NETWORK INFRASTRUCTURE

ER POWER AND ENVIROMENT ENGINE MAINTENANCE

REPORT
DIRE DAWA

MAY -2023
 Presented by Group P -2 1) Mekuria Hailu
2) Melaku Tefera
3 )Birhanu Refera
4

3-May-23
CONTENTS

1 Introduction

2 The requirement of overhauling maintenance

3 Step taken before overhauling Maintenance i

4 Challenge and recommendation

5 The way forward

1) INTRODUCTION

• Overhauling a Generator comes from different components: you have the engine that drives the
generator, the alternator and the generator it self
• Either one could fail, and that the repair may Couse an overhaul of the engine overhaul of the the
generator it self
• This can take a long period of time because the engine has to disassemble and removed
• Overhauled ,tested and reinstalled and then tested again
• Regular diesel generator maintenance ensures the security of power, whether the diesel generators used
for prime power generator or back-up emergency

06/22/2024
OPERATION
 Site name bus station (141402) Problem observed Inspection

 Site is categorized in FDS site visualize the rocker arm they

Site power solution mains+ haves gap from standard
1 DG  periodically we face the DG is
value when you check by
DG type Cummins 10KVA unable to start start feeler gauge.
two cylinder  indicate low cooperation ratio in
Site is 4G site
one cylinder
 the DG is not start by crank attempt
time and difficult to start

The DG unable to crank attempt time

and become difficult start

Jun 22, 2024

 Cont.,
 The site is down repeatedly as a result of main failure DG unable to start

 The site totally affect ER NAR due to network unavailability

 Degradation ER NUR in the vicinity

 Visiting the site repeatedly and taking our time to solve other down site issue

 To get reliable network increase the site performance

 To provide customer satisfaction

 To save operational time and cost

 To increase revenue

 e

the site is down now and then

Jun 22, 2024

 3) Step taken before overhauling Maintenance
 Observing the DG man problems

 Then before decide to dismantling the parts first collect spare from RWH

 Collecting the type tolls and ,then we assume needs to be changes

 Assuming the main damaged pushrod and tappet

 Collecting the required spare at hand

 Dismantling step by step and putting the items in neat place for cleaning

 e

The proper pulling tools

Jun 22, 2024

 cont.,
 Then disconnect the engine part from alternator
 un loading ,up side to safe place by using pulley DG main problem side

 check each every area with your eyes first to have quite right as maintenance rule

 e

The proper lifting manual

crane

Jun 22, 2024

 cont.,
 First remove the timing gear cover and cam shaft gear
 then retract the cam shaft

 check each every area with your eyes first to have quite right memory as

maintenance rule

 e

The proper lifting manual

Jun 22, 2024 crane
 cont,..
 Pull pout the cam shaft

 As you see the image the cam shaft knob intake side is deformed

 besides the dimension also reduced

 we check each every area with your eyes first to have quite right observation
• So it needs machine shop and refill the damage part

 e

The proper electromechanically

Jun 22, 2024 tools
 cont,.
 After the Machin shop maintenance the cam shaft become as good as new

 As you see the image the cam shaft knob intake side become quite good

 check each every area with your eyes first to have quite right

observation as maintenance rule

 After fill on machine shop the shape also as before

 e

The proper electromechanical

Jun 22, 2024

tools
OPERATIONAL
EXCELLENCE
Assembling of the DG
Activities Detail Final assembling

 Then, finally we assemble the cam shaft with timing gear

 Proper Assembling all the disassembled
 close the cover also
parts
 the cam shaft knob intake side
 loading to the place to fix the cylinder head

 we connect the alternator with flywheel .

 Replacing the timing gear
 After fix all parts were checked to have the normal operation
cover and cam shaft gear
of the DG
 Participants,
 Finally , we checked ,the crank is amazingly well done and
 Melaku .T & Mekuria .H
become very successfully and the engine start easily
Driver :-Temesgen

Jun 22, 2024

 Site name bus station (141092 ) Problem observed Inspection
• Site power solution  oil level is over maximum • When remove the oil pan
2 mains+DG
 The oil color has also changed
pure water drop out from
• DG type john Deere 50kva back Side liner
four cylinder  Then , for further check up ,we open oil .
• Site is hub site and wereda drain
we have also bank  we observed that water and oil was mix
customers
 Then we decide to dismantle oil pan

some scrap steel spare but purchase from market

Jun 22, 2024

CORRECTIVE MAINTENANCE

Observation

 DG Type

Water and oil mixed

Jun 22, 2024

 CANT,

Activity Details

 The arrow indicate water leakage line direction

• These cause is happen when liner seal (O-ring) is

damage so we decide needs to change

• First as before check the seal and cylinder head gasket

is available or not in warehouse.

Jun 22, 2024

 CANT,

Activity Details

 The seal(O-ring) and cylinder head gasket is available

in warehouse

 Next needs simple hand tools for extracting the liner

 By modify some scrap steel purchase from scrap
market and welded as we wont

 to modify some scrap steel purchase from scrap

market and welded as we wont

Jun 22, 2024

 CANT,

Activity Details

 Then start dismantling the engine

 First remove the cylinder head next remove the oil pan

 disconnect connecting road from the crankshaft then

retract the piston
 then fix the modified hand tool to remove the liner

 specially electromechanical tools for overhauling

Jun 22, 2024

CANT,

Activity Details

 specially electromechanical tools for overhauling

Jun 22, 2024

 CANT,

Activity Details

 For one liner it haves three O-rings. one is fix in liner

the other two is fix in engine block side.

 special electro mechanic tools

Jun 22, 2024

 CANT,

Activity Details

,
 By this method we change those four cylinder liner
seal Participant technician:- Birehanu .Rufera
 After fix all liner and parts their is no leakage
 And also save from damage the generator Mekuria.Hailu i
 Now generator is works in full efficient senior driver Gezahagne Haile.

 special electro mechanic tools

Jun 22, 2024

 COST OPTIMIZATION
(DO2SAVE)

Jun 22, 2024 NID Nine Months Performance Report

COST SAVING

Cost saved for Cost Saving for FDS

DG maintenance visit Total Cost
no Strategy
Reduction
(ETB) (ETB)

1
2

Total

Jun 22, 2024

LESSONS LEARNED, CHALLENGE AND
RECOMMENDATION

Jun 22, 2024 NID Nine Months Performance Report

LESSONS LEARNED
ER Bp
If there is great imitation for any kind of maintenance ,it is
a s p e r
c a r o f
possible to achieve the required target
o c a ti o n
h e A ll y a nd
if there is also special tools ,we will manage ER any operational T d o f d u t
u c ia l ,
r
the kin bility very c
challenge
s po n s i o ra t e d
re y c o ll a b
p e ci a ll
let the functional team support us as before to provide this es d r i v e r
n u i n e
ge
LESSONS
special tools
Functional team
spare part
LEARNED w as
r
nage
ma
a n d
r v i s or
s par e t supe a sk
e n o u g h ptim
i s u r t
If there is n o l i s ho
p of
clo u d b e v ery • A
to a c c o m
hki nd
part , things u s s u c
o w ith en t f or
a cco m p l is h al s
u i rem
e as y to
q
s hi f t re
a r a di gm u l ture
• P ce c
n a n
m a inte
g r ea
t Optimisti
c
Jun 22, 2024 NID Nine Months Performance Report
 CHALLENGES &
RECOMMENDATIONS

Jun 22, 2024 NID Nine Months Performance Report

 MAJOR CHALLENGES
• Challenge • Recommendation
 Spare part  Providing the required spare as per
 Electromechanical tools needed
 Manual crane  Purchasing special electromechanical tool
set.
 Pity Cash for external DG engine parts
maintenance workshop  Overhauling of DG training
 Allocating pity cash

Jun 22, 2024

 The way forward

• If there is special tools ,spare part and some

training with functional ,it is possible to
handle our operational difficulty with our
man power

Jun 22, 2024 NID Nine Months Performance Report

 THANK YOU !

Jun 22, 2024