Gas and Diesel Generator Maintenance Cost

Generator Maintenance

I would like to inform you the diesel generator maintenance cost , from the very beginning we found, our Generator has created too much high temperature. Some times Generator has shut off. For that reason, we informed your Engineers to solve this problem but they are unavailing to find out the problem and solve it. Several times our production has hampered. In front of your Engineers we have opened our Generator Heat Exchanger and we’ve found a big size (2.2”X2.2”) round metal pc. GETCO Engineer also agrees with us that this is the main problem for high temperature and also manufacturing fault.

 Generator Maintenance Proposal

 With due respect would like to inform you that our Generator (GAS) have to servicing after every 1000 hours and also lube oil change. For this reason in next Friday January 21, 2010. from 01.00 pm. to 7.00 pm. want to set for servicing the Generator.  So, with beg most respectfully that you will give the permission for servicing the Generator on the above date and time.

 Materials/Spare Parts Rate For Gas Generator:

S/L No.	Description Of The Materials/ Spare Parts	Qty	Rate (Tk.)
01	Generator Total Price	02 Pieces	4,00,00,000
02	Engine Oil	01 Liter	425
03	Oil Filter	01 Piece	3,300
04	Air Filter	01  Piece	10,500
05	Air Filter Shoot	01 Piece	1,300
06	Spark Plug	01 Piece	7,433
07	C.W.T-512	01 Kg	330
08	C.W.T-513	01 Kg	352
09	Coolant/Additive	01 Liter	990
10	Gas Bill	01 Month	8,50,000
11	Over Hauling Cost		5,00,000
12	Other Servicing Cost	01 Month	5,000

 Life Time = 15 Years

= (15×12) Months

= 180 Months

 Generator Maintenance Cost

S/L No.	Description Of The Materials/ Spare Parts	Qty	Rate (Tk.)	Total (Tk.)
01	Generator Price	02 Pieces	(2×2,00,00,000÷180)	2,22,222
02	Back-Up Oil	338 Liters	425	1,43,650
03	Changed Oil	208 Liters	425	88,400
04	Oil Filter	1.5 Pieces	3,300	4,950
05	Air Filter	1.25 Pieces	10,500	13,125
06	Air Filter Shoot	1.25 Pieces	1,300	1,625
07	Spark Plug	3.33 Pieces	7,433	24,752
08	C.W.T-512	10 Kg	330	3,300
09	C.W.T-513	10 Kg	352	3,520
10	Coolant/Additive	10 Liters	990	9,900
11	Gas Bill	01 Month	8,50,000	8,50,000
12	Over Hauling Cost			5,00,000
13	Other Servicing Cost	01 Month	5,000	5,000
			Total=	18,70,444

• Total Cost per Month for Generator = 18, 70,444 Tk.
• Total Cost per Year for Generator = (18, 70,444×12) Tk. = 2, 24, 45,328 Tk.
• Total Cost per Day for Generator = (2, 24, 45,328÷365) Tk. = 61,494 Tk.
• Total Cost per Hour for Generator = (61,494÷24) Tk. = 2,562 Tk.

Generation Per Day (Average):

• Old Caterpillar Gas Generator = 12 MW
• New Caterpillar Gas Generator = 12 MW
• Total Generation per Day = (12+12) MW

= 24 MW

= (24×1,000) KW

= 24,000 KW

• Total Generation per Month = (24,000×28) KW

= 6, 72,000 KW

• Per KWH Cost = (18, 70,444÷6, 72,000) Tk.

= 2.78 Tk.

Load Calculation For All Units (Average)

Units Name	Amp.	KWH	Rate/KW (Tk.)	Total Cost (Tk.)
Textile	478	265	2.78	736.70
Generator Room	70	39	2.78	108.42
Utility (Boiler Room)	560	310	2.78	861.80
Washing	158	88	2.78	244.64
E.T.P-2	160	89	2.78	247.42
Knitting	171	95	2.78	264.10
Garments	701	389	2.78	1081.42
E.T.P-1	133	74	2.78	205.72
Embroidery	100	56	2.78	155.68

Per Month Electricity Cost for All Units:

• Per Day electricity cost for Textile = (736.70×24) = 17,680.80 Tk.
• Per Month electricity cost for Textile = (17,680.80×28) = 4, 95,062.4 Tk.
• Per Day electricity cost for Generator Room = (108.42×24) = 2,602.08 Tk.
• Per Month electricity cost for Generator Room = (2602.08×28) = 72,858.24 Tk.
• Per Day electricity cost for Utility (Boiler Room) = (861.80×24) = 20,683.2 Tk.
• Per month electricity cost for Utility (Boiler Room) = (20,683.2×28) = 5, 79,129.6 Tk.
• Per Day electricity cost for Washing = (244.64×24) = 5871.36 Tk.
• Per Month electricity cost for Washing = (5871.36×28) = 1, 64,398.08 Tk.
• Per Day electricity cost for E.T.P-2 = (247.42×24) = 5,938.08 Tk.
• Per Month electricity cost for E.T.P-2 = (5,938.08×28) = 1, 66,266.24 Tk.
• Per Day electricity cost for Knitting = (264.10×24) = 6,338.4 Tk.
• Per Month electricity cost for Knitting = (6,338.4×28) = 1, 77,475.2 Tk.
• Per Day electricity cost for Garments = (1081.42×24) = 25,954.08 Tk.
• Per Month electricity cost for Garments = (25,954.08×28) = 7, 26,714.24 Tk.
• Per Day electricity cost for E.T.P-1 = (205.72×24) = 4,937.28 Tk.
• Per Month electricity cost for E.T.P-1 = (4,937.28×28) = 1, 38,243.84 Tk.
• Per Day electricity cost for Embroidery = (155.68×24) =3,736.32 Tk.
• Per Month electricity cost for Embroidery = (3,736.32×28) = 1, 04,616.96 Tk.

Generator maintenance  – Cooling Tower

1. Ball Valve 1”
2. Butterfly Valve 4”(with Flange)
3. Butterfly Valve 6”(with Flange)
4. Butterfly Valve5”(with Flange)
5. Centrifuge High lift Pump

• Flow rate 120M/H
• Head 20M
• Suction 6”
• Delivery 5”

1. Expunction Joint 4” (with Flange)
2. Expunction Joint 5”(with Flange)
3. Foot Valve 6”(Flange type, with Flange)
4. MS Elbow 2”
5. MS Elbow 4”
6. MS Elbow 5”
7. MS Elbow 6”
8. MS Reducer 4”*2”
9.  MS Reducer 4”*5”
10. MS Ring Flange 4”
11. MS Ring Flange 5”
12. MS Ring Flange 6”
13. MS Simless Pipe 4”
14. MS Simless Pipe 5”
15. MS Simless Pipe 6”
16. MS Simless Pipe 8”
17.  Non return Valve 5”(disk type)
18. Nut bolt with washer (full thread) 16*120
19. Nut bolt with washer 16*50
20. Nut bolt with washer 16*65
21. Nut bolt with washer 20*50
22. Nut bolt with washer 20*50
23. Pressure gauge
24. Strainer 6”       (Flange type, with Flange)
25. Temperature gauge (0-100,300)

Generator maintenance – Exhaust Gas Line

1. MS Flange (as per sample)
2. MS Simless Pipe 12”
3. Temperature meter (0-500 c)

Generator maintenance – Inlet Gas Line

1. Ball valve ½”
2. Ball Valve 4” (Flange type)
3. Gas Filter 4”(with Generator)
4. MS Elbow 4”
5. MS Flange 4”
6. MS Pipe 4”
7. MS Reducer ( 4”*3” welded type)
8. Niddle valve with sypone pipe ½”
9. Pressure gauge (0-200 PSI)
10. PRV (Gas regulator Valve3”)
11. S S Expansion Joint 4” (with flange)
12. Solenoid Valve 4” (with flange) with Generator

Gas and diesel generator maintenance cost is described in this article