Supervision Manual_SUM Part 1 – Operation & maintenance

Table of contents

STAND-BY OPERATION
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Stand-by routines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Continuously running equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Once a year . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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Table of contents

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 Supervision Manual_SUM Part 1 – Operation & maintenance
STAND-BY OPERATION
General
This chapter gives information and ac-
tions to be done when the power plant
is in stand by or stoppage.
To base maintenance on the accumu-
lated running hours for gensets which
are not in normal operation is not satis-
factory due to the limited running hours
of the equipment. However these in-
structions shall be read together with
the ordinary running hour dependent
Stand-by routines
Continuously running equip-
ment
It is recommend to keep the prelubricat-
ing oil pump, preheating unit and anti-
condensation heater continuously in
AUTO position.
Every second day
+ Check the function of above men-
tioned equipment.
+ Prime the engine using the prelubri-
cating oil pump.
+ Rotate the crankshaft to a new posi-
tion using the turning device.
This reduces the risk of corrosion on
journals and bearings when the engine
is exposed to vibrations.
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maintenance information found in the
Z
unit specific instruction manuals.
NOTE :
Following information mainly deals
with the upkeep of the engine and
generator. For the upkeep of other
equipment please refer to the man-
ufacturers manuals found in system
specific binder series.
Weekly
The engine has to be started once a
week to check that everything is in or-
der.
1 Prime the engine using the prelubri-
cating oil pump.
2 Start the engine according to the in-
structions in chapter “Genset”,
binder 2A 01 “Operation manual”.
3 With the genset in operation, ob-
serve all operating pressures, tem-
peratures and the units ability to
accept load.
4 Check for alarms.
5 Stop the engine according to the in-
structions in chapter “Genset”.
The running time is approximately 5
minutes.
In utmost rare situations, when the
weekly running of the genset is not pos-
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STAND-BY OPERATION
sible, the engine shall be cranked by
means of the turning device or by using
starting air, and the shaft put in a dif-
Z
ferent position.
NOTE :
Please observe that cranking the
engine with the turning device or
starting air doesn’t replace a normal
test run and should merely be used
once a year. A check run shall be
performed as soon as practical.
Monthly
This is basically an extended weekly
check-run with a performance test
added and with the operation data re-
cord form to fill in.
1
Prime the engine using the prelubri-
cating oil pump.
2 Start the genset according to the in-
structions in chapter “Genset”.
3 Run the genset with at least 50 %
load.
! The loading should, in order to
achieve trend function, be the
same as during previous operation
tests.
4 Read all gauges and thermometers
! It is important that pressure
gauges, thermometers and load of
the engine are read and recorded
at the same time, because all val-
ues are more or less dependent on
the load situation.
5 Compare the values obtained with
previous values recorded at corre-
sponding load.
! Try to discover long term trends
because most changes in operating
conditions comes slowly and are
hard to discover without having
previous data and test records to
compare with.
6 With the genset in operation, check
the following:
! Check that there is no leakage of
gas, water, fuel or lubricating oil.
! Especially observe the fuel lines,
injection pumps and injection
valves.
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! Watch the quantities emerging
from the leak oil pipes.
! Check the starting air distributing
pipe.
‹
WARNING !
An abnormally hot pipe indicates
a leaking starting air valve which
may cause an explosion!
Normally you should be able to
hear such a leakage as well.
7 Stop the engine according to the in-
structions in chapter “Genset”.
If the monthly test-run of the genset is
not possible, the engine shall be
cranked by means of the turning device
or by using starting air as described
above, and the shaft put in a different
Z
position.
NOTE :
Please observe that cranking the
engine with the turning device or
starting air doesn’t replace a normal
test run and should merely be used
once a year. A check run shall be
performed as soon as practical.
Once a year
Lube oil sample
Even if the engine has not accumulated
the running hours needed, it would be
prudent to take a yearly oil sample of
the oil from the engine crankcase and
having it analysed to ensure that the
quality of the oil remain within accept-
able limits. Change the oil in the turbo-
charger and the alternator bearings.
Filters
Inspect all fuel- and lubricating oil fil-
ters and replace if necessary.
Clean the centrifugal filter(s). Remem-
ber to open the valve before the filter
after cleaning and installation. For in-
structions, read the diesel engine in-
struction manual 7A 02 02, section 18.
Control mechanism
Special attention should be paid to the
function of this system as a defect may
result in engine overspeed or load prob-
 Supervision Manual_SUM Part 1 – Operation & maintenance
lems. Check and lubricate racks, bear-
ings and ball joints of the control mech-
anism to ensure a free and easy
movement of all gliding surfaces.
Mechanical overspeed protection
Trip the mechanical overspeed device
manually. The system should work with
minimal friction. Read section 22 in the
engine instruction manual 7A 02 02.
Injection valves
Check the injection valves opening pres-
sure. Dismantle and clean the nozzles.
See section 16 in the engine instruction
manual 7A 02 02. Update the nozzle
maintenance chart.
Turbocharger
Water cleaning of the turbocharger has
to be done during operation. The neces-
sary flow of cleaning water depends on
the volume of exhaust gas and its tem-
perature. Washing time is normally
about 10 minutes, but can be deter-
mined by observing the cleanliness and
clarity of the draining water.
! CAUTION !
The exhaust-side of the turbo
charger shall be cleaned at re-
duced load, 30…50 % of full rated
load. Maximum exhaust gas tem-
perature after the cylinders is
380 °C.
The air-side of the turbocharger shall be
cleaned at full rated load, or highest
possible load.
For detailed operating information on
turbochargers read section 15 in the en-
gine instruction manual 7A 02 02.
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A.C. generator
Dampness is the enemy of insulation
and although modern insulations do not
absorb water to the extent of some older
types, dampness on the insulation sur-
face can lead to electrical tracking over
the surface.
When the genset is idle, normal
changes in ambient temperature can
cause the air to saturate as the temper-
ature drops below the dew point, so that
dew is deposited on solid surfaces. This
phenomena can cause dampness on the
insulation surfaces of the generators
with any type of enclosure, including to-
tally enclosed ones.
Also, when the genset is idle, changes
in the ambient temperature will affect
the generator temperature, but at a
slower rate. When the air temperature
rises quickly the rise in the generator
temperature will lag behind that of the
air and the layer of air in contact with
the generator will be cooled. If this
brings it below the dew point, the mois-
ture in the air will be deposited on the
generator surfaces.
To avoid these effects, the generators
are fitted with heaters to raise the
windings temperature a few degrees
above the steady air temperature.
It is recommended that the heaters
should be switched on whenever the
genset is stopped and off when the
genset is started.
‹
WARNING !
Ensure that the heaters are
switched off before working on
the generator.
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STAND-BY OPERATION

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