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SOP for Preventive Maintenance of Diesel Generator

This SOP outlines the procedure for the preventive maintenance of Diesel Generator Sets, detailing responsibilities, accountability, and specific maintenance checks at various intervals (daily, 300 hours, 1500 hours, and 6000 hours). Technicians and engineering heads are responsible for execution and review, ensuring all necessary spare parts are available. The document also includes a checklist for operational checks and maintenance tasks to be performed, along with references and distribution lists.

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सुशील कुमार कुशवाहा
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5 views6 pages

SOP for Preventive Maintenance of Diesel Generator

This SOP outlines the procedure for the preventive maintenance of Diesel Generator Sets, detailing responsibilities, accountability, and specific maintenance checks at various intervals (daily, 300 hours, 1500 hours, and 6000 hours). Technicians and engineering heads are responsible for execution and review, ensuring all necessary spare parts are available. The document also includes a checklist for operational checks and maintenance tasks to be performed, along with references and distribution lists.

Uploaded by

सुशील कुमार कुशवाहा
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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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 Rema

“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.

“A” Daily Operational Checks


Sr.No.
Check Points

Daily warm up start for 5 Minutes.


1.

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
Checked By:

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