Forced Outages 2

[khara]

Hi all I am trying to reduce the amount of forced outages at my company. I would appreciate your input in the form of tips,websites or any recommeneded reading.
PS.My company is a diesel generated utility company.

 

[rbulsara]

You do not provide any details or specifics. Hard to answer.

Do you have a particular type of repeat failures?
Forced by what?

How about hiring a consultant who knows diesel plant?

Rafiq Bulsara

http://www.srengineersct.com

 

[waross]

Are you using manual control or a load panel? Are your outages electrical or mechanical?
You are going to have to tell us a lot more about your plant to get much help.

Bill
--------------------
"Why not the best?"
Jimmy Carter

 

[byrdj]

Triple Redundancy....When you can make one reliable.

 

[khara]

we currently have Nine (9) synchronous generating sets. three (3) are MAK Units rated at 6.4MW each and six Wartsilas each rated at 10.2MW.
some of the forced outages are water leaks on expansion tank, high crankcase oil mist, low lube oil outlet pressure exhaust gas deviation alarms on cylinder, trip with no indication, exhaust temp, excessive load and voltage fluctuation, tripped on mechanical overspeed,fuel oil inlet pressure low busted bellow excitation problem high jacket water temp etc.

 

[catserveng]

Both the Mak and Wartsilas are generally pretty robust engines, based on yor info, you have a wide range of problems. I would think based on the info provided so far you likely lack a proactive maintenance plan.

As an example, you mention water leaks at expansion tank. Why are the tanks leaking? Corrosion causing pin holes due to lack of proper water chemistry? Of stress cracks due to vibration? How are you fixing it? Why does a minor leak result in an outage?

How about your oil mist detectors? Is there really an excessive oil mist problem, or are the mist detectors giving false indications due to lack of proper maintenance? If there really was an oil mist problem you'd likely have a bad crank by now.

Trip with no indication, why no indication? Maybe you have a protective device that gives a trip signal that is not latching or properly monitored? How often do you test/calibrate your protective devices?

Load and voltage fluctuations can have many root causes, plugge fuel filters, sticky fuel pumps, worn or loose linkages, governor actuator problems, etc. Hard to provide any real answers based on what info you have provide so far.

Sounds like you need an experienced diesel plant engineer to walk your plant, review your system and maintenance practises, and provide you proper recommendations.

Mike L.

 

[rbulsara]

khara:
Your plant appears to be in need of serious overhaul and upgrade. Hire professionals to review, test and make recommendations.

Rafiq Bulsara

http://www.srengineersct.com

 

[rmw]

How about diddlers? What are diddlers? Diddlers are operators (and mechanics to some extent) that can't keep their hands off of "things"; controls, equipment settings, and the like.

A lesson I learned early in life even before I graduated University was about diddlers as told to me by an old navy cook of all things. He knew I was an engineering student and wanted to let me know that he had run a power plant once.

Seems he was in transit during WWII on his way to Europe and was in Iceland at a transit barracks just hanging out while waiting for a change of ships when suddenly approached by an officer who demanded of him; "do you know anything about electricity?" To which his answer was "I know it will kill you." Next question; "do you know anything about a Waukesha Generator?" Answer: "I know if it is running you can hear it." The officer said "you are just the guy I am looking for, come with me."

He goes on to describe that they put him in charge of the island's power plant, and he replaced a 'diddler' - someone who couldn't keep their hand off of things and was constantly tripping the plant as he 'diddled' with stuff. He said he stayed there for several months running the power plant, naturally, since he touched nothing, because he didn't understand it and was afraid of it, the plant just sat there and ran.

Later in life, when I was the engineer specifying, installing and starting up controls, I had to make some of them "diddler proof" because diddlers are a reality in plants. This was back in the days of pneumatic controls when there were lots of knobs, set screws, etc.

There is a real lesson taught here by the cook - that might be part of your problem.

rmw

 

[rasevskii]

Yes many plants run better on the Nightshift after the commissioning people, testing people, electricians, wiremen, cable pullers, consultants, supervisors, and maintenance staff have all gone home for the day...

rasevskii

 

[jumaj]

Having worked with Wartsila engines for some time, I shall second the others in recommending you call in a consultant. E-advice may not be effective this time. The preventive maintenance tasks recommended by the OEM are targeted torwards dealing with what you are facing now. Carry them out diligently and you will have a happy life.
Clean connections,correct air pressure for the Oil mist detector, genuine sealing materials and recommended lubes and coolants should be a starting point. For engine tripping without any fault indication (Wartsila), check your stop solenoids and air lines.
You should receive better answers from your consultant.

Curiosity has its reasons for existence - Albert Einstein

 

[marks1080]

Have more planned maintenance outages.