Repair Work Report

Electrical / Mechanical Issues

THIS REPORT MUST BE COMPLETED AFTER INVESTIGATION HAS DONE & SUBMITTED AFTER
ALL HAS FINISHED.

Site: Pekanbaru 50MW In charge by :

Location: Jl. Tanjung Datuk. PLN Teluk Lembu 1. FTS PKU

Date : Sept 24th 2019 2. Maintenance Team

Time : 09:00

Fuel Engine ESN Engine Model Generator Model

Natural Gas 17218 B35:40V20AG2 ABB AMG 1120SM08

DSE
Start date End date Generator ESN Running hour

Sept 24th 2019 Sept 24th 2019 (G#5) 4631675 34452

Trip Blackout Troubleshoot Others

Problem Describe
G#5 (17218)
Summary
· Rack/Load dev high 15.46%
· Bearing and shaft actuator damage
· Bearing rack CYL head B10 damage
· Adjust Admission rack
· Calibration Woodward
oodward (Fuel rack and VTG)

Rack/Load dev high 15.46%

Action
1. Replacement Bearing fuel rack CYL Head B10 with new one

Bearing rack B10

Spare part consumption list

NO Part no Description Qty

1 B00446792 Bearing housing reg. shaft 42mm (new type) 1pc

2. Swapping shaft and bearing actuator form G4 and install to G5

Shaft actuator G5 damage Shaft G4and new bearing ready install to G5

Spare part consumption list

NO Part no Description Qty

1 B00446792 Bearing housing reg. shaft 42mm (new type) 2pcs

Vpower format form / applicable for all troubleshoot issues

3. Adjust Admission Rack

Admission rack

Progress Calibration
Perform fuel rack calibrated by following step by step. The engine is stopped. Starting fuel rack calibrated must
be the Load 50%, 90%, 70%, 30% and 10%.
The function of the calibrated is to match the value of the fuel from HMI to the value average fuel rack on the
Cyl A & B Bank. Fuel rack from HMI must the following average fuel rack A & B Bank.

The way it is with increased mA (MiliAmpere) on HMI for Decreased value fuel rack on HMI. And then
decreased mA on HMI for increased value fuel rack on HMI.

4. Calibrated fuel rack from Woodward

A. Calibrated Load 50% on fuel rack Cyl head

Fuel Rack Position

Before Calibrated After Calibrated

Vpower format form / applicable for all troubleshoot issues

Measurement fuel rack on Cyl Head A-Bank and B-Bank

Before Calibrated After Calibrated

NO A-Bank B-Bank NO A-Bank B-Bank
1 55 45 1 55 45
2 54 51 2 54 51
3 52 50 3 52 50
4 52 51 4 52 51
5 5 49 5 5 49
6 2 50 6 2 50
7 54 52 7 54 52
8 51 51 8 51 51
9 51 53 9 51 53
10 52 50 10 52 50
Average A&B Bank 52.27% Average A&B Bank 51.30%

B. Calibrated Load 90% on fuel rack Cyl head

Fuel Rack Position

Before Calibrated After Calibrated

Vpower format form / applicable for all troubleshoot issues

Measurement fuel rack on Cyl Head A-Bank and B-Bank

Before Calibrated After Calibrated

NO A-Bank B-Bank NO A-Bank B-Bank
1 92 86 1 92 86
2 90 90 2 90 90
3 93 990 3 93 990
4 91 89 4 91 89
5 90 87 5 90 87
6 90 90 6 90 90
7 91 91 7 91 91
8 90 90 8 90 90
9 90 91 9 90 91
10 90 90 10 90 90
Average A&B Bank 91.73% Average A&B Bank 90.03%

C. Calibrated Load 70% on fuel rack Cyl head

Fuel Rack Position

Before Calibrated After Calibrated

Vpower format form / applicable for all troubleshoot issues

Measurement fuel rack on Cyl Head A-Bank and B-Bank

Before Calibrated After Calibrated

NO A-Bank B-Bank NO A-Bank B-Bank
1 72 67 1 72 67
2 71 70 2 71 70
3 72 70 3 72 70
4 72 70 4 72 70
5 70 67 5 70 67
6 70 70 6 70 70
7 73 71 7 73 71
8 71 70 8 71 70
9 70 72 9 70 72
10 73 70 10 73 70
Average A&B Bank 73.20% Average A&B Bank 70.55%

D. Calibrated Load 30% on fuel rack Cyl head

Fuel Rack Position

Before Calibrated After Calibrated

Vpower format form / applicable for all troubleshoot issues

Measurement fuel rack on Cyl Head A-Bank and B-Bank

Before Calibrated After Calibrated

NO A-Bank B-Bank NO A-Bank B-Bank
1 34 26 1 34 26
2 35 30 2 35 30
3 34 32 3 34 32
4 35 33 4 35 33
5 33 30 5 33 30
6 32 32 6 32 32
7 35 31 7 35 31
8 32 31 8 32 31
9 31 32 9 31 32
10 32 30 10 32 30
Average A&B Bank 34.70% Average A&B Bank 32.04%

E. Calibrated Load 10% on fuel rack Cyl head

Fuel Rack Position

Before Calibrated After Calibrated

Vpower format form / applicable for all troubleshoot issues

Measurement fuel rack on Cyl Head A-Bank and B-Bank

Before Calibrated After Calibrated

NO A-Bank B-Bank NO A-Bank B-Bank
1 15 7 14 15 7
2 15 11 17 15 11
3 15 14 13 15 14
4 14 16 13 14 16
5 13 12 14 13 12
6 13 15 13 13 15
7 15 11 15 15 11
8 13 13 12 13 13
9 11 15 10 11 15
10 13 10 10 13 10
Average A&B Bank 15.22% Average A&B Bank 13.06%

5. Calibration VTG from Woodward

Ø VTG Position

VTG Position on HMI 100% VTG Position on IP 0.0%

Vpower format form / applicable for all troubleshoot issues

Ø Rack VTG Position

Rack Position Bank A (-2) Rack Position Bank B (-2)

Ø VTG Position

VTG Position on HMI 0.0% VTG Position on IP 100%

Vpower format form / applicable for all troubleshoot issues

Ø Rack VTG Position

Rack Position Bank A (+4) Rack Position Bank B (+4)

Suggestion
If there is one of the abnormal VTG linkages in Bank A/B linkage we can make linkage adjustment following
the result of the HMI and IP.

Vpower format form / applicable for all troubleshoot issues

 OPERATION TEST DATA GAS ENGINE

Site Engine Type Engine S/N Engine RPM Date

PLTMG 50MW B35:40V20AG2 17218 750 23-09-2019
Location Engine Load Gen Load Service Engineer
Pekanbaru 90% 8.457 MW FTS TEAM
Running hrs 34452

Exhaust gas Temp Gas Cooling Water

Cylinder No
A-Bank B-Bank Supply 6.20 Bar 3.0 Bar
HT in o
1 516.9 521.1 Press Main 3.92 Bar 73.5 C
o
2 509.5 508.6 Pre-chamb 3.54 Bar HT Out 81.7 C
o o
3 506.8 507 Temp Eng-inlet 24.1 C LT in 42.7 C
4 514.6 505 Pressure Parameter Temperature Parameter
o
5 501.9 502.4 Charger Air 2.94 Bar Charger Air 57.6 C
o
6 516.9 515.1 Lube oil 3.9 Bar Lube oil 59.7 C
o
7 516.3 519.4 Rocker Arm 2.4 Bar Suction Air 30.9 C
8 522.3 514.9 Crank-case 2.9 Bar Generator
o
9 508.6 516.8 Lube Oil TC-A 1.82 Bar Gen. Bearing D 66.6 C
o
10 511.7 521.9 Lube Oil TC-B 1.84 Bar Gen. Bearing N 66.9 C
o
AVG Exh. Temp. 512.4 513 Oil Mist Level 1 Gen. Wind 1 93.5 C
o
Temp BTC 561.6 557.5 Start Air 27.6 Bar Gen. Wind 2 93.2 C
o o
Dev. A/B 0.6 C Control air 6.4 Bar Gen. Wind 3 93.3 C
Splash Oil Temperature MISC
o o
Crank 1 79.8 C Crank 6 76.9 C VTG 69.95 %
o o
Crank 2 78.4 C Crank 7 77.6 C Rack/Load Dev 0.07 %
o o
Crank 3 77.2 C Crank 8 77.1 C Rack on ECC 74.2 %
o o
Crank 4 77.3 C Crank 9 77.5 C
o o
Crank 5 77.0 C Crank 10 76.0 C

Job. Completion
Reported by Acknowledged by Approved by

Vpower format form / applicable for all troubleshoot issues

Remaks
Ø Each RMS ( Routine Maintenance Service) 2K must calibrate fuel rack.
after calibrated, when the engine is running has a problem at exhaust temperature is high or low.
Recommended for checking 4 items:
1. Check spark plug
2. Check PCC/ bolt valve
3. Check tappet clearance
Check gas supply/orifice
Ø Fuel rack has been calibration with software RR it is suitable between HMI with IP
Ø VTG has been calibration with software RR it is suitable between HMI with IP
Ø Actuator three way valve need to check or have a look what the problem. Because when engine start the
temperature HT out up and down suddenly.
Ø After running test with load 90% engine continue running with system

Conclusion
Not recommended for adjust fuel rack on cyl after has been calibrated, when engine is stop or when engine
running.

Suggestion
Ø Recommended to adjust fuel rack by using peak pressure. By using a tool Kitsler 2516.
Ø When replacement bearing rack and bearing fuel rack are required to Calibrated.

` TYPE FAILURE: Mechanical Faulty Electrical Faulty Others

Repair : YES
Service : YES
Replace Part : YES
Done by Vendor :-
Others :-
Reported by: FTS Team Checked by: FTS Dept Head Acknowledged By
Signed: Signed: Signed:
Date : Date : Date :

Vpower format form / applicable for all troubleshoot issues

Attachment

Adjustment Admission Rack Calibration woodward

HMI woodward Parameters Load

Parameters Exhaust Temperature CYL Head Parameters Pressure system

Vpower format form / applicable for all troubleshoot issues

Parameters Temperature system Load Trend

Vpower format form / applicable for all troubleshoot issues