O & M of Electrical Equipment

WSD 5231

Generators

Module 2

WSD 5231, Mod. 3 1

Agenda

 Introduction to generators
 Basic assembly design of generators
 Components of generator
 SOP’s and Best Industry Practices
 Periodic Maintenance and record keeping
 Reliability based preventative
maintenance.
 Troubleshooting for various failures
WSD 5231, Mod. 3 2

1
 Class Introduction

 Importance of Generators in WASA operations

 What do we cover in this module?

 What to expect in this module?

 Goal and objectives of this module?

WSD 5231, Mod. 3 3

Introduction to Generators
A generator is machinery that converts mechanical energy to electrical energy by
electromagnetic action to generate electrical power

Principle of Generator

Frequency of the synchronous generator is determined according to the rate of rotation

Basic components of Generator:

1. Diesel Engine

2. Alternator

3. Control Panel

WSD 5231, Mod. 3 4

2
 Flow of Systems
1. Starter motor starts operation using power supplied by batteries

2. Crank Shaft of engine starts rotating

3. Combustion cycle starts

4. Rotor of alternator starts to rotate

5. Stator of alternator generates power

WSD 5231, Mod. 3 5

Basic design of generator

 Major components of a diesel generator
1. Engine
2. Alternator
3. Fuel Tank and related system 7

4. Voltage Regulator
5. Air Intake and Exhaust Systems 9 6

6. Cooling Systems
7. Lubrication System
8. Battery (Engine Starting System) 8
10
9. Control Panel
10. Main Assembly / Frame
WSD 5231, Mod. 3 6

3
 Block Diagram of generator

Fuel Air
Electric Panel
Exhaust

Diesel Engine Alternator Electricity

Engine Starting
Lubricant Coolant
System
WSD 5231, Mod. 3 7

Fuel System Flow Diagram

Fuel Tank Fuel Lift Pump
Air System
Fuel Filter/Water Separator
Air Filter

Injection Pump
Turbocharger
Nozzle
Exhaust

Electric
Panel

Diesel Engine Alternator

Electric
Oil Filter
Starting Motor
Radiator
Oil Pan Oil Lift Pump Batteries

Cooling System Engine Starting

Lubrication Oil System
WSD 5231, Mod. 3
System 8

4
1.Engine
 The engine is the source of the input
mechanical energy to the generator.

 The size of the engine is directly

proportional to the maximum power
output the generator can supply.

 Source of energy for the operation of

Generator
Engine
WSD 5231, Mod. 3 9

2. Alternator

 The alternator is the mechanical equipment

that produces electrical output from the
mechanical input supplied by the engine.

 It is coupled to the diesel engine through a

drive shaft.
Alternator

WSD 5231, Mod. 3 10

5
2. Alternator

Alternator

WSD 5231, Mod. 3 11

2. Alternator

WSD 5231, Mod. 3 12

6
3.Fuel System
Injectors (Nozzles)
Injector
Pipes
Leak off pipe

Fuel Lift Pump

Fuel pipe under suction Fuel Tank

Injection
Pump Fuel Filter

WSD 5231, Mod. 3 13

Components of Fuel System

Fuel Tank Fuel Lift Pump Fuel Filter

Store enough fuel for Lift the fuel from the Remove any solid
combustion. fuel tank particle in fuel

WSD 5231, Mod. 3 14

7
 Components of Fuel System
Fuel Water Separator Injection Pump Nozzle

Separate and remove water Inject fuel through nozzles Throw fuel into the
from the fuel at certain pressure cylinders in small particle
form
WSD 5231, Mod. 3 15

4. Automatic Voltage Regulator (AVR)

AVR function is to control the magnetic
field of the generator such that the output
voltage will be constant.

WSD 5231, Mod. 3

16

8
5. Air Intake & Exhaust Systems
Turbo
Charger Muffler

Air Filter

Fresh air Hot Gas

Diesel Engine

Typical Air Intake and Exhaust System

WSD 5231, Mod. 3 17

Components of Air Intake & Exhaust System

Air Filter Turbocharger

Clean air from dust Compress air before

particles intake for better
combustion
WSD 5231, Mod. 3 18

9
 6. Cooling System
Function:
This system maintains the temperature of the engine assembly by introducing coolant
into cooling channels. After completing the cycle coolant temperature increases which is
then passed through radiator to radiate heat.

Components:
1. Radiator/ Charge air cooler
2. Thermostat

WSD 5231, Mod. 3 19

6. Cooling System Diesel Engine

Radiator cap

Fan
Coolant

Coolant

Radiator

: Coolant Flow
Radiator

Cooling System

WSD 5231, Mod. 3 20

10
 Components of Cooling System
Radiator Fan

Reduce the temperature of Provide fresh air to

the coolant radiator for cooling coolant

WSD 5231, Mod. 3 21

7. Lubricating System

 Generator comprises moving parts in

it’s engine, So lubrication is required
for long lasting operation.

 The generator’s engine is lubricated

by oil stored in an oil pan.

Lubrication system

WSD 5231, Mod. 3 22

11
 Components of Lubricating System
Ｏｉｌ Pan Oil Lift Pump Oil Filter

Store enough engine oil Lift and send oil from the Remove any pollution
for lubrication oil pan to the oil filter or solid particle in
and keep circulation engine oil
WSD 5231, Mod. 3 23

8. Engine Starting System

 The start function of a generator is

battery-operated.

 The engine needs initial rotating power to start

combustion cycle so that starting motor provides
the power by consuming battery DC power
Starter Motor
 Battery is charged by DC alternator
during generator operation Battery

WSD 5231, Mod. 3 24

12
 Components of Fuel System
Alternator For
Battery Starter Motor
Battery Charge

Provide starting current to Start rotation of engine Generate power and charge
the starter motor from the rest position the battery by utilizing
engine rotation
WSD 5231, Mod. 3 25

9. Control Panel
 This is the user interface of the generator and contains
provisions for electrical outlets and controls.
 Electric start and shut-down
 Engine gauges
 Generator gauges
 Alarm monitoring
 Data logging
 Other controls

Electrical Control panel

WSD 5231, Mod. 3 26

13
 Components of Electrical System
Alternator (Main) Electrical Panel Cables

Provide main alternative Monitor and control the Provide electrical

power supply system through sensors and connectivity between the
provide electrical energy alternator and other
with protection electrical component
WSD 5231, Mod. 3 27

10.Main Assembly / Frame

 All generators, portable or stationary, have

customized housings that provide a structural base
support.

 The frame also allows for the generated to be

earthed for safety.

Main frame of Diesel

Generator
WSD 5231, Mod. 3 28

14
 Fuel System Flow Diagram
Fuel Tank Fuel Lift Pump
Air System
Fuel Filter/Water Separator
Air Filter

Injection Pump
Turbocharger
Nozzle
Exhaust

Electric
Panel
Diesel Engine Alternator

Electric
Oil Filter
Starting Motor
Radiator
Oil Pan Oil Lift Pump Batteries

Cooling System Engine Starting

Lubrication Oil System
WSD 5231, Mod. 3
System 29

WSD 5231, Mod. 3 30

15
Capacity Calculations
• No specific or standard sizing solution is available.
• Highly depends upon the site conditions and running loads.
• Some manufacturers provide guide to estimate the required generator
sizes.

WSD 5231, Mod. 3 31

Capacity Calculations
Following steps are required to calculate required size of the generator:
Step 1: Calculate the power of all non-motor loads
Step 2: Calculate starting power of the largest motor and running power of
all other motors.
Step 3: Add all motor’s running load and starting load of the largest motor
Step 4: Add non motor loads into the value of step 3
Step 5: Select Generator’s rating of at least 125% of the final answer of
step 4

WSD 5231, Mod. 3 32

16
 Standard Operation Procedure
for Generator

WSD 5231, Mod. 3 1

Electrical Connection’s Overview

Standby Diesel Generators

Changeover Switch
Motor of Pump

Electrical Panel

WAPDA Line Incoming

2
(11kV, 3phases) Pole

WSD 5231, Mod. 3

 Electrical Connection’s Overview

Standby Diesel Generators

Changeover Switch
Motor of Pump

Electrical Panel

Incoming Main Circuit

WAPDA Line Breaker Terminal Box 3
(11kV, 3phases) Pole Transformer
11kV → 400V

Changeover Switch Operation

 Change over Panels are used to switch

Electrical Generator
between primary and auxiliary power Company

source. It is used in case of multiple

connections from the electric supply
company or generators
Changeover
Switch

Motor Control Unit

Motor

2
 How to operate changeover switch ??
 Don’t directly open/turn the
changeover switch during operation
of load Electrical Generator
Company

 Turn off the circuit breaker/magnetic

contactor first !! Second
Turn the
Changeover
changeover switch
Switch
 Otherwise, The terminal of
changeover switch would encounter
sparking First!!
Circuit Breaker
should be turned off Motor Control Unit

Motor

Best practices in Generator Operations

Standard operating procedure before operation

•No Leakages
Inspect •No Unusual smell/ odour
the site

•Circuit breaker of the generator

•Connections of batteries are fine
Inspect the •No loose screw/ bolt
generator •Enough amount of fuel
•No indication or warning lamps are turned on

•Turn off the following devices first:

•Main circuit breaker of Electrical Company’s line
Electrical •Circuit breaker of Motor control unit
isolation •Circuit breaker of the generator
•Rotate changeover switch to generator

WSD 5231, Mod. 3 6

3
 Best practices in Generator Operations
Standard operating procedure during operation
•Turn on the Main Circuit Breaker of the Generator
•Start the generator
Start and
•The sound of generator should be normal
Observe
•Examine the frequency and voltages

•Wait for 30-40 seconds till confirming voltage and

frequency get stable enough
Inspect te the
Connect •Turn on the circuit breaker of the motor control unit
generator
generator

•Sound should be normal

Observe the •No leakages of air, gas and oil from expected parts
operation

WSD 5231, Mod. 3 7

Parameters To Be Cared For

Before Operation
1. Circuit Breaker Off 2. Fuel Level 3. Battery water Level 4. Oil Level

WSD 5231, Mod. 3 8

4
Parameters To Be Cared For
Before Operation
6. Site Inspection
5. Coolant Level
General condition of
Leakage Odor
Generator

WSD 5231, Mod. 3 9

Parameters To Be Cared For

During Operation
1. Voltage 2. Frequency 3. Current 4. Over Heat

WSD 5231, Mod. 3 10

5
Parameters To Be Cared For
During Operation
5. Earth Leakage 6. Gas, Air, Oil Leakage, Vibrations/ Abnormal noise

WSD 5231, Mod. 3 11

Preventative Maintenance
＆
Record Keeping

WSD 5231, Mod. 3 12

6
 Preventive Maintenance

Reduce uncomfortable operation for main components and

increase the lifetime of facility

Tracking data indicates latent failures in the early stage

before it leads to a breakdown

Fault detection in the early stage contributes to sustainable

water supply service

WSD 5231, Mod. 3 13

Necessity of Maintenance
An early warning is generated by the generator before the occurrence of many failure.
One should keep special intension to the device during operation, maintenance and
regular inspection to avoid major problems. Some of the problem which can be observed
during the operation of the device are:
a. Engine misfire
b. Vibration
c. Unusual engine noise
d. Sudden changes in engine operating temperatures
e. Excessive smoke
f. Increase in oil consumption
g. Increase in fuel consumption

WSD 5231, Mod. 3 14

7
 How should the generator be?
Fuel System Air System
Secure Enough Fuel
Fuel Tank Fuel Lift Pump Air Filter
Keep Clean
Fuel Filter Turbocharger
Keep Clean VLL=400V
Injection Pump Charge Air Cooler F=50Hz
Noz
zle Proper Insulation

Electric
Panel
Diesel Engine Alternator

Injection Pump Electric

Keep Clean Starting Motor
Oil Filter Radiator
Batteries
Oil Pan Oil Lift Pump Cooling System

Maintain Coolant Level Maintain Electrolyte Level

Change Oil Regularly
Lubrication Oil System
WSD 5231, Mod. 3 15

Necessity of maintenance
Fuel Tank Fuel Lift Pump

Turbo
Air Filter
Charger
Fuel Filter

Not Clean Not Clean Charge Air

Injection
Cooler
Pump

Diesel Engine Diesel Engine

Problems: Problems:
 Engine Misfires  Engine Misfires
 Engine Runs Rough  Dark Smoke
 Low Output Power  Lower Acceleration

Remedy: Remedy:
 Replace or clean the fuel filter  Replace or clean the air filter
WSD 5231, Mod. 3 16

8
 Daily and Periodic Maintenance Sheet
Service Type Year____
Last Activity Month____
Sr. No. Activities
Daily Weekly Monthly 6 Months Date 1 2 3 4 5
1 Visual Inspection
2 Check Coolant Level
3 Check Oil Level
4 Check Fuel Level
5 Check Charge Air Piping
6 Check and Clean Air Cleaner
7 Check Battery Charger
8 Drain Fuel Filter
9 Drain Water From Fuel Tank
10 Check Coolant Concentration
11 Check Drive Belt Tension
12 Drain Exhaust Condensate
13 Check Starting Batteries
14 Change Oil and Filter
15 Change Coolant Filter
16 Clean Crankcase Breather
17 Change Air Cleaner Element
18 Check Radiator Hoses
19 Change Fuel Filters WSD 5231, Mod. 3 17
20 Clean Cooling System

WSD 5231, Mod. 3 18

9
Daily Operation & Maintenance Record
Daily Operation and Maintenance Record (Generator)

Month/Year : ／ Approved by (Engineer)

　　　　Date : 　　～ Prepared by (Operator)

Standard/ Date
Items Unit
Rated
Average Total
( ) ( ) ( ) ( ) ( ) ( ) ( ) ( )
:　　 ～ 　　 : :　　 ～ 　　 : :　　 ～ 　　 : :　　 ～ 　　 : :　　 ～ 　　 : :　　 ～ 　　 : :　　 ～ 　　 : :　　 ～ 　　 :
Operating Time -

Operating Hours hrs.

Operation Record
Operation Record

Voltage RS V 400

ST V 400 Operation Time, Operation

TR

Frequency
V

Hz
400

50
Hour, Voltage, Frequency,
Energy Consumption KWh Energy Consumption

Coolant Level ✔ Remarks

Fuel Level L

Engine Oil Level Daily Maintenance Record

Maintenance Record

Alternator and Fan Belts

Driven Equipment
✔

✔
Coolant Level, Fuel Level, Oil
Walk Around Inspection ✔ Level, Fan Belt, Driven Parts,
Waｌk-Around Inspection

WSD 5231, Mod. 3 19

Daily Maintenance Checks

・ Electric panel
Electric and control panel must be inspect before operation. There must be no spark
or smell etc. In case of spark or smell, check the connections of the devices and
rectify the problem immediately.

・Air intake piping

Visual inspect:
- Intake piping wear points
- Damages to piping
- Loose clamps or punctures that can damage the engine
Replace damaged pipe and tighten loose clamps, as necessary,
to prevent the air system from leaking.

WSD 5231, Mod. 3 20

10
Daily Maintenance Checks
Walk-around inspection
To look for any…
• Leaks
• Damaged Parts
• Worn of Damaged belts
• Any change in engine appearance
• Odor of fuel

Daily Maintenance Checks

• Maintenance check
Visually inspect piping points for
wear points and damage, loose
clamps or punctures.

Replace damage piping and

replace loose clamps.

11
 Daily Maintenance Checks
Cooling fan

 A visual inspection is required daily.

Check for cracks, loose rivets, bent or loose blades.
Check the fan if it is securely mounted.

 Do not rotate the engine by pulling or prying on

the fan. Use the accessory driveshaft or the
crankshaft barring tool to rotate the crank shaft.

WSD 5231, Mod. 3 23

Cooling System

 The charge-air cooler piping and

hoses should be inspected regularly
for leaks, holes, cracks, or loose
connections. Tighten the hose clamps
as necessary. In addition, inspect the
charge-air cooler for dirt and debris
that may be blocking the fins. Check
for cracks, holes, or other damage.

WSD 5231, Mod. 3 24

12
 Cooling System

• Inspect for Reuse

Visually inspection is required to
check for cracks, loose rivets and
bent or loose blades.

Do not rotate the engine by

pulling or prying on the fan. Fan
blades can be damaged causing
the fan to fail and cause personal
injury.

Daily Maintenance Checks

 External coolant leaks
 Belt condition-cracked or loose
 Block heater – on constantly or leaking
 Hoses – leaking, soft, brittle, bulging
 Radiator – Leaking, plugged, broken fan shroud

WSD 5231, Mod. 3 26

13
 Daily Maintenance Checks
Engine coolant level
 Do not remove the pressure cap from
the hot generator. Wait until the coolant
temperature is below 50 ℃ before
removing the pressure cap.

 To add coolant, the ratio of coolant and

anti-freeze must be according to the
recommended weather conditions.

WSD 5231, Mod. 3 27

Daily Maintenance Checks

Drive belts
Inspect the belt daily. Check the belt for intersecting
cracks. Replace the belt if it is frayed or has pieces of
material missing.
Belt damage can be caused by:
•Incorrect tension, size or length
•Pulley misalignment
•Severe operating environment
•Oil or grease on the side of the belt
•Aging degradation

WSD 5231, Mod. 3 28

14
Checking the belt tension

• Use a ruler to find the midway point

on the belt's longest run between
pulleys. Hold the belt between
finger and thumb at this point and
move it from side to side.

• See how much it deflects at the

center of the run.

• If it moves more than 1/2 in. (13

mm) it is too slack - any less
movement and it is too tight. Check
the exact deflection recommended
in the car handbook.

WSD 5231, Mod. 3 29

Fuel System Check

 With the generator set operating,

inspect the fuel supply lines,
return lines, filters, and fittings
for cracks or abrasions.
 Make sure the lines are not
rubbing against anything that
could cause an eventual failure.
 Repair any leaks or alter line
routing to eliminate wear
immediately.
Fuel System

WSD 5231, Mod. 3 30

15
 Daily Maintenance Checks
Engine lubrication oil level
 The engine must be level to check the
lubrication oil level.

 Shut off the engine for an accurate reading.

Wait at least 15 minutes after shutting off the
engine to check the oil level.
This allows oil the time to drain into the oil pan.

WSD 5231, Mod. 3

31

DC Electrical- Areas of concern

DC electrical system: Check the terminals on the starting

batteries to make sure the connections are clean and tight.
Loose or corroded connections create resistance, which can
hinder starting.

1. Battery Charger - voltage and amperage

2. Condition of batteries-Change every 24-
36mths
3. Wiring - connections
4. D/C Alternator – Belts, connections

WSD 5231, Mod. 3 32

16
 Battery maintenance check

 Avoid starting failures by making

sure the starting batteries are fully
charged and tested regularly under a
load.

WSD 5231, Mod. 3 33

Daily Maintenance Checks

Fuel water separator/ filter
Drain the water and sediments from the separator daily.
But before draining, shut off the engine. Use hand to
open the drain valve. Drain the filter sump until the
clear fuel is visible.

After that close the valve

and turn it until it is hand-tight.
Do not over tighten the valve.
It can cause the damage of the threads.

WSD 5231, Mod. 3 34

17
 Engine Operation Report
Report any of the following issues:
• Low lubrication oil pressure
• Low Power
• Power increases or Engine surge
• Erratic or no accelerator response or control
• Warning lights
• Unusual Engine noise
• Excessive Smoke

Necessary Tools
1. Insulated Rubber Glove 2. Screw Drivers Set 3.Helmet

4.Ratchet Screwdriver 5. Ratchet Socket Wrench Set 6. Adjustable Wench

7. Voltage Tester 8. Clamp Type Multi-meter

WSD 5231, Mod. 3 36

18
 O&M Manual & Specification

WSD 5231, Mod. 3 1

Introduction of manufacturer’s O&M manual

Depending upon the power rating, design and
manufacturer, different generators may have
different flow of maintenance. So O&M manual
of each device must always be available at the
site.

You have to keep

O&M Manual of
YOUR Generator
with you
WSD 5231, Mod. 3 2

1
Introduction of manufacturer’s O&M manual

WSD 5231, Mod. 3 3

Specifications
Example: Generator at Aljazari Academy

WSD 5231, Mod. 3 4

2
Specifications

WSD 5231, Mod. 3 5

Specifications

WSD 5231, Mod. 3 6

3
 Troubleshooting

WSD 5231, Mod. 3 7

General Repair Process

WSD 5231, Mod. 3 8

4
Trouble shooting systemsystem
7.1 Troubleshooting chart chart
Alternator not working
Causes Correction
Alternator pulley loose Tighten the pulley, refer to owner’s manual

OK
Batteries have malfunctioned Check condition of batteries replace if necessary

OK
Battery cable connections loose/broken Check the battery cables and connections

OK
Alternator is overloaded Install an alternator with higher capacity, refer
owner’s manual
OK
Alternator or AVR malfunctioning Test the alternator output, replace alternator or
AVR if necessary
OK
Battery temperature above specification Position the batteries away from heat source,
refer manual

OK
Check the wire, fuses and connection. Refer to
Electrical system open or blown fuse
manual

OK
Check the gauge, refer to owner’s service
Gauge is malfunctioning
manual

OK
Contact authorize repair facility WSD 5231, Mod. 3 9

Possible Fault Situation

Many faults can be occurred due to over use of generators,
in addition to the user manual, troubleshooting charts are also provided by the
manufacturer i.e. M/S Siemens for guidance in possible fault situation.

WSD 5231, Mod. 3 10

5
 Possible Fault Situation
Engine Relate Faults
Sr. # Problem Potential Cause Remedies
Lack of fuel., Fuel tank empty Fill it
Air in fuel injection system Bleed the air
Check Battery with Multi-meter Replace or Charge battery
Water contaminants in the fuel Change it
Fault in the fuel lift pump, cold stat system Repair and adjust it
1 Engine does not start Wrong type of grade fuel used Change & use proper
Fault in fuel injection pump Check & repair
Timing of fuel injection pump is incorrect Correct is as required
Inspect rings & pistons and adjust
Bad compression, Shut-off valve closed
valve clearances
Fuel connections are loose on suction side of the fuel pump Check & tight the connections
Lack of fuel., Fuel tank empty Fill it
Air in fuel injection system Bleed the air
Water contaminants in the fuel Change it
2 Engine difficult to start Starter motor defective Repair or replace it
Restriction in filter/ cleaner or in air induction system clean or replace it
Restriction in fuel vent Remove & clean
Restriction in exhaust pipe WSD 5231, Mod. 3 Remove & clean exhaust system11

Possible Fault Situation

Alternator Related Faults
Sr. # Problem Potential Cause Remedies

Check speed control of drive

If Generator voltage below 400V & not Drive speed too low
1 engine
adjustable via potentiometer
Voltage regulator defective Replace voltage
Tighten connections according to
Interuption of excitor circuit
connection diagram
2 Generator voltage too low (say less than 100V)
Surge supressor faulty Replace the supressor
Rotating rectifier faulty Repair the diaodes of the rectifier

Check engine speed and adjust it to

Drive spped too high
1500 rpm
If Generator voltage above 450 V & not
3
adjustable via potentiometer Interruption of reference valve of
Check AVR Connections
AVR
Voltange regulator defective Replace voltage regulator

WSD 5231, Mod. 3 12

6
 Wrap-up
• Things to take home…

• Generators drive your Operation.

• Always do a root cause analysis

• Repair is not preventive maintenance

• Keep records, always !!!

WSD 5231, Mod. 3 13

7
 EC-M2-01
Generator Flow Diagram Intake
from
Exhaust
Fuel System Air System
1. 2. 3. 4.
1. 2.

Nozzle

Exhaust Electric
Diesel Engine Alternator Panel

1. 2. 3. 1. 2. 1. 3.

Cooling Engine Starting System

Lubrication Oil System System

Name of Participant: _______________________________ 08/12/17

EC-M2-02
Components for Engine
(Solution)
Fuel System Air System

Turbocharger Air Filter

Fuel Lift Pump Fuel Tank Fuel Filter Fuel Injector

Gets the fuel Stores Cleans fuel Injects fuel Compress Cleans air
from the tank enough fuel from air before from Dust
and send it
at certain
for contamination intake Particles
towards filters consumption or particles pressure

Oil Filter Oil Pan Oil Lift Pump Battery Alternator Starting Motor
Radiator

Keep Lift oil from Rotate the

Cleans oil from Decrease Supply power
enough pan and send Charge the
contamination temperature to the starting shaft in the
or particles amount of it towards motor Battery
oil for use of coolant beginning
filters
Cooling Engine Starting System
Lubrication Oil System
System

08/12/17

1
 EC-M2-03
Generator Flow Diagram Intake
from
Exhaust
Fuel System Air System
1. 2. 3. 4.
1. 2.

Fuel Tank Fuel Lift Pump Fuel Filter Injection Pump Air Filter Turbocharger

Nozzle

Exhaust Electric
Diesel Engine Alternator Panel

1. 2. 3. 1. 2. 1. 3.

Starting Motor Battery Alternator

Oil Pan Oil Lift Pump Oil Filter Radiator

Cooling Engine Starting System

Lubrication Oil System System

08/12/17

2
 EC-M2-05

Maintenance Interval Schedule

（Sample for Practice）

Daily
・Alternator and Fan Belts – Inspect/Adjust/Replace
・Cooling System Coolant Level – Check
・Driven Equipment – Check
・Engine Oil Level – Check
・Fuel System Primary Filter/Water Separator – Drain
・Walk Around Inspection

Every 50 Service Hours or Weekly

・Fuel Tank Water and Sediment – Drain

Every 500 Service Hours or 1 Year

・Battery Electrolyte Condition & Level – Check
・Engine Air Cleaner Element – Clean/Replace
・Engine Oil and Filter – Change
・Fuel System Filter Element - Replace
・Hoses and Clamps – Inspect/Replace

Every 1000 Service Hours or 1 Year

・Engine Valve Lash – Inspect/Adjust

Every 2000 Service Hours or 1 Year

・Alternator – Inspect
・Engine Mounts – Inspect
・Starting Motor – Inspect

Every 2 Year
・Cooling System Coolant – Change

8-12-17
 EC-M2-08
Generaotr Annual Maintenace Plan (Sample) -Year 2017- Legend : Plan "●", Done "✔"

First Setting for Trial Activity

Average Operation Time per day 5 hours/day 2017 2018
Ｉｔｅｍ
Average Operation Time per month
150 hours/month DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV
(※30days)
※Days for each month are considered as 30days for ease. Operation Hours of the Month 150 150 150 150 150 150 150 150 150 150 150 150

Total Operation Hours 150 300 450 600 750 900 1050 1200 1350 1500 1650 1800

DEC JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV
Required maintenance
Item Product to be required
cycle
Plan Done Plan Done Plan Done Plan Done Plan Done Plan Done Plan Done Plan Done Plan Done Plan Done Plan Done Plan Done

Fuel Tank Water and Sediment Drain Every 50 hours None ● ● ● ● ● ● ● ● ● ● ● ●

Battery Electrolyte Level – Check Every 500 hours Electrolyte ●

Engine Air Cleaner Element – Clean/Replace Every 500 hours Air Cleaner Element ●

Engine Oil and Filter – Change Every 500 hours Engine Oil Filter ●

Fuel System Filter Element - Replace Every 500 hours Fuel Filter ●

Hoses and Clamps – Inspect/Replace Every 500 hours Hoses, Clamps ●

Engine Valve Lash – Inspect/Adjust Every 1000 hours ●

Alternator – Inspect Every 2000 hours

Engine Mounts – Inspect Every 2000 hours

Starting Motor – Inspect Every 2000 hours

Cooling System Coolant – Change Every 2 Years

12/08/2017
 EC-M2-09

Page 1 of 5 8-12-17
Page 2 of 5
Page 3 of 5
Page 4 of 5
Page 5 of 5
 EC-M2-10

Name of Participant: _______________________________

Q1: Write down the procedure of cleaning air cleaner element in your own words

Q2: Write down the procedure of checking electrolyte level and condition of battery in your own words

8-12-17
 Operations and Maintenance of
Electrical Equipment

2/22

Quality Tool for Operational Excellence

3/22

1
 Objectives of Application of 5S

Application of 5S for enhancing:

• Productivity
• Efficiency
• Quality
• Safety

3/30

4/22

2
 5S – A Quality, Productivity, Efficiency and
Safety Tool

 5S is an approach to eliminate waste, organize work place to save time and effort to
achieve operational efficiency.

 Implementation of 5S improves operational quality and efficiency.

 It enhances safety by reducing hazards, which may occur due to an unorganized

work place.

5/22

 Necessary items are separated from unnecessary items and removed.

 Unnecessary items’ accumulation makes it difficult to find and keep important items
organized.
 Red tag campaign is conducted to evaluate items based on their usefulness and
frequency of use.
 Items can include obsolete equipment and inventory, broken tools, scrap, old files, etc.
 Safety and productivity are improved as a result of an organized work place.

6/22

3
 Place un-necessary items in the red tag area
 Allow course participants to re-evaluate the needed items
 At the end of evaluation, required items should be returned to proper area

7/22

 It involves setting of necessary items, which are always located in logically

predetermined locations.
 Based on the inventory classification of the red tag campaign, items are placed in
locations based on frequency of use.
 Frequently used items are placed at or near the work place.
 Infrequently used items are stored in store.
 Items in store would help employees save time, otherwise wasted in trying to locate
scattered items.

8/22

4
 It is a regular cleaning activity at and near the work area.
 Removing unnecessary stickers, posters, pictures and other items.
 During operations and maintenance ergonomically establishing the positions for
tools and equipment.
 Continuously achieve better level of organized and efficient work place through
brainstorming.

9/22

10/22

5
 The goal of this step is to set a standard work place (organized)
 This is achieved by providing visual labels and signs
 Work place is marked and labeled so that organization is made simple and easy
 Organized and marked tool boards etc.

11/22

 It involves developing habits to implement the 5S philosophy on an ongoing basis.

 If 5S is to be successful, a regular appraisal of the electrical panel is required.
 This ensures the focus remains on maintaining the electrical panel.
 It is a housekeeping and a structured program.
 5S activity is conducted systematically and regularly.
 5S activity is tracked through a visual control board.

12/22

6
Before After

13/22

WASA Outfall Workshop, Lahore

Before After

14/22

7
 WASA South Yard, Lahore

Before After
SCBA equipment was buried under this

15/25

16/25

8
 5S is a continuous improvement tool !!!
 Create necessary documents or forms to support/optimize your operations
 Process flow charts
 Contact lists
 Emergency response procedures
 SOPs
 Post job instructions
 Label equipment for operators

17/25

Panel without Labels 18/25

9
Panel with Labels 19/25

Panel with Labels

20/25

10
Panel with Instructions
21/25

Panel with Drawings

22/25

11
Post important forms here !
23/25

Emergency Procedures
24/25

12
Emergency Contact List
25/25

13
 5S Activity Track Sheet
January, 2017 Date (activity performed):
Quantity Notes
Items Sorted
Items Stored
Items Discarded
Total Items
February, 2017 Date (activity performed):
Quantity Notes
Items Sorted
Items Stored
Items Discarded
Total Items
March, 2017 Date (activity performed):
Quantity Notes
Items Sorted
Items Stored
Items Discarded
Total Items
April, 2017 Date (activity performed):
Quantity Notes
Items Sorted
Items Stored
Items Discarded
Total Items
May, 2017 Date (activity performed):
Quantity Notes
Items Sorted
Items Stored
Items Discarded
Total Items
June, 2017 Date (activity performed):
Quantity Notes
Items Sorted
Items Stored
Items Discarded
Total Items
Device Inspection Sheet
Evaluation Criteria
：Good ×: No care at all or need to be newly installed
△：Need to be improved －: Not available to be checked

Continuity Test of components (Using Clamp Meter) Relays Adjustments

Over/Under Over Current Y-Δ
Circuit Breakers Magnetic Contactor
Voltage Relay (Thermal) Relay Timer
Sr. Inspection
Site /Pump Name Under Over ±10% of
No. Date Fuse Not less
Voltage Voltage rated Tripping Value
MCCB MCB 1 MCB 2 MCB 3 MCB 4 K1 K2 K3 than 5
Tripping Tripping voltage of Function Set
seconds
Function Function motor
Disposal Station, Chungi
1 3/28/2017         - × × - × - 
# 9, Panel # 2
Disposal Station, Chungi
2 3/28/2017 - ×      × - × × - × - 
# 9, Panel # 4
Disposal Station, Chungi
3 3/28/2017  × △      - × × - × - 
# 9, Panel # 7
Disposal Station, Chungi
4 3/28/2017         - × × -  - 
# 9, Panel # 8
Disposal Station, Chungi
5 3/28/2017  △ △ △     - × × - × - 
# 9, Panel # 11
Total Numbers of items required to be
0 3 2 1 0 0 0 1 - 5 4 0
replaced*
- Remarks -
MCB 4 of panel number 2 was malfunctioned and already replaced

* All components should be purchased as per required specification of each panel according to the installed motor
 Preventive Maintenance Sheet for Electrical Facility
Site Name : Motor Specification Evaluation Criteria
：Good
Rated Capacity Rated Voltage Rated Ampere Efficiency Power Factor ×: No care at all or need to be newly installed
△：Need to be improved
Sub Division : (kW) (V) (A) - - －: Not available to be checked

Preventive Maintenance
Visual Condition/Cleanliness Voltage by Clamp Meter (V) Ampere by Clamp Meter (A) Insulation Resistance (MΩ) Vibration Temperature
No. Date Weather Approved by Inspected by Cable/ Bolt 𝑈1 𝑉1 𝑊1 𝑈𝑝𝑝𝑒𝑟 𝐵𝑒𝑎𝑟𝑖𝑛𝑔 Evaluation
Cleanlin Neatness Cable Proper Terminal
wire Tightening RY YB BR R Y B
ess of Cabling Color Sealing Cover 𝐿𝑜𝑤𝑒𝑟 𝐵𝑒𝑎𝑟𝑖𝑛𝑔
Label 𝑈2 𝑉2 𝑊2

1
 Preventive Maintenance Sheet for Electrical Facility
Rated
Sub
Division :
Motor Specification Capacity
(kW/HP)
Rated Rated Power
Site Name: Voltage Ampere
Efficiency
Factor
RPM

Equipment
(V) (A) - -
Name:

Date

Inspected By

Weather

Bolt Tightening
U1-E U2-E
V1-E V2-E
Insulation
W1-E W2-E
Resistance
(MΩ) U1-V1 U2-V2
V1-W1 V2-W2
W1-U1 W2-U2
Voltage by RY
Clamp Meter YB
(V) BR
Ampere by R
Clamp Meter Y
(A) B
Power Factor
Upper Lower
Vibration
BearingBearing
Revolution Per Minute (RPM)
Upper Lower
Temperatur Bearing Bearing
e
Shaft
Reference for Insulation Resistance Value: Good → more than 1.0MΩ
Need to Adjust, Clean,Care　→ 1.0MΩ ~ 0.4MΩ　
Need to repair immediately →less than 0.4MΩ
- Remarks -
 Check List of Standard Operation Procedure for Electrical Facility
Motor Specification: Rated Capacity (kW/HP) ___________
Approved by : Evaluation Criteria
Rated Voltage (V) ______________Rated Current(A) ___________ ：Good ×: No care at all or need to be newly installed
Inspected by : △：Need to be improved －: Not available to be checked
Efficiency_____Power Factor_______RPM_________
Inspection Items for Electrical Panel Condition
Document Visual (Outside) Visual (Inside) Operation
Status/ How to
Identification Frequency
Operation Vender Fault Ampere Voltage Status Selector Intrusion Bypass- Neatness operate
Drawings of Cleanliness of
Record Manual Indication Meter Meter Switch Path Circuit of cabling changeover
Sr. Inspection Lamp/Switch Start/Stop
Site/Pump Name Lamps switch
No. Date
Pump No hole/
all lamps Proper Proper No dust, No
Compare installation Pump/ all lamps crack to Turn off by Maximum
are visibly functioning functioning sand, spider's bypass /
with the , electrical Panel /switches have Ampere Voltage let foreign breaker or 2-3 times/
bright and zero and zero nest, insect, burnt
sample line devices name tag matters switch first. hour
enough adjustment adjustment small animals mark
diagram come in

- Remarks -
 Check List of Standard Operation Procedure for Electrical Facility

Evaluation Criteria
：Good ×: No care at all or need to be newly installed
△：Need to be improved －: Not available to be checked
Document Visual (Outside) Visual (Inside) Operation
How to
Identification Status/Fault
Operation Vender Ampere Intrusion Bypass- Neatness of operate Frequency of
Drawings s of Indication Voltage Meter Status Selector Switch Cleanliness
Record Manual Meter Path Circuit cabling changeover Start/Stop
Lamp/Switch Lamps
switch

Pump No dust, No
Proper Proper
Compare installation Pump/ all lamps all lamps are sand, hole/crack to Turn off by
functioning functioning No bypass / Maximum 2-
with the , electrical Panel /switches have visibly bright Ampere Voltage spider's nest, let foreign breaker or
and zero and zero burnt mark 3 times/hour
sample line devices name tag enough insect, small matters come switch first.
adjustment adjustment
diagram animals in

Disposal Station, Chungi

1
# 9, Panel # 2
3/28/2017  △ ×    -  - △ △    

Disposal Station, Chungi

2
# 9, Panel # 4
3/28/2017  △ ×    - △ - △ △ △ △  

Disposal Station, Chungi

3 3/28/2017  △ ×   △ - △ - △ △  △  
# 9, Panel # 7

Disposal Station, Chungi

4 3/28/2017  △ ×   △  △ -  △    
# 9, Panel # 8

Off lamp
Disposal Station, Chungi
5 3/28/2017  △ ×  is not △ - △ - △ △    
# 9, Panel # 11
working
Total Numbers of items required to be
1 4
replaced*
- Remarks - Motor Specification: Motor Specification:
1. No lamp test was available so status of O/L Lamp can not be checked Rated Capacity: Rated Capacity:
2. Confirm that Current Transformers (CTs) are working fine before replacement of Ampere meter. In case of Rated Voltage (V) : Rated Voltage (V) :
malfunctioning CT, please change CT first and if Ampere meter still not giving correct value then replace it. Rated Current(A) : Rated Current(A) :
Efficiency: Efficiency:
Power Factor: Power Factor:
RPM: RPM:

* All components should be purchased as per required specification of each panel according to the installed motor
Device Inspection Sheet
Motor Specification: Rated Capacity (kW/HP) __________
Approved by : Evaluation Criteria
Rated Voltage (V) _____Rated Current(A) ______Efficiency_____ ：Good ×: No care at all or need to be newly installed
Inspected by :
△：Need to be improved －: Not available to be checked
Power Factor_______RPM_________

Continuity Test of components (Using Clamp Meter) Relays Adjustments

Current
Magnetic Over/Under Over Current
Circuit Breakers Transformer Y-Δ Timer
Contactor Voltage Relay (Thermal) Relay
Sr. Inspection
Site /Pump Name Under Over ±10% of
No. Date Fuse
Voltage Voltage rated Tripping Value Not less than
MCCB MCB 1 MCB 2 MCB 3 MCB 4 K1 K2 K3 CT1 CT2 CT3
Tripping Tripping voltage of Function Set 5 seconds
Function Function motor

- Remarks -
 Fault Reporting and Maintenance Request Form

Name of Operator (reporting person):_________________________________________

Mobile No.______________________
Facility Location:___________________________________________________________
Date: _________________ Time: __________________________
Site In-charge:__________________________________________

Is it an emergency: Yes/No
If yes, please follow the posted emergency reporting procedure

Fault Type
Electrical: Yes/No
Mechanical: Yes/No
Other: (Please describe)___________________________________

Public Safety Related: Yes/No

If yes, follow emergency reporting procedures

Fault Details
______________________________________________________________________________
______________________________________________________________________________

Maintenance Request:

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________
 Fault Reporting and Maintenance Request Form

Name of Operator (reporting person): Jawad Shahid

Mobile No. 033334445555
Facility Location: Aljazari Academy, Township, Lahore
Date: April 11, 2017 Time: 2:00 PM
Site In-charge: Muasb Uzair

Is it an emergency: Yes/No
If yes, please follow the posted emergency reporting procedure

Fault Type
Electrical: Yes/No
Mechanical: Yes/No
Other: (Please describe)_______________________________

Public Safety Related: Yes/No

If yes, follow emergency reporting procedures

Fault Details
Control Panel is short circuited due to faulty insulation (wires), operator, property and general
public are at risk of electric shock and fire.

Maintenance Request:

An Electrician is required onsite to ensure proper insulation and address the short circuit issue.

______________________________________________________________________________
 Incident / Emergency Response Flow Chart

INCIDENT / EMERGENCY

INCIDENT CONTROL / MANAGEMENT

[Ensure safety of Group]
INJURY / LOSS Serious Injury
Potential (Near Miss)
Missing Person

Continue Incident Control +

FIRST AID
[Basic Life support and Extended Conduct initial search and rescue response
Patient Care]

Is an Immediate Emergency Response Required? NO

Are there
signs/symptoms of
YES
Continue Incident significant
Control, Patient Care, and YES psychological
CONTACT EMERGENCY SERVICES Group Management distress?
Rescue: 1122
Site First Responder: 0321406516
(Mr. Ihsanul Haq Javed) CONTACT SITE ADMIN
Mr. Musab Uzair: NO
03337023700

CONTACT SITE ADMIN

Arrange Non-Critical  Record Relevant Details
Mr. Musab Uzair: 03337023700 YES Evacuation if Appropriate [Photos etc]
 Continue Incident
Control and Group
NO Management

 Contact local authorities  Record Relevant Details

(Local Hospital, Fire Brigade, Police) [Photos etc]
 Record Relevant Details [Photos etc.]  Contact local
 Contact Higher Management (Principal) authorities
 (Local Hospital, Fire
Brigade, Police)

Gather all near the emergency exit (muster point)
 Emergency Contact List

Name Contact No.

First Responders 03214065716

Mr. Ihsan Ul Haque Javed

Site Administrator Name 03337023700

Mr. Musab Uzair

Fire Brigade 16, 9211280, 9200281, 9200282, 9200283

Rescue 1122 1122

Police Station Town Ship Lahore 0429262171, 03087771827

Police Station Green Town 04235118000, 35113868

Counter Terrorism Department 0800111111

Nearest Hospital

Address: Ch. Rehmat Ali Trust Hospital 042 35154812

(Next Door)
Jinnah Hospital Lahore 04235168660

CPO Lahore 042992100623

DIG Operations 0429920030

Bomb Disposal 04299212111, 0423752828

 4/11/2018

Operation and Maintenance of

Electrical Equipment

O&M of Electrical Installations

contains potential hazards which
may cause:
 Human Death or Injury
 Time Loss
 Equipment Loss
 Environment Degradation

1
 4/11/2018

2
 4/11/2018

What is a Hazard?

Situation that poses a level of threat to

Life, Health, Property or Environment.

Electric shock Electric fire

Broken base plate Exposed electrical parts

3
 4/11/2018

Trip , Fall & electric shock Wet & moist condition

Hazard Hunting & Job Safety Analysis

Hazard Hunting:
On-going process to identify & assess work place hazards, and propose control measures according
to hierarchy of control
Job Safety Analysis:
Process of studying and recording each step of a job, identifying existing or potential hazards, and
determining the best way to perform the job safely.

Based on four steps:

1.Selection of jobs for analysis
2.Breakup of selected job into steps
3.Identify hazards associated with each step
4.Eliminate or control the hazards
8

4
 4/11/2018

Probability

Extent to which a hazard may cause harm.

Probability Rating Comments

Frequent 5 Frequently at risk

Probable 4 Likely to cause harm

Occasional 3 Occasionally at risk

Possible/remote 2 Could cause harm, but is unlikely to

Improbable 1 Unlikely to cause harm.

Severity

Seriousness of harm.

Severity Rating Comments

Catastrophic 5 Death / destruction
Critical 4 Severe injury / equipment damage
Serious 3 Injury / equipment damage
Marginal 2 Minor Injury
Negligible 1 No Injury

10

5
 4/11/2018

Priority Level
Hazard =Probability x Severity
Probability Severity Priority level
2 3 6
2 2 4
3 1 3

Hazard Coding
Priority rating Hazard Level Hazard Code
11 – 25 High H
5 – 10 Medium M
1-4 Low L
11

Electrical Safety
Steps to respond:

If you come across a person receiving an electric

shock:

1. Disconnect electrical main supply

2. Protect yourself & anyone else in the vicinity

3. Move casualty to safe area

4. Call Rescue 1122

5. Perform CPR
12

6
 4/11/2018

Electrical Fire Safety

Do not use water to Extinguish electrical fire 13

Electrical Fire Safety

Plan for Fire Emergencies

• Allocate locations for emergency exits

• Allocate location of fire alarm and fire extinguishers

• Conduct electrical fire drills

• Identification of Electrical Fire Extinguisher (C or E class)

• Guide procedure to use the fire extinguisher

14

7
 4/11/2018

Electrical Safety & Control Measures

• Shut off main power supply before O & M

• No work alone policy

• Keep clear spacing & emergency exits

Unblocked

• No Smoking policy

• Place trash in receptacles

15

Hazard control during operations & maintenance

More Effective
1 Elimination : Remove unsafe conditions Turn off power supply

2 Substitution: Replacement of parts should be done as per generator O &M Manual

3 Isolation: Protection of generator from rain fall , provision of Fencing

4 Engineering Control: Install Earthing to prevent electric shock , Catalytic convertor

5 Administrative Control: Lock out / Tag out of faulty installation

6 PPE: Use PPE, wear insulation gloves , Shoes with insulated sole and toe protection
Less Effective

16

8
 4/11/2018

Electrical Safety & Control Measures

Grounding

Electrical appliance that has not Faulty Electrical appliance that

been earthed and has become live has been earthed.
due to a fault.

Local Sub Station Local Sub Station

Path of fault
current

17

Electrical Safety & Control Measures

Guarding

18

9
 4/11/2018

Electrical Safety of High Voltage Panels

• Trained & qualified high voltage

electrical employee
• Shut off main power supply
• Free clear spacing
• No work alone policy
• Certified PPE
• Pre-inspection of tools
• Protective shield for live parts

19

Safety about Arcing & Flash

1. Check & Verify voltages on electrical contact points

2. Avoid using metal or conductive tools

3. Avoid pointing or placing metal tools near live contact points

4. Keep live electrical parts cover & close during O&M

20

10
 4/11/2018

Use of Personal Protective Equipment (PPE)

21

A safety kit for technician working on electrical

installations, etc.
Following are the components of this kit:-
• Fire blanket
• Low voltage rescue crook
• Isolation tag
• Trauma dressing *
• High resolution torch
• Bag * Always examine expiry date before use.
22

11
 4/11/2018

Ihsan ul Haque Javed

Sr. Instructor (HSE)
ihaque@urbanunit.gov.pk

23

12
 Job Safety Analysis
Name: ______________________________
Date: __________________

Job:
Sequence of Tasks Potential Hazards Preventive Measures
 Hazard Identification of a Tube well room
Please go through the given picture of a Tube well, identify at least five hazards related to electrical installations, assess priority and propose
action.
 2

3
2
4

1 5
 Name: __________________________ Date: ________________

Priority Due Comment

Sr# Hazard Proposed Action
(H/M/L) Date
1

5
 Name: __________________________ Date: ________________

Sr Priority Due
Condition (Hazard) Proposed Action Comment
# (H/M/L) Date
1 Obstruction to vacate H i) Exit strategy
area (Confined space) ii) Obtain permit to work
iii) Use of PPE
iv) No work alone
2 Missing warning signs H
& labeling of electrical i) Posting of warning
installations signs and labeling
3 Storage of unnecessary H i) Removal of
items unnecessary items
(Trip & Fall) ii) Housekeeping
4 Loose connection & H i) Provision of CO2 fire
unprotected live wires extinguisher
(Electrical shock & fire) ii) Impart training on use
of fire extinguisher
iii) Record keeping of
refilling
5 Opening in wall (rodents M Sealing of wall opening
& creepers)

6 Electrical cable laying H Provision of ducting

on floor insulation and Earthing of
( Electric shock, Trip & electrical installations
fall )