Hi All and have a nice day..........

Today i am doing PM Schedule for two type of engines.
1. Fire pump drive engine, "Cummins",V378f1/f2
2. Generator set engine - "CATERPILLAR", 3406

Need to creat one schedule for both and as a manual pm need only Weekly and Annualy,but i plan it W/M/Q/A basis, If somebody have similar schedule pls help me it will more helpfull to finalise my report.

Nihal
nwhewage@yahoo.com

Hope this helps
Dave

Engine_Driven_Pump.xls (112 KB, 21 downloads)

Why do you need to start from scratch? The PM schedule for each engine is in the OEM manual? Odn't have the user manual? Or are you optimizing the PM schedules?

Hi Dave

Thanks for ur referance, it will helpful for me.

Dear Josh

I have OEM but u know practically our usage and OME not coincide, say example as OEM only schedule Weekly and Annually, but as me and all of u agreed like belt tension, bolt tightness, noise level, vibration level and etc using instruments not enough on only annually and also no need every weekly. also equipments are exciting little far to the engineering office and pm perform by foramens and technicians.

So as consider above things we want to create practical PM schedule and as my knowledge only OEM depend is not enough.

Also I appreciate ur involvement for my issue, and always ur advise very helpful for me..

Thanks
Nihal

I don't know your local conditions but you need to have sound reasons to deviate from OEM recommended PM, not just for practical reasons as you cited.

If you have special conditions or environmental situation. Contact Cat and Cummins They have performed extensive durability testing. I have dealt with some of that stuff before and could recomend a few things myself.

Nihal,
I assume you are testing these engines every fortnight or week, presumably in the presence of operators and maintainers.
Assuming you run the machines on full load for a couple of hours at least, the observers will be able to produce a list of faults or potential faults. That alone would be a fair amount of work.
For the rest, routine checks per vendor guidelines should be adequate.

NIHAL,
I have been responsible for maintenance of engines of ratings starting from 100 KW upto 2.5MW . In most of the cases OEM recommendation is for continuous running engines based on hours of running . The situation is totally different in your case. You are doing weekly testing and the equipment runs only under emergency requirement, may be for fire water or captive power. In this case, you will have to prepare your own schedule. What we are doing, is keeping watch on all running parameters during weekly schedule, and so we are doing more condition monitoring than PM. Based on the condition, you can come up with your own PM routine checks (for example, suction filter, lub oil filter, fuel oil filters cleaning/ replacement). Lub oil replacement, belt tension checking, tappet clearances checking, thermostatic valves functioning, vibration recording, checking for leakage of fuel, lub oil, water , checking for exhaust emission quality, fasteners tightness checking, jacket water level checking, governor calibration checking, piston rings clearances checking, torquing of fasteners, exhaust gas temperature checking, are a few points to check in addition to running parameters and take decision based on your experience. We have Wartsila make DG sets for the last 12 years and maximum running has been 700 hrs. We have decided not to go for overhaul based on condition. Manufacturer recommends overhauling after 20000 hrs which will never be completed in the life of the plant.Obviously, we may have to go for overhaul much much before 20000 hrs. We have evolved our own strategy to avoid any major work as long as the condition monitoring does not call for it.
You may have to go through your engine technical manual for better acquaintance with your engine and you may find a lot of things to monitor and check.
Irshad

For brands like Caterpillar, there will be 2 PM schedule recommended by OEM ie. one for continous running and the other for intermittent use. Pls check your OEM manual first.

Sorry, we do not have Caterpillar brand but we have Cummins, Greaves, Wartsila and DLW make. None of them has PM schedule for intermittent duty.
Regards
Irshad