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).

List of items is attached with box and also with techs.4 OBSERAVTION One should have strong observation. In this form one can find each and every task. So its name shows that one has to do PM in such a manner that nothing should be pending in order to avoid alarms. out side.he Should note each and every thing outside. 1. (c)-Check (d)-Load the PM tool kit.2 BEFORE INTERVENE THE SITE (a)-Before intervene the site. if there is any alarm then don’t make intervention and call to your area head. 1. 1. filling of blocks. (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. For PM one can keenly read the PM check list form. which needs repair or Maintenance. these points according to the planning. etc.5 CONCENTRATION ON PM FORM (a)-Fill the form according to the work in progress. during this.6 RESERVES . This form will be of last done PM. laptop. provided by Client. make the reserves on last page of form. 4……On call Engineer of Client or hot line of Client. 3……Client area manager of related center. meters camera etc and bring these with you by filling Hand over form. 1……Project Manager of FAE 2……Area head (F & A Engg. Keep one list with you too. inside of site. PM means Preventive Maintenance. call OMC and ask the alarms. at the time of intervention in the site. second Tech will do this.PROCEDURE FOR PREVENTIVE MAINTENANCE OF BTS You are supposed to do PMs.) of your area. 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. the vehicle in front of you and finally asked from techs if they need some thing to take with them. (2)------Arrange (3)------Give your plan to Techs and give them tasks and steps that at first solve this issue and then that issue. 1. inside and every item. during your duties according to schedule.1 CHECKING OF PM MATERIEL BOX IN OFFICE (a)-Check the PM box that all required items (materiel) are present in this box. (b)-Missing materiel will be filled by store keeper. for this engineer will provide the materiel consumption form (with signatures) to store keeper. (1)------Make the list of such points on paper. (b)-Besides. present in office.3 BEFORE STARTING THE PM (a)-Take snaps of site. 1. For this purpose.

(d)-Load Balance 1… Engineer should check the balance of load in three phases by checking the load sharing. 1. ----Observe the position of ODUs. (c)-Observe the cable path between 100amp breaker and DP and from DP to ATS. (b)-Cables. should apply clamp meter on batteries for measuring voltages and currents during test. the separate pending form (available in office) for pending items. (a)--------Earth (b)--------Earth (c)--------Don’t cable path should be as short as possible and in arranged manner. Also ODU should not be near genset exhaust pipe. Use PVC pipe.Two 1. 1. ACs must be on 2 different phases. if voltages drop to 48v during test. under ground and under duct.7 BATTERY TEST (a)-Engineer (b)-Engineer must have a look on rectifier display for observing the battery voltages and currents. (c)-One should stop the test. cable should not follow the zigzag path or angular path. here is the way of doing earth which should be followed. (d)--------Connection (e)--------Greesing with earth plate should be in straight line.10 AC SERVICE (a) (b) (c) ----First apply blower on ODU and IDU. This should be in good manner. ----Do the earthing of ACs ODU stands. . 1. If path is not good. ATS panel and DP should be with earth strip.8 POWER SUPPLY (a)-Check the path of main power cable. One should not trust on display of rectifier. should be done. all pending items with mark (Pending). after making the plates clean and not in heavy amount. if these are in between the shelter and boundary wall and distance between two walls is very less. It should be as short as possible and in good manner.9 EARTHING Engineer can find all items which are to be earthed. of Cable Ladder. entering in 100amp breaker should be as short as possible inside the box of breaker and also at inlet point of breaker box. not with earth cable. use flexible pipe for covering earth cable or any cable. then wash the ODU and IDU filters with water. it might be faulty or might giving wrong values due to wrong setting of MCU. then place these IDUs on suitable place. 2…. out side the site. as this pipe is not reliable for weather condition.(a)-Write (b)-Write (c)-Fill each and every task which has been done with (Done) mark. in PM form. you can make suggestion with drawing.

18 REPORTING AFTER PM (a)-----Engineer is supposed to make timely. Etc spare item in site boundary.Any 2……. which is security risk(fill RIR form too for this) device faulty. un repairable. empty fire extg. F. NOTE: Reports must be with clear snaps. For details.U issues are result of PM and how can we make the result.Any 3…….W PANNEL 17 F. you will enter · user name · commtee · password · commtee · Then you will enter the BTS Terminal · Be sure that the port setting are OK.Any construction work required. present in site. effective and good reports of any critical issue. O & M OF AIRCON .W in Rectifier Alcatel BTS cabinet Inner view of Alcatel BTS Fans of radios in Motorola cabinet should be clean.11 BTS CABNET (a)-----log on to bts and check the alarm status. 1. Some important issues for example are as under: 1…….(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. the alarm status at DDF with the help of LED. like AC. For this report snaps are attached below: Ascom Rectifier Inner view of Rectifier Modules of Rectifier Breakers for BTS.UP is more important than the PM itself. (b)-----Check (c)-----Engineer 1. should apply the blower by himself on BTS . with low pressure. fire panel.U AFTER PM (a)-----Please keep in your mind that F. pending. So complete all pending issues as soon as possible and update the pending file. Getting started with BTS Terminal:When you click on the BTS Terminal screen will show the following snaps.M.Inner view of Motorola cabinet. issue.12 M.Any 4……. contact to your area head. We do the PM for solving the problems and sorting the problems.

The coils should be cleaned using Pressure Water Pump. 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. 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. Overhauling of a generator is related to Preventive Maintenance. 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. OVERHAULING PROCEDURE Before discussing of Overhauling procedure. 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 during such monthly visit shall inspect and provide routine maintenance and service to the Equipment installed at the Sites. . so we will have to do this job according to Manufacturer’s Recommendations which is normally due after 8.000 Running Hours. The gas charging The FAE shall be bound to visit Sites once every month regular compulsorily for provision of Services.000 to 10.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. 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. 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 Manufacturer’s Recommendations.

. we take the snaps of a generator. 4. Machining & Calibration.Alternator We will remove all wiring in the beginning. 1. it is going to be dismantled in following Steps. • . 3. 6. • Dismantling First of all. 5. Safeties switches Shields & Safe Guards Radiator with Hose Pipes Radiator Fan Fly Wheel Fuel Pump & Nozzles Self & Dynamo Intake Manifold Exhaust Manifold . • • • • Rotor Exciter Stator Bearings Dismantle above mentioned one by one with proper dismantling Tools. 7. also please be noted that always use proper dismantling tools for dismantling. Basically generator consists of two major parts Alternator & Engine. Assembling Testing Canopy Repairing & Paint Now we discussed in details of above mentioned Activities. Following are major components of an Alternator. 2. 9.Engine Fix the Engine on work Bench for Dismantling with following Sequence. 8. 1.• • • • • • Dismantling Inspection & Cleaning Repairing.

During the Repairing & Service. Carried out Pressure Tests of Engine Block & Head. Cleaning Process Starts.10. Clean all above mentioned Parts of an Alternator & Engine with a recommended Cleaning Material according to Manufacturer’s Service Manual. Repairing. 2. 2. 18. Self Starting Motor Dynamo Radiator . 3. 11. Head. After Inspection & Cleaning Process. 3. 1. 12. After inspection of parts. Repairing & Service Machining Calibration Replacement of parts Repairing & Service. 13. Machining & Calibration. Inspection & Cleaning Following Parameters will be carried out in Inspection process. 1. 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 Manufacturer’s Manual. we will focus below mentioned items. 14. and Connecting Rod & Cam Shaft. Machining & Calibration Process starts in which following major actions should be taken & we will discuss in details one by one. 17. 15. Repairing. o o o o 1. Inspect Moving Portion of Crankshaft and Rotors & Exciter Winding. 1. 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. 19. 16. so this is very critical portion of an overhauling. it is very Critical & Important Process in Overhauling of Diesel Engine. 1. Inspect the Alignment of Block.

Water Pump Repairing & Service of above mentioned should be done according to the Recommended spares to be changed of above mentioned according Manufacturer’s 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. 7. 2. Fuel Pump & Water Pump) Valves . 3.Guides . 6. 1. Timing Gear Train.4. 1. 1. Replacement of parts Following are details of replacement of parts with new one which is recommended by Manufacturer’s Service Manual. also please be noted that repairing kit of mentioned should be changed 1. 2. 4. 5. 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 Manufacturer’s Measures. Calibration In this process following are going to be calibrated compulsory 1. Machining In this process following are going to be machined compulsory after very strong inspection & cleaning processes. Fuel Injection Pump Atomizers Calibration of above mentioned should be done Compulsory. Seats & Seals Push Rod (if required) Lube Oil Pump (if required) Connecting Rod Bushes (if required) .

Also please be noted that replaced above mentioned with genuine part for sake of long life of an engine. 5. 2. 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 Manufacturer’s Service Manual. Assembling: Before start this process.1. 3. 1. Following Sequence is required for assembling according to the Manufacturer’s Service Manual. 6. 1. After this process. please make sure that work bunch should be neat & clean and tools used for assembling are also neat & clean and proper. 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 . every thing is ready for assembling of an engine according to Manufacturer’s Recommendations. 4.

Now Genset is Ready for Testing & just installed Battery & Start the Genset. Coupled both Engine & Alternator with each other. Reinstalled Complete Wiring with proper Dressing & connect according to the Drawing.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. Water Temperature is not more than 80◦c. Connect the Panel of Genset for Starting & Parameters. • 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. After Coupling. Checked Abnormal Sound of Engine . We should give a specified Torque with Torque Wrench according to Manufacturer’s Service Manual. Make sure that Safeties are Operational at Load & Unload.

NSTALLATION AND COMMISSIONING Installation. Fuel & Water.. Chillers. Pumps. Changeover and Auto Start High Voltage Switchgear up to 11 kV Power Transformer upto 3000 kVA Rotary equipments i. Checked Charging of Battery from Charger. Generators. Cable Trays. Paint complete Canopy Took Snaps of Generator now is ready for shifting on site. 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. Testing and Commissioning of the following Equipment: Diesel Generator Sets upto 2500 kVA Diesel Generator Panels. 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 . o Canopy Repairing & Paint   Repaired the door & hinges locks and Muffler or replaced them if required.• • • Checked leakages of Oil . Compressors.e. Boilers and Cooling Towers etc. Checked all Meters & Gauges & replaced if required.

Doors and Vibration Isolators · Air Intake Duct / Window for Generator Room and Radiator Exhaust Duct for Genset 4. Civil Construction Work · Diesel Generator Rooms and Genset Foundation Pads · LT Equipment Sub-station building and Cable Trenches / Routs 6. Installation. Compressors. Testing and Commissioning of the following Equipment · Complete “BTS” equipment maintenance of telecommunication sector · Diesel Generator Sets up to 2500 kVA · Diesel Generator Panels. 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. 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.e. 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 . Cable Duct and Cable · Power Distribution Boards (DB’s) and Cable Ladders · Electric Motors and Motor Control Panel / Equipment 2.. Generators. 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. Pumps. Cable Trays.1. Changeover and Auto Start · High Voltage Switchgear up to 11 kV · Power Transformer up to 3000 kVA · Rotary equipments i. Chillers. 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. 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.

· 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. 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 . 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. Timers and Heat Controllers · Industrial Switches. D-Fuse · Air Breaks Magnetic Contactors · Control Relays.

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