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_OF_AN_ELECTRIC_GENERATOR_PROF._ANASTACIO_PERALTA_GAONA._MAINTENANCE_
EMERGENCY_ELECTRICAL_SYSTEMS

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Primary Data:

Generator groups in the plant: 2

1st 2°
Brand InteliLite (Comp Ap) InteliLite (Comp App)
Model Intelilite MRS 16 InteliLite AMF 9
Time of Use
Missing parts
Requires change
Critical Parts
Photography

Maintenance Plan for Generator Set

What is a generator?

A generator refers to a device that has the main function of transforming the
heat capacity provided by the fuel in mechanical energy at the outlet
crankshaft of the engine and then into electrical energy. Briefly, it consists of an engine
and an alternator that are coupled and inserted into a base with other elements. A group
A generator is a machine that moves an electric generator through a motor.
internal combustion. They are commonly used when there is a deficit in generation.
electric energy from some place, or when power outages are frequent.
Likewise, the legislation of different countries may require the installation of a generator.
in places where there are high densities of people, such as hospitals, data centers,
shopping centers, restaurants, prisons, administrative buildings, etc. One of the utilities
the most common is to generate electricity in those places where there is no supply
electric. Generally, they are remote areas with few infrastructures and very little
inhabited. Another case would be in public places: hospitals, factories, etc., places
in which the grid electric energy is insufficient and another energy source is needed
alternative to supply oneself.

Types of Generating Sets:

Emergency backup (Stand By1):

They are the Groups that are used only for very short use, because the main energy is gone.
for some reason: 1 Stand by: Generator for emergency use 18. Maximum use time 50-200
hours. For small industries, businesses, homes, buildings, events, etc. They can be powered
Gasoline. Low, medium loads (do not require feeding so much equipment) At the moment when the
main energy supply arrives, will stop functioning, corresponds to the use of Generating Sets in the face of
unexpected power outages.

Working Day / Peak Hours:

It corresponds to the use of Generator Groups to work during the Work Day. Group
Main Power Generator, this Group is used as the main source of energy, it is
also called Prime Power. • Usage time in hours: Unlimited • Variable load that does not
it can exceed 25 hours of overload per year • For large Industrial Plants, Mines,
Works, Crushers, drilling rigs • Fuel type Diesel or Gas oil as it is more
economic • Single Source (Full Prime), corresponds to the use of the Generator Set as the only
power source. This equipment performs the same function as the main one, only it does remain
all the time in use, because there are operations that can never be turned off. It is called
also Continuous Power2: Usage time in hours: Unlimited. Fixed load as it is calculated at
start of the operation Power is generally supplied from 80% to 100%, while
the Main Power should not exceed 70% It is used for pump stations of
water, base load in a power plant, etc.

Parts of a Generator Set

Diesel Engine

The diesel engine that drives the generator set has been selected for its reliability and for the
fact that it has been specifically designed to operate generators. The power
The one that is wanted to be supplied will be provided by the engine, so for a certain
power, there will be a specific engine that meets the required conditions.
Electric motor system

The motor's electrical system is of [ ] 5, except for those engines which are
fed to [ ] negative to mass. The system includes a starter motor
electric, one/more maintenance-free battery/batteries (lead accumulators), however, is
they can install other types of batteries if specified, and the sensors and devices of
alarms available for the engine. Normally, an engine has a hand contact.
oil pressure, a temperature sensor contact, and a contact in the alternator
motor load to detect a load failure in the battery.

Cooling system

The engine cooling system can be through water, oil, or air. The system of
air cooling consists of a large capacity fan that blows cold air through
length of the engine to cool it. The water/oil cooling system consists of a
radiator, an internal fan to cool its own components or cooled through the
seawater cooling system.

Alternator

The output electric energy is produced by a shielded alternator, protected.

against splashes, self-excited, self-regulated and brushless precisely coupled to the
motor, although brush alternators can also be coupled for those groups
whose operation will be limited and, under no circumstances, forced into regimes
larger. Fuel deposit and bench. The engine and the alternator are coupled and
mounted on a high-strength steel bench. The bench may include a
fuel tank with a minimum capacity of 8 hours of full operation
load, otherwise one can be built that complies with the house rules
classifier to which the ship is subject.

Measurement Parameters:

Load tests of the generators:

Load banks are used to test power sources. They simulate load conditions.
variables in a way that they can be controlled, measured, and recorded accurately. It turns out
It is vital to test their systems to see if they meet the demands placed on them;
whether you are starting new generators or need to perform maintenance
routine. It is also important to start up the backup generators.
Periodically to burn off the fuel, the oil, and any condensation that may be present.

Loading steps:

The equipment is subjected to sudden load variations to check the regulator's response.
of speed and therefore the variations in voltage and frequency that must be according to the
established by the rules of the classification houses. Figure 2-3 Test load bank
generadores Carga [%] Tiempo [min] Vacío 15 25% 15 50% 15 75% 15 100% 60 110% 45 Tabla
2-1 Generator Load 26 The most demanding thing is to run the engine at 100% of its
load at 0%, the reaction time must be 2 seconds, with a voltage variation of +/-
16% and a frequency of +/-4%.

Reverse current stop check:

The phenomenon of reverse current in a generator set is due to the fact that when two equipment
They are working in parallel and one of them is working with less workload, the
This equipment's alternator with less charge tends to absorb current and instead of working
as the alternator absorbs load as if it were a motor, for which it was not designed, for the
These equipment have a reverse current disconnection, the test consists of
in the following:

Alarm and Security Systems Check:

Different faults are simulated using specialized equipment that sends signals to the
local control panel, in order not to subject the generators to conditions
unnecessarily demanding work. This test is divided into conditions that generate
visual alarm, acoustic and ensure the equipment and conditions that only generate visual alarm and
acoustic, the first are: low oil pressure, high coolant temperature and over
speed, the second are: low refrigerant water pressure, low liquid level Action
Setrabaja reaction with generators in parallel with generator 1 at 10% load.
disconnect generator 1 (the reaction should not take more than 5 seconds) work is being done with
parallel generators with generator 2 at 10% load. Generator 2 is disconnected.
reaction should not take more than 5 seconds) Table 2-2 Reverse current stop test. 27
refrigerant, fuel leaks, pressure differential in the oil filters and temperature
of the oil.

Insulation tests:
The alternator is subjected to insulation tests: with Multtester7 in which the verification is carried out.
isolation between phases, between earth and soundproof chassis and between each phase (R, S, T) and earth,
these measurements are made with the generator cold (this means with the generator out of
service) and then it is performed with the hot generator (immediately after having
out of service the generator), these ranges must understand to infinity in the measurements
between each phase and between phase and earth, in the case of the mass on earth and the hull, this must give
zero, then when comparing the measurements in cold and hot these should be the same.

MAIN MAINTENANCES OF A GENERATOR SET

From the primary motor:

Check the oil level. The engine must be horizontally leveled, it must be ensured
that the level is between the MIN and MAX marks on the stick. If the engine is hot, it should be
wait between 3 and 5 minutes after stopping the engine. Oil and oil filters. Respect
always the recommended oil change interval and replace the oil filter at the same time
Time. Do not remove the lower plug on stopped engines. In the case of dry sump or sumptank.
It is advisable to clean and check the tank when the oil is completely changed.
in case of finding particles like cloths, metals, or glasses that could accidentally cause damage
lubrication system. Air filter. The air filter should be replaced when the indicator of
filter as indicated. The degree of dirtiness of the intake air filter depends on the
concentration of dust in the air and the chosen size of the filter. Therefore, the intervals of
cleaning cannot be generalized; rather, it is necessary to define them for each individual case.
Auxiliary element belts. Verification and adjustment. The inspection and adjustment must
perform after the engine has run, when the belts are hot. Loosen the
screws before tensioning the alternator belts. The belts should give 10mm between the
pulleys. Worn belts that work in pairs must be changed at the same time.
fan belts have an automatic tensioner and do not need adjustment. However, the
The condition of the belts must be checked. Cooling system. The system of
The cooling system must be filled with a coolant that protects the engine against corrosion.
internal and against freezing if the weather demands it. Never use water alone. The additives
Anticorrosion becomes less effective over time. Therefore, the coolant must
replace. The cooling system must be cleaned when replacing the refrigerant. The best thing is
refer to the engine manual for cooling system cleaning. Fuel filter.
Substitution. Cleaning: dirt or contaminants must not enter the injection system.
fuel. The replacement of the fuel must be carried out with the engine cold to avoid
the risk of fire caused by spilling fuel on hot surfaces.
Maintenance of the alternator:

During routine maintenance, periodic attention to the state of the

deactivated (especially when the generators have been inactive for a long time)
and of the bearings. Condition of the windings. The condition of the windings can be determined.
measuring the ground insulation resistance, that is, the ohmic resistance that offers the
machine casing regarding grounding. This resistance changes when there is moisture or
dirt in the windings, therefore, the insulation measurement of the generator will indicate us
the current state of the winding. The device used to measure insulation is the
megohmmeter10 or Megger11. The AVR12 (automatic voltage regulator) must be
disconnected in the event that the generator is self-excited. So that the measures
to have its exact value the machine must be stopped. It is difficult to determine what the value is of the
insulation resistance of a generator, but as a standard to follow the formula is used: R
(resistance in Megohms) = Rated voltage in V. / Rated power KW + 1000 always and
when the machine is hot, that is, in full operation.

To measure insulation resistance, the positive pole of the megohmmeter is connected to one of
the terminals of the motor and the negative to its metallic mass; we turn the handle of the
megohmmeter if I had one, since there are digital megohmmeters, and it will be observed that the needle will
move to a position on the scale until it is noticeable that it slips and at that same moment
The insulation resistance is read directly on the device's scale. During the measurement,
the generator must be completely separated from the installation, disconnecting from it. If the
insulation resistance is lower than the winding resistance, it would be
it is essential to dry them. Drying can be carried out by directing hot air coming from
from a heater fan or similar device through the intake and/or exhaust grills
air from the generator, although another quick and effective method would be drying using an oven by
heating of resistors. Alternatively, the windings can be short-circuited.
main stator, causing a total three-phase short circuit at the main terminals with the
generator set in operation. This method allows to dry the windings in a very short time.
time, although for this it must consult the method and the way to do it according to the type of
alternator in its corresponding manual.

Bearings

All the bearings are permanent lubrication for a free operation

maintenance. During a general inspection, it is recommended, however, to check them for
wear or loss of oil and replace them if necessary.

It is also recommended to periodically check if the bearings are overheating or if

They produce excessive noise during their operation. In case of verifying vibrations.
excessive after a certain time. This would be due to the wear of the bearing, in which case
It is advisable to examine it for defects or loss of fat and replace it if necessary.
In any case, the bearings should be replaced after 40,000 hours of service. Another way
To determine the wear of the bearings, measure the distance between the stator and the rotor.
through a Feller13, in this way reviewing the original measurements of the set
you can know the presence of any misalignment.

Rubbing rings and brushes. Very often the sparking in the brushes is due to the
dirt on the rubbing rings, or some other mechanical cause. The position must be examined.
from the brushes in such a way that they have to touch the rubbing rings on their entire surface,
they must also be replaced when a quarter of their length has been used up.
to thoroughly clean the rubbing rings cyclically, removing all dust or dirt from them
to cover them, especially when the brushes are changed.

Battery

The normal use and charging of batteries will result in water evaporation. Therefore,
So, you will have to recharge the battery from time to time. First, clean the battery to
prevent dirt from entering and then remove the stoppers. Add distilled water until the
Level should be 8 mm above the spacers. Reposition the spacers.
 Situation of the Plant:

Found Generators: 2

Functional Electrogenic Generators: 1

It has been defined that for this type of equipment it is necessary to determine the guidelines for
preventive maintenance, which has been defined as:

Periodic Inspection Schedule (PPM)

Check motor operation status at idle

Air Filter Element Review
Review status indicator restriction / saturation air filter
Fuel Hose Inspection
Review status of clamps
Fuel level inspection
Coolant level check
Engine oil level inspection
Review TTA

2. Preventive Maintenance Schedule

Check the engine operation status in idle

Air filter change It is recommended to switch to
Oil Filter Change wrong time.
Oil change
Fuel filter change
Refrigerant filter change
Review status of fan quotes (FAN21)
Review status of the vent hose canister
Motor wiring status review
Belt accessory revision
Battery charge review
Control Panel Status Review
Heater status review
Pump clock review (Transfusion)
Battery Maintainer Status Review

PPM: Preventive Maintenance Agenda

Top Overhaul: Major repair mounted in the cabin

Overhaul: Major Repair Outside of the Cabin

TTA: Automatic Transfer Board

Fan
Canister: Activated carbon filter

replace the bearings after 40,000 hours in service

Spare parts that should be in stock.

According to the responsibility within the team:

I. Parts Subject to Wear

To this group belong those elements that connect fixed and movable parts, or those parts in
contact with fluids, such as bearings, bushings, seals, gaskets. They are parts subjected to
to wear and to abrasion. In this group we can also include joints, seals,
Pipelines subject to fatigue, corrosion, and cavitation.

II. Consumables

They are those elements with a duration of less than one year, with a life that is easily
predictable, low-cost, which are usually replaced without waiting for them to yield
Symptoms of poor condition. They are filters and lubricants. Their failure and neglect can
cause serious breakdowns.

III. Elements of regulation and command:

They are those elements whose mission is to control the processes and the functioning of
the installation: valves, springs, crankshafts, etc. They are elements that despite not
to be subjected to unfavorable operating conditions
capital importance within the team. Its frequent failure is due to fatigue.

IV. Moving parts:

They are those intended to transmit motion. They are gears, shafts, belts,
chains, reducers, etc. Their usual failure is due to fatigue.

V. Electronic components (instrumentation):

Despite their high reliability, a problem with them usually means a halt in the
equipment. Its usual failure is due to overheating, short circuit, or overvoltage, and
They generally occur when the equipment is subjected to certain working conditions.
different from those for which they were designed. A common example is a failure in another
element that causes abnormal operation of the equipment; another can be to work
under extreme atmospheric conditions of heat, cold, humidity, or dust.

General use spare parts stock needed in the warehouse:

Description Part Number Quantity

/Stock
1 Mobile Mining Refrigerant Coolant 33% G000001 300 liters
2 Repsol 15W40 motor oil G000002 300 liters
3 Radiator cover G000003 5 unity
 4 Positive terminal Battery G000004 10 unit
5 Negative terminal Battery G000005 10 unity
6 Radiator support G000006 10 unit
7 Omega 60mm clamps G000007 30 unity

List of Critical Stock Supply

Description Part Number Quantity

1 Lens security E000001 3 Unit
transparent
2 Peltor safety headphones E000002 3 Unit
3 Polpin Geological Vest E000003 5 Unit
Size M
4 Nitrile Glove Size M E000004 3 Boxes
5 Standard Goatskin Glove E000005 25 Unit
6 Tyvektalla M Sweater E000006 25 Unit
7 Safety Helmet E000007 5 Unit
8 Safety Button T40
9

Critical Stock Warehouse Materials

Description Part Number Quantity

1 Rollo Cloth Waypall IN000001 2 Unit
2 Wurth Mechanical Soap IN000002 2 Unit
3 Degreasing liquid IN000003 20 Liters
4 Checkbook IN000004 2 Unit
5 Technical Report Booklet IN000005 2 Unit
Service
6 Extinguisher PQS 10kg IN000006 4 Unit

FOR THE EXECUTION OF THE WORK:

Activity log:

The record must consider:

Country of origin and legal name of the manufacturer.

Representative: The name of the company that has the representation must be indicated.
from the team in Chile and in the area.
Team: The name of the team is recorded.
Type or Model: The type or model of the equipment is indicated.
Registration Number: The number corresponding to the equipment's registration is noted in the
inventory.
Technical Characteristics of the Equipment: The size measurements and capacities are recorded.
such as capacity, power, torque, etc.
Serial Number: It is obtained from the equipment's plate.
Location: the section where the equipment is located is indicated, in case it is a
stationary equipment.
Acquisition: the acquisition date and the purchase value of the equipment are recorded.
Installation Expenses: Understand everything invested in terms of materials and
labor used in the installation of the equipment