All Generator List and Standard Operating Procedure

by Engr. Kh. Mashiur Rahman | Aug 31, 2016 | Power & Energy

Generator List

The objective of this Standard Operating Procedure is to describe the procedure for operating the Diesel Generator of Engineering department of Auto Generator Medicine Ltd. This procedure is applicable for operating Diesel Generator under engineering department of Auto Medicine Ltd. Area of operation is Service Building under engineering department. The content lists are –

What is Servo Motor? How Servo Motors Work?

Led Work Light for Sewing Machine

What is Electrical Safety Training System ?

SOP for Electrical Management and Maintenance

What is Generator Cooling Tank Chemical Process?

Diesel Generator Maintenance Check List

Gas and Diesel Generator Maintenance Cost

Gas and Diesel Generator Maintenance Cost

Gas and Diesel Generator Maintenance Checklist

Responsibility

Operators under engineering department are responsible for following this SOP.

Routine responsibility for ensuring that this procedure is implemented as and where necessary rests with the Head of Engineering department.

Quality Assurance Department is responsible for SOP compliance.

Involved

All concern Operators, Executives / Officers and Head of Engineering Department.

Definition & Abbreviation 

Definition: There is (are) no unique term(s) in this document.

Abbreviation: There is (are) no unique term(s) in this document.

Health &  Safety Consideration

Wear sound & Eye protective devices during machine operation.

System / Process Owner

Engineering Department

Description & Specification Of Machine

Manufacturer: Auto Engineering Co. Ltd. Model: WPS400: Supplier :Sim Power, Machine No: 0174707/012&015, Material: All  parts are made of MS Metal with paint. Generator Details: 3 Phase,415V, 50Hz.1500 RPM Capacity: 400KVA each

Procedure

Preoperational  Steps

At first check & certify that the machine is workable & ready for operation

Check the oil level. The pointer should register in the upper field of the green range. If the pointer registers in the red range (Low range), Remove the plug & add oil until the level reaches the filter        opening. Fit & tighten the plug.  Check the radiator water level .  Check the Lub oil level & Quality. Check the Battery Voltage 24 Volt

Operational Steps

Staring

Switch on the Generator Display in Manual Mode, then Press ‘Start’

Run the Generator Set for Minimum Two minutes

Switch on the Generator panel ACB

Select Synchronizing panel in Auto/Manual Mode)

Switch on the LT-2 ACB

Switch on the BBT ACB

Stopping

Switch off the BBT ACB

Switch off the LT-2 ACB

Switch off the Generator ACB, Press ’O’

Run the Generator for five minutes with out load(No load)

At the end of operation, switch off the Generator Off Push.

Caution

During operation, if any unusual or abnormal sound or noise is heard or problem arises, stop the machine immediately and inform it to the Engineering in charge.

Before carrying out any maintenance, repair or adjustment, stop the Generator, Press emergency stop button, switch off the ACB.

Post operational steps

Check the Generator Voltage, 400Volt AC.

Check the running Ampere

Check the Generator Temperature,80-10c

Check the Generator Oil Pressure,70-100 psi

Check the Generator Frequency,50Hz

Check the Generator RPM,1500 rpm

Record the Generator running hour reading

Special Instruction

Should there be anything in this SOP that you do not clearly understand or cannot implement, please communicate it immediately to your superior officer.

Review / Change History                               

The procedure must be re-prepared, checked and duly approved whenever any change in the system/   method/ process, or in any circumstance, indicates the need for the same.

The SOP must be reviewed every 3 (three) years from the date of issue, in the light of current practice, to determine whether any change or revision is necessary.

All copies of the SOP which will be superseded by any revision must be withdrawn from active use.

After recalling all the copies of the superseded SOPs, redistribute the reviewed one by keeping records in Log books.

Preserve a copy of the superseded SOP in document archive and destroy rest of the copies keeping records.

Example of Costing for Utility and Maintenance Section

   Generator Costing:

• Total Cost per Year for Generator = 2, 244545, 45,328 Tk.
• Total Cost per Month for Generator = 18, 74540,444 Tk.
• Total Cost per Day for Generator = 61,4945454 Tk.
• Total Cost per Hour for Generator = 2,554562 Tk.
• Per KW Electricity Cost = 2.74548 Tk.

Boiler Costing:

• Total Cost per Year for Boiler = 1, 87, 04542,744 Tk.
• Total Cost per Month for Boiler = 15, 58,5454562 Tk.
• Total Cost per Day for Boiler = 51,254540 Tk.
• Total Cost per Hour for Boiler = 2,1345455 Tk.
• Per Kg Steam Cost = 0.145457 Tk.

Compressor Costing:

• Total Cost per Year for Compressors = 31, 514545,908 Tk.
• Total Cost per Month for Compressors = 2, 624545,659 Tk.
• Total Cost per Day for Compressors = 8,635455 Tk.
• Total Cost per Hour for Compressors = 3454560 Tk.
• Per m3 Air Cost = 0.35453 Tk.

E.T.P Costing:

• Total Cost per Year for E.T.P = 1, 36, 67,5645458 Tk.
• Total Cost per Month for E.T.P = 11, 38,954564 Tk.
• Total Cost per Day for E.T.P = 37,4565645.39 Tk.
• Total Cost per Hour for E.T.P = 1,565e6560.22 Tk.
• Per m3 Water cost for E.T.P = 1667676.95 Tk.

W.T.P Costing:

• Total Cost per Year for W.T.P = 43, 67,46767684 Tk.
• Total Cost per Month for W.T.P = 3, 63,56565957 Tk.
• Total Cost per Day for W.T.P = 11,96565656 Tk.
• Total Cost per Hour for W.T.P = 4994545 Tk.
• Per m3 Water Cost for W.T.P = 5.23434 Tk.
• Per m3 Water Cost for Washing = 1.34342 Tk

MAINTENANCE TOTAL COSTING

• Total Maintenance cost = 2,22329,95,642 Taka
• Total Maintenance cost per month = 19, 16,3232304 Taka
• Total Maintenance cost per day =63,8232377 Taka
• Total Maintenance cost per hour =2,623262 Taka
  

MAINTENANCE TOTAL COSTING

• Total Maintenance cost per day =98,732300 Taka
• Total Maintenance cost per month = 223239, 60,971
• Total Maintenance cost per Hour =4,113233 Taka                                                                                                                                                                                        
  

MAINTENANCE TOTAL COSTING SUMMARY

• Total Maintenance cost in 2011 = 3,07,98323,474 Taka
• Total Maintenance cost per month = 25, 623236,540 Taka
• Total Maintenance cost per day =85,552321 Taka
• Total Maintenance cost per Hour =3,532365 Taka

MAINTENANCE TOTAL COSTING SUMMAR

• Total Maintenance cost in 2012 = 5,73,91,632367 Taka
• Total Maintenance cost per month = 47, 82,632339 Taka
• Total Maintenance cost per day = 1, 59,423231 Taka
• Total Maintenance cost per Hour = 6,643233 Taka

Gas and Diesel Generator Maintenance Checklist

by Engr. Kh. Mashiur Rahman | Aug 31, 2016 | Power & Energy

Gas and Diesel Generator Maintenance Checklist 

In order to meet gas and diesel generator maintenance to growth of production and extension of the project we immediate need the bigger capacity of Power Gas Generator Unit. This is why we are interested to improve the 900KW/1125 KVA Gas Generator.

Panel – Gas and Diesel Generator Maintenance Checklist 

• Adequate illumination available infront of DB?
• Is panel board at accessible height?
• Are Instruction Board (both) displayed on the DB?
• Electric Danger/Caution sign available on the panel?
• Are indicator lamps available and functional?
• Are Ammeters (for LT & MDB) available?
• Are Voltmeter (for LT & MDB) available?
• List and diagram (SLD) of circuits available?
• Notice for periodic inspection and testing (at LT) available?
• Are means for identification available for the final circuits?
• Are the no. of outgoing Circuit Neutral conductors equal to the no. of outgoing Circuits?
• Are means for identification available for Circuit-Neutral conductors?
• Are the no. of outgoing Circuit Earthing conductors equal to the no. of outgoing circuits?
• Are means for identification available for all of circuits?
• Is there any means inside panel to prevent excessive protective devices?
• Are Phase bus-bars used in the panel?
• Is Neutral bus-bar used in the panel?
• Is Earth Bus-bar used in the panel?
• Is Earth Bus-bar properly connected with the loads?
• Are all Phase conductors following colour code?
• Are all Neutral conductors following colour code?
• Are all Earth conductors following colour code?
• Are Neutral and Earth Bus-bar shorted?
• Is the Panel Body connected with ECC?
• Is the Panel Door connected with ECC?
• Rubber/Insulating mat available infront of boards?
• If available, adequate?
• If available, graded?
• Proper bushing/glands for incoming and outgoing cables available?
• Interlocks provided for multiple power sources (LT & MDB)?
• Is the main incomer of the panel is operable?

Generator Room – Gas and Diesel Generator Maintenance Checklist 

• No/Insufficient /Unsafe stair at the entrance of the Generator room is it true?
• Is Combustible material in the Generator room?
• Is Rains water enters into the generator room
• No/insufficient lighting inside the generator room?
• Are Lints/dirts present in the Generator room?
• Are Combustible Materials in cable trench ?
• No Cover on cable trench, is it true?
• Improper Installation of LT meter, is it true?
• Generator frame earthing not done, is it true?
• Generator frame earthing done partially (One instead two), is it true?
• Is Battery terminal is open?
• Top and bottom of the generator supply terminal box open, is it true?
• Generator supply terminal box not staled, is it true?

Substation Room- Gas and Diesel Generator Maintenance Checklist 

• No/Insufficient /Unsafe stair at the entrance of the Substation room, is it true?
• Is Combustible material in the /Substation room?
• Is Combustible material near the HT?
• Is Rains water enters into the substation room?
• No/insufficient lighting inside the Substation room ?
• Are Lints/dirts present in the Substation room?
• Are Combustible Materials in cable trench?
• No Cover on cable trench, is it true?
• Improper Installation of LT meter, is it true?
• Transformer
• X-former installed on combustible wooden stick,is it true?
• Horn gape Upper/lower part missing, is it true?
• Horn gape not aligned, is it true?
• Is Silica gel of x-former breather becomes brown?
• Transformer Breather oil pot empty, is it true?
• Equipment -earthing and systemearthing shorted?
• Huge dirt present on the top and at the bottom of the transformer
• Huge dirt present in the transformer area?
• Earthing connected with x-former body w/o lug

Spear Parts Air Compresor Ceccato

1) Oil Separator Kit

2) Oil Stop Kit

3) Cheek Valve Kit

4) Mini Pressure Valve Kit

5) Thermostatic Valve Kit

6) Pressure Switch – 600657.

7) Solenoid Valve – 599949

Temperature Meter – 600626

Thermo Switch

Piston for Minimum Valve

Seal for minimum Valve

U4 Valve

Pressure Regulator

Spear Parts For All Motor Pump:

• Coupling Rubber Bush – As Per Sample.
• Magnetic Contactor – As Per Sample.(Control Volt 220V.)
• Timer – As Per Sample.
• Pressure Controller Switch – As Per Sample.
• Really – As Per Sample.
• Pressure Gauge – As Per Sample.

Spear Parts Caterpillar Generator

• Spark Plug – 2N – 2839 – Caterpillar.
• Wire A – 7W – 8542.
• Oil Filter – IR – 0716.
• Filter Shoot – 8N – 2555.
• Element Air – 8N – 6309.
• Indicator Assay – 3E – 7238.
• NGEO (Mobil) – EL 250 SAE 40. (Change After: 1200 Hours)
• Lubricant (Grease) – 2S – 3230.

Spear Parts Petbow Generator

• Air Filter – AF – 928 M.
• Water Filter – WF – 2075.
• Fuel Filter – FS – 1212.
• Lube Oil Filter – LF – 3000.
• Diesel
• Mobil – SAE – 40.

Conclusion

We have significantly increased the production capacity by commissioning the new set of fully Gas and Diesel Generator Maintenance and Semi Auto corrugated board making machine. In addition to this we have added two color Offset printing machinery in our offset printing section. Also turning the offset printing Floor Air condition to meet buyer’s demand. Further, to meet the quality product we will have to commission high capacity Boiler. Know more about Diesel Generator Maintenance Checklist and cost.

Gas and Diesel Generator Maintenance Cost

by Engr. Kh. Mashiur Rahman | Aug 30, 2016 | Power & Energy

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:

 Life Time = 15 Years

= (15×12) Months

= 180 Months

 Generator Maintenance Cost

• 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)

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