radiator conditions (check for radiator clogging, cooling fine condition, V belts etc.
• Checking of K- cool super level, piping corrosions & any sign of radiator leaks.
• Checking of hoses & connections deterioration / wear tear.
• Checking of fan pulley misalignment / deterioration, defective bearings, corroded surface, grease condition.
• Checking the water pump leaks, noisy operation, abnormal vibration, impeller defects, cracked housing, worn out shaft etc.
• Checking of belt tension & deterioration.
• Checking air opening, obstruction, ” hot air recirculation”, corrosion / deterioration etc.
• Checking of thermostat for proper functioning.
• Checking water level sensor in radiator for DG set engines.

Engine fuel system:-

• Checking fuel lines connections (any sign of fuel leak, loose connections, corroded piping, fuel restrictions, defective clamps, deteriorated hose etc.
• Checking governors & controls condition (any sign of deterioration, loose connections & system malfunction / not responding etc.
• Checking injector nozzles condition (any sign of stocked-up, broken spring, bent rack corroded body, plugged tip, damaged tip etc.
• Checking actuator of electronic governing system.
• Checking priming pump condition.
• Checking fuel filter condition – replace the filters as found necessary.
• Checking water separator
• Checking fuel tank condition (any sign of water contamination, no water drain, corrosion / deteriorations etc.
• Checking Exhaust smoke condition to identify health of the engine.

Engine Lub System Inspection:

• Check oil lines connections any (any sings of oil leak loose connections, corroded piping, defective clamps, deteriorated hose etc,
• Checking oil pressure condition (any sing of erratic operation, defective gauge
• defective pressure sensors defective wiring harness, etc.
• Checking oil level & oil quality condition.
• Checking last oil change & oil filter replacement.
• Checking make up oil availability at site

Engine Air Induction system:

• Checking air filter indicator reading (any sing of defective sensor, erratic operation)
• Checking air filter (any sign of filter clogging, dirt accumulation, air obstruction, defective seal, damage/deteriorated housing etc.
• Checking turbocharger condition (any sign of excessive and play, oil /gas leak, abnormal operating noise, excessive vibration, overheating etc.
• Checking hoses & connections deterioration / wear & tear.
• Checking charge air cooler condition, if any sign of clogged core, fins air and leak at connection, damaged, gaskets etc.

Engine Exhaust system:

• Checking the exhaust manifold condition (any sign of leak, missing bolts and nuts, red hot manifold, oil leak, deteriorated etc.
• Checking the flexible bellow / hoses & connections deterioration / wear tear.
• Checking muffler condition (any sign of support insufficiency, corrosion, pipe valve not installed, not shielded etc,
• Checking exhaust pipe insulation condition / deterioration.
• Checking smoke emission quality (any sign of excessive black smoke, bluish smoke, white smoke, restricted gas flow etc.

Alternator & Panels: Engine Electrical system;

• Checking batteries condition (electrolyte level distilled water level, defective plate, voltage drop during cranking-refer to manufacture acceptable voltage drop, etc/ battery capacity evaluation this can be done by battery discharge test, replacement of batteries is to be planned
• Checking the starting motor condition (any sign defective solenoid defective brushes, grounded / shorted connection, struck up rotor etc.
• Checking the wiring harness condition (any sign of defects, grounded, loose connections, shorted, open circuit any deterioration.
• Checking the charging alternator condition.
• Checking control wiring terminal connections (any sign of corrosion, loose connections, terminal lugs deterioration etc.

Generator Control Panel system Inspection:

• Checking start /stop/ manual switch condition & functionality.
• Checking voltmeter / ammeter, frequency meter for proper functionality.
• Checking contactor ACB for proper functioning / operations.
• Checking wiring termination for proper tightness.
• Checking indicating lamps for proper functioning.
• Checking if fault /tripping circuit are working satisfactory.

Acoustic:

• Checking if doors are closing properly.
• Checking if there is no blockage of air from rear ducts.
• Checking if the front opening is directing the hot air outside room.
• Checking if the canvas fitted to radiator is intact with no return hot air recirculation.
• Checking indicating lamps for proper functioning.
• Checking for any loose bolts on the Acoustic Enclosure and tighten.TRIRATNA