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 Fucntion & 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 diconnected. 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 cicuit 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 ,motorised 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. Incase 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 cicuit 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 cicuit 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 currect, 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.
