Method Statement

for
Testing &
Commissioning of
DG Set
Purpose:
The purpose of this method statement is to define the testing & commissioning
procedure of the Diesel Generator within the project.
This includes Pre-Commissioning checks, commissioning tests & system interface
tests.

Scope:
The scope of this method statement is to define the system checks, type &
duration of testing that will be required to test standby generator sets to bring it into
a faulty working & approved mode of operations.

System Description:
DG set provides power to the emergency & life safety systems in the event of a
mains failure.

Location Gen Set Plant Plant Engine Engine Alternator Alternator

Model No. Capacity Model Type Make Type

Interface:

After successful commissioning of DG as a standalone piece of equipment, it will

be interfaced with the ATS panel located within the LV main distribution board &
tested for its operation, by simulating a Mains power failure.
BMS interface to be done through RS485 Generator panel.

Abbreviation:

HCT : High Coolant Temperature

HOT : High Oil Temperature
LOP : Low Oil Pressure
AMF : Auto Mains Failure
ATS : Automatic Transfer Switch
AC : Alternating Current
DC : Direct Current

Pre-Commissioning Phase
All installation checks must be carried out & approved by the relevant parties.
Further more the generator room must also be sufficiently completed to
facilitate successful & accurate testing & commissioning to be achieved I.e.
completion of construction work etc.
a) All connection are tight & leak
proof, including cabling to auxiliary
terminal box
b) All protective covering used in
packing are removed
c) Check the fuel, lubricating oil &
coolant levels are adequate, top up
if necessary
d) Change battery & connect to unit
e) Check alternator connections
f) Check the fuses are in holds
g) Isolate circuit breaker from load
h) Make sure the generator operating
switch in the off position
Physically checked & tighten
Physically checked
Coolant & Oil will be filled at site. Fuel
will be supplied by contractor/Client.
Batteries are dry changed, they will be
filled with electrolyte at site.
Physically checked.
Physically checked
Switch off circuit breaker
Physically checked

Warning tapes will be placed around generator room & warning sign board will be
kept to indicate unauthorized personals not to enter in the area.

During start up & testing Generator, sound level of about 120dB will be observed so
ear protection head set will be worn by each one.

Commissioning Procedure
a) Check the exhaust flow is not obstructed or Visual check
damaged in order to avoid harmful fumes
b) Check that the Ventilation system is not Visual check
obstructed
c) Check the battery cable to generator set Connect battery cable to
starter Motor & batteries
d) Check if the generator is in running Test Run

Run Generator for 5 mins without load & record the following
Oil Temperature : Deg C
Engine Temperature : Deg C
Oil Pressure : Deg C
Engine Speed : RPM
Output Voltage : Vac
Output Frequency : Hz
Phase Rotation :
Function of all Instrument :

Before Commissioning load test demonstrate following operation shutdown devices

& alarm.
 1 Fail to start (Over Crank) Starter motor solenoid wire will be
removed
2 Emergency stop Press emergency while engine
running
3 Auto start Short Remote Start terminal
4 Over speed Reduce set point below actual
voltage
5 High engine temperature Ground sensing terminal
6 High Oil Temperature Ground sensing terminal
7 Low oil pressure Ground sensing terminal
8 Alternator Under / Over Voltage Increase/ decrease voltage on AVR
9 Battery volt low Increase set point above actual
voltage
10 High winding temperature Open circuit temperature sensor
wire.
11 Radiator low coolant level Drain coolant below switch level.

Performance Test (Load Test)

Standard performance testing is a test to ensure that a generator set will give
the required 100% output at specified voltage & frequency.

1) Start the DG set & adjust voltage & speed to required value
2) Check all the control equipment meets the functional requirement of the system.
3) Apply 50% of rated load & record all parameters.
4) Add 25% rated load & record all parameters.
5) Add 25% load to achieve 100% of rated load & record all parameters in the
format.
6) At 100% load, run the DG set for 7 hrs & check every 30 mins to see that the
engine normal operating temperature range, oil pressure drop are not exceeded.
7) Add 10% over load & run DG set for 1 hour. Record all parameter every 15 mins.
8) Remove rated load & allow the DG set to stabilize for 5 mins
9) Check the set for oil leak, coolant leak & any loose items.
10) Shutdown the DG set
11) Disconnect temporary load cables;es.

With 100% rated load, Operate DC, set for 7 hours continuously & without
interruption at 50 deg C ambient, taking readings at every 30 mins & record
following.

1) Time of Reading
2) Running Time
3) Ambient Temp in Deg C
4) Lube Oil pressure in k Pa
5) Lube Oil temperature in Deg C
6) Engine coolant temperature in Deg C
7) Exhaust stack temperature in Deg C
8) Alternator voltage, phase 1, 2 & 3
9) Alternator current phase 1, 2 & 3
10) Power in kW
11) Frequency in Hz
12) Power Factor
13) Battery charger current in A
14) Battery voltage
15) Alternator starter temperature in Deg C

At the end of 7 hours run increase the load to 110% of the rated value & take
readings every 15 mins during 1 hour of operation.

Before commissioning 8 hours run, decrease following shut down device & alarm.

1) High engine temperature

2) Low lube oil pressure
3) Short circuit
4) Alternator over voltage
5) Low Battery voltage, no battery voltage
6) Manual remote emergency stop
7) Reverse power
8) High lube oil temperature
9) Alternator low voltage
10) High winding temperature alarm
11) Radiator low water level.

Next install continuous strip chart recorders to record frequency & voltage variation
during load switching procedures with strip chart 1.3mm/s

No load to 80% load to no load

No load to 70% load to no load
No load to 20% load to no load
20% load to 40% load to no load
40% load to 60% load to no load
60% load to 80% load to no load.

Generator control panel shall be tested as follows for each section.

1) High Pot Test

2) Operation Checks of meters, Instruments & relays under service tests by
impressing properly phased current & voltage
3) Operation of breaker control, sequence & interlocking circuits
4) Operation of pane;l in conjunction with Generator set to demonstrate proper
operation as a system.