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 –
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
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.
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.
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
Ball Valve 1”
Butterfly Valve 4”(with Flange)
Butterfly Valve 6”(with Flange)
Butterfly Valve5”(with Flange)
Centrifuge High lift Pump
Flow rate 120M/H
Head 20M
Suction 6”
Delivery 5”
Expunction Joint 4” (with Flange)
Expunction Joint 5”(with Flange)
Foot Valve 6”(Flange type, with Flange)
MS Elbow 2”
MS Elbow 4”
MS Elbow 5”
MS Elbow 6”
MS Reducer 4”*2”
MS Reducer 4”*5”
MS Ring Flange 4”
MS Ring Flange 5”
MS Ring Flange 6”
MS Simless Pipe 4”
MS Simless Pipe 5”
MS Simless Pipe 6”
MS Simless Pipe 8”
Non return Valve 5”(disk type)
Nut bolt with washer (full thread) 16*120
Nut bolt with washer 16*50
Nut bolt with washer 16*65
Nut bolt with washer 20*50
Nut bolt with washer 20*50
Pressure gauge
Strainer 6” (Flange type, with Flange)
Temperature gauge (0-100,300)
Generator maintenance – Exhaust Gas Line
MS Flange (as per sample)
MS Simless Pipe 12”
Temperature meter (0-500 c)
Generator maintenance – Inlet Gas Line
Ball valve ½”
Ball Valve 4” (Flange type)
Gas Filter 4”(with Generator)
MS Elbow 4”
MS Flange 4”
MS Pipe 4”
MS Reducer ( 4”*3” welded type)
Niddle valve with sypone pipe ½”
Pressure gauge (0-200 PSI)
PRV (Gas regulator Valve3”)
S S Expansion Joint 4” (with flange)
Solenoid Valve 4” (with flange) with Generator
Gas and diesel generator maintenance cost is described in this article
