GENSET SYSTEM MAINTENANCE PROCEDURE 1.

FAE is engaged in the business of providing cellular Mobile Communication services to Mobile Communication Companies. 2. The FAE is engaged in the business of providing Generator maintenance services in order to ensure complete, effective and continuous operation of the Generators installed at Sites in accordance with requirements of Clients and hereby represents, warrants, assures and undertakes to Clients that it has the requisite experience and expertise with respect to provision of the Generator maintenance services;

SERVICES PROCEDURE
1. The FAE shall be bound to visits site once in a month regular compulsory for provision of services. The FAE during such monthly visit shall inspect and 2. provide routine maintenance and service to the Equipment installed at the sites. It is hereby clarified for the convenience of parties that the monthly visit of the 3. FAE as envisaged herein shall not be affected and shall be in addition to all or any emergency visits made by the FAE to the Site. 4. The FAE shall maintain a help desk and emergency on-call team of skilled technicians and engineers equipped with mobile phones and necessary tools round the clock the said team shall be available round the clock to Client so to cater all or any emergency or routine complaint in the Equipment installed at Sites. The FAE shall provide update on-call roster with contact numbers of the technicians and engineers to Client for the purpose of establishing immediate contact in case of emergency. 5. The emergency visits would be unlimited and shall not be charged for any extra amount other than the amount agreed to be paid to the FAE by Client for provision of Services every month. In case of emergency the Company may contact at help desk numbers on-call technicians/ engineers (at numbers advised by the F & A Engg.). In either case, the FAE shall ensure that its technicians/ engineers attend the Site(s) immediately after the matter is reported to the FAE (as aforesaid) regardless of the time of the day /night when the matter is reported. The FAE shall ensure that its technicians/ engineers shall investigate and remove the cause of breakdown/malfunction in a prompt and expeditious manner and remain engaged in the rectification of the problem until the operation of the Equipment is restored to the satisfaction of the Company. The F & A Engg.s technicians/ engineers shall not leave the Site, without making the entry in the logbook placed at the site. 6. In case of emergency or otherwise if the equipment cannot be repaired at the Site and has to be removed from the Site to be taken to F & A Engg.s workshop for repair, the FAE hereby undertakes, assures, guarantees and represents to Client that in such an eventuality the FAE shall immediately replace the defective Equipment with the temporary Equipment of the same specification till the time that the defective equipment is repaired and installed at the Site. The FAE hereby represents, undertakes, assures and guarantees to Client that it has sufficient number of temporary Equipment for the purposes of installation in place of the defective Equipment in case of need. 7. The FAE will submit on a monthly basis, copies of reports on approved format with respect to preventive and corrective/breakdown Maintenance works. The FAE would place service sticker on each unit recording every service activity with date and time. Further, the FAE shall maintain a regular Service Schedule, which will include servicing of units and comprehensive inspection and maintenance of parts as per requirements. 8. The FAE agrees to maintain an inventory of part required for the maintenance of the Equipment and to make replacement of all faulty parts (whether in case of emergency or during routine visits) from its own stock at the earliest. Client shall however reimburse to the FAE actual cost incurred in this behalf, if the replacement of said parts it is not covered by the warranty on submission of bill along with delivery challan/call report duly verified by the Company representative in accordance with the procedure provided in article 4 hereinabove. The FAE should ensure that genuine and best quality spare parts shall be used while carrying out the Services (including emergency services and preventive maintenance).

PROCEDURE FOR PREVENTIVE MAINTENANCE OF BTS You are supposed to do PMs, during your duties according to schedule. PM means Preventive Maintenance. So its name shows that one has to do PM in such a manner that nothing should be pending in order to avoid alarms. For PM one can keenly read the PM check list form, provided by Client. In this form one can find each and every task, so I will not mention every item but give only guide lines that how to perform these task and what are the standards which are followed. 1.1 CHECKING OF PM MATERIEL BOX IN OFFICE
(a)-Check

the PM box that all required items (materiel) are present in this box. List of items is attached with box and also with techs. Keep one list with you too.
(b)-Missing

materiel will be filled by store keeper, for this engineer will provide the materiel consumption form (with signatures) to store keeper. This form will be of last done PM.
(c)-Check (d)-Load

the PM tool kit, laptop, meters camera etc and bring these with you by filling Hand over form, present in office.

the vehicle in front of you and finally asked from techs if they need some thing to take with them.

1.2 BEFORE INTERVENE THE SITE (a)-Before intervene the site, call OMC and ask the alarms, if there is any alarm then dont make intervention and call to your area head. (b)-If site is clear from all alarms then make intervention and send the SMS to the following about your intervention with site name and purpose of intervention.
1Project Manager of FAE 2Area head (F & A Engg.) of your area. 3Client area manager of related center. 4On call Engineer of Client or hot line of

Client.

1.3 BEFORE STARTING THE PM (a)-Take snaps of site, out side, inside and every item. 1.4 OBSERAVTION One should have strong observation, at the time of intervention in the site,he Should note each and every thing outside, inside of site, which needs repair or Maintenance. For this purpose,
(1)------Make

the list of such points on paper. these points according to the planning.

(2)------Arrange (3)------Give

your plan to Techs and give them tasks and steps that at first solve this issue and then that issue, during this, second Tech will do this, etc. 1.5 CONCENTRATION ON PM FORM
(a)-Fill

the form according to the work in progress. filling of blocks, make the reserves on last page of form.

(b)-Besides,

1.6 RESERVES

(a)-Write (b)-Write (c)-Fill

each and every task which has been done with (Done) mark. all pending items with mark (Pending).

the separate pending form (available in office) for pending items.

1.7 BATTERY TEST

(a)-Engineer (b)-Engineer

must have a look on rectifier display for observing the battery voltages and currents.

should apply clamp meter on batteries for measuring voltages and currents during test. One should not trust on display of rectifier, it might be faulty or might giving wrong values due to wrong setting of MCU.
(c)-One

should stop the test, if voltages drop to 48v during test.

1.8 POWER SUPPLY

(a)-Check

the path of main power cable. It should be as short as possible and in good manner, under ground and under duct. If path is not good, you can make suggestion with drawing.
(b)-Cables,

entering in 100amp breaker should be as short as possible inside the box of breaker and also at inlet point of breaker

box.
(c)-Observe

the cable path between 100amp breaker and DP and from DP to ATS. This should be in good manner.

(d)-Load Balance
1

Engineer should check the balance of load in three phases by checking the load sharing. ACs must be on 2 different phases.

2.Two

1.9 EARTHING Engineer can find all items which are to be earthed, in PM form, here is the way of doing earth which should be followed.
(a)--------Earth (b)--------Earth (c)--------Dont

cable path should be as short as possible and in arranged manner. of Cable Ladder, ATS panel and DP should be with earth strip, not with earth cable.

use flexible pipe for covering earth cable or any cable, out side the site, as this pipe is not reliable for weather condition. Use PVC pipe.
(d)--------Connection (e)--------Greesing

with earth plate should be in straight line, cable should not follow the zigzag path or angular path.

should be done, after making the plates clean and not in heavy amount.

1.10 AC SERVICE
(a) (b) (c)

----First apply blower on ODU and IDU, then wash the ODU and IDU filters with water. ----Do the earthing of ACs ODU stands.

----Observe the position of ODUs, if these are in between the shelter and boundary wall and distance between two walls is very less, then place these IDUs on suitable place. Also ODU should not be near genset exhaust pipe.

(d)

----Path of Drain system with PVC pipe should be in good manner and out let at some suit able point near boundary walls

1.11 BTS CABNET

(a)-----log

on to bts and check the alarm status. the alarm status at DDF with the help of LED. should apply the blower by himself on BTS , with low pressure.

(b)-----Check

(c)-----Engineer

1.12 M.W PANNEL 17 F.U AFTER PM

(a)-----Please

keep in your mind that F.UP is more important than the PM itself. We do the PM for solving the problems and sorting the problems. F.U issues are result of PM and how can we make the result, pending. So complete all pending issues as soon as possible and update the pending file. 1.18 REPORTING AFTER PM
(a)-----Engineer

is supposed to make timely, effective and good reports of any critical issue, present in site. For details, contact to your area head. Some important issues for example are as under:
1.Any 2.Any 3.Any 4.Any

construction work required. issue, which is security risk(fill RIR form too for this) device faulty, un repairable, like AC, fire panel, empty fire extg. Etc spare item in site boundary.

NOTE: Reports must be with clear snaps. For this report snaps are attached below: Ascom Rectifier Inner view of Rectifier Modules of Rectifier Breakers for BTS,M.W in Rectifier Alcatel BTS cabinet Inner view of Alcatel BTS Fans of radios in Motorola cabinet should be clean- Inner view of Motorola cabinet. Getting started with BTS Terminal:When you click on the BTS Terminal screen will show the following snaps, you will enter user name commtee password commtee Then you will enter the BTS Terminal Be sure that the port setting are OK.

O & M OF AIRCON

Air Condition Service Procedure:

Maintenance services of the Equipment system shall include but shall not be limited to maintenance and inspection of the following items: Filter Cleaning Coil Cleaning of Outdoor Units Coil Cleaning of Indoor Units Drain Pan Cleaning and Inspection Drain Pan Cleaning for Fungus Inspection of Contactors Inspection of Thermostat Inspection of PCB Inspection of Setting of Thermostat & Control Panel Inspection of Gas Pressure Inspection & checking of motors for abnormal sound Inspection and setting of Sequential Operation Control Panel. The coils should be cleaned using Pressure Water Pump. The gas charging The FAE shall be bound to visit Sites once every month regular compulsorily for provision of Services. The FAE during such monthly visit shall inspect and provide routine maintenance and service to the Equipment installed at the Sites. It is hereby clarified for the convenience of parties that the monthly visit of the FAE as envisaged herein shall not be affected and shall be in addition to all or any emergency visits made by the FAE to the Site. The FAE shall maintain a help desk and emergency on-call team of skilled technicians and engineers equipped with mobile phones and necessary tools round the clock. The said team shall be available round the clock to Client so to cater all or any emergency or routine complaint in the Equipment installed at Sites. The Contractor shall provide update on-call roster with contact numbers of the technicians and engineers to Client for the purpose of establishing immediate contact in case of emergency.

OVERHAULING PROCEDURE

Before discussing of Overhauling procedure, a question raised in our mind that why we are going to do Overhauling Job ? It is a periodic Major Maintenance of a Generator by which we increase the life of an engine according to Manufacturers Recommendations. Overhauling of a generator is related to Preventive Maintenance, so we will have to do this job according to Manufacturers Recommendations which is normally due after 8,000 to 10,000 Running Hours. Also keep this thing in mind that Preventive Maintenance increases Life of an Engine while Destructive Maintenance decreases the life of an engine Following Major Activity should be carried out in Overhauling.

Dismantling Inspection & Cleaning Repairing, Machining & Calibration. Assembling Testing Canopy Repairing & Paint

Now we discussed in details of above mentioned Activities.

Dismantling

First of all, we take the snaps of a generator; it is going to be dismantled in following Steps. Basically generator consists of two major parts Alternator & Engine.

- Alternator

We will remove all wiring in the beginning. Following are major components of an Alternator, also please be noted that always use proper dismantling tools for dismantling.

Rotor Exciter Stator Bearings

Dismantle above mentioned one by one with proper dismantling Tools. 1. - Engine

Fix the Engine on work Bench for Dismantling with following Sequence. 1. 2. 3. 4. 5. 6. 7. 8. 9. Safeties switches Shields & Safe Guards Radiator with Hose Pipes Radiator Fan Fly Wheel Fuel Pump & Nozzles Self & Dynamo Intake Manifold Exhaust Manifold

10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Water Pump Sump Lube Oil Pump Rocker Arm Assembly Engine Head Gear Train Rings & Pistons Connecting & Push Rods Crank & Cam Shafts Engine Block

Dismantle above mentioned one by one with proper dismantling Tools according Manufacturers Manual. 1. Inspection & Cleaning

Following Parameters will be carried out in Inspection process. 1. 2. 3. Carried out Pressure Tests of Engine Block & Head. Inspect the Alignment of Block, Head, and Connecting Rod & Cam Shaft. Inspect Moving Portion of Crankshaft and Rotors & Exciter Winding.

After inspection of parts, Cleaning Process Starts, it is very Critical & Important Process in Overhauling of Diesel Engine. Efficiency & life of an engine depend upon it because if a smallest element of dust left out after cleaning then it can become major loss of an engine during operation, so this is very critical portion of an overhauling. Clean all above mentioned Parts of an Alternator & Engine with a recommended Cleaning Material according to Manufacturers Service Manual. 1. Repairing, Machining & Calibration.

After Inspection & Cleaning Process, Repairing, Machining & Calibration Process starts in which following major actions should be taken & we will discuss in details one by one.

o o o o 1.

Repairing & Service Machining Calibration Replacement of parts Repairing & Service.

During the Repairing & Service, we will focus below mentioned items. 1. 2. 3. Self Starting Motor Dynamo Radiator

4.

Water Pump

Repairing & Service of above mentioned should be done according to the Recommended spares to be changed of above mentioned according Manufacturers Service Manual. 1. Machining

In this process following are going to be machined compulsory after very strong inspection & cleaning processes. 1. 2. 3. 4. 5. 6. 7. Engine Head Engine Block Valve & Seats Guides Sleeves Connecting Rod Bushes Crank Shaft

Please be noted that these all machining measures are very precise & accurate according to Manufacturers Measures. 1. Calibration

In this process following are going to be calibrated compulsory 1. 2. Fuel Injection Pump Atomizers

Calibration of above mentioned should be done Compulsory, also please be noted that repairing kit of mentioned should be changed 1. Replacement of parts

Following are details of replacement of parts with new one which is recommended by Manufacturers Service Manual.

o o o o o o o o o o

Ring Set Piston Set Main & Big end Bearings Head Gasket Front & Rear Oil Seal Gaskets (sump, Timing Gear Train, Fuel Pump & Water Pump) Valves ,Guides , Seats & Seals Push Rod (if required) Lube Oil Pump (if required) Connecting Rod Bushes (if required)

1. 2. 3. 4. 5. 6.

Cam Shaft Bushes (if required) Sleeves Sleeve Rings Fan Belt Fuel Nozzles (if required) Connecting Rods (if required)

Please be noted that above mentioned should be changed compulsory according to Manufacturers Service Manual. Also please be noted that replaced above mentioned with genuine part for sake of long life of an engine. After this process, every thing is ready for assembling of an engine according to Manufacturers Recommendations. 1. Assembling:

Before start this process, please make sure that work bunch should be neat & clean and tools used for assembling are also neat & clean and proper. Following Sequence is required for assembling according to the Manufacturers Service Manual. 1. Engine Assembling

Following is sequence of Engine

o o o o o o o o o o o o o o o o o

Engine Block with Sleeves Crank Shaft with Main Bearings Front & Rear Oil Seals New Piston with Rings Fitting Connecting Rod with Big end Bearing Cam Shaft Push Rod with Guides Head Gasket Engine Head Rocker Arm Assembling Water Pump Oil Pump Gear Train Gear Train Cover with Gasket Fan Pulley & Fan Fly Wheel Intake Manifold & Air Filter

o o o o o o o o o o o o

Exhaust Manifold Oil Sump with Gasket & Oil Filter Fuel Pump Nozzles with Proper Fuel Line Connections Fuel Filter Self Starting Motor Dynamo Radiator & Hose Pipe Safety Switches & Relays Shields & Safe Guards Water with Specified Quantity of Coolant Fresh Engine Oil

Alternator Assembling

Following is Sequence of Assembling

Bearing Rotor Excite

Keep one thing in mind especially in assembling of all parts of generator during Overhauling. We should give a specified Torque with Torque Wrench according to Manufacturers Service Manual. Coupled both Engine & Alternator with each other. After Coupling, Reinstalled Complete Wiring with proper Dressing & connect according to the Drawing. Connect the Panel of Genset for Starting & Parameters. Now Genset is Ready for Testing & just installed Battery & Start the Genset.

Testing

Start the Engine for Half an Hour without Load then shift dummy Load on Genset according following Intervals of Time Shift 25% Load on Genset Shift 50% Load on Genset Shift 75% Load on Genset Shift 100% Load on Genset Observations & Remarks 1st Hour 2nd Hour 3rd Hour 4th Hour

Make sure that Oil Pressure is not less than 5 bars. Water Temperature is not more than 80c. Make sure that Safeties are Operational at Load & Unload. Checked Abnormal Sound of Engine

Checked leakages of Oil , Fuel & Water. Checked Charging of Battery from Charger. Checked all Meters & Gauges & replaced if required.

Canopy Repairing & Paint

Repaired the door & hinges locks and Muffler or replaced them if required. Paint complete Canopy

Took Snaps of Generator now is ready for shifting on site.

NSTALLATION AND COMMISSIONING Installation, Testing and Commissioning of the following Equipment:

Diesel Generator Sets upto 2500 kVA Diesel Generator Panels, Changeover and Auto Start High Voltage Switchgear up to 11 kV Power Transformer upto 3000 kVA Rotary equipments i.e., Compressors, Generators, Pumps, Chillers, Boilers and Cooling Towers etc. Copper Bus Tie Ducts 4000 Amps Main LT Panel 4000 Amps LT Electrical Switchgear / Panel Board Power Factor Improvement Plants (Capacitor Bank) HT Power Cables 11 kV and LT Power Cables 415 VAC Earth Protection System AMF & Auto Load Transfer Panels Industrial/Commercial Electrification and Lighting Fixtures Cable Support Systems, Cable Trays, Cable Duct and Cable Power Distribution Boards (DB's) and Cable Ladders Electric Motors and Motor Control Panel / Equipmen

MANUFACTURING & FABRICATIONS WORK SCOPE OF BUSINESS WORK

1. Installation, Testing and Commissioning of the following Equipment Complete BTS equipment maintenance of telecommunication sector Diesel Generator Sets up to 2500 kVA Diesel Generator Panels, Changeover and Auto Start High Voltage Switchgear up to 11 kV Power Transformer up to 3000 kVA Rotary equipments i.e., Compressors, Generators, Pumps, Chillers, Boilers and Cooling Towers etc. Copper Bus Tie Ducts 4000 Amps Main LT Panel 4000 Amps LT Electrical Switchgear / Panel Board Power Factor Improvement Plants (Capacitor Bank) HT Power Cables 11 kV and LT Power Cables 415 VAC Earth Protection System AMF & Auto Load Transfer Panels Industrial/Commercial Electrification and Lighting Fixtures Cable Support Systems, Cable Trays, Cable Duct and Cable Power Distribution Boards (DBs) and Cable Ladders Electric Motors and Motor Control Panel / Equipment 2. Electrical and Mechanical Fabrication Works Main LT Panels and Power DBs Power Factor Improvement (PFI) Plants Motor Control Centers Auto Mains Failure (AMF) Panels Generators Synchronizing Equipment Cable Support Systems Cable Trays, Cable Ladders and accessories All types of Electric Industrial Heaters Temperature Control Panels Industrial Automatic Process Control Panels Weather/Sound Attenuated Canopies and Mobile Trolleys Diesel Fuel Storage Tanks Genset Based Frame Fuel Tanks Genset Bulk Quantity Fuel Storage Tanks Industrial Grade Generator Exhaust Muffler and Exhaust Kit Ducting of HVAC system 3. Sound Reduction of Diesel Generator Sets Sound Attenuated enclosures for Diesel Generator Sets Construction of Sound Attenuated Room for Diesel Generator Set Exhaust Muffler for Diesel Generator Set, Doors and Vibration Isolators Air Intake Duct / Window for Generator Room and Radiator Exhaust Duct for Genset 4. Repairs Maintenance and Services Repair overhauling of Diesel Generator Sets Service Maintenance Contracting of Diesel Generator Sets Service Maintenance Contracting of Air Conditioning Sets Repair and maintenance of rotary equipments Pneumatic and Hydraulic Equipments 5. Civil Construction Work Diesel Generator Rooms and Genset Foundation Pads LT Equipment Sub-station building and Cable Trenches / Routs 6. WE ARE DEALING AND TRADING IN THE FOLLOWING ITEMS Diesel Generator Sets All type of compressors Diesel Engine Spare Parts Industrial and Diesel Engine Instruments Electrical / Mechanical Guages and Senders All type of Lube Oil and Greases Alternator AVR Auto Mains Failure Electronic Modules

 Generator Synchronizing Equipment Automatic Battery Charger Valves and Solenoids Indication Lights Automatic Voltage Regulators Molded Case Circuit Breakers Air Circuit Breakers Miniature Circuit Breakers HRC Fuse, D-Fuse Air Breaks Magnetic Contactors Control Relays, Timers and Heat Controllers Industrial Switches, Sensors and Limit Switches Panel Metering and Measuring Instruments Power Capacitors and PF Relays Power and Control Cables Enamel Winding Wires and Insulation Papers Copper Bus Bars Copper Earthling Strips and accessories Cable Lugs, Cramping Tools & Termination Kits Cable Wiring accessories Light Fixtures Cable Support accessories Conduit Pipe and accessories Panel Board accessories / Insulators Flexible Pipes Fire Fighting Equipment Security System Equipment Electric & Mechanical Tools Batteries Electric Motors Water Pumps Fuel Lifting Pumps Electronic Equipment Racks and Cabinets