USER MANUAL FOR GHP / 8035U (OFFSHORE) Document M02

Document No.: M02.0193 Document Title: USER MANUAL

GHP/8035U(Offshore) Issue: A

Date: 08/09/05

USER MANUAL FOR

GHP / 8035U (OFFSHORE) Document M02.0193



Date: 08/09/05

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TABLE OF CONTENTS

1.0 SAFETY 1.1. GENERAL INFORMATION.....................................................................................................1 1.2. ELECTRICAL POWER ...........................................................................................................1 1.3. MATERIALS............................................................................................................................1 1.4. OPERATIONAL PRECAUTIONS ...........................................................................................1 1.5. SAFETY LABELS ...................................................................................................................2

2.0 NOISE EMISSION 2.1. NOISE CONTROL PROHIBITED ACTS.................................................................................4 2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION .............................................4

3.0 HANDLING 3.1. LIFTING / HANDLING.............................................................................................................5 3.2. STORAGE / TRANSPORT .....................................................................................................5

4.0 INSTALLATION 4.1. UNPACKING...........................................................................................................................6 4.2. LOCATION OF THE PLANT...................................................................................................6 4.3. COMMISSIONING...................................................................................................................6 4.4. PRIOR TO STARTING............................................................................................................6 4.5. ELECTRICAL CONNECTION.................................................................................................6 4.6. EARTHING..............................................................................................................................6 4.7. REMOTE FUELLING ..............................................................................................................7

5.0 GENERAL DATA 5.1. GENERAL OPERATION.........................................................................................................8 5.2. DESIGN LOAD CAPACITY ....................................................................................................8 5.3. DESIGN TEMPERATURES ....................................................................................................8 5.4. CANOPY & BASE FRAME.....................................................................................................8 5.5. DIESEL ENGINE.....................................................................................................................9 5.6. ENGINE LUBRICATION SYSTEM .........................................................................................9 5.7. ENGINE COOLING SYSTEM .................................................................................................9 5.8. ENGINE FUEL SYSTEM.........................................................................................................9 5.9. EXHAUST SYSTEM................................................................................................................9 5.10. ENGINE CONTROL SYSTEM ..............................................................................................10 5.11. GENERATOR........................................................................................................................10 5.12. MAIN CIRCUIT BREAKER ...................................................................................................10

6.0 OPERATING INSTRUCTIONS 6.1. OPERATING CONTROLS AND INSTRUMENTS................................................................12



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6.2. PRIOR TO START ................................................................................................................14 6.3. STARTING ............................................................................................................................14 6.4. LOADING ..............................................................................................................................15 6.5. SHUT-DOWN ........................................................................................................................15 6.6. STANDBY OPERATION (OPTIONAL).................................................................................15

7.0 MAINTENANCE 7.1. GENERAL .............................................................................................................................16 7.2. MAINTENANCE SCHEDULE ...............................................................................................17 7.3. WEEKLY MAINTENANCE....................................................................................................19

8.0 LUBRICATION 8.1. GENERAL INFORMATION...................................................................................................20 8.2. GENERATOR OIL CHANGE ................................................................................................20 8.3. OIL SPECIFICATION............................................................................................................20

9.0 TROUBLE SHOOTING 9.1. INTRODUCTION ...................................................................................................................21 9.2. ACTION PLAN ......................................................................................................................21 9.3. TROUBLE SHOOTING CHART ...........................................................................................22

APPENDIX A: Material Safety Data Sheets APPENDIX B: Equipment Data Sheet Document No. Rev.

G080260 SHT. 1 to 3 A APPENDIX C: Installation Outline Drawing Drawing No. Rev.

A050183 SHT. 1 of 1 A APPENDIX D: Control Panel Layout Drawing No. Rev.

D210611 SHT. 1 of 1 B APPENDIX E: Alternator & AVR Schematic Diagram Drawing No. Rev. Title

D080834 SHT. 1 of 3 A Alternator & AVR Schematic Diagram

APPENDIX F: Main Load & Metering Schematic Diagram Drawing No. Rev. Title

D080834 SHT. 2 of 3 A Main Load & Metering Schematic Diagram

APPENDIX G: DC Control Schematic Diagram Drawing No. Rev. Title

D080834 SHT. 3 of 3 C DC Control Schematic Diagram



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APPENDIX H: Terminal Layout & Engine Wiring Drawing No. Rev. Title

D140192 SHT. 1 of 1 B Terminal Layout & Engine Wiring APPENDIX J: Livery Layout Drawing No. Rev.

D200157 SHT. 1 of 1 A APPENDIX K: Manufacturers Component Data Document No. Rev.

M040104 SHT. 1 of 1 A APPENDIX L: Lifting Beam Certificate – 221300508/001 APPENDIX M: DNV Spark Arrestor Certificate – M10084 APPENDIX N: International Contact Information



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1.0 SAFETY 1.1. GENERAL INFORMATION

• Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

• Ensure that the Operation and Maintenance manual, and the manual holder, are not removed permanently from the machine.

• Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

• Make sure that all protective covers are in place and that the canopy/doors are closed during operation.

• The specification of this machine is such that the machine is not suitable for use in flammable gas

risk areas. WARNING: NO ATTEMPT SHOULD BE MADE TO OPERATE IN SUCH AREAS WITHOUT THE EXPRESS AUTHORITY FROM AGGREKO.

• Installation of this generator must be in accordance with recognised electrical codes and any local Health and Safety Codes.

1.2. ELECTRICAL POWER • Prior to installation of the generating set you should check that the electrical load to be applied is

within the rated output of the machine at the site ambient conditions.

• Before carrying out any maintenance or repairs to the Engine/Alternator assembly, disconnect the starting battery and isolate the alternator from the switchboard.

• Before carrying out any maintenance repair to the AC and DC circuits, isolate these from external control panel and power supplies.

• Ensure that the generator set and the load it is connected to, are properly earthed.

• The generating set should be connected to the load only by a qualified electrician and in accordance with the applicable regulations.

1.3. MATERIALS The following substances are used in the manufacture of this machine and may be hazardous to health if used incorrectly:

• Antifreeze

• Engine Lubricating Oil

• Preservative Grease

• Rust Preventative

• Diesel Fuel

• Battery Electrolyte.

AVOID INGESTION, SKIN CONTACT AND INHALATION OF FUMES.

When handling fuel, lubricating oil, cooling fluid and battery electrolyte, wear appropriate personal protection equipment.

For further information, consult Material Safety Data Sheet contained in this manual.

Avoid build-up of Engine Exhaust Fumes in confined spaces.

Avoid breathing Exhaust Fumes.

1.4. OPERATIONAL PRECAUTIONS Never operate unit without first observing all safety warnings and carefully reading the operation and maintenance manual shipped from the factory with this machine.

IF IN DOUBT CONTACT AGGREKO.



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DANGER FIRE RISK

DO NOT STAND IN FRONT OF ALTENATOR

AIR OUTLETS WHEN UNIT IS RUNNING

Never operate the engine of this machine inside a building without adequate ventilation. Avoid breathing exhaust fumes when working on or near the machine. Do not alter or modify this machine.

A battery contains sulphuric acid and can give off gases, which are corrosive and potentially explosive. Avoid contact with skin, eyes and clothing. In case of contact, flush area immediately with water.

Exercise extreme caution when using booster battery. To jump battery, connect ends of one booster cable to the positive (+) terminal of each battery. Connect one end of other cable to the negative (-) terminal of the booster battery and other end to a ground connection away from dead battery (to avoid a spark occurring near any explosive gases that may be present). After starting unit, always disconnect cables in reverse order.

Never operate unit without first observing all safety warnings and carefully reading the operation manual.

This machine may include such materials as oil, diesel fuel, antifreeze, oil/air filters and batteries which may require proper disposal when performing maintenance and service tasks. Contact local authorities for proper disposal of these materials.

This machine produces loud noise with the doors open. Extended exposure to loud noise can cause hearing loss. Always wear hearing protection when doors are open.

Never inspect or service unit without first disconnecting battery cable(s) or using the battery isolator switch to prevent accidental starting.

Do not remove the pressure cap from a HOT radiator. Allow radiator to cool down before removing pressure cap.

Do not use petroleum products (solvents or fuels) under high pressure as this can penetrate the skin and result in serious illness. Wear eye protection while cleaning unit with compressed air to prevent debris from injuring eye(s).

Hot pressurized fluid can cause serious burns. Do not open radiator while hot.

Rotating fan blade can cause serious injury. Do not operate without guard in place.

Use care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).

Never operate unit with guards, covers or screens removed. Keep hands, hair, clothing, tools, etc. well away from moving parts.

1.5. SAFETY LABELS Look for these signs on machine, which point out potential hazards to the safety of you and others. Read and understand thoroughly. Heed warnings and follow instructions.

(Risk of electric shock)



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DISCONNECT STARTING BATTERY AND ISOLATE

LOAD BEFORE WORKING ON ENGINE /

ALTENATOR ASSEMBLY

CAUTION Hot



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2.0 NOISE EMISSION 2.1. NOISE CONTROL PROHIBITED ACTS

Tampering with noise control system prohibited The following acts or misuse of the unit are prohibited:

1) The removal or rendering inoperative by any persons, other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new generator for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use

Or

2) The use of the generator after such device or element of design has been removed or rendered inoperative by any person.

Among those acts included in the prohibition against tampering are these:

• Removal or rendering inoperative any of the following:

a) The engine exhaust system or parts thereof.

b) The air intake system or parts thereof.

c) Enclosure or parts thereof.

• Removal of any of the following:

a) Fan shroud

b) Vibration mounts

c) Sound absorption material

• Operation of the generator with any of the enclosure doors open.

2.2. GENERATOR NOISE EMISSION CONTROL INFORMATION A. The removal or rendering inoperative, other than for the purpose of maintenance, repair, or

replacement of any noise control device or element of design incorporated into this generator in compliance with the noise control act;

B. The use of this generator after such device or element of design has been removed or rendered inoperative.

THIS GENERATOR HAS BEEN SPECIFICALLY DESIGNED WITH A SOUND ATTENUATING ENCLOSURE. THE CANOPY DOORS SHOULD REMAIN LOCKED SHUT UNDER NORMAL OPERATING CONDITIONS. UNDER ANY OTHER CONDITIONS EXCESSIVE NOISE LEVELS CAN BE PRODUCED AND PROLONGED EXPOSURE IS HAZARDOUS TO HEARING.

FOR SAFETY, EAR PROTECTION SHOULD ALWAYS BE WORN WHEN WORKING IN THE VICINITY OF AN

OPERATING GENERATOR SET.

WARNING



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3.0 HANDLING 3.1. LIFTING / HANDLING

• The generator set includes 1 lifting beam and forklift pockets.

• All lifting and handling equipment must be adequately rated for applicable weights.

• During all lifting and handling operations the following weights must be considered.

Complete Package Max. Fuel 3410 lbs (1550 kgs)

Complete Package Without Fuel 3818 lbs (1735 kgs)

• Bolt on steel plate buffers are located at the front and rear of the base to protect the body of the generator.

• Where 2 point lifting is provided, ensure that the correct length of strap / wire rope is used on each lifting beam to ensure a level lift. Also ensure that the included angle does not exceed 90°.

CAUTION: THE GENERATOR SET SHOULD NOT BE LIFTED OR DRAGGED BY THE END BUFFERS.

3.2. STORAGE / TRANSPORT • Carry out the following points before transporting the generator or preparing the generator for

storage.

• Empty the fuel tank (in case of overseas transport).

• Disconnect the battery terminals (in case of overseas transport).

• Ensure that the radiator cap is fitted securely and the exhaust rain cap is closed.

• Close all doors.

All units are to be loaded flat onto transport and properly secured.



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4.0 INSTALLATION 4.1. UNPACKING

Ensure that the correct fork lift truck slots or marked lifting / tie down points are used whenever the machine is lifted or transported.

4.2. LOCATION OF THE PLANT The generator can be installed on any solid, flat and level surface capable of supporting the full operating load of the package. A dry, well-ventilated area where the atmosphere is as clean as possible is recommended. Ensure that the machine is positioned securely and on a stable foundation.

CAUTION: A minimum of 1 metre (3 ft) all round the generator is recommended. Hot air will exit from the roof outlet. It is important that this hot air does not re-circulate to the package inlet.

The generator must be allowed sufficient space all round and above, to enable the effective removal of the cooling air which, in turn, will reduce the risk of re–circulating the cooling air back through the generator. Adequate clearance needs to be allowed around and above the machine to permit safe access for specified maintenance tasks. Hard surfaces may reflect noise with an apparent increase in the decibel level. It is recommended that provision be made for lifting heavy components during major overhaul.

NOTE: When operating at elevated altitude please refer to engine manufacturer’s guidelines for power deration.

4.3. COMMISSIONING Upon receipt of the unit, and prior to putting it into service, it is important to adhere strictly to the instructions given below in section 4.4 PRIOR TO STARTING.

• Ensure all persons concerned are suitably competent with generator installations.

• Ensure that the operator reads and understands the decals and consults the manuals before maintenance or operation.

• Ensure that the position of the emergency stop device is known and recognised by its markings. Ensure that it is functioning correctly and that the method of operation is known.

4.4. PRIOR TO STARTING • Ensure that the unit is clean, free from debris and fluids. All connections, joints, seals must be

correctly fitted and tightened. All filters, louvers and air inlets are free and open.

• Ensure that there is a safe working procedure which has been issued by supervisory personnel, and that all persons concerned with the operation of the generator understand it.

• Ensure that the safety procedure to be applied is based on the appropriate national and local regulations.

• Ensure that the safety procedure is followed at all times.

4.5. ELECTRICAL CONNECTION • A suitably trained electrician should carry out all electrical connections.

• Ensure the generator main isolator is off and that the power cables are in good condition.

• Ensure that the phases are correct after the cables have been connected.

• Ensure all safety covers are back in place after electrical connection is complete.

4.6. EARTHING An external earthing boss is fitted onto the base frame. This allows a dedicated earthing connection if required.



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4.7. REMOTE FUELLING External fuel tank supply can be connected to the generator set.

• One ½” NPTM Quick Release Coupling (Supply)

• One ½” NPTF Quick Release Coupling (Return)

There is an access hole in the base frame to allow access to the internal fuel connections.



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5.0 GENERAL DATA NOTE: Each generator of this type is uniquely identified by a Plant Number and Serial Number indicated on the identification plate affixed to the outside of the control panel. This information is required when ordering spare parts. Major component serial numbers are contained within the manual.

The technical data defining the generator and the limits on its operating environment are tabulated in the Equipment Data Sheet. A copy of the Equipment Data Sheet has been included in the manual.

In order to assist in the operation and maintenance of the generator, a full set of electrical and installation drawings has been included in the manual.

5.1. GENERAL OPERATION The generator is a diesel engine driven alternator with control electronics, mounted on a bedplate with internal fuel tank. The standard package is composed of the following:

• Alternator and engine assembly

• Pressurised oil system

• Automated control system

• Instrumentation

• Safety provisions

• Engine cooler pack

• Spark arrestor / Silencer

• Internal fuel tank

The engine and alternator are integrally mounted. This assembly is isolated from the base by rubber isolation mounts.

5.2. DESIGN LOAD CAPACITY The GHP/8035U (30kW) generator set can be run up to a maximum of 26.7kW at prime power rating 60Hz.

5.3. DESIGN TEMPERATURES The GHP/8035U (30kW) generator set can operate through an ambient temperature range of:

• -10°C (14°F) to 38°C (100°F)

5.4. CANOPY & BASE FRAME The overall dimensions for the generator set are 2420 X 1100 X 1800 mm.

The canopy is manufactured from welded Zintec and has access to the inside of the generator through lockable doors.

The base frame has 120% capacity of the fuel tank to prevent fuel leaking out of the generator set in the event of a fuel leakage inside the generator.



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5.5. DIESEL ENGINE The generator set uses an Iveco 8065E diesel engine, which is capable for either 50 Hz or 60 Hz. Details of the engine are outlined below.

Type: Four Stroke, 3 Cylinder In-line

Model: Iveco 8035U

RPM: 1500 / 1800

Nominal Engine Output @ 1800rpm: 26.7kW @ Prime Power

Governor: GAC Electronic

Starting System: 12V Battery System

Fuel Consumption @ Continuous 1800rpm: 8.8 L/Hr @ 100% Prime Power

5.6. ENGINE LUBRICATION SYSTEM The engine oil lubrication system includes pump, strainer, oil-water heat exchanger and sump all fitted internally within the engine block. Oil filtration is fitted to the side of the engine block for ease of access and maintenance.

Sump Capacity: 7.7 Litres

The Lube oil specification is as per API/ASTM/SAE/CD (equivalent to series MIL-L-415993). Recommended oils are Castrol Tection T 15W-40 (previously called RX Super Plus), Shell Rimula 15W 40.

Refer to manufacturers data for all filter information.

5.7. ENGINE COOLING SYSTEM The engine cooling consists of a pump, thermostat, heater and radiator assembly.

Cooling fluid is from the radiator, through the pump, which is belt driven from the engine pulley. The thermostat controls the flow to the radiator. The radiator assembly is mounted at the front of the engine, with the fan mounted on the front of the pump.

Cooling air enters the generator through the canopy end louvers and noise attenuation baffles. This air then passes into the canopy space then across the radiator assembly.

The heated air from the radiator exits through the roof of the package.

The coolant is factory filled with Shell anti-freeze and anti-corrosion coolant, in 50-50 water-coolant concentration, providing protection to –38°C. Please consult Aggreko if filling is required.

5.8. ENGINE FUEL SYSTEM The engine fuel system consists of an internal fuel tank, Racor filter (see Figure 5.1), fine fuel filter, fuel pump, injection pump & nozzles.

Fuel can be taken from either an external or the internal fuel tank. Fuel is pumped through the Racor filter to the fine fuel filters and then passed to the injectors and then to the injection nozzles.

The internal fuel tank has a useable fuel capacity of 200 Litres. The fuel tank fill point is internal. There is 1 cleaning port on the fuel tank that is accessible through the canopy doors.

External fuel supply can be connected to the package by fitting external fuel supply and return hoses via quick release couplings to the fuel changeover valve. The valve handle should then be moved to the external supply position. (see Figure 5.1).

The use of ASTM No. 2D fuel is recommended for optimum engine performance. At operating temperatures below 0°C, acceptable performance can be obtained using blends of No. 1 and No. 2D. The use of lighter fuels can reduce economy. The viscosity of fuels must be kept above 1.3 cSt to provide adequate lubrication.

Refer to manufacturers data for all filter information.

5.9. EXHAUST SYSTEM The exhaust system consists of the exhaust ducting, exhaust silencer complete with spark arrestor and rain cap assembly. The exhaust gases exit the engine and are passed through the exhaust ducting and exhaust, out the top of the canopy through the rain cap assembly. Insulation and heat shields are fitted to the exhaust ducting to prevent user contact with high temperature surfaces.



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Manufacturer: IMS

Spark Arrestor: DNV Certificate No M10084

5.10. ENGINE CONTROL SYSTEM An Electronic GAC governor controls the engine output.

A Deep Sea Electronic P552 protection module is used to monitor the safety circuits and set the operation mode of the generator. See section 6.1.2 Safety Module for more detail.

5.11. GENERATOR Manufacturer: Newage Stamford

Type: UCI224C4

50Hz: 380-440 Volts Voltage Range

60Hz: 440-480 Volts

Excitation System: Self Excited

• Voltage Regulator within 1.5% from no load to full load SX440

• 1 Phase configurable on Alternator TB

5.12. MAIN CIRCUIT BREAKER Manufacturer: Merlin Gerin

Type: NSF150N Fixed Three Pole



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Figure 5.1 - 30 kVA Generator Part Locations

RACOR FUEL FILTER

FUEL

CHANGEOVER VALVE

OIL PRESSURE GAUGE

EMERGENCY VENT

VALVE

AMOT VALVE



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6.0 OPERATING INSTRUCTIONS 6.1. OPERATING CONTROLS AND INSTRUMENTS

6.1.1. CONTROL PANEL The operating controls and instruments are arranged on the control panel as shown in figure 6.1. A description of each panel device is given in table 6.1.

Figure 6.1 – Control Panel Exterior

Deep Sea 5310 Controller

DC Power On/Off Switch

Main Breaker Switch

Key for figure 6.1

1

2

3

1

2

3



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Figure 6.2 – Control Panel Internals

1 MCB1 6 Terminals 1-23 11 AVR

2 MCB2 7 Earth Block 12 Volts Trim

3 MCB/EXC 20A 8 Merlin Gerin MCCB 13 Speed Trim

4 Relay R1 9 3-in-1 Current Transformer

14 Load Terminals

5 Term 1-4 Diodes 10 Governor Control

Key for figure 6.2

3

4

5

8

6

7

1

9

2

10

11

12

13

14



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6.1.2. SAFETY MODULE The safety module for the generator is a Deep Sea Electronics P522 shown in figure 6.3. The module consists of the following items:

• Safety On indicator

• Fail to start indicator

• Underspeed indicator

• Overspeed indicator

• Earth Leakage

• Common alarm

• Charge Fail indicator

• High Water Temperature indicator

• Low Oil Pressure indicator

• AUTO/OFF/MANUAL switch

• Start button

6.1.3. ALARM FUNCTIONS The table below lists alarm indicators and the point at which the individual alarm function is activated. The LED’s indicate the fault condition and will activate with one of the following characteristics:

• A flashing LED. - Indicates a first up fault with subsequent faults that occur simultaneously indicated by steady LED.

• A steady LED - Indicates warnings. The LED will remain illuminated until the input is cleared.

This feature also allows the module to be operated as an enunciator.

Alarm Activation Point

Safety On This will illuminate green continuously and, for a default 10 secs at initial start up, allows the various inputs to stabilise without tripping the associated alarm.

Fail to Start Will illuminate if the engine fails to fire after the one local or 3 remote cranks, the start sequence is terminated and the LED will flash.

Underspeed When the engine speed falls below the pre-set trip after the Safety On timer has expired. The LED will flash and a shutdown initiated.

Overspeed When the engine speed exceeds the pre-set trip. A shutdown is initiated. The Overspeed LED will flash. Overspeed is not delayed, and will initiate an immediate shutdown.

Common Alarm

Will illuminate to indicate all shutdown and warning faults. Mainly used to indicate fault conditions that do not have their own individual LED to indicate the fault. A warning indication is illuminated steady, while shutdown indications flash.

Charge Fail When charge alternator voltage falls below the pre-set trip voltage after the end of the Safety On timer. The LED will illuminate steady.

High Water Temperature

When the water temperature is too high after the safety on timer has expired. The LED will flash and a shutdown initiated.

Low Oil Pressure

When the oil pressure is too low after the safety on timer has expired. The LED will flash and a shutdown initiated.

6.2. PRIOR TO START Execute Daily Maintenance see section 7.1.

6.3. STARTING 1) Put the switch in MANUAL position (Clockwise).

2) Press the START button and hold until the motor starts running.

Figure 6.3 – Safety Module



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3) Check the frequency on the control panel and adjust if necessary with the frequency potentiometer.

4) Check the voltage and if necessary adjust using the potentiometer.

5) Walk around the engine and check for any leakages.

6.4. LOADING 1) Allow the engine to warm-up prior to applying load.

6.5. SHUT-DOWN 1) Open the circuit breaker.

2) Allow the engine to cool down for at least 5 minutes. Especially when the set has been running at high level.

3) Stop the engine by returning the switch to the OFF position.

CAUTION:- Always open the battery isolator switch to avoid unauthorised starting during transport and maintenance.

6.6. STANDBY OPERATION (OPTIONAL) 1) Put the contact key to AUTO position.

2) Select the circuit breaker to closed.

3) Refer to separate manual for operation of remote option.

4) A test run should be carried at least once a week.



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7.0 MAINTENANCE 7.1. GENERAL

In addition to periodic inspections, many of the components in these units require periodic servicing to provide maximum output and performance. Servicing may consist of pre-operation and post-operation procedures to be performed by the operating or maintenance personnel. The primary function of preventive maintenance is to prevent failure, and consequently, the need for repair. Preventive maintenance is the easiest and the least expensive type of maintenance. Maintaining your unit and keeping it clean at all times will facilitate servicing.

Ensure that maintenance personnel are adequately trained, competent and have read the Maintenance Manuals.

Prior to attempting any maintenance work, be aware of the following:

• Any unauthorized modification or failure to maintain this equipment may make it unsafe and out of factory warranty.

• Use extreme care to avoid contacting hot surfaces (engine exhaust manifold and piping, etc.).

• Never operate this machine with any guards removed.

• Imperial and Metric hardware was used in the design and assembly of this unit. Consult the parts manual for clarification of usage.

• The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate anti–start devices.

• All residual electrical power sources (mains and battery) are isolated.

Prior to opening or removing panels or covers to work inside a machine, ensure that:

• Anyone entering the machine is aware of the reduced level of protection and the additional hazards, including hot surfaces and intermittently moving parts.

• The machine cannot be started accidentally or otherwise, by posting warning signs and/or fitting appropriate anti–start devices.

Prior to attempting any maintenance work on a running machine, ensure that:

• The work carried out is limited to only those tasks which require the machine to run.

• The work carried out with safety protection devices disabled or removed is limited to only those tasks which require the machine to be running with safety protection devices disabled or removed.

• All hazards present are known (e.g. pressurised components, electrically live components, removed panels, covers and guards, extreme temperatures, inflow and outflow of air, intermittently moving parts, safety valve discharge etc.).

• Appropriate personal protective equipment is worn.

• Loose clothing, jewellery, long hair etc. is made safe.

• Warning signs indicating that Maintenance Work is in Progress are posted in a position that can be clearly seen.

Upon completion of maintenance tasks and prior to returning the machine into service, ensure that:

• The machine is suitably tested.

• All guards and safety protection devices are refitted.

• All panels are replaced, canopy and doors closed.

• Hazardous materials are effectively contained and disposed of.

To assist with ordering spare parts and other service activities, a short form list of Component Manufacturers data has been included in this manual.

Prior to engine starting, check the oil and coolant levels.

Carry out a visual check of the following:

• Leaks.



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• Loose or damage parts.

• Worn or damaged belts, change in engine appearance.

• Refer to the Maintenance Schedule for quick reference.

Report unusual noise/vibration and/or exhaust smoke and ensure the generator set is kept clean, both inside and out.

7.2. MAINTENANCE SCHEDULE

7.2.1. INSPECTION CRITERIA

Daily Weekly Monthly 3 Months / 500 Hrs

Up to 6 Months / 1000 Hrs

12 Months / 2000 hrs

Engine Oil Level C

Fuel Tank (Fill at end of day) C

Gauges / Lamps C

Air Filter C

Fuel / Water Separator Drain C

Battery Connections / Electrolyte C

Radiator Coolant Level C

Fan / Alternator Belts C

Hoses (oil, air, intake, etc.) C

Automatic Shutdown System Visual C

Fasteners / Guards C

Engine Coolant Test C

Shutdown Switch Settings Test C

C=check (adjust if necessary)

Refer to manufacturers operating and maintenance instructions for additional information and all other maintenance.

7.2.2. SERVICE CRITERIA

Daily Weekly Monthly 3 Months / 400 Hrs*

Up to 6 Months /

1000 Hrs *

12 Months / 2000 hrs

Engine Oil & Filters R

Air Filter Element R

Fuel / Water Separator Element R

Fine Fuel Element R

Engine Coolant R

R=replace

Refer to manufacturers operating and maintenance instructions for additional information and all other maintenance.

* This figure should be in line with current service best practise.



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7.2.3. DAILY MAINTENANCE 1) Check the engine oil level:

2) Stop the engine and wait 5 minutes to allow the oil to drain to the oil pan.

3) Remove the dipstick and check the oil level.

4) Replenish if necessary using a recommended grade of engine oil (see section 8).

CAUTION: Never operate the engine with the oil level below the ‘L’ mark or above the ‘H’ mark. See FIG. 7.1 below.

Figure 7.1 - Engine Oil Level Check

7.2.4. CHECK THE FUEL TANK LEVEL. Check the fuel level gauge on the control panel.

Replenish as necessary using clean, good quality, diesel/Derv/Gas Oil that conforms to ISO or equivalent. Always ensure that the filler cap is replaced after replenishment.

7.2.5. CHECK THAT ALL METERS AND GAUGES FUNCTION CORRECTLY. Start the generator and inspect the following items:

• Oil pressure gauge is between 65 & 75psi.

• After 5 minutes check that the engine oil temperature gauge reads between 45°C & 55°C.

• The voltage and frequency gauges are within specification.

• Fuel gauge indicates the tank is not empty.

• Engine hours display increases after 10 minutes.

• Safety module has no alarm indicators on.

• Press the “LAMP TEST” button on the control panel and confirm that all indicator lamps are working.

7.2.6. CHECK THE AIR FILTER.

NOTE: In dusty conditions clean the primary filters regularly.

Check the air filter restriction indicator (if fitted) next to the air filter above the engine. If this has changed to the restricted position, then the filter will need replaced.



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7.2.7. CHECK THE BATTERY. Check that the battery connections are properly installed and that the electrolyte level in each cell covers the top plates. If necessary, top up with clean distilled water.

7.2.8. CHECK FOR LEAKS. There are several fluids used inside the generator, e.g. diesel, oil, coolant. Look for signs of leakage all around the engine.

Any source of leak should be checked and fixed. Clean up any fluid lying inside the generator and dispose of according to the appropriate local regulations.

Recurring leaks should be reported to AGGREKO.

7.3. WEEKLY MAINTENANCE

7.3.1. CHECK THE WATER/ANTIFREEZE LEVEL. Stop the engine and wait for the temperature to cool before checking the coolant level.

Remove the pressure cap slowly to relieve the pressure of the cooling system. Failure to do so could result in personal injury from heated coolant spray (See Figure 7.2).

Check the coolant level. Replenish with the correct coolant fluid as necessary (see section 8).

Figure 7.2 - Coolant Level Check

7.3.2. CARRY OUT A VISUAL CHECK OF THE DRIVE BELTS. The cooling pump, alternator and radiator fan are driven by a dual belt arrangement from the engine pulley. Check the belts for signs of wear. Check the belt tension.

NOTE: Do not remove guards.



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8.0 LUBRICATION 8.1. GENERAL INFORMATION

Lubrication is an essential part of preventive maintenance, affecting to a great extent the useful life of the unit. Different lubricants are needed and some components in the unit require more frequent lubrication than others. Therefore, it is important that the instructions regarding types of lubricants and the frequency of their application be explicitly followed. Periodic lubrication of the moving parts reduces to a minimum the possibility of mechanical failures.

The Preventive Maintenance Schedule shows those items requiring regular service and the interval in which they should be performed. A regular service program should be developed to include all items and fluids. These intervals are based on average operating conditions. In the event of extremely severe (hot, cold, dusty or wet) operating conditions, more frequent lubrication than specified may be necessary. Details concerning lubrication of the running gear are in Maintenance Section.

8.2. GENERATOR OIL CHANGE These units are normally furnished with an initial supply of oil sufficient to allow operation of the unit for approximately 6 months or up to 1000 hours in line with current service recommendations, whichever comes first. The unit will however need to be topped up with oil during this period. If a unit has been completely drained of all oil, it must be refilled with new oil before it is placed in operation. Refer to specifications in Lubrication Table.

NOTICE: Some oil types are incompatible when mixed and result in the formation of varnishes, shellacs, or lacquers that may be insoluble. Such deposits can cause serious problems including clogging of the filters. Where possible, do NOT mix oils of different types and avoid mixing different brands. A type or brand change is best made at the time of a complete oil drain and refill.

If the unit has been operated for the time/ hours mentioned above, it should be completely drained of oil. If the unit has been operated under adverse conditions, or after long periods in storage, an earlier change period may be necessary as oil deteriorates with time as well as by operating conditions.

An oil change is good insurance against the accumulation of dirt, sludge, or oxidized oil products.

Completely drain the reservoir, piping, and Purafiner system. If the oil is drained immediately after the unit has been run for some time, most of the sediment will be in suspension and, therefore, will drain more readily. However, the fluid will be hot and care must be taken to avoid contact with the skin or eyes.

After the unit has been completely drained of all old fluid, close the drain valve. Add oil in the specified quantity at the filler plug. Tighten the filler plug and run the machine to circulate the oil. Check the oil level when unit is warm and not running. If not near the middle of the dipstick, stop the unit and make corrections. DO NOT OVERFILL.

8.3. OIL SPECIFICATION The oil required for this engine is:

Manufacturer: Castrol

Product Name: Tection T 15W-40 (Formerly RX Super Plus)

Relative Density @ 25°C 0.89 g/cm³

Viscosity @ 40°C 110 mm²/s

Viscosity @ 100°C 14.5 mm²/s

Viscosity Index 135

CCS –20ºC 6450 mPA.s

Total Base Number (TBN) 11.6 mgKOH/g

Flash Point (COC) 228 °C

Pour Point -36 °C

Sulphated Ash 1.5 %m



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9.0 TROUBLE SHOOTING 9.1. INTRODUCTION

Trouble shooting for a generator set is an organized study of a particular problem or series of problems and a planned method of procedure for investigation and correction. The trouble-shooting chart that follows in Section 9.3 includes some of the problems that an operator may encounter during the operation of a generator set.

The chart does not attempt to list all of the troubles that may occur, nor does it attempt to give all of the answers for correction of the problems. The chart does give those problems that are most probable to occur. To use the trouble shooting chart:

1) Find the problem being experienced in the Symptom column on the far left.

2) Proceed to work through the possible causes in the next column, instigating the appropriate corrective action where required from the next column.

9.2. ACTION PLAN A. Think Before Acting: Study the problem thoroughly and ask yourself these questions:

1) What were the warning signals that preceded the trouble? 2) Has a similar trouble occurred before? 3) What previous maintenance work has been done? If the generator will still operate, is it safe to continue operating it to make further checks?

B. Do The Simplest Things First: Most problems are simple and easily corrected. Always check the easiest and most obvious things first, following this simple rule will save time and trouble.

Note: For trouble shooting electrical problems, refer to the Wiring Diagram Schematic found in logbook.

C. Double Check Before Disassembly: The source of most generator troubles can be traced not to one component alone, but to the relationship of one component with another. Too often, a generator can be partially disassembled in search of the cause of a certain trouble and all evidence is destroyed during disassembly. Check again to be sure an easy solution to the problem has not been overlooked.

D. Find And Correct Basic Cause: After a mechanical failure has been corrected, be sure to locate and correct the cause of the trouble so the same failure will not be repeated. A complaint of "premature breakdown" may be corrected by repairing any improper wiring connections, but something caused the defective wiring. The cause may be excessive vibration.



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9.3. TROUBLE SHOOTING CHART

SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION

Batteries flat or bad. Read value on battery voltage meter

(must be 12V or more). Replace or charge batteries.

Mini circuit breaker of 10A in terminal box is open. Reset.

ENGINE DOES NOT CRANK WITH 12V ELECTRIC MOTOR

Start relay at cranking motor defective.

Measure the voltage over the start relay.

Fuel tank empty. Fill up fuel tank.

Air in the fuel system. Check system for leaks. Bleed the fuel system.

Dirty fuel filters. Replace fuel filters.

Check voltage (12V) over fuel shut-off valve during crank. Call for AGGREKO support.

Optional air shutdown valve closed. Open air shutdown valve.

ENGINE CRANKS BUT DOES NOT START

Overspeed protection is activated.

Put key back to 0 and try to start the engine again.



Overspeed during acceleration. Decrease frequency setting. ENGINE STARTS UP BUT STOPS AFTERWARDS

Shutdown after 6 seconds.

Check safeties: Oil pressure – Water

temperature – Water pressure – Oil temperature (option)

Frequency too high. Adjust frequency to the correct level.

Connection between governor and fuel pump interrupted. Repair connection. ENGINE OVERSPEEDS


Engine not yet at operating temperature.

Wait until engine has reached the normal operating

temperature of 80-90ºC.

Dirty fuel filters. Replace fuel filters. ENGINE SPEED NOT

STABLE

Wear in ball eyes, linkage governor / fuel pump. Replace ball eyes.

Dirty air filters. Replace air filters.



ENGINE SHOWS EXCESS SMOKE AND / OR LACK OF

POWER

Overload. Check load.

Voltmeter defective. Measure voltage at outlet

terminals of alternator. If voltage measured replace voltmeter.

ALTENATOR DOESN’T GENERATE VOLTAGE

Voltage regulator defective. Replace voltage regulator,



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SYMPTOM POSSIBLE CAUSE CORRECTIVE ACTION


Speed frequency too high / low.

Check frequency meter and adjust if required.

Incorrect voltage setting. Adjust voltage regulator. ALTENATOR VOLTAGE TOO

HIGH / LOW

No identifiable cause. Consult AGGREKO.

Engine speed not stable. Check stability of engine speed. ALTENATOR VOLTAGE NOT

STABLE Incorrect stability adjustment. Adjust stability on the voltage regulator.

Circuit breaker control switch (Figure 6.1) set remote control. Select local position. MAIN CIRCUIT BREAKER

WILL NOT CLOSE Circuit breaker tripped. Reset circuit breaker.

MAIN CIRCUIT BREAKER CLOSES BUT TRIPS AGAIN

Switch on overload or short circuit. Remove load.



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Appendix A - i

MATERIAL SAFETY DATA SHEETS

APP

END

IX A



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Appendix A - ii

CASTROL TECTION T 15W-40



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Appendix A - iii



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Appendix A - iv



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Appendix A - v



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Appendix A - vi

LEAD ACID BATTERIES

HEALTH & SAFETY LEAD ACID BATTERIES

############# The handling and proper use of lead-acid batteries is not hazardous provided sensible precautions are observed and that Operatives having been trained in their use are adequately supervised. The purpose of this letter is threefold:- [ i] to indicate potential hazards that may arise. [ ii] to outline the precautions to be taken to minimise such hazards. [iii] to indicate action to be taken in the event of an accident. 1. SULPHURIC ACID [S.G. 1.260 - 1.300] Batteries contain sulphuric acid which may leak for a variety of reasons and may be given off as droplets and/or spray during recharging. [The Hazards] Sulphuric Acid is a poisonous and corrosive clear liquid which can burn/irritate skin and eyes and could burn clothing. [Precautions] Always handle batteries with care Always store upright Never over-fill with acid Always charge in a well ventilated area. Maximum voltage 15v per each 12v Battery. Use eye protection and protective clothing if there is any risk of acid splashing. [Emergency Action] Skin Contact: Immediately wash the affected area with copious amounts of clean water. Remove any contaminated clothing. Eye Contact Immediately irrigate eyes for at least 10 minutes with clean water. Swallowing Make the victim drink volumes of water, milk or milk of magnesia. DO NOT GIVE EMETIC In all cases seek medical attention. Speed of action is vital. [Spillages] Small spillages can be swilled away with volumes of water. [Disposal] See Section 5. 2. ELECTRICAL ENERGY [The Hazards] The accidental connection of battery terminals by conductive objects, e.g. metal tools or metal personal jewellery etc., may generate sufficient heat to cause burns, create arcing or cause molten metal to splash.



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Appendix A - vii

[PAGE TWO]. [Precautions] Always ensure correct installation. The positive cable must be attatched to the terminal marked [+] and the negative to the terminal marked [-]. Cables and terminals should be kept clean and securely fitted. Before using metallic tools on a battery remove metallic objects from hands and wrists. Before working on a vehicle electrical system disconnect the Battery, disconnecting the earth strap first and reconnecting last. Do not place tools on top of batteries. [Emergency Action] Burns: Apply sterile bandage. Electric Shock: Approach victim with care. Switch off or otherwise break current. If not possible, detach victim from contact by means of insulating material [wood, rubber or plastic hosepipe, folded newspaper etc] Do not touch with bare hands. In each case seek medical advice. Speed of action is vital. 3. EMISSION OF GASES A mixture of oxygen and hydrogen is emitted during charging and may be emitted if a battery is moved or shaken. [The Hazards] An explosive atmosphere exists if the concentration of hydrogen exceeds 4%. [Precautions] Always charge in a well ventilated environment. No naked flames NO SMOKING Be certain that current is switched off before making breaking connection. Always remove earth strap first and re-connect last. [Emergency Action] Explosion: Seek medical advice remembering that acid may have been sprayed. 4. WEIGHT In general terms batteries are heavy and awkward to handle. Care should be taken and correct lifting techniques employed. 5. DISPOSAL Batteries, Battery Acid, Lead and Lead compounds must be disposed of in accordance with: [a] The deposit of Poisonous Waste Act 1972 [b] The Control of Pollution Act 1974 [c] Consumer Protection Act 1987 If in doubt, consult the Environmental Department of your Local Authority. For further information refer to:- BRITISH STANDARD BS 6604; 1985 SAFE OPERATION OF STARTER BATTERIES.



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Appendix A - viii

SUPERCOOLMASTER ANTIFREEZE



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Appendix A - ix



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Appendix A - x



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Appendix A - xi



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Appendix A - xii



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Appendix B - i

EQUIPMENT DATA SHEET

APP

END

IX B



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Appendix B - ii



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Appendix B - iii



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Appendix B - iiii

Document No.: M02.0193 Document Title: USER MANUAL GHP/8035U (Offshore) Issue: A Date: 08/09/05

Appendix C - i

INSTALLATION OUTLINE DRAWING

APP

END

IX C


Appendix C - ii


Appendix E - i

CONTROL PANEL LAYOUT

APP

END

IX D


Appendix E - ii


Appendix E - i

ALTERNATOR & AVR SCHEMATIC DIAGRAM

APP

END

IX E


Appendix E - ii


Appendix F - i

MAIN LOAD & METERING SCHEMATIC DIAGRAM

APP

END

IX F


Appendix F - ii


Appendix G - i

DC CONTROL SYSTEM SCHEMATIC DIAGRAM

APP

END

IX G


Appendix G - ii


Appendix H - i

TERMINAL LAYOUT & ENGINE WIRING

APP

END

IX H


Appendix H - ii


Appendix J - i

LIVERY LAYOUT DRAWING

APP

END

IX J


Appendix J - ii


Appendix K - i

MANUFACTURERS COMPONENT DATA

APP

END

IX K


Appendix K - ii

Document No.: M040104 Date: 19/09/05 Rev: A Title: GHP / 8035U (US) Spares List & Manufacturers Data.

DESCRIPTION QTY SUPPLIER / MANUFACTURER SUPPLIER PART No. AGGREKO PART

No. Radiator 1 Iveco 8008817 N/A

Radiator Fan 1 Iveco 4606454 N/A Coupling, Disc 2 Newage 45-0758 N/A

Charging Belt / Fan Belt 2 common Iveco 98473706 N/A Starter Motor 1 Iveco/Bosch 500338952 N/A

Battery Charging Alternator 1 Iveco/Marelli 4808497 N/A

Engine Protection Module 1 Deep Sea Electronics 5310 275156A

Circuit Breaker NSF150N (100A) 1 Merlin Gerin 37210 293334A Current Transformer 100/5A 3 Crompton CT35M100/5-1.5/1 273163A Water Temperature Switch 1 Iveco 08104141 N/A

Oil Pressure Switch 1 Iveco 08104140 N/A Lube Oil Filter 2 Iveco 1907567 N/A

Combustion Air Filter 1 Iveco 08014420 N/A Secondary Fuel Filter 2 Iveco 1902138 N/A

Primary Fuel Filter for 500FGS/S 1 Racor 2010-PM N/A


Appendix L - i

LIFTING BEAM CERTIFICATE

APP

END

IX L


Appendix L - ii


Appendix M - i

DNV SPARK ARRESTOR CERTIFICATE

APP

END

IX M


Appendix M - ii


Appendix M - iii


Appendix N - i

INTERNATIONAL CONTACT INFORMATION

APP

END

IX N


Appendix N - ii

In case of emergencies please contact the nearest service department of AGGREKO. They can be reached 24 hours a day and are operational at any place in the world

BELGIUM Aggreko N.V. Smallandlaan 7 2660 Hoboken Belgium Tel: (+32) 03 825 02 71 Fax: (+32) 03 825 11 81

FRANCE Aggreko S.a.r.l. 1 Chemin de l’Ancien Parc 91220 Bretigny Sur Orge France Tel: +33 (0)825 008007 Fax: +33 (0)1 69 737119

GREAT BRITAIN Aggreko Generators Ltd. Overburn Avenue DUMBARTON G82 2RL Tel: (+44) 1389 767821 Fax: (+44) 1389 761577

NETHERLANDS Aggreko International (Ned) B.V. Ketelweg 77 3356 LD Papendrecht Netherlands Tel: (+31) 078 64 41 441 Fax: (+31) 078 642 80 83

NORWAY Aggreko Norway A.S. Sorlandsveien 318 Postboks 543 EGERSUND N-4379 Norway Tel: (+47) 810 00 333 Fax: (+47) 051 46 45 90

SPAIN Aggreko Iberia S.A. Avda. Torre Mateu, 35-37 Polg. Industrial Can Salvatella 08210 Barbera del Valles BARCELONA Tel: (+34) 93 747 93 90 Fax: (+34) 93 729 02 83

EUROPE

GERMANY Frankfurt (Central Europe South East) Aggreko Deutschland GmbHDarmstadter Straße 66-68 64572 Büttelborn Germany Tel: +49 (0)61 52 93 93 0 Fax: +49 (0)61 52 93 93 99

GERMANY Mulheim (Central Europe North) Aggreko Deutschland GmbH Ruhrorter Straße 112 45478 Mülheim/Ruhr Germany Tel: +49 (0)208 58 09 70 Fax: +49 (0)208 58 09 798

ITALY Aggreko Italia srl Via Copernico, 60 20090 Trezzano sul Naviglio (Milano) Italy Tel: +39 02 4846 3024 Fax: +39 02 4451 243

NORTH AMERICA

CANADA Aggreko Inc. 300 Clarence Street Brampton, ONTARIO L6W 1T5 Tel: (+1) 905 459 3321 Fax: (+1) 905 459 3392

U.S.A. Aggreko LLC 4607 W Admiral Doyle Drive PO Box 10004 NEW IBERIA, LA 70562-0004 Tel: (+1) 337 365 5479 Fax: (+1) 337 367 0870

ASIA

REPUBLIC OF SINGAPORE Aggreko Singapore Pte Ltd 10 Pioneer Sector 1 SINGAPORE 62844 Tel: (+65) 6862 1501 Fax: (+65) 6862 0182

MIDDLE EAST

UNITED ARAB EMIRATES Aggreko Inc. PO Box 17576 Jebel Ali DUBAI Tel: (+971) 04 834059 Fax: (+971) 04 834145

AUSTRALIA / PACIFIC

AUSTRALIA/PACIFIC Aggreko Generator Rentals Pty Ltd 101 Woodlands Drive Braeside Victoria 3195 MELBOURNE Tel: (+61) 03 586 5050 Fax: (+61) 03 586 50514

USER MANUAL FOR GHP / 8035U (OFFSHORE) Document M02

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