DUTIES AND RESPONSIBILITIES1. OPERATION AND SUPERVISION ROUTINES Auxiliary systems ‘The auxiliary systems support the diesel engines. They are vi- tal to the function of the geuset and must never be shut down, unless a prolouged stop is planned! ‘The preheating and the prelube pump must always be sot ia AvTO-mode and never switched of unless for maintenance pur- poses. These units sball always start when the diesel engine stops. "The auxiliary systems shall always be in operation circulating, cleaning and heating the fluids, thus ensuring best perform- ‘ance and trouble free operation of the gensets, The start-up time is reduced and it enables the operator to start and load the engines very quickly.” Supervision In addition to supervising the power plant from the control room itis also necessary that the operator walks through the plant and take readings of thermometers, manometers, pres- Sures gauges and the load. Readings must be recorded since the values are dependent on the Toad situation, Values should be compared with previous values at the same load. This gives an indication of the engine condition. ‘Try also to note long trend terms because most changes in op- erating conditions develop slowly and are difficult to record. Data collected and properly recorded, will form a valuable “wear history” for the equipment, giving the operator a source of reference when comparing new data. Inspection techniques and routines "The word “Inspection technique” covers a wide range of proce- dures used by plant operators to find out the actual condition of equipment in their care. This may entail the continuous monitoring of essential services and also predetermined stop of units for actual dismantling and inspection / measurement of parts subjected to wear. It is very important to set up proper routines for the inspec tion of snachinery and the collection of operating data. Estab- lishing such routines help to ensure that inspections and collection of data are carried out in the same manner each ‘time, The routine helps the operator to remember the various checks without having to refer to charts and check lists. ‘Walling a certain path each round will help him remember ‘the actions to take at each location. Hints ‘Use a floor map on a reduced scale, or draw a simple map of ‘your own, Remember that each inspection routine should be planned and every check point along the route should have a Getailed check list, stating exactly which checks or inspections to perform at that’ point. EAST ASA POWER CORPORATION “Ting 3 Bavlapman DaparimantA typical “checkpoint” list, should contain information regard- ing the following: © gauges and meters to read. © operational values to record © possible adjustments to make © switches/valve positions to check ‘© typical spots to check for leaks, wear, vibrations ete. NOTE! In order to detect deviations it is essential to have the inspections performed in the same way each time While the hourly, daily, weekly and monthly inspection rounds will have different activities listed for each location, it is worth- while planning the rounds using a common pathway, permit- ting the operator to check all equipment. DAILY SUPERVISION AND CARE "Supervision by all human senses" See - eyes, and using special instruments Hear - ears Smet! - nose Feel - hands and feet But most important is connect the above observations to the mind and ask: + WHAT IS NORMAL? + WHAT COULD HAPPEN? + WHAT SHOULD 1 D0? Leam the routines : + To check and find + To evaluate and decide + To rectify and take instant action Have proper accessories and tools available eg. : ~ ear protectors ~ coverall - pen - notebook torch light ~ screwdriver ~ spanner Note ; for emergency use only ~rags - manuals DAILY CARE * tighten every bolt and nut that should be fixed, immediately when you spot * check if possible to reduce a leak by additional tighteni overtightening may even be DANGEROUS. | clean around leaking spot to exactly locate the leak “use oil or top up oil levels when required, know the oils to use keep gauges and thermometers in good condition « keep clean, use water washing frequertly, however carefully around electrical fitings and devices but be careful EAST SIA POWER CORPORATION Ting and Davina Caparo+SEE = LEAKS, “LOOSE BOLTS, NUTS, FITTINGS SMOKE = VIBRATIONS "GAUGE BEHAVIOUR, TYPICAL SPOTS: + HEAR “ENGINE SOUNDS “+no variations +no hard sounds + general noise leve! TYPICAL SPOTS: - RUBBER , PLASTIC ~"ELECTRICAL" , OVERHEATINGS TYPICAL SPOTS : + TOUCHIFEEL - CAREFULLY! “VIBRATING PARTS - FLOW IN PIPES - WEAR, LOOSE PARTS “HOT OR COLD SPOTS: = AIR FLOWS: TYPICAL SPOTS : _ GENERAL CONDITION MONITORING engine gauge panel exhaust gases, chimney exhaust manifold = floxible connections al gossip holes hot box, injection equipment - ballroller bearings ~ eyinder covers ~ exhaust manifold, piping electrical equipment all engine mounted accessories EAST ASA POWER CORPORATION "tig ar Baetopran SeparinaatPLANT EQUIPMENT OPERATOR 1 General Function Under the direction of the Shift Engineer, the Plant Equipment Operator operates, maintains and monitors all operating plant equipment to achieve a safe, efficient and continuous operation. 1 Main Concern 1. Safety 2.” Operating Cost 3. Cleanliness HI Duties and Responsibilities 1. Receives carefully all tumovers and instructions relayed by the outgoing shift. 2. Conducts hourly, routinary and occular inspections of all. diesel generating units and its related auxiliaries such as separators, exhaust gas boilers, water distillers, booster modules, sea water pumps and rotary band screens and evaluate its operating condition. 3. Conducts hourly readings on all operating equipment monitoring devices such as thermometers, pressure gauges and level indicators to ensure that all parameters are within recommended operating limits, - 4. Reports to the Shift Engineer any detected deviation or abnormality that arises for immediate corrective measure/s to prevent unscheduled shutdown or power losses. 5. Conducts regular inspection on all lubricating oil levels such as engine crankcase, generator bearings, turbochargers, governors, separator gear case, compressor crankcase, sea water pumps and top- up if necessary to avoid damages caused by lack of lubrication, 6. Prepares the engine for starting/stopping and also its related auxiliaries as directed by the Shift Engineer in accordance with the standard operating procedures. 7. Isolates operation equipment intended for mechanical repair or due for preventive maintenance. 8. Performs regular monitoring of storage tank levels such as Heavy Fuel Oil (HFO) Day Tank, Settling Tanks, Diesel Tank, Lube Oil Tank, Potable and Distilled Water Tanks to ensure sufficient stock for the plant’s continuous operation requirement, Conducts regular monitoring of sludge and waste oil tanks to avoid overflowing and for proper disposals. 10, Conducts turbocharger compressor and turbine washing at regular intervals to attain engine optimum performance. 11. Initiates necessary action in case of emergencies and reports the incident to the Shift Engineer. Turnover to the incoming Shift the present plant equipment status including the activities performed, problems that were encountered and other things to monitor or follow up to let the incoming shift aware of the equipments present operating conditions, 13, Remains at assigned post unless properly relieved, 14, Perform other duties that may be assigned from time to time. EAST ASIA POWER CORPORATION Teng a Devcaoien Bazar