MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASKS 084 091 1. 1.1

DIESEL GENERATOR SETS TASK INSTRUCTIONS

1.2

1.3

1.4

HEALTH & SAFETY Comply with any warning notices or site restrictions identified within the site safety plan held by the responsible person, and with any other specific or temporary hazards identified during site induction/at time of visit. Be aware of the hazards associated with diesel generator sets, e.g. automatic starting, noise, moving parts and surfaces at high temperature. Under no circumstances must any attempt be made to carry out any work not specified within this instruction without first obtaining a valid Standing instruction or Permit to Work from the responsible person. Operatives should be aware of the hazards associated with batteries, e.g. electric shock, explosion from charging gases, short circuit from metallic objects, and electrolyte spillage; also the dangers of compressed air systems, and use appropriate PPE. A specific risk assessment, to satisfy The Management of Health & Safety at Work Regulations 1999, must be carried out. Due consideration to this and any other statutory regulations e.g. COSHH 1999, Manual Handling Reg's 1992. Etc. must be made prior to carrying out any task detailed below. Risk assessments are to be carried out by the operatives employer. Relevant PPE shall be used as indicated by risk assessments. GENERAL REQUIREMENTS Liase with the building manager before starting and finishing work, particularly regarding interruptions to the normal building electrical supply during on-load test runs. Wherever possible the operating and maintenance instructions provided by the machine manufacturer shall be followed. Where there is a difference between these instructions and those of the manufacturer, the latter shall take precedence. The work described in these tasks is only to be undertaken by suitably skilled and experienced operatives having the correct knowledge and equipment to perform this task. Test runs shall be alternated between off-load and on-load. Where problems are experienced in obtaining client agreement to on-load test runs, resulting in frequent off-load test runs, it shall be reported to the responsible person. All measuring equipment shall have a current certificate of calibration: Certificate No shall be written on PPM work sheet. The attached Diesel Generator Logbook Sheets apply. Where possible operating parameters have been included, however it is the Responsible responsibility to insert in the Log Sheets those parameters applicable to their specific systems. Also any parameter that does not apply to a specific system is to be deleted from the Log Sheet before issue. A copy of the Task Instructions is to be kept with the Logbook for information. Log Book Defect Sheet This is to be included at the front of the Log Book and completed on each occasion a defect is located and repaired whether within the Contract Lump Sum or not. Checklist 1 relates to the task 084 Checklist 2 relates to the task 085 Checklist 3 relates to the task 086 Checklist 4 relates to the tasks 087 and 091 Checklist 5 relates to the task 088 Checklist 6 relates to the task 089 Checklist 7 relates to the task 090 The attached Checklists are to be included on the Work Docket issued to the craftsman. The sub-contractor shall supply all water treatment chemicals and lubricating oil associated with these tasks Record all inspection findings. All items requiring repair shall be listed on the PPM work docket, any repairs carried out under the Contract Lump Sum shall be indicated as complete, any other items in this category requiring shut downs or spares shall be carried out following agreed procedures. Any deviation from accepted operation or any defects considered to present a safety hazard shall be reported to the responsible person, who will advise the client as required. The attached task instructions highlight the basic elements that should be carried out as a minimum requirement. The sub-contractor may adopt these instructions or submit there their own method statements for approval. The task instructions provided are generic in form and will require modifying to suit specific equipment/systems being maintained. It should be noted that the full requirements of the relevant reference documents must be complied with; the list provided here is not exhaustive. Lead reference documents: Page 1 of 12

2. 2.1 2.2

2.3 2.4

2.5 2.6

2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18

2.19

TASK GROUP 18

MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK INSTRUCTIONS

PSA MEEG Vol. 5 Sections 21:1984 CIBSE Applications Manual: AM8 1992 - Private and Standby Generation of electricity, BS 4999-140:1987 General requirements for rotating electrical machines. Specification for voltage regulation and parallel operation of a.c. synchronous generators. BS 7698-3:1993 Reciprocating combustion engine driven alternating current generating set. Specification for alternating current generator for generating sets. BS EN 60034-22: 1998 Rotary electrical machines. AC generators for rating internal combustion engine driven generating sets. HSG176 The storage of flammable liquids in tanks HSG85 Electricity at work-Safe working practices 1993 HSR25 Memorandum of guidance on the Electricity at Work Regulations 1989. Guidance on Regulations Electricity at Work Regulations 1989 INDG139 Electric storage batteries. Safe charging and use. HSG39 Compressed Air safety.

Task Numbers AD-PPM 084-091 to be shown on all PPM dockets as appropriate *Mandatory Frequencies to individually assessed per site, approved through Authorising Engineers * Table below guideline only.
Item Description Task No 84 Task Lead Ref. CIBSE AM8 CIBSE AM8 Status Frequency Remarks

DIESEL GENERATOR SETS

Check state of readiness (battery, heater, oil, water, etc) Check oil, water, filters, heaters, pipework, controls; run off and on load 6 monthly/500 hour checks and maintenance Annual maintenance

Mandatory

2 WEEKLY (2W)

85

Mandatory

MONTHLY (M)

If dummy load used, check monthly on live load

86

CIBSE AM8 CIBSE AM8 CIBSE AM8 CIBSE AM8 CIBSE AM8 CIBSE AM8

Mandatory

6 MONTHLY (6M) ANNUALLY (1Y)

Use manufacturers recommendations Use manufacturers recommendations Use manufacturers recommendations Use manufacturers recommendations Use manufacturers recommendations

87

Mandatory

88 89

2 yearly/1500 hour maintenance 4 yearly/2000 hour maintenance

Mandatory Mandatory

2 YEARLY (2Y) 4 YEARLY (4Y)

90

Major overhaul

Mandatory

8 YEARLY (8Y)

91

Test operation of interlocks and simulate mains failure

Mandatory

ANNUALLY (1Y)

TASK GROUP 18
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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK INSTRUCTIONS

TASK 084 (2W) CHECK STATE OF READINESS (BATTERY, HEATERS, OIL WATER ETC.) PROCEDURES 1. Check the following items at every visit: a) b) c) d) e) f) g) h) Sufficient fuel within the engine daily service fuel tank Adequate lubricating oil within the engine sump Correct level of cooling water in the engine cooling system That pre-heaters where fitted are energised and operational Check no visible oil, water, and air leaks on engine or surrounding pipework. Check that phone where fitted operates correctly. Carry out lamp test on control panel, replace lamps as required. Check Buckholtz not operated where warning lights fitted

2. Check the engine starting system is functional as follows: Electrical start systems Check, where appropriate that the battery is under trickle charge, and that the level of charge is adequate. Check that the level of battery electrolyte is within the permitted upper and lower levels. Where the electrolyte has to be topped up, measure the specific gravity of the battery after a reasonable period of charge. Air start systems Check that the air receiver is charged and that for signs of air leaks from either the receiver or the associated pipework. Where non-automatic drain valves are fitted, drain off the air receiver to remove any water from base of vessel. Bleed off sufficient stored air to reduce the receiver pressure to check that the air compressor starts and operates to restore working pressure.

TASK GROUP 18
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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK INSTRUCTIONS

DIESEL GENERATOR SETS TASK 085 (M) CHECK OIL, WATER, FILTERS, PIPEWORK AND CONTROLS. RUN SET BOTH ON AND OFF LOAD PROCEDURES 1 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Carry out the checks detailed within task 84 Carry out the following additional checks: Check all pipework and radiators and coolers for signs of leakage or corrosion. Check radiators for cleanliness of airways. Check, where fitted, air cleaner restriction indicators. Inspect control dampers and shutters for freedom of action Inspect the oil level in a pedestal bearing and verify that any oil rings are rotating freely. TEST RUN OFF LOAD Lock off the generator output circuit breaker/load isolator. Start the set by switching to hand control and manually starting the set or by other appropriate means. Run the set on no-load for a maximum period of 20 minutes or as specified by the manufacturer. Record all operating parameters of the engine; e.g. oil pressure, coolant temperature etc., cylinder water temperature, exhaust gas temperature Record hours run from meter, if no meter record time run. Record exciter and output voltage when generator running Check where fitted that start warning device operates On completion of the test run take final engine operating readings and then shut down the engine. After a period of at least 30 minutes engine cooling time, check and top up as required engine fuel, lubricating oil and coolant. TEST RUN ON LOAD Obtain the client permission and agreement of Air Traffic Control when appropriate as to the date and time to start and end the test run. Check the load shedding switch is in the correct position, and that the Buckholtz relay has not operated. Start the set by simulating a mains failure, either by operating the test facility or by withdrawing a phase failure relay fuse. Measure and record the time taken from start command to engine taking up load. Where this exceeds the period stated on the commissioning data by 10% advise the responsible person. Run the set on load for a minimum period of 2 hours unless otherwise stated by the manufacturer/client/ responsible person. After 15 minutes operation and then at 1 hour intervals during the remainder of the test run, record all operating parameters of the engine, e.g. oil pressure, coolant temperature, cylinder water temperature, exhaust gas temperature etc. Report any unusual readings, noise, vibration etc. to the responsible person. Record time of start and completion of run. Record time to changeover at start and completion of run. Record hours run from meter, if no meter record time, run. Record electrical output readings initially at 15 minute intervals for the first 30 minutes, and each 30 minuets there after, e.g. exciter and output voltage KWh, Amps/phase, Voltage, frequency, when generator running On completion of the test run, take final engine operating readings and then shut down the engine. After a period of at least 30 minutes engine cooling time, check and top up as required engine fuel, lubricating oil and coolant.

4 4.1 4.2 4.2

4.3 4.4

4.5 4.6

4.5

TASK GROUP 18
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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK 086 (6M) 6 MONTHLY/500 HOUR CHECKS & MAINTENANCE PROCEDURES 1 2 3 (a) (b) (c) (d) (e) (f) (g) (h)

DIESEL GENERATOR SETS TASK INSTRUCTIONS

(i)

Carry out the checks detailed within tasks 84, and 85. Carry out manufacturers recommended maintenance items for 6 monthly (standby generating sets) or 500-hour (base load generating sets) service requirements. In the absence of the makers criteria the following limits should be observed. The difference between individual cylinder water outlet temperatures should not exceed 5oC. An individual cylinder exhaust temperature should not vary by more than 30oC from the mean for all cylinders. The mean of all cylinder exhaust temperatures should not exceed the mean of temperatures shown on the commissioning test sheet by more than 40oC for a similar load. The difference between cooling water inlet and outlet temperatures should not exceed 10oC. The cooling water outlet temperature should not exceed 90oC. (Except for high temperature pressurised cooling systems). The lubricating oil pressure should not vary from the figure shown on the commissioning test sheet by more than 10%. The temperature of the lubricating oil leaving the engine should not vary from the figure shown on the commissioning test sheet by more than 10oC for the same load. Inspect the Engine Heating on non-running sets. Record the temperatures indicated by thermometers fitted in the engine cooling and lubricating oil systems. The thermostat controlled heaters in an engine cooling water or lubricating oil system should be set to operate at 7oC when fitted for frost protection or 38oC when fitted for rapid starting purposes. The stator current shall not exceed the rated value in any phase. The degree of imbalance between stator currents shall not exceed that permitted by the generator manufacturer and

I max I min should not in any case exceed 0.15. I max

(j)

(k)

The generator is to be maintained within + or - 5% of the rated voltage and when on AVR control within + or 2 1/2% of the set value. After any change of load, the voltage excursion and the time to return to + or - 3% are not to exceed the limits stated in BS4999 Part 40 Table 40.36 for the class of AVR provided. The voltage overshoot on starting is not to exceed 15% of the rated voltage and is to return to the rated voltage within 3 seconds. Rotor current shall be within the limits allowed by the generator manufacturer whether in the form of a capability diagram or otherwise. Generators are not to be operated at leading power factors, when operated in parallel with the Electricity Authority Supply (EAS) or other generators.

TASK GROUP 18
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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK 087 (1Y) ANNUAL MAINTENANCE PROCEDURES

DIESEL GENERATOR SETS TASK INSTRUCTIONS

1. Carry out manufacturers recommended maintenance items for annual service requirements. 2. In the absence of the makers criteria the following should be observed. (a) Test the indicator lamps by operation of the lamp test switch, where available, OR by removing the lamps from the panel and testing in a lampholder on a supply of suitable voltage, OR by temporarily energising each lamp from its normal supply in a safe manner. Replace defective lamps and every three months all continuously burning lamps. (b) Test audible alarms by operating the "Audible Alarm Test Switch", OR simulate an alarm condition by manually operating a sensing device, e.g. float switch. See that the audible alarm is silenced by operating the "Audible Alarm Silenced Switch" where provided (c) Inspect control and synchronising panels. See that the control panel is free from defects such as burnt contacts, loose connections; signs of overheating or burning; dust accumulation. (d) Test the earth fault indication on the Electrical Distribution Control Unit (EDCU), by earthing in turn the Link Disconnecting Unit terminals, observing if the Earth fault lamp lights in each case. (e) Check that where an auto run on system is fitted for cooling down purposes that it operates after switching off the load for the correct amount of time. (f) Check that there are no systems locked out on High Temperature before leaving the generator station. 3. Carry out the checks detailed within task 84, task 85 and task 86 on completion of maintenance

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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK 088 - 2 YEARLY/1500 HOUR MAINTENANCE PROCEDURES 1 2 Carry out the checks detailed within task 87.

DIESEL GENERATOR SETS TASK INSTRUCTIONS

Carry out manufacturers recommended maintenance items for two yearly (standby generating sets) or 1500 hour (base load generating sets) service requirements. Carry out the checks detailed within task 84, task 85, and task 86, on completion of above maintenance.

TASK GROUP 18
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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK 089 - 4 YEARLY/2000 HOUR MAINTENANCE PROCEDURES 1 2

DIESEL GENERATOR SETS TASK INSTRUCTIONS

Carry out the checks detailed within task 87 and task 88. Carry out manufacturers recommended maintenance items for four yearly (standby generating sets) or 2000 hour (base load generating sets) service requirements. 3 Obtain a sample of lubricating oil from the engine sump and send for analysis. An analysis should be made including the following: (a) Specific gravity (b) Total base number (c) Insolubles (d) Water content (e) Viscosity (f) Flash point 4 A full report of the condition of the oil should be obtained including a recommendation as to whether the oil should be changed or not, and based on hours run an approximate run period until an oil change is required. 1. TEST THE OPERATION OF ENGINE PROTECTION CIRCUITS. (a) Automatic Starting - Either disconnect the electric start motor at the starter control or turn off the compressed air supply to the engine air start control. Initiate the start signal. Note and record the number of automatic attempts to start and the time taken from the initiation of the start signal to the automatic locking out of the engine. Confirm that the 'Engine failed to start'/'Engine locked out' alarms/indicating lights are operating correctly. (b) Low Engine Speed - Before commencement of the test de-energise the excitation system by opening the switch on the excitation panel or removing fuses, as appropriate. In cases where switches or fuses are not provided, e.g. some brushless or static excitation systems, reference should be made to the maker's handbook and wiring diagram to determine how de-energising may be affected. If in doubt, the advice of the maker should be obtained. Start the engine. Slowly wind the governor down and using a hand tachometer, measure the speed at the 'Low Engine Speed' switch contacts close and verify that the low engine speed alarm operates (where applicable). Reset the governor, the excitation system and the trip. (c) High Engine Speed - Start the engine and manually override the governor to obtain the overspeed condition but the utmost care must be exercised to prevent the engine 'running away'. It is pointed out that without the controlling effect of the governor, an engine can race itself to destruction in a very few seconds. With the engine running and unloaded, measure, with a calibrated hand tachometer, the speed at which the electrical overspeed device operates by VERY SLOWLY increasing the speed towards the engine safe maximum speed. Do not exceed the normal running speed plus 15% (i.e.......rpm). Verify that operation of the overspeed device trips the engine. Reset the trip. Where an engine is provided with both electrical and mechanical overspeed protective devices, the former should be set to trip at 12% above normal running speed with the mechanical trip set at 15% above normal running speed. (d) Low Oil Pressure - With the engine running, test the low oil pressure indication and alarm circuit by bridging the contacts on the low oil pressure switch. Repeat the tests for the low oil pressure shut down circuit. (e) High Temperature Sensors (i) For an air-cooled engine, run the engine until it is running at approximately normal operating temperature. Test the cylinder high temperature engine shut down, alarm and indication circuits by lowering the set value of the cylinder high temperature thermostat to the normal operating temperature of the engine. Reset the thermostat to the correct value. (ii) For a water cooled engine, test the cooling water high temperature shutdown, alarm and indication circuits by running the engine and lowering the setting of the high temperature thermostat to the normal working temperature of the engine cooling water. (iii) Reset or reinstall the high temperature thermostat as appropriate. (f) Low Temperature Sensors - Test the operation of a frost warning alarm and indication circuit by either raising the set value of the thermostat to the engine room temperature OR by bridging the thermostat contacts, where the thermostat is of the pre-set type.

TASK GROUP 18
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MANAGEMENT OF PLANNED MAINTENANCE

(g)

DIESEL GENERATOR SETS TASK INSTRUCTIONS

Cooling Water Flow - With the engine running test the indication, alarm and the engine shut down circuits for cooling water flow failure, by closing the valve in the engine cooling water system. On completion of the test open the valve. (h) Emergency Stops - With the engine running, test the emergency stop indication, alarm and engine shutdown circuits by operating the emergency stop button. Reset the emergency stop button, where appropriate. (i) Other Protection Devices - Test any other protection device in accordance with the maker's instructions. 2. Automatic Running/Standby Operation - On a multiset installation, which is arranged for automatic starting and automatic synchronising, complete the tasks (a) to (i) above on each engine in turn before commencing further. With all sets synchronised and on load and with EAS disconnected, apply in turn each of the below mentioned fault conditions to the set which has its neutral connected to Earth. Apply each fault condition to each of the other sets in turn. Note the behaviour of all sets as each fault is applied. (a) Alter the normal set value of the lubricating oil low-pressure switch to the operating pressure of the engine. (b) (c) Verify that the following sequences occur after the application of each fault condition (a) & (b): (i) The engine shuts down. (ii) The alternator circuit breaker and field contactor associated with the set being tested that both trip. (iii) The secondary load shedding operates (if applicable). (iv) The other set(s) continue in operation and the appropriate set has its neutral connected to earth. (v) The respective alarms operate. (vi) On completion of the above start the engine which has been shut down, synchronise the set manually, cancel the secondary load shedding, adjust the load sharing and reset the selector switch(s) on the automatic synchronising panel to 'AUTO'. With all sets stationary and EAS normal apply in turn each of the below mentioned fault conditions to the set which has its neutral connected to Earth. Apply each fault condition to each of the other sets in turn. Note the behaviour of all sets as each fault is applied. The fault conditions are: (d) Disconnect the field contactor coil and simulate an EAS failure. Verify after application of fault condition (i) To the duty set that its alarm 'Set failed to synchronise' operates. (ii) The next set in the selected sequences automatically runs up, takes load and has its neutral connected to Earth. (iii) The time taken from initiation of EAS simulated failure to the second machine taking load. (e) With each engine on 'Auto', turn off the air supply or electricity supply to the starter motor as appropriate and simulate an EAS failure. Verify after application of fault condition (i) That the set attempts to start followed by initiation of the alarm 'Set failed to start'. (ii) The time taken from initiation of EAS simulated failure to the initiation of the alarm. (iii) That the next set in the selected sequence automatically runs up, takes load and has its neutral connected to Earth. On completion of the above ensure that all items altered for test purposes have been restored to the correct condition i.e. valve positions, set values of pressure switches, thermostat etc., contactor coil connections. Test run the complete installation. The engine protective devices and circuits are to operate as recorded when the set was commissioned, or within the tolerances laid down by the maker. 3. Carry out the checks detailed within task 84, task 85, and task 86, on completion of above maintenance

TASK GROUP 18
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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK 090 (8Y) MAJOR OVERHAUL PROCEDURES 1 2 3

DIESEL GENERATOR SETS TASK INSTRUCTIONS

Carry out the checks detailed within tasks 87 task 88 and task 89. Carry out manufacturers recommended procedures for a major overhaul of the generating set. Carry out the checks detailed within task 84, task 85, and task 86, on completion of the above maintenance.

TASK GROUP 18
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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK INSTRUCTIONS

DIESEL GENERATOR SETS TASK 091 (1Y) TEST OPERATION OF INTERLOCKS AND SIMULATE MAINS FAILURE PROCEDURES 1. Obtain the client permission and agreement of Air Traffic Control when appropriate as to the date and time to start and end the test run. 2. Carry out the checks detailed within task 84, task 85, and task 86, 3. Run the set on load for a minimum period of 2 hours unless otherwise stated by the manufacturer/client/ responsible person. 4. Refer to the system operating handbook for detailed procedures to be followed when carrying out his task. 5. Single Set Engine Control and Synchronising Systems (a) Set the control selector switch(s) on the engine control panel to MANUAL/LOCAL as appropriate, and test the starting of the engine. When the engine has reached full speed, operate the MANUAL/LOCAL stop push button. (b) Set the control selector switch(s) to the 'REMOTE' position, where appropriate, and start the engine from the remote position. When the engine has reached full speed, operate the emergency stop push button. (c) Where applicable, confirm that any manually operated generator circuit breaker is closed. Set the control selector switch(s) to 'AUTO' and operate the 'TEST START' push-button (if available), OR set the control selector switch(s) to 'AUTO' and simulate an EAS failure by EITHER operating the test switch OR withdrawing the EAS failure detector fuse (this is normally the fuse protecting the phase failure relay). Record the time taken from the initiation of the start signal to the set taking load. (i) If the control requires a manual return to EAS, trip the standby supply and restore the EAS. (ii) If the control allows automatic synchronising, confirm that after restoration the set synchronises with the EAS, the bus section circuit breaker opens and the set shuts down. Measure the time taken to resume supply on EAS return, e.g. the time taken from replacement of the phase failure relay fuse to final closure of EAS circuit breaker or contactor. (d) On completion of the tests restore the selector switches to the required position. 6. Multiset Engine Control and Synchronising Systems. (a) Test each set individually in accordance with procedure for (4.) above. (b) Where applicable, confirm that any manually operated generator circuit breaker is closed. (c) On each engine starting/control panel set the control selector switch to 'AUTO' and the duty selector switch to give the required sequence of starting of the sets. Confirm that the bus section circuit breaker is open and that the generator busbar is de-energised. Confirm that the EAS circuit breaker is closed and that the EAS/load busbar is energised. (d) To test the sequence operation of the engine starting/control panels and the automatic synchronising panel set the control selector switches to 'AUTO' and operate the 'TEST START' push-button (if available) OR set the control selector switch(s) to 'AUTO' and simulate an EAS failure by EITHER operating the test switch OR withdrawing the EAS failure detector fuse. Record the time taken from initiation of the start signal to the sets taking load. (e) If the control requires a manual return to EAS, trip the standby supply and restore the EAS. If the control allows automatic synchronising, confirm that after restoration the sets synchronise with the EAS, the bus-section circuit breaker opens, and the sets shut down in sequence. Measure the times taken to resume supply on EAS return, e.g. the times taken from replacement of the phase failure relay fuse to final closure of the EAS circuit breaker and to each set coming to rest. (f) On completion of the tests restore the selector switches to the required positions. 7. Check that all alarms and display indicators correctly function 8. Check that an engine test start functions correctly - the set starts generates voltage and shuts down again automatically. (a) Set the generator selector switch on control panel to Hand operation. (b) Press the Start push button and check that the set starts and attains normal speed and voltage. (c) Operate the Close Standby CB button and check that the standby set takes the load (d) Inspect load shedding unit to confirm that the loads have been shed.

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MANAGEMENT OF PLANNED MAINTENANCE

DIESEL GENERATOR SETS TASK INSTRUCTIONS

(e) Operate the Trip Standby push button on control panel in sub-station. (f) Check that the standby set CB trips. 9. Start the set by simulating a mains failure, either by operating the test facility or by withdrawing a phase failure relay fuse. Measure and record the time taken from start command to engine taking up load. Where this exceeds the period stated on the commissioning data by 10% advise the responsible person. 10. On a fully automatic set, the time delay for resumption of EAS is to be within + or - 10% of the set time. 11. Upon completion of tests, check and verify that all controls etc. have been reset to their normal operating positions and that the generating set is ready for automatic operation. 12. After 15 minutes operation and then at 30 minute intervals during the remainder of the test run, record all operating parameters of the engine, e.g. oil pressure, coolant temperature etc. Report any unusual readings, noise, vibration etc. to the responsible person. 13. On completion of the test run, take final engine operating readings and then shut down the engine. After a period of at least 30 minutes engine cooling time, check and top up as required engine fuel, lubricating oil and coolant

TASK GROUP 18
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Establishment_____________________ Location_________________________ Area Covered Frequency- (2W) AS Required Record S/NS. NS record action taken Record any defects here: -

Task Group 18 Diesel Generator Sets Checklist No1 Tasks-084

Date-Week Comm. Week No. (2W) Check state of readiness (battery, heater, oil, water, etc) Log Book Sheets Completed in Generator House No.
Generator No. Engine readiness checks carried out and log book completed Electrical Engine Start system checked Compressed Air Engine start system checked Generator No. Initials

Issue: 1 Rev:0

29/04/03

Establishment_____________________ Location_________________________ Area Covered Frequency- (M)(AR) Record S/NS. NS record action taken Record any defects here: -

Task Group 18 Diesel Generator Sets Checklist No2 Tasks-085

Date-Week Comm. Week No. (M) Check oil, water, filters, heaters, pipework, controls; run off and on load Log Book Sheets Completed in Generator House No.
Generator 2W (AR) checks carried out All pipework, radiators etc. checked for leakage corrosion Radiator external surfaces clean, no blockages. Air cleaner indicators where fitted Control dampers and shutters, freedom of movement. Pedestal bearing oil level checked and oil rings free to rotate. TEST RUN OFF LOAD-Complete Log Sheet After 20 mins record engine operating conditions Check start warning device where fitted operates 30 mins after stop top up as required fuel, lub oil and coolant. TEST RUN ON LOAD-Complete Log Sheet Client permission obtained, test start and end times agreed. Check load shedding switch and Buckholz relay in correct positions Start set by simulating mains failure. Record time taken form start command to load taken up. Run for Minimum of 2hrs recording operating parameters every 15 mins. Record start and end times of run. Record time to changeover back to mains. 30 mins after stop top up as required fuel, lub oil and coolant. Initials

Issue: 1 Rev: 0

29/04/03

Establishment_____________________ Location_________________________ Area Covered Frequency- (6M) Record S/NS. NS record action taken Record any defects here: -

Task Group 18 Diesel Generator Sets Checklist No3 Tasks-086

Date-Week Comm. Week No. (6M) 6 monthly/500 hour checks and maintenance. To be carried out wherever possible during on load run. Log Book Sheets Completed in Generator House No.
Generator 2W checks carried out M checks carried out Difference between individual cylinder water o outlet temps should not exceed 5 C. Individual cylinder exhaust temps should not vary o by more than 30 C from the mean for all cylinders. The mean of all cylinder exhaust temps should not exceed the mean of temps shown on the commissioning test sheet by more than 40oC for a similar load. The difference between cooling water inlet and o outlet temps should not exceed 10 C. The cooling water outlet temp should not exceed 90oC. (Except for high temp pressurised cooling systems). The lub oil pressure should not vary from the figure shown on the commissioning test sheet by more than 10%. Engine Heating on non-running sets. Record the temps indicated on the engine cooling and lub oil systems. The heater thermostats should be set to o operate at 7 C when fitted for frost protection or o 38 C when fitted for rapid starting purposes. Initials

The stator current shall not exceed the rated value in any phase. The degree of imbalance between stator currents shall not exceed that permitted by the generator

manufacturer and not in any case exceed 0.15.

should

The generator is to be maintained within + or 5% of the rated voltage and when on AVR control within + or 2 1/2% of the set value. After any change of load, the voltage excursion and the time to return to + or - 3% are not to exceed the limits stated in BS4999 Part 40 Table 40.36 for the class of AVR provided. The voltage overshoot on starting is not to exceed 15% of the rated voltage and is to return to the rated voltage within 3 seconds. Rotor current shall be within the limits allowed by the generator manufacturer whether in the form of a capability diagram or otherwise. Generators are not to be operated at leading power factors, when operated in parallel with the Electricity Authority Supply (EAS) or other generators.

Issue: 1 Rev: 0

29/04/03

Establishment_____________________ Location_________________________ Area Covered Frequency- (1Y) Record S/NS. NS record action taken Record any defects here: -

Task Group 18 Diesel Generator Sets Checklist No4 Tasks-087 and 091

Date-Week Comm. Week No. To be carried out wherever possible during on load run (1Y) Annual maintenance (1Y) Test operation of interlock and simulate mains failure. Log Book Sheets Completed in Generator House No.
Task 87 Test indicator lamps; replace any defective and any continuously operating lamps. Test audible alarms Inspect control and synchronising panels any defects. Test earth fault indication on the Electrical Distribution Control Unit. Check any auto run on systems fitted for cooling down purposes after shut down operate for the correct amount of time. Check no systems locked out on High Temperature before leaving system On completion of above Tasks carry out tasks below 2W checks carried out M checks carried out 6M checks carried out Task 091 Test operation of interlocks and simulate mains failure Carry out tests as detailed in Task Instruction Generator Initials

Issue: 1 Rev: 0

29/04/03

Establishment_____________________ Location_________________________ Area Covered Frequency- (2Y) Record S/NS. NS record action taken Record any defects here: -

Task Group 18 Diesel Generator Sets Checklist No5 Tasks-088

Date-Week Comm. Week No. (2Y) 2 yearly/1500 hour maintenance Log Book Sheets Completed in Generator House No.
Generator 1Y checks carried out Carry out manufacturers recommended maintenance items for two yearly (standby generating sets) or 1500 hour (base load generating sets) service requirements. On completion of above Tasks carry out tasks below 2W checks carried out M checks carried out 6M checks carried out Initials

Issue: 1 Rev: 0

29/04/03

Establishment_____________________ Location_________________________ Area Covered Frequency- (4Y) Record S/NS. NS record action taken Record any defects Overleaf Date-Week Comm. Week No. (4Y) 4 yearly/2000 hour maintenance Log Book Sheets Completed in Generator House No.

Task Group 18 Diesel Generator Sets Checklist No6 Tasks-089

Generator 1Y checks carried out 2Y checks carried out Obtain lub oil sample and send for analysis. Change oil as advised. Test Operation of Engine Protection Circuits (a) Automatic Starting (b) Low Engine Speed (c) High Engine Speed (d) Low Oil Pressure (e) High Temperature Sensors. (f) Low Temperature Sensors

Initials

(g) Cooling water Flow (h) Emergency Stops (i) Any other Protection devices. (State device) With set synchronised and on load and with EAS disconnected, apply in turn each of the fault conditions to the set having its neutral connected to Earth. Note the behaviour of set as each fault is applied. Where multiple sets apply to all in turn (a) Alter the normal set value of the lubricating oil low-pressure switch to the operating pressure of the engine. (b) Alter the normal set value of the cooling water high temperature thermostat to the operating temperature of the cooling water. Verify that sequences occur after the application of each fault condition (a) & (b) as identified in task instruction With set stationary and EAS normal apply fault conditions to the set having its neutral connected to Earth. Apply fault conditions to set. Note behaviour of set as fault conditions applied: (a) Disconnect the field contactor coil and simulate an EAS failure. (b) With each engine on 'Auto', turn off the air supply or electricity supply to the starter motor as appropriate and simulate an EAS failure. Verify that the conditions occur after application of each fault condition (a) & (b) as identified in task instruction On completion of above Tasks carry out tasks below 2W checks carried out M checks carried out 6M checks carried out

Issue: 1 Rev:0

29/04/03

Establishment_____________________ Location_________________________ Area Covered Frequency- (8Y) Record S/NS. NS record action taken Record any defects here: -

Task Group 18 Diesel Generator Sets Checklist No7 Tasks-090

Date-Week Comm. Week No. (8Y) Major overhaul Log Book Sheets Completed in Generator House No.
Generator 1Y checks carried out 2Y checks carried out 4Y checks carried out Carry out manufactures recommendation for a major overhaul On completion of above Tasks carry out tasks below 2W checks carried out M checks carried out 6M checks carried out Initials

Issue: 1 Rev: 0

29/04/03

Log Book Page Defect Sheet

Date Defect Remedial Action Taken Initials

Maintenance Log Book Page

For Standby Generators Location

MOD Tasks As Below See Task instructions for Task Group 18 Frequency See Below

NOTES

1. 2.

Enter in the appropriate column below S for satisfactory, N/S for not satisfactory or a measurement. Record overleaf as appropriate:(a) Details of defects and remedial action taken, note when a defect occurs before the part concerned has had a reasonable life (b) Any major change in the trend of the measurements recorded below, together with the reason.

Month

Task Instruction Procedure

Task 84 Check State of readiness (battery, oil, water etc.) Task 85 Check Oil, Water, Filters, Heaters, Pipework, Controls. Run off and on load.
Monthly

Date

2 Weekly

Initials

G18/LBT84-85 Issue 1 Rev 0

28/03/2003

Operational Log Book Page

For Job Standby Generators Run Set Both On and Off Load

Location: ... Generator:.........................................................................

MOD Task No 85 Electrical See Task Instruction for Task Group 18 Frequency Monthly or As Required

Date Time Hours Run Generator Frequency Generator RPM Generator Volts R Generator Current Y B Generator KW Power Factor Field Current Field Voltage

Record Below any Notes or comments. Date/Time Date/Time

Date/Time

Date/Time

Date/Time

G18/LBT85 Electrical Issue:1 Rev: 0

29/04/03

Operational Log Book Page

For Job Standby Generators Run Set Both On and Off Load

Location: . Generator:.........................................................................

MOD Task No 85 Mechanical See Task Instruction for Task Group 18 Frequency Monthly or As Required

Date Time Hours Run Oil Pressure Oil Temperature In Oil Temperature Out Water Temperature In Water Temperature Out Water Temperature In Water Temperature Out

A Bank A Bank B Bank B Bank 1 2 3 4 Exhaust Temperatures A Bank 5 6 7 8 1 2 3 4 Exhaust Temperatures B Bank 5 6 7 8 Turbo Charger Pressure Free End A Turbo Charger Pressure Free End B Turbo Charger Pressure Fly End A Turbo Charger Pressure Fly End B Fuel Meter Reading galls/litres Tank 1 Tank 2 Tank 3 Fuel Tank Readings Tank 4 Tank 5 Tank 6

G18/LBT85 Mechanical Issue: 1 Rev:0

29/04/03

Operational Log Book Page

For Job Standby Generators Run Set Both On and Off Load

Location: .. Generator:.........................................................................

MOD Task No 85 Small Sets See Task Instruction for Task Group 18 Frequency Monthly or As Required

Date Time Hours Run Oil Pressure Oil Temperature Water Temperature Fuel Meter Reading galls/litres Fuel Tank Contents

Generator Frequency Generator RPM R Generator Current Y B Generator Volts Generator Power Factor Generator KW

Record Below any Notes or comments. Date/Time Date/Time

Date/Time

Date/Time

Date/Time

G18/LBT85 Small Sets

Mechanical and Electrical Services

MOD Tasks As Below See Task instructions for Task Group 18 Frequency See Below

Maintenance Log Book Page

For Standby Generators Location ..
NOTES 1. 2. Record overleaf as appropriate:-

Enter in the appropriate column below Hours Run and S for satisfactory, N/S for not satisfactory or a measurement. (a) Details of defects and remedial action taken, note when a defect occurs before the part concerned has had a reasonable life (b) Any major change in the trend of the measurements recorded below, together with the reason.

Task Instruction Procedure

Task 86 6 Monthly checks & Maintenance Date
6 Monthly

Task 87 Annual Maintenance

Annually

Task 88 2 Yearly Maintenance

2 Yearly

Task 89 4 Yearly Maintenance

4 Yearly

Task 90 Major Overhaul

8 Yearly

Task 91 Test Operation of interlocks and simulate mains failure

Annually

Initials

G18/LBT86-91 Issue 1 Rev 0

28/03/2003