Gen Set History

Engineering Department of Sibu Island Resort Mersing, Johor Prepared by Mohd Nazim / Khairul Asra

Generator set history Updated January 2012. ________________________________________ Page 1 of 10

Layout of generator set inside Generator Plant Room

Iveco Generator Set 400kVa

Deutz Generator Set 500kVa

No. 1 2010

No.2 2006

No.3 2005

No.4 2008

POWER supply for Sibu Island Resort

(SIR) is from generator set located at power house behind the main office building, consisted of 4 units generator sets cater for energy consumption approximately in total of 1300 Amps Total Connected Load (TCL). Main office building is the main consume power that core purpose of it is administration, operation, restaurant, kitchen, meeting rooms, prayer room and etc. Individual chalet that supply by feeder pillar, approximately 10 nos. main feeder pillars for 121 units of chalets. Continues operation of Sewerage Treatment Plant and twelve hours operation of Reverse Osmosis Water Treatment plant with pump house with the pump capacity. Others will be swimming pool and accessories related to small consumption of it. Based on 66% connected load, Sibu Island Resort required at least two running generator set to be on time

without fail to run in the events. Another one unit to be run for the load above and/or nearly 85% an another unit standby for any emergency said, i.e. failure to operated under extreme conditions. There are four majors players in power distribution system consumed where air conditioning is the highest power consumable of 566 amps while load is running 66%, continue with water heater of total 618.68 amps, RO treatment plant pumps and others pump consumed about 628.32 amp; and lighting alone 110.48 amps.

Generator set history Updated January 2012. ________________________________________ Page 2 of 10

Deutz Generator Set 400kVa

Caterpillar Generator Set 410kVa

Diesel storage tanks.

Synchronizing Panel Board for generator sets

Generator set history Updated January 2012. ________________________________________ Page 3 of 10

Main Switch Board rated of 2500Amp.

Generator set history Updated January 2012. ________________________________________ Page 4 of 10

Generator set No. 1

Sales Model: C15 DITA Combustion: DI Aspr: TA / Engine Power: 376.0 KW 328 W/F EKW 344 W/O F / EKW Speed: 1,500 RPM After Cooler: ATAAC / Manifold Type: DRY Governor Type: LEC After Cooler Temp(C): 49 / Turbo Quantity: 1 Engine App: GP Turbo Arrangement:Hertz: 50 / Application Type: PACKAGE-DIE / Engine Rating: PGS Strategy: Low BSFC Strategy / Rating Type: PRIME Certification: N-C 1970 2100 No 1 Date Description Purchase of New Generator set c/w new 2500A Main Switch Board 21/4/2011 Cat engine cant synchronizing for long hours with others gen set (Deutz 3 & 4). SDI staff come in and change avr card, also find tuning the synchronizing system until done Suspect engine moving from ground base due to connection between manifold and exhaust miss alignment. Contractor SDI come and fix mounting base and exhaust connection. Amounted By SDI

0.00

SDI

28/6/2011

0.00

SDI

Turbo charger and manifold turning to red when generate power more than 200 KW. 09-06-11 ( 1unit injector no 4 worn out ) SDI change new unit, under warranty. 26/9/2011 26/9/2011 Battery not charging voltage present 17vdc (normal 27vdc). Screw tensioning belt missing. Fix back function good. Flexible piping crack and tear off. SDI come and change new unit. Under warranty.

0.00

SDI

5 6

0.00 0.00

SDI SDI

Generator set history Updated January 2012. ________________________________________ Page 5 of 10

Generator Set No.2

IVECO / ECO40-2S / Model : IVECO CURSOR / 13-TE3/Meccalte (400 KVA) / Engine Serial no. : 47244 Alternator serial no. : 1192066 / No of cylinder : 6, in line / Bore x stroke : 135 X 150 mm / Total displacement : 12,880 cm3 / Air system : supercharged after cooled / Injection type : EUI (PDE), / electronically managed / Dry weight. : No Date Description Amounted By Out of order due to auxiliary winding open 1 25/9/2007 circuit and main rotor winding mongered grounded 2 3 4 5 6 7 8 25/1/2008 26/1/2008 27/1/2008 17/4/2009 18/4/2009 18/4/2009 05-03-09 Sent out alternator ECO-2s for repair at Hattan Engineering Received new alternator, replacement from faulty unit Fix back alternator, and running back on normal condition Eveco gen-set no.2 engine hunting when Syncronise with gen-set no.4. at 8.30 pm. Eveco gen-set no 2 trip-off MCCB when With single unit at 9.30 am Pan-Sar to re-program the ECU engine data Gen-set no. 4 deutz 400 kva to suit gen-set No. 2 control system. Gen set no. 2 Eveco overload trip at 7.20 Carrying load 320 kw. 0.00 HATTAN 0.00 HATTAN 0.00 HATTAN

0.00 PANSAR 0.00

9 10

Certified value of work 97.55% by BK Teo on generator set. Base on Original Contract of 02-09-10 Supply, Repair, Overhaul and Trade-in of Diesel Generators. 16/4/2010 Supply, install and repair radiator top reseviour tank, radiator water hose, genset running smooth, however founded another leaks near to flywheel oil sump (this will f/up with another quot). 18/5/2010 Founded alternator malfunction (Code 51-P), Raise PR2501 28/11/2010 Raise PR2447: To supply new high pressure prime power radiator. 01-05-11 Engine Inspection report, engine fail to crank. Recorded

319,330.00 0.00

HATAN HATAN

11 12 13

0.00 3,650.00

RECORD K.TINGGI

0.00 NYLINK 3,650.00

Generator set history Updated January 2012. ________________________________________ Page 6 of 10

1040 kg / Date Purchased: December 2006

Generator Set No.3

DEUTZ TPD500 / Model : TPD500 (500 KVA) / Engine Model : BF8M1015CP / Aspiration system : Turbocharged & after cooled / Starting system : Electric system / Cylinder nos / configuration : 8 Cylinder / Displacement : 19.0 / Date Purchase : April 1, 2005 / Total price : RM 187,000.00 No 1 2 Date Description 19/10/2007 Two wyre AVR burn 30/1/2008 Top Overhaul by Hattan Engineering Deutz 500kva generator trip at 9.45am carry out 180 Kilowatt because of earth fault relay activated there is leakage current of 0.2 Amp 04-09-09 detected fluctuated to 0.5 amps setting for tripping the power supply. (R.O) plant not running at this time. Deutz Generator 500kva carry out 270 kilowatt Power usage synchronizing with Iveco generator at 8.35am. When power surge to 04-11-09 high amp there is an earth leakage 0.2 fluctuated to 0.5 amp cause of Tripping. (R.O plant Running) 15/4/2009 Inv:43018759 / Service & repair duetz controlling wiring and replacement filter Amounted 0.00 By RECORD HATTAN

0.00

RECORD

0.00

RECORD

1,690.00

PANSAR

Deutz Generator 500kva single running carry out 260 kilowatt power usage at 6.45pm, after 18/4/2009 check and rectify the earth leakage by Pan Sarawak the Generator still trip after 2 hour running. The problem Still cant be solved 25/4/2009 Deutz Generator 500 kva earth fault trip carrying Load 300kw. At 9.26am 0.00

PANSAR

RECORD

Pansar replace new protection CTs,move neutral wire From gen-set no 4 to gen-set no 3 after CT position. After that check the leakage 05-01-09 current fall to zero and Test run for 1hour,found the gen-set running in good Operating condition. 26/11/2009 Major Service been carried? Top Overhaul Radiator / Fuel Injector & Head / 15/12/2009 Fuel Injector Pump 109,000.00 48,300.00

PANSAR

9 10

PANSAR PANSAR

Generator set history Updated January 2012. ________________________________________ Page 7 of 10

11 12 13 14 15

02-02-10 28/4/2010 05-01-10 17/5/2010 23/6/2010

Labour & parts to service radiator coil, mounting & fuel pump Founded exhaust manifold & exhaust charger getting red while load is running Radiator head cap blow off ehile running PANSAR came to verify the engine. Repaired forced draft fan, narrow v-belt, filler cap

8,096.00 0.00 0.00 0.00 15,450.00

PANSAR RECORD RECORD PANSAR PANSAR

16

Pansar came continue repair as previous record, genertor canbot be start, however still 08-06-10 fail, reason of fuel pump need to claibrate and service Install fuel injector pump after overhaul, drive 09-09-10 shaft, completed with started the engine, running ok. 28/11/2010 01-10-11 21/1/2011 31/1/2011 02-02-11 24/3/2011 19/4/2011 23/6/2011 19/7/2011 RPM tacho meter malfunction (Raise PR2448 record) Record of genset continuously having oil leaks from the top of engine. Raise PR0691: High pressure injector pipe for cylinder A1. Inspection and repair high pressure injector pipe for cylinder A1 and B4. Continued repair leaking on high pressure pipe line Repair High Pressure pipe line, high temp pressure O-ring/seal & testing & comissioning Computer analysis and inspections been carried Change head valve cover seal, battery alternator, V belt & L type radiator hose. Battery alternator malfunction: Quot received by Nylink Recorded

0.00

PANSAR

17 18 19 20 21 22 23 24 25 26

10,430.00 0.00 0.00 0.00 910.00 0.00 5,371.00 0.00

PANSAR RECORD RECORD RECORD NYLINK NYLINK NYLINK PANSAR

565.00

NYLINK

199,812.00

Generator set history Updated January 2012. ________________________________________ Page 8 of 10

Generator Set No.4

DEUTZ TPD400 / TYPE:MECCALTE ECO 40-1s/4 / KVA:400,HERZ:50 / RPM:1500, 3 PHASE / VOLT: 415, AMP: 550 / Date Purchase: 2008

No 1 2 3 4 5 6 7 8 9 10 11 12 13

Date Description Supply new generator set c/w accessories 15/12/2008 Inv:43018152 RM437800 18/4/2009 Setting ECU engine data 400kVA Deutz. Founded exhaust manifold & exhaust charger 28/4/2010 getting red while load is running 28/4/2010 IDMT setting not stable Cylinder head gasket leaks, oils drip into 05-01-10 exhaust manifold Repaired head gasket leaks, top cover, lower 05-05-10 gasket, exhaust manifold gasket, inlet manifold gasket 05-06-10 05-08-10 17/5/2010 07-08-10 19/4/2011 25/6/2011 19/7/2011 Repair alternator main stator coil & synchronizing panel wiring Carried load test after servicing been done PANSAR came to verify the engine. And do top overhaul Labour & parts to perform top overhaul Computer analysis and inspections been carried UVR 6 card short, Change 1 unit UVR card. AVR Card & T18 rotating diode not functioning - Received quot from NYLink. Recorded

Amounted 437,800.00

By PANSAR

0.00 0.00 0.00 8,750.00 3,000.00 0.00 0.00 7,000.00

RECORD RECORD RECORD PANSAR PANSAR RECORD PANSAR PANSAR PANSAR

0.00 2,500.00

RECORD NYLINK

21,250.00

Other records.

Generator set history Updated January 2012. ________________________________________ Page 9 of 10

No 1 2 3

Description Supply 1 no. T18 rotating diode RM3350 14/4/2009 (Inv:43018757) Repair Perkins 400kVa genset & supply diesel 02-11-09 fuel tank Supply, install & calibration of oil dashpot 05-06-10 MCCB Recorded

Date

Amounted 3,350.00 22,000.00 10,300.00

By PANSAR PANSAR PANSAR

35,650.00

- End of Report -

Generator set history Updated January 2012. ________________________________________ Page 10 of 10