2. Customer Details
Name : BERI (Biomass Energy for rural India Society
Address : Seebinayanapalaya village, Madhugiri taluka,
Tumkur dist. karnataka
ESN : 25301573
Engine Model : GTA 855 G BC (Producer Gas Engine)
Problem desc. : Engine not taking more than 40 % load
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3. Ignition system observation & Action taken
1) Spark Plugs : Spark plugs not changed since 4 years,
Hence replaced the same.
2) Altronic : While cranking generating < 90 VDC for all
six cylinders.
3) Ignition transformer : Checked Ignition transformer found below
values.
Ignition Coil number Primary coil (Ohm) Secondary coil ( K Ohm)
Cylinder 1 1.2 6.50
Cylinder 2 1.1 6.10
Cylinder 3 1.4 6.68
Cylinder 4 1.2 6.40
Cylinder 5 1.2 6.22
Cylinder 6 1.2 6.10
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4. Gas train observations & Action taken
Opened ZPR top
cover observed no
TAR formation
Opened Carburetor
observed no Observed Gas
TAR formation pressure before
regulator : 300 mm
of H2O
Observed Gas
pressure after
ZPR : - 40 mm of
H2O (suction
Pressure )
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5. Base Engine observations & Action taken
Checked Turbo
Rotation &
cleanliness found OK
Found dry Carbon
In After cooler.
Cleaned by
Pressurized air
Checked opening &
Closing of Butterfly
Valve found OK
Cheked altroic
Checked Blow by of
Cranking Voltage
Engine found 2” of H2O
found within limit
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6. Gasifier side observations
Chiller temperature
7 Deg C
Oxygen in Exhaust
Gas : 1.5 to 0.4 %
Gas flame reddish in
colour
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7. Problem resolution
Observed Exhaust back
pressure more than 7 “ of
Hg due to restriction in
exhaust piping / silencer .
After removal of bellow
Turbo functioned properly &
Engine taken 100 % load.
Observed Exhaust
Back pressure
more than 7-8 “ of Hg
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8. Suggestions
• To clean Exhaust piping in every one year if Engine is
being kept idle for more time.
• To keep maintenance spares at site premises.
• To clean Gas line & after cooler in every 500 hrs.
• To carry out maintenance of engine at regular
recommended time intervals.
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9. Maniranjan Diesel Sales & service - Service Escalation Process
HOD
C N Deshmukh
9448496910
deshmukh@maniranjan.com
CEO
Atul Thakur
9480697266
atul@maniranjan.com
Service Head
M G Kulkarni
9448496917
kulkarni@maniranjan.com
Service Engineer
Ganesh Madhiwal
9480697264
Ganesh.nmk@gmail.com
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10. Cummins India Limited - Service Escalation Process
Zonal Service head
Krishnan Arumugam
9448396742
krishnan.arumugam@cummins.com
Area Service manager
Koushik Manna
9448496770
koushik.s.manna@cummins.com
Tech Support Gas
Atul Patil
9444045713
atul.patil@cummins.com
Sr. Manager Service
S Loganath
9448396741
loganathan.s@cummins.com
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