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Method Statement For Testing & Commissioning Of Diesel Generator

The purpose of this procedure is to define the step by step method to implement the correct practices for the testing, precommissioning & commissioning of “Diesel Generator”.

Through the guidelines contained herein so as to ensure that the job execution complies with the project requirements and serves the intended function to satisfactory level.

Required Equipments:

Precommissioning Procedure for Diesel Generator

Ensure that the Diesel Generator installation is complete and mechanical completion is approved.

Ensure that no damage has occurred between mechanical completion & precommissioning.

Repair / replace damaged components, if any.

  1. Check for proper installation of vibration isolators for the generator.
  2. Ensure the installation of the generator exhaust piping is complete & approved.
  3. Ensure that the air intake system to the generator room is complete.
  4. Ensure that the Fuel oil piping with fuel pump installation is complete, pressure tested & approved.
  5. Ensure the installation of the generator exhaust ducting is complete & approved.
  6. Ensure proper installation of the exhaust muffler.
  7. Ensure that the cables to the generator are properly terminated & are tight & secure.
  8. Ensure that all the control cables between the generator EMCP and generator sensing panel are completed & terminated at both ends.
  9. Ensure 240 V A/C supply is provided to the generator sensing panel.
  10. Ensure all ducting, piping & conduiting to the generator are connected vide a flexible connector to avoid the transmission of vibration to the service connected.
  11. Check for proper earthing of the generator & connection to the building earthing system using earth megger.
  12. Ensure that the battery charger is installed & the batteries are charged.
  13. Ensure that interfacing with BMS is completed properly.

Commissioning Procedure for Diesel Generator

  1. Ensure that all the precommissioning checks are carried out successfully and the fuel oil system & pump is commissioned.
  2. The priming of the fuel oil pumps shall be checked.
  3. The batteries shall be connected & the Emergency Stop Function & Crank Termination shall be checked as follows:
    Emergency Stop
    (a) Start the engine
    (b) Run the unit under no load condition
    (c) Press emergency stop
    (d) Confirm the generator set stops immediately
    Crank Termination
    (a) Reset all alarm / shut down by turning engine control switch
    to OFF/RESET position.
    (b) Disable fuel injection system
    (c) Start the generator set
    (d) Confirm generator set try to start for 3 cycles (10 secs start
    and then 10 secs stop).
    (e) Confirm generator over crank shut down.
  4. The engine shall be simulated to running condition & the oil pressure trip, high jacket water trip & over speed trip shall be simulated & checked as per attached manufacturer’s guidelines.
  5. The AVR fuses shall be now disconnected.
  6. The DC polarity of engine controls shall be checked.
  7. The setting of the governor shall be recorded inline with manufacturer’s guidelines.
  8. The engine shall be started & adjusted for stability. The start up procedure shall be as per manufacturer’s guidelines.
  9. After adjusting the engine shall be stopped & the rated speed shall be connected & the stability shall be adjusted again. Engine stability adjustment procedures shall be as per manufacturer’s guidelines.
  10. The AVR fuses shall be installed & the engine shall be started again.
  11. The voltage potentio meter shall be adjusted & the volt droop potentio meter shall be set as per manufacturer’s guidelines.
  12. The oil pressure, temperature, speed, volt, frequency, phase sequence, fuel pressure, battery voltage & battery amps shall be recorded.
  13. The alarms & trips shall be tested by shorting fault contacts.

Electronic Governor

Cooling water system

Fuel Oil system

Lube Oil system

Generator Load Test

Digital Voltage regulator (DVR)

Generator Sensing Panel

Automatic Transfer Switch (ATS)

ATTACHMENTS

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