D5-D16 Commissioning Report - Genset - Aux - 2011-05-21 - US PDF

Volvo Penta
Commissioning
Guidelines & Report
Marine Genset &
Auxiliary Engines
D5 - D16 series
Engine type: .........................................................................
Engine serial no.: ................................................................
Yard name: ............................................................................
Yard no.: ................................................................................
Genset no. (e.g. 1 of 3): ....................................................
IMO no.: ................................................................................
Flagstate: ..............................................................................
Classification: ......................................................................
Other certificate: .................................................................
Date of commissioning: .....................................................

Year Month Day
Approved without remarks

Approved with remarks specified at Notes
Content
Installation Check-Up and Commissioning Report ................................. 2
Introduction .............................................................................................. 2
Table of Contents ..................................................................................... 3
Pre Commission Part HAT (Harbour Acceptance Test) ....................... 4
Checklist ................................................................................................. 16
Alphabetical index .................................................................................... 27
1
Installation Check-Up and Commissioning Report
Introduction
About this document
This Installation Check-up and Commissioning Normally Acrobat Reader only allows read-only
Report comprises two parts; Pre Commission Part access to PDF files without the ability to write or save,
HAT gives instructions on how installation inspections but the form provides extended document rights and
must be carried out while Checklist is an electronic tools for the purpose. The extended document rights
form upon which Volvo Penta Dealers record com- also allow writing and the ability to sign the PDF file
pleted Installation check-ups. The form is completed electronically (see separate instruction on the CXC
in the computer and is saved and mailed directly to website). The form is designed such that some fields
the local Volvo Penta region for handling. The region are controlled, e.g. only numerals are allowed but no
checks the Commissioning Report and, if it is text. Once the form is completed and saved according
approved, sends Proof of Acceptance back to the to the instructions under "Save Form" it may be mailed
dealer. The dealer must also print and provide a copy directly (if the computer has an internal connection) to
of the saved Commissioning Report to the customer. the regional sales office by selecting the "mail to" link
If it is not possible to use a laptop during the inspection for the sales office concerned. Before mailing the form
the entire document can be printed and completed by it is always advisable to print it and carefully check that
hand on board; information entered must then be all information is correct. A mistake is more easily
transferred to the electronic form back at the office. detected in print than it is on screen.
Volvo Penta does not accept Commissioning Reports
Save the form
sent in by mail or fax.
In order for all CXC agreements to be easily search-
How to proceed able in our systems, engine serial numbers are used
In order to fill in the form it is necessary to install Acro- as search keys. For this reason the form filename
bat Reader version 8 freeware or later, in the com- must be constructed as follows: serial num-
puter. Acrobat Reader is normally already installed in ber_CR.pdf. The serial number has at least 10 digits
a computer; however, should it be lacking or be of an and an underscore (_) is used as a space. Example;
earlier version the latest version can be downloaded 1234567890_CR.pdf.
from www.adobe.com: look for the link "download
Save the document in a folder especially created for
Acrobat Reader". Download and install the software.
CXC reports. A copy of the report must also be printed
In the case of uncertainty regarding already installed
and handed to the customer once Proof of Accept-
Acrobat Reader, information regarding the software
ance is received. When the Commissioning Report is
version can be found under the Help menu.
saved in the folder as described above it must be
mailed to your sales office. The email addresses for
all regional sales offices are found at the bottom of the
form; click the "send" button after selecting the
address.
2 47701818 04-2011
Installation Check-Up and Commissioning Report, Table of Contents
Table of Contents
A Installation layout in engine room
Engine position in boat.
B Installation and lining up
Description of how to checking engine mountings, flanges etc.
C Parallel operation - Load sharing
D Description of exhaust system and crankcase ventilation
Crankcase ventilation, backpressure, pipe expansion, exhaust line etc.
E Description of radiator cooling system
Engine room ventilation.
F Formula
Engine calculation and electrical formula.
G Metric Conversion Chart
H General information
Information of customer; shipyard etc. Equipment specification. Engine application.
I Engine installation information
Description of engine location, accessibility and engine support.
J Installation Check-Up
Inlet- and exhaust system, fuel system, cooling system etc.
K Before Starting Checklist
Tests and checks before start.
L Starting the Engine
Adjusting rpm, checking voltage droop etc.
M Testing the generator set
Parameters to be checked on engine / generator at full load.
N Finalization
Overall comments, remarks, modifications and signatures.
O Saving the report
Attachments
Factory test reports if not found can be ordered from the Application department in Sweden.
47701818 04-2011 3
Installation Check-Up and Commissioning Report, Pre Commission Part HAT (Harbour Acceptance Test)
Pre Commission Part HAT

(Harbour Acceptance Test)
A. Installation layout in engine room
Possible engine positions
OK OK
X
p0010626
Example on installation
Fore
Engine
Engine
Generator 1
Generator 2
Port Stb
Generator 3
Engine
p0010627 Aft
4 47701818 04-2011
B. Installation and lining up
Checking of foundation heights

A Generator sets and auxilary engines reguire a flatness
of vessel foundation / plate within 3 mm / 1 m (0.118” /
3.28 ft.).
Measure the height of each flexible mounting from the

bottom of the frame (A) to the floor (B).
B
P0010624
1 2 Start with the flexible mounting closest to the front

Start right side of the engine and continue around the
engine clockwise.
Engine Generator
End of loop Flexible mounting height values can also be added in

1 mm 4 mm 7 mm section Installation Check-Up and Commissioning
2 mm 5 mm 8 mm
Report page 18 when typing the check values.
P0010625 3 mm 6 mm
IMPORTANT!
Make sure that all flexible mountings are equally com-
pressed.
P0010495
47701818 04-2011 5
C. Parallel operation - Load sharing
VOLTAGE ACTIVE CURRENT

(50 or 60 Hz) p.f 1 (Kw)
App
aren
t pow
Reactive er (k
Va),
(kVAR), lag Time
lagging Active power (kW)cos φ
Reactive cos φ
ad
(kVAR), a), le
we r (kV
leading t po
aren
App
REACTIVE CURRENT LAG REACTIVE CURRENT LEAD

P0010634
p.f (0) p.f (0)
• Active current is in phase with the voltage.

• Reactive current (inductive) lags the voltage by 90°.
• Reactive current (capacitive) leads the voltage by 90°.
App • Active current is pure power (power factor 1), meas-

aren
Reactive t pow ured in kW.
er (k
(kVAR), Va),
la g • Reactive current is wattless current, measured in
lagging kVAR.
Active power (kW) cos φ
• Reactive current can lead or lag the voltage.
cos φ
Reactive
d
• Power factor (cos φ) is the resultant of kW/kVA (the
a
(kVAR), a), le apparent power).
leading we r (kV
are nt po
App
P0010635
6 47701818 04-2011
Power factor (p.f.)

a.c. voltage
V Zero p.f.
a.c. current
lead
VA
.f .k
zero i 0,9p
line 1.0 p.f. kW=kVA
0.
8
p.
f.
la
g
ra
te
d
kV
A
Phase or time displacement

(current lagging voltage)
P0010636
0.2 p
Limit of full
.f. la
In this case the load applied causes the current wave- load current
g
form to lag behind the voltage waveform by a constant
kVA
amount i.e. the voltage peaks and zeros occur at the
constant time before the current peaks and zeros.
This is a normal situation in a.c. work where a phase

or a difference exists between the voltage and current
waveforms. The instantaneous real power in watts is
always the voltage-current for the instant in time. Line of constant
Since voltage and current are no longer in phase, the power (kW)
summation of all of the instantaneous powers over
one cycle will be less than the summation of the in- P0010637
phase case.
Hence the power factor figure will reduce from 1.0 to

a figure proportional to the amount of phase or time It is possible for a load to demand a current which is
displacement. Consequently, as the phase difference almost totally out of phase with the generated voltage.
between the voltage and current waveforms Also the current may be lagging the voltage (inductive
increases, the power factor figure will reduce, as will or motor loads) or leading the voltage (capacitive
the real power output figure. loads). This therefore completes the range of power
factors for a.c. generators from zero p.f. lagging
Since quite large powers are obtained the unit kW is through conventional 0.8 p.f. lagging to unity (1.0) p.f.
preferred to the watt (W) where 1000 W = 1 kW. to zero p.f. leading. One aspect of this is that though
only a small real power (kW) is demanded by the load
The nature of the load in an a.c. circuit will determine
which is well within the machine’s capability, damage
if the current drawn is in phase or out of phase with
can easily result if the load is a very low power factor
the generated voltage. The load again determines if
load demanding a very high kVA level.
that current waveform “leads” the voltage waveform
or ”lags” the voltage waveform. For normal industrial The diagram shows different power factor-kVA loads
loads, e.g. motors, the current will lag the voltage by all supplying the same real power (kW) level. For nor-
some time interval or phase angle. See also kVA and mal constant voltage operation the length of the kVA
power. line is directly proportional to load current. The high
current overloads at low power factors can be easily
The optimum situation is where current and voltage
seen from this diagram.
are in phase. This makes the power factor unity (1.0)
and hence the real power (kW) the same as the prod-
uct of voltage and current (kVA). Conventionally a.c.
generator work considers a lagging power factor of
0.8. In this case the current will lag the voltage by an
amount which causes the real power level supplied
(kW) to fall below the kVA-level by a factor of 0.8
times.
47701818 04-2011 7
D. Description of exhaust system and crankcase ventilation
Crankcase ventilation
General description
Connect the crankcase ventilation pipe to the engine
connection point; refer to the installation drawing for
5 the engine concerned.
6 NOTICE! Some engines have closed crankcase ven-

tilation as standard, others as an accessory.
The pipe must always slope upwards at least 5°. The

1 pipe diameter ØB after the drainage tank (1) must
7 always be at least 5 mm (0.2"). It must also be at least
4 50 % greater than the flexible hose (4) diameter ØA up
3
to a length of 10 m (32.8 ft.).
2 If the pipe exceeds 10 m (32.8 ft.), the diameter
ØBafter 10 m (32.8 ft.) must be at least 100 % greater
than ØA.
WARNING!
Crankcase ventilation piping shall not be connected to
any other piping system.
If connected to the exhaust system there will be a great
risk of explosion.
There should always be one ventilation system for
each engine.
NOTICE! The ventilation pipe should always be insu-

lated for operations in low (arctic) temperature condi-
tions where there is a risk of condensed water freezing.
B
NOTICE! Blow-by is around 35 l/min (1.24 ft3/min) per
cylinder at 100 % load. This will increase with operating
1 hours owing to piston ring wear.
7
A 1 Drainage tank
4
2 Drain valve, normally closed
3 Drain pipe
100mm 4 Flexible hose
(3.9”)
5 - 10mm 5 Flame arrestor
2 (0.2 - 0.4”) Min. 5
6 Exhaust fume trap
3
7 Connection for measuring crankcase pressure
P0011532
NOTICE! The valve can be held open using a drain

pipe (3).
8 47701818 04-2011
If the piping system is not sufficiently large exhaust

fumes will build up pressure in the engine. This excess
pressure will increase stress and wear on the crank-
shaft, seals and engine gaskets. The engine may also
begin to leak oil.
Engine and crankcase ventilation system condition

can be checked by measuring crankcase pressure. A
good method is to measure the pressure during sea
trials for future reference. Crankcase pressure may not
be exceeded. Refer to Technical data in the Sales
guide, marine diesel engines, Marine Genset for
maximum permissible crankcase pressure.
NOTICE! Normal crankcase pressure is approx. 0.1

kPa (10 mm water column, 0.015 psi).
WARNING!
Only start the engine in a well-ventilated area. If oper-
ating the engine in a closed area ensure that there is
exhaust ventilation leading out of the work area to
remove exhaust gases and crankcase ventilation
emissions.
IMPORTANT!
If the crankcase ventilation gases are led into the
engine compartment they will first block the air filter.
Damage to the turbocharger and the engine will follow.
47701818 04-2011 9
Exhaust system
IMPORTANT!
4
The exhaust system should be designed and installed
in such a way that the exhaust emissions are taken out
of the boat without any harmful backpressure for the
1 engine and so that there is no risk of overheating any
adjacent parts of the boat. The demand for silencing
must also be met and the system must arranged in
such a way to prevent the gases from entering the
A boat. All exhaust systems must be installed so that
water cannot force its way back into the engine when
the engine has been switched off.
2 When designing the exhaust system, note that the
3
backpressure must not exceed the values in the table.
Backpressure
P0011520
The exhaust system will produce a certain resistance
to the exhaust gas flow. This resistance or backpres-
sure must be kept within specified limits.
1 Nipple for connection of hose
2 Exhaust elbow Excessive backpressure can cause damage and will
3 Transparent plastic hose partly filled with water
lead to:
4 Manometer. Alternative to plastic hose • Loss of power output

A Exhaust backpressure in mm wc
• Poor fuel economy
• High exhaust temperature
These conditions produce overheating and excessive
smoke from the installation, and reduce the service life
of the valves and turbocharger.
The backpressure is measured by means of a water
gauge.
Max permissible backpressure in exhaust pipe at rated rpm, kPa*

(kPa) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
D5 X X X
D7 X X X
D9/D11/D12/D13/D16 — X X
* 1 kPa = 100 mm water column
No performance losses.
(In relation to technical data. Maximum permissible backpressure for emission certified
engines).
— Small performance losses.

(Non-approved backpressure for emission-certified engines).
X Not permitted.
10 47701818 04-2011
Pipe expansion
The exhaust pipe will expand when running. The
expansion bellows must be placed so no stress is built
up. The compensator should not be bended too much
when engine is running at 100 %.
The compensator is installed directly to the turbo

despite for some engines that has an original exhaust
bend on the turbo where the compensator is installed.
Silencer
The Volvo Penta silencer can come in various design
e.g. 25dBa or 35dBa and with or without spark arrestor.
Check that the right silencer is installed.
The condensation and rain drain out from the silencer

3 and the pipe system has to be designed so the water
P0011504
won’t enter the engine.
Condensation water collector
6 Dry exhaust line

6 1 Compensator
2 Insulation
4
3 Fiber glass on outside of insulation
5 2 4 Three-point attachment fitting
1 5 Silencer
2
3 6 Flexible attachment fitting
P0011509
D5 water by-pass
A water by-pass hose (1) must always be installed on
D5 engines to achieve permissible backpressure. The
hose must be installed on the exhaust elbow and the
water outlet through the hull.
P0011488
47701818 04-2011 11
E. Description of radiator cooling system

Engine room ventilation
When a set with an integrally mounted radiator is instal-
led in an engine room, the basic principle is to extract
hot air from the room and induce air at the ambient
temperature outside the engine room with minimum re-
circulation.
The figure illustrates the most suitable position of the

engine in elation to the walls of the engine room. The
object is to get cool air in at the lowest possible point,
push it through the radiator matrix and then out of the
engine room.
1,12 m (44”) ~1,25 m (50”) It is unsatisfactory to position the set so that the radi-
ator is adjacent to the opening in the wall. When in
operation hot air will re-circulate back into the radiator
1,12 m (44”)
fan via the gap between the radiator and the wall.
~1,25m (50”)
1.25 m2 + 25%
1.25 m2 = 1.56 m2 This will lead to inefficient cooling and could result in
(1938 in2) (2418 in2) overheating problems. The outlet opening in the wall
should have free flow area about 25 % larger than the
frontal area of the radiator matrix and be of the same
A rectangular shape.
B
A sheet metal or plastic duct is fixed to the opening
frame using a flexible connection to the radiator duct
flange. The flexible section is particularly necessary
1,4m (55”) when the set is mounted on flexible mountings.
The inlet air opening should also have a flow area at

least 25 % larger than the radiator matrix.
1,4m (55”)
With the design of inlet and outlet openings it must be

1.56
C 0.8 = 1.95 m
2 remembered that the radiator fan has a limited total
(3023 in2)
allowable external resistance - i.e. “inlet to fan plus inlet
to radiator” - this must not be exceeded or cooling air
flow will be reduced.
D
The inlet and outlet openings will usually be fit to with
a mesh grille, louvres, noise attenuating panels or
inside and outside ducting. Whatever is fitted will pro-
1,4m (55”) mote resistance to air flow and it may be necessary to
F further increase the opening area.
E
A Radiator frontal area
B Air inlet or outlet
1,4m (55”)
1.95 m2
(3023 in2)
C Mesh 80 % free aparture
D Size of air inlet / outlet to fit mesh
E Effective height
P0004141
F Size of air inlet / outlet to fit grille
12 47701818 04-2011
F. Formula
Engine calculation formula

Three phase alternating current.
To find: Calculate:
Power 2π xT x n
P = ————— (kW)
1000 x 60
Torque P x 60
T = ——————— (Nm)
2π x n x 1000
Mean effective pressure 2P

PME = ——— (MPa)
VxN
Torque rise Tp - Tr
——— x 100 (%)
Tr
Speed drop np - nr
——— x 100 (%)
nr
Thermal efficiency 100.000

————
Hs 8432(1)
——— x 100 = ——— (%)
SFC SFC
Abbreviations
P Power (kW) n Engine speed (rpm)
T Torque (Nm) no No load high idle speed
V Displacement (litre) nr Full load rated speed
PME Mean effective pressure (MPa) np No load speed
N Speed (S-1) Hs Thermal (calorific) value (kW/kg)
Tp Peak torque SFC Specific fuel consumption (g/kWh)
Tr Torque at rated speed
1. With calorific value = 42.7 Mj/kg = 11.86 kW/kg
47701818 04-2011 13
Electrical formula
To find: Calculate:
Electrical power Pe = Pm x ηg (kWe)
Electrical power U x I x 1.73 x PF

Pe = ——————— = S x PF (kWe)
1000
Apparent power U x I x 1.73 Pe

S = ————— = —— (kVA)
1000 PF
Reactive power U x I x 1.73 x √1-(PF)2

Q = —————————— (kVAr)
1000
Current Pe x 1000
IL = —————— (A)
U x 1.73 x PF
Frequency rpm x poles

f = ————— (Hz)
2 x 60
rpm 2 x 60 x f
n = ———— (rpm)
poles
Abbreviations
Pm Mechanical power (kWm) ηg Generator efficiency
Pe Electrical power (kWe) IL Current (A)
S Apperent power (kVa) U Voltage (V)
Q Reactive power (kVAr) f Frequency (Hz)
PF Power factor (cos φ) n Revolutions per minute (rpm)
14 47701818 04-2011
G. Metric Conversion Chart
Metric to U.S. or IMP. conversion factors: U.S. or IMP. to metric conversion factors:
To convert Multiply To convert Multiply
From To by From To by
Length mm inch 0,03937 inch mm 25,40
cm inch 0,3937 inch cm 2,540
m foot 3,3808 foot m 0,3048
Area mm² sq. in. 0,00155 sq. in. mm² 645,3
m² sq.ft. 10,76 sq.ft. m² 0,093
Volume cm³ cu. in. 0,06102 cu. in. cm³ 16,388
l, dm³ cu. ft. 0,03531 cu. ft. cm³ 28,320
l, dm³ cu. in. 61,023 cu. in. cm³ 0,01639
l, dm³ imp. gallon 0,220 imp. gallon cm³ 4,545
l, dm³ U.S. gallon 0,2642 U.S. gallon cm³ 3,785
m³ cu. ft. 35,315 cu. ft. cm³ 0,0283
Force N lbf 0,2248 lbf N 4,448
Weight kg lb. 2,205 lb. kg 0,454
Power kW hk (metrisk)(1) 1,36 hk (metrisk)(1) kW 0,735
kW bhp kW 0,7457
kW BTU/min kW 0,0176
Torque Nm lbf ft 0,738 lbf ft Nm 1,356
Pressure Bar psi 14,5038 psi Bar 0,06895
MPa psi 145,038 psi MPa 0,006895
Pa mm Wc 0,102 mm Wc Pa 9,807
Pa i Wc 0,004 i Wc Pa 249,098
kPa i Wc 4,0 i Wc kPa 0,24908
mWg i Wc 39,37 i Wc mWg 0,0254
Energy kJ/kWh BTU/hph 0,697 BTU/hph kJ/kWh 1,435
Work kJ/kg BTU/lb 0,430 BTU/lb kJ/kg 2,326
MJ/kg BTU/lb 430 BTU/lb MJ/kg 0,00233
kJ/kg kcal/kg 0,239 kcal/kg kJ/kg 4,184
Fuel con- g/kWh g/hph 0,736 g/hph g/kWh 1,36
sump.
g/kWh lb/hph 0,00162 lb/hph g/kWh 616,78
Inertia kgm² lbft² 23,734 lbft² kgm² 0,042
Flow, gas m³/h cu.ft./min. 0,5886 cu.ft./min. m³/h 1,699
Flow, liquid m³/h US gal/min 4,403 US gal/min m³/h 0,2271
Speed m/s ft./s 3,381 ft./s m/s 0,3048
mph knop 0,869 knop mph 1,1508
Temperature Celsius Fahrenheit °F=9/5 x °C Fahrenheit Celsius °C=5/9 x (°F–
+32 32)
1) All hp figures stated in the catalogue are metric.
47701818 04-2011 15
Installation Check-Up and Commissioning Report, Checklist
Checklist
H. General information
Shipyard / Installer
Name: Yard no.:
Address: Representative:
Zip code: Telephone no.:
City: Fax no.:
State / E-mail address:

Province:
Country:
Volvo Penta Dealer / Importer

Name: Contact person:
Address: Mobile phone no.:
Zip code: Telephone no.:
City: Fax no.:
State / E-mail address:

Province:
Country:
End user / Owner

Name: Ship’s name:
Address: Owner’s repre-

sentative:
Zip code: Mobile phone no.:
City: Telephone no.:
State / Fax no.:

Province:
Country: E-mail address:
16 47701818 04-2011
Diesel engine
Make: Volvo Penta
Type:
Serial no.:
□ Normal genset □ Emergency genset □ Combined genset
□ Other, please describe:
Flexible coupling (if different than standard)

Make:
Type:
Rubber hardness:
Supplied by:
Generator / Other Consumer

Make:
Serial no.:
Apparant power (kVa):
□ Single bearing □ Double bearing
□ Other, please describe:
Other, please describe:
47701818 04-2011 17
I. Engine installation information
Engine location
• Engine installed on tank top □ Yes □ No
• Installed on floor over main engine in engine room □ Yes □ No
• Installed outside engine room □ Yes □ No
• Extra strength plates / longitudinal under the frame □ Yes □ No
Accessibility
• Possibility to change filter □ Yes □ No
• Service access to crank case cover □ Yes □ No
• Possibility to change oil in the pan □ Yes □ No
• Service access sideways □ Yes □ No
• Service access up / down □ Yes □ No
• Service access front / rear □ Yes □ No
• Service area according to GA-drawings □ Yes □ No
Engine support
• Steel plate (welding plate) under the flexible engine □ Yes □ No
mountings
• Flexible mountings fitted □ Yes □ No
• Volvo Penta standard flexible mountings □ Yes □ No
If not, type: ....................................................................................
Flexible mounting height, between frame (A) and floor (B)

1 2
Start
Engine Generator
End of loop
1 mm 4 mm 7 mm
2 mm 5 mm 8 mm
P0010625 3 mm 6 mm
18 47701818 04-2011
J. Installation Check-Up
Air ventilation system

• Sufficient ventilation around the installation □ Yes □ No
• Non-blocked air inlets / -outlets on installation □ Yes □ No
• Any risk of re-circulated cooling air □ Yes □ No
• Correct air supply for combustion on engine □ Yes □ No
• Ambient temperature (outside) ....................................................................................
Air ventilation system for radiator cooling

• Correct dimensions on air ducts to / from the radiator, □ Yes □ No
please refer to Installation Check-Up and Commissioning
Report page 12.
If no, specify dimensions: Inlet ........................ Outlet ........................
• Any flow restrictions due to filter grids or water protec- □ Yes □ No
tions
Exhaust system
• Exhaust system has been calculated regarding back- □ Yes □ No
pressure
If yes, by whom? ....................................................................................
• Exhaust pipe outlet has rain protection □ Yes □ No
• Exhaust compensator is fitted □ Yes □ No
• Exhaust compensator is correctly aligned □ Yes □ No
Fuel system
• Fuel system according to recommendations □ Yes □ No
• Fuel pre-filters are fitted □ Yes □ No
• Flexible fuel hoses are fitted □ Yes □ No
• Pipe dimensions: Supply Ø ............ mm Return Ø ............ mm
• Type of fuel. Quality: ....................................................................................
Fresh water cooling system

• System has the correct amount and mixture of cooling □ Yes □ No
liquid additives.
NOTICE! Volvo Penta Coolant VCS (yellow) is recom-
mended. If the customer uses a different brand it will be
on the customer’s responsibility, due to warranty cover-
age.
• Coolant type □ VP Coolant VCS □ Other
If other, what type? ....................................................................................
• Flexible hoses are fitted □ Yes □ No
• Sea water temperature during test: ....................................................................................
Crankcase ventilation system

• Installation is according to the information in Installation □ Yes □ No
Check-Up and Commissioning Report page 8.
If no, closed crankcase ventilation? □ Yes □ No
Torsional vibration calculation (TVC)

• If not standard genset, has TVC been performed? □ Yes □ No
If yes, by whom? ....................................................................................
(A copy is to be attached)
Generator
• Power cables according to generator manufacturer □ Yes □ No
47701818 04-2011 19
K. Before Starting Checklist
1 If electric starters are used, make sure the polarity of the voltage supply is correct. □
2 Before turning on the power to the engine connector box, make sure the polarity is correct. □
3 Only D5/D7: □
Disconnect all connections except the “six cable” connection on the rpm control.
The following cables must remain connected: rpm, actuator and power supply.
4 Check the oil level in the sump. □
5 Check the water level in the engine. □
6 Check the fuel delivery to the engine. □
7 Clean the exhaust pipe near the turbo from metallic welding ashes. □
8 Disconnect the air hose near the starter / regulator and blow all welding remains and dirt □
out by using starting air.
CAUTION!
Risk of eye injury. Eye protection required.
NOTICE! The high pressure can cause great reaction forces on the hose. Take actions to
avoid personal injury.
9 Check that there is no dirt or welding remains in the air inlets. □
10 Open the top cover of the generator and check the cable connections. Check that there □
are no objects present which can cause a short circuit. The generator must be free from
metallic dust.
11 The phase cables must not be run through the side plates one by one. □
The reason is that the magnetic field in the cables will heat the steel plate. If a non-magnetic
plate is used close to the cable, it is ok to run the cables one by one. Running all phase
cables through a steel plate and through one hole only is ok, because the three fields will
eliminate each other.
12 Ask for a confirmation from the shipyard that the other ends of the cables (main switch- □
board) are connected correctly.
Yard / responsible signature: ............................................................................................
13 Verify all safety shutdowns and emergency steps. □
14 If required by classification surveyor, check that all remaining alarms give correct informa- □
tion.
20 47701818 04-2011
L. Starting the Engine
1 Start the engine.
2 Only D5/D7:
Adjust the rpm to nominal rpm.
3 Check for leakages and strange noises. Check the cooling system.
4 Let the engine run and warm up to the temperature where the thermostat starts opening. Check cooling liquid
level.
5 Set the voltage on the AVR unit; compare this value with the switchboard instrumentation.
6 Start applying load to the generator set slowly up to 100 % load. Check all temperatures and pressures during
the load increase.
7 D5/D7 GAC, D9–D16 Vodia, EMS:

If generator sets should run in parallel, activate the speed droop.
Parallel operation, engines
RPM
- 4%
No load ½ Full load

P0010628
8 When reaching 100 % load, set the voltage droop on the AVR unit. Run the next generator set and do exactly
the same, i.e. make sure that the generators have the same voltage setting on no load and full load. This will
ensure no circulation currents in the system. This procedure is only necessary when having two or more
generator sets.
9 The voltage droop at 100 % load has to be checked when having two or more generator sets.
47701818 04-2011 21
M. Testing the generator set
Engine
At 100 % load, check the following parameters:
• Cooling water temperature .................. °C
• Lubrication oil temperature .................. °C
• Exhaust temperature .................. °C
• Exhaust backpressure .................. mm H2O (log with Vodia if possible)
Generator
At 100 % load, check the following parameters:
• Voltage U .................. Volt
• Voltage I .................. Ampere
• Apparent power S .................. kVA
• Active power P .................. kW
• Reactive power Q .................. kVAr
• Power factor .................. (cos φ)
• Frequency at full load .................. Hz
• Frequency at no load .................. Hz
• Main generator breaker setting .................. Ampere
NOTICE! If the generator is equipped with temperature sensors in the winding, make a note of this.
• Temperature 1 .................. ° C
2 .................. ° C
3 .................. ° C
NOTICE! If the generator is equipped with bearing temperature sensors, make a note of this.
• Drive end bearing .................. ° C

• Support bearing .................. ° C
Load (carried out on request, not mandatory)

Applying of load
• Applying load of .................. .................. .................. .................. kW
• Transient voltage dip .................. .................. .................. .................. % (1)
• Steady state voltage .................. .................. .................. .................. V
• Voltage recovery time on load application .................. .................. .................. .................. s
Removal of load
• Transient voltage overshoot .................. .................. .................. .................. %
• Voltage recovery time load removal .................. .................. .................. .................. s (2)
• Steady state voltage regulation (3) .................. .................. .................. .................. min V
.................. .................. .................. .................. max V
1. (Dip voltage / nominal voltage) - 1 x 100

2. Normally time to get in to ±3 % of nominal voltage.
3. Should be within ±2 % of nominal voltage, from cold to hot, from
no load to full load, from pf 0.8 to 1.0.
22 47701818 04-2011
N. Finalization
Yard: ............................................................ Telefax: ............................................................

Date: ............................................................ Direct telephone: ............................................................
Att.: ............................................................ Our reference: ............................................................
Make sure that the following tasks are fulfilled before Volvo Penta commisioning
engineers arrive. Please tick in the list below.
Starting system □
• Adequate start batteries / starting air connected
Electrical system □
• All needed signals connected
Cooling system □
• Hoses connected
• System filled with Volvo Penta Coolant VCS
Fuel system □
• Fuel lines flushed and connected
• Fuel in tank
• Day tank installed according to Volvo Penta recommendations
Lubrication system □
• Volvo Penta recommended oil in system
Exhaust system □
• Exhaust pipe connected
Alignment □
• Make sure that all flexible mountings are equally compressed
Air supply □
• Air inlets according to Volvo Penta recommendations
Generator □
• Power cables connected to the generator
Load bank □
• Make sure that a load bank is available if needed for the Genset test
Yard commisioning responsible
............................................. ............................................. ..................... .............................................

Name Sign Date E-mail
47701818 04-2011 23
Overall comments
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
Volvo Penta representative remarks about installation
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
Classification surveyor remarks about installation
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
Modifications to be carried out before handing over the vessel
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
.................................................................................................................................................................................
................................................................................................................................................................. □ Done
Warranty card filled in? □ Yes □ No

Date of warranty start: ...........................................
Complete report discussed with responsible rep- VOLVO PENTA

resentative Commissioning engineer
........................................................................... ...........................................................................
Signature Signature
........................................................................... ...........................................................................
Name Name
........................................................................... ...........................................................................
Place Date
24 47701818 04-2011
O. Saving the report
Save the report in Adobe Reader by selecting ‘Save As’. Name the file as the engine serial number
(“XXXXXXXXXX_CR.pdf”).
When the file is saved, click on one of the e-mail addresses below to send all fillable information to the concerned
market unit.
- cxc_europe@teamplace.volvo.com
cxc_europe@teamplace.volvo.com
- cxc_na@teamplace.volvo.com
cxc_na@teamplace.volvo.com
- cxc_asia@teamplace.volvo.com
cxc_asia@teamplace.volvo.com
- cxc_int@teamplace.volvo.com
cxc_int@teamplace.volvo.com
47701818 04-2011 25
Alphabetical index
Checklist................................................................ 16
Installation Check-Up and Commissioning
Report....................................................................... 2
Introduction................................................................ 2
Pre Commission Part HAT (Harbour Accept-
ance Test)................................................................. 4
Table of Contents.................................................... 3
47701818 04-2011 27
47701818 04– 2011
AB Volvo Penta
SE-405 08 Göteborg, Sweden

D5-D16 Commissioning Report - Genset - Aux - 2011-05-21 - US PDF

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Volvo Penta

Engine type: .........................................................................

Engine serial no.: ................................................................

Yard name: ............................................................................

Yard no.: ................................................................................

Genset no. (e.g. 1 of 3): ....................................................

IMO no.: ................................................................................

Other certificate: .................................................................

Date of commissioning: .....................................................

Approved without remarks

Pre Commission Part HAT

Possible engine positions

B. Installation and lining up

Checking of foundation heights

Measure the height of each flexible mounting from the

1 2 Start with the flexible mounting closest to the front

End of loop Flexible mounting height values can also be added in

C. Parallel operation - Load sharing

VOLTAGE ACTIVE CURRENT

REACTIVE CURRENT LAG REACTIVE CURRENT LEAD

• Active current is in phase with the voltage.

App • Active current is pure power (power factor 1), meas-

Power factor (p.f.)

Phase or time displacement

This is a normal situation in a.c. work where a phase

Hence the power factor figure will reduce from 1.0 to

D. Description of exhaust system and crankcase ventilation

6 NOTICE! Some engines have closed crankcase ven-

The pipe must always slope upwards at least 5°. The

NOTICE! The ventilation pipe should always be insu-

NOTICE! The valve can be held open using a drain

If the piping system is not sufficiently large exhaust

Engine and crankcase ventilation system condition

NOTICE! Normal crankcase pressure is approx. 0.1

4 Manometer. Alternative to plastic hose • Loss of power output

Max permissible backpressure in exhaust pipe at rated rpm, kPa*

* 1 kPa = 100 mm water column

— Small performance losses.

The compensator is installed directly to the turbo

The condensation and rain drain out from the silencer

Condensation water collector

6 Dry exhaust line

E. Description of radiator cooling system

The figure illustrates the most suitable position of the

The inlet air opening should also have a flow area at

With the design of inlet and outlet openings it must be

Engine calculation formula

Mean effective pressure 2P

Thermal efficiency 100.000

1. With calorific value = 42.7 Mj/kg = 11.86 kW/kg

Electrical power Pe = Pm x ηg (kWe)

Electrical power U x I x 1.73 x PF

Apparent power U x I x 1.73 Pe

Reactive power U x I x 1.73 x √1-(PF)2

Frequency rpm x poles

G. Metric Conversion Chart

Zip code: Telephone no.:

City: Fax no.:

State / E-mail address:

Volvo Penta Dealer / Importer

Address: Mobile phone no.:

Zip code: Telephone no.:

City: Fax no.: