The objective of SOP for preventive maintenance of diesel generator set is to ensure its reliable performance, extend its lifespan, and minimize unexpected breakdowns by conducting regular maintenance and inspections.
SOP for Preventive Maintenance of Diesel Generator:
- OBJECTIVE:
- To lay down the Procedure for Preventive Maintenance of Diesel Generator Set.
- SCOPE:
- This SOP is applicable to Preventive Maintenance of Diesel Generator Set installed at Utility Block .
- RESPONSIBILITY:
- Technician/ Officer engineering shall be responsible for proper execution of Preventive Maintenance of Diesel Generator as per SOP.
- Engineering – Head shall be responsible for reviewing the SOP and for ensuring proper execution of preventive maintenance of Preventive Maintenance of Diesel Generator.
- ACCOUNTABILITY:
- Engineering – Head shall be accountable for proper implementation of the SOP.
- DEFINITIONS:
- Nil
- PROCEDURE:
- Preventive Maintenance of Diesel Generator shall be executed as per the SOP No.: SOP/EN/XXXYYY – Execution of Preventive Maintenance.
- Ensure that the spare parts shall be available at the time of preventive maintenance
- “A” Daily Operational Checks
- Fill the daily operational checks of DG report for following points as per Format no. SOP/EN/XXXYYY
- Daily warm up start for 5 Minutes.
- Check the engine oil level.
- Check fuel supply.
- Drain sediment from fuel tanks.
- Check and clean the water separator.
- Check air Filter.
- Check coolant level.
- Check voltage of batteries.
- Check for any leakage in DG set.
- Check engine belts and in line engine water pump belts for belt tension.
- “B” 300 Hrs Preventive Maintenance Checks in Preventive Maintenance of Diesel Generator
- Lubricating oil systems; if the lubricating oil is drained from the oil pan to make an engine repair, top up with new fresh oil, never used oil after has been drained from oil pan.
- Analyze the oil for the contamination, if required add the fresh oil.
- Change engine oil and lubricating oil if required change filter elements.
- Record oil pressure.
- Clean and change crankcase breather
- Check coolant inhibitor, add coolant concentrate if required.
- Check the working of governor in DG set.
- Change fuel filter element.
- Clean fuel tank breather.
- Check air piping linkage.
- Check safety control and alarms.
- “C” 1500 Hrs. Preventive Maintenance Checks
- Check cooling system.
- Clean fuel tank from inside.
- Check the alternator/ starter, replace as required.
- Check the engine exhaust for restriction.
- Check for vibration damper.
- Checks switch gear/circuit breaker for proper operation.
- Check air inlet and outlet connections for restrictions.
- Check windings and electrical connections.
- Check power distribution and wiring connections.
- Apply grease on bearings.
- Check for air filters.
- Check the sound level test accordingly ISO 8528 Part 10 for each year.
- “D” 6000 Hrs. Preventive Maintenance Checks in Preventive Maintenance of Diesel Generator
- Repeat the Daily, Half yearly and Yearly Preventive maintenance checks.
- Clean and calibrate the fuel injectors if required.
- Replace the rocker cover gaskets in air system.
- Tighten the manifold nuts or cap screws.
- Check turbocharger compressor and turbine wheel.
- Check turbocharger bearing clearance.
- Check crankshaft and clearance.
- Check the vibration damper.
- Check safety controls.
- Change coolant, de-scale the cooling system.
- Replace the coolant after 6000 Hrs or top up level with water which comes earlier.
- Post Preventive Maintenance Check List
- Whenever any modifications and major works are carried out to the equipment, the same shall be mentioned in the equipment history card as per the respective SOP.
- Connect the equipment main power supply and start the equipment.
- Ensure that the equipment is running smoothly, without any abnormality.
- If any abnormality is observed in the above, same will be attended in co-ordination with User department Head.
- Record the details as per the Format No.: SOP/EN/XXXYYY“Preventive Maintenance Checklist & Record for Diesel Generator Set”.
- The preventive maintenance will be carried out with OEM /Authorized vendor.
- ABBREVIATIONS
- CRF No. : Change Request Form number
- QA : Quality Assurance
- PM : Preventive Maintenance
- OEM : Original Equipment Manufacturer
- SOP : Standard operating procedure
- ISO : Indian standard organization
- DG : Diesel generator
- REFERENCES
- Operational & Maintenance Manual of Preventive Maintenance of Diesel Generator Set.
- DISTRIBUTION LIST
- SOP shall be distributed to following departments Quality Assurance, Engineering as per user request
- ANNEXURES
- Preventive Maintenance Checklist & Record for Diesel Generator Set : SOP/EN/XXXYYY
- “A” Daily operational Checks : SOP/EN/XXXYYY
Preventive Maintenance of Diesel Generator Checklist and Records:
| Equipment Name | Location | ||
| Equipment ID | Frequency |
| Things to be done: | Check List | Remarks |
| “B” 300 Hrs Preventive Maintenance Checks | ||
| Check raw water strainer. | ||
| Lubricating oil system. | ||
| Analyze the oil for the contamination, if required add the fresh oil. | ||
| Change engine oil and lubricating oil if required change filter elements. | ||
| Record oil pressure. | ||
| Clean and change the crankcase breather. | ||
| Check hydraulic governor oil level. | ||
| Change fuel filter element. | ||
| Clean fuel tank breather. | ||
| Check air piping, throttle linkage. | ||
| Check safety control and alarms. | ||
| “C” 1500 Hrs. Preventive Maintenance Checks | ||
| Check cooling system. | ||
| Clean fuel tank from inside. | ||
| Check the alternator / starter, replace as required. | ||
| Check for vibration damper. | ||
| Checks switch gear / circuit breaker for proper operation. | ||
| Check air inlet and outlet connections for restriction. | ||
| Check power distribution and wiring connections. | ||
| Check winding and electrical connections. | ||
| Apply grease on bearings. | ||
| Check for air filter. | ||
| Check the sound level test accordingly ISO 8528 Part 10 for each year. | ||
| “D” 6000 Hrs. Preventive Maintenance Checks | ||
| Repeat the Daily, Weekly, Half yearly and Yearly Preventive maintenance checks. | ||
| Clean and calibrate the fuel injectors if required. | ||
| Replace the rocker cover gaskets in air system | ||
| Tighten the manifold nuts or cap screws. | ||
| Check turbo charger compressor and turbine wheel. | ||
| Check turbo charger bearing clearance. | ||
| Check crankshaft and clearance. | ||
| Check vibration damper | ||
| Check safety controls | ||
| Change coolant, de-scale the cooling system. | ||
| Replace the coolant after 6000 Hrs or after two years which comes earlier. |
| Sr.No. | Check Points | |
| 1. | Daily warm up start for 5 Minutes. | |
| 2. | Check the engine oil level. | |
| 3. | Check fuel supply. | |
| 4. | Drain sediment from fuel tanks. | |
| 5. | Check and clean the water separator. | |
| 6. | Check air Filter. | |
| 7. | Check coolant level. | |
| 8. | Check voltage of batteries | |
| 9. | Check for any leakage in DG set | |
| Done By | ||
| Signature | ||
