- Project Name: E-60 Maintenance of Gas Generators No. 3, 4 & 5
- Location: DLF Building - 5, E-60
- Duration: January 2018 to March 2018
- Client: DLF Group
- Category: Preventive Maintenance | Engineering Services
Project Overview
In a bid to ensure uninterrupted power performance and operational longevity, DLF Building No. 5 initiated a comprehensive E-60 maintenance program for Gas Generators (GG) No. 3, 4, and 5. The project was executed over a tight schedule between January and March 2018. With an emphasis on safety, precision, and innovation, the GG team successfully completed the maintenance, setting new benchmarks in efficiency and cost optimization.
Scope of Work
- Dismantling & Assembling of Head Units
- Mounting of Liner-Piston Assemblies
- Fitment of Main & Big-End Bearings
- Complete Assembly of Liner-Piston-Connecting Rod on Engine Block
- Modifications in GG BOP Motor Units
- Installation of Lub Oil Heaters in Gas Turbine Lube Oil Tanks
Key Innovations and Solutions
- BOP Motor End Cover & Fan Upgrade
To combat the frequent breakdowns caused by plastic fans, the team introduced a new approach—replacing the BOP motor’s end cover and cooling fan with aluminum castings. This not only improved reliability but also contributed to cost savings and minimized downtime. - Lub Oil Heater Installation in GT Tanks
During standby conditions, analysis revealed high TAN (Total Acid Number) values in the lube oil of Gas Turbines 1 and 2. Collaborating with the OEM, the team implemented a solution by installing lubricating oil heaters in the circulation tanks. With temperature controls set at 45°C (cut-in) and 50°C (cut-out), the intervention significantly improved oil condition and equipment readiness.
Impact and Outcome
- Timely completion of E-60 maintenance across three critical generators
- Improved reliability and reduced operational downtime
- Enhanced oil stability and extended turbine readiness during standby
- Demonstrated innovation-driven problem-solving and teamwork
Conclusion
This project exemplifies how a proactive maintenance strategy, backed by technical ingenuity and coordinated teamwork, can deliver superior operational results. The successful execution of E-60 maintenance at DLF Building No. 5 stands as a testament to engineering excellence and commitment to performance.
