Generator Overhauling Assessment Form

Site Information General DG Information

Total DG Running Hours Hour Meter Changed (In case Hour Meter not
Site ID DG Rating (KVA) 27 KVA (As per Actual Rating)
(Actual) changed/reset provide acutal runniung Hours)
Total DG Running Hours
Region Based on total fuel consumption (if actual not available) DG Make SDMO
(Estimation)
Total OH Counts since On
Commercial Category 1 DG OH in Warranty Yes ✘ No
Air

Operational Load Per Phase Last Overhauling Date 1/1/2016 (Mention the record avaialable with PMO) DG Serial No. xxxxxxxx (Provide Picture)

DG Status Prime Stand by Last OH Running Hours 10000 Engine Serial No. xxxxxxxx (Provide Picture/Must Match with Inspur database/Update )

Current Running Hours as per

Current Running Hours 2nd Last Overhauling Date Not Done DG Asset Code xxxxxxxx (Provide Picture)
Hour Meter (Provide Pic)

2nd Last OH Running DG Operational

Engine Temperature oC Engine Seized Not Done Operational Seized
✘
Hours Status

Engine Manual
Engine Block Damage Yes No ✘ Yes ✘ No
Rotation/Cranking
DG information (Make, Rating, Serial No.) must be correctly registered in Inspur DG
database All Fuel
Nozzles/Injectors/ ✘ Yes No
Cranking Working

Sr Test Test Method Standard Value Complete overhaul Checked value Remarks
To be checked from Oil pressure gage. In case of faulty
1 Oil Pressure Visual inspection 3.5 bar Less than or equal to 2.5 bar
gauge, maintenance team must have a spare gauge to test.
Picture of Oil gauge while genset running.
2 Compression Pressure Compression tester Greater than or equal 27 bar Less than or equal to 22 bar Need to ensure that Genset head gasket is not leaked.
Video for compression test
3 Exhaust Color Visual inspection No color Blue/ Black color Excessive Blue/Black Smoke Video for exhaust smoke
Greater than or Equal 10000 Hr (1st OH). Historical Data from NOC DG Running and Running Hour
4 DG Running Historical Data 10000 hr Historical Record(Based on Fueling/Maintenance Records)
Greater than or Equal to 2000 Hr (Subsequent OH) meter
Audio Inspection/Sound No Abnormal Sound Abnormal sound must be from Genset block for connecting
5 Noise/Abnormal Sound Abnormal Sound (>85dB)
Tester (<=60dB) rod or crank.
10 - 15 mm/s (As per
6 Vibration Test Vibration Meter Check the vibration on the engine block
Manufacturer Manual) Provide the video of the test
7 Oil Indication at exhaust pipe Visual inspection No indication Oil indication at the manifold (air-exhaust) Engine blow need to be checked from exhaust pipe. Picture of oil blow on a white paper
ensuring no oil leakage from cylinder head, from and main oil PM Data of Total oil consumed (Including top up) for last 6
8 Oil Consumption Historical Data Rated as per DG KVA More than ( 30 % to 50 %) of the rated Value@250 Hours month along with total DG Running record for the same
seals, rocker assembly seals etc.
period.
Dummy load(Resistive)/on Genset will be tested on site load and ratio will be determined Video for site load (To be tested with Clamp meter at DG
9 Load Test 110 % of the rated Less than or equal to 70 % of the rated load output on all three phases after load balancing) and
site load accordingly.
genset operation.
10 Fuel Consumption Test Common Method in the field As per Manufacturer Manual Manufacturer Manual
Provide the value of fuel consumed per hour
11 Oil Drain Test Visual inspection No Metal Particles found Visible metal particles Oil to be drained and physically checked

Final Requirement
Major Overhauling ✘ Top Overhauling Weak DG

Cluster Owner Power Expert FOPs Manager RCTO Approval

Name Name Name Name

Signature Signature Signature Signature

Detailed Remarks/findings based on which above mentioned decision is taken

Engine is siezed and requrie immeidate OH.

NOTE:
** This Form is based on small DGs less than 30KVA but manufacturing manual will provide support to the standard values

** For DG Overhauling, previous overhauling record need to be checked and OH will be awarded if DG RH are more than 10,000 running hours at least for first overhauling. For subsequent overhauling's, minimum of 2000 running hours must be completed.

**Incase of DG Heat up, Complete water circulation need to be checked including head gasket, Thermostat valve, Water body, radiator etc. Overhauling will not be awarded in this case

**Final decision will be based on available budgeted quota, DG condition, availability impact and Site priority, which shall be set by region after conducting overhauling test

BSS HQ - CMPak Confidential - 14/2/2017

 Check List Evidence Type Provided Remarks
Filled and Signed Assessment Form Signed Form Yes No
Genset General Inspection Pictures Yes No
Seized + Operatonal

Operational Load Per Phase Pictures Yes No

Hour Meter Reading Pictures Yes No
Estimated DG Running Hours (Since On Air) 696 Report Excel Working Yes No
Estimated DG Running Hours (Since Last OH) 696 Report Excel Working Yes No
DG Serial Number Pictures Yes No
DG Engine Serial Number Pictures Yes No
DG Asset Code Pictures Yes No
Oil Pressure Test Picture Yes No
Compression Pressure Test Video Yes No
Operatonal

Exhaust Color Test Video Yes No

Noise/Abnormal Sound Test Picture Yes No
Oil Indication at Exhaust Pipe Picture Yes No
Load test Video Yes No