Predictive and Preventive Maintenance for Diesel Generator

Introduction

Diesel Engine is one of the most Internal Combustion Engines, where it is used for many purposes. It can be utilized as a prime mover for any of Rotating Equipment Machinery such as Pumps, Compressors and Fans, in addition to its use for all Power Plants as Black Start Units.

This course is to provide an overview of the most important components of the Diesel Engine and the function of each, as well as an auxiliary system such as lubrication system, cooling system and different methods used for start-up of Diesel Engine. Also, on this course will explain how to utilize the Diesel Engine as a prime mover of rotating machinery or to Generate Power. Moreover, will cover all aspects of a modern Diesel Engine and associated systems. Descriptions of the Electrical systems associated with a Diesel Engine are then covered in detail including Generator Operations, Generator components, excitation systems, and voltage regulation.

In addition, we will discuss how the steps in Operating and Maintenance Programs differ for these engines; in the end, we will discuss all Problems and Troubleshooting and how to overcome them through Logical Solutions with various examples of signature to achieve understanding the operation. This course is designed to assist maintenance management personnel responsible for delivering maximum reliability and availability of equipment at the lowest possible cost. The course will present techniques designed to improve the effectiveness of maintenance management activities, to ensure that physical assets perform their required functions, operate reliably, and support corporate goals. Preventive and Predictive maintenance techniques provide data that define required servicing and inspection periods so that maintenance departments can determine in advance when equipment must be shut down for overhaul. Statistics are proving that these programs, when properly implemented, can minimize equipment and system breakdowns, resulting in a major reduction in total maintenance and operating costs. 

The course’s sessions will focus on modern methods and techniques on the most critical aspects of maintenance and reliability management. It will cover all facets of preventive & predictive maintenance such as organizing maintenance resources, selecting the right maintenance work, analyzing failures, setting and conducting a maintenance plan, planning spare parts, estimating and controlling maintenance costs, computerizing maintenance planning and measurement operations. The delegate will also be introduced to reliability tools and the effect that human reliability has on plant availability. 

The course is designed to benefit every level of maintenance management personnel, providing the most up-to-date facts and techniques on the maintenance and reliability technology that is revolutionizing the way our industry operates. To maximize the benefits of the course, delegates should be prepared to actively participate in the course and bring examples of standard work plans, a list of plant performance metrics, the work priority system in-place, and any other maintenance or reliability material they would like to review and discuss.

Objectives

Upon the successful completion of this course, participants will be able to:

• Have a very good understanding of the excellence in maintenance & reliability management and become a World-Class performer in preventive & predictive maintenance
• Recognize the world-class aspects of maintenance today through the various types of maintenance including maintenance strategy, business model, maintenance organization, R&M policy and productive maintenance
• Identify the different equipment failure patterns and discuss the significance of equipment plan development
• Employ the methods of preventive maintenance including lubrication, time-based, dynamic-based and CLAIR
• Employ the methods of predictive maintenance and condition-based monitoring including vibration monitoring, pump monitoring frequency, infrared Thermography, physical effect monitoring and lube oil analysis
• Identify the various elements, key factors, tasks & procedures toward achieving the roadmap to a world-class PPM program 
• Properly manage the work selection & prioritization, the work planning & scheduling, turnaround projects, the work execution & contracting, stewardship & performance and work quality
• Distinguish the factors of human reliability, utilize the various reliability tools and discuss the key elements of reliability engineering and CMMS
• Consolidate and update understanding of the Diesel Engine Components and Auxiliaries
• Understand the Diesel Engine construction and rating for Diesel Generators
• Maintain the engine in a safer way and will make a more effective contribution to the operation of machinery
• Learn the basics of Engine operating value evaluation and maintenance planning. Special focus is on the economic aspects of Engine Operation and Utilization
• Understand the Diesel Generator vibration problems and vibration stress and how to reduce it
• Understand the modern Diesel Engine Electronic Management System
• Familiarize with the troubleshooting of Diesel Engine Generator & Its Auxiliaries System

Training Methodology

This is a highly interactive training course with opportunities to advance your opinions and ideas. Participation is encouraged in a supportive environment. To ensure the concepts introduced during the program are understood, they will be

Who Should Attend?

This course is intended for all employees involved in the Operations and Maintenance of Diesel Engine Generator. It would be of specific benefit to those who are involved in the use of DEG as Emergency Generators which would include most Power Stations, Oil Platforms and Petrochemical Plants.

Course Outline

DAY ONE:  Module (01): Overview on Diesel Engine

• Introduction
• Diesel as Prime Movers
• Spark Ignition Engine
• Compression-Ignition Cycle
• Diesel Engine & Gasoline Engine
• 4 Strokes
• 4 Cycle Engine
• Air / Fuel Ratio

Module (02): Diesel Engines Components

• Cylinders
• Pistons
• Crankshaft
• Cylinder Liners
• Connecting Rods
• Cylinder Heads and Valves
• Piston Rings
• Cam Shaft
• Flywheel
• Governor

DAY TWO: Module (03): Engines Related Systems

• The Fuel Injector
• Supercharging
• Turbochargers
• Crankcase Ventilation
• Exhaust & Induction System

Module (04): Diesel Engine Auxiliary Systems

• Air Filtration System
• Fuel Storage and Supply System
• Air Supply System
• Exhaust System
• Water Cooling System
• Starting System
• Lubrication System
• Power Governing System

DAY THREE: Module (05): Combustion Process

• Ignition System
• Torque vs. Seat Load
• Ignition Voltage vs. Timing

Module (06): Power Generation

• Introduction to Alternating Current (AC)
• Producing Magnetism with Electricity
• AC Generator
• Power Factor
• Synchronizing and Operating Generator
• Automatic Voltage Regulator
• Protection and Interlock System
• Abnormal Operation Conditions
• Standard Isolation Procedures

Module (08): Common Problems for Diesel Engine

• Cracked Heads
• Scaled Exhaust
• Fouling Deposits
• Corrosion
• Cavitation's
• Splash Lubrication
• Abnormal Sound / Noise
• Vibration
• Overheating
• Overloading

DAY FIVE:  Module (09): Diesel Engine / Generator Maintenance

• Reactive Maintenance
• Preventive Maintenance Program
• Schedule Overhauls
• Predictive Maintenance
• Reliability Centered Maintenance
• How to initiate RCM?
• Maintenance Reporting

Module (10): Troubleshooting of Diesel Engine

• Developing a Logical Systematic approach
• Common Diesel Engine Problem
• Diesel Generator Faults
• Fault Tree Analysis
• Troubleshooting Matrix