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IV INSPECTION AND TESTING

The Supplier is to co-operate with Purchaser Inspection Representative to carry out the complete range of routine
tests as specified by IEC. These are to include, but not limited to, the following:
4.1 GENERAL
4.1.1 Physical check of general appearance, finish, mechanical assembly including good
welding, full nuts on bolted parts, undamaged condition and general worthiness.
4.1.2 Dimensional check, particularly overall length, breadth, height and fixing centers
against the Supplier's certified drawings.
4.1.3 Check of cable termination locations, direction, type and materials against specification and
Supplier's certified drawings.
4.2 GENERATOR TESTS
4.2.1 Measurement of winding resistance (cold).
4.2.2 FULL-LOAD HEAT RUN TEST WITH ZERO POWER FACTOR METHOD
EQUIVALENT
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1/2 load test (1 hour minimum at 0 p.f)


3/4 load test (1 hour minimum at 0 p.f)
Full load test (1 hour minimum at 0 p.f)
Over load test (110% full load for 1 hour at 0 p.f).

4.2.3 Temperature rise test and calculating winding temperature rise.


4.2.4 Measurement of winding resistance (hot).
4.2.5 INSULATION RESISTANCE ON
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Generator windings (before heat run and after heat run & dielectric test).
Exciter windings (before heat run and after heat run & dielectric test).
Heater
Built in temperature detectors
Bearing insulation

4.2.6 DIELECTRIC TEST ON


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Generator windings.
Exciter windings.
Heater.
Built in temperature detectors.

4.2.7 Bearing inspection and temperature rise.


4.2.8 Vibration Test.
4.2.9 Noise level test.
4.2.10 Waveform test.
4.3 ENGINE TEST Engine tests shall be in accordance with Engine Specification 100-17.

OR

4.4 BATTERY AND CHARGER INSPECTION AND TESTING The supplier is to carry out the
complete range of routine tests as specified by IEC and as shown in the material requisition and its relevant
attachments. These are to include, but not limited to the following:
4.4.1 Tests included in the material requisition and its relevant attachments.
4.4.2 Insulation resistance measurement.
4.4.3 Dielectric test.
4.4.4 Proper mechanical and electrical operation of all functional parts including auxiliaries,
meters, indicators,relays,...etc.
4.4.5 All electronic components shall be operationally and quality tested before installing in
the equipment.
4.4.6 LOAD TEST The battery chargers shall be operated at full load and ambient temperature
of 40 degrees C for a period of 24 hours, to ensure that no overheating of any component occurs.
4.4.7 OUTPUT CHARACTERISTICS The supplier shall demonstrate the output
characteristics of the equipment by recording input voltage, frequency, current and power
factor, and output voltage, current and ripple at the following output loads:
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No load.
25 % full load.
50 % full load.
100 % full load.
110 % full load.
150 % full load for 5 seconds

4.4.8 Battery cells shall undergo standard factory tests.


4.4.9 All above tests shall be carried out in manufacturer shop at his care and expenses.
4.5 GENERATOR CONTROL PANEL TEST The generator control panel and auxiliaries equipment shall
be subjected for the following tests
4.5.1 Insulation tests.
4.5.2 Full functional test.
4.5.3 Temperature rise test.
4.6 PACKAGE STRING TEST
4.6.1 Engine start-up system, including measurement of the starting time. A minimum of two
start and stop tests shall be performed.
4.6.2 Automatic start-up system if provided.
4.6.3 For emergency generator sets verification of the time between initiation of a start
command and acceptance of the nominal load for a cold start.
4.6.4 All engine alarm and shutdown functions (*).
4.6.5 All generator alarm and trip functions, including the verification of protection relay
operation (*).
4.6.6 Operation of the battery charger.
4.6.7 The status/ alarm / trip/ shutdown indication of the control panels.

4.6.8 Local manual start/ stop/ emergency stop functions.


4.6.9 Remote start/stop/emergency stop functions (input signals).
4.6.10 The remote signaling contacts for principal's use.
4.6.11 Operation of the AVR.
4.6.12 Operation of the AVR automatic transfer system.
4.6.13 Operation of the automatic power factor controller.
4.6.14 Operation of the synchronizing equipment .
4.6.15 Calibration of measuring and protective devices.
Note: (*) these functions do not all have to be tested with a running generator set.

4.7 ON SITE TEST During running the generator set the following inspections to be performed:
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Check for leaks.


Check for loose fasteners.
Exercise the safety devices.
Oil level check.
Water level check.
Engine to control interconnects check.
Check of direction rotation.
Control panel tests.
Check of the adjustment of all safety devices & protective relay.
Check of excitation & voltage regulator.
Load test (on available load at site) - 8 hours operation after one hour stabilization period.
Engine shutdown & safety devices shall be demonstrated.
Paralleling test and complete function test.