Doc NO.

PH-IMS-SP08-WI01
GENERATOR TEST INSTRUCTION REVISION / ISSUE:01/01
DATE:6/5/2015

ISO 9001:2008
ISO 14001:2004
ISO 50001:2011
BS OHSAS 18001:2007

Document Title : Generator Test Instructions

Document No : PH-IMS-SP08-WI1
Issue No. : 1

Issued Date : May 2015

Prepared By : Eng. Mohamed Wageh QC Manager.

Approved By : Eng. Bassam Mokhtar TQM & MR

Confidentiality
The information contained in this document is confidential to Power House Co.
Accordingly, copyright for this document is retained with Power House Co. and
no copying in any format of this document is permitted without the written
permission from Power House Co. top management.

Date of Requested
Issue No. Description/ Details of Amendment
Amendment By
 Doc NO. PH-IMS-SP08-WI01
GENERATOR TEST INSTRUCTION REVISION / ISSUE:01/01
DATE:6/5/2015

First Issue 1 TUV External Audit TQM

1. Purpose:
To establish instructions for incoming and final inspection of generators.

2. Scope:
This instruction is applicable for Generators . which could be grouped as following :
 Doc NO. PH-IMS-SP08-WI01
GENERATOR TEST INSTRUCTION REVISION / ISSUE:01/01
DATE:6/5/2015

1-Owner ( Powerhouse , clients and suppliers )

2- Power Rating ( All Power Rating ).
3- Enclosure Conditions ( in Sound Proof , without Sound Proof ).
4- Fuel type ( Diesel , Gas )
5- Generator Condition (New Generators, in Services, After Maintenance activity)

3. Resposability :
Quality Control Manager is responsible for ensuring efftive implementation of this
work instruction.

4. Instructions:
4.1 For incoming generators and final inspection
4.1.1 The visual inspection:
4.1.1.1 Shall be performed on (Wiring, Electrical Components, Cables, Protection devices
and all mechanical parts.
4.1.1.2 Check Name plate before starting.
4.1.1.3 Check earth connection
4.1.1.4 Check Battery before start up the generator.
4.1.1.5 Check Cooling circuit.
4.1.1.6 Check Water level Switch.
4.1.1.7 Check Fuel and fuel circuit visually.
4.1.1.8 Check Oil level.
4.1.1.9 Check Oil pressure Sensor.
4.1.1.10 Check Water Temp. Sensor.
4.1.1.11 Check Spark arrestor (For Hazard Area)
4.1.1.12 Start up the generator.
4.1.1.13 Testing Protection system (Cause and effect).
According to form visual inspection Doc NO. PH-IMS-SP08-WI01-FR01

4.1.2 Acceptance Test:

4.1.2.1 Take Record for each Following steps (Voltage, Frequency, Load Current, Water Temp.,
and Run hours, P.F, Battery Voltage, Oil Pressure and Exhaust Temp.)
4.1.2.2 No Load Record
4.1.2.3 From 0% to 25% for 5-15 minutes and record the result
4.1.2.4 Increase the load from 25% to 50% for 5-15 minutes and record the result
4.1.2.5 Increase the load from 50% to 75% for 5-15 minutes and record the result
4.1.2.6 Increase the load from 75% to 100% for 5-15 minutes and record the result
4.1.2.7 Decrease the load from 100% to 0% step by step.
4.1.2.8 Sudden Load to about 50% of the Total Load. For (Diesel Fuel Only).
4.1.2.9 Vibration measurement.
4.1.2.10 Boost pressure measurements according to manufacture manual.
4.1.2.11 Blow-by measurements according to manufacture manual
All these steps and measurements and its evolution will record in doc NO. PH-IMS-SP-08-1-
FR02
 Doc NO. PH-IMS-SP08-WI01
GENERATOR TEST INSTRUCTION REVISION / ISSUE:01/01
DATE:6/5/2015

4.1.3 Oil analysis will occurred according to special work

instruction (Doc NO. PH-IMS-SP08-WI012 )

4.2 In process inspection :-

4.2.1 Engine Overhaul inspection :-

4.2.1.1 Top Overhaul Inspection:
As per caterpillar service manual for series 3300, 3400, 3500
and C top overhaul required at to check all parts and
take the necessary action as the following
As per Perkins

4.2.1.1.1 Replaced Parts

4.2.1.1.2 Reused Parts

4.2.1.1.3 Repaired Parts

4.2.1.2 Complete Overhaul Inspection

4.2.1.2.1 Replaced Parts

4.2.1.2.2 Reused Parts

4.2.1.2.3 Repaired Parts

4.2.1.3 Unplanned repair

4.2.2 Alternator inspection will occurred if required according

to its special work instruction Doc NO. ( PH-IMS-SP08-
WI013)
4.2.3 Compression test done when complete overhaul done to
this generator.

5. Reference
Performance test According to ISO 8528-6:2005
Vibration Measurement According to ISO 8528-9:1995
 Doc NO. PH-IMS-SP08-WI01
GENERATOR TEST INSTRUCTION REVISION / ISSUE:01/01
DATE:6/5/2015

6. Acceptance criteria
All acceptance criteria according to manufacturing manual.

7. Forms:
Generator Visual inspection check list: PH-IMS-SP08-WI001-FR01
Sound proof visual inspection check list. No : PH-IMS-SP08-WI001-FR02
Performance test report: PH-IMS-SP08-WI001-FR03
Generator Following card PH-IMS-SP08-WI001-FR04
Acceptance report. No : PH-IMS-SP08-WI001-FR05
Alternator inspection report : PH-IMS-SP08-WI013-FR06

8. Flow chart
 Doc NO. PH-IMS-SP08-WI01
GENERATOR TEST INSTRUCTION REVISION / ISSUE:01/01
DATE:6/5/2015