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:

• Portable Hand tools
• Step Ladder
• Load Bank & cables
• Computer
• Multimeters
• Earth Megger

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

• The low idle speed, rated speed, start fuel limit & ramp time shall be measured & recorded against the setting value.
• The actuator compensation, gain, reset, droop, load gain & over speed settings shall be recorded against the setting value. All setting values shall be as per manufacturer’s guidelines.

Cooling water system

• The system shall be filled with potable water with rust inhibitor & the air shall be purged.
• The water level shall be checked & any leakage in the system shall be checked.
• The engine shall be run at no load & the circuit shall be checked for any leakage.
• The operation of the low coolant level sensor shall be checked as per manufacturer’s guidelines.
• The jacket water temperature high alarm & shut down simulation shall be checked as per manufacturer’s guidelines.

Fuel Oil system

• Fuel oil system with fire valve, 2 port, motorized valve, pressure switch & level sensor shall be checked for proper installation with alignment.
• The tank shall be filled & the system shall be checked for leakage.
• In case of a leak, the leak will be detected by a drip tray mounted float switch which shall be connected to sound an alarm.
• The engine shall be run at no load & the circuit shall be checked for any leakage.
• The fuel oil high level & low level alarm switch shall be checked.
• The fuel oil high level & low level pump stop switch shall be checked.

Lube Oil system

• The system shall be filled with the oil recommended by the manufacturer.
• The oil level shall be checked & it shall be ensured that there are no leaks in sump & drain.
• The engine shall be started & the oil pressure shall be observed as per manufacturer’s guidelines.
• The engine shall be run at no load & the circuit shall be checked for any leakage.
• The engine shall be stopped & the oil level shall be checked again.
• The lube oil high temperature alarm & shut down shall be checked as per manufacturer’s guidelines.
• The lube oil low pressure alarm & shut down shall be checked.

Generator Load Test

• The load test on the generator shall be carried out increasing the load from 0% to 100% in steps of 25% using load bank.
• At 0% the run time shall be 5 mins, for 25%- 10 mins, for 50-10 mins, for 75%- 3 Hrs & for 100% – 3 Hrs.
• The fuel consumption, actual KW, line voltage, line current, oil pressure, coolant temperature, RPM & battery voltage shall be recorded at agreed intervals of run time.

Digital Voltage regulator (DVR)

• It shall be confirmed 24V DC is available for the digital voltage regulator.
• The programmable parameters shall be set to the default values as recommended by the manufacturer.
• The generator shall be started & the view parameters & the status of the switch parameters shall be recorded.

Generator Sensing Panel

• During simulation test check that the appropriate annunciation windows/alarms LEDs in the generator sensing panel are illuminated.
• Check the ON & OFF function of the generator from the sensing panel by simulation.
• Check the OFF function of the generator by the emergency stop push button.

Automatic Transfer Switch (ATS)

• Check the voltage availability in the line side of the ATS. If the voltage is available, the changeover switch remains unchanged.
• When the voltage is not available in the line side, check for signal from the ATS to the generator sensing panel to start generator.
• Once the generator full voltage is available at the ATS emergency terminals, check the ATS change over to generator supply.

ATTACHMENTS

• Precommissioning check sheet for Diesel Generator
• Commissioning check sheet for Diesel Generator
• Commissioning check sheet for Electronic Governor
• Commissioning check sheet for Cooling water system
• Commissioning check sheet for Fuel Oil system
• Commissioning check sheet for Lube Oil system
• Generator Load Test Records
• Commissioning check sheet for Digital Voltage Regulator
• Risk Assessment