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
Camshaft
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
Pushrods
Rocker arms
Spacer plates
Turbocharger
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.
Crankshaft
Inspect, and if necessary replace the following additional components.
Cylinder liners
Pistons
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:

Position 1:

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)

Position 2:

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

Position 3:

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

Position 4:

Generator control panel (Right side)
Right air shut-off solenoid
Right air filter assembly

Position 5:

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

Position 6:

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.

Megohmeter Testing

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