Operation Supports - Power Plant

Petrogas(Basin) Ltd.

Work Order No. :

Execution Date :
Main Task : Top Overhaul Services
Frequency : 5000 Hours
Unit : Diesel Engine Generator
Functional Location : Peaking Power Plant
Operation Requirements : Diesel Engine Shut-down
Estimated Execution : 2 weeks
Time
Allocated Manpower :  3 Mechanical Technicians
 2 Electrical Technicians

MAINTENANCE TASKS

1. Complete to prepare require parts and consumable materials in Top

Overhaul Services.
2. Take reading diesel engine parameters and generator.
3. Normally shutdown the diesel engine generator
4. Disconnect & move out the battery
5. Moving up the diesel engine generator to work shop
6. Disconnect exhaust & remove with machine shelter
7. Lift out the diesel engine generator from shelter and move to
overhaul room
8. Ensure that any system is safe to start the Generator Overhaul
Maintenance.
9. Drain the oil lube from oil tank & coolant water from radiator
10. Perform the steps for dismatling Diesel Engine Set are as follows:
 Electric control panel
 Wiring electrical system
 Sarter dinamo
 All safety device
 Dismantle exciter rotor and stator, main rotor & stator of
generator
 Dismantle coupling
 All radiator component
 Cooling system e.g water pump, oil cooler & oil filter, after
cooler, housing & air filter
 Fuel system e.g governor, injection pump & line, nozzle &
chamber

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 Operation Supports - Power Plant
Petrogas(Basin) Ltd.

 Turbocharge
 Cylinder head, rocker arm & push road
 All gear incl. Flywheel
 Oil pump, oil line & oil pan
 Con-rod & piston
 Liner, camshaft & bearing sleeve
 Main bearing & crankshaft
 Skid base
11. Perform the steps to maintain the generator are as follows :
 Clean up and heat up rotor and stator of generator
 Clean up and heat up exciters of rotor and stator
 Clean up and heat up flange exciter and coupling including its
accessories
 Megger the stator and rotor of generator
 Megger the exciter stator and rotor
12. Clean up the skid base & block cylinder
13. Carry out General Overhaul Services and reassembly the diesel
engine as following steps :
 Crankshaft & camshaft
 Clean the crank shaft, check for defects, scratches or
deformations (Collect data)
 Replace main bearing
 Clean and check for defects, scratches or deformations on
the outside diameter, measure & collect data
 Clean and inspect the cam bush for defects, scratches or
deformations on the working surface
 Measure the diameter in the cam bush on the engine block
(Collect data)
 Piston & con-rod
 Replace piston & ring
 Replace pin piston
 Replace con-rod
 Check the condition of the connecting rod bolt, measure the
length of the bolt, replace if damaged or exceed the
tolerance limit

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Operation Supports - Power Plant
Petrogas(Basin) Ltd.

 Cylinder head
 Replace the cyl. head gasket
 Perform the valve clearance setting. Check the trigger on
the rocker arm, replace if damaged
 Replace all valve & perform leaks testing to ensure all
valve is in good condition
 Recheck the cyl.head condition and ensure the cylinder head
fastening bolt, manifold fastening bolt and rocker arm
fastening bolt is tightening well
 Reinstall the cyl. head to engine and ensure the cyl.head
is tightening well
 Cylinder liner
 Replace cyl. liner
 Replace seal O-ring
 Lubrication System
 Replace the oil filter and seal kit
 Clean the oil cooler, impermeable test, replace the seal
kit
 Dismantle, clean and check the oil pump, replace the
damaged and worn parts
 Check the condition of the system pipes, make repairs if
necessary
 Cooling System
 Check and test the thermostat function
 Clean the radiator, water cooler, impermeable test, replace
the seals
 Check the water pump, replace damaged or worn parts
 Fuel System
 Replace the fuel filter element and repair kit
 Service injectors, recalibrate the injection pressure
 Replace the nozzle and repair kit, recalibrate
 Overhaul & clean injection pump and governor, replace
damaged or worn parts
 Drain and clean the fuel tank
 Check injection timing

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 Operation Supports - Power Plant
Petrogas(Basin) Ltd.

 Check the condition of the system pipes, replace if

necessary
 Intake & Exhaust System
 Clean up intake & exhaust manifold
 Inspect intake & exhaust for any possible leaks or
corrosions
 Repaint intake & exhaust to maintain the possibility of
corrosion
 Reinstall the coupling
 Reconnect the main rotor & stator, reconnect the exciter
 Perform alignment between generator & coupling (collect data)

14. Perform inspection & calibrate the Control Panel

15. Services alternator, electrical system, safety device & battery
as follows :
 Check the function of the operation buttons and emergency stop
 Check the condition of the output cable connection
 Check foreign sounds when test the alternator
 Check the mains output voltage
 Clean and check the condition of each component, replace
damaged or worn components, replace the carbon brush if
necessary
 Top up liquid into battery
 Check and take voltage battery data
16. Prepare and perform diesel engine wash.
17. Walk around inspection to check for any possible leaks, tools and
rags left in the diesel package.
18. Start-up, running and test load the diesel engine generator,
record important parameters for base line data and reset running
hours
19. Clean up the work area & tools

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 Operation Supports - Power Plant
Petrogas(Basin) Ltd.

COMPLETION REMARKS/NOTES:

WORK ORDER - TECHNICAL COMPLETE

GENERAL MECHANICAL SUPERVISOR

Name :
Date :

SR. MECHANICAL SUPERVISOR

Name :
Date :

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