Maintenance Manual for

Auxiliaries
Karnaphuli EPZ
P/18046

Document ID DBAF386084-

Classification Confidential

Date of issue 24.05.2019

Status Approved
 © Copyright by Wärtsilä Finland Oy
All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic,
mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior
written permission of the copyright owner.
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REGARDING THE SUBJECTS COVERED AS WAS AVAILABLE AT THE TIME OF WRITING. HOWEVER, THE
PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS AND THE DESIGN OF THE SUBJECT AND
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ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT
FROM THOSE SHOWN IN THIS PUBLICATION. THE PUBLISHER AND COPYRIGHT OWNER SHALL NOT BE
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 Maintenance Manual for Auxiliaries

Table of Contents

Introduction to the maintenance manual.............................................................................1 - 1

Maintenance routines.................................................................................................................................... 1 - 2
Safety aspects for maintenance work........................................................................................................... 1 - 3
Locking and tagging out for maintenance or inspection............................................................................... 1 - 5
Glossary.........................................................................................................................................................1 - 6

Generating set..................................................................................................................... 2 - 1
Generating set maintenance..........................................................................................................................2 - 2
Generator.......................................................................................................................................................2 - 3
Generator
Generator maintenance program........................................................................................................... 2 - 5
Level 1 maintenance of the AMG generator...........................................................................................2 - 7
Level 2 maintenance of the AMG generator.........................................................................................2 - 11
Level 3 maintenance of the AMG generator.........................................................................................2 - 13
Level 4 maintenance of the AMG generator.........................................................................................2 - 15

Fuel gas system...................................................................................................................3 - 1

Fuel gas system maintenance....................................................................................................................... 3 - 2
Shutting down the compact gas ramp for maintenance............................................................................... 3 - 3
Compact gas ramp........................................................................................................................................ 3 - 4
Gas filter
Maintaining the gas filter........................................................................................................................ 3 - 5
Instrument air filter
Checking the condensate trap............................................................................................................... 3 - 7
Replacing the filter element.................................................................................................................... 3 - 9
Mass flow meter
Maintaining the flow meter................................................................................................................... 3 - 11
Gas shut-off valve (Pekos)
Maintaining the ball valve..................................................................................................................... 3 - 13
Overhauling the ball valve.....................................................................................................................3 - 15
Gas shut-off/vent valve (Starline)
Maintaining the ball valve..................................................................................................................... 3 - 17
Overhauling the ball valve.....................................................................................................................3 - 19
Gas pressure regulating valve
Calibrating the gas regulator................................................................................................................ 3 - 21
Replacing the packing and gaskets..................................................................................................... 3 - 23
Control air inlet valve
Maintaining the ball valve..................................................................................................................... 3 - 25
Overhauling the ball valve.....................................................................................................................3 - 27
Control air pressure regulator
Maintaining the pressure reducing regulator........................................................................................3 - 29

Lubricating oil system..........................................................................................................4 - 1

Lubricating oil system maintenance.............................................................................................................. 4 - 2
Oil mist separator.......................................................................................................................................... 4 - 3
Oil mist separator
Checking the oil mist separator..............................................................................................................4 - 5
Maintaining the oil mist separator.......................................................................................................... 4 - 7
Replacing the rubber isolators............................................................................................................. 4 - 11
Variable frequency drive
Maintaining the VFD............................................................................................................................. 4 - 13
Replacing the VFD main fan................................................................................................................. 4 - 15

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 Maintenance Manual for Auxiliaries

Replacing the VFD real time clock battery........................................................................................... 4 - 17

Compressed air system.......................................................................................................5 - 1

Compressed air system maintenance........................................................................................................... 5 - 2
Instrument air unit.......................................................................................................................................... 5 - 3
Air tank
Inspecting the compressed air vessel.................................................................................................... 5 - 5
Compressor
Tightening the connections.................................................................................................................... 5 - 7
Lubricating the motor bearings.............................................................................................................. 5 - 9
Maintaining the compressor................................................................................................................. 5 - 11
Maintaining the compressor................................................................................................................. 5 - 13
Testing the compressor........................................................................................................................5 - 15
Maintaining the compressor................................................................................................................. 5 - 17
Replacing the motor bearings.............................................................................................................. 5 - 19
Replacing the compressor air end....................................................................................................... 5 - 21
Dryer
Checking the condensate drain............................................................................................................5 - 23
Maintaining the refrigeration dryer........................................................................................................5 - 25
Maintaining the refrigeration dryer........................................................................................................5 - 27
Filter
Checking the oil content of the filter.....................................................................................................5 - 29
Replacing the filter element and cartridge............................................................................................5 - 31
Maintaining the filter............................................................................................................................. 5 - 33
Drain valve
Maintaining the condensate drain valve............................................................................................... 5 - 35
Starting air unit............................................................................................................................................ 5 - 36
Compressor
Changing the oil....................................................................................................................................5 - 37
Replacing the air filter...........................................................................................................................5 - 39
Maintaining the compressor................................................................................................................. 5 - 41
Maintaining the compressor................................................................................................................. 5 - 43
Overhauling the compressor................................................................................................................ 5 - 45
Overhauling the compressor................................................................................................................ 5 - 47
Starting air bottle......................................................................................................................................... 5 - 48
Air vessel
Inspecting the air vessel....................................................................................................................... 5 - 49
Inspecting the air vessel....................................................................................................................... 5 - 51
Drain valve
Maintaining the Bekomat condensate drain.........................................................................................5 - 53

Cooling water system.......................................................................................................... 6 - 1

Cooling water system maintenance.............................................................................................................. 6 - 2
Radiator......................................................................................................................................................... 6 - 3
Radiator
Maintaining the radiator..........................................................................................................................6 - 5
Frequency converter
Maintaining the VFD............................................................................................................................... 6 - 7
Replacing the VFD main fan................................................................................................................... 6 - 9
Replacing the VFD real time clock battery........................................................................................... 6 - 11
Electric preheating unit................................................................................................................................ 6 - 12
Electric heater
Checking the electrical connections.................................................................................................... 6 - 13
Circulation pump
Inspecting the circulation pump........................................................................................................... 6 - 15
Safety valve
Testing the safety valve........................................................................................................................ 6 - 17
Automatic air venting valve

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Replacing the automatic air vent valve.................................................................................................6 - 19

Expansion vessel......................................................................................................................................... 6 - 20
Level switch
Maintaining the level switch................................................................................................................. 6 - 21

Charge air and exhaust gas system.................................................................................... 7 - 1

Charge air and exhaust gas system maintenance.........................................................................................7 - 2
Charge air system..........................................................................................................................................7 - 3
Charge air system maintenance
Maintaining the charge air system..........................................................................................................7 - 5
Charge air filter.............................................................................................................................................. 7 - 6
Oil bath filter
Removing sludge from the filter............................................................................................................. 7 - 7
Inspecting the MultiDuty filter.................................................................................................................7 - 9
Replacing the Viscosine....................................................................................................................... 7 - 11
Fine filter
Cleaning or replacing the fine filter.......................................................................................................7 - 13
Exhaust gas system.....................................................................................................................................7 - 14
Exhaust gas silencer
Maintaining the exhaust gas silencer................................................................................................... 7 - 15
Exhaust gas module.................................................................................................................................... 7 - 16
Charge air silencer
Inspecting the charge air silencer.........................................................................................................7 - 17

Combined system modules.................................................................................................8 - 1

Maintaining the engine auxiliary module....................................................................................................... 8 - 2
Engine auxiliary module.................................................................................................................................8 - 3
Instrument air filter
Checking the condensate trap............................................................................................................... 8 - 5
Replacing the filter element.................................................................................................................... 8 - 7
Water temperature control valve
Maintaining the 3-way control valve.......................................................................................................8 - 9
Starting air valve
Maintaining the ball valve..................................................................................................................... 8 - 11
Overhauling the ball valve.....................................................................................................................8 - 13
Cooling appendix.........................................................................................................................................8 - 15
Jacket water temperature control valve
Maintaining the valve............................................................................................................................8 - 17
Overhauling the valve........................................................................................................................... 8 - 19

Electrical system..................................................................................................................9 - 1
Electrical system maintenance...................................................................................................................... 9 - 2
LV switchgear................................................................................................................................................ 9 - 3
Switchgear
Inspecting the switchgear components................................................................................................. 9 - 5
Maintaining the switchgear.....................................................................................................................9 - 7
Inspecting the switchgear...................................................................................................................... 9 - 9
DC system................................................................................................................................................... 9 - 10
Battery
Checking the battery voltage................................................................................................................9 - 11

Maintenance-related spare parts........................................................................................ A - 1

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 Maintenance Manual for Auxiliaries

Maintenance schedule

Calendar-based maintenance schedule

System and unit Job JobID Page
1 Week
Fuel gas system, Compact gas ramp Checking the condensate trap WCA3600 3-7

Compressed air system, Instrument air unit Checking the condensate drain WCA4141 5 - 23

Combined system modules, Engine auxiliary Checking the condensate trap WCA3600 8-5
module

1 Month
Compressed air system, Instrument air unit Checking the oil content of the filter WCA3723 5 - 29
The oil indicator is an optional component.

Cooling water system, Radiator Maintaining the radiator WCA0132 6-5

Charge air and exhaust gas system, Charge air Removing sludge from the filter WCA0023 7-7
filter

Electrical system, DC system Checking the battery voltage WCA2019 9 - 11

3 Months
Compressed air system, Instrument air unit Replacing the filter element and cartridge WCA3724 5 - 31
The filter element needs to be changed every 3 months, when the residual oil content becomes
worse, the differential pressure is over 50 mbar with 0–4 bar operating pressure, or the
differential pressure is over 350 mbar with 5–16 bar operating pressure. The filter cartridge
needs to be replaced every 6 months or when the residual oil content becomes worse.

4 Months
Compressed air system, Instrument air unit Maintaining the refrigeration dryer WCA4142 5 - 25

6 Months (Only after first start or major overhaul)

Generating set, Generator Level 1 maintenance of the AMG generator WCA3537 2-7

Compressed air system, Starting air unit Changing the oil WCA4893 5 - 37

6 Months
Lubricating oil system, Oil mist separator Maintaining the VFD WCA3420 4 - 13
This inspection of the VFD (Variable Frequency Drive) should be done every 6 months to 2
years, depending on the operating conditions.

Compressed air system, Instrument air unit Replacing the filter element and cartridge WCA3724 5 - 31
The filter element needs to be changed every 3 months, when the residual oil content becomes
worse, the differential pressure is over 50 mbar with 0–4 bar operating pressure, or the
differential pressure is over 350 mbar with 5–16 bar operating pressure. The filter cartridge
needs to be replaced every 6 months or when the residual oil content becomes worse.

Cooling water system, Radiator Maintaining the VFD WCA3420 6-7

This inspection of the VFD (Variable Frequency Drive) should be done every 6 months to 2
years, depending on the operating conditions.

Charge air and exhaust gas system, Charge air Inspecting the MultiDuty filter WCA0022 7-9
filter

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 Maintenance Manual for Auxiliaries

System and unit Job JobID Page

Charge air and exhaust gas system, Exhaust gas Maintaining the exhaust gas silencer WCA3156 7 - 15
system

Charge air and exhaust gas system, Exhaust gas Inspecting the charge air silencer WCA1560 7 - 17
module

9 Months
Compressed air system, Starting air unit Replacing the air filter WCA4894 5 - 39

18 Months
Compressed air system, Starting air unit Maintaining the compressor WCA2572 5 - 41

1 Year (Only after first start or major overhaul)

Cooling water system, Electric preheating unit Checking the electrical connections WCA4074 6 - 13
The electrical connections should be checked during the first scheduled service but no later
than 1 year after start-up.

1 Year
Generating set, Generator Level 1 maintenance of the AMG generator WCA3537 2-7

Fuel gas system, Compact gas ramp Replacing the filter element WCA1873 3-9
The filter element must be replaced annually or when the differential pressure reaches 0.35
bars.

Fuel gas system, Compact gas ramp Calibrating the gas regulator WCA1554 3 - 21

Compressed air system, Instrument air unit Testing the compressor WCA3256 5 - 15
These tests are to done as required by local and national regulations and at least once a year.

Compressed air system, Instrument air unit Maintaining the refrigeration dryer WCA4143 5 - 27

Compressed air system, Starting air bottle Maintaining the Bekomat condensate drain WCA3095 5 - 53

Cooling water system, Electric preheating unit Testing the safety valve WCA1342 6 - 17

Cooling water system, Expansion vessel Maintaining the level switch WCA2029 6 - 21
This maintenance should be done at least once a year, when the tank is out-of-service.

Charge air and exhaust gas system, Charge air Replacing the Viscosine WCA0580 7 - 11
filter

Combined system modules, Engine auxiliary Replacing the filter element WCA1873 8-7
module
The filter element must be replaced annually or when the differential pressure reaches 0.35
bars.

Electrical system, LV switchgear Maintaining the switchgear WCA0013 9-7

2 Years
Generating set, Generator Level 2 maintenance of the AMG generator WCA3538 2 - 11

Fuel gas system, Compact gas ramp Maintaining the ball valve WCA3038 3 - 13

Fuel gas system, Compact gas ramp Maintaining the ball valve WCA2710 3 - 17

Fuel gas system, Compact gas ramp Maintaining the ball valve WCA2710 3 - 25

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System and unit Job JobID Page

Charge air and exhaust gas system, Charge air Maintaining the charge air system WCA3116 7-5
system
This maintenance should be done during large maintenance breaks and at least every 2 years.

Combined system modules, Engine auxiliary Maintaining the ball valve WCA2708 8 - 11
module

Combined system modules, Cooling appendix Maintaining the valve WCA2716 8 - 17

3 Years
Compressed air system, Starting air unit Maintaining the compressor WCA2573 5 - 43

4 Years
Compressed air system, Starting air bottle Inspecting the air vessel WCA0206 5 - 49
An internal inspection is done at least every four years.

Combined system modules, Cooling appendix Overhauling the valve WCA2717 8 - 19

Replace or overhaul the valve as required.

5 Years
Fuel gas system, Compact gas ramp Overhauling the ball valve WCA3039 3 - 15

Fuel gas system, Compact gas ramp Overhauling the ball valve WCA2711 3 - 19

Fuel gas system, Compact gas ramp Overhauling the ball valve WCA2711 3 - 27

Lubricating oil system, Oil mist separator Replacing the rubber isolators WCA3374 4 - 11

Combined system modules, Engine auxiliary Overhauling the ball valve WCA2709 8 - 13
module

Electrical system, LV switchgear Inspecting the switchgear WCA0012 9-9

6 Years
Lubricating oil system, Oil mist separator Replacing the VFD main fan WCA3421 4 - 15
The main fan for the VFD (Variable Frequency Drive) should be replaced every 6 to 10 years,
depending on the operating conditions.

Compressed air system, Starting air unit Overhauling the compressor WCA2574 5 - 45

Cooling water system, Radiator Replacing the VFD main fan WCA3421 6-9
The main fan for the VFD (Variable Frequency Drive) should be replaced every 6 to 10 years,
depending on the operating conditions.

8 Years
Compressed air system, Starting air bottle Inspecting the air vessel WCA0207 5 - 51
A full inspection is done at least every eight years.

10 Years
Lubricating oil system, Oil mist separator Replacing the VFD real time clock battery WCA3422 4 - 17

Cooling water system, Radiator Replacing the VFD real time clock battery WCA3422 6 - 11

12 Years
Compressed air system, Starting air unit Overhauling the compressor WCA2575 5 - 47

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 Maintenance Manual for Auxiliaries

Maintenance schedule based on running hours

System and unit Job JobID Page
200 Hours
Compressed air system, Instrument air unit Tightening the connections WCA3253 5-7

250 Hours (Only after first start or major overhaul)

Compressed air system, Starting air unit Changing the oil WCA4893 5 - 37

750 Hours
Compressed air system, Starting air unit Replacing the air filter WCA4894 5 - 39

1000 Hours (Only after first start or major overhaul)

Fuel gas system, Compact gas ramp Maintaining the gas filter WCA1271 3-5
The filter elements need to be replaced when the pressure difference is 0.2 bar or higher.

1500 Hours
Compressed air system, Instrument air unit Maintaining the compressor WCA3254 5 - 11
Replace the oil every 1500 operating hours or every second year, whichever occurs first.

Compressed air system, Starting air unit Maintaining the compressor WCA2572 5 - 41

3000 Hours
Compressed air system, Instrument air unit Maintaining the compressor WCA3255 5 - 13

Compressed air system, Starting air unit Maintaining the compressor WCA2573 5 - 43

4000 Hours (Only after first start or major overhaul)

Generating set, Generator Level 1 maintenance of the AMG generator WCA3537 2-7

4000 Hours

Fuel gas system, Compact gas ramp Maintaining the gas filter WCA1271 3-5
The filter elements need to be replaced when the pressure difference is 0.2 bar or higher.

Charge air and exhaust gas system, Charge air Inspecting the MultiDuty filter WCA0022 7-9
filter

6000 Hours
Compressed air system, Starting air unit Overhauling the compressor WCA2574 5 - 45

9000 Hours
Compressed air system, Instrument air unit Maintaining the compressor WCA3257 5 - 17

10000 Hours
Generating set, Generator Level 1 maintenance of the AMG generator WCA3537 2-7

12000 Hours
Compressed air system, Starting air unit Overhauling the compressor WCA2575 5 - 47

16000 Hours
Lubricating oil system, Oil mist separator Maintaining the oil mist separator WCA3373 4-7

Lubricating oil system, Oil mist separator Replacing the rubber isolators WCA3374 4 - 11

20000 Hours
Generating set, Generator Level 2 maintenance of the AMG generator WCA3538 2 - 11

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System and unit Job JobID Page

Compressed air system, Instrument air unit Replacing the motor bearings WCA3258 5 - 19

30000 Hours
Compressed air system, Instrument air unit Replacing the compressor air end WCA3259 5 - 21

40000 Hours
Generating set, Generator Level 3 maintenance of the AMG generator WCA3539 2 - 13
Perform this maintenance every 40000 equivalent hours or every 3 to 5 years.

80000 Hours
Generating set, Generator Level 4 maintenance of the AMG generator WCA3540 2 - 15

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 Maintenance Manual for Auxiliaries

Maintenance interval determined by operating conditions

System and unit Job JobID Page
Fuel gas system, Compact gas ramp Maintaining the flow meter WCA2099 3 - 11
Clean the flow meter when needed. Replace the seals if necessary.

Fuel gas system, Compact gas ramp Replacing the packing and gaskets WCA1555 3 - 23
Replace the packing and gaskets as required by plant operating conditions and national laws.

Fuel gas system, Compact gas ramp Maintaining the pressure reducing regulator WCA4949 3 - 29
The frequency of inspection and replacement of parts depends on the severity of service
conditions and applicable codes and government regulations.

Compressed air system, Instrument air unit Inspecting the compressed air vessel WCA3167 5-5
Observe the applicable national regulations for pressure vessel inspections.

Compressed air system, Instrument air unit Lubricating the motor bearings WCA3262 5-9
Lubricate the electric motor bearing when required.

Compressed air system, Instrument air unit Testing the compressor WCA3256 5 - 15
These tests are to done as required by local and national regulations and at least once a year.

Compressed air system, Instrument air unit Replacing the filter element and cartridge WCA3724 5 - 31
The filter element needs to be changed every 3 months, when the residual oil content becomes
worse, the differential pressure is over 50 mbar with 0–4 bar operating pressure, or the
differential pressure is over 350 mbar with 5–16 bar operating pressure. The filter cartridge
needs to be replaced every 6 months or when the residual oil content becomes worse.

Compressed air system, Instrument air unit Maintaining the filter WCA3725 5 - 33

Compressed air system, Instrument air unit Maintaining the condensate drain valve WCA3853 5 - 35

Cooling water system, Electric preheating unit Inspecting the circulation pump WCA3532 6 - 15

Cooling water system, Electric preheating unit Replacing the automatic air vent valve WCA1580 6 - 19
Replace the air venting valve if it starts to leak.

Charge air and exhaust gas system, Charge air Maintaining the charge air system WCA3116 7-5
system
This maintenance should be done during large maintenance breaks and at least every 2 years.

Charge air and exhaust gas system, Charge air Replacing the Viscosine WCA0580 7 - 11
filter

Charge air and exhaust gas system, Charge air Cleaning or replacing the fine filter WCA3557 7 - 13
filter
The fine filter must be cleaned when the pressure drop across the filter assembly (including the
MultiDuty oil-wetted filter) exceeds 650 Pa. See also the maintenance procedure for the
MultiDuty section of the filter.

Combined system modules, Engine auxiliary Maintaining the 3-way control valve WCA2552 8-9
module

Electrical system, LV switchgear Inspecting the switchgear components WCA3560 9-5

The inspection interval depends on the components and the operating conditions.

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Maintenance Manual for Auxiliaries 1. Introduction to the maintenance manual

Introduction to the maintenance manual

The purpose of the maintenance manual is to provide guidelines for inspection and
maintenance of the auxiliary systems that are within the Wärtsilä scope of supply.

NOTE
Maintenance instructions for the Main engine are found in the Engine Manual.

The instructions are based on information provided by the equipment manufacturer or

supplier. If there are any discrepancies or doubts about a certain unit or component, refer to
the original manuals located in the system manual for the component. Even though the
maintenance programs have been customized to match the plant, it might contain
references to accessories not available in your plant.

NOTE
Even when following the maintenance instructions, normal supervision and
observation of the equipment is required.

Maintenance intervals
As the maintenance intervals often depend on the operating conditions, the stated intervals
are to be considered as guidelines. Take note of these guidelines when creating your overall
maintenance plan for the plant.

The maintenance intervals are given either as running hours for the device or as calendar-
based intervals (weeks, months or years).

The hour-based intervals are to be followed up by an hour counter on the specific device or
running hours of the engine. If none of these are applicable, the best estimation must be
applied.

The calendar-based intervals are counted as total elapsed time. If not otherwise stated, this
interval applies regardless of the running hours of the device.

It is left to the discretion of the maintenance planner to apply the stated interval correctly.

Maintenance-related spare parts and required special tools

Some of the maintenance work described in this manual will require that certain parts are
changed or renewed in connection with the work. These parts, also called maintenance-
related spare parts, will be listed by their descriptive name on each work card. They are
also shown in the appendix in the section "Maintenance-related spare parts".

The actual code for that part must then be looked up in the spare part list provided either by
Wärtsilä or the equipment supplier.

When ordering spare parts, always include all the data needed to identify the component
and part installed. The following identification data should be included:
● Manufacturer and type
● Serial number
● Type of application
● Name and description of the spare part
● Spare part code, if available

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1. Introduction to the maintenance manual Maintenance Manual for Auxiliaries

Maintenance routines GUID-38EB0464-81CE-419D-97F0-92BCEB249274

The auxiliary systems are vital to the function of the plant. Therefore, all maintenance
activities must be carefully done at the correct intervals. All measures taken and why they
are taken must be well recorded.

The maintenance activities are divided into three categories:

● Condition monitoring– by taking the readings of all meters and gauges. If the readings
show a falling or rising trend, the reason has to be found and action taken.
● Preventive maintenance – Daily inspection and checks of all equipment visually or by
listening to the components with the purpose to detect abnormalities.
● Preventive maintenance – Scheduled inspections, cleaning and replacement of
components or fluids.
It is to be expected that the operators possess a good general knowledge of this type of
plant and that they are familiar with both common and local safety regulations that must be
strictly followed.

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Safety aspects for maintenance work GUID-30586285-1227-4BA9-B9A4-C1DA8E11D578

General
Only persons with adequate training are allowed to perform maintenance on the equipment.
● Before starting to operate or perform any maintenance on the components, read the
manuals provided by the component manufacturers.
● Read and obey the safety instructions provided by the equipment manufacturers and the
manufacturers of the liquids handled in the plant.
● Read and obey the safety instructions in the power plant O&M Manuals.
● Observe the warning signs on the equipment. The signs must not be removed.

Handling of chemicals
Before using a chemical, study the material safety data sheets (MSDS) provided by the
supplier of the chemical. Any chemical should be considered potentially hazardous unless it
is known to be harmless. When handling chemicals, contact with skin and eyes must be
avoided. Protective clothing has to be used, including safety glasses and impermeable
gloves. Also respiratory protective equipment may be required. The chemicals must be kept
in a well ventilated place. Do not eat or drink while handling chemicals. Spills must be
properly collected and the chemicals disposed of in accordance with local regulations.

Pay attention to the risk of ignition

The equipment may contain combustible material.
● Do not light matches or open flames in the vicinity.
● Prevent electrical sparks from occurring.
● Check that the area is free of combustible gases, liquids or dust before using any power
tool or welding equipment.

Carry a portable gas detector in the engine hall to detect gas leaks.

Prevent unintended starting during maintenance work

Before starting any maintenance work, make sure that the equipment cannot be
accidentally started.
● Set the safety switch to the OFF position and lock the switch.
● Disconnect the electrical power and tag out the device.
● If needed, isolate the unit by closing and securing inlet and outlet valves and releasing
the pressure.

Prevent electrical shocks

Only trained electricians may perform work on electrical equipment.
● Do not open the electrical cabinet during operation.
● Do not touch electrical wiring and components until the main switch has been switched
off and secured.
● If the equipment contains capacitors, be aware that the capacitors can retain a charge
even after being disconnected from the mains.

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1. Introduction to the maintenance manual Maintenance Manual for Auxiliaries

Avoid burns and splashes

Before dismantling or opening any process equipment, consider what the system may
contain and take the necessary precautions to avoid burns, exposure to hazardous
substances, spills or splashing.

During operation, the pipes will contain hot liquids, and the surface may be hot. Allow all
elements cool down before performing any maintenance work on them. Remove all
pressure from the system before opening any part of it.

Be aware of the power of pressurized air

The compressed air system contains air under very high pressure.
● Do not open any component, unit or part of the system before ensuring that it is not
pressurized.
● Look out for jets of pressurized air.
● If a part of the system is isolated for maintenance work, the valves must be locked and
properly tagged out in order to prevent accidental opening.

Take precautions for confined entry

Before working in a confined space, take the following precautions:
● Close and lock all inlet valves and outlet valves to the space.
● If the space has contained chemicals that can produce vapours, the space must be
properly vented and the air must be tested.
● Assign two people for hole watch. They must remain stationed outside the space where
they can observe the workers inside.
● Test the air again at the beginning of each shift.

Prevent falls when working at heights

Use an appropriate safety harness and safety lanyard.

Use a proper man lift, movable platform, or scaffolding if no permanent access is available.

Use a removable ladder only to provide temporary access. Do not work while standing on a
removable ladder unless there is fixed, secure point for attaching the personal safety
lanyard.

Use protective clothes

Use overalls made according to safety regulations, protective gloves, safety glasses,
industrial shoes, ear protection and helmet. Use an appropriate respirator when working
with hazardous materials.

Keep the area tidy

Wipe up oil spills and dispose of all debris that might cause accidents.

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Locking and tagging out for maintenance or inspection

GUID-05C7F416-CE2C-448D-BF47-0463EA11D6EE

Before starting any maintenance work, it is extremely important to make sure that the
equipment cannot be accidentally started while it is being serviced.

Procedure
1 Notify all persons that will be affected that the lockout is about to begin.
2 Verify that the equipment to be serviced is turned off.
3 Locate all energy sources (electrical, pneumatic, steam etc.) that supply the equipment and
turn them off.
4 Secure all energy sources with an appropriate locking device.
5 Place an appropriate warning tag on the energy sources.

NOTE
If several persons are involved in the maintenance, all persons must attach their
own locking device and tag.

6 Release any stored energy (circuit breakers, pneumatic valves, springs etc.).
7 Operate the controls (switches, valves etc.) to make sure that the equipment will not
operate.
8 Perform the required maintenance work on the equipment.
9 When the maintenance work is finished, the equipment may be taken into service again:
a Check that all tools and loose parts have been removed.
b Replace all safety guards.
c Ensure that all workers are clear of the equipment.
d Remove all tags and locking devices.

NOTE
Only the person that applied the tag or locking device may remove it.

e Turn on the energy sources.

DBAF386084- 1-5
1. Introduction to the maintenance manual Maintenance Manual for Auxiliaries

Glossary GUID-E5E8D856-C890-40C7-9DDB-13D8B4CD9922

AC Alternating Current
AVR Automatic Voltage Regulator
CPU Central Processing Unit
CRO Crude Oil
CT Circuit Transformer
DC Direct Current
DH District Heating
HFO Heavy Fuel Oil
HT High Temperature
HR Heat Recovery
HV High Voltage
JW Jacket Water
LBF Liquid Biofuel
LFO Light Fuel Oil
LO Lubricating Oil
LT Low Temperature
LV Low Voltage
MV Medium Voltage
NDT Non Destructive Testing
OEM Original Equipment Manufacturer
PLC Programmable Logic Controller
PPE Personal Protective Equipment
PMG Permanent Magnet Generator
UPS Uninterrupted Power Supply
UT Ultrasonic Testing
VFD Variable Frequency Drive
VT Voltage Transformer

1-6 DBAF386084-
Maintenance Manual for Auxiliaries 2. Generating set

Generating set

Content
Generating set maintenance..........................................................................................................................2 - 2
Generator.......................................................................................................................................................2 - 3

DBAF386084- 2-1
2. Generating set Maintenance Manual for Auxiliaries

Generating set maintenance GUID-B30BCB74-72B7-45DD-862C-872760A37C7B

Before commencing any maintenance work on the main generating set, the engine must be
locked out to prevent accidental starting. This includes locking the compressed air supply
valves in the closed position and engaging the turning gear. Depending on the type of
maintenance, it may also be necessary to shut down some of the auxiliary systems
(including the units for standby heating and circulation) and drain the circuits.

The maintenance of the generating sets shall be carefully planned, to secure that the power
production capacity of the operational units covers the foreseeable power demand. When
an engine is stopped for maintenance, take the opportunity to service also essential
auxiliaries at the same time, to avoid repeated engine stops.

NOTE
The maintenance requirements for the main engine are described in the engine
manual, together with instructions on restarting after overhaul.

2-2 DBAF386084-
 Maintenance Manual for Auxiliaries 2. Generating set

Generator

Content
Generator
Generator maintenance program........................................................................................................... 2 - 5
This section presents a recommended maintenance program for ABB machines.
Level 1 maintenance of the AMG generator...........................................................................................2 - 7
Level 2 maintenance of the AMG generator.........................................................................................2 - 11
Level 3 maintenance of the AMG generator.........................................................................................2 - 13
Perform this maintenance every 40000 equivalent hours or every 3 to 5 years.
Level 4 maintenance of the AMG generator.........................................................................................2 - 15

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 Maintenance Manual for Auxiliaries 2. Generating set

Generator maintenance program GUID-0C22C9A9-9469-49EF-9561-561250EE0A25

The maintenance program is based on four levels of maintenance, which rotate according
to operating hours. The amount of work and down time vary, so that level 1 includes mainly
quick visual inspections and level 4 more demanding measurements and replacements.

The operation hour recommendation is given as equivalent operating hours (Eq. h), that can
be counted by the following formula:

Equivalent operating hours (Eq. h) = Actual operating hours + Number of starts * 20

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2-6 DBAF386084-
 Maintenance Manual for Auxiliaries 2. Generating set

Level 1 maintenance of the AMG generator

GUID-E6756749-4364-4CA3-8BB8-04519C481F99

Component
Unit: Generator BAG0_1 Type: AMG DSE
Component: Generator Manufacturer: ABB

Work Information
JobID: wca3537 Work time: 1 Days
Type of job: Planned maintenance Stop time: 1 Days
Interval: 10000 Hours Service personnel: Electrician, 1 / Unit
1 Years Mechanical, / Unit
4000 Hours (Only after first start or major overhaul)
6 Months (Only after first start or major overhaul)

Prerequisites

WARNING
● General electrical safety precautions are to be taken into account.
● The personnel must be trained in and familiar with the procedures required
for maintaining and testing rotating electrical machines.

NOTE
After commissioning or maintenance, the supervision should be intensive. The
temperature of bearings and windings, load, current, cooling, lubrication, and
vibration must be checked frequently.

NOTE
V = Visual checking C = Cleaning D = Disassembling and assembling (including
checking and cleaning) R = Reconditioning or replacing T = Testing or
measuring

Required spareparts

Qty Description
1 Preventive maintenance kit L1

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Check the general condition of the machine:
a Machine operation: Starting, shut down, vibration measurement, no-load point, trend
values of temperatures, V/T
b Mounting and foundation: Cracks, rust, alignment, tightness, V
c Exterior: Rust, leakage, condition, V
d Fastenings: Tightness of all fastenings, V
e Anchor bolts: Fastening, condition, V
2 Check the high voltage connection:
a High voltage cabling: Wear, fastening, V
b High voltage connections: Oxidation, fastening, crimping, V
c Terminal box accessories, for example, surge capacitors and arresters: General
condition, tightness, V
d Cable transits: Condition of cables entering the machine and inside the machine, V

DBAF386084- 2-7
2. Generating set Maintenance Manual for Auxiliaries

3 Check the stator and the rotor:

a Stator core: Fixing, cracks, welds, V
b Stator winding insulation: Wear, cleanliness, V
c Stator coil overhangs: Insulation damage, V
d Stator coil supports: Insulation damage, V
e Stator slot wedges: Movement, tightness, V
f Stator terminal bars: Fixing, insulation, V
g Stator cable terminal fastenings and crimps: Tightness, condition, V
h Instrumentation: Condition of cables and cable ties, V
i Rotor poles: Movement, tightness, fixing, V
j Rotor winding insulation, Wear, cleanliness, V
k Rotor coil supports: Movement bending, V
l Rotor balancing weights: Movement, V
m Damper bars, damper joints, and fans: Cracks, corrosion, V
n Shaft and rotor center: Cracks, corrosion, V
o Air gap: Equality, V
p Connections in rotor: Fixing, general condition, V
q Earthing brushes: Operation and general condition, V
r Rotor shaft insulation: General condition, V
4 Check the excitation system, control and protection:
a Exciter diode bridge: Cleanliness, operation, V
b Exciter semiconductor, diodes, varistors: Operation, fixing, V
c Excitation connections: Fixing, general condition, V
d Exciter winding insulation: Wear, cleanliness, V
e Exciter air gap: Equality, V
f AVR unit: Operation, settings, V
g AVR board: Operation, connections, V
h PMG (Permanent Magnet Generator): Operation, connections, V
i Voltage transformer: Operation, cleanliness, V
j Short circuit current transformer (CT): Operation, cleanliness, V
k Actual value CT: Operation, cleanliness, V
l Measurement and protection CTs: Operation, cleanliness, V
m Pt-100 elements (stator, cooling air, bearing): Condition, V
n Anti-condensation heaters: Operation, V
o Auxiliary terminals boxes: General condition, terminals, wiring condition, V
p Exciter stator fixing: General condition, cracks, V
5 Check the lubrication system and the bearings:
a Bearing: Fixing, general condition, V
b Bearing shells: General condition, wear, V
c Seals and gaskets: Leakage, V
d Bearing insulation: Condition, V
e Lubrication piping: Leakage, operation, V
f Lubrication oil: Quality, quantity, flow, V/R
g Oil ring: Operation, V
h Oil flow regulator: Operation, V
i Oil tank: Cleanliness, leakage, V
j Lubrication unit or jack-up system: Operation, V
k Filters for lubrication and jack-up unit: Replace, R
l Oil cooler/heater: Oil temperature, T
6 Check the cooling system:
a Fan and motors: Operation condition, V/T
b Filters: Cleanliness, operation, V/C
c Air ways: Operation, cleanliness, V
d Heat exchanger: Leakage, operation, V
e Tubes: Cleanliness, corrosion, V
f Ducts: Operation, cleanliness, V
g End chambers: Leakage, condition, V
h End chamber seals and gaskets: Leakage, condition, V
i Top module housing gaskets: Leakage, condition, V

2-8 DBAF386084-
Maintenance Manual for Auxiliaries 2. Generating set

j Plate fins: General condition, V

k Vibration dampers: Condition and profile, V
l Water flow regulator: Operation, V/T
m Leakage detector: Inspection and testing, V/T

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Level 2 maintenance of the AMG generator

GUID-B4EF3080-FF78-4832-8D2F-149C8BB9A7D1

Component
Unit: Generator BAG0_1 Type: AMG DSE
Component: Generator Manufacturer: ABB

Work Information
JobID: wca3538 Work time: 2 Days
Type of job: Planned maintenance Stop time: 2 Days
Interval: 20000 Hours Service personnel: Electrician, 1 / Unit
2 Years Mechanical, 1 / Unit

Prerequisites

WARNING
● General electrical safety precautions are to be taken into account.
● The personnel must be trained in and familiar with the procedures required
for maintaining and testing rotating electrical machines.

NOTE
After commissioning or maintenance, the supervision should be intensive. The
temperature of bearings and windings, load, current, cooling, lubrication, and
vibration must be checked frequently.

NOTE
V = Visual checking C = Cleaning D = Disassembling and assembling (including
checking and cleaning) R = Reconditioning or replacing T = Testing or
measuring

NOTE
Level 1 tasks are not included, but must be performed at the same time.

Required spareparts

Qty Description
1 Preventive maintenance kit L2

Required tools

Code Description
Multi meter

Insulation resistance tester

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Check the general condition of the machine:
a Mounting and foundation: Alignment, tightness, T

DBAF386084- 2 - 11
2. Generating set Maintenance Manual for Auxiliaries

b Fastenings: Tightness of all fastenings, T

2 Check the high voltage connection:
a High voltage cabling: Fastening, T
b High voltage connections: Fastening T
3 Check the stator and the rotor:
a Stator winding insulation: Insulation resistance, turn insulation test, (high voltage test), T
b Stator cable terminal fastenings and crimps: Tightness, T
c Rotor poles: Tightness, fixing, tightness of possible dovetail connection wedges, T
d Rotor winding insulation: Insulation resistance, voltage drop test, T
e Damper bars, damper joints, and fans: Ultra sound and knocking test, T
f Air gap: Equality, T
4 Check the excitation system, control and protection:
a Exciter diode bridge: Cleanliness, operation, T/C
b Exciter semiconductor, diodes, and varistors: Operation, fixing, T/C
c Excitation connections: Fixing, general condition, T/C
d Exciter winding insulation: Insulation resistance, T
e Exciter air gap: Equality, T
f AVR unit: Operation, settings, stability test, T
g AVR board: Operation, connections, T
h Voltage transformer: Operation, T
i Pt-100 elements (stator, cooling air, bearing): Resistance, insulation resistance, T
j Anti-condensation heaters: Operation, insulation resistance, T
k Auxiliary terminals boxes: General condition, terminals, wiring condition, T
5 Check the lubrication system and the bearings:
a Bearing: Fixing, general condition, T
b Bearing insulation: Condition, insulation resistance, T
c Oil flow regulator: Operation, T
d Oil tank: Cleanliness, leakage, C
e Lubrication unit or jack-up system: Operation, T
6 Check the cooling system:
a Filters: Replace, R
b Air ways: Clean, C
c Heat exchanger: Pressure test, T
d End chambers: Clean, C

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 Maintenance Manual for Auxiliaries 2. Generating set

Level 3 maintenance of the AMG generator

GUID-FB8EE9AD-ACE9-4DB0-806A-D430B7512710

Perform this maintenance every 40000 equivalent hours or every 3 to 5 years.

Component
Unit: Generator BAG0_1 Type: AMG DSE
Component: Generator Manufacturer: ABB

Work Information
JobID: wca3539 Work time: 5 Days
Type of job: Planned maintenance Stop time: 5 Days
Interval: 40000 Hours Service personnel: Electrician, 1 / Unit
Mechanical, 1 / Unit

Prerequisites

WARNING
● General electrical safety precautions are to be taken into account.
● The personnel must be trained in and familiar with the procedures required
for maintaining and testing rotating electrical machines.

NOTE
After commissioning or maintenance, the supervision should be intensive. The
temperature of bearings and windings, load, current, cooling, lubrication, and
vibration must be checked frequently.

NOTE
V = Visual checking C = Cleaning D = Disassembling and assembling (including
checking and cleaning) R = Reconditioning or replacing T = Testing or
measuring

NOTE
Level 1 and 2 tasks are not included, but must be performed at the same time.

Required spareparts

Qty Description
1 Preventive maintenance kit L3

Required tools

Code Description
Oscilloscope

Endoscope

Tube brush set for cooling tubes cleaning

Refer to the manufacturer’s documentation for additional information. Correct all defects.

DBAF386084- 2 - 13
 2. Generating set Maintenance Manual for Auxiliaries

Procedure
1 Check the general condition of the machine.
a Anchor bolts: Fastening, condition, T
2 Check the stator and the rotor:
a Stator winding insulation: Clean, C
b Rotor winding insulation: Clean, C
c Connections in rotor: Fixing, general condition, T
d Rotor shaft insulation: Insulation resistance, T
3 Check the excitation system, control and protection:
a PMG (Permanent Magnet Generator): Operation, connections, T
b Short circuit current transformer (CT): Operation, T
c Actual value CT: Operation, T
d Measurement and protection CTs: Operation, T
4 Check the lubrication system and the bearings:
a Bearing shells: General condition, wear, T/D
b Seals and gaskets: Leakage, T/D
c Bearing insulation: Condition, insulation resistance, D
d Lubrication piping: Leakage, operation, replace high pressure parts, T/D/R
5 Check the cooling system:
a Heat exchanger: Pressure test, D
b Tubes: Clean the tube with a tube brush, C
c Ducts: Clean, C
d End chambers: Disassemble and inspect, D
e End chamber seals and gaskets: Replace if necessary, R
f Plate fins: Clean, C
g Vibration dampers: Replace if necessary, R
h Protective anodes: Condition, activity, V/C

2 - 14 DBAF386084-
 Maintenance Manual for Auxiliaries 2. Generating set

Level 4 maintenance of the AMG generator

GUID-D31D3626-F9B8-44F3-B6BD-0327490B16DA

Component
Unit: Generator BAG0_1 Type: AMG DSE
Component: Generator Manufacturer: ABB

Work Information
JobID: wca3540 Work time: 10 Days
Type of job: Planned maintenance Stop time: 10 Days
Interval: 80000 Hours Service personnel: Electrician, 2 / Unit
Mechanical, 1 / Unit

Prerequisites

WARNING
● General electrical safety precautions are to be taken into account.
● The personnel must be trained in and familiar with the procedures required
for maintaining and testing rotating electrical machines.

NOTE
After commissioning or maintenance, the supervision should be intensive. The
temperature of bearings and windings, load, current, cooling, lubrication, and
vibration must be checked frequently.

NOTE
V = Visual checking C = Cleaning D = Disassembling and assembling (including
checking and cleaning) R = Reconditioning or replacing T = Testing or
measuring

NOTE
Level 1, 2 and 3 tasks are not included, but must be performed at the same
time.

Required spareparts

Qty Description
1 Preventive maintenance kit L4

Required tools

Code Description
Rotor removal equipment

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Check the high voltage connection:
a High voltage cabling: Replace, R
b High voltage connections: Replace, R
c Cable transits: Clean, C

DBAF386084- 2 - 15
2. Generating set Maintenance Manual for Auxiliaries

2 Check the stator and the rotor:

a Stator core: Clean, C
b Air gap: Equality, D
c Earthing brushes: Replace, R
3 Check the excitation system, control, and protection:
a Exciter semiconductors, diodes, and varistors: Replace, R
b Exciter air gap: Equality, D
c AVR unit: Recondition or replace, R
d AVR board: Recondition or replace, R
e Anti-condensation heaters: Recondition or replace, R
4 Check the lubrication system and the bearings:
a Bearing assembly: Fixing, general condition, D
b Seals and gaskets: Replace, R
c Bearing shells: Replace, R
d Oil ring: Replace, R
e Oil flow regulator: Operation, D
f Lubrication unit or jack-up system, Recondition or replace, R
5 Check the cooling system.
a Top module housing gaskets: Replace, R
b Leakage detector: Replace, R

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Maintenance Manual for Auxiliaries 3. Fuel gas system

Fuel gas system

Content
Fuel gas system maintenance....................................................................................................................... 3 - 2
Shutting down the compact gas ramp for maintenance............................................................................... 3 - 3
Compact gas ramp........................................................................................................................................ 3 - 4

DBAF386084- 3-1
3. Fuel gas system Maintenance Manual for Auxiliaries

Fuel gas system maintenance GUID-5F412FA6-975E-44F6-A71A-A2980C54339E

An engine in operation requires a continuous supply of fuel gas. The engines must therefore
be stopped if the fuel gas supply needs to be cut off due to maintenance work.
Maintenance work in the engine-specific gas regulation system only necessitates stopping
of the corresponding engine.

WARNING
Hazardous gas. If the fuel gas system of a single engine is stopped for
maintenance while the common gas supply line is kept pressurized, it is of the
utmost importance that the related shut-off valves be locked in the closed
position and tagged out. Make absolutely sure that the valves cannot be
accidentally opened. A high gas concentration poses both a direct health risk
and an explosion hazard.

Some units in the fuel gas system may be provided with bypass or backup means, allowing
the system to be kept in operation while a component is disabled and isolated for
maintenance work.
● Gas filters and other units comprising two parallel gas lines for backup purposes can be
serviced during system operation by isolating one line at a time for maintenance. The
required maintenance shall be done as soon as possible after taking a gas line out of
use, to restore the backup capacity and secure an uninterrupted gas supply.
● Flow meters that are equipped with bypass valves can be isolated for maintenance
provided that continuous gas consumption monitoring is not required.

Take proper precautions to ensure that the maintenance activities do not cause a risk of
gas explosions during the actual maintenance work or when restarting the fuel gas system.
To avoid an explosive mixture of fuel gas and air, the system shall be purged with inert gas
(nitrogen) before opening it for maintenance work. Purging with inert gas shall be performed
also before taking the system into use again and filling it with fuel gas once the
maintenance work is finished. The fuel gas piping has connections specifically intended for
inert gas purging.

The fuel gas system involves hazardous areas, where explosive gas atmospheres may form
during normal operation. The hazardous area classification must be strictly observed also in
maintenance situations. Always carry a portable gas detector when performing work on the
fuel gas system or in related areas.

WARNING
Explosion hazard. Do not use any equipment or perform any activity that may
produce flames or sparks or otherwise cause a risk of ignition within a
hazardous area before ensuring that the explosion hazard has been eliminated.

3-2 DBAF386084-
Maintenance Manual for Auxiliaries 3. Fuel gas system

Shutting down the compact gas ramp for

maintenance GUID-77BD3E73-E215-4FEE-9B60-82F78F15819F

When stopping the compact gas ramp for maintenance work or prolonged shutdown, the
supply of gas and compressed air should be stopped, and the power supply disconnected.
● Close the manual gas inlet valve and the control air supply valve. Lock the valves in the
closed position, to prevent accidental opening.
● If the unit will be opened, purge the system with inert gas to reduce the explosion risk. A
connection for inert gas is located in the inlet line of the unit (valve V002).
● If maintenance is to be performed on a specific component, such as a valve or a
measuring instrument, disconnect the component from the terminal block in the control
cabinet of the unit.

DBAF386084- 3-3
3. Fuel gas system Maintenance Manual for Auxiliaries

Compact gas ramp

Content
Gas filter
Maintaining the gas filter........................................................................................................................ 3 - 5
The filter elements need to be replaced when the pressure difference is 0.2 bar or higher.
Instrument air filter
Checking the condensate trap............................................................................................................... 3 - 7
Replacing the filter element.................................................................................................................... 3 - 9
The filter element must be replaced annually or when the differential pressure reaches 0.35 bars.
Mass flow meter
Maintaining the flow meter................................................................................................................... 3 - 11
Clean the flow meter when needed. Replace the seals if necessary.
Gas shut-off valve
Maintaining the ball valve..................................................................................................................... 3 - 13
Overhauling the ball valve.....................................................................................................................3 - 15
Gas shut-off/vent valve
Maintaining the ball valve..................................................................................................................... 3 - 17
Overhauling the ball valve.....................................................................................................................3 - 19
Gas pressure regulating valve
Calibrating the gas regulator................................................................................................................ 3 - 21
Replacing the packing and gaskets..................................................................................................... 3 - 23
Replace the packing and gaskets as required by plant operating conditions and national laws.
Control air inlet valve
Maintaining the ball valve..................................................................................................................... 3 - 25
Overhauling the ball valve.....................................................................................................................3 - 27
Control air pressure regulator
Maintaining the pressure reducing regulator........................................................................................3 - 29
The frequency of inspection and replacement of parts depends on the severity of service conditions and
applicable codes and government regulations.

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 Maintenance Manual for Auxiliaries 3. Fuel gas system

Maintaining the gas filter

GUID-127E4EB4-CC7A-48F8-A14D-A162CBA29416

The filter elements need to be replaced when the pressure difference is 0.2 bar or higher.

Component
Unit: Compact gas ramp ZAC0_1 Type: SF1040
Component: Gas filter B001 Manufacturer: Parker

Work Information
JobID: wca1271 Work time: 2 Hours
Type of job: Planned maintenance Stop time: 2 Hours
Interval: 4000 Hours Service personnel: Mechanical, 1 / Component
1000 Hours (Only after first start or major overhaul)

Prerequisites

WARNING
Before starting any work on the gas regulating equipment, make sure it is
properly isolated, vented and secured from accidental starting.

Required spareparts

Qty Description
2 Filter element

As required Sealing kit

Procedure
1 Disassemble the filter
a Loosen the nuts and remove the cover.
b Unscrew the nut on the centre rod and remove the holder cover.
c Remove the used filter elements.
d Lift off the bottom plate and the spring along the centre rod.
2 Clean the tank, the cover of the tank, the holder cover, and the bottom plate.
3 Check the condition of the O-rings on the cover, in the holder cover, and in the bottom
plate.
Replace the O-rings, if needed.
4 Assemble the filter with new filter elements in opposite order.
5 Check the filter for possible leaks.

Postrequisites

CAUTION
The used filter element is to be treated as hazardous waste.

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Checking the condensate trap

GUID-5AC70A0B-DD0B-4534-BA6D-7660D3BE6E22

Component
Unit: Compact gas ramp ZAC0_1 Type: G2 - G19/XP
Component: Instrument air filter B002 Manufacturer: Zander

Work Information
JobID: wca3600
Type of job: Check job
Interval: 1 Weeks Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
As required O-ring

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Check the function of the condensate trap.

NOTE
The instructions in the following steps do not apply to filters that are equipped
with a manual relief valve.

a Check if a permanent flow noise can be heard when the discharge valve is closed. This
indicates a leakage.
b Turn the knurled screw on the housing bottom to the right in order to open the drain
valve manually.
If the condensate trap:
- works correctly, a small amount of condensate, compressed air or inert gas will
discharge.
- is defective, an unusual amount of condensate discharges.

NOTE
If you have doubts about the correct function of the trap proceed as described
below:

c Shut off the compressed air or gas supply.

d Open the manual drain valve and depressurize the filter.
e Unscrew the filter bowl.
Refer to the section "Renew filter element" in the manufacturer’s documentation.
f Remove the condensate trap, clean or fit a new condensate trap.
g Refit the filter bowl.
Refer to the section "Renew filter element" in the manufacturer’s documentation.

DBAF386084- 3-7
3. Fuel gas system Maintenance Manual for Auxiliaries

h Re-check the operation of the condensate trap.

i Ensure that the knurled nut is tightened so that the automatic drain functions correctly.

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 Maintenance Manual for Auxiliaries 3. Fuel gas system

Replacing the filter element

GUID-5CA51CA6-2460-45C3-B64A-965496E28B9B

The filter element must be replaced annually or when the differential pressure reaches 0.35 bars.

Component
Unit: Compact gas ramp ZAC0_1 Type: G2 - G19/XP
Component: Instrument air filter B002 Manufacturer: Zander

Work Information
JobID: wca1873
Type of job: Planned maintenance
Interval: 1 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Filter element

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Replace the filter element.
a Shut off compressed air or gas supply to the filter.
b Depressurize the filter housing.
Operate drain valve as follows:
- for manual drain valves: open manual valve and wait until the pressure has escaped.
- for automatic condensate drains: turn knurled screw to the right and wait until the
pressure has escaped.
- for an electronic condensate drain: press the push button, if necessary several times.
The filter is depressurized when flow noise can no longer be heard.
c Unscrew the filter bowl section and remove it.
d Unscrew the filter element and remove it.

NOTE
New filter elements with external foam socks (series Z, X) should only be
handled by the end caps; otherwise, the foam sock could be damaged.

e Insert the new filter element and O-ring. Tighten the filter element until it is hand tight;
ensure that the O-ring is seated correctly.
f Before assembly, lightly grease the threads of the housing sections with Molykote or a
comparable lubricant.
g Reconnect the filter bowl to the head and tighten by hand.
h Unscrew the filter bowl by 30°.
This allows the filter to be opened easily even after an extended period of operation and
frequent pressure changes.
i Close the manual or automatic drain.
j Check the housing for leaks.

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Maintaining the flow meter

GUID-21988977-FE7A-4EEB-B0DE-459591E5EF74

Clean the flow meter when needed. Replace the seals if necessary.

Component
Unit: Compact gas ramp ZAC0_1 Type: Promass 80/83
Component: Mass flow meter F001 Manufacturer: Endress+Hauser

Work Information
JobID: wca2099
Type of job: Planned maintenance
Interval: As required Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
As required Seals

Refer to the manufacturer's manual for additional information.

Procedure
1 Clean the flow meter.
When cleaning the exterior of measuring devices, always use cleaning agents that do not
attack the surface of the housing and the seals.
If pigs are used for internal cleaning, it is essential to take the inside diameters of measuring
tube and process connection into account.
2 Replace the seals if necessary.

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Maintaining the ball valve

GUID-DD46D237-7B96-4A11-94E3-9341A72B20F6

Component
Unit: Compact gas ramp ZAC0_1 Type: Fig Z04/Z24
Component: Gas shut-off valve V001, V003, V004 Manufacturer: Pekos

Work Information
JobID: wca3038
Type of job: Planned maintenance
Interval: 2 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
The valve may be pressurised – before doing maintenance, empty the pipeline
and ball valve body by opening the valve part way to release any pressure.

Required spareparts

Qty Description
1 Sealing set

Procedure
1 Disassemble the valve.
Make alignment marks on the body 1 (1) and the body 2 (2) flanges to ensure correct
reassembly.
Place the parts on a clean surface. To make reassembly easier, arrange the parts in order of
disassembly.
2 Replace the following parts in the ball valve (see Fig 3-1):
4 - Seat
6 - Stem seal
7 - Stem packing 1
7d - Stem packing 2
14 - Body seal 1
31 - Bearing (PN10–16 DN250–300 and PN25–40 DN150–300)
32 - Bearing disc (PN10–16 DN250–300 and PN25–40 DN150–300)
34 - Body seal 2
35 - Stem o-ring (if used)
165 - Stem bearing
Inspect the other parts and replace any parts that are worn or damaged. Clean the body
cavity and all parts.

DBAF386084- 3 - 13
3. Fuel gas system Maintenance Manual for Auxiliaries

16 A
22
13b 11

13a 17
165
11
50 B
110 9 33
2
8b 31
32
15
8a
7d

14
34
3 C
35 23
4
6
1 24
5
16
20
17
19

A – Valves DN15–DN32, B – Guided ball valves, C – Valves DN125–DN300, 1. Body 1, 2.

Body 2, 3. Ball, 4. Seat, 5. Stem, 6. Stem seal, 7. Stem packing 1, 7d. Stem packing 2, 8a.
Gland packing 1, 8b. Gland packing 2, 9. Spring washer, 11. Cover, 13a. Cover bolt 1, 13b.
Cover bolt 2 (DN40–DN300), 14. Body seal 1, 15. Body bolt, 16. Handle, 17. Handle bolt,
19. Spring, 20. Antistatic ball, 22. Stop pin (DN15–DN32), 23. Handle pin (DN125–DN300),
24. Lengthening handle (DN125–DN300), 31. Bearing (PN10–16 DN250–300 and PN25–40
DN150–300), 32. Bearing disc (PN10–16 DN250–300 and PN25–40 DN150–300), 33.
Support bearing, 34. Body seal 2, 35. Stem o-ring, 50. Subjection ring, 110. O subjection
ring (DN125–DN300). 165. Stem bearing

Fig 3-1 GUID-ADEAC059-54F7-4B02-AEAE-D5A947CC10F0 v1

3 Assemble the valve with new parts.

Refer to the manufacturer's documentation for instructions.

3 - 14 DBAF386084-
 Maintenance Manual for Auxiliaries 3. Fuel gas system

Overhauling the ball valve

GUID-0650B02F-000E-4F94-ADC9-C4BF111E6188

Component
Unit: Compact gas ramp ZAC0_1 Type: Fig Z04/Z24
Component: Gas shut-off valve V001, V003, V004 Manufacturer: Pekos

Work Information
JobID: wca3039
Type of job: Planned maintenance
Interval: 5 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
The valve may be pressurised – before doing maintenance, empty the pipeline
and ball valve body by opening the valve part way to release any pressure.

Required spareparts

Qty Description
1 Ball

1 Stem

2 Spring

2 Antistatic ball

Procedure
1 Disassemble the valve.
Make alignment marks on the body 1 (1) and the body 2 (2) flanges to ensure correct
reassembly.
Place the parts on a clean surface. To make reassembly easier, arrange the parts in order of
disassembly.
2 Replace the following parts in the ball valve:
3 - Ball
5 - Stem
19 - Spring
20 - Antistatic ball
Refer to Fig 3-2for the location of the parts in the valve.
Inspect the other parts and replace any parts that are worn or damaged. Clean the body
cavity and all parts.

DBAF386084- 3 - 15
3. Fuel gas system Maintenance Manual for Auxiliaries

16 A
22
13b 11

13a 17
165
11
50 B
110 9 33
2
8b 31
32
15
8a
7d

14
34
3 C
35 23
4
6
1 24
5
16
20
17
19

A – Valves DN15–DN32, B – Guided ball valves, C – Valves DN125–DN300, 1. Body 1, 2.

Body 2, 3. Ball, 4. Seat, 5. Stem, 6. Stem seal, 7. Stem packing 1, 7d. Stem packing 2, 8a.
Gland packing 1, 8b. Gland packing 2, 9. Spring washer, 11. Cover, 13a. Cover bolt 1, 13b.
Cover bolt 2 (DN40–DN300), 14. Body seal 1, 15. Body bolt, 16. Handle, 17. Handle bolt,
19. Spring, 20. Antistatic ball, 22. Stop pin (DN15–DN32), 23. Handle pin (DN125–DN300),
24. Lengthening handle (DN125–DN300), 31. Bearing, 32. Bearing disc, 33. Support
bearing, 34. Body seal 2, 35. Stem o-ring, 50. Subjection ring, 110. O subjection ring
(DN125–DN300). 165. Stem bearing

Fig 3-2 GUID-ADEAC059-54F7-4B02-AEAE-D5A947CC10F0 v1

3 Assemble the valve with new parts.

Refer to the manufacturer's documentation for instructions.

3 - 16 DBAF386084-
 Maintenance Manual for Auxiliaries 3. Fuel gas system

Maintaining the ball valve

GUID-AEA4AC42-80AA-4CEE-9BF2-1944E3F35C83

Component
Unit: Compact gas ramp ZAC0_1 Type: Master Star
Component: Gas shut-off/vent valve V002, V007, V008, V009, V014, Manufacturer: Starline
V015

Work Information
JobID: wca2710 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 2 Years Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
1 Gasket set (packing set)

Procedure
1 Disassemble the valve.
Place the parts on a clean surface. To make re-assembly easier, arrange the parts in order
of disassembly.
2 Replace the following parts in the ball valve:
3 - Packing ring
7 - Thrust washer
8 - O-ring
10 - Seats
11, 18 - Body seals.
Refer to Fig 3-3 for the location of the parts in the valve.
Inspect the other parts and replace any parts that are worn or damaged.

DBAF386084- 3 - 17
3. Fuel gas system Maintenance Manual for Auxiliaries

1 2A

8
17
7 13 16
5

2B
4
6
3

18
11
9 10
14

12

1. Handle, 2 (A, B) Nut, 3. Packing ring, 4. Spring washer, 5. Antistatic stem, 6. Gland
packing, 7. Thrust washer, 8. O-ring stem, 9 Ball, 10. Seats, 11. Body seal, 12. Body, 13.
End connections, 14. Stop-pin, 16. Bolts, 17. Stop washer, 18. Body seal

Fig 3-3 Parts for ball valve GUID-AA226961-077A-4F34-92DD-1D44B664FDD6 v2

3 Assemble the valve with the new parts.

3 - 18 DBAF386084-
 Maintenance Manual for Auxiliaries 3. Fuel gas system

Overhauling the ball valve

GUID-FA00FA56-C1E0-469A-9BDA-2DCF557B2E87

Component
Unit: Compact gas ramp ZAC0_1 Type: Master Star
Component: Gas shut-off/vent valve V002, V007, V008, V009, V014, Manufacturer: Starline
V015

Work Information
JobID: wca2711 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 5 Years Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
1 Spare part set

Procedure
1 Disassemble the valve.
Place the parts on a clean surface. To make re-assembly easier, arrange the parts in order
of disassembly.
2 Replace the following parts in the ball valve:
2 (a, b) Nuts
4 Spring washer
5 Antistatic stem
9 Ball
17 Stop washer.
Refer to Fig 3-4 for the location of the parts.
Inspect the other parts and replace any parts that are worn or damaged.

DBAF386084- 3 - 19
3. Fuel gas system Maintenance Manual for Auxiliaries

1 2A

8
17
7 13 16
5

2B
4
6
3

18
11
9 10
14

12

1. Handle, 2 (A, B) Nut, 3. Packing ring, 4. Spring washer, 5. Antistatic stem, 6. Gland
packing, 7. Thrust washer, 8. O-ring stem, 9 Ball, 10. Seats, 11. Body seal, 12. Body, 13.
End connections, 14. Stop-pin, 16. Bolts, 17. Stop washer, 18. Body seal

Fig 3-4 Parts for ball valve GUID-AA226961-077A-4F34-92DD-1D44B664FDD6 v2

3 Assemble the valve with the new parts.

3 - 20 DBAF386084-
 Maintenance Manual for Auxiliaries 3. Fuel gas system

Calibrating the gas regulator

GUID-00EE160E-1264-4A2F-8896-81454C94FF8E

Component
Unit: Compact gas ramp ZAC0_1 Type: GX
Component: Gas pressure regulating V005, V006 Manufacturer: Fisher
valve

Work Information
JobID: wca1554 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 2 Hours
Interval: 1 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Before starting any maintenance work on the gas regulating equipment, make
sure that it is properly isolated, vented, and secured from accidental starting.

Make an auto calibration of the DVC2000 (travel calibration).

Procedure
1 Re-calibrate the auto positioner.
This calibration must be done when the unit is off-line and the regulator is vented (empty).

DBAF386084- 3 - 21
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3 - 22 DBAF386084-
 Maintenance Manual for Auxiliaries 3. Fuel gas system

Replacing the packing and gaskets

GUID-B4C7374A-A140-4B5C-A101-1420D66D54DE

Replace the packing and gaskets as required by plant operating conditions and national laws.

Component
Unit: Compact gas ramp ZAC0_1 Type: GX
Component: Gas pressure regulating V005, V006 Manufacturer: Fisher
valve

Work Information
JobID: wca1555
Type of job: Overhaul
Interval: As required Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Before starting any maintenance on the gas regulating equipment, make sure
that it is properly isolated, vented, and secured from accidental starting.

Required spareparts

Qty Description
1 Service kit (Packing set)

1 Body/bonnet gasket

Replace the packing and gaskets. Use the appropriate packing and gaskets for the valve
size.

Procedure
● Replace the packing, when needed.
Use the appropriate packing set.
● Replace the gasket between the body and bonnet.
Use the appropriate body/bonnet gasket.

DBAF386084- 3 - 23
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3 - 24 DBAF386084-
 Maintenance Manual for Auxiliaries 3. Fuel gas system

Maintaining the ball valve

GUID-AEA4AC42-80AA-4CEE-9BF2-1944E3F35C83

Component
Unit: Compact gas ramp ZAC0_1 Type: Master Star
Component: Control air inlet valve V013 Manufacturer: Starline

Work Information
JobID: wca2710 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 2 Years Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
1 Gasket set (packing set)

Procedure
1 Disassemble the valve.
Place the parts on a clean surface. To make re-assembly easier, arrange the parts in order
of disassembly.
2 Replace the following parts in the ball valve:
3 - Packing ring
7 - Thrust washer
8 - O-ring
10 - Seats
11, 18 - Body seals.
Refer to Fig 3-5 for the location of the parts in the valve.
Inspect the other parts and replace any parts that are worn or damaged.

DBAF386084- 3 - 25
3. Fuel gas system Maintenance Manual for Auxiliaries

1 2A

8
17
7 13 16
5

2B
4
6
3

18
11
9 10
14

12

1. Handle, 2 (A, B) Nut, 3. Packing ring, 4. Spring washer, 5. Antistatic stem, 6. Gland
packing, 7. Thrust washer, 8. O-ring stem, 9 Ball, 10. Seats, 11. Body seal, 12. Body, 13.
End connections, 14. Stop-pin, 16. Bolts, 17. Stop washer, 18. Body seal

Fig 3-5 Parts for ball valve GUID-AA226961-077A-4F34-92DD-1D44B664FDD6 v2

3 Assemble the valve with the new parts.

3 - 26 DBAF386084-
 Maintenance Manual for Auxiliaries 3. Fuel gas system

Overhauling the ball valve

GUID-FA00FA56-C1E0-469A-9BDA-2DCF557B2E87

Component
Unit: Compact gas ramp ZAC0_1 Type: Master Star
Component: Control air inlet valve V013 Manufacturer: Starline

Work Information
JobID: wca2711 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 5 Years Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
1 Spare part set

Procedure
1 Disassemble the valve.
Place the parts on a clean surface. To make re-assembly easier, arrange the parts in order
of disassembly.
2 Replace the following parts in the ball valve:
2 (a, b) Nuts
4 Spring washer
5 Antistatic stem
9 Ball
17 Stop washer.
Refer to Fig 3-6 for the location of the parts.
Inspect the other parts and replace any parts that are worn or damaged.

DBAF386084- 3 - 27
3. Fuel gas system Maintenance Manual for Auxiliaries

1 2A

8
17
7 13 16
5

2B
4
6
3

18
11
9 10
14

12

1. Handle, 2 (A, B) Nut, 3. Packing ring, 4. Spring washer, 5. Antistatic stem, 6. Gland
packing, 7. Thrust washer, 8. O-ring stem, 9 Ball, 10. Seats, 11. Body seal, 12. Body, 13.
End connections, 14. Stop-pin, 16. Bolts, 17. Stop washer, 18. Body seal

Fig 3-6 Parts for ball valve GUID-AA226961-077A-4F34-92DD-1D44B664FDD6 v2

3 Assemble the valve with the new parts.

3 - 28 DBAF386084-
 Maintenance Manual for Auxiliaries 3. Fuel gas system

Maintaining the pressure reducing regulator

GUID-94FAE3C3-DC47-44C7-85DB-2BD8913D21F1

The frequency of inspection and replacement of parts depends on the severity of service conditions and
applicable codes and government regulations.

Component
Unit: Compact gas ramp ZAC0_1 Type: 67D
Component: Control air pressure V018 Manufacturer: Fisher
regulator

Work Information
JobID: wca4949
Type of job: Maintenance
Interval: As required Service personnel: Mechanical, 1 / Component

Refer to manufacturer’s documentation for additional information. Correct all defects.

Procedure
● Inspect the regulator parts.
○ Replace if necessary.
○ If sufficient clearance exists, the body may remain mounted on other equipment or in a
line or panel during maintenance unless the entire regulator will be replaced.
● Open the drain valve to empty accumulated liquid from the dripwell (types 67DF, 67DFR,
67DFS and 67DFSR only).

DBAF386084- 3 - 29
3. Fuel gas system Maintenance Manual for Auxiliaries

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3 - 30 DBAF386084-
Maintenance Manual for Auxiliaries 4. Lubricating oil system

Lubricating oil system

Content
Lubricating oil system maintenance.............................................................................................................. 4 - 2
Oil mist separator.......................................................................................................................................... 4 - 3

DBAF386084- 4-1
4. Lubricating oil system Maintenance Manual for Auxiliaries

Lubricating oil system maintenance GUID-40703FF6-6164-4C99-9100-48A5B7879FA6

The lubricating oil circulation system is vital to the engine operation. The circulation, cooling
and cleaning of the lubricating oil must never be interrupted when the engine is running.
Major maintenance work in the lubricating oil circulation system therefore requires that the
engine be stopped. As the entire lubricating oil circulation system is engine-specific, any
other engines in the plant can be kept in operation. To minimize the downtime, it is
recommended to perform the scheduled maintenance of the lubricating oil circulation
system in connection with the engine maintenance stops when possible.

NOTE
The prelubrication pump may be set for intermittent operation during engine
standstill. The pump shall be locked out as a precaution for maintenance work in
the lubricating oil circulation system, to prevent accidental starting.

The oil mist separator unit is installed primarily for environmental reasons. Stopping this
separator unit does not prevent operation of the engine, but will cause the crankcase
ventilation gases to be released without cleaning. The throttle valve in the inlet line shall be
closed if the separator unit is taken out of use for maintenance work. When the
maintenance work is finished, the throttle valve shall be carefully readjusted to ensure high
separation efficiency.

The units in the lubricating oil storage and transfer system are used only when filling and
emptying the engine oil sump and the storage tanks, and can therefore be temporarily
disabled for maintenance without this affecting the engine operability. If the engine oil sump
needs to be emptied for engine maintenance work, the reusable oil can be pumped to the
service tank for temporary storage and transferred back to the oil sump after the
maintenance.

4-2 DBAF386084-
 Maintenance Manual for Auxiliaries 4. Lubricating oil system

Oil mist separator

Content
Oil mist separator
Checking the oil mist separator..............................................................................................................4 - 5
Maintaining the oil mist separator.......................................................................................................... 4 - 7
Replacing the rubber isolators............................................................................................................. 4 - 11
Variable frequency drive
Maintaining the VFD............................................................................................................................. 4 - 13
This inspection of the VFD (Variable Frequency Drive) should be done every 6 months to 2 years,
depending on the operating conditions.
Replacing the VFD main fan................................................................................................................. 4 - 15
The main fan for the VFD (Variable Frequency Drive) should be replaced every 6 to 10 years, depending
on the operating conditions.
Replacing the VFD real time clock battery........................................................................................... 4 - 17

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4-4 DBAF386084-
 Maintenance Manual for Auxiliaries 4. Lubricating oil system

Checking the oil mist separator

GUID-945928C8-B8BA-4DB7-8ECE-BB9F1C4B4B1B

Component
Unit: Oil mist separator QBF0_1 Type: PureVent 2.0 single
Component: Oil mist separator B001 Manufacturer: Alfa Laval

Work Information
JobID: wca3372
Type of job: Check job
Interval: 1 Days Service personnel: Mechanical, 1 / Unit

Prerequisites

WARNING
Disintegration hazard. At any sign of abnormal vibrations or noise, shut off the
unit and contact Alfa Laval or Wärtsilä Service.

Perform daily checks to verify normal separator operation.

Procedure
1 Check all hose connections for leaks.
2 Check the separator for abnormal noise and vibration.
3 Check that the oil outlet is not blocked.
4 Check the oil mist inlet piping for damage.
5 Check the clean air outlet piping for damage.

Postrequisites

If problems are found, report them to a supervisor for correction. Shut off the unit if there is
abnormal vibration or noise.

DBAF386084- 4-5
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4-6 DBAF386084-
 Maintenance Manual for Auxiliaries 4. Lubricating oil system

Maintaining the oil mist separator

GUID-7687BA11-2F16-4072-8DD1-DB45146189E5

Component
Unit: Oil mist separator QBF0_1 Type: PureVent 2.0 single
Component: Oil mist separator B001 Manufacturer: Alfa Laval

Work Information
JobID: wca3373
Type of job: Planned maintenance
Interval: 16000 Hours Service personnel: Mechanical, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING - ELECTRICITY
Risk of electric shock. Charged capacitors in the frequency converter may
cause electrical shock. Wait 5 minutes before starting any dismantling work.

Required spareparts

Qty Description
1 Rotor kit

1 Sealing kit

Required tools

Code Description
Lifting equipment for disc stack and motor

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Disconnect the power and grounding cables (2) from the motor.

DBAF386084- 4-7
4. Lubricating oil system Maintenance Manual for Auxiliaries

1
2

3
4

8 7

10

1 - bolts holding the motor and disc stack in place, 2 - power and grounding cables, 3 - eye
bolts, 4 - nuts, 5 - O-ring, 6 - O-ring, 7 - inside of housing, 8 - upper and lower oil drains, 9 -
O-ring, 10 - rubber isolators

Fig 4-1 Separator main components GUID-F9CE4C03-24C7-4F70-8CD7-BABFB0716BD3 v1

2 Loosen and remove the six bolts (1) that hold the motor and disc stack in place.
3 Lift the motor and disc stack out of the housing.
Use the eye bolts (3) secured with the nuts.

WARNING
Risk of cuts. Sharp edges can cause cuts. Wear protective gloves.

4-8 DBAF386084-
 Maintenance Manual for Auxiliaries 4. Lubricating oil system

4 Clean the inside of the housing (7).

5 Inspect the upper and lower oil drains (8) and verify that they are still open.
6 Replace the O-ring (5).
7 Lift the new motor and disc stack in place.
Use the eye bolts (3) secured with the nuts.
8 Fasten the 6 screws (1) that hold the motor and disc stack in place.
The tightening torque is 25 Nm.
9 Reconnect the power and grounding cables (2).

Postrequisites

After maintenance, follow the operating instructions for the first start after a major service.
Pay particular attention to how to verify direction of rotation.

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4. Lubricating oil system Maintenance Manual for Auxiliaries

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4 - 10 DBAF386084-
 Maintenance Manual for Auxiliaries 4. Lubricating oil system

Replacing the rubber isolators

GUID-BF48D02D-F3EF-429F-8912-2E3BEAEA8F07

Component
Unit: Oil mist separator QBF0_1 Type: PureVent 2.0 single
Component: Oil mist separator B001 Manufacturer: Alfa Laval

Work Information
JobID: wca3374
Type of job: Planned maintenance
Interval: 16000 Hours Service personnel: Mechanical, 1 / Unit
5 Years

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING - ELECTRICITY
Risk of electric shock. Charged capacitors in the frequency converter may
cause electrical shock. Wait 5 minutes before starting any dismantling work.

Required spareparts

Qty Description
1 Isolator kit

Required tools

Code Description
Lifting equipment for separator unit

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Unscrew the separator unit from the mounting brackets.
2 Disconnect the hoses and power cable if necessary.
3 Lift the unit.
Refer to the manufacturer’s documentation for safe lifting instructions.
4 Replace the rubber isolators.
5 Remount the separator.
6 Connect the power cable and hoses if necessary.

DBAF386084- 4 - 11
4. Lubricating oil system Maintenance Manual for Auxiliaries

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4 - 12 DBAF386084-
 Maintenance Manual for Auxiliaries 4. Lubricating oil system

Maintaining the VFD

GUID-7078178B-2AFB-4453-A310-34F238698872

This inspection of the VFD (Variable Frequency Drive) should be done every 6 months to 2 years, depending on
the operating conditions.

Component
Unit: Oil mist separator QBF0_1 Type: 100
Component: Variable frequency drive B001 Manufacturer: Vacon

Work Information
JobID: wca3420
Type of job: Planned maintenance
Interval: 6 Months Service personnel: Mechanical, 1 / Unit
Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING - ELECTRICITY
Risk of electric shock. Charged capacitors in the VFD may cause electrical
shock. Wait 5 minutes before opening the unit.

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Check the input and output terminals and control I/O terminals.
2 Check the operation of the cooling fan.
3 Check the heat sink for dust.
Clean if necessary.
4 Check the tightening torque of the terminals.

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4 - 14 DBAF386084-
 Maintenance Manual for Auxiliaries 4. Lubricating oil system

Replacing the VFD main fan

GUID-21CECCA4-D4CD-474F-9850-BCB18BFCBC32

The main fan for the VFD (Variable Frequency Drive) should be replaced every 6 to 10 years, depending on the
operating conditions.

Component
Unit: Oil mist separator QBF0_1 Type: 100
Component: Variable frequency drive B001 Manufacturer: Vacon

Work Information
JobID: wca3421
Type of job: Planned maintenance
Interval: 6 Years Service personnel: Mechanical, 1 / Unit
Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING - ELECTRICITY
Risk of electric shock. Charged capacitors in the VFD may cause electrical
shock. Wait 5 minutes before opening the unit.

Required spareparts

Qty Description
1 VFD main fan

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Replace the main fan of the VFD.

DBAF386084- 4 - 15
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4 - 16 DBAF386084-
 Maintenance Manual for Auxiliaries 4. Lubricating oil system

Replacing the VFD real time clock battery

GUID-A4C394BA-5FC1-4091-9ECA-6E75D13B50BC

Component
Unit: Oil mist separator QBF0_1 Type: 100
Component: Variable frequency drive B001 Manufacturer: Vacon

Work Information
JobID: wca3422
Type of job: Planned maintenance
Interval: 10 Years Service personnel: Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING - ELECTRICITY
Risk of electric shock. Charged capacitors in the VFD may cause electrical
shock. Wait 5 minutes before opening the unit.

Required spareparts

Qty Description
1 RTC (Real Time Clock) battery

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Replace the battery of the RTC.

DBAF386084- 4 - 17
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4 - 18 DBAF386084-
 Maintenance Manual for Auxiliaries 5. Compressed air system

Compressed air system

Content
Compressed air system maintenance........................................................................................................... 5 - 2
Instrument air unit.......................................................................................................................................... 5 - 3
Starting air unit............................................................................................................................................ 5 - 36
Starting air bottle......................................................................................................................................... 5 - 48

DBAF386084- 5-1
5. Compressed air system Maintenance Manual for Auxiliaries

Compressed air system maintenance GUID-C162177A-F6A4-49F4-91EB-D92B58A3D079

The compressed air system supplies both high-pressure air for starting the engine and
instrument air for pneumatic equipment. The engine uses control air from the starting air
system for important control and safety functions. The air vessels provide a buffer for
compressed air, but if the compressed air supply to the engine or some essential auxiliaries
needs to be cut off or if a sufficient air pressure cannot be guaranteed, the engine has to be
stopped. Instrument air is used by various equipment throughout the plant, and an
interruption in the instrument air supply may therefore prevent the operation of many
auxiliary systems and plant support functions. This shall be considered when planning the
compressed air system maintenance.

The use of several parallel air compressors provides backup capacity and may enable a
single compressor to be taken out of use for maintenance without harming the overall plant
operability. In addition, an interconnection line with a pressure reducer between the starting
air and instrument air systems enables use of the starting air compressor unit as a backup
source of instrument air in exceptional situations. Due to the difference in air quality, this
instrument air backup line shall be regarded only as an emergency backup and shall not be
used for long periods. A single starting air vessel can be isolated for maintenance if the air
storage capacity of the vessels remaining in use is sufficient for reliable plant operation.

The high pressure in the compressed air system requires proper precautions in
maintenance situations to prevent personal injury.

WARNING
Content under pressure. Before starting any maintenance work or opening any
part of the compressed air system, make sure that the system is not
pressurized. If a part of the system is isolated for maintenance, the related shut-
off valves must be locked in the closed position to prevent accidental opening.

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 Maintenance Manual for Auxiliaries 5. Compressed air system

Instrument air unit

Content
Air tank
Inspecting the compressed air vessel.................................................................................................... 5 - 5
Observe the applicable national regulations for pressure vessel inspections.
Compressor
Tightening the connections.................................................................................................................... 5 - 7
Lubricating the motor bearings.............................................................................................................. 5 - 9
Lubricate the electric motor bearing when required.
Maintaining the compressor................................................................................................................. 5 - 11
Replace the oil every 1500 operating hours or every second year, whichever occurs first.
Maintaining the compressor................................................................................................................. 5 - 13
Testing the compressor........................................................................................................................5 - 15
These tests are to done as required by local and national regulations and at least once a year.
Maintaining the compressor................................................................................................................. 5 - 17
Replacing the motor bearings.............................................................................................................. 5 - 19
Replacing the compressor air end....................................................................................................... 5 - 21
Dryer
Checking the condensate drain............................................................................................................5 - 23
Maintaining the refrigeration dryer........................................................................................................5 - 25
Maintaining the refrigeration dryer........................................................................................................5 - 27
Filter
Checking the oil content of the filter.....................................................................................................5 - 29
The oil indicator is an optional component.
Replacing the filter element and cartridge............................................................................................5 - 31
The filter element needs to be changed every 3 months, when the residual oil content becomes worse,
the differential pressure is over 50 mbar with 0–4 bar operating pressure, or the differential pressure is
over 350 mbar with 5–16 bar operating pressure. The filter cartridge needs to be replaced every 6
months or when the residual oil content becomes worse.
Maintaining the filter............................................................................................................................. 5 - 33
Drain valve
Maintaining the condensate drain valve............................................................................................... 5 - 35

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Inspecting the compressed air vessel

GUID-D6380E68-FC68-486B-930A-EAECE35311AE

Observe the applicable national regulations for pressure vessel inspections.

Component
Unit: Instrument air unit TCA901 Type: Pressure vessel
Component: Air tank B01 Manufacturer: Tamrotor

Work Information
JobID: wca3167
Type of job: Inspection
Interval: As required Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
As required Seals for inspection openings

Procedure
1 Inspect the compressed air vessel according to national regulations.
2 Replace the inspection opening seals after any internal inspections.

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Tightening the connections

GUID-FDC2A1FE-89B2-4355-B1EF-C98D59AD3EF7

Component
Unit: Instrument air unit TCA901 Type: WD 7-22
Component: Compressor D01 Manufacturer: Gardner Denver

Work Information
JobID: wca3253
Type of job: Planned maintenance
Interval: 200 Hours Service personnel: Mechanical, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

Required tools

Code Description
Torque wrench

Procedure
1 Check the tightness of the electrical connections.
Refer to the manufacturer’s documentation for detailed information and torques.
Tighten the connections if necessary.
2 Check the tightness of all other connections and screws.
Tighten if necessary.

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Lubricating the motor bearings

GUID-83AB2F7E-3C82-4CB1-B799-D5364A3469DB

Lubricate the electric motor bearing when required.

Component
Unit: Instrument air unit TCA901 Type: WD 7-22
Component: Compressor D01 Manufacturer: Gardner Denver

Work Information
JobID: wca3262
Type of job: Lubrication
Interval: As required Service personnel: Mechanical, 1 / Unit

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

Procedure
● Lubricate the electric motor bearings.
For the amount and type of grease, refer to the motor identification plate or the motor
manual.

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Maintaining the compressor

GUID-2CB67498-1953-4A36-8A75-347559ADB024

Replace the oil every 1500 operating hours or every second year, whichever occurs first.

Component
Unit: Instrument air unit TCA901 Type: WD 7-22 air-cooled
Component: Compressor D01 Manufacturer: Gardner Denver

Work Information
JobID: wca3254
Type of job: Planned maintenance
Interval: 1500 Hours Service personnel: Mechanical, 1 / Unit
Electrician, 1 / Unit

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

WARNING
Hot liquids. Wear protective equipment.

Required spareparts

Qty Description
1 Oil filter

1 Air filter

As required Gaskets and O-rings for the air cooler

Consumables

Description Maker Amount

Container for used oil

Gardner Denver AEON lubricant Gardner Denver

Refer to the manufacturer’s documentation for detailed instructions. Correct all defects.

Procedure
1 Stop the compressor operation.
a Stop the compressor and make sure that there is no pressure in the receiver.
The blow-down function empties the receiver after stopping; wait for 2 minutes.
b Switch off the compressor with the main switch and make sure the compressor can not
be started unintentionally.
c Close the shut-off valve between the compressor and the compressed air system.
d Open the pressure relief valve cap 4 to 5 turns to release the pressure.
2 Change the oil.
Refer to the manufacturer’s documentation or contact Gardner Denver for the
recommended type of AEON lubricant. Do not mix oil types.

DBAF386084- 5 - 11
5. Compressed air system Maintenance Manual for Auxiliaries

3 Replace the oil filter.

4 Replace the air filter.
Do not reuse the filter cartridge.
5 Clean the air cooler externally.
6 Inspect the air end and the motor pulley.
7 Inspect the contactor points in the electrical system.

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Maintaining the compressor

GUID-CB52253C-0953-4339-9A4F-D6F491124F23

Component
Unit: Instrument air unit TCA901 Type: WD 7-22
Component: Compressor D01 Manufacturer: Gardner Denver

Work Information
JobID: wca3255
Type of job: Planned maintenance
Interval: 3000 Hours Service personnel: Mechanical, 1 / Unit

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

WARNING
Hot liquids. Wear protective equipment.

Required spareparts

Qty Description
1 Oil separator cartridge

As required Belts

1 Inlet valve

1 Discharge valve

As required Electric box filters

Refer to the manufacturer’s documentation for detailed instructions. Correct all defects.

Procedure
1 Stop the compressor operation.
a Stop the compressor and make sure that there is no pressure in the receiver.
The blow-down function empties the receiver after stopping; wait for 2 minutes.
b Switch off the compressor with the main switch and make sure the compressor can not
be started unintentionally.
c Close the shut-off valve between the compressor and the compressed air system.
d Open the pressure relief valve cap 4 to 5 turns to release the pressure.
2 Replace the oil separator cartridge.
3 Replace the belts.
4 Replace the inlet and discharge valve.
5 Replace the electric box filters.

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Testing the compressor

GUID-AE948017-C20F-43A7-ADA4-6C92AE619ADC

These tests are to done as required by local and national regulations and at least once a year.

Component
Unit: Instrument air unit TCA901 Type: WD 7-22 air-cooled
Component: Compressor D01 Manufacturer: Gardner Denver

Work Information
JobID: wca3256
Type of job: Planned maintenance
Interval: As required Service personnel: Mechanical, 1 / Unit
1 Years

Prerequisites
Required spareparts

Qty Description
As required Pressure relief valve

Required tools

Code Description
Hot air gun

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Test the temperature alarm and automatic shutdown for the air-cooled compressor.
Contact Gardner Denver if the alarms or automatic shutdown do not function.
The alarms may have a short delay time (for example 30 seconds).
a Test the air outlet temperature alarm and shutdown.
Use a hot air gun to heat the sensor until the alarm is reached at 65 °C. Continue to heat
the sensor until shutdown is reached at 70 °C.
b Test the internal temperature alarm and shutdown.
Block the cooler air flow or open the service doors until the internal running temperature
reaches the alarm temperature of 110 °C. Continue until the shutdown point is reached
at 115 °C.
2 Test the pressure relief valve.
The test must be done by qualified personnel.
a Stop the compressor and remove the pressure relief valve.

WARNING
Never operate the compressor without the pressure relief valve. Secure the
compressor from automatic restart before removing the valve.

b Install the pressure relief valve in a separate pressurized air line for testing.
c Test the operation of the valve by turning the cap counter-clockwise 1 to 2 turns.
d Install the pressure relief valve on the air compressor.
e Tighten the pressure relief valve cap properly in order to prevent damage caused by
vibration.

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Maintaining the compressor

GUID-E6F46D6B-B50A-4107-BC84-4D442B53BEA5

Component
Unit: Instrument air unit TCA901 Type: WD 7-22
Component: Compressor D01 Manufacturer: Gardner Denver

Work Information
JobID: wca3257
Type of job: Planned maintenance
Interval: 9000 Hours Service personnel: Machinist, 1 / Unit

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Solenoid valve for load function

1 Oil temperature thermostat element

As required Oil and air hoses

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Stop the compressor operation.
a Stop the compressor and make sure that there is no pressure in the receiver.
The blow-down function empties the receiver after stopping; wait for 2 minutes.
b Switch off the compressor with the main switch and make sure the compressor can not
be started unintentionally.
2 Replace the solenoid valve for the load function.
3 Replace the oil thermostat element.
4 Replace the oil and air hoses.

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Replacing the motor bearings

GUID-59D7FCB3-F0BB-4B7C-A34C-06E8316DFB4C

Component
Unit: Instrument air unit TCA901 Type: WD 7-22
Component: Compressor D01 Manufacturer: Gardner Denver

Work Information
JobID: wca3258
Type of job: Planned maintenance
Interval: 20000 Hours Service personnel: Mechanical, 1 / Unit

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

Required spareparts

Qty Description
As required Motor bearings

Refer to the manufacturer’s documentation for additional information.

Procedure
● Replace the motor bearings.

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Replacing the compressor air end

GUID-0F5785F9-AAB1-4593-B7C3-4F80B69C565D

Component
Unit: Instrument air unit TCA901 Type: WD 7-22
Component: Compressor D01 Manufacturer: Gardner Denver

Work Information
JobID: wca3259
Type of job: Replacement
Interval: 30000 Hours Service personnel: Mechanical, 1 / Unit

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Complete air end (factory reconditioned)

Procedure
● Replace the air end with a factory reconditioned unit.

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Checking the condensate drain

GUID-346591B0-9390-4BC0-AA50-9C67D31A6BEE

Component
Unit: Instrument air unit TCA901 Type: GDD4S - GDD100S
Component: Dryer D02 Manufacturer: Gardner Denver

Work Information
JobID: wca4141
Type of job: Check job
Interval: 1 Weeks Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
● Check the dryer drain for correct operation.

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Maintaining the refrigeration dryer

GUID-0DDF7FDE-51E9-435B-8249-F968664254A3

Component
Unit: Instrument air unit TCA901 Type: GDD4S - GDD100S
Component: Dryer D02 Manufacturer: Gardner Denver

Work Information
JobID: wca4142
Type of job: Planned maintenance
Interval: 4 Months Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
● Clean the condenser fins.
● Check the electrical absorption.

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Maintaining the refrigeration dryer

GUID-EF205F14-76B2-4C99-B6EC-54522B9466F2

Component
Unit: Instrument air unit TCA901 Type: GDD4S - GDD100S
Component: Dryer D02 Manufacturer: Gardner Denver

Work Information
JobID: wca4143
Type of job: Planned maintenance
Interval: 1 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
As required Prefilter elements

As required Postfilter elements

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Completely disassemble the drain and clean all of its components.
2 Maintain the drain.
3 Replace the pre- and post-filter elements.
4 Assemble the drain and check the function.

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Checking the oil content of the filter

GUID-B22D1FFA-E613-4502-AF32-47F0A6640CCA

The oil indicator is an optional component.

Component
Unit: Instrument air unit TCA901 Type: FCA20-190
Component: Filter F01 Manufacturer: FST

Work Information
JobID: wca3723
Type of job: Check job
Interval: 1 Months Service personnel: Mechanical, 1 / Component

Procedure
● Check the residual oil content of compressed air from the oil indicator (optional).

DBAF386084- 5 - 29
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Replacing the filter element and cartridge

GUID-A79AB3E6-EE55-4292-87DE-93ED0A21AA2B

The filter element needs to be changed every 3 months, when the residual oil content becomes worse, the
differential pressure is over 50 mbar with 0–4 bar operating pressure, or the differential pressure is over 350
mbar with 5–16 bar operating pressure. The filter cartridge needs to be replaced every 6 months or when the
residual oil content becomes worse.

Component
Unit: Instrument air unit TCA901 Type: FCA20-190
Component: Filter F01 Manufacturer: FST

Work Information
JobID: wca3724
Type of job: Replacement
Interval: 3 Months Service personnel: Mechanical, 1 / Component
6 Months
As required

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Filter element

1 Filter cartridge

As required O-ring

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Open the filter housing.
a Depressurize the filter.
b Remove the condensate line from the filter if installed.
Disassemble the condensate drain if it obstructs the access to the filter bowl.
Externally installed condensate drains are supplied with a shut-off valve and a screwed
joint with a cap nut. Open the connection between the shut-off valve and the
condensate drain by loosening the cap nut.
c Open the depressurised filter housing by unscrewing the filter bowl anticlockwise from
the upper filter part.
If compressed air flows out of the thread, the opening procedure must be immediately
interrupted and the filter needs to be depressurised.
Usually, the filter bowl can be removed by hand. In the event of larger filters or filters that
have been operated for some time, it may be necessary to use a conventional spanner
wrench. If the filter bowl cannot be opened by these means, please first check whether
the filter is still under pressure.
2 Replace the filter element.
a Slightly turn and pull the old filter element to remove it from the upper filter part.
b Clean the filter holder and the threads of the housing parts.
c Replace the O-ring of the filter housing if necessary.

DBAF386084- 5 - 31
5. Compressed air system Maintenance Manual for Auxiliaries

Undamaged O-rings can be used again.

d Lubricate the filter holder and the threads of the housing parts.
e Insert the filter element by slightly turning and pushing it into the filter holder.
3 Close the filter housing.
a Close the filter housing by screwing the filter bowl clockwise into the upper filter part.
Make sure that the filter element remains securely fixed in the filter holder.
Only turn until the two housing parts block noticeably when running onto the end stop.
There should be no gap between the two housing parts through which the thread of the
filter bowl can be seen. Only turn until reaching the end stop position. Further turning
does not increase the tightness of the housing.
b Mount all the parts that have been removed.
c Check that all the connections are securely fixed.

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Maintaining the filter

GUID-C31D4770-5100-43AF-AD1E-17D3B07F3894

Component
Unit: Instrument air unit TCA901 Type: FCA20-190
Component: Filter F01 Manufacturer: FST

Work Information
JobID: wca3725
Type of job: Planned maintenance
Interval: As required Service personnel: Mechanical, 1 / Component

Prerequisites
.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
As required Oil indicator tube

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Replace the oil indicator (optional) tube.
2 Clean the water separator insert and filter bowl.

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Maintaining the condensate drain valve

GUID-FAC7BD85-E056-49B5-B632-DF597A082871

Component
Unit: Instrument air unit TCA901 Type: COMBO-D-LUX
Component: Drain valve S01, S02 Manufacturer: Jorc

Work Information
JobID: wca3853
Type of job: Planned maintenance
Interval: As required Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Service kit and instructions

Required tools

Code Description
23 mm wrench

23 mm torque wrench

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Close the condensate supply ball valve.
2 Press the test button.
This will empty any condensate from the unit and will depressurize the valve.
3 Switch off the electrical supply.
4 Unscrew the valve top nut.
5 Remove the connector, coil, and timer assembly from the valve shaft.
6 Unscrew the valve shaft using a 23 mm wrench.
Do not use the valve shaft as a lever.
7 Clean and inspect the valve parts, body, and shaft.
Replace any damaged parts using the service kit.
8 Reassemble the inner parts and shaft.
9 Screw the shaft assembly back onto the valve body using a 23 mm torque wrench.
The maximum torque is 10 Nm.
10 Reassemble the coil, connector, and timer assembly onto the valve.
11 Screw on the top nut.
Make sure the gaskets are placed properly to ensure IP65 rating.
12 Switch on the electrical supply.
13 Slowly open the ball valve to restore the normal system pressure.
14 Press the test button to check the valve operation.

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5. Compressed air system Maintenance Manual for Auxiliaries

Starting air unit

Content
Compressor
Changing the oil....................................................................................................................................5 - 37
Replacing the air filter...........................................................................................................................5 - 39
Maintaining the compressor................................................................................................................. 5 - 41
Maintaining the compressor................................................................................................................. 5 - 43
Overhauling the compressor................................................................................................................ 5 - 45
Overhauling the compressor................................................................................................................ 5 - 47

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Changing the oil

GUID-9B19DC41-61AD-4382-9CEB-27D81692F3B4

Component
Unit: Starting air unit TSA901 Type: X-range
Component: Compressor D001, D002 Manufacturer: Sperre

Work Information
JobID: wca4893
Type of job: Planned maintenance
Interval: 250 Hours (Only after first start or major overhaul) Service personnel: Mechanical, 1 / Unit
6 Months (Only after first start or major overhaul)

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Service kit A

Consumables

Description Maker Amount

Fully synthetic, ISO 100 grade piston compressor oil

Refer to the manufacturer's manual for detailed instructions and drawings. Correct all
defects.

Procedure
1 Drain the oil.
a Remove the LP cooler.
b Place a tray below the draining plug and remove the draining plug.
c Unscrew the six screws and remove the crankcase cover.
d Unscrew the filling plug.
e Drain the oil from the compressor.
Dispose of the oil according to local regulations.
2 Clean the magnet plug (types XA120–XA300 only).
3 Replace the oil filter (types XA120–XA300 only).
a Unscrew the old oil filter.
b Mount the new oil filter.
4 Mount the draining plug.
5 Assemble the crankcase cover with the six screws.
6 Fill with new oil.
a Fill with fully synthetic, ISO 100 grade piston compressor oil.

DBAF386084- 5 - 37
5. Compressed air system Maintenance Manual for Auxiliaries

b Check the oil level on the X-control and sight glass.

Add more oil if needed.
c Mount the filling plug.
7 Replace the air filter.

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Replacing the air filter

GUID-5CE654FB-E2F5-490A-B848-456B7353C8B0

Component
Unit: Starting air unit TSA901 Type: X-range
Component: Compressor D001, D002 Manufacturer: Sperre

Work Information
JobID: wca4894
Type of job: Planned maintenance
Interval: 750 Hours Service personnel: Mechanical, 1 / Unit
9 Months

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Service kit A2

Refer to the manufacturer's manual for detailed instructions and drawings. Correct all
defects.

Procedure
1 Unscrew the two screws.
2 Replace the air filter unit.
3 Mount the two screws.

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Maintaining the compressor

GUID-DC447ABA-7DAE-4CC8-9E01-EFBE8667F5B3

Component
Unit: Starting air unit TSA901 Type: X-range
Component: Compressor D001, D002 Manufacturer: Sperre

Work Information
JobID: wca2572
Type of job: Planned maintenance
Interval: 1500 Hours Service personnel: Mechanical, 1 / Unit
18 Months

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Service kit B

Consumables

Description Maker Amount

Fully synthetic, ISO 100 grade piston compressor oil

Refer to the manufacturer's manual for detailed instructions and drawings. Correct all
defects.

Procedure
1 Drain the oil.
a Remove the LP cooler.
b Place a tray below the draining plug and remove the draining plug.
c Unscrew the six screws and remove the crankcase cover.
d Unscrew the filling plug.
e Drain the oil from the compressor.
Dispose of the oil according to local regulations.
2 Inspect and clean the crankcase.
Use lint-free cleaning cloths.
3 Clean the magnet plug (types XA120–XA300 only).
4 Replace the oil filter (types XA120–XA300 only).
a Unscrew the old oil filter.
b Mount the new oil filter.
5 Mount the draining plug.
6 Assemble the crankcase cover with the six screws.

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5. Compressed air system Maintenance Manual for Auxiliaries

7 Fill with new oil.

a Fill with fully synthetic, type ISO 100 grade piston compressor oil.
b Check the oil level on the X-control and sight glass.
Add more oil if needed.
c Mount the filling plug.
8 Replace the air filter.
9 Inspect LP and HP valves.
Replace the valves(s) if there are carbon deposits.
The flat gaskets must always be replaced. Clean the adjacent surfaces before fitting the
new gaskets.

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Maintaining the compressor

GUID-B7493038-2999-4373-AFC0-2F3070F97D1E

Component
Unit: Starting air unit TSA901 Type: X-range
Component: Compressor D001, D002 Manufacturer: Sperre

Work Information
JobID: wca2573
Type of job: Planned maintenance
Interval: 3000 Hours Service personnel: Mechanical, 1 / Unit
3 Years

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Service kit C

Refer to the manufacturer's manual for detailed instructions and drawings.

Correct all defects.

Procedure
1 Replace the LP valve.
The copper gaskets and O-ring must always be replaced. Clean the adjacent surfaces
before the new copper gaskets are fitted.
2 Replace the LP valve.
The flat gaskets must always be replaced. Clean the adjacent surfaces before fitting the
new gaskets.
3 Inspect the LP and HP gudgeon bearings, and pins.
4 Inspect the LP and HP crank bearing.
Replace the complete bearing if the parts are worn or damaged.
5 Inspect the LP piston and piston rings.
a Inspect the oil ring and the 2 piston rings.
Replace the rings if the wear limits are exceeded.
b Inspect the piston groove.
c Inspect for wear on the outside of the piston.
Replace the piston if necessary.
6 Inspect the HP piston and piston rings.
a Inspect the oil ring and the 3 piston rings.
Replace the rings if the wear limits are exceeded.
b Inspect the piston groove.
c Inspect for wear on the outside of the piston.

DBAF386084- 5 - 43
5. Compressed air system Maintenance Manual for Auxiliaries

Replace the piston and rings if needed.

7 Inspect the LP and HP air coolers.
Replace the cooler(s) if there are particles in the internal air flow area.

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 Maintenance Manual for Auxiliaries 5. Compressed air system

Overhauling the compressor

GUID-B62B880A-970A-4C1F-B7BF-DE6349A7CA72

Component
Unit: Starting air unit TSA901 Type: X-range
Component: Compressor D001, D002 Manufacturer: Sperre

Work Information
JobID: wca2574
Type of job: Planned maintenance
Interval: 6000 Hours Service personnel: Mechanical, 1 / Unit
6 Years

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Service kit D

Required tools

Code Description
Heat gun for removing the bearing ring

Refer to the manufacturer's manual for detailed instructions and drawings.

Correct all defects.

Procedure
1 Replace the LP and HP gudgeon bearing and pin.
2 Replace the crank bearing.
3 Replace the fan side bearing.

NOTE
Heat the inner bearing ring with a heat gun when dismantling and assembling on
the shaft.

4 Replace the non return valve in the cyclone separator.

a Replace the non return valve and the copper ring.
b Inspect the cyclone tube for corrosion.
Replace if necessary.
5 Replace the HP drain / upload valve and coil.

DBAF386084- 5 - 45
5. Compressed air system Maintenance Manual for Auxiliaries

6 Inspect the flexible tubes for the air coolers.

7 Inspect and test the HP safety valve.
a Inspect the safety valve for dirt.
Clean if needed. Replace the valve if the inlet is clogged.
b Test the safety valve.
The valve should blow at maximum working pressure + 10%. Replace if not functioning
correctly.

5 - 46 DBAF386084-
 Maintenance Manual for Auxiliaries 5. Compressed air system

Overhauling the compressor

GUID-916CC266-897E-4090-A54A-0E90764E83FC

Component
Unit: Starting air unit TSA901 Type: X-range
Component: Compressor D001, D002 Manufacturer: Sperre

Work Information
JobID: wca2575
Type of job: Planned maintenance
Interval: 12000 Hours Service personnel: Mechanical, 1 / Unit
12 Years

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Service kit E

Refer to the manufacturer's manual for detailed instructions and drawings. Correct all
defects.

Procedure
1 Inspect the LP safety valve.
a Clean if dirty.
b Replace the valve if the inlet is clogged.
2 Replace the LP piston rings.
a Replace the two piston rings.
b Replace the oil ring.
c Inspect the piston for wear.
Replace if necessary.
3 Replace the HP piston rings.
a Replace the three piston rings.
b Replace the oil ring.
c Inspect the piston for wear.
Replace if necessary.
4 Replace the bearing on the motor side.

NOTE
Heat the bearing with a heat gun when dismantling and assembling on the shaft.

DBAF386084- 5 - 47
5. Compressed air system Maintenance Manual for Auxiliaries

Starting air bottle

Content
Air vessel
Inspecting the air vessel....................................................................................................................... 5 - 49
An internal inspection is done at least every four years.
Inspecting the air vessel....................................................................................................................... 5 - 51
A full inspection is done at least every eight years.
Drain valve
Maintaining the Bekomat condensate drain.........................................................................................5 - 53

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 Maintenance Manual for Auxiliaries 5. Compressed air system

Inspecting the air vessel

GUID-2BD25F10-5CB6-416A-842B-A7B14CC02E75

An internal inspection is done at least every four years.

Component
Unit: Starting air bottle TSB901, TSB902 Type: 125L - 4800L
Component: Air vessel Manufacturer: Uwira

Work Information
JobID: wca0206
Type of job: Inspection
Interval: 4 Years Service personnel: O&M Supervisor, 1 / Component

Prerequisites

NOTE
For specific spare parts numbers, refer to the component drawings. Use only
original spare parts.

Remove the valve head and flanges and carefully inspect the inside of the vessel.

Procedure
1 Secure the vessel from the compressed air source.
2 Drain the vessel of compressed air.

WARNING
Improper release of compressed air can be hazardous. Only personnel who
have been trained in the correct procedures should drain this vessel.

3 Remove the valve head and flanges.

This provides access for the internal inspection.
4 Inspect the inner surface of the vessel.
5 Carefully make a visual inspection of all welded joints.
Additional inspections can be made by ultrasonic, dye penetrant, or X-ray testing.
6 Install the valve head and flanges.
Use new gaskets for all flange connections.

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5. Compressed air system Maintenance Manual for Auxiliaries

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 Maintenance Manual for Auxiliaries 5. Compressed air system

Inspecting the air vessel

GUID-B1A3F7A4-C6FD-4454-87BA-DF17CABE531E

A full inspection is done at least every eight years.

Component
Unit: Starting air bottle TSB901, TSB902 Type: 125L - 4800L
Component: Air vessel Manufacturer: Uwira

Work Information
JobID: wca0207
Type of job: Inspection
Interval: 8 Years Service personnel: O&M Supervisor, 1 / Component

Prerequisites

NOTE
For specific spare parts numbers, refer to the component drawings. Use only
original spare parts.

Perform a pressure test, inspect the inside of the vessel, and check the equipment and
gauges.

Procedure
1 Secure the vessel from the compressed air source.
2 Drain the vessel of compressed air.

WARNING
Improper release of compressed air can be hazardous. Only personnel who
have been trained in the correct procedures should drain this vessel.

3 Perform a hydraulic pressure test using at least 1,43 times the maximum working pressure.
Follow the recommended hydraulic test procedures for this test.
4 Inspect the inside of the vessel.
a Remove the valve head and flanges.
This provides access for the internal inspection.
b Inspect the inner surface of the vessel.
c Carefully make a visual inspection of all welded joints.
Additional inspections can be made by ultrasonic, dye penetrant, or X-ray testing.
d Install the valve head and flanges.
Use new gaskets for all flange connections.
5 Check the condition of the tank supports and possible additional support construction.
6 Perform an operation test.
Check that all equipment and gauges are working properly.

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Maintaining the Bekomat condensate drain

GUID-9BF953BE-458B-4EC8-82EB-5D20F4024756

Component
Unit: Starting air bottle TSB901, TSB902 Type: Bekomat 12
Component: Drain valve Manufacturer: Bekomat

Work Information
JobID: wca3095
Type of job: Planned maintenance
Interval: 1 Years Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
1 Maintenance kit (wearing parts)

Refer to the manufacturers documentation for additional information. Correct all defects.

Procedure
● Clean the housing and valve.
● Replace the wearing parts.
● Perform a functional test.
a Press the TEST button for 2 seconds.
The valve opens and condensate is discharged.
● Perform an alarm test.
a Shut off the condensate inlet.
b Press the TEST button for 1 minute.
Check that the red LED flashes after 1 minute.
c Check that an alarm signal has been sent.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Cooling water system

Content
Cooling water system maintenance.............................................................................................................. 6 - 2
Radiator......................................................................................................................................................... 6 - 3
Electric preheating unit................................................................................................................................ 6 - 12
Expansion vessel......................................................................................................................................... 6 - 20

DBAF386084- 6-1
6. Cooling water system Maintenance Manual for Auxiliaries

Cooling water system maintenance GUID-DBC8BF96-25BA-4894-8222-96BBBF4D50AB

The cooling water system is vital to the engine operation. The circulation of cooling water
must never be interrupted when the engine is running. Major maintenance work in the
engine cooling system therefore requires that the engine be stopped. As the cooling water
circulation system is engine-specific, any other engines in the plant can be kept in
operation. To minimize the downtime, it is recommended to perform the scheduled
maintenance of the engine cooling water system in connection with the engine maintenance
stops when possible.

Careful planning of the maintenance activities may enable some maintenance tasks to be
performed without stopping the engine.
● Supporting units that are not involved in the main water circulation – such as the
maintenance water tank – can be taken out of use without any direct effect on the
engine operability.
● The preheating unit is not in operation when the engine is running, and minor
maintenance of this unit can thus be done without stopping the engine.
● Single radiators can be taken out of use if the radiators remaining in operation provide
sufficient cooling capacity considering the current heat load and the ambient conditions.
Disabling a radiator for maintenance includes turning off the safety switch and closing
the inlet and outlet valves.
● Heat recovery units can be bypassed provided that the backup coolers are able to meet
the increased load.

If the engine cooling system needs to be drained, the treated cooling water can be stored in
the maintenance water tank and pumped back to the engine cooling system for reuse once
the maintenance work is finished. A smaller part of the system can be isolated for draining
by closing the related shut-off valves if this is seen practical.

The cooling water circuits have to be vented to remove any air when putting the cooling
system back in operation after the maintenance.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Radiator

Content
Radiator
Maintaining the radiator..........................................................................................................................6 - 5
Frequency converter
Maintaining the VFD............................................................................................................................... 6 - 7
This inspection of the VFD (Variable Frequency Drive) should be done every 6 months to 2 years,
depending on the operating conditions.
Replacing the VFD main fan................................................................................................................... 6 - 9
The main fan for the VFD (Variable Frequency Drive) should be replaced every 6 to 10 years, depending
on the operating conditions.
Replacing the VFD real time clock battery........................................................................................... 6 - 11

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Maintaining the radiator

GUID-D6A0CBFA-6AFA-405B-A0C8-988CA03678E0

Component
Unit: Radiator VCA0_1, VCA0_2, VCA0_3 Type: FBLG
Component: Radiator Manufacturer: Alfa Laval

Work Information
JobID: wca0132 Work time: 2 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 1 Months Service personnel: Mechanical, 1 / Component

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Check the condition of the motors and fans.
a Check for noise or vibrations.
This may be caused by a damaged bearing or by a damaged fan.
b If the bearings make a rustling noise, either the electric motor or its bearings shall be
replaced.
c Lubricate the bearings if needed.
The normal lubrication period is 15 000 – 30 000 hours. The amount and type of grease
is given in the manufacturer's instructions. Before using grease of any other type, check
the compatibility.
Lubricate the bearings while the motor is in operation.

CAUTION
Do not over grease the bearings.

d Check the condition of the electrical insulation.

e Check the bolts holding the drive arrangement.
f Check the bolts for the radiators and fans.
Other components (blade, motor bracket, fan guard) do not require any maintenance.
2 Check the condition of the heat transfer section and clean, if necessary.

NOTE
The heat transfer section needs cleaning only if over 30% of fin space is
blocked-up or if the cooling capacity is remarkably reduced.

CAUTION
Ensure that the cleaning does not damage the heat transfer section.

a Check for leaks.

b Remove dust gathered on the fins of the heat transfer section.
Dust gathered on the fins of the heat transfer section can be removed with a vacuum
cleaner on the side of incoming air, or blown off by means of compressed air from the
side of the outgoing air.
c Wash the fins with water, if they are still dusty.
Wash the fins with running fresh water on the discharge air side if necessary.
If it is necessary to wash from below (inlet side), dust and other particles must be
removed with a vacuum cleaner before washing.

DBAF386084- 6-5
6. Cooling water system Maintenance Manual for Auxiliaries

Do not use too strong water jet; the maximum pressure is 2 bar. Direct the water parallel
to the fins in order not to bend them.
d Clean with a detergent, if the other cleaning steps are not sufficient.

CAUTION
Don’t use alkaline detergents or acids. The detergent has to be suitable for
aluminium, copper and galvanized steel. See manufacturer's recommendations.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Maintaining the VFD

GUID-7078178B-2AFB-4453-A310-34F238698872

This inspection of the VFD (Variable Frequency Drive) should be done every 6 months to 2 years, depending on
the operating conditions.

Component
Unit: Radiator VCA0_1, VCA0_2, VCA0_3 Type: 100
Component: Frequency converter Manufacturer: Vacon

Work Information
JobID: wca3420
Type of job: Planned maintenance
Interval: 6 Months Service personnel: Mechanical, 1 / Unit
Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING - ELECTRICITY
Risk of electric shock. Charged capacitors in the VFD may cause electrical
shock. Wait 5 minutes before opening the unit.

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Check the input and output terminals and control I/O terminals.
2 Check the operation of the cooling fan.
3 Check the heat sink for dust.
Clean if necessary.
4 Check the tightening torque of the terminals.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Replacing the VFD main fan

GUID-21CECCA4-D4CD-474F-9850-BCB18BFCBC32

The main fan for the VFD (Variable Frequency Drive) should be replaced every 6 to 10 years, depending on the
operating conditions.

Component
Unit: Radiator VCA0_1, VCA0_2, VCA0_3 Type: 100
Component: Frequency converter Manufacturer: Vacon

Work Information
JobID: wca3421
Type of job: Planned maintenance
Interval: 6 Years Service personnel: Mechanical, 1 / Unit
Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING - ELECTRICITY
Risk of electric shock. Charged capacitors in the VFD may cause electrical
shock. Wait 5 minutes before opening the unit.

Required spareparts

Qty Description
1 VFD main fan

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Replace the main fan of the VFD.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Replacing the VFD real time clock battery

GUID-A4C394BA-5FC1-4091-9ECA-6E75D13B50BC

Component
Unit: Radiator VCA0_1, VCA0_2, VCA0_3 Type: 100
Component: Frequency converter Manufacturer: Vacon

Work Information
JobID: wca3422
Type of job: Planned maintenance
Interval: 10 Years Service personnel: Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

WARNING - ELECTRICITY
Risk of electric shock. Charged capacitors in the VFD may cause electrical
shock. Wait 5 minutes before opening the unit.

Required spareparts

Qty Description
1 RTC (Real Time Clock) battery

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Replace the battery of the RTC.

DBAF386084- 6 - 11
6. Cooling water system Maintenance Manual for Auxiliaries

Electric preheating unit

Content
Electric heater
Checking the electrical connections.................................................................................................... 6 - 13
The electrical connections should be checked during the first scheduled service but no later than 1 year
after start-up.
Circulation pump
Inspecting the circulation pump........................................................................................................... 6 - 15
Safety valve
Testing the safety valve........................................................................................................................ 6 - 17
Automatic air venting valve
Replacing the automatic air vent valve.................................................................................................6 - 19
Replace the air venting valve if it starts to leak.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Checking the electrical connections

GUID-B7E94B02-CF4F-41E9-9B35-42663DE3332A

The electrical connections should be checked during the first scheduled service but no later than 1 year after
start-up.

Component
Unit: Electric preheating unit VDA0_1 Type: Liquid heater
Component: Electric heater B001 Manufacturer: Loval

Work Information
JobID: wca4074
Type of job: Check job
Interval: 1 Years (Only after first start or major overhaul) Service personnel: Electrician, 1 / Component

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

Required tools

Code Description
Torque wrench or screw driver box wrench for 1.5 Nm

Refer to the manufacturer’s documentation for additional information.

Procedure
● Check the electrical connections.
The recommended tightening torque is 1.5 Nm.
Do not overtighten.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Inspecting the circulation pump

GUID-1558B1D8-0AF9-476D-9728-F8002DB43DF0

Component
Unit: Electric preheating unit VDA0_1 Type: T, AT, KL, KN_, N_, KM, L_, AL_,
AKN_, AS_, AE_, AP, K_
Component: Circulation pump D001 Manufacturer: KOLMEKS

Work Information
JobID: wca3532
Type of job: Inspection
Interval: As required Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
As required Gasket set

Inspect the pump for leakage.

Procedure
● Look for leakage from the shaft seal, if detected the pump must be opened and the seal
replaced.
A few drops of leakage per hour is normal.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Testing the safety valve

GUID-5532429D-DC23-4216-9CC5-19EAC2DC6719

Component
Unit: Electric preheating unit VDA0_1 Type: 615, 616, 618
Component: Safety valve V004 Manufacturer: Götze

Work Information
JobID: wca1342 Work time: 1 Hours
Type of job: Test Stop time: 1 Hours
Interval: 1 Years Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
As required Replacement valve

Replace the valve if there are any defects.

Procedure
1 Test that the safety valve opens.
2 Inspect the valve for leakage.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Replacing the automatic air vent valve

GUID-EB8B56DD-C348-4020-9D4E-191482CC884E

Replace the air venting valve if it starts to leak.

Component
Unit: Electric preheating unit VDA0_1 Type: Spirotop
Component: Automatic air venting valve V005 Manufacturer: Spirotech

Work Information
JobID: wca1580
Type of job: Replacement
Interval: As required Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
1 Replacement air venting valve

Replace the automatic vent valve if it starts to leak, or every two years.

Procedure
1 Isolate the system and drain the piping.
2 Remove the valve.
3 Replace the valve with a new valve of the same type.

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6. Cooling water system Maintenance Manual for Auxiliaries

Expansion vessel

Content
Level switch
Maintaining the level switch................................................................................................................. 6 - 21
This maintenance should be done at least once a year, when the tank is out-of-service.

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 Maintenance Manual for Auxiliaries 6. Cooling water system

Maintaining the level switch

GUID-4C050F96-E5B6-43E1-BC9F-74DA6EBBEE3C

This maintenance should be done at least once a year, when the tank is out-of-service.

Component
Unit: Expansion vessel VEA0_1 Type: A, B, AA, BB
Component: Level switch L001 Manufacturer: Besta

Work Information
JobID: wca2029 Work time: 2 Hours
Type of job: Inspection Stop time: 2 Hours
Interval: 1 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING - ELECTRICITY
Cut off power before opening the enclosure cover.

Required spareparts

Qty Description
As required Flange gasket and O-rings

Inspect and clean the level switch.

Procedure
1 Remove the level switch.
a Vent the process vessel to atmosphere. If necessary, lower the liquid level.

WARNING
Follow applicable regulations when venting the tank.

b If the limit switch is fitted to a float chamber, isolate the chamber by closing relevant
valves and vent or drain as applicable.
c Unbolt the connection flange and remove the level switch.
2 Check the float for easy and free movement over its entire travel.
3 Clean the float.
a Remove any sludge or scale deposits.
b Remove any metallic particles adhering to the float magnet.
Use putty or adhesive tape to remove the deposits.
c For floats with a protective bellow (shroud): remove the bellow and clean any deposits
from the inside.
4 If the split steel (cotter) pins need to be replaced, use only stainless steel pins.
5 Test the proper operation of the level switch.
Use an acoustic circuit indicator (buzzer) and move the float between its two stop positions.
6 Mount the level switch.
Replace the flange gasket and O-rings, if necessary.
7 Close the hinged cover.
8 Energize the power supply.

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Maintenance Manual for Auxiliaries 7. Charge air and exhaust gas system

Charge air and exhaust gas system

Content
Charge air and exhaust gas system maintenance.........................................................................................7 - 2
Charge air system..........................................................................................................................................7 - 3
Charge air filter.............................................................................................................................................. 7 - 6
Exhaust gas system.....................................................................................................................................7 - 14
Exhaust gas module.................................................................................................................................... 7 - 16

DBAF386084- 7-1
7. Charge air and exhaust gas system Maintenance Manual for Auxiliaries

Charge air and exhaust gas system

maintenance GUID-8A16F64B-2975-4313-9F65-9D2FB1A5238F

The charge air and exhaust gas system provides the engine with clean air for the fuel
combustion and safely disposes of the exhaust gases from the engine. Major maintenance
work in the system normally requires that the engine be stopped. As the system is entirely
engine-specific, any other engines in the plant can be kept in operation.

If the engine is stopped for maintenance, let the exhaust gas ventilation sequence finish
before switching off the ventilation unit. The exhaust gas ventilation unit is not used during
normal engine running, and minor maintenance of this unit can thus be done without
stopping the engine.

If maintenance work is performed on the exhaust gas system or in related areas during
engine operation, pay attention to the hazardous areas caused by the explosion vents
(rupture discs).

WARNING
Do not go near the explosion vents when the engine is running or perform any
maintenance work in the vicinity during the engine startup. An explosion in the
exhaust gas system will cause the rupture disc to burst.

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Charge air system

Content
Charge air system maintenance
Maintaining the charge air system..........................................................................................................7 - 5
This maintenance should be done during large maintenance breaks and at least every 2 years.

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 Maintenance Manual for Auxiliaries 7. Charge air and exhaust gas system

Maintaining the charge air system

GUID-1874B192-3C04-4CA6-B000-9BD311BE74E8

This maintenance should be done during large maintenance breaks and at least every 2 years.

Component
Unit: Charge air system Type:
Component: Charge air system Manufacturer:
maintenance

Work Information
JobID: wca3116
Type of job: Planned maintenance
Interval: As required Service personnel: Mechanical, 1 / Unit
2 Years

This maintenance should be done whenever the engine is shut down for a long
maintenance break and at least every 2 years.

Refer to the manufacturers’ documentation for detailed component instructions.

Procedure
1 Open up the charge air system for internal inspection access.
This includes the filter housing, ducts, and charge air silencers.
2 Inspect the filter housing and all ducts for corrosion and damage.
a Remove any corrosion from the housing and ducts.

CAUTION
Overhaul the ducts immediately if there is severe loose corrosion, where the
corrosion products can enter and damage the turbochargers.

b Apply anti-corrosive treatment and repair painting as required.

3 Inspect the hoods, louvers, and any insect nets.
Repair if required.
4 Inspect and maintain the silencers.
a Inspect the silencers internally and externally for corrosion.
b Clean the silencers to remove all loose particles.
c Spray a thin coat of preservation oil on the black steel parts.
5 Inspect the bellows.
Ensure that bellows are well aligned, tight, and in good condition.

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7. Charge air and exhaust gas system Maintenance Manual for Auxiliaries

Charge air filter

Content
Oil bath filter
Removing sludge from the filter............................................................................................................. 7 - 7
Inspecting the MultiDuty filter.................................................................................................................7 - 9
Replacing the Viscosine....................................................................................................................... 7 - 11
Fine filter
Cleaning or replacing the fine filter.......................................................................................................7 - 13
The fine filter must be cleaned when the pressure drop across the filter assembly (including the
MultiDuty oil-wetted filter) exceeds 650 Pa. See also the maintenance procedure for the MultiDuty
section of the filter.

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 Maintenance Manual for Auxiliaries 7. Charge air and exhaust gas system

Removing sludge from the filter

CITEC-20061219-YNRUFKODSOAWBZRNRXANW

Component
Unit: Charge air filter NGA0_0 Type: MultiDuty
Component: Oil bath filter B001 Manufacturer: AAF

Work Information
JobID: wca0023
Type of job: Planned maintenance
Interval: 1 Months Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
The equipment may start automatically. Turn off and tag out before starting any
maintenance.

Required tools

Code Description
Sludge scraper and pan

Consumables

Description Maker Amount

Viscosine AAF

Remove sludge and add Viscosine if needed.

NOTE
When filling with new Viscosine, make sure that there is no sludge left at the
bottom of the Viscosine oil tank.

Procedure
1 Remove sludge with the sludge scraper and pan.
2 Fill Viscosine tank to the level mark.
The Viscosine type is indicated on the guarantee plate.

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Inspecting the MultiDuty filter

CITEC-20061219-AGQDYXMIFVXXIFTLQWINK

Component
Unit: Charge air filter NGA0_0 Type: MultiDuty
Component: Oil bath filter B001 Manufacturer: AAF

Work Information
JobID: wca0022
Type of job: Inspection
Interval: 6 Months Service personnel: Mechanical, 1 / Component
4000 Hours

Procedure
1 Check that the timer works properly.
The filter is equipped with a timer which operates the curtain at 15 minutes intervals so that
the filter curtain makes a complete revolution in 24 hours.
2 Take a Viscosine sample from the tank.
a Put the sample into a graduated glass of about 1 litre.
b Let the Viscosine settle for 48 hours.
c If the sludge deposit is above or equal to ¼ of the oil height, replace the Viscosine.
The Viscosine type is indicated on the guarantee plate.

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Replacing the Viscosine

GUID-A4BE976A-DB4A-48A5-906A-9A1E2AD21481

Component
Unit: Charge air filter NGA0_0 Type: MultiDuty
Component: Oil bath filter B001 Manufacturer: AAF

Work Information
JobID: wca0580
Type of job: Planned maintenance
Interval: As required Service personnel: Mechanical, 1 / Component
1 Years

Prerequisites

Viscosine can be supplied in two different grades:

● BA Viscosine is used in countries with a moderate climate
● MA Viscosine is to be used in warm countries, average temperature above 35 °C.
Consumables

Description Maker Amount

Viscosine for section width of 3 feet AAF 95 Liter

Viscosine for section width of 4 feet AAF 125 Liter

Viscosine for section width of 5 feet AAF 155 Liter

Viscosine for section width of 6 feet AAF 185 Liter

Completely renew the Viscosine periodically, especially when the filtered air may cause
physical or chemical Viscosine variation. The minimum interval is once a year.

Procedure
1 Drain the Viscosine tank.
Refer to the manufacturer's manual for instructions for treatment and disposal, or follow
local regulations.
2 Make sure that there is no sludge left in the bottom of the Viscosine oil tank.
3 Fill the Viscosine tank to the correct level.

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Cleaning or replacing the fine filter

GUID-3D993BAB-A250-44EE-B48C-5DF1965F86A9

The fine filter must be cleaned when the pressure drop across the filter assembly (including the MultiDuty oil-
wetted filter) exceeds 650 Pa. See also the maintenance procedure for the MultiDuty section of the filter.

Component
Unit: Charge air filter NGA0_0 Type: CHEVRONET
Component: Fine filter B001 Manufacturer: AAF

Work Information
JobID: wca3557
Type of job: Wash/Clean
Interval: As required Service personnel: Mechanical, 2 / Component

Prerequisites
Required spareparts

Qty Description
As required Spare part kit (filters and viscosine)

As required Adhesive gaskets

As required Door gaskets

Clean the CHEVRONET filters when the pressure drop across the filter assembly (including
the MultiDuty oil-wetted filter) exceeds 650 Pa. Replace the filters if they have already been
cleaned two times.

Procedure
1 Remove the CHEVRONET filters.
a Loosen the cover screws located on one side of the clean air transition piece/plenum
chamber.
b Remove the cover.
Grasp the cover, lift it up to free it from the bottom support, and remove it.
c Pull out the CHEVRONET filters from their rails.
2 Clean or replace the CHEVRONET filters.
Clean the filters with oil-free compressed air at 7 bars. Sweep the filter with the air nozzle
approximately 50 cm from the filter.

CAUTION
Do not clean the CHEVRONET filters more than two times.

After two cleanings, the filters have to be replaced by new CHEVRONET filters.
3 Inspect the door gaskets.
If the gaskets are in poor condition (flattened, loose, or torn), replace them.
4 Install the new or cleaned filters.
a Slide each CHEVRONET filter into the rail in its original position.
The metal grid must be upwards and on the air exit side.
b Put the cover back on the supports.
c Tighten the screws firmly.
Use washers with the screws.

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7. Charge air and exhaust gas system Maintenance Manual for Auxiliaries

Exhaust gas system

Content
Exhaust gas silencer
Maintaining the exhaust gas silencer................................................................................................... 7 - 15

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Maintaining the exhaust gas silencer

GUID-D5ADFE6E-EE64-45EF-9077-53C36B49DBF8

Component
Unit: Exhaust gas system NHA0_0 Type: EN4X
Component: Exhaust gas silencer B006 Manufacturer: Universal Silencer

Work Information
JobID: wca3156
Type of job: Planned maintenance
Interval: 6 Months Service personnel: Mechanical, 1 / Unit

Prerequisites

WARNING
Danger of burns - Use care when working near the exhaust gas system during
operation and during the cool down period.

Procedure
1 Inspect for weld cracks.
If weld cracks are found, repair using qualified welders and procedures.
2 Inspect for loose fasteners.
If loose fasteners are found, tighten in accordance with Wärtsilä specifications for assembly
of flange hardware.

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7. Charge air and exhaust gas system Maintenance Manual for Auxiliaries

Exhaust gas module

Content
Charge air silencer
Inspecting the charge air silencer.........................................................................................................7 - 17

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Inspecting the charge air silencer

GUID-3653F97F-54A7-4604-8D99-C090DBE69BF3

Component
Unit: Exhaust gas module NHA0_1 Type: SU5
Component: Charge air silencer B002, B003 Manufacturer: Universal Silencer

Work Information
JobID: wca1560 Work time: 4 Hours
Type of job: Inspection Stop time: 6 Hours
Interval: 6 Months Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Danger of burns - Use care when working near the system during operation and
during the cool down period.

Required spareparts

Qty Description
As required Donit Tesnit BA-S gasket or equivalent

Procedure
1 Inspect for excessive corrosion.
2 Inspect for material or weld cracks.
3 Check the gasketed flange connections.
Re-tighten the bolts if necessary.
Bolted connections should be tightened to 275 Nm.
If flanged connections are disconnected, a new gasket must be used. Use a similar type
gasket as a replacement.

Postrequisites
Ensure the all tools and other materials are removed if maintenance is performed inside the
silencer.

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Combined system modules

Content
Maintaining the engine auxiliary module....................................................................................................... 8 - 2
Engine auxiliary module.................................................................................................................................8 - 3
Cooling appendix.........................................................................................................................................8 - 15

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8. Combined system modules Maintenance Manual for Auxiliaries

Maintaining the engine auxiliary module GUID-3F94FB31-460E-4E04-AD14-3F776CDFC806

The engine auxiliary module is essential for the operation of the engine, and the
maintenance of the module typically requires that the engine be stopped. As supply lines
run through adjacent modules, avoid unnecessary maintenance that will interrupt operation
of other engines. To minimize the stop time, the maintenance of the auxiliary module should
be performed in connection with the engine maintenance stops, when possible.

Most of the equipment in the module is in continuous operation when the engine is running.
The circulation of cooling water and supply of compressed air must never be interrupted
when the engine is in operation. The preheating unit runs only when the engine is on
standby, and minor maintenance can be performed on it without stopping the engine.

Some maintenance tasks require that the system be drained. To facilitate the maintenance,
the system or unit to be serviced can be isolated by closing all inlet and outlet valves.

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Engine auxiliary module

Content
Instrument air filter
Checking the condensate trap............................................................................................................... 8 - 5
Replacing the filter element.................................................................................................................... 8 - 7
The filter element must be replaced annually or when the differential pressure reaches 0.35 bars.
Water temperature control valve
Maintaining the 3-way control valve.......................................................................................................8 - 9
Starting air valve
Maintaining the ball valve..................................................................................................................... 8 - 11
Overhauling the ball valve.....................................................................................................................8 - 13

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Checking the condensate trap

GUID-5AC70A0B-DD0B-4534-BA6D-7660D3BE6E22

Component
Unit: Engine auxiliary module MOD0_1 Type: G2 - G19/XP
Component: Instrument air filter B024 Manufacturer: Zander

Work Information
JobID: wca3600
Type of job: Check job
Interval: 1 Weeks Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
As required O-ring

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Check the function of the condensate trap.

NOTE
The instructions in the following steps do not apply to filters that are equipped
with a manual relief valve.

a Check if a permanent flow noise can be heard when the discharge valve is closed. This
indicates a leakage.
b Turn the knurled screw on the housing bottom to the right in order to open the drain
valve manually.
If the condensate trap:
- works correctly, a small amount of condensate, compressed air or inert gas will
discharge.
- is defective, an unusual amount of condensate discharges.

NOTE
If you have doubts about the correct function of the trap proceed as described
below:

c Shut off the compressed air or gas supply.

d Open the manual drain valve and depressurize the filter.
e Unscrew the filter bowl.
Refer to the section "Renew filter element" in the manufacturer’s documentation.
f Remove the condensate trap, clean or fit a new condensate trap.
g Refit the filter bowl.
Refer to the section "Renew filter element" in the manufacturer’s documentation.

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8. Combined system modules Maintenance Manual for Auxiliaries

h Re-check the operation of the condensate trap.

i Ensure that the knurled nut is tightened so that the automatic drain functions correctly.

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Replacing the filter element

GUID-5CA51CA6-2460-45C3-B64A-965496E28B9B

The filter element must be replaced annually or when the differential pressure reaches 0.35 bars.

Component
Unit: Engine auxiliary module MOD0_1 Type: G2 - G19/XP
Component: Instrument air filter B024 Manufacturer: Zander

Work Information
JobID: wca1873
Type of job: Planned maintenance
Interval: 1 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
1 Filter element

Refer to the manufacturer’s documentation for additional information.

Procedure
1 Replace the filter element.
a Shut off compressed air or gas supply to the filter.
b Depressurize the filter housing.
Operate drain valve as follows:
- for manual drain valves: open manual valve and wait until the pressure has escaped.
- for automatic condensate drains: turn knurled screw to the right and wait until the
pressure has escaped.
- for an electronic condensate drain: press the push button, if necessary several times.
The filter is depressurized when flow noise can no longer be heard.
c Unscrew the filter bowl section and remove it.
d Unscrew the filter element and remove it.

NOTE
New filter elements with external foam socks (series Z, X) should only be
handled by the end caps; otherwise, the foam sock could be damaged.

e Insert the new filter element and O-ring. Tighten the filter element until it is hand tight;
ensure that the O-ring is seated correctly.
f Before assembly, lightly grease the threads of the housing sections with Molykote or a
comparable lubricant.
g Reconnect the filter bowl to the head and tighten by hand.
h Unscrew the filter bowl by 30°.
This allows the filter to be opened easily even after an extended period of operation and
frequent pressure changes.
i Close the manual or automatic drain.
j Check the housing for leaks.

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Maintaining the 3-way control valve

GUID-9CE1F001-A3F0-457E-95DB-1F69B606268F

Component
Unit: Engine auxiliary module MOD0_1 Type: STEVI 450/451
Component: Water temperature control V001, V002 Manufacturer: Ari Armaturen
valve

Work Information
JobID: wca2552
Type of job: Maintenance
Interval: As required Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
Content under pressure. Isolate and release the pressure before starting any
maintenance.

Required spareparts

Qty Description
As required Stem seal kit

As required Body gasket

As required Valve stem

Procedure
1 Tighten or replace the stem seals if the valve is leaking.
a Remove the actuator.
Refer to the operating instructions for the specific actuator.
b Tighten or replace the seal according to the specific type.
Refer to the manufacturer's documentation. Some types of seals can be tightened; other
types must be replaced.
c Inspect the valve stem and replace it if damaged.
The valve will continue to leak if the stem is damaged.
2 Inspect the internal parts of the valve if necessary.
Replace worn or damaged parts. Replace gaskets as necessary. Refer to the
manufacturer's documentation.

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Maintaining the ball valve

GUID-90172CD7-61C8-49AC-80F6-C2A8356F68F5

Component
Unit: Engine auxiliary module MOD0_1 Type: Standard
Component: Starting air valve V016 Manufacturer: Starline

Work Information
JobID: wca2708 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 2 Years Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
1 Gasket set (packing set)

Procedure
1 Disassemble the valve.
Place the parts on a clean surface. To make re-assembly easier, arrange the parts in order
of disassembly.
2 Replace the following parts in the ball valve:
3 - Packing ring
7 - Thrust washer
8 - O-ring
10 - Seats
11, 18 - Body seals.
Refer to Fig 8-1 for the location of the parts of the valves.
Inspect the other parts and replace any parts that are worn or damaged.

DBAF386084- 8 - 11
8. Combined system modules Maintenance Manual for Auxiliaries

2A

1
17 19
2B
4
6
3
8
7

5
9
10
16 13
11
18
12

18
11
10

1. Handle 2. (A, B) Nut 3. Packing ring 4. Spring washer 5. Antistatic stem 6. Gland packing
7. Thrust washer 8. O-ring stem 9. Ball 10. Seats 11. Body seal 12. Body 13. End
connection 14. Stop-pin 16. Bolts 17. Stop washer 18. Body seal 19. Nuts

Fig 8-1 Parts for the ball valve GUID-BB7BD0D7-E7E4-46B0-A43B-8DA4685259CB v1

3 Assemble the valve with the new parts.

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Overhauling the ball valve

GUID-2F64AF20-922C-4301-AD96-49EBABA17550

Component
Unit: Engine auxiliary module MOD0_1 Type: Standard
Component: Starting air valve V016 Manufacturer: Starline

Work Information
JobID: wca2709 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 5 Years Service personnel: Mechanical, 1 / Component

Prerequisites
Required spareparts

Qty Description
1 Spare part set

Procedure
1 Disassemble the valve.
Place the parts on a clean surface. To make re-assembly easier, arrange the parts in order
of disassembly.
2 Replace the following parts in the ball valve:
2 (A, B) Nut
4 Spring washer
5 Antistatic stem
9 Ball
17 Stop washer
Refer to Fig 8-2 for the location of the parts.
Inspect the other parts and replace any parts that are worn or damaged.

DBAF386084- 8 - 13
8. Combined system modules Maintenance Manual for Auxiliaries

2A

1
17 19
2B
4
6
3
8
7

5
9
10
16 13
11
18
12

18
11
10

1. Handle 2. (A, B) Nut 3. Packing ring 4. Spring washer 5. Antistatic stem 6. Gland packing
7. Thrust washer 8. O-ring stem 9. Ball 10. Seats 11. Body seal 12. Body 13. End
connection 14. Stop-pin 16. Bolts 17. Stop washer 18. Body seal 19. Nuts

Fig 8-2 Parts for the ball valve GUID-BB7BD0D7-E7E4-46B0-A43B-8DA4685259CB v1

3 Assemble the valve with the new parts.

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Cooling appendix

Content
Jacket water temperature control valve
Maintaining the valve............................................................................................................................8 - 17
Overhauling the valve........................................................................................................................... 8 - 19
Replace or overhaul the valve as required.

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Maintaining the valve

GUID-88CB452B-25C9-4F8B-A1B0-6A7C8F618F6C

Component
Unit: Cooling appendix MOD0_2 Type: G Valve
Component: Jacket water temperature V006 Manufacturer: AMOT
control valve

Work Information
JobID: wca2716
Type of job: Planned maintenance
Interval: 2 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
The valve may contain hot or pressurised fluid. Ensure the valve is isolated,
drained, and allowed to cool to a safe working level before dismantling.

Required spareparts

Qty Description
1 Minor service kit

Refer to the manufacturer's documentation for complete instructions. Refer to the specific
valve size and type of actuator.

Procedure
1 Remove the valve actuator.

CAUTION
If an actuator is removed from a valve fitted in a live system, the valve rotor may
rotate uncontrollably in the body. An actuator must never be removed from a
valve installed in a live system.

2 Inspect the actuator and perform any required maintenance.

3 Disassemble the valve.
Remove the valve from the system if necessary.
4 Inspect the valve parts for wear or damage.
Replace parts as necessary. Spare part kits can be used.
Especially inspect the following:
● The inside walls of the valve body
● The rotor
● All screws and bolts (check that they are tight).
5 Assemble the valve.
Use a new O-ring for the valve body and shaft.
6 Connect the valve actuator and make any needed adjustments.

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Overhauling the valve

GUID-D7996544-6A94-4D0D-B163-5F587C602127

Replace or overhaul the valve as required.

Component
Unit: Cooling appendix MOD0_2 Type: G Valve
Component: Jacket water temperature V006 Manufacturer: AMOT
control valve

Work Information
JobID: wca2717
Type of job: Planned maintenance
Interval: 4 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
The valve may contain hot or pressurised fluid. Ensure the valve is isolated,
drained, and allowed to cool to a safe working level before dismantling.

Required spareparts

Qty Description
1 Major service kit

Overhaul or replace the valve.

Refer to the manufacturer's documentation for complete instructions. Refer to the specific
valve size and type of actuator.

Procedure
1 Remove the valve from the system.
2 Disassemble and inspect the valve and actuator.
3 Replace parts as necessary.
Replace the composite bearing, actuator seals, and all O-rings.
If necessary, replace the valve.
4 Assemble and install the valve.

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Electrical system

Content
Electrical system maintenance...................................................................................................................... 9 - 2
LV switchgear................................................................................................................................................ 9 - 3
DC system................................................................................................................................................... 9 - 10

DBAF386084- 9-1
9. Electrical system Maintenance Manual for Auxiliaries

Electrical system maintenance GUID-07CF8AC9-CE32-420D-B7A4-0685DD9CEB0D

NOTE
Maintenance work on electrical equipment must be performed by trained
electricians only.

A work permit must be obtained before commencing maintenance work on an electrical

system.

Take at least the following safety precautions when working on any high-voltage (HV),
medium-voltage (MV) or low-voltage (LV) system:
● Lock and tag out the affected equipment to prevent accidental operation.
○ Place a signboard for maintenance at all feeder ends.
○ Inform the remote control station and the operators about the maintenance.
○ Keep the control mode selector switches in position for local control, so that no
remote operations can be done accidentally.
○ Keep the padlocks in place to avoid accidental operations.
○ If the auxiliaries that are to be serviced are essential for the safety of the main
equipment, also the main equipment shall be tagged out for maintenance.
● De-energize and earth the system before starting the maintenance work.
○ When maintaining a transformer, make sure that the circuit breakers on the HV side
are open and the earthing switches are closed. The MV-side breaker shall be racked
out with the earthing switch in the closed position.
○ Make sure that the HV bay is earthed and the static energy is discharged before
performing any maintenance.
○ Make sure that feeder is not energized and that the breaker is not in the closed
position before opening the front door of the cubicle.
○ Make sure that complete bus is de-energized and then earthed before performing
maintenance work on the switchgear.
○ Before performing maintenance of the auxiliaries, make sure that the electrical feeder
is switched off, the feeder is kept isolated (if it is of withdrawable type) and the fuses
are removed.
○ Make sure that the control voltage circuits are also turned off for the particular feeder
or panel during the maintenance, to avoid electrical shocks.
● Make sure that the safety gear (gloves, earthing rod, etc.) is of suitable voltage range.
● Use proper safety gear (gloves and goggles) when working on batteries and filling them
with electrolyte.

Before reconnecting the equipment to the mains once the maintenance work is completed,
make sure that the cables are connected, the covers are in place and the earthing switch is
open (it is closed for maintenance).

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LV switchgear

Content
Switchgear
Inspecting the switchgear components................................................................................................. 9 - 5
The inspection interval depends on the components and the operating conditions.
Maintaining the switchgear.....................................................................................................................9 - 7
Inspecting the switchgear...................................................................................................................... 9 - 9

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Inspecting the switchgear components

GUID-C109AAFD-7F56-4708-9E48-ED1EAE3CB619

The inspection interval depends on the components and the operating conditions.

Component
Unit: LV switchgear BFA901 Type: VEDA 5000
Component: Switchgear Manufacturer: VEO

Work Information
JobID: wca3560
Type of job: Inspection
Interval: As required Service personnel: Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

Refer to the specific manufacturers’ documentation for additional information. Correct all
defects.

Procedure
1 Inspect the following components:
● Contacts (knife blades)
● Breaking chamber (extinguish)
● Magnets with coils
● Locking devices
● Auxiliary contacts
● Bearings
● Lever mechanisms and their pivots
● Springs
● Insulators.

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Maintaining the switchgear

GUID-61A57187-390D-42B8-BDA3-CB439708DA74

Component
Unit: LV switchgear BFA901 Type: VEDA 5000
Component: Switchgear Manufacturer: VEO

Work Information
JobID: wca0013 Work time: 2 Hours
Type of job: Planned maintenance Stop time: 2 Hours
Interval: 1 Years Service personnel: Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

Required tools

Code Description
Industrial vacuum cleaner

Consumables

Description Maker Amount

ISOFLEX TOPAS NB52 or equivalent

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Inspect the following electrical functions:
● Local and remote control
● Locking devices and lock-outs
● Triggers
● Alarms
● Relay settings.
2 Inspect the markings on the following:
● Plates
● Fuse designations
● Device markings
● Drawings and schematics.
3 Inspect the cable installation and the wiring markings.
4 Inspect the operating equipment, including the following:
● Temporary earthing devices
● Servicing guards
● Fuse change handles

DBAF386084- 9-7
9. Electrical system Maintenance Manual for Auxiliaries

● Live electrical tools.

5 Test the mechanical functions.
This reveals, for example, transfer resistances caused by dirty contacts.
6 Clean the switchgear.
Use an industrial vacuum cleaner.
When vacuuming/cleaning, watch out for loose parts and markings (e.g. terminal numbers
and device designations). Also take into consideration the special requirements of
electronic devices when cleaning (anti-static devices).
7 Check the condition of the contacts in withdrawable switch and apparatus slide structures
after approximately 20 withdraw times.
a Check the overall condition of the contacts, such as spring force and cleanliness.
b Inspect the contact bases.
c Check that the auxiliary wire plugs function properly.
d Grease the contacts.
Use ISOFLEX TOPAS NB52 or equivalent.
8 Remove excessive jointing grease from parts made of insulating materials.
Always use water or cleaning spirits for dirty plastic parts.

CAUTION
Do not use pure acetone, chloroethane or trichloroethane.

CAUTION
Do not reconnect the switchgear before the cleaning agents have evaporated.

9 Check the connections visually (colour changes) or with thermal photography approximately
one year after commissioning.
If a random check reveals more than 1% loose connections, inspect all connections.
10 Inspect the switchgear structure and contact covers.

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 Maintenance Manual for Auxiliaries 9. Electrical system

Inspecting the switchgear

GUID-6DA87CFA-16E3-41F3-92BB-09E3145F99A1

Component
Unit: LV switchgear BFA901 Type: VEDA 5000
Component: Switchgear Manufacturer: VEO

Work Information
JobID: wca0012 Work time: 2 Hours
Type of job: Inspection Stop time: 2 Hours
Interval: 5 Years Service personnel: Electrician, 1 / Unit

Prerequisites

WARNING - ELECTRICITY
Risk of electric shock. Before doing any maintenance, make sure that the
equipment is disconnected from the electrical mains and tagged out.

Refer to the manufacturer’s documentation for additional information. Correct all defects.

Procedure
1 Check the condition of overcurrent protectors etc.
This is for distribution networks of no more than 1 kV.
2 Measure the earthing resistance (impedance).
The measurement should be performed whenever regulations set a maximum limit.
a Make sure that the condition of the internal earthings of the switchgear complies with
the regulations.
b Check connection points, earthings of instrument transformers and the condition and
cross-section of protective conductors.
3 Check the condition of the indoor switchyard earthing leads.

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9. Electrical system Maintenance Manual for Auxiliaries

DC system

Content
Battery
Checking the battery voltage................................................................................................................9 - 11

9 - 10 DBAF386084-
 Maintenance Manual for Auxiliaries 9. Electrical system

Checking the battery voltage

GUID-66E48F77-D330-422C-965C-94D89E9B79DF

Component
Unit: DC system BEY901, BEY902 Type: PowerSafe - V
Component: Battery Manufacturer: EnerSys

Work Information
JobID: wca2019 Work time: 0.5 Hours
Type of job: Planned maintenance Stop time: 0 Hours
Interval: 1 Months Service personnel: Electrician, 1 / Component

Procedure
1 Check the battery total voltage.
Check monthly that the total voltage at battery terminals is equal to (N x 2.28 V) at 20 °C. (N
being the number of cells in the battery).
For additional information, refer to the instructions regarding float voltage in the
manufacturer's documentation.

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9. Electrical system Maintenance Manual for Auxiliaries

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Maintenance Manual for Auxiliaries A. Maintenance-related spare parts

Maintenance-related spare parts

This is a list of parts needed to carry out scheduled maintenance of the auxiliary systems in
the power plant. Only spare parts for equipment supplied by Wärtsilä are included.
● The table head row identifies the component name, manufacturer, type and process
code.
● The first column gives the part reference. The spare part code must be looked up in the
referenced section of the Auxiliary spare parts catalogue. If the equipment is not
included in the spare parts catalogue, see the OEM manual or contact Wärtsilä Service.
● The second column gives the number of parts needed for maintaining one piece of
equipment. “As required” indicates that the part is changed only if it is broken or worn
beyond the safety limits.

When ordering spare parts, always include all the data needed to identify the component
and part installed.
● Brand and model
● Serial number
● Type of application
● Name and description of the spare part
● Contact information of the person making the order.

Generating set

Table 1-1 Generator, BAG0_1

Generator, ABB, AMG 1120LT08 DSE

1 Pcs Preventive maintenance kit L1 10000 Hours

Contact 1 Pcs Preventive maintenance kit L2 20000 Hours

Wärtsilä Services 1 Pcs Preventive maintenance kit L3 40000 Hours
1 Pcs Preventive maintenance kit L4 80000 Hours

Fuel gas system

Table 1-2 Compact gas ramp, ZAC0_1

Gas filter, Parker, SFH1040205QVNXD80CS01, B001

See ZAC-0099 2 Pcs Filter element 4000 Hours
in the Auxiliary
As required Sealing kit 4000 Hours
spare parts
catalogue

Instrument air filter, Zander, G5 XP4-D, B002

See ZAC-0099 As required O-ring 1 Weeks
in the Auxiliary
1 Pcs Filter element 1 Years
spare parts
catalogue

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A. Maintenance-related spare parts Maintenance Manual for Auxiliaries

Mass flow meter, Endress+Hauser, 83F50-AD2SACHCABBQ, F001

See ZAC-0099 As required Seals As required
in the Auxiliary
spare parts
catalogue

Gas shut-off valve, Pekos, FIG Z04-TTTG, V001, V003, V004

1 Pcs Sealing set 2 Years
See ZAC-0099 1 Pcs Ball 5 Years
in the Auxiliary
1 Pcs Stem 5 Years
spare parts
catalogue 2 Pcs Spring 5 Years
2 Pcs Antistatic ball 5 Years

Gas shut-off/vent valve, Starline, 235 SGS-G/BSP-P, V002, V007, V008, V009, V014, V015
See ZAC-0099 1 Pcs Gasket set (packing set) 2 Years
in the Auxiliary
1 Pcs Spare part set 5 Years
spare parts
catalogue

Gas pressure regulating valve, Fisher, GX DN50 + DVC 6200, V005, V006
See ZAC-0099 1 Pcs Service kit (Packing set) As required
in the Auxiliary
1 Pcs Body/bonnet gasket As required
spare parts
catalogue

Control air inlet valve, Starline, 235SGS-G/BSP-P/R1/2, V013

See ZAC-0099 1 Pcs Gasket set (packing set) 2 Years
in the Auxiliary
1 Pcs Spare part set 5 Years
spare parts
catalogue

Lubricating oil system

Table 1-3 Oil mist separator, QBF0_1

Oil mist separator, Alfa Laval, Purevent 2.0 single, B001

See QBF-0037 1 Pcs Rotor kit 16000 Hours

in the Auxiliary
1 Pcs Sealing kit 16000 Hours
spare parts
catalogue 1 Pcs Isolator kit 16000 Hours

Variable frequency drive, Vacon, 0100-3L-0008-4-X, B001

See QBF-0037 1 Pcs VFD main fan 6 Years
in the Auxiliary
1 Pcs RTC (Real Time Clock) battery 10 Years
spare parts
catalogue

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Maintenance Manual for Auxiliaries A. Maintenance-related spare parts

Compressed air system

Table 1-4 Instrument air unit, TCA901

Air tank, Tamrotor, TR020 CE, B01

Contact As required Seals for inspection openings As required
Wärtsilä Services

Compressor, Gardner Denver, WDN 22, D01

1 Pcs Oil filter 1500 Hours
1 Pcs Air filter 1500 Hours
As required Gaskets and O-rings for the air cooler 1500 Hours
1 Pcs Oil separator cartridge 3000 Hours
As required Belts 3000 Hours
1 Pcs Inlet valve 3000 Hours

Contact 1 Pcs Discharge valve 3000 Hours

Wärtsilä Services As required Electric box filters 3000 Hours
As required Pressure relief valve As required
1 Pcs Solenoid valve for load function 9000 Hours
1 Pcs Oil temperature thermostat element 9000 Hours
As required Oil and air hoses 9000 Hours
As required Motor bearings 20000 Hours
1 Pcs Complete air end (factory reconditioned) 30000 Hours

Dryer, Gardner Denver, GDD80S, D02

Contact As required Prefilter elements 1 Years

Wärtsilä Services As required Postfilter elements 1 Years

Filter, FST, FCA110XNDF, F01

1 Pcs Filter element 3 Months

Contact 1 Pcs Filter cartridge 3 Months

Wärtsilä Services As required O-ring 3 Months
As required Oil indicator tube As required

Drain valve, Jorc, Combo-D-Lux, S01, S02

Contact 1 Pcs Service kit and instructions As required
Wärtsilä Services

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A. Maintenance-related spare parts Maintenance Manual for Auxiliaries

Table 1-5 Starting air unit, TSA901

Compressor, Sperre, XA250, D001, D002

1 Pcs Service kit A 250 Hours
1 Pcs Service kit A2 750 Hours

Contact 1 Pcs Service kit B 1500 Hours

Wärtsilä Services 1 Pcs Service kit C 3000 Hours
1 Pcs Service kit D 6000 Hours
1 Pcs Service kit E 12000 Hours

Table 1-6 Starting air bottle, TSB901, TSB902

Drain valve, Bekomat, Bekomat 12

Contact 1 Pcs Maintenance kit (wearing parts) 1 Years
Wärtsilä Services

Cooling water system

Table 1-7 Radiator, VCA0_1, VCA0_2, VCA0_3

Frequency converter, Vacon, 0100-3L-0310-5-ED

Contact 1 Pcs VFD main fan 6 Years

Wärtsilä Services 1 Pcs RTC (Real Time Clock) battery 10 Years

Table 1-8 Electric preheating unit, VDA0_1

Circulation pump, KOLMEKS, L-32A/2 (80MM) + KP-80-1 N12, D001

See VDA-0135 As required Gasket set As required
in the Auxiliary
spare parts
catalogue

Safety valve, Götze, 618tGFO, V004

See VDA-0135 As required Replacement valve 1 Years
in the Auxiliary
spare parts
catalogue

Automatic air venting valve, Spirotech, AB050, V005

See VDA-0135 1 Pcs Replacement air venting valve As required
in the Auxiliary
spare parts
catalogue

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Maintenance Manual for Auxiliaries A. Maintenance-related spare parts

Table 1-9 Expansion vessel, VEA0_1

Level switch, Besta, Type A 01041, L001

See VEA-0020 As required Flange gasket and O-rings 1 Years
in the Auxiliary
spare parts
catalogue

Charge air and exhaust gas system

Table 1-10 Charge air filter, NGA0_0

Fine filter, AAF, Chevronnet F30, B001

As required Spare part kit (filters and viscosine) As required
Contact
As required Adhesive gaskets As required
Wärtsilä Services
As required Door gaskets As required

Table 1-11 Exhaust gas module, NHA0_1

Charge air silencer, Universal Silencer, SPECIAL SU5X-600, B002, B003

Contact As required Donit Tesnit BA-S gasket or equivalent 6 Months
Wärtsilä Services

Combined system modules

Table 1-12 Engine auxiliary module, MOD0_1

Instrument air filter, Zander, G5 XP4-D, B024

See MOD-0397 As required O-ring 1 Weeks
in the Auxiliary
1 Pcs Filter element 1 Years
spare parts
catalogue

Water temperature control valve, Ari Armaturen, FIG 22.450 + DP34 + EPS 15.2, V001, V002

See MOD-0397 As required Stem seal kit As required

in the Auxiliary
As required Body gasket As required
spare parts
catalogue As required Valve stem As required

Starting air valve, Starline, 225SGS-F/IBW, V016

See MOD-0397 1 Pcs Gasket set (packing set) 2 Years
in the Auxiliary
1 Pcs Spare part set 5 Years
spare parts
catalogue

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A. Maintenance-related spare parts Maintenance Manual for Auxiliaries

Table 1-13 Cooling appendix, MOD0_2

Jacket water temperature control valve, AMOT, 06GGHDBS12P1200-AA, V006

See MOD-0433 1 Pcs Minor service kit 2 Years
in the Auxiliary
1 Pcs Major service kit 4 Years
spare parts
catalogue

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Wärtsilä is a global leader in smart technologies and complete lifecycle solutions for the marine and
energy markets. By emphasising sustainable innovation, total efficiency and data analytics, Wärtsilä
maximises the environmental and economic performance of the vessels and power plants of its
customers. Wärtsilä is listed on the NASDAQ OMX Helsinki, Finland.

See also [Link]

WÄRTSILÄ® is a registered trademark. © 2019 Wärtsilä Corporation.

Wärtsilä Finland Oy
Switchboard +358 10 709 0000
Find local offices at [Link]/contact