Scribd
Upload
97 views11 pages

EMD Generator Maintenance Guide

This document is a maintenance guide for EMD Engine Driven Generator Sets, detailing the necessary services, labor, and materials to ensure optimal operation for standby and base load power. It outlines standard assumptions, daily operating tasks, and a comprehensive schedule of maintenance tasks based on running time and calendar periods. The guide emphasizes the importance of using OEM recommended parts and adhering to specified maintenance intervals to maintain engine efficiency and reliability.

Uploaded by

جبران العريقي
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
97 views11 pages

EMD Generator Maintenance Guide

This document is a maintenance guide for EMD Engine Driven Generator Sets, detailing the necessary services, labor, and materials to ensure optimal operation for standby and base load power. It outlines standard assumptions, daily operating tasks, and a comprehensive schedule of maintenance tasks based on running time and calendar periods. The guide emphasizes the importance of using OEM recommended parts and adhering to specified maintenance intervals to maintain engine efficiency and reliability.

Uploaded by

جبران العريقي
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

09

Scheduled Maintenance

Scheduled Maintenance Service for EMD Engine Driven


Stationary Power Units for Standby or Base Load Operation
INTRODUCTION

This Maintenance Guide outlines the minimal services, labor and materials necessary to provide the standard
maintenance required to meet OEM (PowerTeam) recommendations for standby and base load power plant
operations of our EMD Engine Driven Generator Sets to ensure satisfactory engine operation and economical
maintenance costs where average stated load factors and average stated climate conditions (as listed standard
performance specifications of each model unit) are encountered.

General Description
This guide provides all normal maintenance required on all EMD equipment. Operator to utilize recommended
engine parts, consumables (oil, air and fuel filters) and spare parts.

Standard Assumptions:

 Fuel oil used will meet original specifications provided.


 Lubricating oil used will meet the specifications of original specifications provided and will be changed at
the intervals specified.
 Engine coolant used will meet the original specifications provided.
 Lubricating oil, fuel and air filters and replacement parts will be of a quality equal to original equipment
and will be changed at the intervals specified.
 All warranty work is performed by PowerTeam or its authorized representative or it’s assigns.
 Operating load limitations will be adhered to.
 Units are installed in accordance with OEM (PowerTeam) minimum recommendations

NOTE

 The following recommendations are applicable to stationary power units used for standby or base load
power operations.

 In the case that the units are being operated in a standby mode, each unit should be operated at least once a
week. Each unit should be operated at idle for a sufficient period of time to allow coolant temperature to
stabilize at 49°C (120°F) or higher. Once a month each unit should be operated at full speed, full load for a
minimum of one half hour.
 The operator is required to contact PowerTeam in the case that each unit is not to be operated below a
minimal output requirements for maximum efficiency. (Reference appropriate maintenance manual with
model number for associated output clarifications)

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
SECTION 1
Equipment Operating Task be Provided by
Plant Operating Personnel on a Daily Basis
IMMEDIATELY AFTER EACH START
(Automatic or Manual Start Units)

Unit Start Up Procedures


BEFORE EACH START

Check the following:


Cooling System
Check coolant level and add coolant if required

Fuel System
Check main fuel supply to each unit

Air System
Drain condensate.
Check system pressure
Check oil supply in air line lubricator

Governor
Check lube oil level

Lube Oil System


Pre-lube engine if unit has been shutdown for over 48 hours.

Fuel System
Prime system.

Air System
Drain condensate.
Check system pressure.
Check oil supply in airline lubricator.

Engine
Open cylinder test valves and manually bar over engine one complete revolution, check for liquid ejected from
valves, and close test valves. If fluid discharge is observed from any cylinder, find the cause and make necessary
repairs prior to staring the engine.

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
FOLLOWING START UP

While Engine is Running

Inspect For Leaks


Cooling system
Fuel system
Lube system
Exhaust system
Lube Oil System
Check lube oil level in pan with engine at idle
Check lube oil pressure at engine
Engine
Check cylinder test valves for leakage. Tighten if required.
Check hand-hole covers for leakage. Tighten if required.
Check air box drains for proper operation and clean.
* If drains are kept closed, drain every 4 hours.

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
SECTION 2
Description Maintenance Task to be performed by Plant Operators
On a “Running Time” basis.

BASIC INSPECTION RESPONSIBILITIES

EVERY MONTH
Lube Oil System
Take sample for analysis*
*The services of a competent laboratory should be used to monitor the suitability of the oil for continued use.
Lube Oil Circulating Pump and Motor
Check for proper operation
Immersion Heater
Check for proper operation
EVERY TWO MONTH
Auxiliary Turbocharger Filter (As necessary)
Check for proper operation / pressure and leaks inpections
In-Line “Y” Oil Strainer (Inspect and clean as necessary)
Clean strainer screen

EVERY YEAR
Lube Oil Circulating Pump and Motor
Inspect and clean with dry air.
Remove and clean check valve.

EVERY THREE YEARS


Cooling System Thermostatic Valve
Replace “O” rings and thermostatic elements.

EVERY FOUR YEARS


Cooling System Pressure Cap
Replace.*
*Unless 16,000 hour replacement has occurred first.

EVERY SIX YEARS


Engine
Replace top deck cover seals and check latches.*
*Unless 8000 hour replacement has occurred first.
Replace cylinder head grommets, inlet and outlet seals, and lower liner seals.
*Unless cylinder assembly replacement has occurred first.
Main Generator
Remove bearing cover and inspect for grease contamination, excessive wear and overheating. Apply new grease.*
*Unless 48,000 hour lubrication has occurred first. If generator is other than EMD, refer to manufacturer’s manual.

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
PERFORM THE FOLLOWING ITEMS PER ACCUMILATING RUN TIME HOURS

AFTER THE FIRST 350 HOURS OF OPERATION


Engine Nut and Bolt Tightness Check
Torque to values specified the following:
Cylinder head crab nuts.
Exhaust manifold flange bolts.
Cylinder liner water inlet line nuts and bolts.
Head frame to crankcase bolts.
Turbocharger to air duct bolts, after-cooler to air duct bolts and air duct to crankcase bolt
Inspect injectors

EVERY 350 HOURS THEREAFTER


Fuel Filter
Check pressure gauge with engine at rated RPM.*
*On units where gauge is connected to filter input side, change filter elements if pressure is greater than 50 psi.
Lube Oil Filter
Check lube oil pressure at filter cover with engine running at rated RPM.*
*Change filter elements if input pressure is greater than 25 psi.

EVERY 700 HOURS


Engine Protector
Check operation.
Soak Back Pump And Motor
Check operation*

*With the engine shut down and soak back pump motor running, remove left rear hand-hole cover and check oil
flow through gear train.

*Observe camshaft bearings. If lube oil flows from camshaft bearings with soak back pump running and engine shut
down, inspect turbo filter outlet check valve for proper operation.

Engine Air Filter Fiberglass Type


Check indicator. * The interval of change for turbocharger air intake filter elements is influenced by load factor,
kind of lubricating oil, type of operation, climatic conditions and maintenance of main lube oil filters.

Heat Exchanger
Inspect corrosion zincs.
Lube Oil Filters
Check indicators and replaces filter elements as necessary
Clean lube oil strainer.*
*Fill strainer housing with oil before starting engine.
Turbocharger Oil Filter
Replace filter elements.*
*The interval of change for turbocharger and soak back filter elements is influenced by load factor, kind of
lubricating oil, type of operation, climatic conditions and maintenance of main lube oil filters.

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
Soak Back Oil Filter
Replace filter elements.*
*Filter elements must be of a quality equal to original equipment. The interval of change for turbocharger and soak
back filter elements is influenced by load factor, kind of lubricating oil, type of operation, climatic conditions and
maintenance of main lube oil filters.

EVERY 1400 HOURS

Lube Oil Filters


Change filter elements
Clean lube oil strainer.*
*Fill strainer housing with oil before starting engine.

Turbocharger Oil Filter


Replace filter elements.*
*Filter elements must be of a quality equal to original equipment. The interval of change for turbocharger and soak
back filter elements is influenced by load factor, kind of lubricating oil, type of operation, climatic conditions and
maintenance of main lube oil filters.

Soak Back Oil Filter


Replace filter elements.*
*Filter elements must be of a quality equal to original equipment. The interval of change for turbocharger and soak
back filter elements is influenced by load factor, kind of lubricating oil, type of operation, climatic conditions and
maintenance of main lube oil filters.

Protective Devices and alarms controls system


Check operation and functionality and repair or replace defective components as necessary.

Fuel Filters
Inspect, clean or replace suction strainer element.
Change engine mounted filter elements.*

Oil System
Change engine oil.* Depending upon fuel sulfur content and quality of lubricating oil, it may be necessary to change
lube oil even more frequently.
Clean oil pan.
Clean filter housing.
Clean oil suction screens.
Clean scavenging oil screens.*
*Fill strainer housing with oil before starting engine.

EVERY 2000 HOURS


Fuel Filters
Clean or replace suction strainer element.
Change engine mounted filter elements.*
*Use only elements equal to original equipment.
Cooling System
Check inhibitor concentration.

Engine Air Filter-Fiberglass Type


Replace elements.

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
Engine
Inspect air box.
Inspect crankcase.
Inspect crankshaft and connecting rods.
Inspect pistons and piston rings.
Inspect cylinder liners.
Inspect cylinder head mechanism with engine idling and at operating temperature.
Inspect engine fuel lines and connections for leaks.
Inspect engine water system for leaks.

EVERY 4000 HOURS


Exhaust System
Remove manifold screen and trap. Check for cracks and clean.
Eductor Tube (Exhaust Stack Mounted)
Inspect for carbon deposits and clean, if necessary.
Oil System
Change engine oil.*
*Evaluation of engine and oil condition should indicate the frequency of this item. Type of service, type of oil,
quality of filter elements and condition of engine will influence the frequency of oil change.
Clean oil pan.
Clean filter housing.
Clean oil suction screens.
Clean scavenging oil screens.*
*Fill strainer housing with oil before starting engine.
Engine
Check pressure drop across after-coolers*
*Clean air passages if necessary.
Check exhaust manifold base flange bolts for proper tightness.
Main Generator
Inspect collector rings and brushes and replace brushes if required.*
*If generator is other than EMD, refer to manufacturer’s manual.
Reverse polarity of collector rings.
Governor
Change oil.
Lubricate linkage moving parts.
Lubricate governor synchronizing motor, motor bearings.

EVERY 8000 HOURS


Engine Nut And Bolt Re-torque
Cylinder head crab nuts.* Loosen and then torque to values as specified in PowerTeam Specifications.
Head frame to crankcase bolts.
Turbocharger to air duct bolts, after-cooler to air duct bolts and air duct to crankcase bolts.
Engine
Replace top deck cover seals and check latches
Qualify injectors.
Check injector timing and injector rack length.
Check engine speed.
Remove and clean oil separator element.
Check pressure drop across aftercooler.*
PowerTeam Generation Solutions
600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
*Clean air passages if necessary.
Inspect vibration gear dampener
Remove, clean, and inspect: replace if necessary.
Soak back check valve in the turbo filter inlet.
Soak back oil pressure relief valve in the soak back filter head.
Soak back filter bypass valve in the soak back filter head.
Turbo oil filter check valve in the turbo filter head.
Exhaust System
Inspect manifold connectors for liner cracks and replace if necessary.

Main Generator
Visually inspect and clean.
Replace collector ring brushes.
Exciter
Clean and visually inspect.
Inspect and replace brushes when required. Replace brushes in sets only.
Starting Motors
Clean Strainer and lines of any water or sludge
Soak Back Pump Motor
Inspect and clean with dry air.
Replace brushes.

Cooling System
Inspect and perform pressure test.
Replace pressure cap if defective.
Lube Oil Filter
Remove oil filter bypass valve; clean, inspect and test.

EVERY 16,000 HOURS

Starting Motors (Air)


Disassemble, clean and lubricate.
Renew parts if necessary.

Fuel Pump
Replace coupling spider.

Soak Back Pump


Replace coupling spider.

EVERY 24,000 HOURS

Engine
Install new thrust collars.
Install new lower main bearings.
Replace water pump seals and all worn parts.

Cooling System
Replace flexible coupling seals.

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
Lube Oil Cooler
Inspect, clean and test.

Heat Exchanger
Inspect, clean and test.

Main Generator
Remove bearing cover and inspect for grease contaminations, excessive wear and overheating. Apply new grease.*
*If generator is other than EMD, refer to manufacturer’s manual.

EVERY 35,000 – 40,000 HOURS

Engine
Replace oil pumps
Replace water Pumps
Inspect and Qualify Turbocharger for replacement
Remove oil pressure relief valve; clean, inspect, test and reset
Replace Injector Fuel Control Rods
Replace Power Assemblies
Replace Fuel Injectors
Replace Connecting Rods & Bearings
Inspect and Qualify Main Bearings for replacement
Inspect and qualify piston cooling tubes
Replace Rocker Arms Assemblies
Replace Valve Bridge Assemblies
Reset Exhaust and Injector Timing.

Cooling System
Replace pressure cap.
Inspect filler neck for damage. Replace if damaged.
Take cooling water sample for lab analysis and corrosion test.

Turbocharger-To Filter Air Duct and clamps


Replace.

Governor
Recondition.

Fuel Pump
Replace Fuel Pump.

Soak Back Pump and Motor


Recondition.

Generator
Inspect and qualify generator bearing for replacement and replace as necessary.
Check RTD’s and repair as necessary
Inspect Terminations and repair as necessary
Check all Generator Connection Box and repair as necessary
Check engine/generator alignment and re-torque mounting bolts

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
Section 3
Description of Maintenance Task performed by Plant Operators on a
“Calendar Period ” basis.
Assuming a limited amount of accumulated RUN TIME on units.

EVERY TWO YEARS


Lube Oil Filters
Change filter elements.*
*Unless filter change, on a running time basis, has occurred first.
Clean lube oil strainer.*
*Fill strainer housing with oil before starting engine.
Turbocharger Oil Filter
Replace filter elements.*
*Unless filter change, on a running time basis, has occurred first.
Soak Back Oil Filter
Replace filter elements.*
*Unless filter change, on a running time basis, has occurred first.
Fuel Filters
Change engine mounted filter elements.*
*Unless filter change, on a running time basis, has occurred first.
Clean or replace suction strainer element*
*Unless filter change, on a running time basis, has occurred first.
Engine Protector
Recondition.*
*Qualify on test stand after renewing springs, “O” rings, and diaphragms.

Lube Oil Circulating Pump and Motor


Recondition.

EVERY TWO WEEKS


Lube Oil System
Take sample for analysis*
*The services of a competent laboratory should be used to monitor the suitability of the oil for continued use.

Inspections with Engine Running

Bi-Weekly
With Engine Running

Inspect For Leaks


Cooling system
Fuel system
Lube oil system

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]
Exhaust system
Air system
Lube Oil System
Check lube oil level in pan with engine at idle
Check lube oil pressure at engine
Engine
Check cylinder test valves for leakage. Tighten if required.
Check hand-hole covers for leakage. Tighten if required.
Check air box drains for proper operation and clean. If necessary.*
*If drains are kept closed, drain every 4 hours.

Bi Monthly
With Engine Not Running

Inspect For Leaks


Cooling system
Fuel system
Lube oil system
Exhaust system
Air system
Lube Oil System
Check lube oil level in pan
Cooling System
Check coolant level
Fuel System
Check fuel supply
Air System
Drain condensate from lines and tanks.
Governor
Check oil level and add oil if required

PowerTeam Generation Solutions


600 Prairie Industrial Parkway, Mulberry, FL 33860
Office: 863.425.3030, Fax: 863.425.3131, [Link]

Common questions

Powered by AI

'Running time' maintenance responsibilities for EMD power units involve systematic checks and replacements corresponding to operational hours to ensure reliability. At every 700 hours, operators check engine protectors and soak back systems, focusing on oil flow and inspecting related components like the turbo filter outlet valve . Every 1400 hours focuses on changing lube oil filters, cleaning oil strainers, and replacing corresponding filter elements, making sure they meet quality standards . At 2000 hours, tasks scale up to include cleaning or replacing fuel filter strainer elements, altering engine-mounted filter elements, checking cooling system inhibitors, and replacing air filter elements . These responsibilities collectively mitigate issues related to prolonged use and wear, maintaining efficiency.

Neglecting detailed maintenance checks for EMD engines operating under specified load and climatic conditions can lead to several detrimental consequences. These include increased risk of component failures due to stress or degradation that goes unchecked, inefficient power generation, and potential for catastrophic engine failures due to compounded mechanical issues. Neglected maintenance could also lead to escalated operational costs from unexpected downtimes, severe equipment damage requiring extensive repairs or replacements, and potential safety hazards from unchecked leaks or malfunctions . Moreover, warranty terms might be voided if maintenance recommendations are ignored, leading to further financial liabilities .

The load factor and climatic conditions significantly affect maintenance frequency and procedures for EMD Engine Driven Generators by dictating the wear and tear experienced by the machinery. High load factors or adverse climates can accelerate degradation of components, necessitating more frequent inspections and replacements, particularly of filters and lubricants. For example, in high load or severe climates, the replacement intervals for turbocharger and soak back filter elements might decrease due to faster accumulation of contaminants and wear . Proper assessment and adaptation to these variables ensure continued efficiency and reliability of the generators while minimizing breakdown risks.

Maintenance for EMD engine driven stationary power units is structured around various intervals, ranging from daily tasks to multiple-year schedules. Daily checks immediately after start-up include inspecting for leaks and ensuring cooling, fuel, and lube systems are at proper levels . Each month, oil samples are taken for analysis to monitor lubricant quality . Bi-monthly, bi-weekly, and beyond—to 16,000 and 35,000-hour intervals—additional, more in-depth tasks include replacing oil filters, inspecting and cleaning the lube oil system and other critical engine components, re-torquing nuts and bolts, and addressing wear or potential failure points identified during inspections . The tasks increase in complexity and detail as the intervals extend, accommodating major component inspections and replacements, crucial for long-term reliability and performance.

The condition of the lube oil system is vital to the operational efficiency of EMD engines as it minimizes friction, cools engine parts, and reduces wear, all of which enhance engine performance and efficiency. Periodic checks include bi-weekly inspections for leaks and oil level verifications, monthly sampling for quality analysis, and scheduled filter changes and cleanliness inspections . Regular checks of lube oil pressure and performance of the circulating pump further ensure that the system functions optimally, thus preventing overheating or excessive friction that could degrade engine components . Ensuring this system's health helps maintain consistent engine performance and reduces maintenance costs.

Torque inspections and adjustments are critical in EMD power unit maintenance, ensuring all mechanical joints maintain the appropriate tension and do not become loose over time, which could lead to failures. Specific components involved include cylinder head crab nuts, exhaust manifold flange bolts, cylinder liner water inlet line nuts and bolts, head frame to crankcase bolts, turbocharger to air duct bolts, and after-cooler to air duct bolts . Proper torque maintenance reduces the chances of leakage or misalignment resulting from vibrations or thermal expansion during operation, thereby safeguarding the engine's structural integrity and performance efficiency over its operational life .

Using consumables and replacement parts that meet original equipment manufacturer (OEM) specifications is significant for maintaining the performance and longevity of EMD engines. Proper specification alignment ensures compatibility and prevents wear or failure due to mismatched parts that could underperform or affect related systems. Adhering to specifications also sustains warranty validity and adherence to maintenance best practices, reducing the risk of costly repairs or outages .

Technological advancements play a significant role in predictive maintenance of EMD power units by leveraging data analytics, IoT sensors, and machine learning algorithms to anticipate possible failures before they occur. These technologies allow continuous monitoring of engine parameters like temperature, pressure, vibration, and wear levels, generating alerts for preemptive service actions . Potential benefits include increased reliability and uptime, optimized maintenance schedules that balance engine performance with maintenance needs, reduced unexpected breakdowns, and extended equipment life. Furthermore, data-driven insights can guide resource allocation and parts inventory management, improving overall cost-efficiency in power unit operations.

Operating EMD Engine Driven Units in standby mode influences the maintenance schedule by necessitating weekly run-ups to maintain operational readiness and efficiency. This includes running the unit at idle to stabilize coolant temperatures, and a monthly run at full load to check for responsiveness and ensure the system is free from operational issues such as leaks or mechanical failures . Regular operation prevents the build-up of condensation, corrosion, and mechanical inertia, thereby ensuring reliability when the units are needed for power generation .

Preparation for operating an EMD Engine Driven Unit after a shutdown period of over 48 hours involves several detailed steps. Before starting, operators must check the cooling system for adequate coolant levels, ensure the fuel system's main supply is intact, and verify the operation and pressure of the air system. Engine pre-lubrication is necessary to prevent wear. The fuel system also needs priming to facilitate combustion startup . Additionally, operators should manually bar over the engine to check for liquid in cylinders, addressing any found issues before starting. These steps are crucial for the engine's safe and efficient operation post-shutdown .

You might also like