Procedural Guidelines - Projects Powered by Expertise
The following lists of USP&E Procedures are standard and are the most thorough demonstration of our unsurpassed commitment to service and maintenance excellence. You see, we are in the expectations business. Our objective is to exceed yours every single time. We do this through detailed, precise, daily reporting, through the strict adherence to our procedural guidelines and through regular, proactive communication.
USP&E'S SERVICE SCHEDULE
Daily Visual Checks
- Fuel system for water and sediment
- Cooling system, coolant level
- Engine air pre-cleaner
- Engine oil level
- R6P Visual 58-point inspection
Service One Check
- The service one check is a standard service check, performed every 500-service hours. On the initial service check the engine valve lash and fuel injectors will be inspected/adjusted
- Engine oil filters - replaced
- Engine fuel filters - replaced
- Engine oil - replaced
- Engine crankcase breather - clean/replace
- Belts - inspected/adjusted/replaced
- Battery - electrolyte level checked
- Engine oil sample - obtained
- Cooling system - coolant sample obtained
- Cooling system - supplemental coolant additive tested/adjusted
- Fan drive bearing - lubricated
- Generator bearings - lubricated
- Hoses and clamps - adjusted/replaced
- Radiator - inspected/cleaned
- Air shut-off - test
Service Two Check (Light-check)
- The service two check looks closely at the mechanical functionality of the engine/generator mounting at 2000 service hours and also incorporates the standard service check.
- Engine mounts - checked
- Generator - isolation mounts - checked
- Crankshaft vibration damper - inspected
- Turbochargers - inspected
Service Three Check (light check)
- The service three check is performed at 4000 service hours and also incorporates the standard service check.
- Engine valve lash - inspect/adjust
- Fuel injector - inspect/adjust
Service Four Check (light check)
- The service four check is performed at 6000 service hours and also incorporates the standard service check.
- Magnetic pick-ups - clean/inspect
- Air shut-off damper - remove/check
- Alternator - inspection
- Cooling system water temperature regulator - replace
- Fuel injector - inspection/adjustment
- Starting motor - inspection
- Prelube pump - inspection
- Water pump - inspection
A-Check (Top End Overhaul)
- The A-Check is performed at 9000 service hours and replaces the Electronic unit injectors. The standard service check is also incorporated.
- Inspect the following components.
- After cooler core
- Driven equipment (alignment)
- Engine Control Module (ECM)
- Oil suction screen (inspect/clean)
- Inspect, and if necessary replace the following components.
- Camshaft followers
- Cylinder head assembly
- Scavenge oil pump
- Engine wiring harness
- Exhaust manifold seals
- Exhaust manifold bellows
- Fuel pressure regulating valve
- Fuel priming pump
- Fuel transfer pump inlet manifold gaskets
- Inlet manifold seals
- Oil pump
- Prelube pump
- Rocker arms
- Spacer plates
- Software updates
B-Check (Second-Top End Overhaul)
- The B-Check is performed at 18000 service hours, it replaces and inspects the same components as the A-Check with the exception of the following components. The standard service check is also incorporated.
- Inspect the following additional component.
- Inspect, and if necessary replace the following additional components.
- Cylinder liners
- Piston pins
- Connecting rods
- Connecting rod bearings
Heavy Check (Major Overhaul)
- The heavy check is performed at 27000 service hours. The standard service check will also be incorporated.
- The heavy check/major overhaul inspects the same components as the B-Check with the exception of the following components.
- Oil cooler core
- Fuel transfer pump
- Engine mounts
- Crankshaft vibration damper
- Camshaft thrust washers
- The heavy check replaces the following components.
- Piston rings
- Main bearings
- Camshaft bearings
- Connecting rod bearings
- Crankshaft seals
- Crankshaft thrust washers
- Electronic unit injectors
- Gear train bushings
- Gear train bearings
Radial Six Position Visual Inspection
USP&E's R6P daily inspection involves a trained technician checking every item visible from six positions around every gen-set. The positions create overlapping zones, ensuring essential redundancy during each inspection. This process was created to eliminate the possibility of errors.
USP&E's R6P visual inspection covers 58 inspection items and is guaranteed to provide 100% overall coverage of the engine/power plant, every day.
THE POSITIONS ONE THROUGH SIX WILL VISUALLY CHECK THE FOLLOWING ITEMS:
- Left side radiator
- Left radiator fan shroud/guard
- Left radiator support brackets
- Left radiator coolant lines and connect points
- Radiator fan drive motor
- Drive motor belts
- After cooler temperature sensor
- Atmospheric pressure sensor
- Primary engine control module
- Left turbo outlet pressure sensor
- Fuel filter pressure sensor (filtered)
- Fuel filter pressure sensor (unfiltered)
- Engine coolant temperature sensor
- Engine oil pressure sensor (filtered)
- Engine oil pressure sensor (unfiltered)
- Engine control module circuit breaker
- Left turbo exhaust temperature sensor
- Engine start aid solenoids
- Crankcase breather assembly
- Left turbo inlet pressure sensor
- Left air filter pressure differential indicator's
- Left turbo chargers
- Left turbo charger lubrication drain lines
- Left turbo charger lubrication supply lines
- Left exhaust system
- Starter motors
- Generator control panel (left side)
- Left air shut-of solenoid
- Engine speed timing sensor
- Engine speed sensor (EMCP)
- Left air filter assembly
- Emergency stop (E-stop) switch
- Generator control panel (Right side)
- Right air shut-off solenoid
- Right air filter assembly
- Right turbo inlet pressure sensor
- Right turbo exhaust temperature sensor
- Oil fill cap security
- Oil cooler assembly
- Engine alternator circuit breaker
- Right turbo chargers
- Right turbo charger lubrication drain lines
- Right turbo charger lubrication supply lines
- Oil level gauge (dip stick)
- Right exhaust system
- Crankcase pressure sensor
- Prelube pressure switch
- Prelube motor
- Electronic instrument panel
- Engine alternator
- Oil filter housing assembly
- Secondary fuel filter housing assembly
- Fuel prime pump assembly
- Right side radiator
- Right radiator fan shroud/guard
- Right radiator support brackets
- Right radiator connect points
- Radiator fan assembly
Note: Visual inspection of all fluid leaks, seeps and sweating. Electrical wiring harness chaffing and fraying, exposed conductors and damaged connectors will be conducted from all six inspection positions during USP&E's daily R6P visual inspection.
Power Transfer Procedure:
Normal Generator Power Transfer from Standby to Prime-Online.
- Pre-check and start standby Power Plant, allow power plant to stabilize.
- Inform switch gear control personnel which power plant is ready to be switched to prime-online and which power plant is to enter the off-line cool down for servicing.
Emergency Generator Power Transfer from Standby to Prime-Online.
- In the event of a power plant failure, or an audible, visual or monitored abnormality that might cause damage to a power plant.
- The standby power plant will be readied for prime-online, while the switchgear control personnel are informed of which unit is coming off-line (depending on the nature of the problem, this power plant may already be off-line).
- The standby power plant will be placed on prime-online as soon as the rpm's and pressures are confirmed normal.
- The target time line for emergency power transfer is less than 5-minutes from the time of indicated abnormality.
This test ensures the integrity of your generators insulation.
- Electrical windings in generators are covered with epoxy insulation. Vibration, general usage or moisture can break the epoxy down and cause electrical shorts.
- A Megohmeter Test will identify any decrease in your generator's epoxy capacity, saving you from a major repair bill or replacement of the generator.
- Recommended every six months for Prime or Continuous applications, every 12 months for load management or standby applications
Infrared Testing of Switchgear procedure
Infrared Testing measures your electrical distribution switchgear for problem areas or hot spots.
- Our experts are trained to visually and manually inspect the physical, electrical and mechanical condition of your electrical distribution switchgear and visually inspect for bus alignment.
- Our experts are trained to scan distribution equipment and:
- Remove all necessary covers prior to scanning
- Provide written report, which includes:
- Problem areas or hot spots
- Temperature rise between hot spot & normal reference area
- Cause of heat rise
- Phase imbalance, if present
- All areas scanned
- Replace removed covers
Load Bank Testing procedure
Load Bank Testing confirms the ability of your generator to produce a given kW and attain proper engine operating temperature. Benefits of Load Bank Testing are:
- Exercising of cooling system
- Reseat engine piston rings in the cylinders and liners
- Burn off carbon deposits in the combustion chamber, injector nozzles, piston rings, turbocharger and exhaust system
- Dissipate any condensation build-up on generator's copper windings
- Engine safety shutdowns will be fully tested