Method of Procedure for

Preventive Maintenace and

Testing Genset With Load

March 20, 2013

Initial Drafted
by:

Managed
Service TOC DEA

Date:

Reviewed by:

Dhiyaul Falah

Date:

Reviewed by:

Date:

Approved by:

Date:

March 20, 2013

MOP for Preventive Maintenance and Testing Genset with Load

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Revision Record
Date

Revised Version

Change description

Author

V1.0

MOP for Preventive Maintenance and Testing Genset with Load

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Table of Contents
1

BACKGROUND AND OBJECTIVES................................................................4

2
PREREQUISITES..................................................................................................
.....................5
3

SCOPE OF WORK........................................................................................ 7

DETAIL TIME TABLE OF OVERALL ACTIVITY.................................................8

DETAIL OPERATION AND EXECUTION.......................................................11

SERVICE AND AREA IMPACT.....................................................................13

ROLLBACK OPERATION.............................................................................14

PERSON IN CHARGE.................................................................................15

SUPPORTING DOCUMENTS.......................................................................16

MOP for Preventive Maintenance and Testing Genset with Load

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1 BACKGROUND AND OBJECTIVES

1.1 Purpose
Purpose of This testing is to determine whether generator can handle the
load TOC Tower DEA when main source from PLN off.

1.1 Schedule
Date : 22 March 2013 to 24 March 2013
Time : 16.00 05:00

1.2 Location
TOC Menara DEA Jakarta
Gedung Menara Dea
Jakarta

MOP for Preventive Maintenance and Testing Genset with Load

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2 PREREQUISITES
This section contains information on the personal Health & Safety
Information, tools, equipment, and conditions required for the installation
procedure.

2.1 Personal Health and Safety Information

Personal health and safety admonitions are used to indicate hazardous
activities and are normally preceded by the common hazard symbol shown in
the figure, or in specific cases by specialized symbols.

Safety Hazard Symbol

The hazard symbol is common for all three admonitions levels. The three
admonition levels are defined below :
Danger
result in death or

Indicate that there is an imminent hazard that is likely to

serious injury.
Note : Danger can be accompanied by other symbols
depending on the country
of operation.
Warning
Indicates that there is a potential hazard that could result in
death or injury.
Caution
injury.

Indicates a hazard that could result in minor or moderate

2.2 Safety Precautions for Avoiding Energy Hazards

The following precautions must be observed when working with DC / AC and
other that present an energy hazard:
1. All metallic objects worn, such as wrist watches, rings, bracelets, and
so on are removed.

MOP for Preventive Maintenance and Testing Genset with Load

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2. Only use Insulated tools
3. Using proper PPE

2.3 Safety
All Emerson Standard safety methods should be understood and practiced.
Protective goggles, gloves, step ladder, hard Hat and Safety Shoes must be
worn while working on the equipment that present hazard. Extreme care
should be taken to prevent injury from falls.

2.4 Document
Make sure that the following documents are read and understood:
1. MOP preventive maintenance and testing genset with load TOC Menara
DEA
2. Approved WP by AXIS

2.5 Tools

Tools standart (screw driver, wrench)

2.6 PPE

Goggles

Leather Gloves

Safety Shoes

MOP for Preventive Maintenance and Testing Genset with Load

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3 SCOPE OF WORK

Preventive maintenance including change oil, change fuel filter,

change oil filter, change radiator water

Emerson will test the genset with load at TOC menara DEA by
simulation PLN blackout and genset should supply TOC load

MOP for Preventive Maintenance and Testing Genset with Load

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4 DETAIL TIME TABLE OF OVERALL ACTIVITY

Time

Operation

Detail Service Impact

Preparation Genset# 1
16:00

Check Fuel level in the bulk tank,

and record from sight glass and No effect
fuel meter reading.

16:05

Check and record Fuel level in the

No effect
daily tank.
No effect
Check Fuel filter

16:10
16:15
16:20
16:30
16:35

16:40
16:45
16:50
17:00
20:25

Check Oil level Engine in dip stick

Check Oil filter
Check Radiator Coolant level
Check the Battery condition
(voltage, electrolyte level,
Physical condition) and add the
pure water if necessary.
Check for cracking, fraying &
tension of all Belts

No effect
No effect
No effect
No effect

No effect

Check and record DC meter value No effect

in genset or ATS
No effect
Check all fuel piping
Check environment of genset
Check environment of genset

No effect
No effect

Testing simulation PLN Blackout and genset should supply TOC Load
00:05

00:10

No effect
Record which genset is set as
prime
Inform NOC that the genset test No effect
will be started. Record the name
of person of NOC, and the time of
notification

MOP for Preventive Maintenance and Testing Genset with Load

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00:15
00:20
00:25
00:30
00:35
00:36
00:37
00:38

00:40

00:40

00:42

00:45

00:47

00:50

Check all UPS and rectifier in

No effect
normal operation and there is no
alarm present
Check selector switch on
No effect
AMF/ATS (B3), should be on
Automatic position
Check timer setting on AMF/ATS No effect
(B3), should be set in 5 second
Check all MCB sensing on
No effect
AMF/ATS (B3), should be ON
position
Check selector switch on
No effect
AMF/ATS (LG), should be on
Automatic position (each Genset)
Check display AMF/ATS (LG),
No effect
should be on Automatic position
(each Genset)
Check selector switch on Genset No effect
Outgoing Panel (LG), should be
on Automatic position
No effect
Make sure prime genset is
genset #2
Push Off Button on ACB at ATS
(B3). PLN power will be
For less than 5 second, TOC will
disconnected, Record number of be back-up by UPS & Rectifier,
second from PLN fail to genset
after that by genset
power online
Network will get no power if
genset fail to run, if it's
All genset (3 unit) must be
happened immediately
running together online
terminate genset test by push
the On button in ACB
After genset running, the Control
Network will be supplied by
of Genset will detect the load to
Genset. A number of genset
calculate how many genset
running depend on the load
should be running. Record how
capacity
many genset running
Check all equipment in all TOC
Network will be supplied by
facilities, should be Normal
genset that running.
condition
Reset all external alarm at B3
Floor, 3rd Floor and 5th Floor. All Network will be supplied by
LED should be Green except
genset that running.
Genset Running LED and PLN Fail
Check Exhaust System ( smoke :
Network will be supplied by
Black or Blue, leakage, excessive
genset that running.
noise.

MOP for Preventive Maintenance and Testing Genset with Load

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01:10

Record all data and complete

genset service report

Network will be supplied by

genset that running.

Back to PLN Power Source

01:40
01:45
01:50
01:55
01:57
01:59
02:00

Turn on ACB at ATS (B3) by push

ON button
Check at AMF/ATS that all load
has switch back from genset to
Main Input (PLN)
Genset still running on Cooling
Down mode for 120 second
Keep genset prime selected to
the current genset for 1 month
Check all equipment in all TOC
facilities, should be Normal
condition
Reset all external alarm at B3
Floor, 3rd Floor and 5th Floor. All
LED should be Green
Set the AMF/ATS (LG), All genset
must be Automatic.

Network will be supplied by

main source (PLN)
No effect
No effect
No effect
No effect
No effect
No effect

Rollback operation If genset fail to run and fail to back up power

00:40
00:43

Turn on ACB at ATS (B3) by push Network will be supplied by

ON button
main source (PLN)
Check at AMF/ATS that all load
has switch back to Main Input
No effect
(PLN)

10

MOP for Preventive Maintenance and Testing Genset with Load

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5 DETAIL OPERATION AND EXECUTION

Preparation
Check Fuel level in the bulk tank, and record from sight glass and fuel
meter reading.
If the level reaches 50% or less, inform NOC and NTS network
operation.
Check and record Fuel level in the daily tank
If fuel level low, check fuel pump running and adding fuel to the daily
tank
Check Fuel filter
Replace fuel filter every 250 running hours Or 6 months
Check Oil level Engine in dip stick
Add if needed to meet the requirement, record quantity of oil added
Replace every 250 running hours Or 6 months (record run hours in
data sheet)
Check Oil filter
Replace every 250 running hours Or 6 months (record the running
hours in data sheet)
Check Radiator Coolant level
Add if needed to meet the requirement (record the additional in
datasheet)
Check the Battery condition (voltage, electrolyte level, Physical
condition)
Check battery voltage using DVM (must between 26V floating volt) if
outside voltage range, request for TT, and do maintenance action
Add distilled water if battery electrolyte is under the lower level limit
Check the leakage on the terminal and clean if needed
Check Battery connection for cleanliness, remove any corrosion and
add battery grease, re-tighten the connection if needed
Check for cracking, fraying & tension of all Belts
Replace if needed
Check and record DC meter value in genset or ATS
Check all fuel piping
Rectify for any leakage occur
Check environment of genset
floor & genset housing cleanliness, remove any debris
Clean any leakage from fuel or water
Testing simulation PLN Blackout and genset should supply TOC Load
Record which ATS is active
Inform NOC that the genset test will be started. Record the name of
person of NOC, and the time of notification
Check all UPS and rectifier in normal operation and there is no alarm
present

11

MOP for Preventive Maintenance and Testing Genset with Load

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Check selector switch on AMF/ATS (B3), should be on Automatic
position
Check timer setting on AMF/ATS (B3), should be set in 5 second
Check all MCB sensing on AMF/ATS (B3), should be ON position
Check selector switch on AMF/ATS (LG), should be on Automatic
position (each Genset)
Check selector switch on Genset Outgoing Panel (LG), should be on
Automatic position
Make sure prime genset is genset #2
Genset #2 on automatic position
Push Off Button on ACB at ATS (B3). PLN power will be disconnected,
Record number of second from PLN fail to genset power online.
Network will be supplied by genset
All genset (3 unit) must be running together online
Check all equipment in all TOC facilities, should be Normal condition
Reset all external alarm at B3 Floor, 3rd Floor and 5th Floor. All LED
should be Green except Genset Running LED and PLN Fail LED
After genset running, the Control of Genset will detect the load to
calculate how many genset should be running. Record how many
genset running
Check Exhaust System ( smoke : Black or Blue, leakage, excessive
noise )
Record all data and complete genset service report
Back To Main Source (PLN)
Turn on ACB at ATS (B3) by push ON button
Network will be supplied by main source (PLN)
Check all equipment in all TOC facilities, should be Normal condition
Reset all external alarm at B3 Floor, 3rd Floor and 5th Floor. All LED
should be Green
Set the AMF/ATS (LG), All genset must be Automatic.
Rollback operation If genset fail to run and fail to back up power
Turn on ACB at ATS (B3) by push ON button
Network will be supplied by main source (PLN)
Check at AMF/ATS that all load has switch back to Main Input (PLN)

12

MOP for Preventive Maintenance and Testing Genset with Load

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6 SERVICE AND AREA IMPACT

Network will be backed-up by UPS and Rectifier while lost power from
PLN or genset for less than 5 seconds.
This is the transfer period of transfer power supplied from main source
(PLN) to Genset

Network will be backed up by UPS and rectifier if genset fail to run, if

its happened immediately terminate genset test by Close MCB Control
of ACB in ATS Panel. Network will be back up by main power (PLN)

Network will be supplied by 3 Genset during the test with load.

Network will be supplied by main source (PLN).

Network will be supplied by main source (PLN) in normal condition.

13

MOP for Preventive Maintenance and Testing Genset with Load

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7 ROLLBACK OPERATION

If genset fail to run, if it's happened immediately terminate genset test

by push the On button in ACB. Network will be back up by main
power (PLN)

Make sure by Checking at AMF/ATS that all load has switch back to
Main Input (PLN)

14

MOP for Preventive Maintenance and Testing Genset with Load

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8 PERSON IN CHARGE
Name
Ade
Kurniawan
Ahmad
Jaelani
Dhiyaul
Falah
Rizal
Arif
Ferry
Komaruddin
Yehuda Deo

Company

Phone Number Roles and Responsibilities

Emerson

08119205656

Emerson

081586239966

Emerson

08211232151

Emerson
Emerson
Emerson
Emerson
Emerson

083897705626
083897705626
083897705626
083894345026
083873057767

Supervisor
Supervisor
MS TOC DEA Engineer
MS TOC DEA Engineer
MS TOC DEA Engineer
MS TOC DEA Engineer
Power Engineer
Power Engineer

15

MOP for Preventive Maintenance and Testing Genset with Load

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9 SUPPORTING DOCUMENTS

16