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Change Record
Revision A Date April 25, 2013 Affected Paragraphs(s) All Reason/Initiation/Remarks Initial release.
TABLE OF CONTENTS
1 Introduction ..................................................................................................................................... 3 1.1 1.2 1.3 1.4 1.5 1.6 1.7 2 Purpose.................................................................................. Error! Bookmark not defined. Scope ..................................................................................... Error! Bookmark not defined. Responsibility ......................................................................... Error! Bookmark not defined. Applicable Documents List (ADL) .......................................... Error! Bookmark not defined. Reference Documents List (RDL) .......................................... Error! Bookmark not defined. Abbreviations and Acronyms ................................................. Error! Bookmark not defined. Terms and Definitions ............................................................ Error! Bookmark not defined.
Plan ................................................................................................ Error! Bookmark not defined. 2.1 2.2 2.3 2.4 2.5 Cleanliness ............................................................................................................................ 1 Re-lubrication of the Bearings ............................................................................................... 1 Helium Supply ........................................................................................................................ 1 Air Filters ................................................................................................................................ 1 Summary................................................................................ Error! Bookmark not defined.
INTRODUCTION
EQUIPMENT TREE
The generic maintenance equipment tree for the flywheels is shown in the following picture:
POWER DISTRIBUTION SYSTEM
System Level
Flywheel
Motor/Generator
Control System
EQUIPMENT LIST
The list of the Piller Uniblock UPS equipments in responsibility of theMG is shown in the following table:
Equipment Uniblock UPS XLA Uniblock UPS XLB Uniblock UPS XLC Uniblock UPS XLD
4
# 1 2
MAINTENANCE PLAN
Maintenance Task Description Monthly General Inspection Quarterly Maintenance Freq (Days) 30 90 Skills OPER MECH 1 ELEC1 Personnel Qty. 2OPER 1MECH1 1ELEC1 Equipment Condition Running Shutdown Typ e PM PM Est. Time (hrs) 5 7
Cmo indico que las actividades 4, 5 y 6 podrn gatillar una accin correctiva?
The Piller UNIBLOCK Flywheels are largely maintenance free, nevertheless, the operations shall be carried since they contribute to trouble-free operation and increase service life of the installation. Following the maintenance tasks are described; all of them are based on recommendations from Piller. 4.1
4.2 4.2.1
Quarterly Maintenance
Cleanliness
The environment around the plant must be free of dust, metal swarf, lubricants, etc. A quarterly check of all the air inlets and outlets must be performed to verify that they are free of dust or any other blocking objects. Air inlet openings must be sucked. No compressed air shall be used, since this can blow dust particles into the set and cause malfunctions 4.2.2 4.2.3 Tightening Re-lubrication of the Bearings
The UNIBLOCK-T Diesel UPS is equipped with two independent automatic greasing pumps that are using two different kinds of lubricants, which cannot be mixed with other lubricants. The grease type is written on the plate of the grease pump. The refilling must be performed when the grease container is totally empty, condition that will trigger an alarm. Also, the grease has a life of 3 years without loss of quality, so at that time it must be always replaced by new. Also, a quarterly check to the grease pipes shall be performed for detecting leakages and to the bearings in order to detect undue noise. Squealing noise can be caused by inadequate lubrication, scrapping or rumbling noises can be caused by dust or a faulty bearing.
4.2.4
Helium Supply
A Helium bottle is used to reduce working temperature, the pressure of this bottle is monitored by the Flywheel and as soon as is 3 bar or lower and alarm is triggered indicating to change the Helium bottle. Replacement doesnt require the machine to be shut down. The purity of the helium in bottle has to be 99,996% or better.
4.2.5
Air Filters
The UNIBLOCK-T is equipped with two different air inlet filters, which are being monitored by the Flywheel and an alarm will trigger in case they are contaminated. Nevertheless, they must be inspected monthly, and replaced if it is necessary. 4.3
SUMMARY
Hour Type OPER MECH1 MECH2 ELEC1 ELEC2 CONTRACTOR TOTAL SHUTDOWN JAN 30 0 0 0 0 0 30 0 FEB 30 0 0 0 0 0 30 0 MAR 30 21 0 21 0 0 72 9 APR 30 0 0 0 0 0 30 0 MAY 30 0 0 0 0 0 30 0 JUN 30 21 0 21 0 0 72 9 JUL 30 0 0 0 0 0 30 0 AUG 30 0 0 0 0 0 30 0 SEP 30 21 0 21 0 0 72 9 OCT 30 0 0 0 0 0 30 0 NOV 30 0 0 0 0 0 30 0 DEC 30 21 0 21 0 0 72 9 ANNUAL 360 84 0 84 0 0 198 36
JAN 0 0 0
FEB 0 0 0
MAR 1 1 1
APR 0 0 0
MAY 0 0 0
JUN 1 1 1
JUL 0 0 0
AUG 0 0 0
SEP 1 1 1
OCT 0 0 0
NOV 0 0 0
DEC 1 1 1
ANNUAL 4 4 4
Cost Type Oper Mech1 Mech2 Elec1 Elec2 Contractor Grease Helium Bottle Air Filter Total
Table 6: Monthly and Annual Costs (US$) Work Order Type Operations Maintenance Total JAN 1 0 1 FEB 1 0 1 MAR 1 1 2 APR 1 0 1 MAY 1 0 1 JUN 1 1 2 JUL 1 0 1 AUG 1 0 1 SEP 1 1 2 OCT 1 0 1 NOV 1 0 1 DEC 1 1 2 ANNUAL 12 4 16