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FINAL REPORT FOR MINOR PREVENTIVE MAINTENANCE, BANKS DIH, LTD ENGINE NO.2

Attention: Mr. Shabir Hussein Power Plant : Banks DIH, LTD

2017

Santo Domingo, DR Prepared by : Jose Torres

26/01/2017

1. INTRODUCTION

BANKS DIH requested the services of ESD Engineering & Services for minor maintenance of engine No.2 to ensure a reliable operation, for this reason we traveled to BANKS DIH power plant to assist with the services requested. 2. WORK OBJECTIVES Intervene the recommend components, to hold the unit operating in normal condition and ensure a high availability. 3. DETAILS OF WORKS REALIZED 3.1. Inspection and conditioning of fuel injection valves. We dismantle the injection valves for repair because their conditions, installing new components such as nozzles, metal gaskets, Also pressure test and inspect the opening pressure recommended in the operation which we present in ranges of 4-6 bar 8-10 bar for LO and HFO fuel. 3.2. Dismantle the injection pump #4 for cleaning and changing O-rings It was dismantled injection pump No. 4 for cleaning and changing O-ring which then reinstalled in the engine 3.3. Dismounting of the fuel duplex filters for conditioning The fuel filters were disassembled for cleaning and inspection as they showed dirt, and then were installed in the engine again in normal conditions. 3.4. Adjustment of tolerances of exhaust and inlet valves. Were readjusted the tolerances of exhaust and inlet valves to 0.50 mm, with the aim of adjustment of normal tolerances. 3.5. Inspection and cleaning of condensate valve We proceed to disassemble the condensate valve for cleaning and inspection thereof and improve drainage of condensate from the engine. 3.6. Inspection of the nuts and bolts of the main components We proceed to inspect the nuts and bolts of the main engine components, which are securing the most important engine components, such as the con. rod, big end bearing, camshaft, counter weights and main bearing. 3.7. Disassembly of oil filters to change due to high pressure oil differential The oil filters were replaced due to the high pressure differential. We installed new filters to normalize the lubrication system. 4. CONCLUSION

During inspection 61,582hrs of engine No.2, it was preceded to realize the inspection of the components included in the maintenance schedule to hold the parameters in normal conditions. The service was completed without any incident and the engine was left in good condition and within normal parameter.

5. RECOMMENDATIONS

- Realize periodically inspection in condensate valve to prevent a large amount of water accumulated in the

combustion system of the engine. - Follow all engine operation process to lengthen the life of engine components.

6. ANNEX

- Measurements records. - Time sheet. - Acceptance Services Works. 7. Photos of activities realized.

Disassembly of the fuel injection valves the fuel injection valves condition found

Disarming of the fuel injection valves High pressure block reconditioned

New nozzle for fuel injection valves Assembly of the fuel injection valves

Fuel injection valves pressure test 450 bar Injection valves repaired

Fuel injection valves installation High pressure block installation

Fuel injection pump #4 plunger dismounting Plunger condition #4 found

Fuel injection pump #4 clean Plunger new Oring installation

Fuel injection pump assembly Fuel injection pump installation

Disassembly of the fuel duplex filter Fuel duplex filter condition found

Fuel duplex filter conditioning Fuel duplex filter drain valve reconditioned

Fuel duplex filter reconditioned Fuel duplex filter Installation

Adjustment of tolerances of exhaust and inlet valves Condensation valve condiction found

Condensation valve reconditioned Condensation valve installation

Connecting rod nut inspection Big end bearing nut inspection

Counter weight nut inspection Engine ready to Star

Star engenet Engine load 1,500 KW

Engine fire presure test Engine parameter inspection

End

Por el mejor grupo de negocio

Performance Measuring Record MDU #2 Visión 2020 = 300M + 10F + CA

General Description Unit Before After Running hours HRS 61,582 61,584 Load KW KW 1,300 1,500 Load Per percentage % 70 85 Current A 2000 2,200 Voltage V 440 440 Frequency HZ 60 60 Engine Speed RPM 900 900 Power Factor F.P. 0.80 0.80 Governor Position MM 4.6 4.6 Turbo charge speed RPM 3462 3760 Temp Press Mm Temp Press mm

Exaust Temp.Cylinder Unit

1

350 ± 400 °C

330 142 23 330 148 25 2 340 142 23 350 148 25 3 300 140 23 330 148 24 4 300 142 23 350 148 26 5 340 140 24 350 150 25 6 300 140 24 360 150 25 7 350 142 23 350 150 25 8 300 140 23 340 150 25 9 310 142 24 360 150 25

Temperatures Exhaust Gas Temp Inlet T/C 450 ~ 520 °C 489 490 Exhaust Gas Temp Outlet T/C 250 ~ 350 °C 360 370 Charge Air Temp. After Cooler 35 ~ 55 °C 45 46 Lube Oil Temp.Inlet Engine 60 ~ 70 °C 65 65 L.T Water Temp. Inlet Outlet Engine 30 ~ 40 °C 36 36 H.T Water Temp. Inlet Outlet Engine 75 ~ 85 °C 75 75 Fuel Oil Temp. Inlet Engine 110 ~ 140 °C 107 107 D.O Temp. Inlet Engine 30 ~ 45 °C N/A N/A

Generator Rear Bearing Temp. (L1) 75 ~ 80

°C 79 79

(L2) 75 ~ 80 82 82 (L3) 75 ~ 80 79 79

Temp. De Bearing De Generador 75 ~ 80 °C 56 56 Pressures Start Air Press. Engine 20.0 ~ 28.0 BAR 20.0 20.0 Charge Air Press. Inlet Engine 2.5 ~ 3.2 BAR 1.5 2.1 Air Press. Emergency Stop 8.0 ~ 10.0 BAR 7.5 7.5 L.T Water Press. Inlet Cooler 1.5 ~ 4.5 BAR 1.8 1.8 H.T Water Press. Inlet Engine 1.5 ~ 4.5 BAR 3.4 3.4 Lube Oil Press. Inlet Turbocharger 2.0 ~ 4.0 BAR 3.2 3.2 Lube Oil Press. Inlet Engine 4.0 ~ 5.0 BAR 4.7 4.7 Lube Oil Press. Inlet Filter 4.0 ~ 5.0 BAR 4.9 4.9 Lube Oil Press. Differential 0.1 ~ 1.0 BAR 0.2 0.2 Fuel Oil Press. Inlet Engine 8.0 ~ 10.0 BAR 9.3 9.3 D.O Press. Inlet Enginet 3.0 ~ 6.0 BAR N/A N/A Customer ESD Engineering & Service