Description

Diesel Power Plant Operation & Maintenance – Diesel Engine Maintenance Focus

Target Audience: Plant operators, maintenance technicians, engineers, and professionals in the power generation sector.

Module 1: Introduction to Diesel Power Plants

1. Overview of Diesel Power Plants
   • Role in power generation (base load, standby, hybrid systems).
   • Key components: diesel engine, alternator, fuel system, cooling system, lubrication system, exhaust system.
   • Applications: Industrial, remote locations, emergency backup.
2. Types of Diesel Engines
   • 2-stroke vs. 4-stroke engines.
   • Turbocharged vs. naturally aspirated engines.
   • High-speed vs. medium-speed vs. low-speed engines.

Module 2: Diesel Engine Fundamentals

1. Engine Structure and Components
   • Cylinder block, pistons, crankshaft, camshaft, valves, fuel injectors, turbochargers.
   • Role of the air intake, exhaust, and combustion systems.
2. Engine Operating Principles
   • Combustion process in diesel engines.
   • Compression ignition vs. spark ignition.
   • Performance parameters: power output, efficiency, specific fuel consumption.

Module 3: Diesel Engine Maintenance Strategies

1. Maintenance Philosophies
   • Preventive Maintenance (PM): Scheduled inspections, lubrication, and replacements.
   • Predictive Maintenance (PdM): Vibration analysis, thermography, oil analysis.
   • Corrective Maintenance: Troubleshooting and repairing failures.
2. Daily/Weekly Maintenance Tasks
   • Visual inspections for leaks, cracks, or corrosion.
   • Checking oil levels, coolant levels, and fuel quality.
   • Monitoring exhaust smoke (e.g., black/white/blue smoke causes).
3. Routine Maintenance Procedures
   • Oil and Filter Changes:
     • Selecting the correct oil grade (SAE, API classification).
     • Filter replacement intervals (oil, fuel, air filters).
   • Cooling System Maintenance:
     • Radiator cleaning, coolant pH testing, antifreeze concentration.
     • Inspecting hoses, pumps, and thermostats.
   • Fuel System Maintenance:
     • Fuel tank cleaning, water separator draining.
     • Injector testing and calibration.
4. Major Overhaul and Component Replacement
   • Timing belt/chain replacement.
   • Piston ring and cylinder liner inspection.
   • Turbocharger cleaning and balancing.

Module 4: Advanced Maintenance Techniques

1. Condition Monitoring Tools
   • Vibration analysis for bearing and alignment issues.
   • Thermography for overheating components.
   • Oil analysis (wear particles, viscosity, contamination).
2. Troubleshooting Common Engine Issues
   • Low compression, overheating, excessive vibration.
   • Starting failures (battery, starter motor, fuel supply issues).
   • Abnormal noises (knocking, misfiring).
3. Fuel Quality Management
   • Impact of contaminated fuel (water, microbes, particulates).
   • Fuel testing and filtration best practices.

Module 5: Cooling and Lubrication Systems

1. Cooling System Maintenance
   • Preventing scale buildup and corrosion.
   • Pressure testing for leaks.
   • Thermostat and fan operation checks.
2. Lubrication System Best Practices
   • Importance of oil viscosity and additives.
   • Detecting oil degradation (sludge, oxidation).
   • Bearing and crankshaft lubrication checks.

Module 6: Electrical and Control Systems

1. Starter Motor and Alternator Maintenance
   • Battery health checks (specific gravity, terminal corrosion).
   • Alternator voltage regulation testing.
2. Engine Control Systems
   • Overview of ECM (Engine Control Module) and sensors.
   • Diagnosing fault codes and sensor failures.

Module 7: Safety and Compliance

1. Safety Protocols
   • Lockout-Tagout (LOTO) procedures during maintenance.
   • Handling hazardous materials (fuel, coolant, batteries).
   • Fire prevention and emergency shutdowns.
2. Environmental Compliance
   • Emission control systems (DPF, SCR, EGR).
   • Proper disposal of used oil, filters, and coolants.

Module 8: Case Studies and Practical Scenarios

1. Real-World Maintenance Challenges
   • Case study: Resolving chronic overheating in a turbocharged engine.
   • Case study: Diagnosing fuel injector failure using oil analysis.
2. Interactive Troubleshooting Sessions
   • Simulated scenarios for trainees to identify and resolve faults.

Assessment and Engagement

1. Quizzes and Knowledge Checks
   • Short assessments after each module.
2. Hands-On Demonstrations (Via Video)
   • Step-by-step filter replacement, oil sampling, etc.
3. Q&A and Discussion Forums

Encourage trainees to share field experiences and challenges.