Report Management

1.
0 Plant Information,
General
2.0 Genset
3.0 Auxiliaries, General
3.1 Fuel systems

Forms/Templates
3.2 Lubricating oil

systems
3.3 Compressed air

systems
3.4
Supervision Cooling water
systems
Manual 5A02 3.5 Charge air

systems
3.6 Exhaust gas

systems
3.7 Waste treatment

systems
3.8 Water supply

systems
4.0 Heat recovery

systems
5.0 Emission control

system
©Wärtsilä Finland Oy, 2002 All Rights Reserved.
The content of this manual shall neither be copied nor
communicated to a third person 6.0 Plant support system
Wärtsilä Finland Oy
P.O. Box 252, FIN-65101 Vaasa, Finland
Tel. +358 10 709 0000
Fax. +358 10 709 1440
7.0 Personnel/Safety Data
Book id: WDAAA265478 -
8.0 Miscellaneous
5A0202-S0.0 Introduction/Gunnar Gustafsson page 1 of 11
Report Management
Introduction
An important part of the management of a power plant consists
of recording operating and maintenance data and preparing
various reports based on the information collected.
This can be a time consuming task and it is therefore common
that reports, checklists and forms are developed and used to
structure and simplify the work.
It is also often required that such reports and forms are archived
in paper format for a certain period of time (often depending on
local rules and regulations).
The forms and templates (provided in this folder) are prepared
with the hope that they shall be useful when preparing
customised forms for the power plant.
It is, of course, impossible to supply all the forms and templates
that may be necessary, and the ones supplied in this folder is by
no means a complete selection.
You are welcome to edit each form to better suit your
requirement and we at Wärtsilä Corporation would be happy if
you could send us a digital copy of the forms you have prepared.
If found suitable we will edit it to conform to our general style
and then include it into this folder for the benefit of other power
plant operators.
Please send your documents to the following eMail address:
gunnar.gustafsson@wartsila.com
Your contribution will be greatly appreciated.
C:\DocuMate\Project\ReportManagement\\5A0202-S00_Introduction.doc
Manual Structure and General Contents

The manual is structured as follows:
Section 00 “Introduction” This section contains the “front
matter” (this document) and is not considered part of the manual
itself. It is only general information that we hope shall help
understand the structure and the contents of thus manual.
Section 1 “Plant Information, General” This section contains
forms and templates that can be used for the plant as a unit, such
as forms for scheduling the operation of the engines installed at
the plant, hourly meter readings, etc.
Section 2 “Genset” This section contains forms and templates
that can be used for recording data on or from the genset itself.
Normally the forms available in the engine instruction manual
should be used, but if none are available these may be of help.
Section 3 “Auxiliary system, general” This section contains
forms and templates that can be used for recording data and
operating parameters from general equipment used on auxiliary
systems.
Section 3.1 “Fuel System” This section contains form to be
used for recording operating data/parameters from the fuel
system and for equipment installed in this system.
Section 3.2 “Lube Oil System” This section contains form to be
used for recording operating data/parameters from the
lubricating system and for equipment installed in this system.
Section 3.3 “Compressed Air System” This section contains
form to be used for recording operating data/parameters from the
compressed air system (including start air-, instrument/control
air-, and work air systems) and for equipment installed in these
systems.
Section 3.4 “Cooling System” This section contains form to be
used for recording operating data/parameters from the cooling
water system and for equipment installed in these systems.
Section 3.5 “Charge Air System” This section contains form to
be used for recording operating data/parameters from the charge
air system.
Section 3.6 “Exhaust Gas System” This section contains form
to be used for recording operating data/parameters from the
exhaust gas system.
Section 3.7 “Waste Treatment System” This section is

delivered empty (no forms available at present) but is reserved
for forms developed or available at site.
Section 3.8 “Water Supply System” Also this system is lacking
forms. However, a few general forms regarding water sampling
are provided.
Section 4 “Heat Recovery System” Only a few general forms
have been provided here. However, the heat recovery system is
normally delivered by subsuppliers and their information should
contain the necessary forms. If not, the forms supplied here
could be useful when developing the site-specific forms
required.
Section 5 “Emission Control System” This section contains
only one form, and this can be used to record the emissions
when testing the exhaust gas from an engine.
Section 6 “Plant Support/Maintenance” This section contains
mainly forms that can be useful for the maintenance department.
Section 7 “Personnel/Safety Data” This section contains only
two forms, and both are provided to help with the risk
management at the plant.
Section 8 “Miscellaneous” Contains forms and templates that
cannot easily be placed under other sections.
Section Structure and General Contents
Form
Instructions List of Forms
Ÿ Introduction
Ÿ Form 1
Ÿ Heading
Ÿ Form 2
Ÿ Heading
Ÿ From n
Ÿ Heading
Blue dividers used only when several

sheets of identical forms are supplied. i.e.
not when only one of each form is supplied.
Each section (except the introduction) will consist of three parts:

• Instructions for how to use the forms (“fill-in” and how to
use the information recorded on the form)
• List of forms (or table of contents)
• A collection of the forms provided for the section. These
forms will be numbered sequentially with the folder and
section number given first (5A0202-S010-01a for folder
5A0202, section 1.0 and form 01a).
The “E” following the form number simply stands for the
language version. “E” being “English”.
The documents included in each section have been made as
uniform in layout as possible. That is, all “List of Forms” (or
“Table of Contents”) all have the same “look”. Also the
“Instructions” have the same look and, to the extent possible,
also cover the instructions in a similar way for each form
described.
Record Management
Blank forms
Completed forms
Released forms
Blank forms
Templates
completed forms
Completed forms
Blank forms
Writers Process Data collection

Workstation workstation(s) Devices
It is recommended that all forms and templates be managed

digitally on a separate computer. This to enable having all forms
developed as templates and stored at the correct Windows folder
system. This will enable the computer operator to simply click
on “File, New” and then select the appropriate template for the
job that shall be performed.
It is recommended that all – or

most of – the “standard”
templates provided by the
MSOffice package be removed
(or at least stored in a separate
folder). Then rename all folders
with names corresponding to
the sections in this folder. This
will make navigation easier and
it will not be difficult to locate
any of the templates so
prepared.
The MSOffice template folders
are normally located on your
“C:” drive and under “Program
files” you will find the
“Microsoft Office” folder with
“Templates” (see illustration at
left).
The folders are named according to programs and according to
the templates provided. The ones for programs may remain
(“Access”, “Spreadsheet Solutions”, etc.) if these contain
templates that are used.
You can also add folders in this section and they will show up
automatically on the dialog box that opens when “File, New” is
selected. In the illustration below this is shown by the folder
“Power Plant” which is a folder added by me.
Store all forms as templates under the correct folder when they
have been edited and customised for the actual requirements at
site.
It is also recommended to set up an appropriate folder structure
for storing the completed document.
Editing forms
The information presented here will give you guidelines on how
to edit and change the forms provided in this folder.
MSWord forms
Note! You should not edit the original form but keep it as a
“back-up” that you can return to should you need to make
another form based on the same original document!
Save a copy of the document under a new name that better suit
the needs or your own power plant.
It is recommended that you save the finished original form as a
template (see “Record Management” for more information).
Save the document in the normal way by selecting “File->Save

As” (see illustration above) and then select “Document
Template (*.dot).
File Protection
All checklist and other forms are protected from editing. The file
protection will also follow files that are duplicated or copied. To
remove the file protection, choose “Unprotect Document” from
the "Tools" menu.
Before editing the form/template, it is important to change the

initials of the “made/approved” found in the upper right corner
of each form. This shall show the initials of the persons editing
and approving the document.
Also the “Document ID” shall be changed. This can be done

manually or by “right-clicking” the field next to the document id
and selecting “Update Fields” in the dialog box that will open
(see illustration below).
Form tools
Form tools can be activated (if not already found on toolbar) and
added to the “standard” toolbar from the “View” menu and
selecting “Toolbar” and then “Forms” (see illustration below).
Form toolbar
Drop Down Field

Check Box
Text
There are three types of forms fields found in word: "Text,"

"Check Box," and "Drop Down" fields. Form fields allow input
of data in word format while the word file is protected.
To insert form fields, position the cursor where the form field
shall be inserted and – depending on your requirement – click on
one of the three form fields available.
Shading
All “Form Fields” are shaded “by default” for easy
identification. Click on the field shading button in the display
toolbar to enable or disable the shading function.
Shade function
Locking/unlocking forms
The "Forms" toolbar as it appears

“Protect form” when the form is protected.
When editing is complete the forms and checklist shall be

locked to prevent any changes to the document other then the
insertion of data to the form fields. This can be done in two
ways. The first is to choose document protection on the "Tools"
menu. The other is to simply “click” on “Protect form” on the
“Forms” toolbar (see illustration above).
Form Field Options
Form Field Options

Another important function is the “Form Field Options” which
you can open when the cursor is placed in a field (see illustration
below).
The most important option is the “Properties” already selected

on the dialog box shown above.
Properties
When the “Properties” has been selected the dialog box shown
below will open.
For a full information about the features that this “Form Field
Options” can give, please refer to the “Help” function in
MSWord. It is a subject that will be too complex to explain
here…we mainly wish to inform about the possibilities
presented by the MSWord form tools.
However, information about one additional feature should be
given here, and that is the “Add Help Text” option. This dialog
box will open when the “Add Help Text” button is activated (see
illustration below).
Here you can add “Help text” that can be shown if you activate
the “Help Key (F1)” or it can be displayed automatically on the
“Status Bar” at the lower left of your screen.
Instructions
Forms & Templates for
Plant Information, General

Introduction............................................................................................. 2
Form: 5A0202-S010-01aE.doc “Operating Schedule” ........................... 2
Form: 5A0202-S010-02E.doc “Daily Operation Log” ........................... 3
Form: 5A0202-S010-03E.doc “Energy Meter Reading” ........................ 4
Form: 5A0202-S010-04E.doc “Hourly Load” ........................................ 5
Form: 5A0202-S010-05E.xls “Power Interruption Log” ........................ 6
Form: 5A0202-S010-06E.xls “Plant Attention Report” ......................... 7
Form: 5A0202-S010-07E.xls “Maintenance Report” ............................. 8
Form: 5A0202-S010-08E.xls “Daily Checklist”..................................... 9
Form: 5A0202-S010-09E.xls “Daily Log book, Engine Operation” .... 10
Form: 5A0202-S010-10E.xls “Log book, Machine Operation Log” .... 11
Form: 5A0202-S010-11E.xls “Station Log”......................................... 12
Form: 5A0202-S010-12E.xls “Station Log Summary” ........................ 13
Form: 5A0202-S010-13E.xls “Machine Operation Log/Summary”..... 14
Form: 5A0202-S010-14E.xls “Daily Machine Log” ............................ 15
Form: 5A0202-S010-15E.xls “Station Fuel Report” ............................ 16
5A0202-S010-Instr.doc Page 1 of 16 pages

Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
Form: 5A0202-S010-01aE.doc “Operating Schedule”

This is a form – produced in MSWord – intended to be used by the Operation Manager when planning
the operation schedule for the engines (at what times they shall be in operation).
Note! Two similar templates are provided. One is intended for “manual” use (print out and check the
times manually) while the other is made as an “MSWord form” where the times can be entered simply
by “clicking” in the appropriate fields (before printing out the form).

Form: 5A0202-S010-02E.doc “Daily Operation Log”
This is a form – produced in MSWord – intended to be used by the Shift Operators when entering
information concerning the daily operation of the plant
Note! The form is intended to be used when entering information via a computer station. That is, it is
an MSWord form with imbedded macros. These are prepared to ensure that data is saved as soon as
the field is filled in.

Form: 5A0202-S010-03E.doc “Energy Meter Reading”
This is a form – produced in MSWord – intended to be used by the Shift Operators when recording the
energy meter readings during the daily operation of the plant

Form: 5A0202-S010-04E.doc “Hourly Load”
This is a form – produced in MSWord – intended to be used by the Shift Operators when recording the
engines hourly load during the daily operation of the plant

Form: 5A0202-S010-05E.xls “Power Interruption Log”
This is a form – produced in Excel – intended to be used by the Shift Operators when recording
information about power interruptions (and the reasons for these) during normal operation of the plant

Form: 5A0202-S010-06E.xls “Plant Attention Report”
This is a form – produced in Excel – intended to be used by the Maintenance personnel when
recording information about maintenance performed (see also the “Maintenance Report” form in
section 6 of this folder).

Form: 5A0202-S010-07E.xls “Maintenance Report”
This is a form – produced in Excel – intended to be used by the Maintenance personnel when
recording information about maintenance performed (see also the “Maintenance Report” form in
section 6 of this folder).
Note! This form is very similar to the previous, but is more general while the previous is mainly
intended for use when recording maintenance work performed on the engines.

Form: 5A0202-S010-08E.xls “Daily Checklist”
This is a form – produced in Excel – intended to be used by the operating personnel when checking off
items performed during the normal operation of the plant.

Form: 5A0202-S010-09E.xls “Daily Log book, Engine Operation”
This is a form – produced in Excel – intended to be used by the operating personnel when recording
information about the daily operation of the engines.

Form: 5A0202-S010-10E.xls “Log book, Machine Operation Log”
information about the daily operation of machinery installed and used at the plant.

Form: 5A0202-S010-11E.xls “Station Log”
information from the electrical supply feeders at the plant.

Form: 5A0202-S010-12E.xls “Station Log Summary”
information about the plants daily performance.

Form: 5A0202-S010-13E.xls “Machine Operation Log/Summary”
information about the engines daily performance.

Form: 5A0202-S010-14E.xls “Daily Machine Log”
daily information about the engines operating parameters.

Form: 5A0202-S010-15E.xls “Station Fuel Report”
information about the amount of fuel available/received and used at the plant during the day

List of Forms
Section 5A0202-S01.0
No: Name:
01aE Operation Schedule
01bE Operation Schedule
02E Daily Operation Log
03E Energy meter reading
04E Hourly load sheet
05E Power Interruption log
06E Plant attention report
07E Maintenance report
08E Daily check list
09E Daily Log Book
10E Machine operation log
11E Station log
12E Station log (summary)
13E Machine operation log/Summary
14E Daily Machine Log
15E Station Fuel Report
5A0202-S010-LoC.doc
Operating Schedule
Document ID: 5A0202-S010-01aE.doc
Made/Approved: MiGus/GuGu
Name of Installation: Day Month Year
Operation Planning schedule

Engine # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Daily Operation
Engine # Start Stop Hrs run Load Comments
Time: Date: Remarks:
Operations Manager
Operating Schedule
Document ID: 5A0202-S010-01bE.doc
Operation Planning schedule

Engine # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Daily Operation
Engine # Start Stop Hrs run Load Comments
Operations Manager
Daily Operation Log
Document ID: 5A0202-S010-02E.doc
Name of Installation: Department Shift Date
Daily Record of Facility Operation

Time: Comments
I hereby certify that the entries above are correct; that all scheduled operations have been accomplished
(except as noted) and that all abnormal occurrences and conditions have been properly recorded.
Shift supervisor
Energy Meter Reading
Hourly Energy Meter Readings

Billing Meter Back-up Meter
Time: Active Energy MWh (+) Active Energy MWh (-) Active Energy MWh (+) Active Energy MWh (-)
01:00
02:00
03:00
04:00
05:00
06:00
07:00
08:00
09:00
10:00
11:00
12:00
13:00
14:00
15:00
16:00
17:00
18:00
19:00
20:00
21:00
22:00
23:00
24:00
Remarks:
Time: Time: Time:
Shift supervisor Shift supervisor Shift supervisor

Hourly Load
Hourly Engine Load Readings

Status “S” stands for Stand-by; “M” for Scheduled Maintenance; “U” for Unscheduled Maintenance and “F” for Forced Outages.
Engine # Engine # Engine # Engine #

Time: Load Status Load Status Load Status Load Status
01:
02:
03:
04:
05:
06:
07:
08:
09:
10:
11:
12:
13:
14:
15:
16:
17:
18:
19:
20:
21:
22:
23:
24:
Remarks:
Time: Time: Time:
Shift supervisor Shift supervisor Shift supervisor

Logbook sheet Orig. Doc Id: WDAAA112423 a
POWER INTERRUPTION LOG Doc Id: 5A0202-S010-05E
Month/Day/Year Made/Approved: MiGus/GuGu
Time Description/reason Area Planned Forced outage External Waiting Shift Sign.
(Eg. trip of feeders or black outs) outage Mech. El. system time
Total duration
No. of forced outage Plant on stand by (h)
PLANT ATTENTION REPORT Doc Id: 5A0202-S010-06E
Station: ________________________________________________________________________________________
Set No.: __________
Eng. No.: ______________________________ Type: ________________________ Date: _____________________ Hours: __________
Name: ________________________________________________________________________________________
Ref. No.: __________
Location of problem:
Description of problem:
Action taken: Date actioned: ________________________________
Spare parts used
Code Description Issued Int. Returned Int. Used Sign
Originator - C/engineer - Shift operator - Supervisor Signature ___________________________________
Attach additional Parts sheet if necessary Sheet ______ of ______

Distribution:
- Chief engineer
- Adminis.
MAINTENANCE REPORT Doc Id: 5A0202-S010-07E
Station: ________________________________________ Set No.: ____________________ Counter:

Equipment: ________________________________________ Div. No.: ____________________ Ref. No.: __________
Description:
Work report:
For next maintenance:
Scheduled, date ______________________ To Account No.

Done, date ______________________
Work type (P/B/S) ______________________ Work order
Maintenance (hours) ______________________
Repair (man hours) ______________________ Spares Requisition No.
Number of persons ______________________
Spare parts used
Code Description Issued Int. Returned Int. Used Sign
P = Planned maintenance, B = Breakdown, S = Survey Signature: ___________________________________
Attach additional Parts sheet if necessery Sheet ______ of ______

Distribution:
- Chief engineer
DAILY CHECK LIST Doc Id: 5A0202-S010-08E
This checklist should be completed during the daily check round Week: ___________ to ___________ Initiated:______________
Date Remarks
Measure Shift No./Sign
Ambient air temperature (C°)
Starting air pressure (bar)

OK OK OK OK OK OK OK
Drain starting bottles
DC-voltage (V)
DC-current (A)
Battery level check
Header tank level
Drain return tank
Check amount of leak fuel
Leak fuel returned, total quantity
Pump L.O. sep. tank
Drain water, storage tanks
Drain water, day tanks
Clean L.O. separator
Clean F.O. separator
Governor oil level check
Turbocharger oil level check
Alternator bearing check
Lub. oil topping-up, set No. 1 (quantity)
Stand by engine test (Weekly)
Cleanliness OK OK OK OK OK OK OK
Daily Log book
Engine Operation
Document ID: 5A0202-S010-09E
Month/Day/Year Made/Approved: MiGus/GGU
Engine number Operating Hours Time Start/Stop Cause Corrective Action Other Action Taken Sign.
Logbook sheet
Machine Operation Log Orig. Document ID: WDAAA112428 a
Documant ID: 5A0202-S010-10E
Time Description, changes in status Stand by Duration of stops Shift Sign.

Stop Planned Repair Waiting
outage
Spares Fuel oil Other
00.00
24.00
Total duration
Number of stops Total stop time
Running hours according to the counter Running hours (24 h - total stop time)
Logbook sheet
Station Log Orig. Document ID: WDAAA112429 a
Documant ID: 5A0202-S010-11E
Month/Day/Year Made/Approved: MiGus/GuGu
Feeder 1 Feeder 1 Feeder 2 Feeder 3 Feeder 4 Feeder 5 Station supply

station MD
Amps kWh Diff. Amps kWh Diff. Amps kWh Diff. Amps kWh Diff. Amps kWh Diff. Amps kWh Diff. kWh Diff.
00.00
01.00
02.00
03.00
04.00
06.00
07.00
08.00
09.00
10.00
11.00
12.00
13.00
14.00
15.00
16.00
17.00
18.00
19.00
20.00
21.00
22.00
23.00
24.00
kWh - + + + + + + =
Total Diff. Production
Shift Log Distribution: Chif engineer

On shift at
Adminis.
Shift
Station Log/Summary Doc Id: 5A0202-S010-12E
Station: Month:
Fuel oil type: Date:
Fuel consumed (quantity) Energy reports Power interruptions (h) +
Supply to feeders (kWh)

Fuel supplied (quantity)
External system failure

Station supply ( kWh)
Plants on stand by
No. of forced outage

Station MD (MW)
Planned outage
Import (kWh)
waiting time
Day
Mech.
El.
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Date: Signature:
Logbook sheet Original Doc Id: WDAAA112426 a
MACHINE OPERATION LOG/SUMMARY Doc Id: 5A0202-S010-13E
Station: ______________________________________________________ Month:

Eng. No.: _____________________ Set No.: _______________________ Date: -
Stop hours
Forced
Waiting
Exhaust gas temp., max (°C)
Receiver air pressure (bar)
HT-water temp., out (°C)

Receiver air temp. (°C)
LT-water temp., in (°C)

Alternator output (kW)
Gen. energy (kWh)

Topping up L.O.
Running hours
No. of stops
Stand by
Planned
Fuel oil
Spares
Repair
Other
Day
h No. h h h h h
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Counter reading at the end of month: Date: _________________ Signature: _______________________

DAILY MACHINE LOG Doc Id: 5A0202-S010-14E
*)These readings should be transfered to the Machine Operation Log Summary Station:______________________ Date:_________________ Set No.:____________
Hour counter 24.00: 01.00 02.00 03.00 04.00 05.00 06.00 07.00 08.00 09.00 10.00 11.00 12.00 13.00 14.00 15.00 16.00 17.00 18.00 19.00 20.00 21.00 22.00 23.00 24.00
Operating hours (h)

Alternator output (kW)
Phase current (A) (max.)
Power factor
Frequency (Hz)
Fuel rack (mm) Max/Min
Turbocharger speed A-bank (r/s)

Turbocharger speed B-bank (r/s)
Exhaust gas temp. A-bank, max (°C)
Exhaust gas temp. A-bank, min (°C)
Exhaust gas temp. B-bank, max (°C)
Exhaust gas temp. A-bank, min (°C)
Receiver pressure (bar)
Receiver air temp. (°C)
LT-water inlet temp. (°C)
LT-water outlet temp. (°C)
Lube oil temp. (°C) (in)
HT-water inlet temp. (°C)
HT-water outlet temp. (°C)
LT-water pressure (bar)
HT-water pressure (bar)
Lube oil pressure (bar)
Fuel oil pressure (bar)
Fuel oil temp. in to engine (°C)
Fuel oil viscosity (cSt/50°C)
Pedestal bearing temp. (°C)
STATION FUEL REPORT Doc Id: 5A0202-S010-15E
Station: _______________________________________ Date: ____________________
Time: ____________________
Fuel meter today: reading
Fuel meter yesterday: reading
Supplied to plant: quantity
Fuel oil storage tank today: reading
Fuel oil storage tank yesterday: reading
Change in volume: quantity
Fuel oil service tank today: reading
Fuel oil service tank yesterday: reading
Change in volume: quantity
TOTAL FUEL OIL CONSUMED BY PLANT: quantity
Sludge tank today: reading
Sludge tank yesterday: reading
Sludge disposed off: quantity
Sludge generated: quantity
Diesel fuel tank today: reading
Diesel fuel tank yesterday: reading
Diesel fuel consumed: quantity
Distribution:
Instructions
Forms & Templates for the
GenSet
Introduction ..................................................................................... 2
Form: 5A0202-S020-01E “Operation Data Record”....................... 2
Form: 5A0202-S020-02E “Operation Data Record”....................... 3
Form: 5A0202-S020-03E “Generator Operation Data” .................. 4
Form: 5A0202-S020-04E “Cylinder Tightness Test” ..................... 5
Form: 5A0202-S020-05E “Turbo Charger Washing”..................... 6
Form: 5A0202-S020-06E “Vibration Record”................................ 7
Form: 5A0202-S020-07E “Vibration Record”................................ 8
Form: 5A0202-S020-08aE “Crankshaft Deflection” ...................... 9
Form: 5A0202-S020-08E “Crankshaft Deflection” ...................... 10
Form: 5A0202-S020-08bE “Crankshaft Deflection” .................... 11
Form: 5A0202-S020-09E “Valve Wear Report”........................... 12
Form: 5A0202-S020-10E “Camshaft Inspection Report”............. 13
Form: 5A0202-S020-11E “Inspection Report, Mechanical Spring
Support”......................................................................................... 14
Form: 5A0202-S020-12E “Borescope Inspection Record”........... 15

Introduction
in this section.
Form: 5A0202-S020-01E “Operation Data Record”

This is a form – produced in MSWord – intended to be used as a general checklist when recording the
operation parameters for an engine.
Note! The form is on two pages and is prepared for a gas engine. It is not suitable for a diesel engine.
Similar forms for the diesel engine are normally available in the engine instruction manual.

Form: 5A0202-S020-02E “Operation Data Record”
operation parameters for an engine.
Note! Also this form has been developed for a gas engine, and contains space for recording main
bearing temperatures also.
Place for main bearing temperatures

at 100 % load, and also area for
entering information about Max
firing pressure and compression
pressure.

Form: 5A0202-S020-03E “Generator Operation Data”
operation parameters for a generator.

Form: 5A0202-S020-04E “Cylinder Tightness Test”
This is a form – produced in MSWord – intended to be used to record data obtained when checking
the cylinder tightness. The procedure is normally described in the engine instruction manual, but if
none is available there you can follow the procedure described below.
A simple test instrument is necessary, and if not available it can be manufactured used standard items.
You will need a pressure reducer, two ball valves and a pressure gauge.
Assemble the items as shown in the illustration below.
The procedure is simply to connect the tool to the indicator valve (with the piston at top dead centre).
Open both valves and adjust the air pressure to a standard set point (the same for all cylinders) and
then close the ball valve closest to the cylinder. Measure the time it takes for the pressure to fall to a
specified low set point value (a point above “0” that is easily read on the pressure gauge).
Note! It is better to have a set point above zero as it is easier to determine than the actual zero point.
Record the pressure setting when timing was started, and also record the time it took for the pressure
to fall to the low set point value.

Form: 5A0202-S020-05E “Turbo Charger Washing”
This is a form – produced in MSWord – intended to be used to record data obtained when washing the
turbo charger. Either the turbine side or the compressor side.
Note! The readings should be taken one (1) hour before washing the turbine, and the readings after
washing should be taken when the parameters have stabilised.
Also Note! The information can also be recorded simply by printing out a screen capture taken before
and after the cleaning process. By comparing the relevant data it will be possible to estimate the
efficiency of the cleaning process.

Form: 5A0202-S020-06E “Vibration Record”
This is a form – produced in MSWord – intended to be used when recording vibration data. Though
the generator set shown is used as a symbol only, the normal measuring spots are indicated on this
unit.
If available, you should include the recommended vibration limits for the engine being monitored.

Form: 5A0202-S020-07E “Vibration Record”
This is a form – produced in MSWord – intended to be used when recording vibration data from the
engine only (normally marine installations). Though the engine shown is used as a symbol only, the
normal measuring spots are indicated on this unit.
If available, you should include the recommended vibration limits for the engine being monitored.

Form: 5A0202-S020-08aE “Crankshaft Deflection”
This is a form – produced in MSWord – intended to be used when recording indicator readings taken
when checking the crankshaft deflection.

Form: 5A0202-S020-08E “Crankshaft Deflection”
This is a form – produced in Excel – intended to be used when calculating indicator readings taken
Note! If you open the template in the Excel program you only need to enter the data recorded on the
previous form. The other data will be calculated automatically by the program.

Form: 5A0202-S020-08bE “Crankshaft Deflection”
This is a form – produced in MSWord – intended to be used when analysing indicator readings taken
Note! The form contains a “graph” section that can be used when analysing the crankshaft deflection.
If this area is too small, use a simple “millimetre” paper obtainable from most stationary shops.

Form: 5A0202-S020-09E “Valve Wear Report”
This is a form – produced in MSWord – intended to be used when estimating the valve wear by
measuring the height between the cylinder cover and the valve spring cap. The “theory” being that this
height will increase as the valve/valve seat wears down.

Form: 5A0202-S020-10E “Camshaft Inspection Report”
This is a form – produced in MSWord – intended to be used when inspecting the cams on the camshaft
and the rollers they are in contact with.
Note! This is a very subjective method of inspecting the camshaft, and for serious damages it is
recommended that the cams/rollers be photographed to provide a visual record of the damage.

Form: 5A0202-S020-11E “Inspection Report, Mechanical Spring Support”
This is a form – produced in MSWord – intended to be used to maintain a control over the mechanical
spring supports (if used). This form should be filled in during commissioning and the data should be
verified during regular inspections of the supports.
Note! The engine shown is used for illustration purposes only, and you may have to alter/edit the form
to better suit the requirement for your engines.

Form: 5A0202-S020-12E “Borescope Inspection Record”
This is a form – produced in MSWord – intended to be used when inspecting the internals of the
cylinders using a borescope.
The form is used to note down the approximate area where notable items have been found. The
“margins” around the illustration is used for “jotting down” the notes required.
Note! This is a very subjective method of inspecting the cylinder, and for serious damages it is
recommended that the internals of the cylinder be photographed (also using the borescope) to provide
a visual record of the damage.
This inspection record is mainly intended to be an “overall” information sheet regarding the
inspection. Use the specific cylinder inspection records available in your engine instruction manual for
more detailed information should this be required.

List of Forms
No: Name:
01E Operation Data Record (2 pages, gas engine)
02E Operation Data (gas engine)
03E Generator Operation Data
03E Cylinder Tightness Test
05E Turbo Charger Washing
06E Vibration Record (genset)
07E Vibration Record (engine only)
08aE Crankshaft Deflection
08E Crankshaft Deflection (Excel sheet for calculations)
08bE Crankshaft Deflection (graph)
09E Valve Wear Report
10E Camshaft Inspection Report
11E Inspection Report, Mechanical Spring Support
12E Borescope Inspection Record
5A0202-S020-LoC.doc
Operation Data Record
Page 1 of 2
Installation: Type of plant: Operating hours:
Engine type: Engine Serial No: kW rpm
Date/Time for test: D/T

Load % of Nominal: %
Engine Speed: RPM
Ignition timing: °btdc
Alternator Voltage/Current: V/A
Alternator Load: kW
E = Exhaust Gas Temperature Cyl. E Du E Du E Du E Du
Du = Duration of main gas valve “A” °C ms °C ms °C ms °C ms
opening in milliseconds
Cylinders Cylinders
"A" Bank "B" Bank
Average value:
Cyl. A B A B A B A B
“B” °C ms °C ms °C ms °C ms
Average value:
Turbocharger speed I/II: RPM
Exhaust temp. after turbocharger: °C
Exhaust press. after turbocharger: kPa
Crankcase pressure bar
Throttle valve position: °
Charge air pressure: kPa
Charge air temperature after CAC: °C
Pressure drop over CAC: kPa
Ignition timing °btdc
Gas consumption m3/h
Gas temperature °C
Gas temperature before engine °C
Gas pressure: Supply bar
Gas pressure: PCC bar
Gas pressure: Main injector bar
Operation Data Record
Page 2 of 2
Engine room temperature: °C
Outside temperature: °C
Ambient air pressure: bar
Relative Humidity: %
Water pressure after pump bar

FW temp before engine °C
FW temp after engine °C
Lube oil pressure after pump bar
Lube oil pressure after filter bar
Oil temp before engine °C
Oil temp after engine °C
FW before CAC °C
FW after CAC °C
HT circuit
HT water temp, inlet to engine °C
HT water temp, engine outlet °C
HT temp before turbocharger °C
HT temp after turbocharger °C
HT temp before central cooler/radiator °C
HT Temp after central cooler/radiator °C
HT Pressure inlet to engine bar
HT Static pressure bar
LT circuit
LT water temp, inlet to engine °C
LT water temp, engine outlet °C
LT Temp before lube oil cooler °C
LT Temp after lube oil cooler °C
LT temp before central cooler/radiator °C
LT Temp after central cooler/radiator °C
Air temp at radiator °C
Raw water temp before central cooler °C
Raw water temp after central cooler °C
LT Pressure to inlet engine bar
LT Static pressure bar
Lube oil circuit
LO temperature engine inlet °C
LO temperature engine outlet °C
LO pressure engine inlet bar
LO temperature before lube oil cooler °C
LO temperature after lube oil cooler °C
Pressure drop over lube oil cooler bar
Pressure drop over auto filtration unit bar
Pressure drop over safety filter bar
Alternator
Winding temperature °C
Bearing temp, DE (drive end) °C
Bearing temp, NDE (non-drive end) °C
Coolant temp inlet/outlet (air or water) °C
Time: Date: Remarks
(Signature)
Operation Data
Engine data
Engine type: Engine Serial No: kW rpm
Turbocharger type: Turbocharger I Serial No: Turbocharger II Serial No:
Generator Data
Generator type: Generator Serial No: kW
kVA Volt Amp Hz Efficiency (h) :
General Data
Main Gas Control Valve: Prechamber Gas Control Valve: Prechamber:
Gas Fuel: Lower Heat Value: Specific Gravity:
Lubrication oil: Viscosity

Recorded Data
Date/Time for test: Day/Time
Outside temperature: °C
Ambient air pressure: kPa
Relative Humidity: %
Gas pressure: Supply bar
Gas Temperature: °C
Gas pressure: Main injector bar
Gas pressure: PCC bar
Duration, PCC valve opening: ms
Gas Consumption: m3
Gas Consumption, period: Min.
Gas Consumption: m3/h
Gas Consumption: nm3/kWh
Main bearing temperature at No 1 2 3 4 5 6 7 8 9
100% nominal load: °C
Max firing pressure at 100% Cyl. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
nominal load bar
Compression pressure: bar
Time: Date: Archive this data record together with the original
test/commissioning record.
Data recorded by (Signature)

Generator Operation Data
Genset General Data
Engine type: Engine Serial No: r/min:
Generator type: Generator Serial No: kW:
Site Conditions
Altitude (MASL): Ambient Temperature: Ambient Pressure: Relative Humidity:

Meter °C kPa %
Recorded Data
Date/Time for test: Day/Time
Heatrun (hours): h
Frame temperature: °C
Winding temperature 1: °C
Bearing temperature NDE: °C
Bearing temperature DE: °C
Air Cooled Generator

Air flow: m3/h
Air Inlet Temperature: °C
Air Outlet Temperature: °C
Pressure drop over filter: Pa
Water cooled Generator

3
Cooling water flow: m /h
Water Inlet Temperature: °C
Water Outlet Temperature °C
Pressure drop: Pa
Remarks
Data recorded by (Signature) AFUP fault code: 490 Generator.

Cylinder Tightness Test
Made/Approved: MiGus/GGU
Name of installation: Engine Type: Engine Serial Number: Operating hours:
Recorded information
Cylinder* No Tightness test: Remarks/Actions taken: Report/reference:
”A” Bank: Pressure: Time (s):
”B” Bank: Pressure: Time (s):
Remarks
*Note! When numbering each cylinder tested, be sure to follow the instructions in the engine manual. The numbering follows
ISO 1204 and starts from the flywheel end.

Turbo Charger Washing
General Data
Installation: Engine type: Engine Serial No: RPM
Turbocharger type: Turbocharger I Serial No: Turbocharger II Serial No:
Recorded Data
Turbine I Turbine II
Description Unit Before Cleaning After Cleaning Before Cleaning After Cleaning
Operating Hours h
Charge Air Pressure: kPa
Turbo Charger Speed RPM
Exhaust gas temperature before TC °C
Exhaust gas temperature after TC °C
Compressor I Compressor II
Description Unit Before Cleaning After Cleaning Before Cleaning After Cleaning
Operating Hours h
Charge Air Pressure: kPa
Turbo Charger Speed RPM
Exhaust gas temperature before TC °C
Exhaust gas temperature after TC °C
Remarks
Note! The temperatures and other operation data should be taken one (1) hour before cleaning the turbine, and once more after
the engines have settled into normal operation after cleaning.

Vibration Record
Engine type: Engine No: rpm Load
Measuring points indicated on illustration below

Z
2Y 2x 3 7 8 10
2z
4 5 6 9
Measurements taken
Test Vibration velocity mm/s RMS direction
Point Description
No. X Y Z Rec. limit
1 Turbocharger, right side* (same pos. as for 2)
2 Turbocharger, left side*
3 Top of block, upper corner, free end.
4 Foot of block, free end.
5 Foot of block, mid section.
6 Foot of block, flywheel end.
7 Top of block, upper corner, flywheel end.
8 Alternator, drive end bearing.
9 Alternator, free-end foot.
10 Alternator, free-end bearing
*Seen from flywheel end.

Vibration Record
Engine type: Engine No: rpm Load
Measuring points indicated on illustration below

Z
1 2Y 2X 2Z 3 6 Y
4 5
Measurements taken
Test Vibration velocity mm/s RMS direction
Point Description
No. X Y Z Rec. limit
1 Turbocharger, right side* (same pos. as for 2)
2 Turbocharger, left side*
3 Top of block, upper forward corner.
4 Foot of block, forward end.
5 Foot of block, aft end.
6 Top of block, upper aft corner.
*Seen from flywheel end.

Crankshaft Deflection
Installation Engine Type: Engine No: Operating Hours:
Crankshaft deflection
Measured at cylinder number:
Indicator position:
1 2 3 4 5 6 7 8 9 10
A: Start position ±0 ±0 ±0 ±0 ±0 ±0 ±0 ±0 ±0 ±0
B: “B” bank
C: Low position (Piston TDC)
D: “A” bank
E: End position
Indicator position
(as seen from flywheel)
+
±0
-
"A" Bank "B" Bank
Rotate crankshaft in
the normal direction
Remarks
Note! When numbering the cylinders please follow the numbering instructions given in the engine instruction manual. The
numbering follows the ISO 1204 standard and starts at the flywheel end.
This sheet is normally used when recording the measurements. Use the Excel worksheet (same name) when calculating and
evaluating the crankshaft deflection.
Time: Date: Archive this work sheet together with the original
crankshaft deflection record.
(Taken when testing/commissioning the engine).
(Signature) AFUP fault code: 110 crankshaft.

Day/Month/Year 21 March 2003 Made/Approved: MiGus/GuGu

Document ID:
5A0202-S020-08E
Crankshaft deflection: Measured at cylinder:

Indicator Position 1 2 3 4 5 6 7 8 9 10
A (Start Position) 0 0 0 0 0 0 0 0 0 0
B (Bank "B" side)
C (Low Position - piston TDC)
D (Bank "A" side)
E (End Position)
Calculated Value Calculated for cylinder:

1 2 3 4 5 6 7 8 9 10
BDC=½(A+E)
Check on readings Readings for cylinder:

1 2 3 4 5 6 7 8 9 10
C+BDC =
B+D =
Note! The readings should be nearly the same. If the difference is found to be too large, repeat the reading.
Defections from Vertical misalignment

1 2 3 4 5 6 7 8 9 10
Top-bottom or C-BDC
Note! See the engine instruction manual for permissible deflection limits..
Defections from horisontal misalignment

1 2 3 4 5 6 7 8 9 10
Bankd "A"-"B" or B-D
Remark
Crankshaft deflection
Measured at cylinder number:
Indicator position:
1 2 3 4 5 6 7 8 9 10
A: Start position ±0 ±0 ±0 ±0 ±0 ±0 ±0 ±0 ±0 ±0
B: “B” bank
C: Low position (Piston TDC)
D: “A” bank
E: End position
Calculated deflection (C-BDC)
Remarks
Note! When numbering the cylinders please follow the numbering instructions given in the engine instruction manual. The
numbering follows the ISO 1204 standard and starts at the flywheel end.
Time: Date: Archive this work sheet together with the original
crankshaft deflection record.
(Taken when testing/commissioning the engine).
(Signature) AFUP fault code: 110 crankshaft.

Valve Wear Report
Valve Wear
Exhaust
1
2
Inlet
3
4
Fig. 1. Use a vernier calliper to measure the Fig. 2. The illustration above shows the
distance between the cylinder head and the top of position and numbers of the valves measured.
the spring retainer . Take two readings 180° apart.
Cylinder Exhaust Valve Inlet Valve Cylinder Head Observations:

Number 1 2 3 4 Serial Number
1
2
3
Cylinder “A” bank
4
5
6
7
8
9
10
1
2
3
Cylinder “B” bank
4
5
6
7
8
9
10
Mean Value Wear limit:

Wear (mm)
Wear (mm/1000h)
Time: Date: Note! For information about the maximum permitted wear
limit, please refer to the engine instruction manual.
However, a maximum of four (4) mm wear can be used as a
guideline
(Signature) AFUP fault code: 121 and 122 valves and valve seats.
Camshaft Inspection Report
Installation: Type of Plant: Engine type: Engine No:
Operating Hours Type of fuel: Type of lube oil: Direction of rotation:

CW CCW
Damage classification:
1. Scratches (felt by fingernail) 5. Fogged surface/Pittings
2. Uniform discoloration 6. Grooves outside normal running track
3. Uneven discoloration (wobbling). 7. Bushing in roller displaced
4. Surface breakdown (migration of material) 8. Sluggish movement of roller
Type of damage Type of damage

Cylinder “A” Bank Cylinder “B” Bank
Cams Cams
Roller Roller
Nr Lifter Opening Closing Nr Lifter Opening Closing
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel
Exhaust Exhaust
Inlet Inlet
Fuel Fuel

AFUP fault codes: 140 for camshaft , 142 rollers
(Signature)
Inspection Report Mech. Spring Support
Engine type: Engine Serial No: Generator Type: rpm
Distance
AA BB CC DD
Forward end Generator end
A B C D
Measured spring compression

Position:
A B C D AA BB CC DD
Distance -1
Distance -2
Distance -3
Max compression
Additional notes
Distance -1: Measured before installing engine on the supports.
Distance -2: Measured after installation of engine.
Distance -3: Measured with engine loaded (engine filled with lubrication oil and Cooling water)
Max compression is “Distance 1” less “Distance 3”
Caution! The maximum deviation permitted between measurements is ± 1mm.
Time: Date: Remarks
(Signature)
Borescope Inspection Record
Installation: Engine Type: Engine Serial Number: Operating hours:
Notes Show item on illustration below Notes

Cylinders Cylinders
in "A" bank in "B" bank
Seen from flywheel end.
Inspection performed by (Signature)

Instructions
Auxiliaries, General
Introduction ..................................................................................... 2
Form: 5A0202-S030-01E “Tank Sounding Record”....................... 2
Form: 5A0202-S030-02E “Tank Sounding Log”............................ 3
Form: 5A0202-S030-03E “Performance Analysis” ........................ 4
Form: 5A0202-S030-09aE/9bE “Performance Analysis”............. 10
Form: 5A0202-S030-10E “Performance Analysis” ...................... 11
Form: 5A0202-S030-11E “Alignment Record” ............................ 12
Form: 5A0202-S030-12E “Pressure test/Leak control” ................ 13

Introduction
in this section.
Form: 5A0202-S030-01E “Tank Sounding Record”

This is a form – produced in MSWord – intended to be used when receiving fuel oil or other liquids
pumped into larger storage tanks (and where an overflow situation must be prevented).
The record also provides a “log” from where it is possible to later identify increases of decreases in the
flow rate (which can affect the environmental safety of the process).
Note! This is important information and

the maximum pressure and flow rate shall
be established before commencing the
operation.

Form: 5A0202-S030-02E “Tank Sounding Log”
This is a form – produced in MSWord – intended to be used when sounding tanks (fuel, lube oil,
water, etc.) as well as waste oil collection pits and other areas where liquids may be collected.
These sounding can be taken on a daily or weekly schedule, all depending on the type of operation and
how rapidly the levels can fluctuate during this perdiod.

Form: 5A0202-S030-03E “Performance Analysis”
This is a form – produced in MSWord – intended to be used when analysing the performance of a heat
exchanger installed in a fluid circulation system. The base date collected can be further evaluated
using the trend diagrams included in this section.
.

This is a form – produced in MSWord – intended to be used when analysing the performance of a
pump installed in a fluid circulation system. The base date collected can be further evaluated using the
trend diagrams included in this section.

This is a form – produced in MSWord – intended to be used when analysing the performance of an air
compressor unit (start air, instrument/control air or work air compressor. The base date collected can
be further evaluated using the trend diagrams included in this section.

radiator unit installed in a fluid circulation system. The base date collected can be further evaluated
Note! The form has been developed for the cooling water system, using radiators with two cooling
sections (HT and LT section). However, it can also be used for other radiator applications after
editing.

This is a form – produced in MSWord – intended to be used when analysing the performance of an air
filtration unit. The base date collected can be further evaluated using the trend diagrams included in
this section.

filtration unit installed in a fluid circulation system. The base date collected can be further evaluated

Form: 5A0202-S030-09aE/9bE “Performance Analysis”
This is a form – produced in MSWord – intended to be used when analysing the unit by plotting
parameters in a diagram. The diagram at below left have all parameters “open” while the one below
right have the “operating hours” parameter prepared.

separator unit installed in a fluid circulation system. The base date collected can be further evaluated

Form: 5A0202-S030-11E “Alignment Record”
This is a form – produced in MSWord – intended to be used when aligning a driven unit with the
driving unit (a pump with electrical motor is used as an example, but the form can be used also for
other types of drive arrangement).
The illustration is made to clearly

show the distances that shall be
measured when calculating the
size of shims to be inserted. The
distance between the coupling
halves “A” is normally not as far
apart as shown on the illustration.
Indicate the direction of rotation

when taking the readings (as seen
from the “driving” end – i.e. the
motor end.
Make the half-circle into an arrow
showing the rotation, or enter the
degrees where the readings have
been taken.
The form is made with several sections to permit a “log” over the alignment process. In practise this is
often done using a “trial and error” approach, though it would be recommended to use the
“mathematical” approach instead. It is also possible to use a “graphical” method where the measured
and distances are drawn up on a millimetre-paper and where the thickness of the required shims can be
measured.
Both these methods are valid and appropriate, but it is not possible to include a full description here in
this instruction. However, the form above can help record the data required for both these methods.

Form: 5A0202-S030-12E “Pressure test/Leak control”
This is a form – produced in MSWord – intended to be used when inspecting/testing pipe systems. The
graph section can be used to draw a simple line diagram over the pipe section investigated. Indicate
the position of leaks found (if any) on this drawing.
The same form can be used for several inspections, and this can be helpful to determine if certain
sections are more prone to leakage – or if the same leak occur again.

List of Forms
No: Name:
01E Tank sounding log sheet (General)
02E Tank sounding record (General)
03E Performance Analysis, heat exchanger
04E Performance Analysis, pump
05E Performance Analysis, compressor
06E Performance Analysis, radiator
07E Performance Analysis, filter
08E Performance Analysis, filter (oil/liquid media)
09aE Trend analysis diagram (3 parameter values)
09bE Trend analysis diagram (2 parameter values +
operating hours)
10E Performance Analysis, separator
11E Alignment Record
12E Pressure test/Leak control
5A0202-S030-LoC.doc
Tank Sounding Record
General Information
Date: Type of fuel:
Max. Pressure: bar Supplier:
Max. Flow Rate: m3/h Maximum level permitted:
Storage Tank Identification Number:

Delivered by:
Unloading Supervisor: Tel:
Volume at start: m3/h Density of oil received:

Volume at stop: 3
m /h Temperature in tank: °C
3
Volume received: m /h Tons received (calculated):
Time: Sounding: Time: Sounding: Time: Sounding:
Time: Date: Note! File completed form with other unloading information.
(Signature)
Tank Sounding Log
Tank # Contents Sounding Tank # Contents Sounding
Pit # Contents Sounding Other Contents Sounding
Remarks
Time: Date:
(Signature)
Performance analysis
Name of installation: Unit Type of Equipment Serial No.

Heat exchanger
5 4 10 9
1 2 3 8 7 6
Process parameters
Description Position Unit Time: Time: Time:

Inlet temperature 1 °C
Cooler media
Inlet pressure 2 bar

Inlet flow 3 m³/h
Outlet temperature 4 °C
Outlet pressure 5 bar
Differential temperature °C
Differential pressure bar
Coolant
Inlet flow 8 m³/h

Ambient temperature °C
Ambient pressure Pa
(Signature)

Pump
1 2 3 4 5
Process parameters

Pumped media

Inlet flow 3 m³/h
Rating kW
Rpm (measured) r/min
Load (ampere) Amps
Pump
Vibration/SPM
Ambient pressure Pa
(Signature)

Compressor
1 2
Process parameters

Discharge temperature 1 m³/h
Process values
Discharge pressure 2 °C
Pressure, when starting bar
Pressure, when stopping °C
Volume of tank(s) filled bar
Rating kW
Compressor data

Load (ampere) Amps
Vibration/SPM
Ambient pressure Pa
Amount airborne particles
(Signature)

Radiator
1 2 3 4 5
HT section
6 7 8 9 10
LT secition
Process parameters
Measured flow 1 m³/h
Inlet, temperature 2 °C
HT section
Inlet, pressure 3 bar

Outlet, temperature 4 °C
Outlet, pressure 5 bar
Differential, temperature °C
Differential, pressure bar
Measured flow 6 m³/h
Inlet, temperature 7 °C
LT section
Inlet, pressure 8 bar

Outlet, temperature 9 °C
Outlet, pressure 10 bar
Differential, temperature °C
Differential, pressure bar
Rating kW
Fan
Load (ampere) Amps

Vibration/SPM
Engine load kW
Ambient pressure Pa
(Signature)

Air filter
Process parameters

Engine load kW
Pressure in ducting after filter bar
Volume air flow m³/h
Ambient pressure Pa
(Signature)

Filter
1 2 3
Process parameters

Type
Filtered
media
Viscosity cSt
Temperature °C
Flow 1 m³/h
Unit

(Signature)
Trend Analysis
Name of Installation: Parameter 1: Parameter 2: Parameter 3:
3 2
Parameter Data
1 2 3 1 2 3
Trend Analysis
Name of Installation: Unit: Parameter 1: Parameter 2:
2 1
Operating hours
Parameter Data
Operating hrs 1 2 Operating hrs 1 2

Name of installation: System Type of Separator Unit Serial No.
3 4 5 6
2 7
1 8
Process Parameters

Feeder pump 1 rpm
Feeder pump 2 amp
Oil inlet flow (to heater) 3 m³/h
Oil inlet temp. (to heater) 4 °C
Oil inlet Pressure (to heater) 5 bar
Oil outlet temp. (from heater) 6 °C
Outlet temp. from seperator 7 °C
Outlet flow from seperator 8 m³/h
Tank level (sludge tank) 9 cm
Ambient Temperature °C
Ambient Pressure Pa
(Signature)
Alignment Record
Name of installation: System Motor/Serial No. Pump/Serial No.
A Measurement
B
B
C C
Measurement 0° 90° 180° 270° 0°
Initial
Final
Shims Inserted Measurement

0° 90° 180° 270° 0°
Drive end None drive end Before After
(Signature)
Pressure test/Leak control
Name of installation: Unit/System: Normal pressure: Media:
Test Record
Description Unit Date: Date: Date: Date:

Normal operating temperature °C
Pressure Test
Max. operating pressure bar

Test pressure bar
Time period h/m
Media
Normal operating temperature °C

Leak Detection
Max. operating pressure bar

Test pressure bar
Media h/m
Test method
Ambient pressure Pa
(Signature)
Instructions
Fuel System
Introduction................................................................................... 2
Form: 5A0202-S031-01E “Inspection Record”............................ 2
Form: 5A0202-S031-02aE “Fuel Oil Sample” ............................. 3
Form: 5A0202-S031-02bE “Gas Fuel Sample”............................ 4
Form: 5A0202-S031-03E “Fuel Sample”..................................... 5
Form: 5A0202-S031-04E “Unloading Procedure” ....................... 6
Form: 5A0202-S031-05E “Bunker Sample” ................................ 7
Form: 5A0202-S031-06E “System Analysis” .............................. 8
Form: 5A0202-S031-08E “System Analysis” ............................ 10

Introduction
in this section.
Form: 5A0202-S031-01E “Inspection Record”

This is a form – produced in MSWord – intended to be used as a general checklist when inspecting the
fuel oil systems at the plant.
Note! The form is – by necessity – very general and should be edited to better correspond to the actual
systems and the equipment used at site

Form: 5A0202-S031-02aE “Fuel Oil Sample”
This is a form – produced in MSWord – shall be prepared and be included with any fuel oil sample
shipped to a laboratory for analysis.
Note! This form is not intended to be used when taking samples when receiving fuel. This is covered
by the form titled “Bunker Samples”.
The required information is:

Sample number. This can be a simple serial
number, preferably having the following form
“year-#”.
Sample taken from shall contain information
about from where the sample was taken, such
as tank, system, etc.
Total volume (tank/system) is the total volume
of fuel in the tank/system from where the
sample was taken.
Has fuel been treated: shall contain
information about the treatment that the fuel
has been subjected to before the sample was
taken, such as filtering, separating,
homogenised, blended, etc. The answer
required is a simple “yes/no” but if the answer
is “yes” then the treatment shall be explained
in the “remark” section.
Treatment chemicals added shall give
information about any chemical treatment that
the fuel has been subjected to. If the answer is
“yes” then this shall be explained in the
section below (If “yes” indicate product.
Name of manufacturer is information about
the commercial product used for the
treatment.

Form: 5A0202-S031-02bE “Gas Fuel Sample”
This is a form – produced in MSWord – shall be prepared and be included with any gas fuel sample
Note! To avoid operational problems such as corrosion, wear, lube oil contamination, etc. it is
necessary to take samples of the gas fuel at regular intervals and to have them analysed with respect to
corrosive trace gases such as H2S, chlorides, halogens, etc.
The following sample frequencies are recommended:
• Weekly during the first three weeks of operation.
• Every three weeks for the next three month
• Thereafter every six weeks.
The samples should be taken and analysed by a qualified laboratory. During the warranty period a
copy of the result should be sent to Wärtsilä service department.

number, preferably having the following
form “year-#”.
about the sampling point. Normally this
would be at the inlet from the utility
supplying the gas.
Pressure/temperature in system is the
reading from instrument placed nearby the
sample point.
Flow rate in the system: shall contain
information about the actual flow rate at the
time the sample was taken (it is not
recommended to take the sample when there
is no flow (that is, with all engines shut
down).
Note! The same log – as used to list the fuel oil samples – can be used to track also the gas fuel
samples (see next page).

Form: 5A0202-S031-03E “Fuel Sample”
This is an MSWord document prepared to help list information about the fuel samples (both general
samples and samples taken when receiving fuel) sent for analysis.
This information will provide a valuable history of any fuel-related problems experienced at the plant.
If the result from the analysis lead to actions to rectify any undesirable condition, this should be
recorded on the log sheet with reference to any reports written (work reports, failure investigation
reports, etc.).

Form: 5A0202-S031-04E “Unloading Procedure”
This is an MSWord document prepared as a checklist to help prepare, supervise and conclude the
unloading of fuel oil from a tanker. It consists of five (5) pages according to the following structure:
Before Operation: General Information (Page 1)
Shore side crew responsibilities (Page 2)
Ship’s crew (Deck department) responsibilities (Page 3)
During Operation: General (Page 4)
After Operation: General (Page 5)
Note! Only the first and the last pages are shown below.

Form: 5A0202-S031-05E “Bunker Sample”
This is a form – produced in MSWord – shall be prepared and be included with any fuel oil sample
taken during the fuel unloading procedure.
Note! It is not always that fuel samples taken during the unloading process is analysed. Often the
samples are simply stored to be used should any questions arise as to the quality of the fuel supplied.
Caution! To be regarded as a valid sample, it is important that the container has been properly sealed
(lead seal) to insure that the sample cannot be tampered with (a broken seal render the sample
“useless”).

Stage of bunker operation when sample was
taken. This section has been filled in showing
when the sample was taken. If only one
sample is taken, it should be taken by the
power plant crew and at a time they decide.
“year-#”.
Type of fuel shall contain information about
the standard designation/product name of fuel
received (according to the shipping papers).
Sample taken by: shall give information about
the individual taking the sample, if the person
belong to the ships crew or the power plant
personnel. If it is a trained chemist who takes
the sample (employed by any of the parts or
an outside resource) it will give more
credibility to the sample (correct procedure).
Sample sent for analysis: If “yes” it would be
prudent to add information about the
laboratory performing the analysis (“Remark”
section) and also a reference to the result of
the analysis.
Location for storing sample shall contain
information about where a sample has been
stored (if not sent for immediate analysis.

Form: 5A0202-S031-06E “System Analysis”
This is a form – produced in MSWord – showing a general unloading system that can be used for both
the HFO and the LFO unloading units. If other fuels are used (Orimulsion® or Crude) it is also
possible to use this form, and it would be suitable also for the lube oil system unloading unit (though it
is not yet placed in that section).
The information obtained can be further analysed by using the “trend analysis” diagram provided in
section 3.0.
Note that even though most parameter values can be recorded on this form, it is only those parameter
values that shall be investigated that need to be recorded (for a full analysis it would be required to
have all parameters recorded).

This is a form – produced in MSWord – showing a general transfer pump unit (with heater) that can be
used for the HFO transfer unit. If other fuels are used (Orimulsion® or Crude) it is also possible to use
this form, and it would be suitable also for the LFO and the lube oil system transfer unit (without
heaters).
section 3.0.

This is a form – produced in MSWord – showing a general separator unit (with heater) that can be
used for the HFO/LFO treatment unit/system. If other fuels are used (Orimulsion® or Crude) it is also
possible to use this form.
section 3.0.

This is a form – produced in MSWord – showing a general transfer/feeder pump unit (with flow meter
but without heater) that can be used for the HFO/LFO feeder unit/system. If other fuels are used
(Orimulsion® or Crude) it is also possible to use this form.
section 3.0.

This is a form – produced in MSWord – showing a general booster unit (with heater) that can be used
for the HFO/LFO booster unit/system. If other fuels are used (Orimulsion® or Crude) it is also
possible to use this form.
section 3.0.

This is a form – produced in MSWord – showing a general fuel oil unit (with heater) that can be used
for the HFO/LFO fuel system. If other fuels are used (Orimulsion® or Crude) it is also possible to use
this form.
section 3.0.

List of Forms
No: Name:
01E Tank farm/fuel system inspection log sheet
02aE Fuel Oil Sample
02bE Gas Fuel Sample
03E Fuel Sample log sheet
04E Bunker procedures form (ship to shore)
05E Bunker Sample
06E Fuel system analysis (unloading)
07E Fuel system analysis (transfer)
08E Fuel system analysis (fuel oil separator)
09E Fuel system analysis (feeder)
10E Fuel system analysis (booster)
11E Fuel system analysis (fuel oil unit)
5A0202-S031-LoC.doc
Inspection Record
Weekly Inspection Report; Fuel Oil System and Equipment

General Information
Date of inspection:
Inspected by:
Inspection Report : .
Note! In the columns below “S” stands for “Satisfactory” while “U” stands for “Unsatisfactory”. The “Remarks” area is only intended for short
notes or to give a reference to a more detailed report should this be required.
S U Description Remarks
Storage tanks, pipe supports and fittings appear in good condition. No rust, bulges,
visible leaks or overflow recorded.
All visible weld seams on the tanks are intact. No leaks visible.
Marking on storage tank intact and contents clearly identified.
All manhole covers installed and fully bolted in place
Tank vents in good condition with flame screens intact. Drip trays are empty.
Collection pits at overflow lines are empty.
Tank farm drainage channels are free of pollution. No oily deposits detected.
Rainwater collection pit within the surrounding containment wall empty. The water
drainage valve is closed.
The level indicators are functioning and giving an accurate reading of the level in
the tank.
The tank heating system is functioning and keeping the contents of the tank at the
desired temperature.
The temperature sensors and indicators are functioning and in good condition.
Insulation on tanks and piping system is in good condition and not damaged.
All pipelines in good order. No leaks or chaffing at supports. All bolted flanges in
place with the correct number of bolts.
All filling/discharge connections capped or blanked. Locks in place on valves at
connections.
Plant discharge channels free of pollution.
Void spaces (where applicable) sounded and empty.
Time: Date: Remarks The inspection reports should be archived for at least
one (1) year.
(Signature)
Fuel Oil Sample
General Information
Name of Installation:
Main fuel:
Product name:
Provided by:
Sample information
Sample number:
Sample taken from:
Total volume (tank/system):
Has fuel been treated? Yes No Yes No Yes No Yes No
Treatment chemicals added? Yes No Yes No Yes No Yes No
If “Yes” indicate product:
Name of manufacturer:
Remarks
Time: Date: The Original shall be sent to the laboratory performing the
analysis.
One copy shall be retained at the site to monitor the
samples sent out for analysis. The copy shall be filed
together with the result from the analyses when received
(Signature) from the laboratory.
Gas Fuel Sample
General Information
Main type of gas fuel:
Provided by:
Sample information
Sample number:
Sample taken from:
Pressure in system:
Temperature in system:
Flow rate in system (when
the sample was taken):
Remarks
analysis.
Fuel Sample
Log sheet
Sample Date
Number Sent Received Remarks/Actions taken Report/reference
Unloading Procedure
Fuel unloading procedure

The information below provides information about how to safely unload fuel oil from a tanker to the main storage
tanks. The responsibility for the power plant personnel starts at the shore side flange.
It is essential that all activities and checks are performed as listed. If an item is not possible to complete, the reason
for this must be given and an agreement between the ship and the receiving company must be reached regarding the
appropriate actions to take before commencing the unloading process.
Before Operation; General information

The following activities/checks should be performed prior to commencing the unloading:
Step Description
Plan the unloading process together with responsible personnel – both on ship and on shore. Items to cover:
q Ships unloading plan (which order the tanks will be emptied, time required when changing over, etc.)
q Power plants loading plan (which tanks to fill, capacity each can accept, etc.)
q Inform the tanker’s unloading supervisor about maximum permissible flow rates and agree on suitable
flow rates and pressures.
q Establish what communication system shall be used (“walkie-talkies” or similar) and check that all units
are functioning.
q Agree on the following signals (hand/siren/flags, etc. or a combination thereof):
Standby to start unloading
Start unloading
Slow down flow rate (mainly used when topping up tanks).
Stop operation
Emergency stop
q Agree on a suitable emergency shutdown procedure, both for emergency shutdowns initiated from the
ship and from the power plant.
Brief all personnel that shall take part in the unloading of fuel oil, including the control room operators.
Log the briefing – both in the ship’s logbook and in the power plants fuel handling reports
Remarks
Page 1 of 5
Before Operation; Shore side crew responsibilities.
The following activities/checks should be performed by the shore side crew prior to commencing the unloading:
Step Description
The flexible unloading hose has been inspected and the test certificate has been checked and the validity
verified.
The hose supports have been checked and it is verified that the hose cannot be damaged during normal
unloading.
Arrangements has been made to prevent strain on hose couplings, both on shore and on ship,
All hose couplings have been properly secured.
Drip trays of suitable size are placed under each connection not protected by a “save-all” enclosure.
Empty containers available to collect contents of drip trays.
Adequate supply of adsorbent material is available.
The valves are checked and in the correct operating position according to the valve list below.
The unloading system and equipment has been inspected and found ready to receive fuel.
“No Smoking” signs are posted in the affected areas.
Suitable fire-fighting equipment is available at the unloading station.
The control room operator is informed that the fuel unloading procedures are ready to begin, and have made
a public message to inform that no hot work may be performed in affected areas.
The tanker’s unloading supervisor is informed that the power plant is ready to receive fuel, and that the
unloading can proceed.
Log the time when the “Standby to operate” and “Start operation” signals was given/received.
Stand by to operate: Start Operation: Stop Operation:
Remarks
Page 2 of 5
Before Operation; Ship’s crew (Deck department) responsibilities.
The following activities/checks should be performed by the ship’s crew prior to commencing the unloading:
Step Description
The vessel is correctly and adequately secured alongside the unloading station.
There is a safe access between the ship and the dock.
The unloading plan has been prepared and the shore personnel have been informed.
Sufficient skilled personnel are available onboard to carry out the unloading operation and any emergency
action that can be foreseen.
The cargo hoses are correctly rigged, with proper supports and in good condition.
All hose couplings have been properly secured.
All scupper plugs are installed and drip trays are placed under connection points and manifolds.
External containment equipment installed or ready to be used (conventional containment boom, deepskirted
boom, etc.) as and when required.
Empty containers available to collect contents of drip trays.
Adequate supply of adsorbent material is available.
Appropriate fire extinguishers are located near the unloading manifolds and ready for use.
“No Smoking” signs are posted in appropriate areas
The valves are checked and in the correct operating position.
The unloading system and equipment has been inspected and found ready to transfer fuel.
The power plants unloading supervisor is informed that the tanker is ready to transfer fuel, and that the
unloading can proceed.
Public announcement has been made, and information that fuel transfer is in progress. Information has been
given that during fuel transfer the following rules are in effect:
Smoking is prohibited on open decks
All outside doors must remain fully closed.
All hot work must be stopped
Log the time when the “Standby to operate” and “Start operation” signals was given/received.
Stand by to operate: Start Operation: Stop Operation:
Remarks
Page 3 of 5
During Operation; General
The following activities/checks should be performed during the unloading procedure:
Step Description
Use the general “Tank Sounding Record” when monitoring the filling of the tanks.
All tank sounding to be taken using sounding tape. For heavy fuel oil it is recommended to take the
sounding as “ullage” (measuring from the top of the tank to the surface of the fuel) when possible and
permitted to do so.
A filling valve to one of the receiving tanks must always be in open position during unloading. It is only to
be closed after having the transfer of fuel stopped – this to prevent over pressurising the system and the
unloading equipment (flexible hoses).
Fuel samples are to be taken at the beginning of the operation, once during the operation and once at the end
of the operation.
The unloading must not be performed without supervision, and the tanker as well as the power plant must
have personnel on duty to maintain a control over the system and equipment to check for overflow and
leakage.
The tanker must maintain a bridge watch during the unloading process.
The tanker’s mooring lines must be monitored to prevent unnecessary movement of the vessel.
Should a leak anywhere in the system occur, all transfer operations must be stopped immediately
(Emergency stop).
q Any fuel leak must be reported to the control room and the emergency co-ordinator. The emergency co-
ordinator will be responsible for handling all reporting requirements and will also supervise the spill
response procedures performed by the power plants own personnel.
q Leaked fuel must be contained and cleaned up as soon as practicable.
q If the leak occur on the vessel the crew must follow the procedures stipulated in their “Shipboard oil
pollution emergency plan”.
q If the leak occur on the power plants area of responsibility, then follow the procedures outlined in the
Spill Response Procedures. Also note that the reporting requirement and incident review procedures
listed in the HAZMAT manual applies.
Topping up tanks
Special care must be taken when topping up tanks due to the risk for overflowing. The following procedure is
recommended:
1. Gradually open the valve to the next tank to be filled.
2. Gradually close the valve to the tank being topped up until it is full
3. When topping up the final tank the tanker crew must be informed about the need to reduce the flow.
4. The filling must be stopped while there still remains sufficient space in the tank to permit that the cargo hoses
and pipes are drained and purged.
Remarks
Page 4 of 5
After Operation; General
The following activities/checks should be performed after the unloading procedure has been stopped:
Step Description
Log the time when the transfer of fuel was stopped
Purge the cargo hose and ensure that it has been drained completely.
Close the valve on the shore side connection and remove the cargo hose (cap both ends to protect it from
contamination).
Purge the fuel pipes (using a “pig” driven through the pipes by compressed air).
Cap open connections and close all valves.
Fuel drained into drip trays when disconnecting hoses must be emptied and cleaned
Dispose of any adsorbent material used when cleaning drip trays and/or minor spills.
Take a final sounding of the tanks having been filled. Complete the tank sounding record.
Inform the control room that the unloading procedure is completed. The control room operator makes a
public announcement stating that the unloading procedure is completed.
Record the following into the fuel record book:
q Name of product (HFO, LFO, Orimulsion®, Crude, etc.)
q Start/stop of unloading procedure.
q Quantity received
q Initial and final soundings of the tanks filled.
q Name/registration number of tanker delivering the fuel
q Name of officer in charge of unloading the tanker.
q Name of unloading supervisor at the plant.
If required, also list the type and quantity of consumables used during the unloading operation (such as
adsorbents, chemical dispersant, etc.)
Remarks
We have reviewed the items listed on this checklist and are satisfied that – to the best of our knowledge – the entries
made are correct.
Date: Time: Date: Time:
(Signature) (Signature)
For Tanker For Power Plant
(enter name & registration number of vessel) (enter name and position)
Page 5 of 5
Bunker Sample
General Information
Date Received:
Tank Sounding Record Prepared by:
Report Located in:
Type of fuel Received:
Product name:
Provided by:
Tanker Name/registration number:
Sample information
Stage of bunker operation At the beginning During the At the end of
when sample was taken: of the operation. operation. the operation.
Sample number:
Type of fuel:
Sample taken by:
Ships crew: Yes No Yes No Yes No Yes No
Power plant personnel: Yes No Yes No Yes No Yes No
Chemist: Yes No Yes No Yes No Yes No
Sample sent for analysis: Yes No Yes No Yes No Yes No
Location for storing sample:
Remarks
Caution! To be regarded as a valid sample, it is important that the container has been properly sealed (lead seal) to insure that
the sample cannot be tampered with (a broken seal render the sample “useless”).
analysis.
System analysis
Name of installation: System Type of pump unit: Type of fuel.

Unloading
1 2 3 4 5
Process parameters

Inlet temperature. 1 °C
Flow meter reading 3

Start m3
Stop m3
Time in operation minutes
Ambient pressure Pa
Type of fuel
Viscosity cSt
(Signature)
System analysis
Name of installation: System Type of pump unit: Type of heater:

Transfer
1 2 3 4 5 6 7 8 9 10 11
Process parameters

Pressure before pump 3 bar
Discharge pressure 4 bar
Discharge temperature 5 °C
Heating media inlet pressure 6 bar
Heating media inlet temperature 7 °C
Heating media outlet pressure 8 bar
Heating media outlet temperature 9 °C
Ambient pressure Pa
Type of fuel
viscosity cSt
(Signature)
System analysis
Name of installation: System Type of Separator Serial No.

Fuel oil separator
3 4 5 6
2 7
1 8
Process Parameters

Feeder pump 1 rpm
Feeder pump 2 amp
Fuel oil inlet flow (to heater) 3 m³/h
Fuel oil inlet temp. (to heater) 4 °C
Fuel oil inlet Pressure (to heater) 5 bar
Fuel oil outlet temp. (from heater) 6 °C
Heating media inlet temp/pressure
Heating media outlet temp/pressure
Outlet temp. from separator 7 °C
Outlet flow from separator 8 m³/h
Tank level (buffer tank) cm
Tank level (day tank) cm
Ambient Pressure Pa
Gravity disk installed
Fuel treated (brand name of oil):
(Signature)
System analysis
Name of installation: System Type of pump unit: Heater (if any):

Feeder unit
2
Day tank
1
3 4 5 6 7 8 9
Process parameters

Day tank, level 1 cm
Day tank, temperature 2 °C
Flow meter start 5 m3
Flow meter stop 5 m3
Time in operation h
Pump inlet, temperature 6 °C
Pump inlet, pressure 7 bar
Pump outlet, temperature 8 °C
Pump outlet, pressure 9 bar
Ambient pressure Pa
Type of fuel
viscosity cSt
(Signature)
System analysis
Name of installation: System Type of unit: Type of heater:

Booster
Level 5
1 2 3 4
8 9 10 11 12 13 14 15
Process parameters
Pressure after filter 3 bar
Temperature after filter 4 °C
Deaeration tank, temperature 6 °C
Deaeration tank, pressure 7 bar
Pressure before pump 8 bar
Temperature before pump 9 °C
Pressure after pump 10 bar
Temperature after pump 11 °C
Heating media, temp, in 12 °C
Heating media, temp, out 13 °C
Ambient pressure Pa
Type of fuel
viscosity cSt
(Signature)
System analysis
Name of installation: System Type of pump unit: Type of heater:

Fuel oil unit
1 2 3 4 5 6 7 8 9 10
Process parameters

Pressure after filter 3 bar
Temperature after filter 4 °C
Pressure after pump 5 bar
Temperature after pump 6 °C
Heating media, temp, in 7 °C
Heating media, temp, out 8 °C
Ambient pressure Pa
Type of fuel
viscosity cSt
(Signature)
Instructions
Lubrication System
Introduction ............................................................................................... 2
Form: 5A0202-S032-01E “Engine oil level sounding report (daily)”....... 2
Form: 5A0202-S032-02aE “Lube oil fill follow-up form (ltr/kWh)” ....... 3
Form: 5A0202-S032-02bE “Lube oil fill follow-up form (g/kWh)”......... 4
Form: 5A0202-S032-03a/bE “Lube Oil Inventory” .................................. 5
Form: 5A0202-S032-04E “Lube Oil Sample”........................................... 6
Form: 5A0202-S032-05E “Lube Oil Sample”........................................... 7
Form: 5A0202-S032-06E “Oil Analysis”.................................................. 8
Form: 5A0202-S032-07E “System Analysis” ........................................... 9
Form: 5A0202-S032-08E “System Analysis” ......................................... 10
Form: 5A0202-S032-09E “Inspection Record”....................................... 11
Form: 5A0202-S032-10E “Station Lube Oil Report” ............................. 12
5A0202-S032-Instr.doc Page 1 of 12
Introduction
The following are short instructions with information for how to use the forms and templates provided in
this section.
Form: 5A0202-S032-01E “Engine oil level sounding report (daily)”

This form is designed in Excel. It can be printed out and filled in by hand, but also contains certain
calculation features which can be useful if the form is filled in digitally.
The field “Month/Day/Year” is now only for manually entered data, but if the form shall be used in Excel
then this cell should have the function for date inserted [=NOW()}]
Also the cells containing the calculated sum of the amount filled into each engine have functions that will
permit the summation of the lube oil filled into each engine.
The form is designed to be filled in manually by the person checking the engine lube oil level. Normally
also the person filling oil into the engine crankcase. This may also be performed automatically and then
the lube oil flow meter is read once daily.
However, then this sheet may still be used to record the amount of oil in each engine.
Form: 5A0202-S032-02aE “Lube oil fill follow-up form (ltr/kWh)”
Also this form is designed in Excel. It can be printed out and filled in by hand, but also contains certain
calculation features which can be useful if the form is filled in digitally.
The items described for the previous form apply also for this one, with the exception that this form covers
the lube oil consumption for a whole month.
The main item is that here also the electrical production (kWh) is entered, and this is used to calculate the
average lubrication oil consumption (in litres per kWh).
This form is intended to be filled in digitally, and these functions (total amount and ltrs/kWh) will be
calculated automatically.
Form: 5A0202-S032-02bE “Lube oil fill follow-up form (g/kWh)”
This form is almost identical to the previous form (5A0202-S32-02a). Also can be printed out and filled
in by hand, but contains further calculation features which can be useful if the form is filled in digitally.
This form includes a cell where the density of the lube oil can be entered.
This will permit having the lube oil consumption given in gram per kWh instead of litres per kWh. To
have the consumption given as grams per kWh is sometimes desired when comparing the actual
consumption with the figures given by the manufacturer.
Note! This consumption figure is only based on fairly inaccurate observations, and cannot be used to
contest any claims made by the manufacturer. It shall only be viewed as guidelines and to help detect an
undesirable increase in consumption. If the consumption is substantially higher than that claimed by the
engine manufacturer, and no other reason for the high consumption can be found (leaks, theft, etc.) then it
is suggested that a more comprehensive and accurate test is made to confirm this consumption figures.
Form: 5A0202-S032-03a/bE “Lube Oil Inventory”
This is a simple form designed to help when taking the weekly lubricant inventory (oil and greases).
The form has been developed in two versions – one in Excel and one in MSWord. The Excel form below
also has features calculating the amount used if the other fields are filled in correctly.
The form produced in MSWord (5A0202-S032-03bE) does not have this calculation feature and is only
meant to be used when manually entering data.
Form: 5A0202-S032-04E “Lube Oil Sample”
This is a document produced in MSWord. Further, it has been produced as a “form” and if it is desired to
change items in the basic form you must open the “Forms” toolbar (see separate instructions).

Sample number. This can be a simple
serial number, preferably having the
following form “year-#”.
Engine Type, Engine Serial Number and
Engine Speed is information that can be
obtained from the engine nameplate.
Total hours in operation can be obtained
from the engine hour counter. The hour
counter may be reset after a major re-
build or major overhaul. This should
then be noted in the “Remark” section.
Volume of oil in circulation is the
amount of oil in the engine crankcase.
Quantity added is the amount of oil
added since the last oil change.
Average load can be given as a
percentage showing an estimated
average since the last oil sample was
taken.
Filter replacement interval is the normal
time based schedule for replacing the
filters in the lube oil circulation system.
If an automatic filtration unit is installed
this should also be noted in the
“Remark” section, and then also the
back-flushing interval should be noted.
This form shall be prepared and be included with the oil samples shipped to the laboratory for analysis.
Form: 5A0202-S032-05E “Lube Oil Sample”
This is an MSWord document prepared to help list information about the lube oil samples sent for
analysis.
This information will provide a valuable history of any lubricant related problems experienced at the
plant. If the result from the analysis lead to actions to rectify any undesirable condition, this should be
recorded on the log sheet with reference to any reports written (work reports, failure investigation reports,
etc.).
Form: 5A0202-S032-06E “Oil Analysis”
This is a very basic form prepared to help when analysing trends for parameters that may influence the oil
quality.
The form is simply a graph where parameter values can be added manually for a visual evaluation of the
trends. The “Operating hours” is the base parameter while the other parameters to be compared can be
selected by the operator. This could be “Amount of oil added” and “Viscosity” or some other parameters
that might influence each other and therefore can be the object for a closer analysis.
This is a form – produced in MSWord – showing a general circulation system for the engine lubrication
oil.
section 3.0.
Note that is even though most parameter values can be recorded on this form, it is only those parameter
values that shall be investigated that need to be recorded (for a full analysis it would be required to have
all parameters recorded).
This is a form – produced in MSWord – showing a general system for the treatment of the engine
lubrication oil. Note that this form can also be used for other separator systems.
section 3.0.
Note! Even though most parameter values can be recorded on this form, it is only those parameter values
that shall be investigated that need to be recorded (for a full analysis it would be required to have all
parameters recorded).
lubrication system at the plant.
system and the equipment used at site
The lube oil level in the

separator gearcase can be
estimated and recorded simply
by drawing a line across the
symbol for the sight glass
shown on the form.
See illustration below:
Form: 5A0202-S032-10E “Station Lube Oil Report”
This form is prepared in Excel. It is an “old” form and has only been updated with the new Wärtsilä logo.
The rest of the information is the same.
The form can be useful for smaller plants (only three engines are listed) and can also be edited/updated
according to a plants specific needs.
List of Forms
No: Name:
01E Engine oil level sounding report (daily)
02aE Lube oil fill follow-up form (ltr/kWh)
02bE Lube oil fill follow-up form (g/kWh)
03aE Lube oil inventory sheet (Excel)
03bE Lube oil inventory sheet (MSWord)
04E Lube oil sample
05E Log sheet for tracking the lube oil samples
06E Analysis of lube oil samples
07E System analysis form (circulation system)
08E System analysis form (oil treatment system)
09E Inspection Record (Lube oil system and equipment)
10E Station Lube Oil Report
5A0202-S032-LoC.doc
Logbook sheet
Engine Oil Level Sounding Report (Daily)
Instructions: The soundings are normally taken with an interval of two (2) hours. Enter the actual time when the sounding or filling took place. Add up the total amount of
oil filled into each engine and enter the sum into form 5A0202-S032-02E
Engine: Engine: Engine: Engine: Engine:
Time Level Filled Level Filled Level Filled Level Filled Level Filled
Total:
Remarks:
Logbook sheet
Lube oil fill follow-up from
Document ID: 5A0202-S032-02aE
Month/Year Made/Approved: MiGus/GGU

Day kWh Fill kWh Fill kWh Fill kWh Fill kWh Fill
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Total:
ltr/kWh
Logbook sheet
Lube oil fill follow-up from
Document ID: 5A0202-S032-02bE
Density Month/Year Made/Approved: MiGus/GGU

Day kWh Fill kWh Fill kWh Fill kWh Fill kWh Fill
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Total:
g/kWh
Lube Oil Inventory
Installation: Day/Month/Year
Document ID: 5A0202-S032-03aE Made/Approved: MiGus/GuGu
The information required is:

Description:Enter the name of the product
Previous: Enter the amount "at hand" from previous inventory
Received: Enter any oil/grease received during the period between inventory.
Sounding: Sounding in cm or other measurement required to calculate the amount at
hand e.g. number of drums.
At hand: Amount this inventory (enter volume according to sounding table)
Used: Amount used during the period( previous + received - at hand)
Descripiton Previous Received Sounding At hand Used
Remark:
Time: Date:
Signature
Lubricant Inventory
General Information
Name of lubricant manufacturer:
Information required:
Description: Enter name of product
Previous: Enter amount “at hand” from previous inventory
Received: Enter any oil/grease received during the period between inventory.
Sounding: Sounding in cm or other measurement required to calculate the amount at hand, e.g. number of drums.
At hand: Amount this inventory (enter volume according to sounding table)
Used: Amount used during the period (previous + received – at hand
Description Previous Received Sounding At hand Used
Remarks
Time: Date: The Original shall be retained at the site to verify the
station lubricant consumption reports sent to Owner and
head office.
The lubricant inventory is normally taken once weekly.
The amount used shall be compared with the consumption
(Signature) recorded for the engines. Discrepancies may indicate leaks
or other losses.
Lube Oil Sample
General Information
Main fuel:
Name of lubrication oil:
Manufactured by:
Sample information
Sample number:
Engine type:
Serial number:
Engine speed (rpm):
Total hours in operation:
Hours in use (oil):
Volume of oil in circulation:
Quantity added:
Average load:
Filter replacement interval
Remarks
analysis.
Lube Oil Sample
Log sheet
Sample Date Engine
Number Sent Received Number Remarks/Actions taken Report/reference
Oil Analysis
Name of Installation: System: Parameter 1: Parameter 2:

Lube oil analysis/trending
2 1
Hours on oil
Parameter Data
Hrs on oil 1 2 Hrs on oil 1 2
System analysis
Name of installation: System Type of Engine Engine No.

Lube oil system
8 9
6
1
5 4 2
3
12 14 10
13 11
Process parameters
Description Position Unit time: time: time:
Oil temperature, engine crankcase 1 °C
Engine load kW
Flow (lube oil circulation pump) 3 m³/h
Oil Temperature, in 9 °C
Oil Temperature, out 2 °C
Oil Pressure, to engine 8 °C
Oil temperature, in PHX 4 °C
Oil temperature, out PHX 5 °C
Coolant temperature, in PHX 11 °C
Coolant temperature, out PHX 13 °C
Coolant pressure, to PHX 10 bar
Coolant pressure, from PHX 12 bar
Flow (coolant) 14 m³/h
Differential pressure, auto filter 6 bar
Differential pressure, safety filter 7 bar
Ambient Pressure Pa
Brand name of oil
(Signature)
System analysis
Name of installation: System Type of Separator Serial No.

Lube oil separator
3 4 5 6
2 7
1 8
Process Parameters

Feeder pump 1 rpm
Feeder pump 2 amp
Lube oil inlet flow (to heater) 3 m³/h
Lube oil inlet temp. (to heater) 4 °C
Lube oil inlet Pressure (to heater) 5 bar
Lube oil outlet temp. (from heater) 6 °C
Outlet temp. from separator 7 °C
Outlet flow from separator 8 m³/h
Hours on oil (engine) h
Ambient Pressure Pa
Gravity disk installed
Media treated (brand name of oil):
(Signature)
Inspection Record
Weekly Inspection Report; Lube Oil System and Equipment

General Information
Date of inspection:
Inspected by:
Storage tanks, pipe supports and fittings appear in good condition. No rust, bulges,
Marking on tanks intact and contents clearly identified.
All manhole covers installed and fully bolted in place
Tank vents in good condition with flame screens intact. Drip trays are empty.
The level indicators are functioning and giving an accurate reading of the level in
the tank.
Insulation on tanks and piping system is in good condition and not damaged.
All trace heating system functioning properly
connections.
Lube oil transfer pump system checked and functioning properly.
Lube oil filling system (to engine) checked and functioning properly.
Lube oil treatment system (separator) checked and functioning properly.
Checked the oil level in the separator units. Oil filled as required (see info below).
Unit 1 Unit 2 Unit 3 Unit 4 Unit 5

Ltr Ltr Ltr Ltr Ltr
Pre-lube pump unit, checked and functioning properly.
Automatic filtration unit, checked and functioning properly.
Safety filtration unit, checked and functioning properly.
Centrifugal filtration unit, checked and functioning properly.
Oil-mist coalescer unit, checked and functioning properly. Unit drained and the
appearance/amount of liquid checked.
one (1) year.
(Signature)
Logbook sheet Doc Id: WDAAA112424 a
STATION LUBE OIL REPORT Made/Approved: JVE/CJM
Station: _______________________________________ Date: ____________________
Time: ____________________
Storage tank
Lube oil storage tank today: reading
Lube oil storage tank yesterday: reading
Total supplied to tank: quantity
Oil type:
Drums
Total drums (# ) today: quantity
Total drums (# ) yesterday: quantity
Total supplied to plant(# ): quantity
Oil type:
Consumption
Engine #1, makeup: quantity
Engine #1, oil change: quantity
Engine #1, lost: quantity
TOTAL ENGINE CONSUMPTION: quantity
Distribution:
Instructions
Compressed Air System
Introduction................................................................................... 2
5A0202-S033-Instr.doc
Introduction
in this section.

This is a form – produced in MSWord – showing a general start air system for the engine.
section 3.0.
Note! Even though most parameter values can be recorded on this form, it is only those parameter
Note! Only one form is shown and described here. However, the same instructions apply for also form
“5A0202-S033-02E Control air system” and “5A0202-S033-03E Work air system”.
compressed air system.
system and equipment at site.
The lube oil level in the

compressor crankcase can be
estimated and recorded simply
by drawing a line across the
symbol for the sight glass
shown on the form.
See illustration below:
List of Forms
No: Name:
01E Start air system analysis form
02E Control air system analysis form
03E Work air system analysis form
04E Inspection Record, compressed air system.
5A0202-S033-LoC.doc
System analysis
Name of installation: System Type of Compressor Serial No.

Start air system analysis
Process parameters

System pressure (in or after receiver) bar
System pressure at engine bar
Compressor load (when in operation) amp
Compressor discharge pressure bar
Compressor discharge temperature °C
Pressure when compressor starts bar
Pressure when compressor stops bar
Time between start and stop min
Operating hours h
Ambient pressure Pa
Volume of tanks m³
(Signature)
System analysis

Control air system analysis
Engine
6
5
Air drier
1 2 3
Process parameters

System pressure ( after or in receivers)
Pressure at engine bar
Compressor load (when in operation) 1 amp
Compressor discharge pressure 2 bar
Compressor discharge temperature 3 °C
Air drier temperature, out 5 °C
Air drier humidity, out 6 %
Operating hours (control cabinet) h
Ambient pressure Pa
Volume of tanks 4 m³
(Signature)
System analysis

Work air system analysis
To consumer
1 2 3
Process parameters

System pressure (in or after receiver) bar
Compressor load (when in operation) 1 amp
Compressor discharge pressure 2 bar
Compressor discharge temperature 3 °C
Pressure when compressor starts bar
Pressure when compressor stops bar
Time between start and stop min
Operating hours h
Ambient pressure Pa
Volume of tank(s) 4 m³
(Signature)
Inspection Record
Weekly Inspection Report; Compressed Air System and Equipment

General Information
Date of inspection:
Inspected by:
Air receivers, pipes and compressors inspected for leakage and obvious defects.
Check the pressure in all air receivers.
Drain moisture from receivers and drain traps in system. Note that unusual large
amount of drained liquid is cause for further investigation!
Check the cleanliness of the compressor units (especially the radiator cooling).
Inspect all compressor units for oil leakage.
Check V-belt adjustment, tension and pulley alignment.
Check the inlet filter to the compressor units. Clean if required.
Check and test all automatic safety devices (see manufacturers instructions).
Check safety valve (manual test if permitted by manufacturer).
Check and test run units to ensure proper operation (if required).
Check the oil level in the compressor units. Fill oil if required. Record amount.

Ltr Ltr Ltr Ltr Ltr
Check and record the compressor load while in operation (amps and voltage)
A A A A A
Check and record the compressor cut-in / cut-out pressure. Record the time between
normal start/stop (or between “loading/unloading”)
Check the air dryer, clean the condensor coil and fan motor.
one (1) year.
(Signature)
Instructions
Cooling System
Introduction ............................................................................................... 2
Form: 5A0202-S034-01E “System Analysis” ........................................... 2
Form: 5A0202-S034-02E “Water/additive fill follow-up form” ............... 3
Form: 5A0202-S034-03E “Water Treatment Analysis”............................ 4
Form: 5A0202-S034-04E “Water Sample” ............................................... 5
Form: 5A0202-S034-05E “Water Sample” ............................................... 6
Form: 5A0202-S034-06E “Inspection Record”......................................... 7
Form: 5A0202-S034-07E “Log sheet “Elysator® unit” ............................ 8
Introduction
in this section.

This is a form – produced in MSWord – showing a general cooling system for the engine. This
particular form shows a system using radiators to remove the heat from the cooling water.
section 3.0.
Form: 5A0202-S034-02E “Water/additive fill follow-up form”
This form is designed in Excel. It can be printed out and filled in by hand, but also contains certain
calculation features which are useful when the form is filled in digitally.
The field “Month/Year” is now only for manually entered data, but if the form shall be used in Excel
then this cell should have the function for date inserted [=NOW()}] Form S03402bE has this feature.
Also the cells containing the calculated sum of the amount filled into each engine have functions that
will permit the summation of the water as well as the amount of additive filled into each engine.
The form is designed to be filled in manually by the person checking the engine’s cooling system.
Normally this is also the person testing the coolant and filling water/additive into the cooling system.
Form: 5A0202-S034-03E “Water Treatment Analysis”
This is a form – produced in MSWord – with a graph to help analyse the treatment of the cooling
system for the engine.
Note! The analysis can help identify if the water loss is the result of evaporation or due to undetected
leakage. If water need to be added without having to add more treatment chemicals the water losses
can be the result of evaporation, but if also treatment chemicals need to be added the loss is normally
the result of leakage.
If other parameters need to be analysed, the “trend analysis” diagram (provided in section 3.0) can be
used.
Form: 5A0202-S034-04E “Water Sample”
This is a form – produced in MSWord – shall be prepared and be included with any water sample

“year-#”.
Engine Type and Engine Serial Number is
information that can be obtained from the
engine nameplate.
Operating hours can be obtained from the
engine hour counter. The hour counter may be
reset after a major re-build or major overhaul.
This should then be noted in the “Remark”
section.
HT or LT system indicates if the sample was
taken from the high temperature circuit (HT)
or the low temperature circuit (LT).
Hours in use indicates the time since the
system was filled with new coolant.
Temperature in system is the temperature of
the water as it leaves the engine.
Volume of water in circulation is the total
amount of water circulating in the cooling
system.
Quantity water added is the total amount of
water added since the last change.
Quantity chemicals added is the total amount
of treatment chemicals added since the last
change.
Type of treatment chemical shall give
information about the main compound used
for the treatment of the coolant.
Name of manufacturer/product is information
about the commercial product used for
treatment of the coolant.
This is an MSWord document prepared to help list information about the water samples sent for
analysis.
This information will provide a valuable history of any water/coolant related problems experienced at
the plant. If the result from the analysis lead to actions to rectify any undesirable condition, this should
be recorded on the log sheet with reference to any reports written (work reports, failure investigation
reports, etc.).
This is a form – produced in MSWord – intended to be used as a general checklist when inspecting a
radiator cooling system.
Form: 5A0202-S034-07E “Log sheet “Elysator® unit”
This form is designed in Excel and prepared according to information regarding the “Elysator®” unit.
This unit treats the coolant in the system and is in operation as soon as the coolant circulate in the
engine, i.e. when the engine is in operation.
The form can be printed out and filled in by hand, but also contains certain calculation features which
are useful when the form is filled in digitally.
The field “Month/Year” is now only for manually entered data, but if the form shall be used in Excel
then this cell should have the function for date inserted [=NOW()}] Form S03402bE has this feature.
The “Operating Hours”

is the time the engine
has been in operation
during the day.
The number must be
given either in whole
numbers or with the
minutes as decimals
only where 0,1 h equals
6 minutes.
The “Meter Reading”

shall contain an accurate
reading of the flow
meter, taken at the same
time every day.
The “Flow” is
automatically calculated
(flow meter reading
divided by the hours in
operation..
List of Forms
No: Name:
01E System analysis form (HT and LT)
02E Water/additive fill follow-up form (HT and LT)
03E Water treatment analysis form
04E Water Sample form
05E Water Sample form (log sheet)
06E Inspection Record (radiator cooling system)
07E Log sheet “Elysator®” unit
5A0202-S034-LoC.doc
System analysis

Cooling system analysis
13 15 7 5 6 8 16 14
HT cooling Lube oil cooling

3 1
11 9 10 12
LT cooling
2 4
Process Parameters

Engine load MW
Operating hours h
System ⇒ HT LT HT LT HT LT
Outlet temperature (Engine) 1,2 °C
Outlet pressures (Engine) 3,4 bar
Inlet temperature (Engine) 5,6 °C
Inlet pressures (Engine) 7,8 bar
System ⇒ HT LT HT LT HT LT
Inlet temperature (Cooler) 9,10 °C
Inlet pressures (Cooler) 11,12 bar
Outlet temperature (Cooler) 13,14 °C
Outlet pressures (Cooler) 15,16 bar
Ambient pressure Pa
Volume of tank(s) m³
Volume of system
(Signature)
Logbook sheet
Water/Additive fill follow-up form
Month/Year Made/Approved: MiGus/GGU
Engine: Engine:
Level in Amount water Coolant condition Treatment Level in Amount water Coolant condition Treatment
expansion tank added chemical added expansion tank added chemical added
Day: Operating hours HT LT HT LT HT LT HT LT HT LT HT LT HT LT HT LT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Total amount:
Water Treatment Analysis
Amount Amount
water additive
added added
Operating hours
Parameter Data
Operating Amount of Amount of Operating Amount of Amount of

Hours Additive Added Water added Hours Additive Added Water added
Water Sample
General Information
Main fuel:
Name of lubrication oil:
Manufactured by:
Sample information
Sample number:
Engine type:
Serial number:
Operating hours:
HT or LT System:
Hours in use (water):
Volume of water in system:
Quantity water added:
Quantity chemicals added:
Type of treatment chemical
Name of manufacturer/product
Remarks
analysis.
Water Sample
Log sheet
Sample Date Engine
Number Sent Received Number Remarks/Actions taken Report/reference
Inspection Record
Weekly Inspection Report; Cooling System and Equipment

General Information
Date of inspection:
Inspected by:
Piping system, pipe supports and fittings appear in good condition. No rust, bulges,
Automatic vents at high points in the system appear to be in good condition. No
leaking units observed.
Drain valves at low point in the system appear to be in good condition and no leaks
observed.
Expansion tanks checked for both circuits (HT and LT). Sight glass checked and in
good working order.
Water samples taken from both circuits (HT and LT). Samples analysed and result
recorded.
connections.
Coolant temperatures checked and the correct function of temperature regulating
valves verified.
Pre-heating pump unit, checked and functioning properly.
Radiator
Radiator coils checked for damages, leaks and accumulation of debris. Cleaned as
required.
Radiator fans checked, motor load (amps) recorded and checked for noise/vibration
Temperature control system checked and functioning properly.
Radiator coils vented and all accumulated air removed from the system.
one (1) year.
(Signature)
Log Sheet "Elysator®" Unit
Month/Year: Made/Approved: MiGus/GuGu
System Low temperature circuit (LT) High temperature circuit (HT)

Day of Meter Meter
Operating pH Conductivity Flow pH Conductivity Flow
the mA Reading mA Reading
hours value (µS/cm) (l/min) value (µS/cm) (l/min)
month (m³) (m³)
0 - - - - - - - -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Remark:
Instructions
Charge Air System
Introduction ..................................................................................... 2
Form: 5A0202-S035-01E “System Analysis”................................. 2
Form: 5A0202-S035-02E “System Analysis”................................. 3
Form: 5A0202-S035-03E “Inspection Record” .............................. 4
Introduction
in this section.

This is a form – produced in MSWord – showing a general charge air system for the engine.
The information obtained can be further analysed by using the general graph diagram form provided in
section 3.0.
The filters and other external units have been identified according to the “side” of the engine at which
it is installed. That is, either to “bank A” or “bank B”. Note that the banks are identified when viewing
the engine from the drive end (where the driven equipment – normally a generator – is installed).
This is a form – produced in MSWord – showing a general charge air system for the engine.
The information obtained can be further analysed by using the general graph diagram form provided in
section 3.0.
Note! This system analysis template is mainly concerning the charge air system on the engine itself
and could be said to belong in section 02.0 instead. However, it may be easier to find the information
in this section since it is identified as the charge air system.
charge air systems.
List of Forms
No: Name:
01E System Analysis (checking filtration performance)
02E System Analysis (checking system performance)
03E Inspection Record
5A0202-S035-LoC.doc
System analysis

Charge air filtration
4 Engines internal system
"B" bank
6 2
Cylinders
Cylinders
7 3
"A" bank
Process parameters

Operating hours h
Engine load 1 MW
Engine bank ⇒ A B A B A B
Turbo charge speed 2,3 rpm
Differential pressure 4,5 Pa
Flow (velocity) 6,7
Ambient pressure bar
Filtration unit, type
(Signature)
System analysis

Charge air performance
Engines internal system
"B" bank
5 3
13 Cylinders
9 7 1
11
12
10 8 2
14 Cylinders
6 4
"A" bank
Process parameters
Description position Unit Time: Time: Time:

Operating hours h
Engine Load MW
Charge air temperature in receiver 1 °C
Charge air pressure in receiver 2 Pa
Coolant temperature before CAC I 5 °C
Coolant temperature after CAC I 6 °C
Coolant temperature before CAC II 3 °C
Coolant temperature after CAC II 4 °C
Charge air temperature, inlet to TC 13,14 °C
Turbo charge speed 11,12 rpm
Charge air temperature, after TC 9,10 °C
Charge air pressure, after TC 7,8 °C
Ambient pressure Pa
Hours since CAC cleaned h
(Signature)
Inspection Record
Weekly Inspection Report; Charge Air System and Equipment

General Information
Date of inspection:
Inspected by:
Charge-air ducting, supports and fittings appear in good condition. No visible
damages recorded.
External louvres inspected and any debris found removed.
Bag type air filtration unit

Pressure differential over filter checked and settings verified.
Filters inspected for damages (damaged filters replaced).
Oil bath air filtration unit

Pressure differential over filter checked and settings verified.
Viscosine® level checked and recorded. Amount of sludge checked and excessive
amount of sludge removed.
Charge air heating system (if installed)

Heating coils inspected for damages and any accumulated debris removed.
Temperature control system checked and functioning properly.
Circulation pump system checked and functioning properly.
Silencer unit
Silencer inspected and any accumulated condensate drained out.
one (1) year.
(Signature)
Instructions
Exhaust System
Introduction................................................................................... 2
Introduction
in this section.

This is a form – produced in MSWord – showing a general exhaust system for the engine.
section 3.0.
exhaust gas systems.
List of Forms
No: Name:
01E Checking exhaust system performance
02E Inspection Record
5A0202-S036-LoC.doc
System analysis

Exhaust gas system
9
Engines internal system
Silencer
"B" bank
2
8 6 4 Cylinders
unit unit
1
2 1
Cylinders
7 5 3
"A" bank
Process parameters

Operating hours h
Engine load MW
Exhaust gas temperature at “A” 3 °C
Exhaust gas temperature at “B” 2 °C
Back pressure in exhaust system 1 bar
Flow, exhaust gas. 9 Kg/s
Exhaust temperature, inlet 4,6 °C
Exhaust temperature, outlet 6,8 °C
Differential pressure 5,7 bar
Ambient pressure bar
(Signature)
Inspection Record
Weekly Inspection Report; Exhaust Gas System and Equipment

General Information
Date of inspection:
Inspected by:
Exhaust gas piping, supports and fittings appear in good condition. No visible
damages recorded.
Expansion joints inspected and in good condition. Neither visible damages nor
leaks recorded.
Pipe insulation inspected and in good condition. Neither visible damages nor leaks
recorded.
Exhaust gas back pressure recorded and within acceptable limits.
Silencer unit
Silencer inspected and any accumulated condensate drained out.
one (1) year.
(Signature)
Instructions
Waste Treatment System
Introduction................................................................................... 2
Introduction
This section is intentionally left empty.
There is not yet any standard forms or templates developed for the waste treatment system. This
mainly because so many and varied systems and equipment is used.
The general form “Tank Sounding Log (5A0202-S030-03E) can be used to record the amount of waste
oil in the waste oil collection pits and in other pits connected to the waste treatment system.
If necessary this log sheet can be edited to better suit the conditions at site.
When and if other forms are developed, they should be included in this section.
Instructions
Water Treatment System
Introduction................................................................................... 2
Form: 5A0202-S038-01E “Water Sample” .................................. 2
Form: 5A0202-S038-02E “Water Sample” .................................. 3
Introduction
in this section.

This is a form – produced in MSWord – shall be prepared and be included with any water sample

“year-#”.
about from where the sample was taken, such
as tank, system, etc.
Temperature in system is the normal
temperature of the water at the sampling point.
Volume of water in system is the total volume
of water from where the sample was taken.
For human consumption is a simple “yes/no”
question to verify if the sample is taken from
water that is intended for human consumption
– that is “potable water”. This is important as
the sampling technique and the analysis
methods are entirely different between the
analysis of process water and potable water.
Process water for: shall contain information
about the intended use of the water. The form
contain selections for cooling water, process
water and boiler water.
Quantity chemicals added is the total amount
of treatment chemicals added to the water
analysed.
Type of treatment chemical shall give
information about the main compound used
for the treatment of the water.
Name of manufacturer/product is information
about the commercial product used for
treatment of the water.
Note! In the “Remark” section, the following important text has been added:
Note! If the sample is taken from a source intended for human consumption, it is important to use
special and sterile containers for the sample. It must normally also be cooled and must be tested as soon
as possible (preferably within 12 hours).
This information must be taken into account when taking samples to analyse potable water.
This is an MSWord document prepared to help list information about the water samples sent for
analysis.
This information will provide a valuable history of any water-related problems experienced at the
plant. If the result from the analysis lead to actions to rectify any undesirable condition, this should be
recorded on the log sheet with reference to any reports written (work reports, failure investigation
reports, etc.).
List of Forms
No: Name:
01E Water Sample
02E Water Sample Log Sheet
5A0202-S038-LoC.doc
Water Sample
General Information
Department:
Sample information
Sample number:
Sample taken from:
Volume of water in system:
For human consumption? Yes No Yes No Yes No Yes No
Process water for:
Quantity chemicals added:

Type of treatment chemical
Name of manufacturer/product
Remarks
Note! If the sample is taken from a source intended for human consumption, it is important to use special and sterile containers
for the sample. It must normally also be cooled and must be tested as soon as possible (preferably within 12 hours).
analysis.
Water Sample
Log sheet
Sample Date
Number Sent Received Remarks/Actions taken Report/reference
Instructions
Heat Recovery units/systems
Introduction..................................................................................................................2
Form: 5A0202-S040-01E “Operating Data”................................................................2
Form: 5A0202-S040-02E “Soot Blowing Record”......................................................3
Form: 5A0202-S040-03E “Inspection Record” ...........................................................4
Form: 5A0202-S040-04E “Steam Trap Inspection Record”........................................5
Form: 5A0202-S040-05E “Performance Analysis”.....................................................6
Introduction
in this section.
Form: 5A0202-S040-01E “Operating Data”

This is a form – produced in MSWord – that may be used to collect operating data from an exhaust gas
boiler while the engine is running under load.
section 3.0.
Form: 5A0202-S040-02E “Soot Blowing Record”
This is a form – produced in MSWord – that may be used to collect operating data before and after a
soot blowing has been performed. To record these parameters is valuable to establish the efficiency of
the cleaning method used.
section 3.0.
heat recovery systems and equipment at the plant.
systems and the equipment used at site
section 3.0.
Form: 5A0202-S040-04E “Steam Trap Inspection Record”
steam traps installed at the plant.
Note! Steam traps are often neglected during normal operation, but can be very costly in terms of lost
energy. It is therefore essential that all steam traps are located and regularly inspected. For most plant
it is recommended to perform this inspection at least annually – but if possible, every six months or
more often if warranted.
steam heating system installed in a tank. The base date collected can be further evaluated using the
trend diagrams included in this section.
steam trace heating system. The base date collected can be further evaluated using the trend diagrams
included in this section.
condensate trap installed on a steam pipe system. The base date collected can be further evaluated
List of Forms
No: Name:
01E Operating Data
02E Soot Blowing Record
03E Inspection Record (system)
04E Steam Trap Inspection Record
05E Performance Analysis, steam heater (tank)
06E Performance Analysis, trace heating
07E Performance Analysis, condensate trap
5A0202-S040-LoC.doc
Operating Data
Installation: Unit number: Date (yy/mm/dd)
Boiler Data
Manufacturer: Serial No: Operating pressure:
Data Recorded
Time h
Engine load %
Stack temperature °C
Steam pressure bar
Steam temperature °C
Steam flow kg/s
Feedwater pressure bar

Feedwater temperature °C
Feedwater flow kg/s
Inlet °C
Exhaust gas
Temp. Outlet °C
Differential °C
Inlet wg/Pa
Pressure Outlet wg/Pa
differential wg/Pa
Soot blowing been performed? Yes No Yes No Yes No

Surface blow-down performed? Yes No Yes No Yes No
Bottom blow-down performed? Yes No Yes No Yes No
Sight-glasses blown through? Yes No Yes No Yes No
Alarms/safeties tested? Yes No Yes No Yes No
Water sample taken? Yes No Yes No Yes No
Boiler Water Analysis

pH-value
Hardness °dH
Salinity µS
Sulphite mg/l
Phosphor mg/l
Data recorded by:

(Signature)
Remarks
AFUP fault code: 800 steam generation system
Soot Blowing Record
Installation: Type of plant: Boiler type:
General Data
Manufacturer: Serial No: Operating pressure:
Site Conditions
Altitude (MASL): Ambient Temperature: Ambient Pressure: Relative Humidity:

Meter °C kPa %
Recorded Data
Date/Time: Day/Time
Engine load %
Steam pressure bar
Total time min
Before Soot Cleaning

Inlet °C
Exhaust gas
Temp. Outlet °C
Differential °C
Inlet wg/Pa
differential wg/Pa
After Soot Cleaning

Inlet °C
Exhaust gas
Temp. Outlet °C
Differential °C
Inlet wg/Pa
differential wg/Pa
Soot blowing performed by:

(Signature)
Remarks
AFUP fault code: 800 steam generation system
Inspection Record
Weekly Inspection Report; Heat Recovery System and Equipment

General Information
Date of inspection:
Inspected by:
The boiler’s steam-, water- and exhaust piping checked for leakage while operating.
All manholes and hand-holes inspected for leakage.
Thermal insulation checked on boiler and steam pipes (damaged or “wetted”).
All pipe supports checked for proper alignment and condition.
Boiler area free of debris and combustible material
Low water level shutdown and alarm checked and tested.
Safety valves outlet free (not obstructed) and the safety valves are not leaking.
All gauges, thermometers and level sight glasses are readable and functioning
properly.
one (1) year.
(Signature) AFUP fault code: 800 Steam Generation System

Steam Trap Inspection Record
General Information Condition Inspection performed

Tag # Location: Type: Size: Capacity: S U Date Signature Reference
Note! In the “Condition” column “S” stands for “Satisfactory” while “U” stands for “Unsatisfactory”. The “Reference” column is intended for a
reference to a more detailed report should this be required.
2 1
4
3
5
7 8 9
Process parameters
Description Position Unit Time: Time: Time: Time: Time: Time:
Steam inlet, temperature 1 °C

Steam inlet, pressure 2 bar
Regulator valve temp. setting 3 °C
Tank level 4 cm
Tank temperature 5 °C
Tank contents 6
Steam outlet temperature 7 °C
Condensate outlet temperature 8 °C
Condensate outlet pressure 9 bar
Ambient pressure Pa
(Signature)
1 2
Process parameters

Condensate outlet, temperature 3 °C
Condensate outlet, pressure 4 bar
Ambient pressure Pa
(Signature)
1 2
3 4
Process parameters

Condensate outlet, temperature 3 °C
Condensate outlet, pressure 4 bar
Ambient pressure Pa
(Signature)
Instructions
Emission Control System
Introduction................................................................................ 2
Form: 5A0202-S050-01E “Exhaust Gas Emission” .................. 2
Introduction
in this section.
Form: 5A0202-S050-01E “Exhaust Gas Emission”

This is a simple sheet used to record the result from the emission measurements performed at the
plant.
Note! It is important to include information about the fuel used as well as information about the actual
composition of the fuel (include a recent analysis of the fuel actually delivered to the plant).
Reference to this analysis should be entered in the “Remark” section.
List of Forms
No: Name:
01E Exhaust gas emission check
5A0202-S050-LoC.doc
Exhaust Gas Emission
Made/Approved: MiGus/GuGU
Installation: Day/month/Year: Company/individual performing the emission test:
Engine Data
Engine type: Engine No: Load (kW) r/min
Type of Fuel
Heavy Fuel Oil: Light Fuel Oil: Natural Gas: Other:
Exhaust Gas Composition
Oxygen (O2): % volume, dry.
Carbon Dioxide (CO2): %volume, dry.
Exhaust Gas Emission
Nitrogen oxides (NOx): ppm, dry.
Carbon monoxides (CO): ppm, dry.
Total Hydrocarbons (C1): ppm, wet.
Remarks
Note! The above data have been measured at 100% nominal load using the fuel specified above.
The composition of the fuel is specified in the enclosed analysis report.
Time: Date:
Check/verified by: (Signature)

Instructions
Power Plant Support/Maintenance
Introduction..................................................................................................................2
Form: 5A0202-S060-01E “Equipment Data” ..............................................................2
Form: 5A0202-S060-02E “Operating Hour Log”........................................................3
Form: 5A0202-S060-03E “Work Request” .................................................................4
Form: 5A0202-S060-04E “Maintenance Planning” ....................................................5
Form: 5A0202-S060-05E “Work Order”.....................................................................6
Form: 5A0202-S060-06E “Project List”......................................................................7
Form: 5A0202-S060-07E “Maintenance Log” ............................................................8
Form: 5A0202-S060-08E “Maintenance Work Performed”........................................9
Form: 5A0202-S060-09E “Maintenance Report”......................................................10
Form: 5A0202-S060-10E “Maintenance Report”......................................................11
Form: 5A0202-S060-11E “Hazardous Work Permit” ...............................................12
Form: 5A0202-S060-12E “Hot Work Permit”...........................................................13
Form: 5A0202-S060-13E “Lock out/Tag out Permit”...............................................14
Form: 5A0202-S060-14E “Confined Space Entry Permit” .......................................15
Introduction
in this section.
Form: 5A0202-S060-01E “Equipment Data”

This is a form – produced in MSWord – that may be used to collect important component data for any
unit in the power plant – data that later shall be included in the plants main maintenance system.
It may also be used to provide the basis for a simple, manual maintenance system.
The section named Genealogy is an area where reference to information about the unit’s “history” could
be entered. That is, information about where the unit previously been installed, etc.
Form: 5A0202-S060-02E “Operating Hour Log”
This is a form – produced in MSWord – which may be used to collect information about the running
hours accumulated for an engine (emergency generator) or other type of equipment.
The operating hours can be read from a meter or be manually entered in this form, this to make it
possible to maintain some control over the actual operating hours accumulated for a unit.
Form: 5A0202-S060-03E “Work Request”
This is a form – produced in MSWord – which may be used by an authorised employee to request
having specific tasks performed – tasks that may be in addition to the normal maintenance work, or
which may include some new installation, etc.
Normally a department head – or someone authorised to approve the additional expenditure that might
be necessary – shall approve this work request.
After approval the Maintenance Manager will take charge of the task to be performed.
Form: 5A0202-S060-04E “Maintenance Planning”
This is a form – produced in MSWord – which may be used by the maintenance manager to help
schedule the maintenance work at the power plant. It is a very simple form, and only the tasks to be
performed can be planned for…there is no facility to include the resources available.
To handle maintenance planning requires experience and knowledge about the resources
(skilled/unskilled workers, external resources, etc.) that cannot easily be included in this simple format.
Enter number of week here…

Enter the date here…
Form: 5A0202-S060-05E “Work Order”
This is a form – produced in MSWord – which may be used by the maintenance manager to issue a
work order for a specific task to be performed.
The work order is designed as a “task description” and the intention is that it shall be prepared in
advance and be possible to re-use when required. The task description shall be reviewed after use, and
shall be updated as necessary (based on information from the maintenance report written after having
performed the task).
Form: 5A0202-S060-06E “Project List”
This is a form – produced in MSWord – which may be used by the maintenance manager to list the
different tasks to be performed at the plant – with or without the work order issued.
The section named Report/reference can contain information about the work request issued or
the maintenance report prepared.
Form: 5A0202-S060-07E “Maintenance Log”
This is a form – produced in MSWord – which may be used by the maintenance manager to log the
maintenance performed on a unit.
The section named Report/reference shall contain information about the maintenance report
prepared.
Form: 5A0202-S060-08E “Maintenance Work Performed”
This is a form – produced in MSWord – which may be used by the maintenance manager to write
down smaller jobs/services performed on a unit (that is, jobs that are “too small” to warrant a regular
report). This can include regular test runs (to check function and operation), etc.
Form: 5A0202-S060-09E “Maintenance Report”
This is a form – produced in MSWord – which may be used to give information about the maintenance
performed on a unit and/or system.
Form: 5A0202-S060-10E “Maintenance Report”
This is a form – produced in MSWord – which may be used to give additional information about the
maintenance performed on a unit and/or system – should the main form not be sufficient.
Form: 5A0202-S060-11E “Hazardous Work Permit”
This is a form – produced in MSWord – which may be used to inform about any hazardous work
performed at the plant. The form also require that the authorised supervisor, as well as the
workers/attendants sign the sheet to verify that the will comply with the safety requirement and that
they have understood the risks involved.
Form: 5A0202-S060-12E “Hot Work Permit”
This is a form – produced in MSWord – which may be used to inform about any hot work performed
at the plant. The form also require that the authorised supervisor, as well as the workers/attendants
sign the sheet to verify that the will comply with the safety requirement and that they have understood
the risks involved.
Form: 5A0202-S060-13E “Lock out/Tag out Permit”
This is a form – produced in MSWord – which may be used to inform about any work performed that
requires having the appropriate “lock out/tag out” procedures in effect before work is permitted to
commence.
Warning! To establish the required “Loch out/Tag out” procedures are essential to prevent injuries to
personnel! This simple form does assume that such procedures have been established.
The form also require that the authorised supervisor, as well as the workers/attendants sign the sheet to
verify that the will comply with the safety requirement and that they have understood the risks
involved.
Form: 5A0202-S060-14E “Confined Space Entry Permit”
This is a form – produced in MSWord – which may be used to inform about any work performed that
requires having the appropriate “confined space entry” procedures in effect before work is permitted to
commence.
Warning! To establish the required “Safe Entry” procedures are essential to prevent injuries to
personnel! This simple form does assume that such procedures have been established.
The form also require that the authorised supervisor, as well as the workers/attendants sign the sheet to
verify that the will comply with the safety requirement and that they have understood the risks
involved.
List of Forms
No: Name:
01E Equipment Data
02E Operating Hour Log
03E Work Request
04E Maintenance Planning
05E Project List
06E Work Order
07E Maintenance Log
08E Maintenance Work Performed
09E Maintenance Report
10E Maintenance Report (“add-on” sheet).
11E Hazardous Work Permit
12E Hot Work Permit
13E Lock out/Tag out Permit
14E Confined Space Entry Permit
5A0202-S060-LoC.doc
Equipment Data
Installation date: PO number: Location: Genealogy: Accounting code: Unit ID number:
Description of
unit/system:
Manufacturer: Manufacturer code:
Supplier: Supplier code:
Type : Hp : Volt :
Model : rpm : Amps :
Serial No : Frame : kW :
References:
Additional
information:
Prepared by: Date: Remarks:

Operating Hour Log
Name of installation: Manufacturer: Unit ID number: Serial No.
Date: Description/Remarks: Total Hrs Maintenance Hrs run this Daily

(meter): due at: month: average:
Work Request
Name of installation: Date: Department: Originator:
Equipment: Maintenance planner’s notes:
Location:
Description of fault or defect:
Probable cause:
Corrective action (suggested):
Access work and required Lock out/Tag out procedures:
Material/parts required:
Remarks:
Approved by: Date: Work order number:

Purchase order number:
(Signature) Reference document:

Maintenance Planning
Name of Installation: Department: Sheet Sheets Day planned: For month: Year
-+ of
Calendar Based Maintenance

Week ⇒
Unit ⇓ Day
Approved by: Date: Remarks:
Maintenance Manager
Work Order
Name of installation: Date Scheduled: Date Performed: Maintenance Report number: Work Order Number:
Craft: References:
Estimated time:
Crew:
Supervisor:
Warnings!
Lock out/tag out required? Yes No Hazardous/hot work permit required? Yes No
Tools and Personal protection equipment required
Preparatory work to be performed:
Material/Spare Parts Required

Quantity: Part number: Description: Total cost:
Task Description:
Work order issued by: Date: Work performed by: Date:

Project List
Name of installation: Department: List number: Year/Month:
List over maintenance projects

Work order #: Description: Report/reference:
Maintenance Work Performed
Installation: Unit/Equipment: Serial No:
Work performed
Description
Date Signature Reference
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Maintenance Report
Name of installation: Date Scheduled: Date Performed: Work Order Numbed:
Skilled man hours: Unskilled man hours Estimated labor cost: Cost of parts used:
Report:
Material Used
Quantity: Part number: Description: Total cost:
Material required but not available

Quantity: Part number: Description: PO number:
Remarks:
Maintenance Report
Name of installation: Work Order Numbed: Date Performed: Prepared by:
Report:
Hazardous Work Permit
Area identification: Estimated duration of work: Date Issued: Work Order number: Permit Number:
Emergency Contact numbers

Operations Centre
Rescue:
Fire:
Ambulance:
Warning! Before commencing the work, read the Procedures for Hazardous Work and Hot Work Permit. This
procedure must be available to - and fully understood by - the individuals assigned to perform the work, which is
verified by their signature below.
Statement:
We, the undersigned, fully understand the precautions to be taken when performing hazardous work, and that it is our
responsibility to ensure safe work practices and to follow the instructions given, including the use of personal protective
equipment required for the job.
We also understand that it is our responsibility to clear the area after the work has been performed and to ensure that no
residual risks remain when leaving the work site.
Authorized workers Initial Attendants (if required) Initial
Procedures/clearances prepared and verified

Procedure/clearance: Performed/Prepared by: Time/date: Signature:
Hot work permit* No:
Draining
Physical Isolation
Electrical Isolation
*Display together with this Hazardous Work Permit.
Certification of Requirements Work Approval Time/Date
The conditions specified in this document are satisfied.
Equipment and personnel are ready to commence work. Work described above may commence at:
To be completed by:
Above work extended until:
Authorised Supervisor Authorised Control Room Operator
Original. Post at job site until completion of work. Retain for 1 year or until annual review.
Copy. Retain in Supervisor’s Permit Logbook until replaced by original at completion of work.
Special Requirements: Equipment/information required to ensure employee safety:
Ventilation Ear Protection Same Area: Work Site Fire Clean
SCBA Special Clothing (spec. below). Gas/Atmospheric Test
Respirator GED Fault Interrupter Qualified Standby (Watch)
Eye Protector Access Barriers (Others)
Remarks:
Atmospheric testing. Perform periodic tests every 30 minutes, record on separate test record.
Permissible entry limits: Initial test: Time/date of test: Tester initials:
Oxygen (above 19.5% and below 23.5%)
Carbon Monoxide (CO), < 35 ppm
Flammability, < 10% of LFL*
*
* Enter the hazard and the entry limit for it (10% of its lower flammability limit).
Post-work critique (Continue on separate sheet if needed)

Hot Work Permit
Area identification: Estimated duration of work: Date Issued: Work Order number: Permit Number:

Operations Centre
Rescue:
Fire:
Ambulance:
Warning! Before commencing the work, read the Procedures for Hazardous Work and Hot Work Permit. This
procedure must be available to - and fully understood by - the individuals assigned to perform the work, which is
verified by their signature below.
Statement:
We, the undersigned, fully understand the precautions to be taken when performing hot work, and that it is our responsibility to
ensure safe work practices and to follow the instructions given, including the use of personal protective equipment required for
the job.
We also understand that it is our responsibility to clear the area after the work has been performed and to ensure that no residual
fire risks remain when leaving the work site
Authorized workers Initial Attendants (Fire Guard) Initial
This is to confirm that I, the undersigned, have carried out an inspection and found the above named area(s) to be
free from flammable material and explosive mixtures.
HOT WORK is hereby permitted at the stated location(s) provided that:
1. Adequate ventilation and sufficient lighting are maintained
2. The stated area(s) are kept free from flammable, combustible and explosive materials
3. Normal fire and safety measures are observed
Date: Time: Validity of Hot Work Permit
from: to:
(Signature) Hot work permit extended until:

Authorised Supervisor
(Signature of Authorised Supervisor)

Original. Post at job site until completion of hot work. Retain for 1 year or until annual review.
Copy. Retain in Supervisor’s Permit Logbook until replaced by original at completion of hot work.
Lock out/Tag out Permit
Equipment location/Description: Estimated duration of work: Date issued: Work Order number: Permit Number:

Operations Centre
Rescue:
Fire:
Ambulance:
Lock out/Tag out Procedure number:

Initiated by: Initial Requested by: Initial
Procedures/clearances prepared and verified

Procedure/clearance: Performed/Prepared by: Time/date: Signature:
Hazardous/hot work permit*
No:
Physical Isolation verified
Electrical Isolation verified
Zero mechanical state verified
*Display together with this LOTO-permit.
I have reviewed the LOTO procedure performed and certify I have inspected the equipment after completion of work and
that the requirements listed in the procedure identified above certify that all foreign material have been removed, the
are adequate and that all workers and affected personnel are equipment is clean, and all lock out/tag outs have been
properly trained and are aware of potential hazards in removed with the equipment re-energised.
connection with the work assignment.
This LOTO-permit is cancelled.
The LOTO procedures are verified and this permit is
authorised.
Authorised LOTO Supervisor Authorised LOTO Supervisor
Original. Post at job site until completion of work assignment. Retain for 1 year or until annual review.
Copy. Retain in LOTO-permit Logbook until replaced by original at completion of work.
Confined Space Entry Permit
Confined Space identification: Estimated duration of work: Date Issued: Work Order number: Permit Number:

Operations Centre
Rescue:
Fire:
Ambulance:
Warning! Before commencing any work in the confined space, read the Safe Entry Procedure for the space. This
procedure shall contain information about potential or existing hazards, about measures to take to isolate, lock
out/tag out and drain the space. It will also contain information about acceptable entry conditions, personal protective
equipment (PPE) that is required, as well as the rescue equipment and rescue procedures that must be used.
Safe Entry Procedure number:

Statement:
We, the undersigned, fully understand the precautions to be taken when entering and working in the confined space
for which this permit has been issued. We understand that it is our responsibility to ensure safe work practices and
to follow the instructions given, including the use of personal protective equipment required for the job.
We also understand that it is our responsibility to clear the area after the work has been performed and to ensure
that no residual risks remain when leaving the work site.
Authorised Entrants: Initial Attendants: Initial
I have reviewed this permit and certify that the I have inspected the space after completion of work and
requirements listed above are adequate for this confined certify that all personnel have exited, all foreign material
space entry and that all authorised entrants and removed, the space is clean, and all entryways have been
attendants are properly trained and are aware of potential properly closed. This permit is cancelled.
hazards within the space. Entry is authorised.
Authorised Entry Supervisor Authorised Entry Supervisor
Original. Post at job site until completion of entry. Retain for 1 year or until annual review.
Copy. Retain in Confined Space Entry Logbook until replaced by original at completion of entry.
Pre-entry atmospheric testing. Perform periodic tests every 30 minutes, record on separate test record.
Permissible entry limits: Initial test: Time/date of test: Tester initials:
Oxygen (above 19.5% and below 23.5%
Carbon Monoxide (CO), < 35 ppm
Flammability, < 10% of LFL*
*
* Enter the hazard and the entry limit for it (10% of its lower flammability limit).
Other equipment/information required to ensure employee safety:
Special Requirements: Equipment/information required to ensure employee safety:

Ventilation Ear Protection Same Area: Work Site Fire Clean
SCBA Special Clothing (spec. below). Gas/Atmospheric Test
Respirator GED Fault Interrupter Qualified Standby (Watch)
Eye Protector Access Barriers (Others)
Remarks:
Post-work critique (Continue on separate sheet if needed)

Instructions
Personnel/Safety Data
Introduction..................................................................................................................2
Form: 5A0202-S070-01E “Audit Check List”.............................................................2
Form: 5A0202-S070-02E “Risk Evaluation Sheet”.....................................................3
Explanation: .................................................................................................................4
Form: 5A0202-S070-03E “Contingency Planning”.....................................................5
Explanation: .................................................................................................................6
Introduction
in this section.
Form: 5A0202-S070-01E “Audit Check List”

This is a form – produced in MSWord – that may be used to evaluate the emergency and contingency
plans at the power plant. Any items listed as “unsatisfactory” should be rectified as soon as possible.
Form: 5A0202-S070-02E “Risk Evaluation Sheet”
This is a form – produced in MSWord – that may be used to identify and evaluate various risks at the
power plant site. This form should only be used as a primary step and must be followed by a serious
effort to eliminate the risks identified. This shall preferably be done be “designing out” the risks, or to
design/install protective devices. If this is not possible it is necessary to establish procedures for hot to
perform the various tasks safely.
Some basic instructions for how to use this form is included on the following page…
Explanation:
1. The number is just a serial number used to identify the entry.
2. The “Type of risk” should be a short description of the risk identified. Further information can be
given in a separate report if necessary.
3. The “Impact” should be a careful analysis of the actual impact the risk can have on personnel,
property or the operation. If no statistics is available, a best “guesstimate” should be entered. The
impact is judged on a scale from 1 to 5, with 5 being the highest impact and 1 the lowest.
4. The “probability” is also a number from 1 to 5; with the same scale as for the “impact” that is, the
lower the number the less likely is the risk to cause any problems.
5. “Resources” is here used to describe the availability of external or internal resources with the
equipment or capabilities to handle the risks if developed into an emergency. Such as having the
“risk of fire” being developed into “a fire”…having a well equipped fire fighting crew at site
would mean that the “Internal resources” would be given a “1” indicating strong resources…with
“weak” resources giving a “5”
6. The “total” is the sum of the numbers…the lower the number the better. This figure is also used as
a “Risk Factor” in other documents.
7. “Procedure” shall contain information about any emergency procedure developed handling this
particular risk.
Form: 5A0202-S070-03E “Contingency Planning”
This is a form – produced in MSWord – that may be used to establish short guidelines to be used as a
contingency plan for the various risks evaluated.
Some basic instructions for how to use this form is included on the following page…
Explanation:
This section is reserved for a short description of the actual system or unit
that has been evaluated. This can be systems such as:
• Cooling water system
• Fire alarm system
• Level control system in sludge tank, etc.
This is the “Total” number obtained from the evaluation of risks (Risk
Evaluation Sheet) and is a combination of the estimated impact and
probability as well as an evaluation of the resources available to handle the
identified risk should an incident occur.
This should be a short description of the effects or problems caused should
the identified risk result in an incident.
This could be a short statement such as “Should the cooling system fail the
engine will shut down automatically.”
This should be a reference to an individual (or job position) that is available
to help develop procedures to handle an incident, or to help preparing for
potential problems identified.
This section should list all the preparations that should be taken to
minimise the potential problem or to prevent an incident from occurring.
This could be statements similar to the following (fire alarm system):
• Perform and document testing on alarm system.
• Perform and document drills and training exercises.
• Train all personnel on alarm awareness.
The section named “What to do if an incident occur” contains two parts,
one named “Assess the situation for” and the other “Action Required”
In the section for “Assessing the situation” a short descriptions about the
preliminary steps should be listed. For a “cooling system failure” this could
be items such as:
• Calmly assess the situation.
• Check if another engine is available to deliver the required load.
• Determine the extent of the problem and estimate the length of time it
will take to get the unit back on line.
In the section for “Action required” a short descriptions about the required
actions should be listed. For a “cooling system failure” this could be items
such as:
• Notify the public utility command centre about the loss of capacity.
• Put the stand-by engine on line.
• Notify the public utility command centre when the capacity is back to
normal.
• Inform maintenance department about the problem.
• Etc.
This section can contain a short reference to a more detailed contingency
plan if such is required and have been developed.
List of Forms
No: Name:
01E Audit Check List
02E Risk Evaluation Sheet
03E Contingency Planning
General Information
The information required to develop standard forms for this section depend on the
laws, rules and regulations that applies in the area where the plant is located.
Forms, developed at site or obtained (from local authorities), should be included in
this section when available.
5A0202-S070-LoC.doc
5A0202-S070-LoC.doc
Audit Check list
Check list, emergency response planning

General Information
Date of audit/inspection:
Performed by:
Report : .
Are emergency plans prepared, tested and functioning?
Are contingency plans prepared, tested and functioning?
Are the plans well prepared and documented?
Have all departments taken part in developing the emergency/contingency plans?
Are procedures in place for updating the plans when changes have occurred (or at
least once yearly)?
Has an individual been clearly identified as responsible for the upkeep and
maintenance of the emergency/contingency plans?
Are all personnel familiar with the various emergency/contingency plans?
Have the personnel been trained and do they know how to act in an emergency?
Has an organisation/command structure been developed to handle interruptions in
plant operation?
Are simple checklists available to show what actions to take during an identified
type of incident (fire, explosion, flooding, environmental spill, etc.)?
Have routines been established for the supervision of serious incidents?
Have current list of emergency contact numbers been posted/distributed?
Have a command centre been established?
Have a secondary centre for supervision of the main operation been established?
Have contingency plans for resuming full operation been established?
Can important information and equipment be moved rapidly in case of threats?
Have routines been established for reporting incidents?
Have routines been established to make a follow-up analysis (“Consequence
analysis”) after a shutdown (“black-out”) or other types of incidents?
Can operation resume within an acceptable time frame?
Time: Date: Remarks The report should be archived for at least one (1)
year.
(Signature)
Risk Evaluation Sheet
Name of Installation: Department: Sheet Sheets Date: Reference, minutes of meeting:

1 of 1
No: Type of risk: Impact on (1 low – 5 high) Probability Resources Total Procedure:
Personnel Property Operation External Internal
Contingency Planning
Name of Installation: Department: Sheet Sheets Date: Prepared by:

1 of 1
Description of Risk Potential effect Contact for Precautions to take What to do if an incident occur Reference
system/service factor on operation assistance
Assess the situation for Action required
Instructions
Miscellaneous use
General Information
This section has been reserved for forms and templates that “doesn’t
belong” in any of the other specified sections.
Presently only a simple “Daily Planner” form is included and this can
be edited to suit the requirement at the plant if so is desired.
When and if other “miscellaneous” forms are developed, they should be
included in this section.
5A0202-S080-GC.doc
Daily Planner
Maintenance Department Week number: Month: Year:

Major Projects: Monday
07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Minor Projects: Tuesday

07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Wednesday
07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Thursday
07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Ref. To notes/reports: Friday

07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Saturday & Sunday

( CALLS
Daily Planner
Operations Department Week number: Month: Year:

Major Projects: Monday
07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Minor Projects: Tuesday

07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Wednesday
07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Thursday
07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Ref. To notes/reports: Friday

07 13 ( CALLS
08 14
09 15
10 16
11 17
12 18
Saturday & Sunday

( CALLS

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1.

3.0 Auxiliaries, General

3.1 Fuel systems

3.2 Lubricating oil

3.3 Compressed air

Manual 5A02 3.5 Charge air

3.6 Exhaust gas

3.7 Waste treatment

3.8 Water supply

4.0 Heat recovery

5.0 Emission control

Book id: WDAAA265478 -

Manual Structure and General Contents

Section 3.7 “Waste Treatment System” This section is

Section Structure and General Contents

Instructions List of Forms

Blue dividers used only when several

Each section (except the introduction) will consist of three parts:

Writers Process Data collection

It is recommended that all forms and templates be managed

It is recommended that all – or

Save the document in the normal way by selecting “File->Save

Before editing the form/template, it is important to change the

Also the “Document ID” shall be changed. This can be done

Drop Down Field

There are three types of forms fields found in word: "Text,"

The "Forms" toolbar as it appears

When editing is complete the forms and checklist shall be

Form Field Options

Form Field Options

The most important option is the “Properties” already selected

Forms & Templates for

Plant Information, General

5A0202-S010-Instr.doc Page 1 of 16 pages

Form: 5A0202-S010-01aE.doc “Operating Schedule”

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Name of Installation: Day Month Year

Operation Planning schedule

Time: Date: Remarks:

Name of Installation: Day Month Year

Operation Planning schedule

Time: Date: Remarks:

Name of Installation: Department Shift Date

Daily Record of Facility Operation

Time: Date: Remarks:

Name of Installation: Day Month Year

Hourly Energy Meter Readings

Time: Time: Time:

Shift supervisor Shift supervisor Shift supervisor

Name of Installation: Day Month Year

Attach additional Parts sheet if necessary Sheet of

Station: ____________________ Set No.: Counter:

Attach additional Parts sheet if necessery Sheet of

Counter reading at the end of month: Date: _ Signature: _______

Station: ___________________ Date: