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Generator set Commissioning

Part of a project

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In this training we will cover:

• Meeting (Scope of work)

• Pre-commissioning work

• Commissioning of the genset

• Documentation

• Post commissioning work

• Questions & Answers Session

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Meeting
•If the commissioning of the genset(s) is assigned to you (Service engineer)
following are the responsibilities.

•If genset is part of a project.

•Meet with engineering representative.
•In meeting ask him about the Commissioning protocol, operation philosophy, SLD, Cable
schedule and other documents which need necessary for the execution of the project.
•Study all documents thoroughly and if any concern is in consideration please discuss
before going to site.
•Follow and discuss the timeline of project execution.

•If genset is commissioned through sales.

•Meet with sales representative.
•Requirement of the site specifically must be known before going to site. (Megger, earth
test etc.)
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Pre-commissioning work
•Onsite first follow and report the pre-commissioning work. Following are the
key works which need to be done as a pre-commissioning stage.
•Arrangement of tools as per site demand + special requirement from
customer or engineering.
•Tools: (Megger, Earth Tester, Blowby tool, Exhaust back pressure tool, Turning tool, Power
Analyzer, Phase sequence, Service Laptop with associated kits, Vibration tester, temperature
gun, clamp meter, Battery electrolyte filling kit, Oil and coolant filling pump, etc.)

•Inspection:
•Physically inspect the genset thoroughly from all aspects (Electrically + Mechanically).
•Leakages, seepages damages and other kind of abnormalities must inform before energizing
the system.
•Control wiring verified as per cable schedule and perform cold testing of the wiring before
energizing it.
•Exhaust system, fuel system, cooling system, air system etc. must be as per design or as per
specification.
•Power cables sizing according to genset capacity. 5
Pre-Commissioning work
•Preparation for startup:
•Auxiliaries should be operational before energizing the genset. (Remote fans, Jacket water
heaters, alternator heaters, battery chargers etc.)
•Coolant, oil must be upto the mark in the system if not than maintain it.
•Battery electrolyte of specific gravity must be filled if batteries which are shipped in dry
condition with genset or check the battery condition.
•Flushing of the fuel tank and fuel lines from tank to genset inlet must be done. Also remove
air from the fuel system. Fuel tank must be fill at adequate level which required till final
testing.
•Megger of the genset alternator must be done and record all the data.
•Power cables insulation test report must be witness.
•Earthing must be test or report must be submitted before energizing the system.
•Neutral and body must be grounded separately.
•Make sure neutral must not common with earth point.
•Engine must rotate at-least two revolutions through turning tool to check any kind of
restriction also the alignment of radiator fan.
•Power cables and alternator cables nuts and bolts torque must be check.
•Turbocharger piping must be inspected internally and externally. 6
Commissioning work
•Startup:
•Energize emergency stop and connect batteries to the system (genset).
•Remove emergency stop and check all the system after energization.
•Two to three times engage or disengage the emergency stop.
•Check all the fuel valves, coolant valves, oil level and battery condition before cranking.
•Check at-least two to three sensors response by removing their connectors. If normal reconnect.
•No unauthorized person present near genset at the time of startup.
•Set the genset at about 750 to 800 RPM and then half crank the genset. (One hand on emergency
stop).
•If everything found normal then start genset and runs in idle mode.
•If everything found normal then run the genset at rated 1500 RPM and check all parameters
offload.
•Perform the control wiring test (real signals).
•Set the breaker threshold as per genset capacity.
•Test the genset safeties (Warning & Shutdowns). (LOP, HCT and ES) others are on demand.
•Check the phase sequence of bus voltages. (If sync of multiple genset is the part of project).
•Connect service laptop and capture all the genset data (Engine + Controller).
•If any 3rd party controller involve in the system their control wiring and safety thresholds must be
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shared and witness before load test.
Commissioning work
•Load test:
•Start data logging / data monitoring.
•Perform the load test as per the commissioning protocol demand or as per customer demand.
•Load test sheet design according to time and load percentage mention all the (engine + alternator)
parameters.
•On load perform the blow-by test of the engine (Follow QuickServe procedure).
(Project or ≧MW genset)
•On load perform the vibration test of the genset complete. (Follow procedure).
•On load perform the exhaust back pressure test. (Follow procedure).
•On load record the genset temperatures (engine + alternator) and mention it in the load test
protocol. (Radiator inlet and outlet, alternator inlet and outlet, Turbocharger inlet and outlet etc.)
•Other parameters must be logged as mention in the load test chart.
•Power Analyzer must be connected to the system to record the in-depth electrical parameters.
•Genset must be operate minimum 30% (not for extended period) and on average of 80% of the
prime rating.
•On load check the current on earth.
•Execute or perform the work as per operation philosophy.
•Testify all the operation philosophy points.
•At commissioning genset should be test @ 100% or ≧110% load of the prime rating. If desired 8 load
Documentation
•Following are the documents which need to be submitted after
commissioning.
•Commissioning reports.
•Field test report (Day by day) or every visit.
•Commissioning check list.
•Megger report (Alternator).
•Megger report (Power Cables). (Customer Scope)
•Earth test report. (Customer Scope)
•Vibration test report.
•Load test chart.
•Capture file and logged data (Inpower). (If applicable)
•Image file and logged data (Insite). (If applicable)
•Safety thresholds.
•Commissioning Protocol (Word Document which shows all the work successfully done or in
pending).

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Questions and Answers session

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