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BERI NOT TAKING LOAD PROBLEM
DATE - 17/02/2012
Customer Details
Name : BERI (Biomass Energy for rural India Society
Address : Seebinayanapalaya village, Madhugiri taluka, Tumkur dist. karnataka
ESN : 25301573
Engine Model : GTA 855 G BC (Producer Gas Engine)
Problem desc. : Engine not taking more than 40 % load
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Ignition system observation & Action taken 1) Spark Plugs : Spark plugs not changed since 4 years,
Hence replaced the same.
2) Altronic : While cranking generating < 90 VDC for all six cylinders.
3) Ignition transformer : Checked Ignition transformer found below values.
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Ignition Coil number Primary coi l (Ohm) Secondary coil ( K Ohm)
Cylinder 1 1.2 6.50
Cylinder 2 1.1 6.10
Cylinder 3 1.4 6.68
Cylinder 4 1.2 6.40
Cylinder 5 1.2 6.22
Cylinder 6 1.2 6.10
Gas train observations & Action taken
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Observed Gas pressure before regulator : 300 mm of H2O
Opened ZPR top cover observed no TAR formation
Opened Carburetor observed no TAR formation
Observed Gas pressure after ZPR : - 40 mm of H2O (suction Pressure )
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Base Engine observations & Action taken
Found dry Carbon In After cooler. Cleaned by Pressurized air
Checked opening & Closing of Butterfly Valve found OK
Checked Blow by of Engine found 2” of H2O
Cheked altroicCranking Voltage found within limit
Checked Turbo Rotation & cleanliness found OK
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Gasifier side observations
Chiller temperature 7 Deg C
Oxygen in ExhaustGas : 1.5 to 0.4 %
Gas flame reddish in colour
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Problem resolution
Observed Exhaust Back pressure more than 7-8 “ of Hg
Observed Exhaust back pressure more than 7 “ of Hg due to restriction in exhaust piping / silencer .
After removal of bellow Turbo functioned properly & Engine taken 100 % load.
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Suggestions
• To clean Exhaust piping in every one year if Engine is being kept idle for more time.
• To keep maintenance spares at site premises.
• To clean Gas line & after cooler in every 500 hrs.
• To carry out maintenance of engine at regular recommended time intervals.
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Maniranjan Diesel Sales & service - Service Escalation Process
Service HeadM G Kulkarni9448496917
CEOAtul Thakur 9480697266
HODC N Deshmukh9448496910
Service EngineerGanesh Madhiwal
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Cummins India Limited - Service Escalation Process
Tech Support GasAtul Patil
Area Service managerKoushik Manna
Zonal Service headKrishnan Arumugam
Sr. Manager ServiceS Loganath 9448396741
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THANKS
