• Maintenance is keep (something) in good condition by making repairs and correcting the problems.

• Diesel engines comprise the vast majority of prime movers for standby power generators because of their reliability, durability and performance under load.

• In standby power applications, diesel generators can start and assume full-rated load in less than 10 seconds, and they typically can go 30,000 hours or more between major overhauls.

• To reduce unplanned downtime.

• To reduce rework job and cost.

• To reduce repair cost and repair time.

• To minimize equipment damage.

• To improve reliability of equipment.

• To extend machinery life.

• To reduce staff’s overtime and urgent job.

• Maintenance budget cut from the management.

• Plant maintenance always claims as the huge expense rather than consider it as investment.

• Management keeps to maintain the reliability of equipment but at same time, budget and manpower was downsized.

• Maintenance execution faced with time constraint. Therefore, quality of maintenance decrease.

• Staffs and technicians not share a value of maintenance best practice.

• Reactive Maintenance

• Time Based Maintenance (TbM)

• Condition Based Monitoring (CbM) Maintenance

• Proactive Maintenance

• Reactive Maintenance means the reaction and respond to a need for maintenance of the machine, because the machine has failed completely.

• Another name for reactive maintenance is breakdown maintenance and corrective maintenance.

• In this type of maintenance, no maintenance is done on the machine, and only when the machine fails it is replaced by an entirely new machine.

• Maintenance carried out at predetermined intervals or according to prescribed criteria ,aimed at reducing the failure risk or performance degradation of the equipment.

• Also known as Scheduled Maintenance or Periodic Maintenance or Offline Maintenance.

• Normally, the original equipment manufacturer (OEM) provides a schedule for the periodic maintenance to be done on the machine. This is Predetermined Interval.

• The equipment need to scheduled by plant owner such as engineer based on best practise. This is Prescribed criteria.

• Maintenance based on the equipment performance monitoring by using additional instrumentation is required on the machine to measure its ‘health’ parameters and the preventive maintenance taken as a result.

• Also know as Predictive Maintenance or Online Maintenance.

• Preventive Maintenance is carried out when certain indicators give the signaling that the equipment is deteriorating and the failure probability is increasing.

• Maintenance strategy that works to correct the root causes of failure and avoid breakdowns caused by underlying equipment conditions.

• The purpose of proactive maintenance is to see machine failures as something that can be anticipated and eliminated before they develop.

• Creating a proactive maintenance program helps organizations find hidden inefficiencies.

• Cost effective

• Well train

• History data

• Time Frame

• Checklist

• MTTR (Mean Time To Repair) can tell us how efficient our maintenance team.

• MTBF (Mean Time Between Failures) points to the reliability of our equipment.

• MTTF (Mean Time To Failure) tries to estimate the average lifespan of non-repairable assets.

• Refers to the amount of time required to repair a system and restore it to full functionality.

• The MTTR clock starts ticking when the repairs start and it goes on until operations are restored.

• It includes:

1. Time to troubleshoot and diagnose the problem

2. Repair time

3. Testing period

4. Time to assemble and start up the asset

Pump was fails three times per months. The first repair lasted for 70 minutes, while the second repair taken 120 minutes and last repair taken 60 minutes

• Measures the predicted time that passes between one previous failure of a mechanical/electrical system to the next failure during normal operation.

• MTBF helps you predict how long an asset can run before the next unplanned breakdown happens.

• MTBF is useful to revise Preventive Maintenance schedule according to the new breakdown period.

Pump was ran about 1440 hours before engine failed to run. After repair, pump operate about 3600 hours and breakdown. Pump was maintain and repair, able to ran 4320 hours.

Let assume we tested 3 desktop hard drives. The first one failed after 500,000 hours, the second one failed after 600,000 hours and the third hard drive failed after 700,000 hours.

• Define as defined as the approaches, tools, and techniques used to uncover causes of problems.

• RCA is one of the most important elements of problem-solving in quality management.

• The famous analysis tools in industry are:

1. Pareto Analysis

2. Ishikawa Analysis

3. 5 Why Analysis

• Pareto charts are one of the seven basic tools of quality described by quality pioneer Joseph Juran.

• Pareto chart is a histogram or bar chart combined with a line graph that groups the frequency or cost of different problems to show their relative significance.

• Pareto charts are based on Pareto’s law, also called the 80/20 rule, which says that 20% of inputs drive 80% of results.

• Ishikawa diagram sorts possible causes into various categories that branch off from the original problem.

• Also called a cause-and-effect or Fishbone diagram, a Ishikawa diagram may have multiple sub-causes branching off of each identified category.

• The main causes are:

1. People

2. Machine

3. Method

4. Measurement

5. Material

6. Environment

• The 5 Whys is a method that uses a series of questions to drill down into successive layers of a problem.

• The basic idea is that each time you ask why, the answer becomes the basis of the next why.

• It’s a simple tool useful for problems where you don’t need advanced statistics, so you don’t necessarily want to use it for complex problems.

• Maintenance of the generator sets shall be made when it has been stopped and the cable which connect to the negative polar of the battery shall be dis‐connected so that to ensure the generator set will not mistakenly start.

• Training is teaching, or developing in oneself or others, any skills and knowledge or fitness that relate to specific useful competencies.

Benefits of Training:

1. Increased job satisfaction and morale among employees

2. Increased employee motivation

3. Increased efficiencies in processes, resulting in financial gain

4. Increased capacity to adopt new technologies and methods

5. Increased innovation in strategies and products

6. Reduced employee turnover

7. Enhanced company image

• In order to obtain maximum operation safety and life expectancy of the generator sets, periodic maintenanceis very important.

• Strictly observance of the terms on generator set’s maintenance can ensure generator set’s performance and reduce its damage to environment.

• Standby Generator

1. Test run Diesel Generatorfor 15 minutesfor every week.

• Each time before start the engine:

1. Check lubricant oil level.

2. Check coolantlevel.

3. Check air filter indicator.

4. Check the ventilation ofradiator and ambient environment.

5. Check engine’stransmissionbelt.

6. Check fuel supply status Generator sets which run frequently need to be checked one time every 6 to 8 hours.

7. Backupgeneratorsets need to be checked once more after being stopped.

• Every week

1. Discharge the water remained in the oil‐water separator.

2. Check the battery’s electrolyte level (except maintenance free battery).

3. Check battery voltage.

4. Check battery charger’s ampere. For backup generator, make sure purchase charger the battery using ‘float’ mode.

5. Clean battery terminal.

6. Check diesel level in tank.

7. Clean and maintain 5S in Diesel Generator Room.

8. Check color exhaust air. If abnormal need to check system.

• A battery is an electrical reservoir.

• It is designed to supply electricity to the various components and accessories needed for the boat’s normal operation.

• It is usually recharged by a generator: the alternator. However, during heavy energy consumption or during winter storage, the battery’s potential decreases.

• The battery’s charge state must be checked every 100 hours or at least once every season.

• The best way of doing this is to measure the density of the electrolyte with the aid of a battery hydrometer.

• A battery hydrometer is an inexpensive tool that allows you to evaluate the battery’s state of charge. Take a density reading for each cell. The weaker the density, the less the battery is charged.

Method:

• Check each cell individually. Use the pipette to draw up just enough water for the float to rise freely. Take care not to let any of it drip on the floor or on to your clothes as the acid is extremely corrosive.

• Hold the hydrometer vertical and at eye level. Read the density.

• A density of 1.28 indicates the battery is fully charged.

• A density of 1.20 tells you the battery is charged to only 50% of its capacityand needs to be charged.

• At 1.1 density, the battery has only 20% of its capacityand needs recharging urgently.

1. Visual test of glow plug

• It is possible to see how well a glow plug is working. To do this: remove the plug. Feed it with approximately 10 volts of power. After a few seconds the plug should heat up, then glow. To avoid damaging the plug, cut the power after 10 seconds.

Maksud - Mengeluarkanudara yang terdapat dalamfuel pressure system(fuel lines).

Tujuan- Memperolehi tekanan bahanapi yang secukupnya sepertimana yang dikehendaki.

Jenis Bleeding

1. Low pressure bleeding.

2. High pressure bleeding.

• Mengeluarkan udara bermula dari hose tangki hingga ke fuel gallary Fuel Injection Pump (FIP).

• Tanpa menghidupkan enjin.

• Menggunakanhand pump yang terdapat pada Fuel Feed Pump (FFP).

• Tempat bleeding ialah pada fuel filter dan bleeder screw pada FIP.

• Caranya ialah dengan melonggarkan bleeder screw dan pam sehingga hanya bahanapi sahaja yang keluar melalui bleeder screw tersebut.

• Mengeluarkanudara bermula dari FIP holder hingga ke injector.

• Perlu menghidupkan enjin.

• Gunakandecompression lever jika ada.

• Tempat bleeding ialah pada injector sahaja.

• Caranya ialah dengan melonggarkan high pressure pipe nut pada injector dan crank enjin sehingga bahanapi ada memberi pancitan keluar melalui nut tersebut dan ikat semula semua nut tersebut

TUJUAN

Menyamakanmasa injection (ignition) dengan lejang (valve mechanism) dalam selinder supaya berlaku pembakaranyang betul dan enjin dapat dihidupkan.

JENIS TIMING

1. FIP Timing.

2. Spill port timing.

3. Injection timing