Auxiliaries

Uflex Limited - Noida
P/10301
Maintenance manual for auxiliaries
DBAB529555 - Confidential 16.09.2010

Table of Contents
Table of Contents
Introduction to the maintenance manual............................................................................1 - 1

Maintenance routines...................................................................................................................................1 - 3
Safety aspects for maintenance work..........................................................................................................1 - 4
Locking and tagging out for maintenance or inspection...............................................................................1 - 6
Genset equipment..............................................................................................................2 - 1
Generating set..............................................................................................................................................2 - 2
Generator
Generator maintenance program..........................................................................................................2 - 3
Level 1 maintenance of ABB Generator, 4000 Hours...........................................................................2 - 5
Level 3 maintenance of ABB Generator, 24000 Hours.......................................................................2 - 11
Fuel gas system.................................................................................................................3 - 1

Gas regulating unit.......................................................................................................................................3 - 2
Gas filter
Maintaining the gas filter, 4 Months......................................................................................................3 - 3
Gas filter with magnetic insert
Gas pressure regulator
Maintaining gas pressure regulator, 3 Months......................................................................................3 - 7
Flow meter
Lubricating the turbine meter, 3 Months...............................................................................................3 - 9
Lubricating oil system.........................................................................................................4 - 1

Lube oil transfer pump (mobile)...................................................................................................................4 - 2
Transfer pump
Inspecting and lubricating the pump, 6 Months....................................................................................4 - 3
Overhauling the screw pump, 3 Years..................................................................................................4 - 5
Compressed air system......................................................................................................5 - 1

Working on the compressed air system.......................................................................................................5 - 2
Starting air unit.............................................................................................................................................5 - 3
Compressor
Maintaining the air compressor, 500 Hours..........................................................................................5 - 5
Maintaining the air compressor, 1000 Hours........................................................................................5 - 7
Cooling system...................................................................................................................6 - 1
Preheating unit.............................................................................................................................................6 - 2
Heater
Inspecting the immersion heater, 1 Years............................................................................................6 - 3
Circulation pump
Inspecting the circulation pump, 6 Months............................................................................................6 - 5
Safety valve
Testing the safety valve, 1 Years..........................................................................................................6 - 7
Air venting valve
Replacing the automatic air vent valve, as required.............................................................................6 - 9
Central cooler.............................................................................................................................................6 - 10
DBAB529555 - Confidential Table of Contents - i

Table of Contents
Heat exchanger
Cleaning the heat exchanger, 1 Years................................................................................................6 - 11
Charge air and exhaust gas system...................................................................................7 - 1

Charge air....................................................................................................................................................7 - 2
Charge air filter
Removing sludge from the filter, 1 Months...........................................................................................7 - 3
Inspecting the MultiDuty filter, 6 Months...............................................................................................7 - 5
Replacing the Viscosine, 1 Years.........................................................................................................7 - 7
Charge air silencer
Inspecting the charge air silencer, 3 Months........................................................................................7 - 9
Exhaust gas............................................................................................................................................... 7 - 10
Exhaust gas silencer
Inspecting the exhaust gas silencer, 4000 Hours............................................................................... 7 - 11
Rupture disks
Inspecting the explosion vent, 1 Years............................................................................................... 7 - 13
Electrical systems...............................................................................................................8 - 1
DC system....................................................................................................................................................8 - 2
EFORE MPS
Inspecting the DC power supply system, 1 Years................................................................................8 - 3
Appendix............................................................................................................................9 - 1
Maintenance-related spare parts.................................................................................................................9 - 2
Table of Contents - ii Confidential DBAB529555 -

Maintenance schedule
Calendar-based maintenance schedule

System and unit Job JobID Page
1 Month
Charge air and exhaust gas system, Charge air Removing sludge from the filter WCA023 7-3
3 Months
Fuel gas system, Gas regulating unit Maintaining gas pressure regulator WCA0357 3-7
Fuel gas system, Gas regulating unit Lubricating the turbine meter WCA0459 3-9
Compressed air system, Starting air unit Maintaining the air compressor WCA1573 5-5
Charge air and exhaust gas system, Charge air Inspecting the charge air silencer WCA204 7-9
4 Months
Fuel gas system, Gas regulating unit Maintaining the gas filter WCA0460 3-3
6 Months
Lubricating oil system, Lube oil transfer pump Inspecting and lubricating the pump WCA0316 4-3
(mobile)
Cooling system, Preheating unit Inspecting the circulation pump WCA0325 6-5
Charge air and exhaust gas system, Charge air Inspecting the MultiDuty filter WCA022 7-5
Charge air and exhaust gas system, Exhaust gas Inspecting the exhaust gas silencer WCA205 7 - 11
1 Year
Cooling system, Preheating unit Inspecting the immersion heater WCA1429 6-3
Cooling system, Preheating unit Testing the safety valve WCA1342 6-7
Cooling system, Central cooler Cleaning the heat exchanger WCA0333 6 - 11
Charge air and exhaust gas system, Charge air Replacing the Viscosine WCA0580 7-7
Charge air and exhaust gas system, Exhaust gas Inspecting the explosion vent WCA0598 7 - 13
Electrical systems, DC system Inspecting the DC power supply system WCA0390 8-3
2 Years
Cooling system, Preheating unit Replacing the automatic air vent valve WCA1580 6-9
3 Years
Lubricating oil system, Lube oil transfer pump Overhauling the screw pump WCA0312 4-5
(mobile)
DBAB529555 - Confidential Maintenance schedule - iii

Maintenance schedule based on running hours

500 Hours
1000 Hours
4000 Hours
Genset equipment, Generating set Level 1 maintenance of ABB Generator WCA014 2-5
Charge air and exhaust gas system, Exhaust gas Inspecting the exhaust gas silencer WCA205 7 - 11
8000 Hours
Genset equipment, Generating set Level 2 maintenance of ABB Generator WCA015 2-9
16000 Hours
Lubricating oil system, Lube oil transfer pump Overhauling the screw pump WCA0312 4-5
(mobile)
24000 Hours
Genset equipment, Generating set Level 3 maintenance of ABB Generator WCA016 2 - 11
80000 Hours
Genset equipment, Generating set Level 4 maintenance of ABB Generator WCA017 2 - 13
Maintenance schedule - iv Confidential DBAB529555 -

Maintenance interval determined by operating conditions

Cooling system, Preheating unit Replacing the automatic air vent valve WCA1580 6-9
Replace the air and dirt separator air vent valve if it starts to leak.
DBAB529555 - Confidential Maintenance schedule - v

Maintenance schedule - vi Confidential DBAB529555 -

1. Introduction to the maintenance manual
Introduction to the maintenance manual V3
The purpose of the maintenance manual is to provide guidelines for inspection and
maintenance of the auxiliary systems that are within the Wrtsil scope of supply.
Note!
Maintenance instructions for the Main engine are found in the Engine Manual.
The instructions are based on information provided by the equipment manufacturer or

supplier. If there are any discrepancies or doubts about a certain unit or component, refer
to the original manuals located in the system manual for the component. Even though the
maintenance programs have been customized to match the plant, it might contain
references to accessories not available in your plant.
Note!
Even when following the maintenance instructions, normal supervision and observation
of the equipment is required.
Maintenance intervals
As the maintenance intervals often depend on the operating conditions, the stated
intervals are to be considered as guidelines. Take note of these guidelines when creating
your overall maintenance plan for the plant.
The maintenance intervals are given either as running hours for the device or as calendar-
based intervals (weeks, months or years).
The hour-based intervals are to be followed up by an hour counter on the specific device
or running hours of the engine. If none of these are applicable, the best estimation must
be applied.
The calendar-based intervals are counted as total elapsed time. If not otherwise stated,
this interval applies regardless of the running hours of the device.
It is left to the discretion of the maintenance planner to apply the stated interval correctly.
Maintenance-related spare parts and required special tools

Some of the maintenance work described in this manual will require that certain parts are
changed or renewed in connection with the work. These parts, also called maintenance-
related spare parts, will be listed by their descriptive name on each work card. They are
also shown in the appendix in the section "Maintenance-related spare parts".
The actual code for that part must then be looked up in the spare part list provided either
by Wrtsil or the equipment supplier.
DBAB529555 - Confidential 1-1

When ordering spare parts, always include all the data needed to identify the component
and part installed. The following identification data should be included:
Brand and model
Serial number
Type of application
Name and description of the spare part
Spare part code, if available
Content
Maintenance routines...................................................................................................................................1 - 3
Safety aspects for maintenance work..........................................................................................................1 - 4
Locking and tagging out for maintenance or inspection...............................................................................1 - 6
1-2 Confidential DBAB529555 -

Maintenance routines V1
The auxiliary systems are vital to the function of the plant. Therefore, all maintenance
activities must be carefully done at the correct intervals. All measures taken and why they
are taken must be well recorded.
The maintenance activities are divided into three categories:

Condition monitoring by taking the readings of all meters and gauges. If the readings
show a falling or rising trend, the reason has to be found and action taken.
Preventive maintenance Daily inspection and checks of all equipment visually or by
listening to the components with the purpose to detect abnormalities.
Preventive maintenance Scheduled inspections, cleaning and replacement of
components or fluids. Maintenance intervals are found in the maintenance chart for
each of the main components together with instructions.
It is to be expected that the operators possess a good general knowledge of this type of
plant and that they are familiar with both common and local safety regulations that must
be strictly followed.

Safety aspects for maintenance work V3
General
Only persons with adequate training are allowed to perform maintenance on the
equipment.
Before starting to operate or perform any maintenance on the components, read the
manuals provided by the component manufacturers.
Read and obey the safety instructions provided by the equipment manufacturers and
the manufacturers of the liquids handled in the plant.
Read and obey the safety instructions in the Power Plant manuals.
Observe the warning signs on the equipment. The signs must not be removed.
Pay attention to the risk of ignition

The equipment may contain combustible material.
Do not light matches or open flames in the vicinity.
Prevent electrical sparks from occurring.
Check that the area is free of combustible gases, liquids or dust before using any power
tool or welding equipment.
Prevent unintended starting during maintenance work

Before starting any maintenance work, make sure that the equipment cannot be
accidentally started.
Set the safety switch to the OFF position and lock the switch.
Disconnect the electrical power and tag out the device.
If needed, isolate the unit by closing and securing inlet and outlet valves and releasing
the pressure.
Prevent electrical shocks

Only trained electricians may perform work on electrical equipment.
Do not open the electrical cabinet during operation.
Do not touch electrical wiring and components until the main switch has been switched
off and secured.
If the equipment contains capacitors, be aware that the capacitors can retain a charge
even after being disconnected from the mains.
Avoid burns and splashes

Before dismantling or opening any process equipment, consider what the system may
contain and take the necessary precautions to avoid burns, exposure to hazardous
substances, spills or splashing.
During operation, the pipes will contain hot liquids, and the surface may be hot. Allow all
elements cool down before performing any maintenance work on them. Remove all
pressure from the system before opening any part of it.

Be aware of the power of pressurized air

The compressed air system contains air under very high pressure.
Do not open any component, unit or part of the system before ensuring that it is not
pressurized.
Look out for jets of pressurized air.
If a part of the system is isolated for maintenance work, the valves must be locked and
properly tagged out in order to prevent accidental opening.
Take precautions for confined entry

Before working in a confined space, take the following precautions:
Close and lock all inlet valves and outlet valves to the space.
If the space has contained chemicals that can produce vapours, the space must be
properly vented and the air must be tested.
Assign two people for hole watch. They must remain stationed outside the space where
they can observe the workers inside.
Test the air again at the beginning of each shift.
Use protective clothes

Use overalls made according to safety regulations, protective gloves, safety glasses,
industrial shoes, ear protection and helmet.
Keep the area tidy

Wipe up oil spills and dispose of all debris that might cause accidents.

Locking and tagging out for maintenance or

inspection V2
Before starting any maintenance work, it is extremely important to make sure that the
equipment can not be accidentally started while it is being serviced.
Job Description
1 Notify all persons that will be affected that the lockout is about to begin.
2 Verify that the equipment to be serviced is turned off.
3 Locate all energy sources (electrical, pneumatic, steam etc.) that supply the equipment
and turn them off.
4 Secure all energy sources with an appropriate locking device.
5 Place an appropriate warning tag on the energy sources.
Note!
If several persons are involved in the maintenance, all persons must attach their own
locking device and tag.
6 Release any stored energy (circuit breakers, pneumatic valves, springs etc.).
7 Operate the controls (switches, valves etc.) to make sure that the equipment will not
operate.
8 Perform the required maintenance work on the equipment.
9 When the maintenance work is finished, the equipment may be taken into service again:
a ) Check that all tools and loose parts have been removed.
b ) Replace all safety guards.
c ) Ensure that all workers are clear of the equipment.
d ) Remove all tags and locking devices.
Note!
Only the person that applied the tag or locking device may remove it.
e ) Turn on the energy sources.

2. Genset equipment
Genset equipment
Content
Generating set..............................................................................................................................................2 - 2
Generator

2. Genset equipment
Generating set
Content
Generator
Generator maintenance program..........................................................................................................2 - 3
This chapter presents a recommended maintenance program for ABB machines.
Generator
2. Genset equipment
Generator maintenance program V2
The maintenance program is based on four levels of maintenance, which rotate according
to operating hours. The amount of work and down time vary, so that level 1 includes mainly
quick visual inspections and level 4 more demanding measurements and replacements.
The operation hour recommendation is given as equivalent operating hours (Eq. h), that
can be counted by the following formula:
Equivalent operating hours (Eq. h) = Actual operating hours + Number of starts * 20

2. Genset equipment

2. Genset equipment
Level 1 maintenance of ABB Generator V5
Component
Unit: Generating set BAG011, BAG021 Type: AMG
Component: Generator Manufacturer: ABB
Work Information
JobID: 014 Work time: 8 Hours
Type of job: Inspection Stop time: 8 Hours
Interval: 4000 Hours Service personnel: Electrician, 1 / Component
Prerequisites
Warning!
General electrical safety precautions are to be taken into account.
The personnel must be trained in, and familiar with, the specific maintenance
procedures and tests required for rotating electrical machines.
Note!
After commissioning or maintenance, the supervision should be intensive. Temperature
of bearings and windings, load, current, cooling, lubrication and vibration shall be checked
frequently.
Note!
V = Visual checking C = cleaning D = Disassembling and assembling R = Reconditioning
or replacement T = Testing and measurement
Required spareparts
Spcode Qty Description

#### 1 Safety package
Job Description
1 Check the general condition of the machine:
a ) Machine operation: Starting, shut down, vibration measurement, no-load point, V/T
b ) Mounting and foundation: Cracks, rust, alignment, V
c ) Exterior: Rust, leakage, condition, V
d ) Fastenings: Tightness of all fastenings, V
e ) Anchor bolts: Fastening, condition, V
2 Check the high voltage connection:
a ) High voltage cabling: Wear, fastening, V
b ) High voltage connections: Oxidation, fastening V
c ) Terminal box accessories, for example, surge capacitors and arresters: General
condition, V
d ) Cable transits: Condition of cables entering the machine and inside the machine, V
3 Check the stator and the rotor:
a ) Stator core: Fixing, cracks, welds, V
b ) Stator winding insulation: Wear, cleanliness, insulation resistance, turn insulation
test, (high voltage test), V

2. Genset equipment
c) Stator coil over hangs: Insulation damages, V

d) Stator coil supports: Insulation damages, V
e) Stator slot wedges: Movement, tightness, V
f) Stator terminal bars: Fixing, insulation, V
g) Stator cable terminal fastenings and crimps: Tightness, condition, V
h) Instrumentation: Condition of cables and cable ties, V
i) Rotor poles: Movement, tightness, fixing, V
j) Rotor winding insulation, Wear, cleanliness, insulation resistance, voltage drop test,
V
k ) Rotor coil supports: Movement bending, V
l ) Rotor balancing weights: Movement, V
m ) Damper bars: Cracks, corrosion, ultra sound and knocking test, V
n ) Shaft and rotor center: Cracks, corrosion, V
o ) Air gap: Equality, V
p ) Connections in rotor: Fixing, general condition
q ) Earthing brushes: Operation and general condition
r ) Rotor shaft insulation: General condition, insulation resistance
4 Check the excitation system, control and protection:
a ) Exciter diode bridge: Cleanliness, operation, V
b ) Exciter semiconductor: Operation, fixing, V
c ) Excitation connections: Fixing, general condition, V
d ) Exciter winding insulation: Wear, cleanliness, insulation resistance, V
e ) Exciter air gap: Equality, V
f ) AVR unit: Operation, settings, stability test, V
g ) AVR board: Operation, connections, V
h ) PMG (Permanent Magnet Generator): Operation, connections, V
i ) Voltage transformer: Operation, cleanliness, V
j ) Short circuit transformer (CT): Operation, cleanliness, V
k ) Actual value CT: Operation, cleanliness, V
l ) Measurement and protection CTs: Operation, cleanliness, V
m ) Pt-100 elements (stator, cooling air, bearing): Resistance, insulation resistance, V
n ) Anti-condensation heaters: Operation, insulation resistance, V
o ) Auxiliary terminals boxes: General condition, terminals, wiring condition, V
p ) Exciter stator fixing: General condition, cracks, V
5 Check the lubrication system and the bearings:
a ) Bearing: Fixing, general condition, V
b ) Bearing shells: General condition, wear, V
c ) Seals and gaskets: Leakage, V
d ) Bearing insulation: Condition, insulation resistance, V
e ) Lubrication piping: Leakage, operation, V
f ) Lubrication oil: Quality, quantity, flow, V/R
g ) Oil ring: Operation, V
h ) Oil flow regulator: Operation, V
i ) Oil tank: Cleanliness, leakage, V
j ) Jack-up system: Operation, V
k ) Oil cooler/heater: Oil temperature, T
6 Check the cooling system:
a ) Fan(s): Operation condition, V
b ) Filters: Cleanliness, operation, V/C
c ) Air ways: Operation, cleanliness, V
d ) Heat exchanger: Leakage, operation, pressure test, V
e ) Fan: Operation, condition, V
f ) Tubes: Cleanliness, corrosion, V
g ) Ducts: Operation, cleanliness, V
h ) End cases: Leakage, condition, V
i ) Seals and gaskets: Leakage, condition, V

2. Genset equipment
j ) Plate fins: General condition, V

k ) Vibration dampers: Condition and profile, V
l ) Water flow regulator: Operation, V/T

2. Genset equipment

2. Genset equipment
Component
Work Information
Prerequisites
Warning!
Note!
frequently.
Note!
Note!
Level 1 tasks not included, but must be performed at the same time.
Required spareparts

#### 1 Maintenance package
Required tools
Code Description
Insulation resistance tester
Job Description
1 Check the general condition of the machine:
a ) Mounting and foundation: Cracks, rust, alignment, T
b ) Fastenings: Tightness of all fastenings, T
c ) Anchor Bolts: Fastening, condition, T
a ) High voltage cabling: Wear, fastening, T

2. Genset equipment
b ) High voltage connections: Oxidation, fastening T

a ) Stator winding insulation: Wear, cleanliness, insulation resistance, turn insulation
test, (high voltage test), T
b ) Stator cable terminal fastenings and crimps: Tightness, condition, T
c ) Rotor poles: Movement, tightness, fixing, T
d ) Rotor winding insulation, Wear, cleanliness, insulation resistance, voltage drop test,
T
e ) Damper bars: Cracks, corrosion, ultra sound and knocking test, T
f ) Air gap: Equality, T
4 Check excitation system, control and protection:
a ) Exciter diode bridge: Cleanliness, operation, T/C
b ) Exciter semiconductor: Operation, fixing, T/C
c ) Excitation connections: Fixing, general condition, T/C
d ) Exciter winding insulation: Wear, cleanliness, insulation resistance, T
e ) Exciter air gap: Equality, T
f ) AVR unit: Operation, settings, stability test, T
g ) AVR board: Operation, connections, T
h ) Voltage transformer: Operation, cleanliness, T
i ) Pt-100 elements (stator, cooling air, bearing): Resistance, insulation resistance, T
j ) Anti-condensation heaters: Operation, insulation resistance, T
k ) Auxiliary terminals boxes: General condition, terminals, wiring condition, T
a ) Bearing: Fixing, general condition, T
b ) Bearing insulation: Condition, insulation resistance, T
c ) Oil flow regulator: Operation, T
d ) Oil tank: Cleanliness, leakage, C
e ) Jack-up system: Operation, T
a ) Air ways: Operation, cleanliness, C
b ) Tubes: Cleanliness, corrosion, C
c ) Ducts: Operation, cleanliness, C
d ) End cases: Leakage, condition, C
e ) Seals and gaskets: Leakage, condition, C
f ) Plate fins: General condition, C
2 - 10 Confidential DBAB529555 -
2. Genset equipment
Component
Work Information
Prerequisites
Warning!
Note!
frequently.
Note!
Note!
Level 1 and 2 tasks not included, but should performed at the same time.
Required spareparts

Required tools
Code Description
Oscilloscope
Endoscope
Job Description
1 Check the general condition of the machine.
a ) Anchor bolts: Fastening, condition, T
a ) Stator winding insulation: Wear, cleanliness, insulation resistance, turn insulation
test, (high voltage test), C
DBAB529555 - Confidential 2 - 11
2. Genset equipment
b ) Rotor winding insulation: Wear, cleanliness, insulation resistance, voltage drop test,
C
c ) Connections in rotor: Fixing, general condition, T
d ) Rotor shaft insulation: General condition, insulation resistance, T
3 Check excitation system, control and protection:
a ) Exciter air gap: Equality, D
b ) PMG (Permanent Magnet Generator: Operation, connections, T
c ) Short circuit transformer (CT): Operation, cleanliness, T
d ) Actual value CT: Operation, cleanliness, T
e ) Measurement and protection CTs: Operation, cleanliness, T
a ) Bearing: Fixing, general condition, V
b ) Bearing shells: General condition, wear, T/D
c ) Seals and gaskets: Leakage, T/D
d ) Bearing insulation: Condition, insulation resistance, D
e ) Lubrication piping: Leakage, operation, T/D
a ) Filters: Cleanliness, operation, R
b ) Protective anodes: Condition, activity, V/C
2. Genset equipment
Component
Work Information
Prerequisites
Warning!
Note!
frequently.
Note!
Note!
Level 1, 2 and 3 tasks not included, but should performed at the same time.
Required spareparts

##### 1 Capital spare part package
Required tools
Code Description
Rotor removal equipment
Job Description
1 Check the general condition of the machine.
a ) Mounting and foundation: Cracks, rust, alignment, D
a ) High voltage cabling: Wear, fastening, D
b ) High voltage connections: Oxidation, fastening D
2. Genset equipment

a ) Stator core: Fixing, cracks, welds, C
b ) Air gap: Equality, D
a ) Oil flow regulator: Operation, D
3. Fuel gas system
Fuel gas system V2
The fuel gas system includes a pressure regulating unit and possibly a gas compressor
or gas reduction unit.
Warning!
If gas is found to be leaking into the engine room, it is essential that the engine and the
gas supply system are shut down immediately. Leave the engine room and do not enter
until the room has been properly ventilated to remove any traces of gas.
Shutting down the gas system for maintenance

If maintenance is to be performed on any part of the system, this may require closing and
locking the main gas valve and ventilating the other parts of the system.
Before doing any maintenance, do the following:

1 Close the main gas valve on the gas train.
2 Close the main shut-off valve outside the building.
3 If the gas regulating unit is to be shut down for any prolonged time, open the manual
ventilation valve (located outside the building).
Content
Gas regulating unit.......................................................................................................................................3 - 2
Gas filter
Flow meter

3. Fuel gas system
Gas regulating unit
Content
Gas filter
The frequency of periodical maintenance is strongly dependant on the prevailing service conditions, the
type and composition of the gaseous medium, the ambient temperature and on dust and dirt within the
pipe system.
The gas cellular filter is cleaned and inspected.
Maintaining gas pressure regulator, 3 Months......................................................................................3 - 7
The gas pressure regulator is inspected by someone trained in gas pressure regulating facilities
maintenance.
Flow meter
Lubricating the turbine meter, 3 Months...............................................................................................3 - 9
The turbine meter is used for measuring gas flow and may require lubrication.
filter
Gas
3. Fuel gas system
Maintaining the gas filter V1
Component
Unit: Gas regulating unit ZAC011, ZAC021 Type: 905
Component: Gas filter B003, B007 Manufacturer: RMG
Work Information
JobID: wca0460 Work time: 2 Hours
Type of job: Check job Stop time: 2 Hours
Interval: 4 Months (Only after first start or major overhaul.) Service personnel: Mechanical, 1 / Component
2 Years
Prerequisites
Caution!
Any maintenance work on the regulator must be done by an expert acquainted with the
purpose and the tasks of gas pressure regulating facilities, with the relevant laws and
guidelines.
Warning!
Before starting any work on the gas regulating equipment, make sure it is properly
isolated, vented and secured from accidental starting.
Required spareparts

RMG-00 026 183 As required Filter insert
RMG-00 020 317 As required O-ring
RMG-00 020 282 As required O-ring
RMG-00 018 842 As required Sealing ring
Inspect the filter after the first 4 months and then increase the interval up to two years if
no defects are found.
Job Description
1 Clean, dissemble and inspect the filter.
Replace the filter insert if needed.
2 Check the correct mounting.
The hole within the filter insert must show at the top.
insert
magnetic
with
filter
Gas
3. Fuel gas system

3. Fuel gas system
Maintaining the gas filter V3
Component
Unit: Gas regulating unit ZAC011, ZAC021 Type: 906, 907, 906a
Component: Gas filter with magnetic B002 Manufacturer: RMG
insert
Work Information
Interval: 6 Months Service personnel: Mechanical, 1 / Component
Prerequisites
Refer to the OEM manual for specific spare parts. All parts marked "EV" are to be kept in
stock for maintenance.
Caution!
guidelines.
Warning!
Required spareparts

As required Paper filters 1, 2, and 3
As required Filter insert 1, 2, and 3
As required Sealing rings
As required Plastic ring (glued onto filter basket)
As required O-rings
Silicone grease for O-rings
Required tools
Code Description
00 027 081 (RMG-stock-nr) silicone grease tube
00 027 079 (RMG-stock-nr) silicone grease can
The maintenance interval depends on the service conditions; however, the maximum
pressure drop across the filter must not exceed 0.5 bar.
Job Description
1 Clean all parts and do a thorough visual inspection.
2 Clean the filter mat or replace it with a new one.
3 Before mounting the O-rings, grease them with silicone grease "400 leict".

3. Fuel gas system
4 Replace damaged seals with new ones.
regulator
pressure
Gas
3. Fuel gas system
Maintaining gas pressure regulator V1
Component
Unit: Gas regulating unit ZAC011, ZAC021 Type: 402
Component: Gas pressure regulator V007, V021 Manufacturer: RMG
Work Information
Interval: 3 Months Service personnel: O&M Supervisor, / Component
Mechanical, / Component
Prerequisites
Refer to the OEM manual for specific spare parts. All parts marked "EV" are to be kept in
stock for maintenance.
Caution!
guidelines.
Warning!
Required spareparts

As required O-rings
As required Sealing rings
As required Closing spring
As required Diaphragm
As required Piston, premounted
Maintenance intervals should start at 3 months for maintenance disassembly. If no defects

within the unit are found, the intervals can be increased in steps to a maximum of 2 years.
Job Description
1 Clean and inspect all parts. Use particular care to inspect the following items:
Seals and diaphragms
The closing spring
All other moving parts.
Replace any damaged parts with new parts.
meter
Flow
3. Fuel gas system

3. Fuel gas system
Lubricating the turbine meter V1
Component
Unit: Gas regulating unit ZAC011, ZAC021 Type: TERZ
Component: Flow meter Manufacturer: RMG
Work Information
Type of job: Lubrication Stop time: 0 Hours
From the nominal size of DN 200 or larger, the meters are fitted with a lubricator (either
an oil nipple, or a pump). The lubrication interval is 3 months for clean gas and more
frequently if dust or condensate-laden gas is used.
Job Description
1 Lubricate the meter in accordance to the lubrication instruction plate located on the turbine
meter.
Note!
All turbine meters up to and including the nominal size of DN 150 are fitted with
permanently lubricated bearings and do not require any maintenance.

3. Fuel gas system
4. Lubricating oil system
Lubricating oil system
Content
Lube oil transfer pump (mobile)...................................................................................................................4 - 2
Transfer pump

Lube oil transfer pump (mobile)
Content
Transfer pump
Inspecting and lubricating the pump, 6 Months....................................................................................4 - 3
In-service inspection of pump - greasing of bearings and cleaning of strainer.
Overhauling the screw pump, 3 Years..................................................................................................4 - 5
The overhaul of the pump includes changing rotor bearings and mechanical seals.
pump
Transfer
Inspecting and lubricating the pump V1
Component
Unit: Lube oil transfer pump QLC901 Type: ACE
(mobile)
Component: Transfer pump D001 Manufacturer: IMO
Work Information
Prerequisites
Note!
When ordering spare parts, please state the required spare part set and the complete
pump identification according to the pump's name plate.
Required spareparts

As required Joint kit, for dismantling of the pump, G057
As required Shaft seal, G050
Lubricate the pump and motor ball bearings and check that the pump operates correctly
without excessive leakage, vibrations, or noise.
Job Description
1 Grease the pump rotor ball bearings, if the pump is provided with external bearings and
grease nipple.
The pump should be running during greasing.
Caution!
Do not overfill with grease. Overfilling will damage the mechanical seal.
2 Grease the motor bearings, if the motor is provided with grease nipples.
The pump should be running during greasing.
Note!
Some motors may have a separate rating plate with information about the bearings and
lubricating intervals. If so, those instructions must be followed.
3 Check the operation of the pump.

a ) Check for reduction in pump performance.
If an indication of a worn pump is noticed, a brief inspection of the idler rotors is
recommended.
b ) Check for excessive noise or vibration.
If the bearings are too hot or too noisy, and greasing failed to lower the temperature
or reduce the noise, the bearings should be replaced.
c ) Check for excessive leakage from the shaft seal.

As the seal faces of a mechanical shaft seal are lubricated by the fluid, a certain
leakage will always be present. Ten drops per hour can be considered as acceptable,
while a greater leakage indicates that the seal is worn and must be replaced.
Excessively leaking shaft seals should be replaced without delay, as the leakage
normally will grow worse and there is a risk that liquids with poor lubrication
properties, (such as heavy fuel oil) will wash out the lubricating grease from the ball
bearing and thereby cause additional damage.
If any deficiencies are detected, the pump needs to be overhauled. Check for wear and
replace worn or damaged parts. Whenever the ball bearing is removed, it is recommended
to exchange it for a new one.
Warning!
Do not start maintenance work unless power is switched off and physically disconnected,
the inlet and outlet valves are shut and accidental opening is prevented, and the device
vented to atmospheric pressure.
4 Clean the strainer.

5 Put the pump back into operation.
a ) Open shut off valves.
b ) Prime the pump.
c ) Do a quick start-stop of the pump to check that it has power and that the rotation is
correct.
If the power cables were disconnected they may have been switched so that the
motor is rotating in the wrong direction. In this case, the two poles must be switched
in order to change the direction. This must be done by an electrician.
d ) Start the pump and check for leakage.
A new mechanical shaft seal may leak slightly more during the first hours of
operation.
Postrequisites
Re-grease the ball bearings after one hour of operation, while the pump is running.

Overhauling the screw pump V4
Component
Unit: Lube oil transfer pump QLC901 Type: ACE
(mobile)
Component: Transfer pump D001 Manufacturer: IMO
Work Information
Type of job: Overhaul Stop time: 3 Hours
Interval: 3 Years Service personnel: Mechanical, 1 / Component
16000 Hours
Prerequisites
Warning!
Before any maintenance work, ensure that the driver is de-energized and the pump
hydraulically isolated.
In installations where unplanned shut downs must be avoided, it is advisable to have a

complete pump available for replacement, should any malfunction occur.
As all internal parts of the pump are lubricated by the pumped liquid, the intervals for
inspection and replacement of wear parts vary greatly with the properties of the pumped
liquid and can only be determined by experience.
Note!
When ordering spare parts, please state the required spare part set and the complete
pump identification according to the pump's name plate.
Required spareparts

1 Joint kit, for dismantling of the pump, G057
1 Shaft seal, G050
As required Rotor set, G012
IMO-189873 As required Valve element, G070
The overhaul of the pump includes checking the operation, inspecting the rotors and
changing rotor bearings and mechanical seals. The motor may need new bearings or re-
greasing.
Job Description
1 Check the operation of the pump.
Worn parts in the pump may be indicated by vibration, noise, loss of capacity, reduction
in flow/pressure, leakage.
See also the instruction "Inspecting and lubricating the pump".
2 Stop and disable the pump.
a ) Tag out and disconnect power to the pump.
This can be done by turning off and locking the main switch and removing the fuses
or disconnecting power cables.

b ) Close the inlet valve and make sure the check valve on the outlet side is tight.
c ) Tag out the valves or remove the handles to prevent accidental opening during
maintenance work.
d ) Place a suitable vessel under the pump and take necessary precautions to avoid
spill.
e ) Relief internal pressure in the pump.
3 Dismantle and inspect the pump.
Follow the instructions in the dismantling/reassembly instruction given in the service
manual.
a ) Replace any worn or damaged parts.
b ) Change rotor bearings and seals.
c ) Change all O-rings and gaskets.
4 Check the motor bearings and replace/re-grease them if necessary.
5 Put the pump back into operation.
a ) Open shut off valves.
b ) Prime the pump.
c ) Do a quick start-stop of the pump to check that it has power and that the rotation is
correct.
If the power cables were disconnected they may have been switched so that the
motor is rotating in the wrong direction. In this case, the two poles must be switched
in order to change the direction. This must be done by an electrician.
d ) Start the pump and check for leakage.
A new mechanical shaft seal may leak slightly more during the first hours of
operation.
Postrequisites
Pumps with an external ball bearing including grease nipple, must be re-greased after one
hour of running, while the pump is operating.

5. Compressed air system
Compressed air system
Content
Working on the compressed air system.......................................................................................................5 - 2
Starting air unit.............................................................................................................................................5 - 3
Compressor

Working on the compressed air system V4
The compressed air system provides each engine with compressed air needed for starting
(maximum 30 bar). It also supplies air for maintenance and cleaning purposes and
instrument control air (maximum 7 bar).
Warning!
Never use compressed air to blow clean your working clothes or any part of your body.
To do so is to risk your life! Air may enter your bloodstream.
Warning!
Before starting to work on, or opening up, any part of the compressed air system, make
sure that it is not pressurized.
Caution!
Sufficient supply of control air is vital to an engine in operation. Therefore the air supply
to the engine shall never be closed when the engine is running. Lack of control air will
cause a great risk of engine overspeed, which may result severe damage to the engine
and/or generator.
Caution!
Use proper blow guns and eye protection when using compressed air for cleaning
purposes.

Starting air unit
Content
Compressor
Maintaining the air compressor, 500 Hours..........................................................................................5 - 5
Maintaining the air compressor, 1000 Hours........................................................................................5 - 7
Compressor

Maintaining the air compressor V1
Component
Unit: Starting air unit TSA901 Type: 15T
Component: Compressor D001, D002 Manufacturer: Ingersoll Rand
Work Information
Type of job: Planned maintenance Stop time: 2 Hours
Interval: 500 Hours Service personnel: Mechanical, 1 / Component
3 Months
Required spareparts

- As required Air inlet filter
Required tools
Code Description
- Torque wrench
Consumables
Description Maker Amount

Petroleum lubricating oil - 5 Liter
Prerequisites
Warning!
The equipment is pressurised. Isolate and release the pressure before starting any
maintenance.
Warning!
Before doing any maintenance, make sure that the equipment is disconnected from the
electrical mains and tagged out.
Job Description
1 Drain condensate from air receiver and condensate traps.
2 Change the oil.
Change the oil when it is hot.
Use non-detergent petroleum lubricating oil.
3 Inspect and clean the air inlet filter.
Vacuum or wash with mild detergent and water. Allow to dry before reinstalling.
4 Clean the intercooler externally.
Remove dust and grease from the surface.
5 Operate the safety valves manually.
6 Clean the cylinder cooling fins.
7 Check the belt tension of the v-belt drive.
8 Clean the motor.

Wipe dust and dirt off the motor.

9 Clean the air cooler of the aftercooler externally.
10 Operate the safety valves of the receiver manually.
11 Check the tightness of all bolts.
Tighten, if needed.
12 Check for unusual noise and vibration.
13 Inspect for air leaks.
14 Check the tightness of all bolts.
Tighten, if needed.

Maintaining the air compressor V1
Component
Unit: Starting air unit TSA901 Type: 15T
Component: Compressor D001, D002 Manufacturer: Ingersoll Rand
Work Information
Required spareparts

- As required Filtering element for the intake air cleaner
- As required Compressor valves
Prerequisites
Warning!
The equipment is pressurised. Isolate and release the pressure before starting any
maintenance.
Warning!
Before doing any maintenance, make sure that the equipment is disconnected from the
electrical mains and tagged out.
Job Description
1 Inspect the intake air cleaner.
Clean or replace the filtering element, if needed.
2 Inspect the compressor valves.
If necessary, clean the valve parts by light scraping or brushing (do not use a wire brush).
Use a non-flammable safety solvent to loose dirt, oil or carbon deposits, if needed.
Replace the valves, if needed.
3 Inspect the electric motor.
Lubricate and clean, if needed.
4 Clean the compressor.
Clean the cylinder externally and the intercooler tubes with a jet of air, if needed.


6. Cooling system
Cooling system
Content
Preheating unit.............................................................................................................................................6 - 2
Heater
Circulation pump
Safety valve
Air venting valve
Central cooler.............................................................................................................................................6 - 10
Heat exchanger

6. Cooling system
Preheating unit
Content
Heater
Inspecting the immersion heater, 1 Years............................................................................................6 - 3
Circulation pump
Inspecting the circulation pump, 6 Months............................................................................................6 - 5
Six month inspection of the circulation pump.
Safety valve
Testing the safety valve, 1 Years..........................................................................................................6 - 7
Air venting valve
Replacing the automatic air vent valve, as required.............................................................................6 - 9
Replace the air and dirt separator air vent valve if it starts to leak.
Heater
6. Cooling system
Inspecting the immersion heater V2
Component
Unit: Preheating unit VDA011, VDA021 Type: electric immersion heater
Component: Heater B001 Manufacturer: Loval
Work Information
Type of job: Check job Stop time: 1 Hours
Interval: 1 Years Service personnel: Electrician, 1 / Component
Job Description
1 Inspect the electric leads for the heater.
a ) Make sure that the electric leads are tightly fastened to the terminals.
b ) Check the terminals for oxidation.
2 If the immersion heater does not function, do the following:
Check that the thermal cut-out device has not tripped.
Check that the heating elements and the thermostat are not damaged.
Note!
A damaged immersion heater must be replaced. It cannot be repaired.
Circulation pump

6. Cooling system

6. Cooling system
Inspecting the circulation pump V4
Component
Unit: Preheating unit VDA011, VDA021 Type: L_, AL_, AKN_; AMK, AHV, AH,
ASH, AE; AKP, ASV, ASP, AP
Component: Circulation pump D001 Manufacturer: KOLMEKS
Work Information
Type of job: Check job Stop time:
Prerequisites
The pump does not need any regular servicing.
Required spareparts

As required Shaft seal
Inspect the pump for leakage.

Job Description
Look for leakage from the shaft seal, if detected the pump must be opened and the seal
replaced. A few drops of leakage per hour is normal.
valve
Safety
6. Cooling system

6. Cooling system
Testing the safety valve V1
Component
Unit: Preheating unit VDA011, VDA021 Type: 616
Component: Safety valve V004 Manufacturer: Gtze
Work Information
Type of job: Test Stop time: 1 Hours
Required spareparts

1 Replacement valve
As required Gaskets
Job Description
1 Test that the safety valve opens.
2 Inspect the valve for leakage.
It may be possible to stop minor leaks by lifting the handle. If this does not work, the valve
must be overhauled or replaced.
valve
venting
Air
6. Cooling system

6. Cooling system
Replacing the automatic air vent valve V1
Component
Unit: Preheating unit VDA011, VDA021 Type: Spirotop
Component: Air venting valve V005 Manufacturer: Spirotech
Work Information
JobID: wca1580 Work time: 0.5 Hours
Type of job: Replacement Stop time: 0.5 Hours
Interval: As required Service personnel: Mechanical, 1 / Component
2 Years
Required spareparts

- 1 Complete Spirotop automatic air vent valve
Replace the automatic vent valve if it starts to leak, or every two years.
Job Description
1 Remove the entire valve from the vessel's (air and dirt separator) vent line.
2 Replace this valve with a new valve of the same type.

6. Cooling system
Central cooler
Content
Heat exchanger
Cleaning the heat exchanger, 1 Years................................................................................................6 - 11
This is a plate heat exchanger and requires periodic cleaning based on the amount of fouling.
exchanger
Heat
6. Cooling system
Cleaning the heat exchanger V2
Component
Unit: Central cooler VCL010, VCL020 Type: M, T
Component: Heat exchanger B003 Manufacturer: Alfa Laval
Work Information
JobID: wca0333 Work time:
Type of job: Inspection Stop time:
Prerequisites
When ordering plates and gaskets, state the serial numbers of the plates and the type
and serial number of the heat exchanger.
Required spareparts

As required Gaskets
Required tools
Code Description
Circulation pump for detergent (Cleaning-in-place)
Clean the heat exchanger at least every year. The cleaning must also be done if there is
a drop in output pressure or temperature.
Job Description
1 Check the history of the temperature and pressure drop to determine the need for
cleaning.
2 Inspect the heat exchanger for signs of leakage or damage.
3 Shut down and clean the heat exchanger (if needed).
a ) Cool the heat exchanger to below 40 degrees C.
b ) Let the pump recirculate and lower the temperature of the cooling water.
Caution!
The temperature drop must not be greater than 10 degrees per minute and the pressure
drop must not be greater than 10 bar per minute.
c ) Unless severe fouling is suspected, clean the heat exchanger in place (CIP) without
separating the frame.
d ) Refer to the manufacturer's manual for CIP cleaning and for the detergent
requirements.
Caution!
Do not use chlorine-containing agents (such as HCl).
4 If further cleaning is needed, follow the manufacturer's instructions for separating the
plates and cleaning.
6. Cooling system
Note!
The manufacturer's manual contains cleaning instructions for different types of fouling.
5 When the cleaning is completed, follow the manufacturer's instructions for removing and
replacing the gaskets.
6 Follow the manufacturer's instructions for assembling the heat exchanger.
7 Start the heat exchanger again by following the manufacturer's instructions for start-up.
7. Charge air and exhaust gas system
Charge air and exhaust gas system
Content
Charge air....................................................................................................................................................7 - 2
Charge air filter
Charge air silencer
Exhaust gas...............................................................................................................................................7 - 10
Rupture disks

Charge air
Content
Charge air filter
Removing sludge from the filter, 1 Months...........................................................................................7 - 3
Remove sludge from the charge air filter every month.
Inspecting the MultiDuty filter, 6 Months...............................................................................................7 - 5
The inspection includes checking of timer and testing the condition of the viscosine oil.
Replacing the Viscosine, 1 Years.........................................................................................................7 - 7
Charge air silencer
Inspecting the charge air silencer, 3 Months........................................................................................7 - 9
Remove condensation water from the silencer.
filter
air
Charge
Removing sludge from the filter V4
Component
Unit: Charge air NGA010, NGA020 Type: MultiDuty
Component: Charge air filter B001 Manufacturer: AAF
Work Information
Type of job: Wash/Clean Stop time: 0 Hours
Required tools
Code Description
Sludge scraper
Consumables

Viscosine AAF Pcs
Remove sludge and add Viscosine if needed.
Note!
When filling with new viscosine, make sure that there is no sludge left at the bottom of the
viscosine oil tank.
Job Description
1 Remove sludge with the sludge scraper and pan.
2 Fill Viscosine tank to the level mark. Viscosine type is indicated on the guarantee plate.


Inspecting the MultiDuty filter V2
Component
Unit: Charge air NGA010, NGA020 Type: Multiduty
Work Information
Check the timer and take a viscosine sample.

Job Description
1 Check if the timer works properly. The filter is equipped with a timer which operates the
curtain at 15 minutes intervals so that the filter curtain makes a complete revolution in 24
hours.
2 Take a viscosine sample from the tank.
a ) Put the sample into a graduated glass around 1 litre.
b ) Let the viscosine settle for 48 hours.
c ) If sludge deposit is above or equal to of oil height, replace viscosine.


Replacing the Viscosine V2
Component
Unit: Charge air NGA010, NGA020 Type: MultiDuty
Work Information
Prerequisites
Viscosine can be supplied in two different grades:

BA Viscosine is used in countries with a moderate climate
MA Viscosine is to be used in warm countries, average temperature above 35 C.
Consumables

Viscosine for section width of 3 feet AAF 95 Liter
Completely renew the Viscosine periodically, especially when the filtered air may cause
physical or chemical Viscosine variation. The minimum interval is once a year.
Job Description
1 Drain the Viscosine tank.
Refer to the manufacturer's manual for instructions for treatment and disposal, or follow
local regulations.
2 Make sure that there is no sludge left in the bottom of the Viscosine oil tank.
3 Fill the Viscosine tank to the correct level.
silencer
air
Charge

Inspecting the charge air silencer V1
Component
Unit: Charge air NGA010, NGA020 Type: SCAS.
Component: Charge air silencer B002, B003 Manufacturer: JTK-POWER
Work Information
Prerequisites
Note!
The standard model charge air silencers are maintenance-free.
Check for condensation water.

Job Description
1 Check that no condensation water has remained in the charge air silencer.
a ) Open and clean all blocked condensation water outlets, if needed.

Exhaust gas
Content
Inspecting the exhaust gas silencer, 4000 Hours...............................................................................7 - 11
Check spark arrestors, if applicable.
Rupture disks
Inspecting the explosion vent, 1 Years...............................................................................................7 - 13
silencer
gas
Exhaust
Inspecting the exhaust gas silencer V3
Component
Unit: Exhaust gas NHA010, NHA020 Type: NS
Component: Exhaust gas silencer B010 Manufacturer: JTK-POWER
Work Information
Type of job: Wash/Clean Stop time: 1 Hours
6 Months
If the exhaust gas silencer has spark arrestors, they need service.
Job Description
1 Grease the threads of the discharge socket and cap with heat-proof graphite lubricating
oil when the spark box is being discharged.
2 Clean the spark box.
disks
Rupture
Inspecting the explosion vent V2
Component
Unit: Exhaust gas NHA010, NHA020 Type: CV-S-I-LV
Component: Rupture disks B004, B005, B007 Manufacturer: FIKE
Work Information
JobID: 0598 Work time: 0.5 Hours
Prerequisites
When ordering exchange parts, always give the vent lot number that is indicated on the
tagplate.
Required spareparts

As required Explosion vent (exchange part)
Job Description
Visually inspect the explosion vent. Change the explosion vent if it appears to be
damaged, leaking or corroded. Follow the manufacturers instructions.
Caution!
Handle the explosion vent with extreme care. Do not bend, poke or in any way distort the
vent membrane.
8. Electrical systems
Electrical systems
Content
DC system....................................................................................................................................................8 - 2
EFORE MPS

DC system
Content
EFORE MPS
Inspecting the DC power supply system, 1 Years................................................................................8 - 3
Annual inspection of the DC power supply system.
MPS
EFORE
Inspecting the DC power supply system V1
Component
Unit: DC system BEY901 Type: MPS
Component: EFORE MPS Manufacturer: EFORE
Work Information
JobID: wca0390 Work time:
Type of job: Inspection Stop time:
Interval: 1 Years Service personnel: Electrician, / Component
O&M Supervisor, / Component
Prerequisites
Warning!
Hazardous energy and voltage are present in the unit and on the interface cables.
They can cause shock or serious injury.
Follow all safety warnings and practices when servicing this equipment.
Required spareparts

As required Rectifier modules
The functions of the system control unit and rectifiers are checked once a year. The
batteries are supplied separately from the rest of the system; refer to the manufacturer's
instructions for specific maintenance requirements.
Job Description
1 Check the batteries.
Check the following:
Cell voltage
Specific weight of the battery acid
Syringe level
Any other items or tests recommended by the battery manufacture.
2 Measure the float charges of the rectifiers.
3 Inspect the functions of the rectifiers.
Refer to the user manuals for the rectifiers.
Note!
Repairs amount to replacing rectifier modules. Remove the faulty module from the system
and replace it with a new rectifier module.
4 Inspect the operational functions of the control unit (RCU).

Refer to the OEM manual and test the following
Over voltage
Under voltage
Boost charge fault
Automatic boost charge

Rectifier fault and mains failure

Distribution fuse fault
Battery fuse fault
Earth fault (in floating system)
Batteries discharged.

9. Appendix
Appendix
Content
Maintenance-related spare parts.................................................................................................................9 - 2

9. Appendix
Maintenance-related spare parts V1
This is a list of parts needed to carry out scheduled maintenance of the auxiliary systems
in the power plant. Only spare parts for units that are supplied by Wrtsil are included.
The table head row identifies the component name, manufacturer, type and process
code.
The first column gives the part number as specified by the manufacturer.
The second column gives the number of parts needed for maintaining one piece of
equipment. As required indicates that the part is changed only if it is broken or worn
beyond the safety limits.
When ordering spare parts, always include all the data needed to identify the component
and part installed.
Brand and model
Serial number
Type of application
Name and description of the spare part
Spare part code, if available
Contact information of the person making the order.
Genset equipment
Table 9-1 Generating set, BAG011, BAG021
Generator, ABB, AMG 1120MP08 DSE

- 1 Pcs Safety package 4000 Hours
- 1 Pcs Maintenance package 8000 Hours
- 1 Pcs Capital spare part package 80000 Hours
Fuel gas system
Table 9-2 Gas regulating unit, ZAC011, ZAC021
Gas filter with magnetic insert, RMG, 906-DN80-16, B002

RMG-15 015 103 As required Paper filter 1 6 Months
- As required Filter insert 1, 2, and 3 6 Months
RMG-00 018 791 As required Sealing rings 6 Months
RMG-00 018 789 As required Sealing rings 6 Months
RMG-15 015 105 As required Plastic ring (glued onto filter basket) 6 Months
RMG-00 021 274 As required O-ring 6 Months

9. Appendix
Gas filter, RMG, 905 EO 12, B003, B007

RMG-00 026 183 As required Filter insert 4 Months
RMG-00 018 842 As required Sealing ring 4 Months
Gas pressure regulator, RMG, 402-80-0-640-So-RL, V007

- As required Closing spring 3 Months
RMG-10 011 305 As required Diaphragm 3 Months
- As required Piston, premounted 3 Months
Gas pressure regulator, RMG, 402-25-0-640-So-RL, V021

RMG-10 024 055 As required Closing spring 3 Months
RMG-10 011 304 As required Diaphragm 3 Months
- As required Piston, premounted 3 Months
Lubricating oil system
Table 9-3 Lube oil transfer pump (mobile), QLC901
Transfer pump, IMO, ACE 032 N3 NVBP, D001

IMO-190714 As required Joint kit, for dismantling of the pump, 6 Months
G057
IMO-189964 As required Shaft seal, G050 6 Months
IMO-190714 1 Pcs Joint kit, for dismantling of the pump, 3 Years
G057
IMO-189964 1 Pcs Shaft seal, G050 3 Years
IMO-190484 As required Rotor set, G012 3 Years
IMO-189873 As required Valve element, G070 3 Years

9. Appendix
Compressed air system
Table 9-4 Starting air unit, TSA901
Compressor, Ingersoll Rand, 15T2, D001, D002

- As required Air inlet filter 500 Hours
- As required Filtering element for the intake air 1000 Hours
cleaner
- As required Compressor valves 1000 Hours
Cooling system
Table 9-5 Preheating unit, VDA011, VDA021
Circulation pump, KOLMEKS, AE-25/2 (100mm), D001

- As required Shaft seal 6 Months
Safety valve, Gtze, GTZE 616E, V004

- 1 Pcs Replacement valve 1 Years
- As required Gaskets 1 Years
Air venting valve, Spirotech, Spirotop, V005

- 1 Pcs Complete Spirotop automatic air vent As required
valve
Table 9-6 Central cooler, VCL010, VCL020
Heat exchanger, Alfa Laval, M15-BFM, B003

- As required Gaskets 1 Years
Charge air and exhaust gas system
Table 9-7 Exhaust gas, NHA010, NHA020
Rupture disks, FIKE, CV-S-I-LW, B004, B005, B007

- As required Explosion vent (exchange part) 1 Years
Electrical systems
Table 9-8 DC system, BEY901
EFORE MPS, EFORE, MPS 24/80+40 320 Ah Pb

- As required Rectifier modules 1 Years

Wrtsil Corporation is the leading global ship power supplier and a major provider of solutions for
decentralized power generation and supporting services.
For more information, please visit www.wartsila.com
Send feedback regarding this manual to:

feedback.wartsila-manual@citec.fi
Wrtsil is a registered trademark. COPYRIGHT 2010, WRTSIL FINLAND OY
Wrtsil Finland Oy
P.O.Box 242
65101 Vaasa, Finland
Tel: +358 10 709 0000

Fax: +358 6 356 7188

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Uflex Limited - Noida

Maintenance manual for auxiliaries

DBAB529555 - Confidential 16.09.2010

Introduction to the maintenance manual............................................................................1 - 1

Fuel gas system.................................................................................................................3 - 1

Lubricating oil system.........................................................................................................4 - 1

Compressed air system......................................................................................................5 - 1

DBAB529555 - Confidential Table of Contents - i

Charge air and exhaust gas system...................................................................................7 - 1

Table of Contents - ii Confidential DBAB529555 -

Calendar-based maintenance schedule

Cooling system, Central cooler Cleaning the heat exchanger WCA0333 6 - 11

DBAB529555 - Confidential Maintenance schedule - iii

Maintenance schedule based on running hours

Maintenance schedule - iv Confidential DBAB529555 -

Maintenance interval determined by operating conditions

DBAB529555 - Confidential Maintenance schedule - v

Maintenance schedule - vi Confidential DBAB529555 -

Introduction to the maintenance manual V3

The instructions are based on information provided by the equipment manufacturer or

Maintenance-related spare parts and required special tools

DBAB529555 - Confidential 1-1

1-2 Confidential DBAB529555 -

The maintenance activities are divided into three categories:

DBAB529555 - Confidential 1-3

Safety aspects for maintenance work V3

Pay attention to the risk of ignition

Prevent unintended starting during maintenance work

Prevent electrical shocks

Avoid burns and splashes

1-4 Confidential DBAB529555 -

Be aware of the power of pressurized air

Take precautions for confined entry

Use protective clothes

Keep the area tidy

DBAB529555 - Confidential 1-5

Locking and tagging out for maintenance or

e ) Turn on the energy sources.

1-6 Confidential DBAB529555 -

DBAB529555 - Confidential 2-1

Generator maintenance program V2

Equivalent operating hours (Eq. h) = Actual operating hours + Number of starts * 20

DBAB529555 - Confidential 2-3

2-4 Confidential DBAB529555 -

Level 1 maintenance of ABB Generator V5

Spcode Qty Description

DBAB529555 - Confidential 2-5

c) Stator coil over hangs: Insulation damages, V

2-6 Confidential DBAB529555 -

j ) Plate fins: General condition, V

DBAB529555 - Confidential 2-7

2-8 Confidential DBAB529555 -

Level 2 maintenance of ABB Generator V5

Spcode Qty Description

DBAB529555 - Confidential 2-9

b ) High voltage connections: Oxidation, fastening T

Level 3 maintenance of ABB Generator V4

Spcode Qty Description

Level 4 maintenance of ABB Generator V4

Spcode Qty Description

3 Check the stator and the rotor:

Fuel gas system V2

Shutting down the gas system for maintenance

Before doing any maintenance, do the following: