40 MW Wartsila 18V32 50 Hz - Powerplants

------------------- Email: info@powerplant-market.com - Phone: +1 206-201-2420 ------------------- 

Sl.No 

PARAMETERS TO 

BE CHECKED 

DG 1 DG 2 DG 3 DG 4 DG 5 DG 6 DG 7 

18V32 18V32 18V32 (6MW 18V32 18V32 (6MW 18V32 (6MW 12V32 (4MW 

(6MW (6MW Engine) (6MW Engine) Engine) Engine) 

1 Why dismantling the No power No power No power No power No power 

demand demand demand demand demand 

2 Equipment data 

a) Machine type 18 V 32 18 V 32 18 V 32 18 V 32 18 V 32 18 V 32 12 V 32 

b) 

Year of manufacture 

/commissioing 

c) Serial number for 

1989 1991 1996 1997 1997 1997 1997 

i. Main engines ESN 4653 ESN 4966 ESN 7130 ESN 7227 ESN 7228 ESN 7802 ESN 7928 

ii.Alternators 

172147-1 dt 

12-1988 

47096 A 264 

- 11 -01 / 

47096 A 264 - 

11 -01 / 1997 

47096 A 264 

- 11 -01 / 

47096 A 264 - 

11 -01 / 1997 

47096 A 264 - 

11 -01 / 1997 

47097 A 264 - 

11 -01 / 1998 

iii.Power transformers M 2358 M 2358 M 2358 M 2358 M 2358 M 2359 

iv.HFO separators 

FOPX 613 TFD 24-50 

HFO sep WHPX 410 

TGD 24-50 

L.O separators WHPX 

407 T 30 24-50 

v. LO separators MOPX 

207 SGT 24 

4081617 & 

4081618 - 

1996 



1997 



1997 



1997 



1997 

NA NA NA 

4043713 4043713 NA NA NA 

NA NA 4080943 408556 4080941 



1997 


1992 


1997 

3 Date commissioned. 15.9.1989 17.3.1991 17.12.1996 12.1.197 25.1.1997 ########### ########### 

4 Commissioning data Available Available Available Available Available Available Available 

a) 

b) 

Specific fuel 

consumption – SFC 

i.Engine wise 

215 

Not available 

215 

ii.Total plant gms/Kwhr 234 gms/Kwhr 218 

0.69 

gms/Kwhr 

0,9 0,9 0,9 0,9 

gms/Kwhr 

0.69 

gms/Kwhr 

Specific lube oil 

consumption – SLOC 

4043712 -1989 

PLANT 3 

PLANT 2 

221 

gms/Kwhr 

0.69 

gms/Kwhr 

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c) Operation data Available Available Available Available Available Available Available 

d) Vibration record Available Available Available Available Available Available Available 

e) Crankshaft alignment Available Available Available Available Available Available Available 

f) Hot deflection Available Available Available Available Available Available Available 

g) Spring pad height NA NA NA NA NA NA NA 

5 Past data records Available Available Available Available Available Available Available 

a) SFC 

i. 

ii. 

Engine wise 

Total plant 

224Gms/Kwhr 

228 

228 

b) 

6 

SLOC 0.80gms/Kw 

hr 

Present data - measured 

at our presence 

a) SFC 

0.80gms/Kw 

hr 

0.80gms/Kwhr 0.80gms/Kw 

hr 

0.80gms/Kwh 

r 

gms/Kwhr 

0.80gms/Kwh gms/Kwhr 

r 

228 

gms/Kwhr 

0.90gms/Kwh 

r 

i. Engine wise 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

223 ~ 234 gms/Kwhr 

gms/Kwhr 

ii. Total plant 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

223 ~ 234 

gms/Kwhr 

b) SLOC 0.86 0.86 0.86 gms/Kwhr 0.86 0.86 0.86 1.2 gms/Kwhr 

7 Plant control system gms/Kwhr gms/Kwhr 

gms/Kwhr gms/Kwhr gms/Kwhr 

a) 

8 

PLC or not Allen 

bradely 

Allen bradely Allen bradely Allen bradely Allen bradely Allen bradely Allen bradely 

Manufacture’s test 

reports mainly for; 

a) Main engines Available Available Available Available Available Available Available 

b) Alternators Available Available 

Separate list enclosed Ref Plant 3 -Elect specification 

c) Power transformers Available Available 

9 

a) 

Last major overhaul 

reports for main engines 

including, 

Liner condition & 

replacement 

Hard copy 

available 

Hard copy 

available 

Hard copy 

available 

Hard copy 

available 

Maintenance data's available 

Hard copy 

available 

A 8 & A 1 Nil 

b) Head replacement - NIL Nil Nil Nil Nil Nil Nil Nil 






c) Block machining data 

d) Sump cracks 

e) Vibration records 

A 

1,2,3,4,5,6,8 

,9,B1,2,3,4, 

Available 

Turbo Max 

20m2/sec in 

Turbo 

A3,A6 

Available 

Turbo 

Max20m2/se 

c in Turbo 

only lappling 

has been done 

Available 

Turbo Max 

20m2/sec in 

Turbo 

A4,6,8,9,B2, 

B8,B9 

Available 

Turbo Max 

20m2/sec in 

Turbo 

A4,5,6,8,B3,4, 

5,6 

Available 

Turbo Max 

20m2/sec in 

Turbo 

A 

1,3,4,5,6,8,9 

B 1,3,5,7,8,9 

Sump 

replaced at 

12847 Hrs on 

Available 

Turbo Max 

14m2/sec in 

Turbo 

A 3,4,5,6 

B 3,4,5,6 

Nil 

Available 

Turbo Max 

10m2/sec in 

Turbo 

f) Crankshaft alignment Available Available Available Available Available Available Available 

10 Main engines 

a) 

Governor control and 

actuator types 

b) Fuel injections pump 

c) 

d) 

type 

Scheduled / forced 

maintenance records 

after last major overhaul 

Special maintenance 

before last overhaul 

Hydraulic 

Governor 

L Orange - 

PEO - G030 

Scheduled- 

Available & 

Froced - Nil 

Hydraulic 

Governor 

L Orange - 

PEO - G030 

Scheduled- 

Available & 

Froced - Nil 

Hydraulic 

Governor 

L Orange - 

PEO - G030 E 

Scheduled- 

Available & 

Froced - Nil 

Hydraulic 

Governor 

L Orange - 

PEO - G030 

Scheduled- 

Available & 

Froced - Nil 

Hydraulic 

Governor 

L Orange - 

PEO - G030 

Scheduled- 

Available & 

Froced - Nil 

nil nil nil nil nil 

721 721 

L Orange - 

PEO - G030 

Scheduled- 

Available & 

Froced - Nil 

L Orange - 

PEO - G030 

Scheduled- 

Available & 

Froced - Nil 

11 Alternator; AlstomAlstom- BHEL Make BHEL Make BHEL Make BHEL Make BHEL Make 

a) Rating plate data francefrance i. Voltage 11 KV 11 KV 11 KV 11 KV 11 KV 11 KV 11 KV 

ii. Current NA NA 394 Amps 394 Amps 394 Amps 394 Amps 262 Amps 

iii. Frequency 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 50 Hz 

iv. Power factor 0.8 Lag 0.8 Lag 0.8 Lag 0.8 Lag 0.8 Lag 0.8 Lag 0.8 Lag 

v. VA rating 8125 7500 KVA 7500 KVA 7500 KVA 7500 KVA 7500 KVA 5000 KVA 

b) AVR type 

Controlled 

Thristor 

Controlled 

Thristor 

Controlled 

Thristor Bridge 

Controlled 

Thristor 

Controlled 

Thristor 

Controlled 

Thristor 

Controlled 

Thristor 

c) 

Whether there is 

parallel operation 

No 

Yes Yes Yes Yes Yes Yes Yes 






d) 

Last major maintenance 

records including 

i. Winding insulation 2000 

ii. Air gap record for 

main rotor and exciter 

iii. No load excitation 

current at rated speed 

and voltage 

e) Other maintenance 

i. Special maintenance 

done after 

commissioning 

ii. All maintenances 

done after last major 

maintenance 

Power transformers / 

12 

Station transformers 

Regular 

AMC jobs 

Alternator 

Overahul 

done & 

DE/NDE 

Regular 

AMC jobs 

Regular AMC 

jobs 

Regular 

AMC jobs 

DE/NDE 

Bearings 

Replaced 

Regular AMC 

jobs 

2000 

12.4 

Megohm 

MM / 1.8 

Megohm 

11.1 MM / 2.2 MM 

MM 

Alternator 

Overahul 

done & 

DE/NDE 

Regular AMC 

jobs 

Current - 1.4 

Amps Volt- 

40V Speed 

750 RPM 

Alternator 

Overahul 

done & NDE 

Bearing 

Regular AMC 

jobs 

a) Maintenance records Available Available Available Available Available Available Available 

b) HV/LV voltages 11893 V 11893 V 11893 V 11893 V 11893 V 11893 V 11893 V 

c) Power ratings 8000 /11000 KVA V 8000 /11000 KVA V 8000 /11000 KVA V 8000 /11000 KVA V 8000 /11000 KVA V 8000 /11000 KVA V 5500 /11000 KVA V 

13 Breaker condition for; 

a) Generator breakers 

b) 

c) 

d) 

Station transformer 

breakers 

Power transformer 

breakers 

Switchyard breakers 

(outdoor) 

Ref Plant 3 Electrical specific 

Breaker Details Plant 2 '!A1 

NA NA NA NA NA NA NA 

Should include NA NA NA NA NA NA NA 






i. Number of 

operation cycles 


ii. Gas pressure NA NA NA NA NA NA NA 

iii. Operation 

(remote/local) 


14 HFO / LO separators 

Fuel oil separator WHPX 

410 - 1 No & Lub oil 

Fuel oil Separator FOPX 613 - 2 nos & Lub 

oil separator MOPX 207 - 3Nos 

FOPX 609 – 

MOPX 207 - 1 No 

2 Nos& 

a) Running hours 70 ,000 Hrs 70 ,000 Hrs 70 ,000 Hrs 70 ,000 Hrs 70 ,000 Hrs 70 ,000 Hrs 69 ,000 Hrs 

b) Controller type EPC 400 EPC 400 

DCU 41 for 

MOPX EPC 

400 for FOPX 

DCU 41 for 

MOPX EPC 

400 for 

DCU 41 for DCU 41 for 

MOPX EPC MOPX EPC 

400 for FOPX 400 for FOPX 

DCU 41 for 

MOPX 

c) 

Heating electric or 

steam 

48 Kw- 

Electrical 

48 Kw- 

Electrical 

Electric 

Electric Heater - 

Heater - 60 

60 KW 

KW 

Electric 

Heater - 60 

KW 

Electric 

Heater - 60 

KW 

Electric 

Heater - 60 

KW 

for L.O seps 

For fuel oil seps 

d) Maintenance data Available Available Available Available Available Available Available 

15 Cooling system Water Water Water cooling Water Water cooling Water cooling Water cooling 

a) Radiators or cooling Cooling cooling Cooling cooling Cooling Cooling cooling Cooling Cooling Cooling 

Centralised Towers Central Towers Heat HTTowers & LT Heat HT Towers & LT HTTowers & LT Heat Central Towers Heat Central Towers Heat 

b) 

Intermediate heat 

exchangers? 

single heat 

exchanger 

for 

exchanger 

for Water - 1 

No & 

exchanger for 

Water each- 1 

No 

Heat 

exchanger 

for Water 

exchanger for exchanger for exchanger for 

Water each- 1 Water - 1 No Water - 1 No 

No Lub oil Heat Lub oil Heat 

LT/HT/L.O Lub oil Heat Lub oil Heat each- 1 No Lub oil Heat exchanger - exchanger - 

c) 

Charge air cooler 

(single stage or double) 

16 Turbo charger 

a) Type 

VTR 354 VTR 354 

Marine Filter Marine Filter 

b) No. of ports 3 Ports/ 3 Ports/ 

17 

Bank Bank 

Charge air filters and 

silencers 

72 Kw - Electrical 90 KW - Electrical 

Double Double Double Double Double Double Double 

VTR 354 P 11 

VTR 354 P 

11 

3 Ports/ Bank 3 Ports/ 

Bank 

VTR 354 P 11 

VTR 354 P 

11 

VTR 304 P 

11 

3 Ports/ Bank 3 Ports/ Bank 2 Ports/Bank 






a) 

Condition to check the 

possibility of bringing 

down and reuse 


18 Exhaust stack 

a) Stack height 34 Mts 34 Mts 55 Mts 55 Mts 55 Mts 55 Meters 55 Meters 

Silencer – condition to 

b) check the possibility of 

bringing down and 

19 Boiler 


Thermax(W Thermax(W Thermax(Wate Thermax(W Thermax(Wat Thermax(Wat Thermax(Wat 

a) Manufacturer and type 

ater tube 

Boiler )- 

ater tube 

Boiler )- 

r tube Boiler )- 

Exhaust Gas 

ater tube 

Boiler )- 

er tube Boiler 

)- Exhaust 


)- Exhaust 


)- Exhaust 

Exhaust Exhaust Gas Recovery Exhaust Gas Gas Recovery Gas Gas 

b) Other rating data 3450 kgs/hr 3450 kgs/hr 2770 kgs/hr 2770 kgs/hr 2770 kgs/hr 2700 Kg/hr 1700 Kg/hr 

c) 

20 

21 

Auxiliary boiler – oil 

fired – available? 

Type and details of 

water treatment 

system for plant use 

Engine hall and other 

buildings 


HP Dosing - 

Tri Sodium 

Phospate 

LP Dosing 

HP Dosing - 

Tri Sodium 

Phospate LP 

Dosing 

HP Dosing - Tri 

Sodium 

Phospate LP 

Dosing 

HP Dosing - 

Tri Sodium 

Phospate LP 

Dosing 

HP Dosing - 

Tri Sodium 

Phospate LP 

Dosing 

HP Dosing - 

Tri Sodium 

Phospate LP 

Dosing 

HP Dosing - 

Tri Sodium 

Phospate LP 

Dosing 

a) Wall materials Concrete Concrete Concrete Concrete Concrete Concrete Concrete 

b) 

c) 

d) 

Buildings – possibility 

of bringing down and reassembling 

Roofing materials – 

reusable? 

Crane and crane beams 

– reusable? 

NO NO NO NO NO NO NO 

NO NO NO NO NO NO NO 


22 Work shop NA NA NA NA NA NA NA 






a) 

23 

Equipment we can bring 

down 

Other auxiliary units 

and equipment we can 

bring down 

a) Name the units 

b) 

c) 

Maintenance records of 

above 

Identified defects of 

above, those have to be 

repaired/corrected 

before re- 


Available Available Available Available Available Available Available 

NIL NIL NIL NIL NIL NIL NIL 

24 Test reports 

a) HFO Available Available Available Available Available Available Available 

b) LO Available Available Available Available Available Available Available 

c) Engine cooling water Available Available Available Available Available Available Available 

d) Boiler water Available Available Available Available Available Available Available 

e) Emission Available Available Available Available Available Available Available 

f) 

Sound levels with 

measuring points at site 

Available Available Available Available Available Available Available 

25 Usable spare parts Available Available Available Available Available Available Available 

a) 

26 

Please provide a list 

with part numbers 

and/or other details 

Dimensional plant 

layout and plan 

Fuel Feeder,Booster, 

Supply 

Units,MOPX,FOPX,Coolin 

g water system,Ventilation 

Fuel Feeder,Booster, Supply 

Units,MOPX,FOPX,Cooling water 

system,Ventilation Fan, Exhaust Fan,Luboil 

Charging,Drain Pumps 

Nil 

Fuel Feeder,Booster, Supply 

Units,MOPX,FOPX,Cooling 

water system,Ventilation 

Fan, Exhaust Fan,Luboil 

Available Available 

Available Available 






HT & LT Breakers Details in Plant 2 

6MW INCOMER & URT 1 4MW INCOMER & URT 2 Auxilary Breaker & LT Braker 

Make ABB ABB ABB 

Sr.No S 7714 & S 7718 Year 1998 S 7717 & S 7720 Year 1998 S 7716 Year 1998 

Type Circuit Breaker HPA 12/2040C Circuit Breaker HPA 12/2040C Circuit Breaker HPA 12/2040C 

Standard IEC 56 IEC 56 IEC 56 

Rated Voltage 12 KV 12 KV 12 KV 

Insulation Level 28 / 75 KV 28 / 75 KV 28 / 75 KV 

Rated Frequency 50 Hz 50 Hz 50 Hz 

Rated Current 2000 A 2000 A 2000 A 

Breaking Current 40 KA 40 KA 40 KA 

Making Capacity 100 KA 100 KA 100 KA 

Rated Shirt time Current 1/3 Sec 40 KA 1/3 Sec 40 KA 1/3 Sec 40 KA 

Mass Apprx 

Auxilary Voltage 

185 Kg 185 Kg 185 Kg 

Closing Coil 110 V DC 110 V DC 110 V DC 

Opening Coil 110 V DC 110 V DC 110 V DC 

Motor 240 V AC 240 V AC 240 V AC 

Indicator V V V 

SF 6 Pressure at 20°c 2-2.5 Bar ( 0.2 -0.25 Mpa) 2-2.5 Bar ( 0.2 -0.25 Mpa) 2-2.5 Bar ( 0.2 -0.25 Mpa) 

SF 6 Gas per Pole at 20°c 0.25 Kg 0.25 Kg 0.25 Kg 

Insulation Manual IN 5409 0001 IN 5409 0001 IN 5409 0001 

Auxilary LT Breaker 

Auxilary LT Breaker 

L & T Larson& Tubro Ltd 

In 1600 A 

Ve 415 V 50/60Hz 

Icu-55 KA Ics 55 KA 

Icw 55 KA for 1 sec 

Utilization Catagery B 

Is 13947-2 IEC 947 -2 CN -CS 

1600 D 






ALTERNATORS 

Description D.G # 1 D.G # 2 D.G # 3 D.G # 4 D.G # 5 

Make Alsthom Alsthom BHEL BHEL BHEL 

Type RP38A RP38AY-8P G851096 G851096 G851096 

Serial No 172147-1 157671-3 45080A264-11-02 45080A264-11-03 45080A264-11-01 

IP 23 23 23 23 23 

KW 6500 6000 6000 6000 6000 

p.f 0,8 0,8 0,8 0,8 0,8 

kVA 8125 7500 7500 7500 7500 

Star Voltage 11000 11000 11000 11000 11000 

Amps 426,3 393,6 394 394 394 

RPM 750 750 750 750 750 

Phase 3 3 3 3 3 

Frequency 50 50 50 50 50 

Insulation Class B F F F F 

Ambient Temp 50 Degree Celcius 50 Degree Celcius 50 Degree Celcius 50 Degree Celcius 50 Degree Celcius 

Duty S1 S1 S1 S1 S1 






Exciter Make RBS RBS BHEL BHEL BHEL 

KW 79 79 79 

Exciter Voltage 225 V 225 V 225 V 

Exciter Amps 350 A 350 A 350 A 

Extation Voltage 86 V 84 V 155 V 155 V 155 V 

Amps 8A 8A 4.5 A 4.5 A 4.5 A 

Regulator 6156 6116 

Weight 30000 Kg 27000Kg 33500 Kg 33500 Kg 33500 Kg 

Year Dez 88 Jan 90 1996 1996 1996 

URT # 1 URT # 2 URT # 3 URT # 4 URT # 5 

KVA 8000 8000 8000 8000 8000 

Rated Voltage No Load 

UNIT RATIO TRANSFORMERS 

Primary 11000 11000 11000 11000 11000 

Secondary 11893 11893 11893 11893 11893 






Rated Current 

Primary 420 420 419,9 419,9 419,9 

Secondary 388,87 388,87 388,4 388,4 388,4 

Phases 

Primary 3 3 3 3 3 

Secondary 3 3 3 3 3 

Make Voltas Voltas Bharat Bijilee Bharat Bijilee Bharat Bijilee 

Makers serial No RY- 3552 RY- 3645/1 4183/1 4183/2 4183/3 

Type of cooling ONAN ONAN ONAN ONAN ONAN 


Impendance Volts 13,10% 12,10% 

Vector group Dyn11 Dyn11 Dyn11 Dyn11 Dyn11 

Core & Winding 8200 Kg 8200 Kg 

Weight of oil 3900 Kg 3900 Kg 4558 kg 4558 kg 4558 kg 

Total Weight 18800 Kg 18800 Kg 18700 kg 18700 kg 18700 kg 

Oil Litre 4500 4500 5300 5300 5300 

Ambient Temprature 45 Degree Celcius 45 Degree Celcius 






Max.Temp. Rise in Oil 50 Degree Celcius 50 Degree Celcius 

Max.Temp. Rise in Winding 55 Degree Celcius 55 Degree Celcius 

Tap Changer 

CIRCUIT BREAKER 

D.G # 1 D.G # 2 D.G # 3 D.G # 4 D.G # 5 

Type Vaccum Vaccum SF6 SF6 SF6 

Make Siemens Siemens ABB ABB ABB 

Type 3AF-1752-4-S 3AF-1752-4-S IEC56 IEC56 IEC56 

Serual No 1926 2578 S5953 S5952 S8396 

Rated votage 11000 11000 11000 11000 11000 

Rated current 1250 1250 1250 1250 1250 

Insulation level 28 / 75 KV 28 / 75 KV 28 / 75 KV 

Making capacity 100 KA 100 KA 100 KA 


Rated short time current 31.5KA/3S 31.5KA/3S 40KA/ 1S 40KA/ 1S 40KA/ 1S 

Rated output duty 0.3S-CO-3min-CO 0.3S-CO-3min-CO 

Provided for all the five URT's. 






Mass 108kg 108kg 185kg 185kg 185kg 

Year 1989 1990 1996 1996 1996 

Closing coil 110V DC 110V DC 110V DC 110V DC 110V DC 

Opening coil 110V DC 110V DC 110V DC 110V DC 110V DC 

Motor supply 230V AC 230V AC 230V AC 230V AC 230V AC 

Gas pressure 2 - 2.5 Bar 2 - 2.5 Bar 2 - 2.5 Bar 

Gas per pole 0.25 kg 0.25 kg 0.25 kg 

All the five D.G Circuit Breakers cannot be taken out of line. 

ONLOAD ISOLATOR 

DG # 1 DG # 2 DG # 3 DG # 4 DG # 5 

Make Driescher Panicker Driescher Panicker Driescher Panicker Driescher Panicker Driescher Panicker 

Type ZLDT 10/630/EA ZLDT 10/630/EA ZLDT 10/630/EA ZLDT 10/630/EA ZLDT 10/630/EA 

Serial no B1368 C1573 B2827 B2828 B2829 

Ur / Un 11000 11000 11000 11000 11000 

In 630 A 630 A 630 A 630 A 630 A 

Jn 5468 5595 6164 6164 6164 

All the five Onload Isolatord are not in good condition. 






NEUTRAL GROUNDING RESISTOR / NEUTRAL GROUNDING TRANSFORMER 

DG # 1 DG # 2 DG # 3 DG # 4 DG # 5 

Make Driescher Panicker Driescher Panicker National switchgear National switchgear National switchgear 

System volts 11000 V 11000 V 11000 V 11000 V 11000 V 

Frequency 50 Hz 50 Hz 50 50 50 

Fault current 53 A 53 A 53 A 

Duration 60 s 60 s 60 s 

Total resistance( +10 % ) 2.42 OHMS 2.42 OHMS 2.42 OHMS 

Material of element Stainless Steel Stainless Steel Stainless Steel 

Type LOTP/Z 10 / 630 F LOTP/Z 10 / 630 F Coil wound Coil wound Coil wound 

Serial No C 1666 0/187 0/188 0/189 

Year 1996 1996 1996 

Ref. Drg No 4-1459R1 4-1459R1 4-1459R1 

AUTOMATIC VOLTAGE REGULATOR 

DG # 1 DG # 2 DG # 3 DG # 4 DG # 5 






Make ACEO ACEO BHEL BHEL BHEL 

Serial No 7508516 7508518 7508517 

OUTPUT RATING 

No load 1.4 A, 65 V DC 1.4 A, 65 V DC 1.4 A, 65 V DC 

Rated load 8A,86 V DC 8A,84 V DC 4.5 A, 155 V DC 4.5 A, 155 V DC 4.5 A, 155 V DC 

VOLTAGE REGULATOR 

Sensing supply 110VAC,10VA,3ph 110VAC,10VA,3ph 110VAC,10VA,3ph 

CT supply 1A,2VA,1ph,50Hz 1A,2VA,1ph,50Hz 1A,2VA,1ph,50Hz 

Auto control range 90-110%En(NL-FL) 90-110%En(NL-FL) 90-110%En(NL-FL) 

Manual control range 70-110%En(NL-FL) 70-110%En(NL-FL) 70-110%En(NL-FL) 

Regulation accuracy 1.0 % (NL-FL) 1.0 % (NL-FL) 1.0 % (NL-FL) 

Compounding 0-10 % En 0-10 % En 0-10 % En 

Compounding supply 110V, 3ph, 50Hz 110V, 3ph, 50Hz 110V, 3ph, 50Hz 

Compounding CT 5A / 1A 5A / 1A 5A / 1A 

Note: 

* All the materials can be given only as it is condition. 

* A.M.C Details available for Maintenance Records 






ESN : 7802 TYPE :18 V 32 

Date 17.08.07 Running Hours 72943 

Engine Load Engine Speed Turbo charger Speed 

4800 KW 80% of Load 748 R.P.M 20149 20277 

Charge Air Temperature / Pressure 

BAR 

Location 

of 

meas.p 

oints 

o C 

Vertical 

Direction 

Vel.mm/s 

Transverse 

Direction 

Vel.mm/s 

VIBRATION MEASUREMENT DATA RECORD 

Turbo chargers make & type HT NO - A - bank HT NO - B -bank 

ABB VTR 354 P - 11 419158 419159 

Longitudinal 

Direction 

Vel.mm/s 

Instrument -make & type Serial no 

Bruel &Kajer 

Location 

points 

Vertical 

Direction 

Vel.mm/s 

Transvers Longitudinal 

e Direction Direction 

Vel mm/s Vel. mm/s 

Acclereati 

Direction 

Vel.m/s² 

A 1 - a 7,0 9,0 5,0 40 - a # # 10,0 4,0 

A 3 - a 8,0 7,0 7,0 41 - a # 14,0 # 10,0 

A 4 - a 10,0 12,0 9,0 42 - a 20,0 # # 8,0 

A 5 - a 44 - a # # 10,0 10,0 

B 2 - a # # 45 - a # 12,0 # 7,0 

C 1 - a 10,0 13,0 9,0 46 - a 13,0 # # 6,0 

C 3 - a 10,0 13,0 7,0 

C 4 - a 10,0 12,0 8,0 40 - b # # 10,0 8,0 

C 5 - a 41 - b # 16,0 # 4,0 

D 2 - a 2,20 1,60 2,20 42 - b 12,0 # # 7,0 

D 4 - a 44 - b # # 10,0 7,0 

E 2 - a 1,00 1,00 2,00 45 - b # 18,0 # 7,0 

E 4 - a 46 - b 16,0 # # 6,0 

A 1 - b # 

A 3 - b 7,0 7,0 7,0 Installation data Purpose of measurement 

Short Base frame Base line measurement 

B 2 - b # # Rubber Pads Periodic check up 






C 1 - b 12,0 10,0 4,0 

C 3 - b 

61 

65 

Remarks : 

Pipe module Pre - overhaul / Repair check 

Post -overhaul / Repair check 

Machine trouble shooting 

Note : All measurements are in RMS values 

Name & Signature 






ESN : 7928 TYPE :12 V 32 

Date 17.08.07 

Running Hours 70599 

Engine Load Engine Speed Turbo Charger Speed 

3500 KW 87.5 % of Load 737 R.P.M 24802 24751 

Charge Air Temperature / Pressure 

o 

C BAR 

Location 

of meas. 

points 

Vertical 

Direction 

Vel.mm/s 

Transverse 

Direction 

Vel.mm/s 

VIBRATION MEASUREMENT DATA RECORD 

Turbo chargers make & type HT NO - A -bank HT NO - B bank 

ABB VTR 304 P - 11 420618 420617 

Longitudinal 

Direction 

Vel.mm/s 

Instrument -make & type Serial no 

Bruel & Kajer 

Location 

of meas. 

points 

Vertical 

Direction 

Vel.mm/s 

Transvers 

e Direction 

Vel mm/s 

Longitudina 

Direction 

Vel. mm/s 

Acclereati 

Direction 

Vel.m/s² 

A 1 - a 7,0 4,5 2,4 40 - a # # 14,0 8,0 

A 3 - a 5,0 5,0 3,0 41 - a # 8,0 # 3,5 

A 4 - a 7,0 10,0 4,0 42 - a 14,0 # # 8,0 

A 5 - a 44 - a # # 13,0 6,0 

B 2 - a # # 45 - a # 10,0 # 5,0 

C 1 - a 7,0 7,0 3,5 46 - a 17,0 # # 5,0 

C 3 - a 6,5 5,5 4,0 

C 4 - a 5,5 6,5 4,0 40 - b # # 18,0 9,0 

C 5 - a 41 - b # 12,0 # 5,0 

D 2 - a 2,00 3,00 1,00 42 - b 14,0 # # 9,0 

D 4 - a 44 - b # # 14,0 8,0 

E 2 - a 2,00 3,00 1,20 45 - b # 14,0 # 7,0 

E 4 - a 46 - b 18,0 # # 7,0 

A 1 - b # 

A 3 - b 4,5 4,5 4,0 Installation data Purpose of measurement 

Short Base frame Base line measurement 

B 2 - b # # Rubber Pads Periodic check up 






C 1 - b 7,0 7,0 3,5 

C 3 - b 

61 

65 

Remarks : 

Pipe module Pre - overhaul / Repair check 

Post -overhaul / Repair check 

Machine trouble shooting 

Note : All measurements are in RMS values 

Name & Signature 






ESN : 7802 TYPE : 18 V 32 Date 09.08.07 Operating Hours 72756 

Engine load Speed Frequency in HZ P . F 

Load,% of nominal 

5000 KW 747 RPM 49,57 

0,85 83% 

Alternator Voltage / Current KV / A 

11.1/ 296 Load Indicator Position 

OPERATION DATA RECORD 

"A" BANK CYLINDER "B" BANK CYLINDER Main bearings 

Cyl.no 

Peak Pr. 

in Bar 

Rack in 

mm 

Exh.Tem 

perature 

Peak Pr. 

Cyl.no 

In Bar 

Rack in 

mm 

Exh.Te 

mperatu 

Temperature 

Thrust 91 

A 1 120 43,0 430 B 1 119 40,0 383 1 91 

A 2 118 40,0 408 B 2 120 42,0 411 2 95 


A 4 116 41,0 419 B 4 120 45,0 445 4 96 


A 6 118 41,0 416 B 6 122 42,5 431 6 96 

A 7 118 40,5 384 B 7 118 42,5 393 7 98 

A 8 120 39,5 403 B 8 120 43,5 398 8 96 

A 9 118 39,0 396 B 9 118 42,0 401 9 96 

Avg. Rack Pos/Temp. 41 407 Avg. Rack Pos/Temp. 42 410 10 91 

Exhaust.Temp.After T/C 308 Exhaust .Temp.After T/C 343 

Turbo speed -"A" 20411 RPM Turbo speed -B 20661 RPM DE 75 

PLATE HEAT EXCHANGER READINGS 

NDE 74 

LT Water 

LUB Oil 

HT Water 

RAW Water 

7,0 

Room Temp 

Pressure in Bar Temperatures in Diff. U 76/78 

IN OUT IN OUT Temp. V 77/75 

2,9 0,9 W 79/75 

6,1 6,2 

0,8 1,3 

3,4 1,7 

o C 

ENGINE READINGS 

Pressure in Bar Temperatures in o C 

Charge Air . 2,35 58 






A Bank CAC B Bank CAC 

LT Water 3,0 

IN OUT IN OUT 

49 56 49 56 

HT Water 3,4 

Before & After Engine 

82 90 

After T/C A & B Bank 

Lub.Oil 5,7 68 82 #### 

Nozzle Coolant 

bf engine af engine 

3,6 3,1 

87 94 #### 

Fuel oil 7,3 132 Viscosity Cst 

CAC Differential Pressure A / B bank mm H 2 O 

Crankcase Pressure mm H 2 O 

ExhaustBack pressure mm H 2 O 

Charge air Filter Diff.Pressure A/B bank mm H 2 O 

17/22 

320 365 

14 






ESN : 7928 TYPE : 12 V 32 Date 17.08.07 Operating Hours 70599 

Engine load Speed Frequency in HZ P . F 

Load,% of nominal 

3500 KW 737 RPM 49,15 

0,99 88% 

Alternator Voltage / Current KV / A 

11/190 

Load Indicator Position 

OPERATION DATA RECORD 

"A" BANK CYLINDER "B" BANK CYLINDER Main bearings 

Cyl.no 

Peak Pr. 

in Bar 

Rack in 

mm 

Exh.Tem 

perature 

Peak Pr. 

Cyl.no 

In Bar 

Rack in 

mm 

Exh.Te 

mperatu 

Temperature 

Thrust 88 

A 1 129 40,0 393 B 1 129 41,5 405 1 90 


A 3 130 40,0 411 B 3 128 40,0 400 3 95 

A 4 128 41,0 412 B 4 126 42,0 414 4 96 

A 5 126 42,0 403 B 5 127 41,0 391 5 94 


7 92 

Avg. Rack Pos/Temp. 41 411 Avg. Rack Pos/Temp. 41 407 

Exhaust.Temp.After T/C 328 Exhaust .Temp.After T/C 322 

Turbo speed -"A" 24802 RPM Turbo speed -B 24751 RPM DE 76 

PLATE HEAT EXCHANGER READINGS 

NDE 75 

6,8 

Room Temp 

Pressure in Bar Temperatures in Diff. U 65 / 65 

IN OUT IN OUT Temp. V 65 / 64 

LT Water 3,0 2,2 47 49 W 67 / 67 

LUB Oil 6,5 6,2 76 58 

1,8 42 

2,4 1,2 46 

o C 

HT Water 54 

RAW Water 36 

ENGINE READINGS 

Pressure in Bar Temperatures in o C 






Charge Air . 

2,0 58 

A Bank CAC B Bank CAC 

LT Water 3,4 

IN OUT IN OUT 

40 46 40 46 

HT Water 3,5 

Before & After Engine 

83 90 

After T/C A & B Bank 

83/92 83/92 

Lub.Oil 5,8 68 80 #### 

Nozzle Coolant 

bf engine af engine 

3,5 2,5 

98 100 #### 

Fuel oil 

6,5 Viscosity Cst 

CAC Differential Pressure A / B bank mm H 2 O 

Crankcase Pressure mm H 2 O 

ExhaustBack pressure mm H 2 O 

Charge air Filter Diff.Pressure A/B bank mm H 2 O 

320 350 

9 

Note: 

* All the materials can be given only as it is condition. 

* A.M.C Details available for Maintenance Records 

6 x 6 MW each, Wartsila make 18V32 Generators & 1 x 4 MW each, 

Wartsila make 12V32 Generators all operating at 11 kV, year of make ranging from 1990 – 1998. 

Price: ask - info@powerplant-market.com - Phone: +1 206-201-2420 

All offers subject to prior sale 








INSPECTION REPORT 




Date : 11-08-2010 

Ordered : 08-08-2010 

Done : 10-08-2010 

Reported : 11-02-2010 

Cust. No. : GEN 

_______________________________________________________________________________________ 

REPORT SUBJECT : Inspection of Power Plant for shifting, revamping and overhauling the engines 

_______________________________________________________________________________________________ 

_________________________________________________________________________________________________ 

_________________________________________________________________________________________________ 

_________________________________________________________________________________________________ 

Total Working hours/days : 

Total Travelling hours/days : 

Total Reporting hours/days : 

ESN TYPE USE RPM FUEL RUN. DATE 

HOURS 

7802 18V32 DG SET 750 LSHS 91,234 10.08.2010 

7928 12V32 DG SET 750 LSHS 81,112 10.08.2010 






Page 2 of 21 






Details of Worked Performed 

Inspection of all the engines, alternator, control system and plant Auxiliary carried out on 9 th and 10 th of August 

2010. 

Plant II 

Plant II has following DG sets: 

1 x 18V32 

1 x 12V32 

DG #1(18V32) 

ESN-7802 

Year of installation:-1998 

Place of manufacturing: Khopoli, India 

R/H of last major maintenance: 86264, dated 08-05-2009 

Present R/H - 91234 

Page 3 of 21 






DG #2(12V32) 

ESN-7928 

KW- 4160 KW 

Year of installation:-1998 

Place of manufacturing: Khopoli, India 

Present R/H-81,112 

CYLINDER HEADS 

DG#1 DG#2 

Visual Inspection 

1. The visual appearance of cylinder heads was clean. No deposits observed on rocker arm, springs, 

push rods and rotocaps. 

2. No leakage observed from exhaust clamp of cylinder head. 

3. Both 10 mm and 8 mm rotocaps (old Type)observed. Inlet valves are also with Springs and rotocaps No 

water leakage observed from most of the cylinder head skirts. 

Observation from Last maintenance report 

18V32 

1. 18 number exhaust valve seat are 1 mm oversize 

2. 15 number exhaust valves were renewed which shows high wear rate. 

3. 8 number inlet valve seats also renewed (30 Deg). All seats will need replacement with new 20 deg 

seats. 

4. Rotocaps are 10 mm and 8 mm old type of design. We can use the 10 mm Rotocaps in inlet valves and 

all exhaust valve seats should be fitted with new design of rotocaps. 

5. No oversize valve guides are used. 

6. Exhaust valves are Stellite. These will have to be replaced by hard nimonic valves. 

Page 4 of 21 






Recommendations 

A. All inlet seats and valves to be replaced with 20 Deg seats and valves. 

B. 10 mm Rotocaps can be used in inlet valves and all exhaust valve seats should be fitted with new 

design of rotocaps. 

C. Oversizing of exhaust seat pocket is max 1 mm only in 18V32. The max recommended size is 3mm. 

PISTON 

Observation from Last maintenance report & Recommendations 

1. Customer has never replaced piston skirts, gudgeon pins and most of the crowns. 

2. Piston of both Mahle and KS were used. 

3. 9 crowns in 18V32 were renewed that can be inspected and based on measurement values can be for 

reused in standby DG set. 

4. Piston have 3 compression and 1 oil scrapper ring. 

5. All piston will need replacement for LN stage II conversion. 

CYLINDER LINER 


1. All the liners were equipped with APR(Anti Polishing rings). 

2. 9-10 liners were close to wear limits of 18V32 at the time of overhaul. 

3. 5 new liners in 18V32 were fitted during the overhaul that can be reused in the standby engine. 

4. No water in engine water passages increases the risk of corrosion. As the engine was operated till 

January 2010 

CONNECTING ROD 


1. All the connecting Rod are H profile. 

2. 18V32 - Maximum Deviation/ovality recorded in last overhaul is 0.020 mm. The limit for rejection is 

0.10 mm. This shows the connecting rods are in very good shape. 

3. 18V32 - All small end bushes are also in ok condition. 

GEAR TRAIN 


1. The gear train is hydraulically tightened screw type. 

2. 18V32 - The gear train bush was inspected and found ok. Customer stated that the gear train bush 

were replaced at every 24K overhaul. 

3. 18V32 - General observation comments, backlash and journal diameter measurement indicates good 

condition of components. 

GOVERNOR 


1. Engine is controlled with an electronic Woodward governor with 721 controller and hydraulic 

actuator. 

2. 18V32 - Drive shaft, clamping ring, gear and bush were renewed in last overhaul. Same drive shaft 

can be reused. 

Page 5 of 21 






GEAR PUMPS(HT, LT & Lube Oil), THERMOSTAT, PHE & PIPING 


1. General condition of the parts was o.k. 

2. 18V32 - One drive gear of HT pump was renewed. 

3. Sealing sets used were not from Wartsila. 

4. Cavitation was observed in Lube Oil pump. Same can be inspected and casing might need 

replacement. 

5. PHE are of Alfa Laval make with clip on gaskets and can be reused after inspection. 

6. Housings are in good condition, elements will be changed based on condition. 

7. The engine is with Pipe module. The modules can be shifted along with all equipments. 

VALVE MECHANISM 


1. 18V32 - All valve Guide blocks were overhauled in last overhaul. 

2. All worn out spares were replaced 

3. Rocker arm bushes needs replacement. 

FIP & INJECTION VALVE 


Make - L`Orange 

Type - POGO 30E 

1. All Fuel pumps were overhauled and worn out parts replaced. 

Page 6 of 21 






2. All pumps will need replacement for LN Stage II conversion. 

3. All FIV are of L’Orange Make will need replacement for LN stage II conversion. 

CAMSHAFT 


1. Camshaft numbers are 

a. 18 V32, 1V14K0144/145 

b. 12V32, 1V14K0129/130 

2. Camshaft bushes were changed in past can be reused after inspection. 

3. Camshaft pieces needs replacement for LN stage II conversion 

CRANKSHAFT & FLEXIBLE COUPLING 


1. All the pins are of standard size. All big end and main bearing are of standard dimensions. 

Coupling pads needs replacement as recommended in the overhauling report of 18V32. 

TURBOCHARGERS 


Make ABB 

18V32 model - 354-11 

12V32 model - 304 P11 

1. Customer has never changed the shaft (recommended interval 100.000 hrs), compressor wheel 

(48,000 hrs), nozzle ring, gas inlet and outlet casings. 

2. Turbochargers needs replacement of shaft, compressor wheel and other components while conversion 

to LN stage II. 

ENGINE BLOCK & BASE FRAME 

Page 7 of 21 







1. The engine is installed on fixing rail with steel chocks and rubber pads are provided between fixing 

rail and foundation. 

2. The alternator is installed on steel chocks. 

3. No damage observed in engine block. 

4. Inside of engine block found clean. 

5. Water leakage marks observed at few places from liner seating surface. Block machining has been 

done in past at various cylinders. 

AUXILIARIES 

FUEL BOOSTER(Comman) 

Observation & Recommendations 

1. The fuel booster unit was manufactured at Khopoli, India and is in bad shape. 

2. The additional small panels above original panel indicates malfunctioning in original panel. 

3. The booster unit is without automatic filter. 

4. A new steam heater was installed recently by customer for reducing electrical auxiliary power. 

5. Complete booster needs replacement. 

Page 8 of 21 






LUBE OIL SEPARATOR (individual) 


Make - Alfa Laval 

Type - MOPX 207. 

1. The separator can be fully refurbished and reused after inspection at our Separator Works. 

LOCAL CONTROL PANEL(individual) 


1. The local control panel is in bad shape. A panel on top of local panel of 4 MW genset indicates 

defective old panel. 

MAINTENANCE WATER TANK (common) 


Found in ok condition, can be reused. 

Page 9 of 21 






AIR COMPRESSOR UNIT (common) & AIR RECEIVER 


Make IR 

1. The hour counter was removed. 

2. Air compressor unit visually is in ok condition and can be reused after refurbishing. 

3. Air receiver are in good condition and can be used after changing necessary gauges and automation. 

Page 10 of 21 






CHARGE AIR FILTER& INTAKE AIR SILENCER 


1. The filter and silencer are in ok condition and can be reused after repair. 

EXHUAST GAS SYSTEM & CHIMNEY 


1. The exhaust gas bellows were removed and kept inside the plant. Condition of pipes can be checked 

only after removing the insulation. Exhaust stack is self supported type and can’t be 

shifted/transported. 

REAMINING COMPONENTS 


1. Charge air cooler are never renewed. Air cooler must be replaced at the time of overhaul. 

2. Pipe module can be shifted but the fuel oil, raw water, DM water piping should be replaced. Only a 

little leakages were observed in hot box and at exhaust. Same can be inspected, recorded during 

running trials. 

3. DM/RO water hydrofore unit will be required additionally. 

4. Only volumetric flow meters were observed in bad condition. Which shows the SFC data was not 

calculated actually. Mass Flow meter should be installed at new installation. 

5. High Load turbine washing machine was also observed. 

6. Most of the gauges were missing/defective. Temperature sensors and pressure switches were also 

missing/faulty. 

7. Unloading unit, fuel storage tank, chimney and other auxiliaries were not inspected. 

8. Details of electrical components is in trailing electrical report for both the plants. 

Page 11 of 21 






Plant III 

Plant II has following DG sets: 



DG #1(18V32 D) 

ESN-4966 

Year of installation:- 1989 

Place of manufacturing-Vassa, Finland 



DG #2(18V32 D) 

ESN-4653 


Place of manufacturing-Vassa, Finland 



DG #3(18V32E) 

ESN-7130 


Place of manufacturing-Khopoli, India 

R/H of last major maintenance: 80,675, dated 17-12-2008 



ESN-7227 






ESN-7228 





Page 12 of 21 






CYLINDER HEADS 

Visual Inspection 

1. The visual appearance of cylinder heads was clean. No deposits observed on rocker arm, springs, 

push rods and rotocaps. 

2. No leakage observed from exhaust clamp of cylinder heads. It appears that the exhaust manifold was 

repaired by customer. 

3. Both 10 mm and 8 mm rotocaps (old Type)observed. Inlet valves are also with Springs and rotocaps 

4. No water leakage observed from most of the cylinder head skirts. 

Observation from Last maintenance report 

DG #1 

1. All inlet seats & valves are of old design, needs replacement. 

2. No record of oversize seats. 

3. 13 number exhaust valves were renewed out of 22 rejected valves, which shows high wear rate. 

4. Rotocaps are 10 mm and 8 mm old type of design. We can use the 10 mm Rotocaps in inlet valves 

and all exhaust valve seats should be fitted with new design of rotocaps. 

5. No oversize valve guides are used. 21 guides replaced. 

6. Exhaust valves used are mix of Stellite, soft nimonic and hard nimonic. 

7. All the collars were machined at site to remove pits/avoid water leakage and assembled with one 

additional gasket. Same to be replaced. 

DG #2 

1. All inlet seats & valves replaced with new 20 deg versions. All parts used were not supplied by 

Wartsila. 


3. 21 number exhaust valves were renewed which shows high wear rate. 





DG #3 

1. All inlet seats & valves are of old design. 







DG #4 



3. 12 number exhaust valves were replaced which shows high wear rate. 





DG #5 


Page 13 of 21 






2. 5 pockets oversize by 1-2mm. 







A. All inlet seats and valves of older version to be replaced with 20 Deg seats and valves. 

B. 10 mm Rotocaps can be used in inlet valves and all exhaust valve seats should be fitted with new 

design of rotocaps. 

C. Over sizing of exhaust seat pocket is 1mm, 2 mm and 3 mm for 4 cylinder heads . The max 

recommended size is 3mm. 

PISTON 


1. Customer has never replaced gudgeon pins and some of the skirts as indicated in work reports. 

2. New crowns in these engines can be inspected and based on measurement values can be for reused in 

standby DG set. 

3. Piston have 3 compression and 1 oil scrapper ring. 

4. Mix of Mahle and KS piston is indicated in the records. 

5. All piston will need replacement for LN stage II conversion. 

CYLINDER LINER 


1. All the liners were equipped with APR(Anti Polishing rings). 

2. Most of the liners are close to wear limits. 

3. New liners fitted during the overhaul can be reused in the standby engine. 

4. No water in engine water passages increases the risk of corrosion. 

5. Most of the liner are with strong back ring design. Same needs to be changed with new design. 

6. Water leakage from liner seating surface observed in most of the engines. All the liner seating surface 

needs machining. For example 16 out of 18 cylinder liner of DG #2 were machined in last overhaul 

and shims were added. 

Page 14 of 21 






CONNECTING ROD 


1. All the connecting Rod are H profile. 

2. 18V32 - Maximum Deviation/ovality recorded in last overhaul is 0.04 mm. The limit for rejection 

is 0.10 mm. This shows the connecting rods are in very good shape. 

3. Most of small end bushes are close to or have crossed the limits for rejection. For example all the 

bushes of DG #3 were above rejection limit in last overhaul and only one was replaced. 

4. Some of the connecting rods of DG #1 were used in DG #3. This indicates DG #3 requires some 

additional connecting rods. 

GEAR TRAIN 


1. The gear train in all engines is hydraulically tightened screw type. 

2. The gear train bush were inspected and not replaced in most of the engines. Customer stated that the 

gear train bush were replaced at every 24K overhaul. 

GOVERNOR 


1. Engine is equipped with Woodward hydraulic governor. All governor needs calibration and 

overhaul. 

2. Back lash of all drive shafts is within limits. Same drive shafts can be reused. 

Page 15 of 21 






GEAR PUMPS(HT, LT & Lube Oil), THERMOSTAT, PHE & PIPING 


1. Sealing sets used were not from Wartsila. 

2. Water pump shaft and impeller of DG #2 needs replacement. 

3. Cavitation was observed in Lube oil pump of DG #3 and same was recommended for replacement. 

Casing of LO pump of DG #2 was replaced in last overhaul. 

4. Lube oil pump of DG #1 was used in DG#4. 

5. PHE are of Alfa Laval and some local make with clip on as well as stick on gaskets. PHE with clip 

on gasket can be reused after inspection. 

6. Thermostat housings are in good condition, elements will be changed based on condition. 

VALVE MECHANISM 


1. All valve Guide blocks were overhauled and worn parts were not replaced. 

Page 16 of 21 






2. Rocker arm bushes needs replacement. 

FIP & INJECTION VALVE 


Make - L`Orange 

Type - POGO 30 

1. All Fuel pumps were overhauled and worn out parts were not replaced in the last overhauls. 

2. All pumps will need replacement for LN Stage II conversion. 

CAMSHAFT 


4. Camshaft numbers are 

a. 3 x 18 V32E, 1V14K0144/145 

b. 1 x 18V32, 1V14K022/27 

c. 1 x 18V32, 1V14K092/93 

5. Camshaft bushes were not changed in past needs replacement. 

6. Camshaft pieces needs replacement for LN stage II conversion 

CRANKSHAFT & FLEXIBLE COUPLING 


1. All the pins are of standard size. All big end and main bearing are of standard dimensions. 

Page 17 of 21 






2. Coupling pads of all the engine needs replacement. 

TURBOCHARGERS 


Make ABB/BBC 

2 x 18V32 model - 354 - 11(BBC) 

3 x 18V32 model - 354 P-11 

1. Customer has never changed the shaft (recommended interval 100.000 hrs), compressor wheel 

(48,000 hrs), nozzle ring, Gas inlet and outlet casings. 

2. Turbochargers needs replacement of shaft, compressor wheel and other components while 

conversion to LN stage II. 

ENGINE BLOCK & BASE FRAME 


1. 3 x 18V32 - The engine is installed on fixing rail with steel chocks and rubber pads are provided 

between fixing rail and foundation. 

2. 2 x 18V32 - The engine is installed on rubber pads. 

3. 3 x 18V32 - The alternator is installed on steel chocks. 

4. No damage observed in engine block. 

5. Inside of engine block found clean. 

6. Water leakage marks observed at few places from liner seating surface. Block machining has been 

done in past at various cylinders. 

Page 18 of 21 






AUXILIARIES 

FUEL BOOSTER(One for 3 x 18V32E and one for 2 x 18V32D ) Observation & 


1. The fuel booster unit for 3 x 18V32E was manufactured at Khopoli, India and is in bad shape. 

2. The fuel booster unit for 23 x 18V32D was supplied by Wartsila Finland and is not in a condition for 

further use. 

3. The booster units are without automatic filter. 

4. Complete booster units needs replacement. 

LUBE OIL SEPARATOR (individual) 


Page 19 of 21 






Make - Alfa Laval 

Type - MOPX 207. 

1. The separator can be fully refurbished and reused after inspection at our Separator Works. 

AIR COMPRESSOR UNIT (common) & AIR RECEIVER 


The compressor unit needs replacement. 

CHARGE AIR FILTER& INTAKE AIR SILENCER 


1. The oil bath filter and silencer of 3 x 18V32 are in are in ok condition and can be reused after repair. 

2. 2 x 18V32 has marine type air filter. 

EXHUAST GAS SYSTEM & CHIMNEY 


1. The exhaust gas bellows were removed and kept inside the plant. Condition of pipes can be checked 

only after removing the insulation. Exhaust stack is self supported type and can’t be 

shifted/transported. 

REAMINING COMPONENTS 


1. Charge air cooler are never renewed. Air cooler must be replaced at the time of overhaul. 

Page 20 of 21 






2. Pipe are not in module but are in trench layout which is very difficult to shift. 

3. DM/RO water hydrofore unit will be required additionally. 

4. The booster unit had volumetric flow meters which are in bad condition. This indicates that the SFC 

data was not calculated actually. Mass Flow meter should be installed at new installation. 

5. Most of the gauges were missing/defective. Temperature sensors and pressure switches were also 

missing/faulty. 

6. Unloading unit, fuel storage tank, chimney and other auxiliaries were not inspected. 

7. Details of electrical components is in trailing electrical report for both the plants. 

Page 21 of 21 






Site Visit Report ‐ NPT‐10‐11‐101‐001 

The site was visited on dt 09‐-08‐-10 & 10‐-08‐-10 for assessment of Electrical & Control system 

equipments for relocating the exisiting 40MW Diesel Captive Power Plant to Uganda. 

Summary of the report: 

The detailed physical inspections were carried out of all electrical, control & automation systems. The 

details are available foe each section individually and following is the summary: 

1. All the Alternators are in working condition and can be re‐-installed at the new location with 

routine force air cleaning and revarnishing wherever required. 

2. Though all the existing AVR’s are too bulky and old, but considering their past performance, it’s 

recommended to re‐-use all exisiting AVR’s. 

3. The Control system is pretty old and very bulky (large in size). All panels are having 

conventional relay logic based control circuits. For trouble free operation & easy trouble 

shootings, It’s highy recommended to go for new Genset control panels with PLC based control 

& PC based SCADA for monitoring. 

4. MV switchgear can be reused without any major overhaul. Routine maintainance/breakers 

overhaul can be carried out before commissioning of the same at the new location. 

5. All the Main LV switchboards are in healthy condition and can be re‐-used without any major 

repairs. Routine maintenance and breakers overhaul is recommended before commissioning at 

the new location. 

6. Some of the local control panels/LV switchboards need replacement due to rusting, damaged 

switchgear & messy wirings. Details are available in the preceeding detailed report. 

7. All engine instrumentation i.e. switches etc needs to be re‐-calibrated and replaced wherever 

required. The engine wirings also need to be retrofitted at certain positions. 

8. All the amplifiers being used for mV to mA conversion, for thermocouple sensors for main 

bearing & exhaust gas temperature sensing, are pretty old and have being giving troubles 

during Genset operation. It’s recommended to remove all these amplifiers and connect the 

thermocouples directly to IO cards of new PLC station. 

9. Considering the criticality of DC system, it’s recommended to go for the new Battery & Battery 

Chargers. 

10. For Neutral grounding, NGTs (Neutral grounding Transformer) are used for Gensets in Plant 2 

and NGRs (Neutral Grounding Resistors) are used for Gensets in Plant 3. It’s recommended to 

replace all the NGTs & NGR with new designed NGRs for High Resistance grounding method. 

Page - 1 - of 11 






Detailed observations & recommendations: 

The following observations & assessments were made: 

Plant 2: 

Wärtsilä 1x18V32 + 1x12V32 

1x4MW + 1x6MW = 10MW 

Generators: 11kV, 1x7500KVA + 1x5000KVA 

Work Report ‐ NPT‐10‐11‐101‐001 

1. Alternators - Synchronous Generator with brushless excitation: 

a. Make: BHEL, Bhopal, India 

b. Year of manufacturing: 1997 & 1998 

c. Exciter is separately mounted on Generator shaft 

d. Excitation PTs are used for excitation power to AVR. PTs are physically in good shape and as 

per operational staff are working fine. 

e. The Alternators were physically inspected and seems to be in working condition 

f. Actual health of alternators can be ascertained only after IR & PI testing. As the alternators 

were in operation till Jan’10, force air cleaning & re‐-varnishing is suggested before 

commissioning of the same at new location. 

BHEL make Synchronous Generator Exciter - Mounted externally on same saft 

Name Plate ‐- Synchronous Generator Name Plate ‐- Exciter 

Page - 2 - of 11 







2. Control system: 

a. Make: Elfab, Mumbai, India 

b. The control system comprises of Control Desk, Relay & Control Panel, AVR panel & 

monitoring system 

c. Customer got the Monitoring system retrofit Allen Bradely PLC & Panel view 550 to display 

the process values of engine analog parameters i.e. mainly Exh gas temperature, main 

bearing temperature, generator winding temperature etc. 

d. Recommendations: 

i. AVR panel can be used. No modifications required 

ii. Control desks are too old and bulky. Hence it’s recommended to replace the same 

with new control panel 

iii. Relay & Control panels are too bulky and comprising of old dated electromagnetic 

protection relays. Hence it’s recommended to eliminate this panel and install the 

latest microprocessor based protection relays in the new control panel 

recommended above. 

Genset Control Desk Synchronizing Control Desk Relay & Control Panel 

iv. 721 Digital controller of Woodward & DESPEMES of Wärtsilä can be taken out and 

re‐-used in new control panel. The 721 controllers are of Droop & Isochronous 

mode operation. Parallel with Grid control 9kW Control mode) is optained through 

external kW regulator. 

Woodward digital governor controller DESPEMES BHEL make AVR 

v. The retrofitted PLC & Panel Views can be used, but the bulbs of display units are 

not working, needs replacement and PLC is also of conventional design i.e. taking 

Page - 3 - of 11 







more space than required e.g. IO cards are just of 4 CH each where as the latest 

designs are available for 8 or even 16 channels for the similar dimensions. Also to be 

noted that: 

The existing PLC is only for analog parameters monitoring without the 

Genset control. The Genset control is still relay logic based and needs 

replacement. To bring the control logic’s in the PLC, more DIO cards will be 

required and hence one more PLC rack will be added to the existing system. 

The thermocouple temperature sensors for main bearing & exhaust gas 

temperature sensors are connected to PLC with interconnected mV/mA 

converter/Amplifiers. The amplifiers need periodic calibration and also fail 

due to vibrations on engines. It’s recommended that the thermocouples 

can be directly connected to the PLC without amplifiers. This will improve 

the maintainability of the system and improved performance. The existing 

AI cards used in the PLC are not compatible of direct T/C connections. 

Considering above and to keep the recommended new panel more spacious & 

better managed, it’s recommended to go for a new PLC station in the new panel. 

Retrofitted PLC - Allen Bradely Display unit - Panel View 550 Thermocouple Amplifiers in local JB 

3. LV system: 

a. Main LV switchboard was inspected and recommended to be re‐-used with few repairs of 

switch handles and replacement of indication lights 

b. Trace heating panel was also checked and found a lot of meters & indications lights not 

working. The panel has also started getting rust and hence it’s recommended to replace the 

trace heating system switchboard with the new one. 

Main LV Switchboard Trace Heating Control panel 

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c. Exhaust fan DB switch handle was found missing and most of the indication lights & 

selector switches not working properly. The DB has started getting rust. Hence it’s 

recommended to replace the two Exhaust Fan DBs with one new Ventilation system floor 

standing panel. 

d. The Fuel supply Unit panels were found too dirty. These can be either reused with proper 

cleaning or may be replaced with new ones. 

Exhaust fan control DB‐-1 Fuel oil supply unit control panel 

e. Engine local control panel of both DG sets are not in good shape. The annunciator of 4MW 

Genset DG panel has been replaced with external annunciator panel on the support 

structure above the panel. Panel internal wirings are also messy and hence it’s 

recommended to replace the Engine Local Control panels of both Gensets. 

Engine control panel Dented panel front door Internal wiring 

4. DC system: 

a. The Battery Charger panel was inspected and found that it has started getting rust 

b. The batteries also need replacement 

Considering criticality of the DC backup system, it’s recommended to go for a new DC system 

110VDC system which shall be common for all the Gensets. 

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Battery Charger Panel - Started getting rust 


5. MV system: 

a. The existing 11kV breakers are of ABB make SF6 breakers, Type ‐- HPA12/1240. Considering 

the physical condition of the breakers, it’s recommended to use the existing MV breakers. 

b. The existing protection relays are electromagnetic type and can be replaced with latest 

microprocessor based relays. 

MV Switchgear - ABB make SF6 breakers 

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Protection Relays section - Electromagnetic relays Name Plate Genset I/C Breakers 

6. Neutral Grounding: 

a. NGTs (Neutral Grounding Transformers) are used for neutral grounding. 

Plant 3: 

NGT panel for 4MW Genset CT specifications 

b. Considering the latest design trends and better grounding practices, we recommend 

replacing the existing NGTs with NGRs (Neutral Grounding Resistors). 

c. It is also to be noted that the Gensets in Plant 3 are having NGRs and hence a common 

design philosophy needs to be considered while all the Gensets will be connected to a 

common system bus. 

Wärtsilä 2x18V32 + 3x18V32 

2x6MW + 3x6MW = 30MW 

Generators: 11kV, 1x8125KVA + 1x7500KVA + 3x7500KVA 

1. Alternators - Synchronous Generator with brushless excitation: 

a. Make: 2xAlsthom, 3xBHEL 

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b. Year of manufacturing: 1988 & 1990 

c. Exciter is separately external mounted on Generator shaft in BHEL Alternators and 

mounted inside the enclosure in Alsthom Alternator. 

d. Excitation PTs are used for excitation power to AVR. PTs are physically in good shape and as 

per operational staff are working fine. 

e. The Alternators were physically inspected and seems to be in working condition 

f. Actual health of alternators can be ascertained only after IR & PI testing. As the alternators 

were in operation till Jan’10, force air cleaning & re‐-varnishing is suggested before 

commissioning of the same at new location. 

BHEL make Synchronous Generator Alsthom make Synchronous Generator 

Name Plate of Genset 1 Name Plate of Genset 2 

Name Plate of Genset 3 Name Plate of Genset 4 

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2. Control system: 

a. Same as Plant 2 

b. Except the Governing system. Governing system is Hydraulic control instead of Electronic 

control in Plant 2 Gensets. The controls can be built into the proposed new control panel 

PLC station. 

Hydraulic Governor Leroy somer AVR in DG1&2 BHEL AVR in DG 3, 4 & 5 Control panel inside 

Control desk for all Genset & Common control Relay & Control Panel ‐- Genset 1 to 5 Auto Synchronizer 

3. LV system: 

a. Main LV switchboard and PCC for Gensets were inspected and recommended to be re‐- 

used. Almost no repairs are required. Panels are well maintained. 

Main LV Switchboard ‐- connected with Busduct PCC cum MCC for Genset‐- 1 &2 and Genset 3, 4 & 5 

b. Engine local PDB can be reused with minor repairs. Heat tracing & return fuel unit panels 

have started getting rust, recommended to be replaced. 

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4. DC system: 


Engine Local PDB - Can be reused Heat tracing panel - Needs replacement Return fuel unit panel 

Considering criticality of the DC backup system, it’s recommended to go for a new DC system 

110VDC system which shall be common for all the Gensets. 

5. MV system: 

a. Siemens make VCB’s are used for Genset 1 &2 and ABB make SF6 breakers are used for 

Remaining Gensets andplant distribution system. 

b. Most of the Siemens make VCB panels have got rusted and also appear to be in poor 

helath. Hence it’s not recommended to reuse these VCBs. 

c. Considering the physical condition os all the ABB make SF6 breakers, Type ‐- HPA12/1240C 

& 2040C, it’s recommended to use these existing MV breakers. 

d. The existing protection relays are of electromagnetic type and can be replaced with latest 

microprocessor based relays. 

6. Neutral Grounding: 

a. NGRs (Neutral Grounding Resistors) are used for neutral grounding. 

b. The fault current is restricted to 53A. 

c. NGRs for Genset 3 to 5 can be used without any substantial repair, but NGR panels of 

Genset 1 & 2 have got started getting rust. 

d. Considering the overall system design (for all 7 numbers Gensets), it’s recommended to 

go for new NGRs limiting the earth fault current to the same value e.g. 5A. The high 

resistance grounding will also provide better operational facility i.e. all NGRs can be kept 

closed all the time and no operations will be required in NGR while running any 

combination of Genset running. 

e. Considering above it’s recommended to replace all existing NGR’s & NGT’s with new 

ones. 

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Genset 1 NGR Genset 4 NGR NGR Specifications 

7. Station Transformer: 

a. Both station transformers i.e. 1MVA (11/0.433kV, %Z ‐- 8.2, Make‐-Voltas, Year ‐- 1989) & 

2.5MVA (11/0.433kV, %Z ‐- 7.8, Make‐-BBL, Year ‐- 1993) are in working condition 

b. 2.5MVA Transformer can be re‐-used with rountine overhaul before commissioning at 

new location. 

c. Considering the overall cost of 1MVA Transformer, it’s recommended not to re‐-use this 

transformer as it’s already >20 years old. 

d. Also to be noted that in the new system design, the higher rating of station transformers 

will be required in combination and this 1 MVA transformer may not be required at all. 

...End of report... 

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40 MW Wartsila 18V32 50 Hz - Powerplants

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