Beruflich Dokumente
Kultur Dokumente
Yes No N/A
ENVIROMENTAL CONDITIONS Ambient Temperature: Engine Room Temp: Atmospheric Conditions: STORAGE AND INSULATION Generator Dried for 48 Hours Before Start-up (See SEHS9124): Drying Method: Visual Inspection Before Start-up -- Grease, Water, Debris, (Foreign Material) Yes No N/A Yes No N/A Elevation: Relative Humidity:
Service Literature As Built Drawings Delivered? Yes No N/A Customer Acceptance Test: Yes No N/A Yes No N/A
All Configurations, Logic, Set Points and Programs Saved to Backup Media? Please List all Lliterature that was Delivered and Reviewed:
SERVICE BULLETINS (List All Service Bulletins Addressed During this Visit):
INSTALLATION AND LOAD 1 Neutral Grounding Systems 2 Enclosure Weather Tight 3 Proper Ventilation 4 Description of load 5 Motor SKVA 6 Motor Total HP 7 UPS Manufacturer 8 UPS Model Number/Size 9 UPS Serial Number COMMENTS AND RECOMMENDATIONS:
Yes No N/A Yes No N/A Yes No N/A
10 Unit connected in parallel 11 Load Diagram Created & Saved 12 Full Load Data Created & Saved
CUSTOMER AUTHORIZATION TO SERVICE/TEST: Customer Rep. Signature: Service Engineer Signature: Date: Date:
Yes No N/A
Automatic Transfer Switch 1 Manufacturer: 2 Model number: 3 Serial number: 5 Yes No N/A 6 Yes No N/A Yes No N/A Yes No N/A Check for loose or missing hardware All wires secure & check wire terminations
1 Verify voltage/amperage
Yes No N/A
2 Verify phase rotation 3 Set all timers & exerciser 4 Check for damage
CUSTOMER ACCEPTANCE: Start-up and commissioning is complete within factory standards. Customer Rep. Signature: Service Engineer Signature: Date: Date:
CAUTION! Only qualified personnel who have been trained to support the product should attempt to proceed with startup. Note: Service Engineer must communicate with customer to understand site requirements for Personal Protective Equipment (PPE), Lockout and other safety procedures. Note: Italicized Items relate to Tier IV Compliance
Start-up
1. Safety and Serviceability
1 Genset is free of damage 2 Hot pipes are wrapped 3 All hoses, piping & wiring is/are secure 4 Spillage containment acceptable 5 Personal protection equipment worn 6 Floors are clean no hazards 7 Floor openings are covered 8 Genset is level with all holding bolts secure 9 Warning decals & plates are installed 10 All guards and heat shields are in place 11 All safety shutdowns & warnings operational Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 12 Fire extinguisher present & charged 13 Fire suppression unlocked & operational 14 Pipe work & services are color coded/labeled 15 Remote start/stop checked & operational 16 Emergency stop functional 17 Sight glasses are visible 18 Gauges are functional (oil, fuel, air, other) 19 Proper grounding (refer to REHS4634) 20 Air intake free of airborne debris 21 Air supply system maintanance service intervals a minium of 4500 hours (if engine manuafacturer solution is not used) Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Notes:
Notes:
3. Lube System
1 Jacket oil heater operational 2 Oil sample taken (SOS) 3 Oil level is correct 4 Pipes routed through front end of base 5 Remove crankcase covers, plugs & tape 6 Install crankcase breather hose if necessary; check for proper installation & routing 7 Oil make-up system installed Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 8 Check for leaks 9 Oil pressures within specifications 10 Oil meets specifications 11 Pre-lubrication system installed 12 Check pre-lube installation 13 CAT DEO-ULS/ API CJ 4 oil sticker on all engine lube filling points 14 Oil renewal system present Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Notes:
4. Alarm Verification
1 Low water level 2 High water temperature 3 Low water temperature 4 Low oil pressure 5 Low oil level 6 Low fuel level 7 High fuel level 8 Over speed 9 E-Stop 10 Crank termination systems 11 Low DC Voltage 12 Over crank 13 Battery charger 14 Fire alarm 15 Shutdown device Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 16 High air inlet manifold temperature 17 High / low battery voltage 18 Jacket water pressure 19 Rupture basin 20 Temperature detectors connected 21 Engine warning lamp communicated to operator (J1939 or lamp) 22 High exhaust system temperature communicated to operator (J1939 or lamp) 23 Diesel particulate filter warning communicated to operator (J1939 or lamp) 24 "Regeneration System Disabled" communicated to operator (J1939 or lamp) 25 Force/Disable Regneration control communicated to operator (J1939 or lamp) Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Notes:
5. Governor Settings
1 Copy saved of the ECM replacement file or other record governor settings saved 2 Was the engine ordered as a constant or variable speed engine Yes No N/A 3 Is the engine installed as a constant or variable speed engine
Notes:
Notes:
7. Aftertreatment
1 Ball joint/slip joint/bellows properly installed 2 Installation must meet one of the following requirements a) Turbo to CEM inlet exhaust pipe length 366 cm or less b) Turbo to CEM inlet temperature drop @ 10% load 10 o C or less 3 Turbo to CEM pipe fully insulated 4 CEM oriented parallel to horizon +/- 5 degrees 5 Turbo outlet to CEM inlet temperature drop at full load 6 Communicate that top of CEM is not suitable for a work platform 7 Dust Ejector connected after the CEM 8 Describe Dust Ejector connection location 9 Dosing cabinet a maximum of 20 feet (6m) from CEM 10 Top of dosing cabinet at or below bottom of CEM mounting pads 11 Dosing cabinet a maximum of 100 feet (30m) from engine 12 Dosing cabinet ambient temperature -40 o C to 50 o C 13 Dosing cabinet mounted not more than 18 degrees from vertical 14 Area around dosing cabinet unobstructed Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 23 Air compressor filter meet EPA requirements 24 Air compressor meet demand of dosing module 25 Air compressor lines properly sized and have no P traps 26 Engine mounted air compressor supply pre-boosted (only pre-boosted is allowed) 27 DEF tank material meet requiremetns in A&I Guide 28 DEF filter meet requiremetns in A&I Guide 29 Ratio of 1 fuel tank refill to 1 DEF tank refill for systems with a constantly visible DEF level indicator 30 Ratio of 2 fuel tank refills to 1 DEF tank refill for systems without a constantly visible DEF level indicator 31 DEF tank protected against frozen urea blocking passage 32 DEF tank sample port installed 33 Exhaust connected properly 34 Exhaust weight transfer to CEM meets A&I specification 35 Engine to CEM inlet connection 400 Nm 36 CEM to atmosphere connection 100 Nm 37 Customer supplied wiring harness properly routed 38 Customer supplied wiring harness not kinked, mounted away fro mheat sources, properly supported, and marked as not a step 39 Customer supplied wiring harness meets the wire specifications for material and length as specified in the wiring diagram 40 Customer supplied wiring harness matches the pin out as specified in the wiring diagram 41 Dosing cabinet to CEM urea lines routed properly 42 Dosing cabinet to CEM urea lines not kinked, mounted away from heat sources, properly supported, and marked as not a step 43 Main tank to dosing cabinet urea lines routed properly 44 Main tank to dosing cabinet urea lines material meets specifications in A&I Guide 45 Urea lines meet urea pump requirement for line restriction 46 Urea lines connected properly Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A
Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
15 Dosing cabinet air connection as specified in A&I Guide 16 Dosing cabinet air connection location as specified in A&I Guide 17 Dosing cabinet vent line routed to storage tank or approved drain 18 Dosing cabinet vent line exit below injector height
Yes No N/A
Yes No N/A
19 No low spots in dosing cabinet vent line 20 Urea quality meets ISO22241-1 21 Dosing cabinet AC supply meets requirements in A&I Guide 22 Dosing cabinet DC supply meets requirements in A&I Guide *Aftertreatment section continued on next page
47 Air lines maintain the air quality as specified in the A&I Guide 48 Air lines routed and mounted properly 49 Air lines connected properly 50 Air compressor appropriate for environment
51 Dosing cabinet air supply meet air quality requirements in A&I Guide 52 Air lines not kinked, mounted away from heat sources, properly supported, and marked as not a step
Notes:
Notes:
Notes:
Yes No N/A
8 Correct condition, alignment, and tension of fan belts / pulleys 9 Auxiliary supply voltage to fans correct
Notes:
11. Mechanical
1 Package properly mounted 2 Package supports & vibration isolators installed 3 Air shut-off is operational Yes No N/A Yes No N/A Yes No N/A 4 Over speed shut-down is correct 5 Over-crank shut-down is correct 6 Motorized dampers are operational Yes No N/A Yes No N/A Yes No N/A
Notes:
Notes:
Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Notes:
Notes:
Notes:
Notes:
Notes:
Commissioning
1. Safety and Serviceability
1 Personal protection equipment worn 2 Floors are clean no hazards 3 Floor openings are covered 4 Genset is level with all holding bolts secure 5 Warning decals & plates are installed 6 All guards and heat shields are in place 7 All safety shutdowns & warnings operational 8 Fire extinguisher present & charged 9 Fire suppression unlocked & operational 10 Pipe work & services are color coded/labeled 11 Remote start/stop checked & operational 12 Emergency stop functional 13 sight glasses are visible Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 14 Gauges are functional (oil, fuel, air, other) 15 Proper grounding (refer to REHS4634) 16 Air intake free of airborne debris 17 Access routes unobstructed 18 Overhead obstructions are clearly marked 19 Overhead & side clearance is acceptable 20 Adequate access to fluid fill areas to prevent spills 21 Air/oil/fuel filters are accessible 22 Level indicators are accessible 23 Key components are labeled 24 Engine room noise level policy satisfied 25 No unauthorized access Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Notes:
Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Notes:
Notes:
4. Lube System
1 Oil level is correct 2 Check for leaks Yes No N/A Yes No N/A 3 Oil pressures within specifications 4 Oil meets specifications Yes No N/A Yes No N/A
Notes:
5. Alarm Verification
1 Low water level 2 High water temperature 3 Low water temperature 4 Low oil pressure 5 Low oil level 6 Low fuel level 7 High fuel level 8 Over speed 9 E-Stop 10 Crank termination systems Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A 11 Low DC Voltage 12 Over crank 13 Battery charger 14 Fire alarm 15 Shutdown device 16 High air inlet manifold temperature 17 High / low battery voltage 18 Jacket water pressure 19 Rupture basin 20 Temperature detectors connected Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
Notes:
Notes:
7. Aftertreatment
1 Following initial start-up procedure from Appendix B in the A&I guide 2 Back pressure differential before CEM 1kPA 3 CEM temperature increase due to proximity of external heat source 4 Maximum 1L water accumulation at 5 degree tilt Yes No N/A Yes No N/A Yes No N/A 12 DEF tank venting meet fumes leak requirements 13 DEF tank venting routed to meet local and OSHA guidelines for ammonia fumes 14 Low urea level warning in time to prevent shutdown 15 If exhaust connection supplied by Caterpillar, see TMI for value and include in customer allowance (Not to exceed 6kPa) 16 If exhaust connection supplied by customer, measure and include in customer allowance (Not to exceed 6kPa) 17 Engine to CEM temperature drop does not exceed maximum figure in A&I Guide 18 Maximum 6 kPa difference from CEM to atomospheric pressure 19 Urea lines meet dosing cabinet requirements of 2-5 psi (14-34.5 kPa) at 1.25-2.5 gal/min (5-9.5 l/min) 20 Urea lines temperature between -5 o C and 50 o C 21 Air lines allow dosing pressure and flow rate specified in A&I Guide 22 Air lines maintain temperature between -40 o C and 50 o C Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A Yes No N/A
5 Dosing cabinet air pressure/air flow at customer supplied compressor as listed in A&I Guide 6 Dosing cabinet urea pressure 2-5 psi (14-35 kPa) at 1.25-2.5 gal/min (4.7-9.5 l/min) flow 7 Dosing Cabinet air supply a minimum of 105 psi (724 kPa) within 3 minutes 8 Compressor capable of delivering 10 cfm for 30 seconds and still maintain a tank pressure gretaer than 80 psi (550 kPa) 9 Dosing cabinet air supply capable of 0-10 SCFM 10 DEF tank temperature between -5 o C and 50 o C 11 DEF tank venting affect head pressure
Yes No N/A
Notes:
Notes:
Notes:
Notes:
11. Mechanical
1 Air shut-off is operational 2 Over speed shut-down is correct 3 Over-crank shut-down is correct Yes No N/A Yes No N/A Yes No N/A 4 Motorized dampers are operational 5 Inspect package supports and vibration isolators 6 Inspect package for proper mounting Yes No N/A Yes No N/A Yes No N/A
Notes:
Notes:
Notes:
Notes:
Notes:
NO LOAD
Exciter Field (F1,F2) Exciter Field (F1,F2) Sensing Line (T1,T2) Sensing Line (T1,T3) Sensing Line (T2,T3) PMG output (1 to 2) PMG output (1 to 3) PMG output (2 to 3) Volts DC Amps DC Volts AC Volts AC Volts AC Volts AC Volts AC Volts AC
Yes No N/A
Notes:
Notes:
Start-upExcitor Rotor Winding Temp. Comments: Start-up-PMG Stator Winding Temp. Comments: Insulation Test Equipment Description:
Notes:
Notes:
Vibration Levels - 2
Vibration levels - use for all in-line 6 (e.g. C9, C15, C18, 3406, 3456C) Built after 1/1/04. Reference ISO 8528-9 The dealer can obtain ISO standards from ISO or an authorized reseller such as ANSI, HIS, and Techstreet. Power kW RMS overall values (2 Hz to 300 Hz)* Engine speed *either measured or calculated direction of movement Measuring Point Number 1 2 3 4 5 6 7 8 ~ ~ Measuring Point Number 1 2 3 4 5 6 7 8 9 ~ ~ Number 1 2 3 4 5 6 7 8 9 ~ ~ a(m/s2) v(mm/s) a(m/s2) s(mm) v(mm/s) s(mm) v(mm) a(m/s2) s(mm)
Note: Terms are according to ISO 2954. Mechanical Connection Measured Value Recorded Value Calibration Date Measuring Range (Amplitude/Frequency)
Notes:
Save screen shots as JPGs to a folder, insert object from a file, choose JPG file
Has all performance documentation been completed & saved for future reference? Yes No N/A