0 Plant Information,
General
2.0 Genset
3.4
Supervision Cooling water
systems
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
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.
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C:\DocuMate\Project\ReportManagement\\5A0202-S00_Introduction.doc
5A0202-S0.0 Introduction/Gunnar Gustafsson page 3 of 11
C:\DocuMate\Project\ReportManagement\\5A0202-S00_Introduction.doc
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Form
Ÿ Introduction
Ÿ Form 1
Ÿ Heading
Ÿ Form 2
Ÿ Heading
Ÿ From n
Ÿ Heading
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.
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5A0202-S0.0 Introduction/Gunnar Gustafsson page 5 of 11
Record Management
Blank forms
Completed forms
Released forms
Blank forms
Templates
completed forms
Completed forms
Blank forms
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5A0202-S0.0 Introduction/Gunnar Gustafsson page 6 of 11
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.
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5A0202-S0.0 Introduction/Gunnar Gustafsson page 7 of 11
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).
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5A0202-S0.0 Introduction/Gunnar Gustafsson page 8 of 11
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.
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5A0202-S0.0 Introduction/Gunnar Gustafsson page 9 of 11
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
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5A0202-S0.0 Introduction/Gunnar Gustafsson page 10 of 11
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
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5A0202-S0.0 Introduction/Gunnar Gustafsson page 11 of 11
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.
C:\DocuMate\Project\ReportManagement\\5A0202-S00_Introduction.doc
Instructions
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
Daily Operation
Engine # Start Stop Hrs run Load Comments
Operations Manager
Operating Schedule
Document ID: 5A0202-S010-01bE.doc
Made/Approved: MiGus/GuGu
Daily Operation
Engine # Start Stop Hrs run Load Comments
Operations Manager
Daily Operation Log
Document ID: 5A0202-S010-02E.doc
Made/Approved: MiGus/GuGu
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
Document ID: 5A0202-S010-03E.doc
Made/Approved: MiGus/GuGu
Remarks:
Remarks:
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)
Logbook sheet Orig. Doc Id: WDAAA112420 a
PLANT ATTENTION REPORT Doc Id: 5A0202-S010-06E
Made/Approved: MiGus/GuGu
Station: ________________________________________________________________________________________
Set No.: __________
Eng. No.: ______________________________ Type: ________________________ Date: _____________________ Hours: __________
Name: ________________________________________________________________________________________
Ref. No.: __________
Location of problem:
Description of problem:
Description:
Work report:
This checklist should be completed during the daily check round Week: ___________ to ___________ Initiated:______________
Date Remarks
Measure Shift No./Sign
OK OK OK OK OK OK OK
Drain return tank
Check amount of leak fuel
Leak fuel returned, total quantity
Pump L.O. sep. tank
OK OK OK OK OK OK OK
Drain water, storage tanks
OK OK OK OK OK OK OK
Drain water, day tanks
OK OK OK OK OK OK OK
Clean L.O. separator
OK OK OK OK OK OK OK
Clean F.O. separator
OK OK OK OK OK OK OK
Governor oil level check
OK OK OK OK OK OK OK
Turbocharger oil level check
OK OK OK OK OK OK OK
Alternator bearing check
OK OK OK OK OK OK OK
Lub. oil topping-up, set No. 1 (quantity)
OK OK OK OK OK OK OK
Lub. oil topping-up, set No. 2 (quantity)
OK OK OK OK OK OK OK
Lub. oil topping-up, set No. 3 (quantity)
OK OK OK OK OK OK OK
Lub. oil topping-up, set No. 4 (quantity)
OK OK OK OK OK OK OK
Lub. oil topping-up, set No. 5 (quantity)
OK OK OK OK OK OK OK
OK OK OK OK OK OK OK
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
Month/Day/Year Made/Approved: MiGus/GGU
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
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
Station: Month:
Fuel oil type: Date:
Plants on stand by
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
Made/Approved: MiGus/GuGu
Stop hours
Forced
Waiting
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
*)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
Made/Approved: MiGus/GuGu
Time: ____________________
Distribution:
Instructions
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
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.
Section 5A0202-S02.0
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
Document ID: 5A0202-S020-01E.doc
Page 1 of 2
Made/Approved: MiGus/GuGu
Installation: Type of plant: Operating hours:
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
Document ID: 5A0202-S020-01E.doc
Page 2 of 2
Made/Approved: MiGus/GuGu
Engine room temperature: °C
Outside temperature: °C
Ambient air pressure: bar
Relative Humidity: %
(Signature)
Operation Data
Document ID: 5A0202-S020-02E.doc
Made/Approved: MiGus/GuGu
Engine data
Generator Data
General Data
Time: Date: Archive this data record together with the original
test/commissioning record.
Site Conditions
Recorded Data
Date/Time for test: Day/Time
Load % of Nominal: %
Engine room temperature: °C
Heatrun (hours): h
Frame temperature: °C
Winding temperature 1: °C
Winding temperature 2: °C
Winding temperature 3: °C
Bearing temperature NDE: °C
Bearing temperature DE: °C
Remarks
Time: Date: Archive this data record together with the original
test/commissioning record.
Recorded information
Cylinder* No Tightness test: Remarks/Actions taken: Report/reference:
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.
Time: Date: Archive this data record together with the original
test/commissioning record.
General Data
Recorded Data
Turbine I Turbine II
Description Unit Before Cleaning After Cleaning Before Cleaning After Cleaning
Operating Hours h
Load % of Nominal: %
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
Load % of Nominal: %
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.
Time: Date: Archive this data record together with the original
test/commissioning record.
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
Time: Date: Archive this data record together with the original
test/commissioning record.
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.
Time: Date: Archive this data record together with the original
test/commissioning record.
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
-
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).
Note! See the engine instruction manual for permissible deflection limits..
Remark
Crankshaft Deflection
Document ID: 5A0202-S020-08bE.doc
Made/Approved: MiGus/GuGu
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
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).
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.
4
5
6
7
8
9
10
1
2
3
Cylinder “B” bank
4
5
6
7
8
9
10
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
Document ID: 5A0202-S020-10E.doc
Made/Approved: MiGus/GuGu
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
(Signature)
Inspection Report Mech. Spring Support
Document ID: 5A0202-S020-11E.doc
Made/Approved: MiGus/GuGu
Distance
AA BB CC DD
A B C D
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”
(Signature)
Borescope Inspection Record
Document ID: 5A0202-S020-12E.doc
Made/Approved: MiGus/GuGu
Time: Date: Archive this data record together with the original
test/commissioning record.
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-S030-04E “Performance Analysis” ........................ 5
Form: 5A0202-S030-05E “Performance Analysis” ........................ 6
Form: 5A0202-S030-06E “Performance Analysis” ........................ 7
Form: 5A0202-S030-07E “Performance Analysis” ........................ 8
Form: 5A0202-S030-08E “Performance Analysis” ........................ 9
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
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.
Section 5A0202-S03.0
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
Document ID: 5A0202-S030-01E.doc
Made/Approved: MiGus/GGU
General Information
Date: Type of fuel:
Max. Pressure: bar Supplier:
Max. Flow Rate: m3/h Maximum level permitted:
Time: Date: Note! File completed form with other unloading information.
(Signature)
Tank Sounding Log
Document ID: 5A0202-S030-02E.doc
Made/Approved: MiGus/GGU
Remarks
Time: Date:
(Signature)
Performance analysis
Document ID: 5A0202-S030-03E.doc
Made/Approved: MiGus/GuGu
5 4 10 9
1 2 3 8 7 6
Process parameters
Ambient temperature °C
Ambient pressure Pa
(Signature)
Performance analysis
Document ID: 5A0202-S030-04E.doc
Made/Approved: MiGus/GuGu
1 2 3 4 5
Process parameters
Vibration/SPM
Ambient temperature °C
Ambient pressure Pa
(Signature)
Performance analysis
Document ID: 5A0202-S030-05E.doc
Made/Approved: MiGus/GuGu
1 2
Process parameters
Discharge pressure 2 °C
Pressure, when starting bar
Pressure, when stopping °C
Volume of tank(s) filled bar
Rating kW
Compressor data
Ambient temperature °C
Ambient pressure Pa
Amount airborne particles
(Signature)
Performance analysis
Document ID: 5A0202-S030-06E.doc
Made/Approved: MiGus/GuGu
1 2 3 4 5
HT section
6 7 8 9 10
LT secition
Process parameters
Description Position Unit Time: Time: Time:
Measured flow 1 m³/h
Inlet, temperature 2 °C
HT section
(Signature)
Performance analysis
Document ID: 5A0202-S030-07E.doc
Made/Approved: MiGus/GuGu
Process parameters
Ambient temperature °C
Ambient pressure Pa
Amount airborne particles
(Signature)
Performance analysis
Document ID: 5A0202-S030-08E.doc
Made/Approved: MiGus/GuGu
1 2 3
Process parameters
Viscosity cSt
Temperature °C
Flow 1 m³/h
Inlet pressure 2 bar
Unit
(Signature)
Trend Analysis
Document ID: 5A0202-S030-09aE.doc
Made/Approved: MiGus/GuGu
3 2
Parameter Data
1 2 3 1 2 3
Trend Analysis
Document ID: 5A0202-S030-09bE.doc
Made/Approved: MiGus/GuGu
2 1
Operating hours
Parameter Data
3 4 5 6
2 7
1 8
Process Parameters
Ambient Temperature °C
Ambient Pressure Pa
(Signature)
Alignment Record
Document ID: 5A0202-S030-11E.doc
Made/Approved: MiGus/GuGu
A Measurement
B
B
C C
Initial
Final
(Signature)
Pressure test/Leak control
Document ID: 5A0202-S030-12E.doc
Made/Approved: MiGus/GuGu
Test Record
Ambient temperature °C
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-S031-07E “System Analysis” .............................. 9
Form: 5A0202-S031-08E “System Analysis” ............................ 10
Form: 5A0202-S031-09E “System Analysis” ............................ 11
Form: 5A0202-S031-10E “System Analysis” ............................ 12
Form: 5A0202-S031-11E “System Analysis” ............................ 13
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).
Section 5A0202-S03.1
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
Document ID: 5A0202-S031-01E.doc
Made/Approved: MiGus/GGU
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
Document ID: 5A0202-S031-02aE.doc
Made/Approved: MiGus/GGU
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
Document ID: 5A0202-S031-02bE.doc
Made/Approved: MiGus/GGU
General Information
Name of Installation:
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
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.
Fuel Sample
Document ID: 5A0202-S031-03E.doc
Made/Approved: MiGus/GGU
Log sheet
Sample Date
Number Sent Received Remarks/Actions taken Report/reference
Unloading Procedure
Document ID: 5A0202-S031-04E.doc
Made/Approved: MiGus/GGU
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
Document ID: 5A0202-S031-05E.doc
Made/Approved: MiGus/GGU
General Information
Name of Installation:
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”).
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.
System analysis
Document ID: 5A0202-S031-06E.doc
Made/Approved: MiGus/GuGu
1 2 3 4 5
Process parameters
Outlet temperature 4 °C
Outlet pressure 5 bar
Ambient temperature °C
Ambient pressure Pa
Type of fuel
Viscosity cSt
(Signature)
System analysis
Document ID: 5A0202-S031-07E.doc
Made/Approved: MiGus/GuGu
1 2 3 4 5 6 7 8 9 10 11
Process parameters
Ambient temperature °C
Ambient pressure Pa
Type of fuel
viscosity cSt
(Signature)
System analysis
Document ID: 5A0202-S031-08E.doc
Made/Approved: MiGus/GuGu
3 4 5 6
2 7
1 8
Process Parameters
Ambient Temperature °C
Ambient Pressure Pa
Gravity disk installed
Fuel treated (brand name of oil):
(Signature)
System analysis
Document ID: 5A0202-S031-09E.doc
Made/Approved: MiGus/GuGu
2
Day tank
1
3 4 5 6 7 8 9
Process parameters
Ambient temperature °C
Ambient pressure Pa
Type of fuel
viscosity cSt
(Signature)
System analysis
Document ID: 5A0202-S031-10E.doc
Made/Approved: MiGus/GuGu
Level 5
1 2 3 4
8 9 10 11 12 13 14 15
Process parameters
Description Position Unit Time: Time: Time:
Inlet temperature 1 °C
Inlet pressure 2 bar
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
Outlet temperature 14 °C
Outlet pressure 15 bar
Ambient temperature °C
Ambient pressure Pa
Type of fuel
viscosity cSt
(Signature)
System analysis
Document ID: 5A0202-S031-11E.doc
Made/Approved: MiGus/GuGu
1 2 3 4 5 6 7 8 9 10
Process parameters
Ambient temperature °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.
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.
5A0202-S032-Instr.doc Page 2 of 12
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.
5A0202-S032-Instr.doc Page 3 of 12
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.
5A0202-S032-Instr.doc Page 4 of 12
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.
5A0202-S032-Instr.doc Page 5 of 12
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).
This form shall be prepared and be included with the oil samples shipped to the laboratory for analysis.
5A0202-S032-Instr.doc Page 6 of 12
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.).
5A0202-S032-Instr.doc Page 7 of 12
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.
5A0202-S032-Instr.doc Page 8 of 12
Form: 5A0202-S032-07E “System Analysis”
This is a form – produced in MSWord – showing a general circulation system for the engine lubrication
oil.
The information obtained can be further analysed by using the “trend analysis” diagram provided in
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).
5A0202-S032-Instr.doc Page 9 of 12
Form: 5A0202-S032-08E “System Analysis”
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.
The information obtained can be further analysed by using the “trend analysis” diagram provided in
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).
5A0202-S032-Instr.doc Page 10 of 12
Form: 5A0202-S032-09E “Inspection Record”
This is a form – produced in MSWord – intended to be used as a general checklist when inspecting the
lubrication system at the plant.
Note! The form is – by necessity – very general and should be edited to better correspond to the actual
system and the equipment used at site
5A0202-S032-Instr.doc Page 11 of 12
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.
5A0202-S032-Instr.doc Page 12 of 12
List of Forms
Section 5A0202-S03.2
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)
Document ID: 5A0202-S032-01E
Month/Day/Year Made/Approved: MiGus/GGU
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
Remark:
Time: Date:
Signature
Lubricant Inventory
Document ID: 5A0202-S032-03bE.doc
Made/Approved: MiGus/GGU
General Information
Name of Installation:
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
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
Document ID: 5A0202-S032-04E.doc
Made/Approved: MiGus/GGU
General Information
Name of Installation:
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
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.
Lube Oil Sample
Document ID: 5A0202-S032-05E.doc
Made/Approved: MiGus/GGU
Log sheet
Sample Date Engine
Number Sent Received Number Remarks/Actions taken Report/reference
Oil Analysis
Document ID: 5A0202-S032-06E.doc
Made/Approved: MiGus/GuGu
2 1
Hours on oil
Parameter Data
Hrs on oil 1 2 Hrs on oil 1 2
System analysis
Document ID: 5A0202-S032-07E.doc
Made/Approved: MiGus/GuGu
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 Temperature °C
Ambient Pressure Pa
Brand name of oil
(Signature)
System analysis
Document ID: 5A0202-S032-08E.doc
Made/Approved: MiGus/GuGu
3 4 5 6
2 7
1 8
Process Parameters
Ambient Temperature °C
Ambient Pressure Pa
Gravity disk installed
Media treated (brand name of oil):
(Signature)
Inspection Record
Document ID: 5A0202-S032-09E.doc
Made/Approved: MiGus/GGU
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.
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
All filling/discharge connections capped or blanked. Locks in place on valves at
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).
Time: Date: Remarks The inspection reports should be archived for at least
one (1) year.
(Signature)
Logbook sheet Doc Id: WDAAA112424 a
STATION LUBE OIL REPORT Made/Approved: JVE/CJM
Time: ____________________
Storage tank
Oil type:
Drums
Oil type:
Consumption
Distribution:
Instructions
Introduction................................................................................... 2
Form: 5A0202-S033-01E “System Analysis” .............................. 2
Form: 5A0202-S033-04E “Inspection Record”............................ 3
5A0202-S033-Instr.doc
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
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”.
5A0202-S033-Instr.doc
Form: 5A0202-S033-04E “Inspection Record”
This is a form – produced in MSWord – intended to be used as a general checklist when inspecting the
compressed air system.
Note! The form is – by necessity – very general and should be edited to better correspond to the actual
system and equipment at site.
5A0202-S033-Instr.doc
List of Forms
Section 5A0202-S03.3
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
Document ID: 5A0202-S033-01E.doc
Made/Approved: MiGus/GuGu
Process parameters
Ambient temperature °C
Ambient pressure Pa
Volume of tanks m³
(Signature)
System analysis
Document ID: 5A0202-S033-02E.doc
Made/Approved: MiGus/GuGu
Engine
6
5
Air drier
1 2 3
Process parameters
Ambient temperature °C
Ambient pressure Pa
Volume of tanks 4 m³
(Signature)
System analysis
Document ID: 5A0202-S033-03E.doc
Made/Approved: MiGus/GuGu
To consumer
1 2 3
Process parameters
Ambient temperature °C
Ambient pressure Pa
Volume of tank(s) 4 m³
(Signature)
Inspection Record
Document ID: 5A0202-S033-04E.doc
Made/Approved: MiGus/GGU
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
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.
Check the air dryer, clean the condensor coil and fan motor.
Time: Date: Remarks The inspection reports should be archived for at least
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
5A0202-S034-Instr.doc
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
5A0202-S034-Instr.doc
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.
5A0202-S034-Instr.doc
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.
5A0202-S034-Instr.doc
Form: 5A0202-S034-04E “Water Sample”
This is a form – produced in MSWord – shall be prepared and be included with any water sample
shipped to a laboratory for analysis.
5A0202-S034-Instr.doc
Form: 5A0202-S034-05E “Water Sample”
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.).
5A0202-S034-Instr.doc
Form: 5A0202-S034-06E “Inspection Record”
This is a form – produced in MSWord – intended to be used as a general checklist when inspecting a
radiator cooling system.
Note! The form is – by necessity – very general and should be edited to better correspond to the actual
system and equipment at site.
5A0202-S034-Instr.doc
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 “Flow” is
automatically calculated
(flow meter reading
divided by the hours in
operation..
5A0202-S034-Instr.doc
List of Forms
Section 5A0202-S03.4
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
Document ID: 5A0202-S034-01E.doc
Made/Approved: MiGus/GuGu
13 15 7 5 6 8 16 14
11 9 10 12
LT cooling
2 4
Process Parameters
Ambient temperature °C
Ambient pressure Pa
Volume of tank(s) m³
Volume of system
(Signature)
Logbook sheet
Water/Additive fill follow-up form
Document ID: 5A0202-S034-02E
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
Document ID: 5A0202-S034-03E.doc
Made/Approved: MiGus/GuGu
Amount Amount
water additive
added added
Operating hours
Parameter Data
General Information
Name of Installation:
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):
Temperature in system:
Volume of water in system:
Quantity water added:
Quantity chemicals added:
Type of treatment chemical
Name of manufacturer/product
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.
Water Sample
Document ID: 5A0202-S034-05E.doc
Made/Approved: MiGus/GGU
Log sheet
Sample Date Engine
Number Sent Received Number Remarks/Actions taken Report/reference
Inspection Record
Document ID: 5A0202-S034-06E.doc
Made/Approved: MiGus/GGU
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
Piping system, pipe supports and fittings appear in good condition. No rust, bulges,
visible leaks or overflow recorded.
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.
All filling/discharge connections capped or blanked. Locks in place on valves at
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.
Time: Date: Remarks The inspection reports should be archived for at least
one (1) year.
(Signature)
Log Sheet "Elysator®" Unit
Document ID: 5A0202-S034-07E
Month/Year: Made/Approved: MiGus/GuGu
Remark:
Instructions
Introduction ..................................................................................... 2
Form: 5A0202-S035-01E “System Analysis”................................. 2
Form: 5A0202-S035-02E “System Analysis”................................. 3
Form: 5A0202-S035-03E “Inspection Record” .............................. 4
5A0202-S035-Instr.doc
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
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).
5A0202-S035-Instr.doc
Form: 5A0202-S035-02E “System Analysis”
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.
5A0202-S035-Instr.doc
Form: 5A0202-S035-03E “Inspection Record”
This is a form – produced in MSWord – intended to be used as a general checklist when inspecting the
charge air systems.
Note! The form is – by necessity – very general and should be edited to better correspond to the actual
system and equipment at site.
5A0202-S035-Instr.doc
List of Forms
Section 5A0202-S03.5
No: Name:
01E System Analysis (checking filtration performance)
02E System Analysis (checking system performance)
03E Inspection Record
5A0202-S035-LoC.doc
System analysis
Document ID: 5A0202-S035-01E.doc
Made/Approved: MiGus/GuGu
"B" bank
6 2
Cylinders
Cylinders
7 3
"A" bank
Process parameters
Engine bank ⇒ A B A B A B
Turbo charge speed 2,3 rpm
Differential pressure 4,5 Pa
Flow (velocity) 6,7
Ambient temperature °C
Ambient pressure bar
Filtration unit, type
(Signature)
System analysis
Document ID: 5A0202-S035-02E.doc
Made/Approved: MiGus/GuGu
"B" bank
5 3
13 Cylinders
9 7 1
11
12
10 8 2
14 Cylinders
6 4
"A" bank
Process parameters
Ambient temperature °C
Ambient pressure Pa
Hours since CAC cleaned h
(Signature)
Inspection Record
Document ID: 5A0202-S035-03E.doc
Made/Approved: MiGus/GGU
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
Charge-air ducting, supports and fittings appear in good condition. No visible
damages recorded.
External louvres inspected and any debris found removed.
Silencer unit
Silencer inspected and any accumulated condensate drained out.
Time: Date: Remarks The inspection reports should be archived for at least
one (1) year.
(Signature)
Instructions
Exhaust System
Introduction................................................................................... 2
Form: 5A0202-S036-01E “System Analysis” .............................. 2
Form: 5A0202-S036-02E “Inspection Record”............................ 3
5A0202-S036-Instr.doc
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
5A0202-S036-Instr.doc
Form: 5A0202-S036-02E “Inspection Record”
This is a form – produced in MSWord – intended to be used as a general checklist when inspecting the
exhaust gas systems.
Note! The form is – by necessity – very general and should be edited to better correspond to the actual
system and equipment at site.
5A0202-S036-Instr.doc
List of Forms
Section 5A0202-S03.6
No: Name:
01E Checking exhaust system performance
02E Inspection Record
5A0202-S036-LoC.doc
System analysis
Document ID: 5A0202-S036-01E.doc
Made/Approved: MiGus/GuGu
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
Engine bank ⇒ A B A B A B
Exhaust temperature, inlet 4,6 °C
Exhaust temperature, outlet 6,8 °C
Differential pressure 5,7 bar
Ambient temperature °C
Ambient pressure bar
(Signature)
Inspection Record
Document ID: 5A0202-S036-02E.doc
Made/Approved: MiGus/GGU
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
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.
Time: Date: Remarks The inspection reports should be archived for at least
one (1) year.
(Signature)
Instructions
Introduction................................................................................... 2
5A0202-S037-Instr.doc
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.
5A0202-S037-Instr.doc
Instructions
Introduction................................................................................... 2
Form: 5A0202-S038-01E “Water Sample” .................................. 2
Form: 5A0202-S038-02E “Water Sample” .................................. 3
5A0202-S038-Instr.doc
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
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.
5A0202-S038-Instr.doc
Form: 5A0202-S038-02E “Water Sample”
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.).
5A0202-S038-Instr.doc
List of Forms
Section 5A0202-S03.8
No: Name:
01E Water Sample
02E Water Sample Log Sheet
5A0202-S038-LoC.doc
Water Sample
Document ID: 5A0202-S038-01E.doc
Made/Approved: MiGus/GGU
General Information
Name of Installation:
Department:
Sample information
Sample number:
Sample taken from:
Temperature in system:
Volume of water in system:
For human consumption? Yes No Yes No Yes No Yes No
Process water for:
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).
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.
Water Sample
Document ID: 5A0202-S038-02E.doc
Made/Approved: MiGus/GGU
Log sheet
Sample Date
Number Sent Received Remarks/Actions taken Report/reference
Instructions
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
Form: 5A0202-S040-06E “Performance Analysis”.....................................................7
Form: 5A0202-S040-07E “Performance Analysis”.....................................................8
5A0202-S040-Instr.doc Page 1 of 8
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
5A0202-S040-Instr.doc Page 2 of 8
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.
The information obtained can be further analysed by using the “trend analysis” diagram provided in
section 3.0.
5A0202-S040-Instr.doc Page 3 of 8
Form: 5A0202-S040-03E “Inspection Record”
This is a form – produced in MSWord – intended to be used as a general checklist when inspecting the
heat recovery systems and equipment 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
The information obtained can be further analysed by using the “trend analysis” diagram provided in
section 3.0.
5A0202-S040-Instr.doc Page 4 of 8
Form: 5A0202-S040-04E “Steam Trap Inspection Record”
This is a form – produced in MSWord – intended to be used as a general checklist when inspecting the
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.
5A0202-S040-Instr.doc Page 5 of 8
Form: 5A0202-S040-05E “Performance Analysis”
This is a form – produced in MSWord – intended to be used when analysing the performance of a
steam heating system installed in a tank. The base date collected can be further evaluated using the
trend diagrams included in this section.
5A0202-S040-Instr.doc Page 6 of 8
Form: 5A0202-S040-06E “Performance Analysis”
This is a form – produced in MSWord – intended to be used when analysing the performance of a
steam trace heating system. The base date collected can be further evaluated using the trend diagrams
included in this section.
5A0202-S040-Instr.doc Page 7 of 8
Form: 5A0202-S040-07E “Performance Analysis”
This is a form – produced in MSWord – intended to be used when analysing the performance of a
condensate trap installed on a steam pipe system. The base date collected can be further evaluated
using the trend diagrams included in this section.
5A0202-S040-Instr.doc Page 8 of 8
List of Forms
Section 5A0202-S04.0
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
Document ID: 5A0202-S040-01E.doc
Made/Approved: MiGus/GuGu
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
Inlet °C
Exhaust gas
Temp. Outlet °C
Differential °C
Inlet wg/Pa
Pressure Outlet wg/Pa
differential wg/Pa
Remarks
AFUP fault code: 800 steam generation system
Soot Blowing Record
Document ID: 5A0202-S040-02E.doc
Made/Approved: MiGus/GuGu
General Data
Site Conditions
Recorded Data
Date/Time: Day/Time
Engine load %
Steam pressure bar
Total time min
Temp. Outlet °C
Differential °C
Inlet wg/Pa
Pressure Outlet wg/Pa
differential wg/Pa
Temp. Outlet °C
Differential °C
Inlet wg/Pa
Pressure Outlet wg/Pa
differential wg/Pa
Remarks
AFUP fault code: 800 steam generation system
Inspection Record
Document ID: 5A0202-S040-03E.doc
Made/Approved: MiGus/GGU
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
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.
Time: Date: Remarks The inspection reports should be archived for at least
one (1) year.
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.
Performance analysis
Document ID: 5A0202-S040-05E.doc
Made/Approved: MiGus/GuGu
2 1
4
3
5
7 8 9
Process parameters
Ambient temperature °C
Ambient pressure Pa
(Signature)
Performance analysis
Document ID: 5A0202-S040-06E.doc
Made/Approved: MiGus/GuGu
1 2
Process parameters
Ambient temperature °C
Ambient pressure Pa
(Signature)
Performance analysis
Document ID: 5A0202-S040-07E.doc
Made/Approved: MiGus/GuGu
1 2
3 4
Process parameters
Ambient temperature °C
Ambient pressure Pa
(Signature)
Instructions
Introduction................................................................................ 2
Form: 5A0202-S050-01E “Exhaust Gas Emission” .................. 2
5A0202-S050-Instr.doc
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
5A0202-S050-Instr.doc
List of Forms
Section 5A0202-S05.0
No: Name:
01E Exhaust gas emission check
5A0202-S050-LoC.doc
Exhaust Gas Emission
Document ID: 5A0202-S05-01E.doc
Made/Approved: MiGus/GuGU
Engine Data
Engine type: Engine No: Load (kW) r/min
Type of Fuel
Heavy Fuel Oil: Light Fuel Oil: Natural Gas: Other:
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:
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
5A0202-S060-Instr.doc Page 1 of 15
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
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.
5A0202-S060-Instr.doc Page 2 of 15
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.
5A0202-S060-Instr.doc Page 3 of 15
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.
5A0202-S060-Instr.doc Page 4 of 15
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.
5A0202-S060-Instr.doc Page 5 of 15
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).
5A0202-S060-Instr.doc Page 6 of 15
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.
5A0202-S060-Instr.doc Page 7 of 15
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.
5A0202-S060-Instr.doc Page 8 of 15
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.
5A0202-S060-Instr.doc Page 9 of 15
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.
5A0202-S060-Instr.doc Page 10 of 15
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.
5A0202-S060-Instr.doc Page 11 of 15
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.
5A0202-S060-Instr.doc Page 12 of 15
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.
5A0202-S060-Instr.doc Page 13 of 15
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.
5A0202-S060-Instr.doc Page 14 of 15
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.
5A0202-S060-Instr.doc Page 15 of 15
List of Forms
Section 5A0202-S06.0
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
Document ID: 5A0202-S060-01E.doc
Made/Approved: MiGus/GGU
Description of
unit/system:
Type : Hp : Volt :
Model : rpm : Amps :
Serial No : Frame : kW :
References:
Additional
information:
Location:
Probable cause:
Material/parts required:
Remarks:
Name of Installation: Department: Sheet Sheets Day planned: For month: Year
-+ of
Maintenance Manager
Work Order
Document ID: 5A0202-S060-05E.doc
Made/Approved: MiGus/GGU
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
Task Description:
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
Document ID: 5A0202-S060-09E.doc
Made/Approved: MiGus/GGU
Skilled man hours: Unskilled man hours Estimated labor cost: Cost of parts used:
Report:
Material Used
Quantity: Part number: Description: Total cost:
Remarks:
Maintenance Report
Document ID: 5A0202-S060-10E.doc
Made/Approved: MiGus/GGU
Report:
Hazardous Work Permit
Document ID: 5A0202-S060-11E.doc
Made/Approved: MiGus/GGU
Area identification: Estimated duration of work: Date Issued: Work Order number: Permit Number:
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.
(Signature) (Signature)
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).
Area identification: Estimated duration of work: Date Issued: Work Order number: Permit Number:
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
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:
Equipment location/Description: Estimated duration of work: Date issued: Work Order number: Permit Number:
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.
Date: Time: Date: Time:
(Signature) (Signature)
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
Document ID: 5A0202-S060-14E.doc
Made/Approved: MiGus/GGU
Confined Space identification: Estimated duration of work: Date Issued: Work Order number: Permit Number:
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.
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.
Date: Time: Date: Time:
(Signature) (Signature)
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).
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
5A0202-S070-Instr.doc Page 1 of 6
Introduction
The following are short instructions with information for how to use the forms and templates provided
in this section.
5A0202-S070-Instr.doc Page 2 of 6
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…
5A0202-S070-Instr.doc Page 3 of 6
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.
5A0202-S070-Instr.doc Page 4 of 6
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…
5A0202-S070-Instr.doc Page 5 of 6
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.
5A0202-S070-Instr.doc Page 6 of 6
List of Forms
Section 5A0202-S07.0
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
Document ID: 5A0202-S070-01E.doc
Made/Approved: MiGus/GGU
Date of audit/inspection:
Performed by:
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
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
Document ID: 5A0202-S070-02E.doc
Made/Approved: MiGus/GuGu
No: Type of risk: Impact on (1 low – 5 high) Probability Resources Total Procedure:
Personnel Property Operation External Internal
Contingency Planning
Document ID: 5A0202-S070-03E.doc
Made/Approved: MiGus/GuGu
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
Document ID: 5A0202-S080-01aE.doc
Made/Approved: MiGus/GuGu
09 15
10 16
11 17
12 18
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
09 15
10 16
11 17
12 18
09 15
10 16
11 17
12 18
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
09 15
10 16
11 17
12 18