INSPECTION TEST RECORD - ELECTRICAL

INSPECTION CHECKLIST INDEXES

FORM NO DESCRIPTION
A1 VISUAL INSPECTION
A2 GCP INTERNAL POWER DISTRIBUTION INSPECTION
A3 INITIAL START-UP FUNCTION TEST
A4 ALARM AND TRIP FUNCTION
A5 MANUAL SYNCHRONIZING OPERATION

A7 OVERCURRENT PROTECTION INSPECTION

A8 EARTH FAULT PROTECTION INSPECTION
A9 OVERVOLTAGE PROTECTION INSPECTION
A10 UNDERVOLTAGE PROTECTION INSPECTION
A11 REVERSE REACTIVE POWER PROTECTION INSPECTION
A12 REVERSE POWER PROTECTION INSPECTION
A13 OVER FREQUENCY PROTECTION INSPECTION
A14 UNDER FREQUENCY PROTECTION INSPECTION
 PECTION
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ON

TION
ON
ION
TION
SPECTION
TION
CTION
ECTION
 FORM A1 - VISUAL INSPECTION FOR GENERATOR CONTROL PANEL
A GENERAL INFORMATION

Tag no. System / Sub System no.

Model / Type IP Rating

Location Ref. Drawing nos.

B NOTES:
Physical inspection to verify the design of the panel is meeting the specification as approved drawings and
specifications.

RESULT
C INSPECTION / TEST REMARK
YES NO
Documents required:
1 a) Generator control panel general arrangement drawing
b)     AVR DECS250 redundant shematic drawing
Verify and ensure that GCP size and color code same as matterial
2
approval (MA)
Verify and ensure that all fabrication activities have been completed
3
as per GA drawing
Check and confirm that GCP nameplate/identification details are as
4
per approved technical drawings.
Verify and confirm the equipment in the GCP are tight & in
5
accordance to project specification.
Check equipment for mechanical damages (dents/scratches,
6
corrosion, broken handles etc.)
Inspect physical condition and arrangement of GCP PLC and its
7 subsequent PLC racks

Verify space heaters, instruments, indication lamps, control switches,

8 identification tags/ labels, interposing relays, PLC are installed as per
drawings.
9 Verify and confirm that all cables are properly terminated
Inspect GCP internal cables connection, wiring, core marking, and
10 tagging to be as per approved technical drawings

Verify the cleanliness of panel internals and confirm all loose wires,
11 packing material etc. are removed.

12 Verify the panel have installed with earthing point

D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE REMARK

1 Inspected By

2 Witnessed By

3 Certified By
 FORM A2 - GCP INTERNAL POWER DISTRIBUTION
A GENERAL INFORMATION
Tag no. System / Sub System no.

Location Ref. Drawing nos.

B TEST GUIDLINE:
This GCP is powered by 415/240 VAC, 50 Hz power supply. Make sure all the breakers are isolated (OPEN).
Input power will be measure at incoming terminal block before the breaker CLOSE to distribute the power to
other breaker. Then, other breakers will be CLOSE one by one to measure the voltage.
Notes : Refer to Generator Control Panel Shecmatic Drawing

C POWER SUPPLY MEASUREMENT

Breaker Tag No/Rating Expected Voltage Result Voltage Remark

1 QAC1/32A 415/240 VAC VAC

2 QAC2/6A 220-240 VAC VAC
3 QAC3/16A 220-240 VAC VAC
4 QAC4/6A 220-240 VAC VAC
5 QAC5/20A 220-240 VAC VAC
6 QAC6/16A 220-240 VAC VAC
7 QAC7/32A 220-240 VAC VAC
8 QAC8/6A 220-240 VAC VAC
9 QAC9/6A 220-240 VAC VAC
10 QDC1/25A 24 VDC VDC
11 QDC2 / 25A 24 VDC VDC
12 QDC3 / 10A 24 VDC VDC
13 QDC4 / 6A 24 VDC VDC
14 QDC5 / 6A 24 VDC VDC
15 QDC6 / 6A 24 VDC VDC
16 QDC7 / 20A 24 VDC VDC
D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE REMARK

1 Inspected By

2 Witnessed By

3 Certified By
 FORM A3 - GCP INITIAL START UP FUNCTION TEST
A GENERAL INFORMATION
Tag no. System / Sub System no.

Module Ref. Drawing nos.

B NOTE:
Initial startup test is conducted to ensure engine speed, generator voltage and frequency and overall control
system start/stop/emergency stop controls are functioning according to the design requirement.

C INSPECTION/TEST

Test Expected Voltage Test Result Remark

1 Start command GCP Engine Start

2 Run for 5 minutes at rated 1500 ± 2%

speed
3 Check for correct voltage 400 VAC ± 2.5%
4 Check for correct frequency 50 Hz ± 2%
5 Time for establish voltage 20 sec
6 Stop command from GCP Engine cooldown & stop
7 Engine Cooldown Time 5 min
8 Emergency STOP Engine Stop immediately
9 Auto Start from GCP Engine Start
D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE REMARK

1 Inspected By

2 Witnessed By

3 Certified By
 FORM A4 - ALARM & TRIP FUNCTION
A GENERAL INFORMATION
Tag no. System / Sub System no.

Module Ref. Drawing nos.

B NOTE:
Initial startup test is conducted to ensure engine speed, generator voltage and frequency and overall control system
start/stop/emergency stop controls are functioning according to the design requirement.

C INSPECTION/TEST

Fault Type Test Expected Result Test Result Remark

Light Fault:
a) Engine failed to start
b) Low lube oil pressure
1 blocks to trigger
c) High coolant temperature
d) Low fuel level
e) Failed to auto parallel
Medium Fault:
a) Overcurrent
b) Undervoltage
2 c) Undervoltage
d) Reverse Var
e) Reverse power
Heavy Fault:
a) Emergency Stop
b) Engine Over Crank
c) Engine Over Speed
3 d) Low Lube Oil Pressure
e) High High Coolant Temp.
f) Overvoltage
g) Ground Fault
D COMMENT(S) AND ADDITIONAL INFORMATION
Simulate any of the
fault from terminal HMI display shows
alarms indication and
buzzer activated
alarm listed
HMI display shows
Simulate any of the alarms indication and
fault from terminal
buzzer activated. C.B
blocks to trigger trip and AVR de-
alarm listed excitation.
HMI display shows
Simulate any of the alarms indication and
fault from terminal buzzer activated. C.B
blocks to trigger trip and AVR de-
alarm listed excitation. Engine
will shut down
immediately.

E CERTIFICATION COMPANY SIGNATURE DATE REMARK

1 Inspected By

2 Witnessed By

3 Certified By
 FORM A5 - MANUAL SYNCHRONIZING OPERATION
A GENERAL INFORMATION
Tag no. System / Sub System no.

Model No Ref. Drawing nos.

B NOTE:
The generator is equipped with synchronizing facility. Operation shall selected to do the synchronizing in manual or auto
by selecting the mode at Operation Mode switch. The voltage and frequency matching of the generator and breaker
closing command will be done automatically by the generator controller once command is given. However, if operator
needs to adjust the frequency and the voltage to the desired level, this action can be done before synchronizing command
is issued to the generator controller.

C INSPECTION/TEST

Summary of Situation Test Expected Result Test Result

Forward Synchronizing The generator voltage and
frequency will be adjusted to
match the running supply
Incoming Supply: voltage and frequency.
Generator Manual synchronizing is done Breaker will be closed, once the
via manually adjusting Voltage sync point is reached and close
Running Supply: Trimmer and Speed Control signal by the generator
Grid switch at GCP to match the controller.
voltage and frequency of the
running supply before closing
the breaker. Then synch check
relay should inhibit closing of
CB Status: the breaker. CB Status:
1) Main Incomer - Close 1) Main Incomer - Close
2) Generator - Open 2) Generator - Close

Back Synchronizing Auto synchronizing is done via

auto synchronizing relay where
by the relay will automatically
Incoming Supply: adjusting the voltage, adjusting
Grid (Main) Manual synchronizing is done the frequency (speed) and
via manually adjusting Voltage close the breaker of the
Trimmer and Speed Control generator that to be synch into
Running Supply: switch at GCP to match the the grid.
Generator voltage and frequency of the
running supply before closing
the breaker. Then synch check
relay should inhibit closing of
CB Status: the breaker. CB Status:
1) Generator - Close 1) Main Incomer - Close
2) Main Incomer - Open 2) Generator - Close

D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE REMARK

1 Inspected By

2 Witnessed By

3 Certified By
 FORM A6 - MANUAL SYNCHRONIZING OPERATION
A GENERAL INFORMATION
Tag no. System / Sub System no.

Model No Ref. Drawing nos.

B NOTE:
The generator is equipped with synchronizing facility. Operation shall selected to do the synchronizing in manual or auto
by selecting the mode at Operation Mode switch. The voltage and frequency matching of the generator and breaker
closing command will be done automatically by the generator controller once command is given. However, if operator
needs to adjust the frequency and the voltage to the desired level, this action can be done before synchronizing command
is issued to the generator controller.

C INSPECTION/TEST

Summary of Situation Test Expected Result Test Result

Forward Synchronizing The generator voltage and
frequency will be adjusted to
match the running supply
Incoming Supply: voltage and frequency.
Generator Manual synchronizing is done Breaker will be closed, once the
via manually adjusting Voltage sync point is reached and close
Running Supply: Trimmer and Speed Control signal by the generator
Grid switch at GCP to match the controller.
voltage and frequency of the
running supply before closing
the breaker. Then synch check
relay should inhibit closing of
CB Status: the breaker. CB Status:
1) Main Incomer - Close 1) Main Incomer - Close
2) Generator - Open 2) Generator - Close

Back Synchronizing Auto synchronizing is done via

auto synchronizing relay where
by the relay will automatically
Incoming Supply: adjusting the voltage, adjusting
Grid (Main) Manual synchronizing is done the frequency (speed) and
via manually adjusting Voltage close the breaker of the
Trimmer and Speed Control generator that to be synch into
Running Supply: switch at GCP to match the the grid.
Generator voltage and frequency of the
running supply before closing
the breaker. Then synch check
relay should inhibit closing of
CB Status: the breaker. CB Status:
1) Generator - Close 1) Main Incomer - Close
2) Main Incomer - Open 2) Generator - Close

D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE REMARK

1 Inspected By

2 Witnessed By

3 Certified By
 FORM AXX - REDUNDANT EXCITATION MODULE CONTROL & OPERATION
A GENERAL INFORMATION
Tag no. System / Sub System no.

Model No Ref. Drawing nos.

B NOTE:
The generator is equipped with redundant excitation module to provide backup should the master AVR is faulty.
Master/Backup interchangeability can be made via manual switch or auto operation. During parallel operation w
mains, the AVR shall be operate under PF control which is at 0.85 p.f.

C INSPECTION/TEST

Summary of Situation Test Expected Result Test Result

AVR Master/Backup Test 1 The Master/Backup AVR Test 1
manual switching Use AVR selector switch to interchageability can be done
during online (hot swap)
change AVR output control without interrupting the
Generator running with from Master to Backup excitation output.
rated voltage output

Rated Voltage Output: Test 2 Test 2

415 VAC , 50Hz Use AVR selector switch to
change AVR output control
AVR In control: from Backup to Master
Master

AVR Master/Backup Test 1 Excitation output control will be Test 1

auto switching To simulate Watchdog
master AVR fail by
Generator running with disconnect Master AVR
rated voltage output DC Supply
automatically changed from
Master to Backup AVR without
any interruption on the
excitation output.

Rated Voltage Output: Test 2 Test 2

415 VAC , 50Hz To Simulate 1st level
Overexcitation trip signal
AVR In control:
Master

D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE REMARK

1 Inspected By

2 Witnessed By

3 Certified By
RATION

he master AVR is faulty. The

ing parallel operation with the

Test Result
st 1

st 2

st 1

st 2
MARK
 FORM AXX - REDUNDANT EXCITATION MODULE CONTROL & OPERATION
A GENERAL INFORMATION
Tag no. System / Sub System no.

Model No Ref. Drawing nos.

B NOTE:
The generator is equipped with redundant excitation module to provide backup should the master AVR is faulty.
Master/Backup interchangeability can be made via manual switch or auto operation. During parallel operation w
mains, the AVR shall be operate under PF control which is at 0.85 p.f.

C INSPECTION/TEST

Summary of Situation Test Expected Result

Power Factor Control
Test 1:
Generator running in
parallel with mains By simulating current and
voltage sensing using
secondary injection, the
Rated Voltage Output: injection is adjusted so that
415 VAC , 50Hz the AVR would sense the
power factor of the system
AVR In control: is >0.85
Master
Test 2:
CB Gen status: By simulating current and
Closed voltage sensing using
secondary injection, the
CB Main Status: injection is adjusted so that
Closed the AVR would sense the
power factor of the system
Power Factor Regulation: is <0.85
0.85
Test 3:
By simulating current and
voltage sensing using
Test 1:
AVR shall respond on the
excitation output by increasing
the excitation output so that
the regulated power factor
shall be within 0.85
Test 2:
AVR shall respond on the
excitation output by decreasing
the excitation output so that
the regulated power factor
shall be within 0.85
Test 3:
AVR shall maintain at its
 secondary injection, the current excitation as the
injection is adjusted so that regulated power factor is
the AVR would sense the within the setpoint value
power factor of the system
is = 0.85
D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE

1 Inspected By

2 Witnessed By

3 Certified By
TROL & OPERATION

up should the master AVR is faulty. The

eration. During parallel operation with the

Test Result
Test 1

Test 2

Test 3:
REMARK
 FORM AXX - GENERATOR AUTO OPERATION - AUTO MAINS FAILURE (AMF)
A GENERAL INFORMATION
Tag no. System / Sub System no.

Model No Ref. Drawing nos.

B NOTE:
The generator shall able to provide emergency backup supply during the loss of the main supply which is called
Failure (AMF) operation. The generator will start, excite to its rated output voltage and recover the emergency b
automatically. This whole operation shall be done within 20 seconds from the time the generator starts due to m
undervoltage.

C INSPECTION/TEST

Summary of Situation Test Expected Result

Auto Mains Failure
The main incomer supply
Generator in standby is simulated so that
mode and healthy it reaches to main incomer
undervoltage setpoint.
Once the main incomer and
Engine Operation Mode: bus is confirmed dead,
Auto the generator will auto
start to its rated speed
Main Incomer Supply: before excites to its rated
415 VAC, 50Hz voltage & frequency.
Once the voltage output
Gen Incomer Supply: reached to its rated output,
Dead generator contol panel
will send command to close
Main Bus Supply: the gen incomer breaker.
415 VAC, 50Hz
CB Gen status:
Open
1) The generator control panel
will send main incomer breaker
open command, once it
detects main incomer is
in undervoltage condition
2) The generator will auto start
once the control panel sense
both main incomer and main
bus are in undervoltage and
main incomer breaker is in
open position.
3) The generator will excite to
its rated voltage output once
it reached to its rated speed

CB Main Status: 4) Command close gen incomer

Closed breaker will be sent once
 the generator has reached
to its rated voltage
output.

D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE

1 Inspected By

2 Witnessed By

3 Certified By
AINS FAILURE (AMF)

of the main supply which is called Auto Mains

tage and recover the emergency bus
time the generator starts due to mains

Test Result

Sequence 1

Sequence 2

Sequence 3

Sequence 4
REMARK
 A GENERAL INFORMATION
Tag no. System / Sub System no.

Model No Ref. Drawing nos.

B NOTE:
The generator shall able to provide system normalization once the main incomer supply is recovered. The gener
perform auto synchronizing operation with main incomer supply before opening the gen incomer breaker once
incomer and main incomer are running in parallel. The generator then will go into cooldown period for 10 minu
shutting down and ready for next operation.

C INSPECTION/TEST

Summary of Situation Test Expected Result

Main Incomer Normalize
The main incomer supply
Generator in running is simulated so that
and supplying the main it reaches to its rated
bus. supply voltage and frequency
The generator will perform
Engine Operation Mode: auto synhronizing operation
Auto with main incomer supply.
The generator will run in
Main Incomer Supply: parallel with the main before
Dead opening gen incomer circuit
breaker and go into
Gen Incomer Supply: cooldown mode and
415V AC, 50Hz shutdown.
1) The generator control panel
will perform auto synchronizing
operation once main incomer
is normalize.
2) The generator will run in
parallel before opening the
gen incomer circuit breaker.
3) The generator will go into
cooldown operation for 10
minutes and shutdown.

Main Bus Supply:

415 VAC, 50Hz

CB Gen status:
Closed

CB Main Status:
Open
D COMMENT(S) AND ADDITIONAL INFORMATION

E CERTIFICATION COMPANY SIGNATURE DATE

1 Inspected By

2 Witnessed By

3 Certified By
mer supply is recovered. The generator will
ng the gen incomer breaker once both gen
nto cooldown period for 10 minutes before

Test Result

Sequence 1

Sequence 2

Sequence 3
REMARK