Section (7)

SECTION (7)
TEST ON COMPLETION AT SITE
CONTENT
7.RELIABILITY TESTS ...................................................................................................... 171
7.1Efficiency Tests ............................................................................................................ 171
7.2RE-TESTING: .............................................................................................................. 172
7.3ADJUSTMENT OF PLANT: ....................................................................................... 172
7.4PERFORMANCE TEST .............................................................................................. 172
7.5GOVERNING TESTS ETC. ........................................................................................ 172
7.6REJECTION OF PLANT: ............................................................................................ 172
7.7TEST RESULTS AT END OF GUARANTEE PERIOD ............................................ 173
7.8POWER STATION CRANE: ...................................................................................... 173
7.9Test On Completion at Site .......................................................................................... 173
7.9.1Mechanical: ........................................................................................................ 173
7.9.2Electrical ............................................................................................................. 174
7.9.2.1Generator : .................................................................................................... 174
7.9.2.2Generator control panel (GCP). ..................................................................... 174
7.9.2.3Common control panel (CCP) ...................................................................... 174
7.9.2.4Engine auxiliary drive panel (EA) ................................................................. 174
7.9.2.5Protection Relays. .......................................................................................... 174
7.9.2.6Transformer test. ........................................................................................... 174
7.9.2.7 11KV busbar................................................................................................. 174
7.9.2.8Current transformer: ..................................................................................... 174
7.9.2.9Voltage transformer Test. .............................................................................. 174
7.9.2.1024V battery charger test............................................................................... 174
7.9.2.11 11KV switchgear test. ................................................................................ 174
7.9.2.12Cable test (High pressure & Continuity test)............................................... 174
7.9.2.13Motor test (by meager) & Load test. ........................................................... 174
7.9.2.14Over speed test. ........................................................................................... 174

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 Section (7)

7. RELIABILITY TESTS
When the contractor has notified the purchaser / Engineer that the plant at the site is
ready for commercial service, The set and all its auxiliaries will be requited to operate
under the working conditions of the station, within the limits of the output specified,
either continuously or intermittently as may be more convenient for the work of the
station, without failure or interruption of any kind for a period or thirty days.
The plant will be operated by the station staff during the reliability test period but the
Contractor will be allowed to make any minor adjustments which may be necessary
provided such adjustments do not In any way interfere with or prevent the commercial
use of the plant by the purchaser or result in reducing the out put or decreasing the
efficiency.
Should any failure or interruption occur in any portion of the plant, due to or arising
from faulty design, materials or workmanship, or due to omission or incorrect erection
but not otherwise, sufficient to prevent the full commercial use of the plant during the
reliability period, then the period will be cancelled and a new reliability period of
thirty days shall commence' after the Contractor has remedied the cause of the defect.
For the purpose of this Clause. The plant shall be sub-divided as follows:
¾ Engine ac generator set and auxiliaries.
¾ Switchgear.
¾ Cabling.
¾ Transformer.
The onus of proving that any defect is due to causes other than those referred to in the
preceding paragraph will lie with the Contractor.
Since the efficiency test is normally performed subsequent to the reliability test
period, the professional acceptance certificate will be issued on the satisfactory
completion of the efficiency test. The issuing of any of this responsibilities in respect
of the proving of the efficiency guarantees nor percent the purchaser from seeking any
of the remedies failing to be proved. The professional Acceptance Certificate shall be
dated to the completion date of the successful reliability period and this shall be the
date from which the twelve month guarantee will operate.

7.1 Efficiency Tests

On the satisfactory completion of the reliability test of the diesel alternator at site the
Contractor shall, within a reasonable time, notify the engineer that the efficiency test
maybe carried out. The efficiency test carried out by Contractor, and witnessed the
purchaser / Engineer.
The instruments used will be those provided with the plant but in addition certain
check instruments to be agreed with the purchaser / Engineer shall also be provided
by the – Contractor.
These check instruments will cover the main quantities to be measured continuously
over the test period but in addition sufficient instruments shall be provided to.
Enable, by spot tests taken at intervals, the reasonable accuracy of all the working
instruments provided to be ascertained.

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 Section (7)

A certified calibration curve shall be provided for each check Instrument and in
particular this must apply to the check instruments which are to be provided to
measure the kwn generated and the fuel and lub. oil consumed. The Contract includes
for the Provision of any recalibration certificate which may be required by the
purchaser/ Engineer to be taken before the tests.

7.2 RE-TESTING:
Should the plant or any portion thereof fail under these tests to give the performance
required. Then any further tests which may be considered necessary by the purchaser/
Engineer may be carried out in a similar manner but the whole cost of the repeated
test shall be borne by the contractor, except that if the retesting is carried out on the
normal commercial load of the station then the fuel, water and lubricating oil used and
the normal operating staff shall be supplied free by the purchaser.
7.3 ADJUSTMENT OF PLANT:
When the plant is completely erected and before the official tests are made, the
Contractor will be given, if desired by him, seven days within which to carry out any
preliminary test and to make any necessary adjustments..
The setting of clearances and all other adjustments provided for the tests shall be the
normal working adjustments and shall be retained without alteration for the full
reliability period.
7.4 PERFORMANCE TEST
The tests on completion, which shall be carried out as described under will include
fuel consumption and electrical tests, together with any other test which the Engineer
may require in order to determine that the plant is in accordance with the
Specification and guarantee.

LOAD% 25 50 75 100 110

OPERATION HOURS 1/2 1/2 1/2 8 1

The load to be used for fuel consumption and temperature rise tests will be the
ordinary load of the station.

7.5 GOVERNING TESTS ETC.

The addition to the above mentioned tests, governor tests, paralleling tests, quick
starting and stopping tests, switching full load off, and such other mechanical and
electrical tests will be made as may be considered necessary by the Engineer to ensure
that the plant complies with the Specification.

7.6 REJECTION OF PLANT:

If the guaranteed figures are exceeded by 2.5% in the case of fuel consumption or by
5 Co in the case of the alternator temperature rise at maximum continuous rating and
the contractor within reasonable time to remedy such excesses, the purchaser shall
have the right to reject the whole of the plant.

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 Section (7)

7.7 TEST RESULTS AT END OF GUARANTEE PERIOD

At the option of the purchaser the efficiency tests may be repeated and the results
obtained immediately after the twelve months guarantee period has expired shall be
within 1% of the results given by the approved official tests on completion.

7.8 POWER STATION CRANE:

The contractor must make his arrangement for provision of testing of crane at site.
The crane shall be fully tested at the works at site, to BS. 466 and witnessed by the
engineer.

7.9 Test On Completion at Site

7.9.1 Mechanical:

Engine auxiliaries Tests:-

Test of alarm and trip settings
Setting test of main bearing temperature
Setting Test for exhaust gas temperature
Settings Test for level switches.
a)LO. Sump tank
b) Fuel daily tank
c) Expansion tanks HT, & LT.
d) Leak oil tank.
Crank, web deflection – engine (Hot)
Crank, web deflection – engine (Cold)
Crank web breathing alignment (after alignment of air gap - Generator).
Gap measurement.
Vibration level test.
Noise level test.
Site load test.
Exhaust gas resistance test.
Intake air resistance test.
Crankcase mist pressure test.
Separator Commissioning Test
Combined preheating aggregate for water and oil Commissioning test piping
hydraulic test.
Load injection test.
Load rejection test.
Crane test at site (5 Ton)
Over speed test.

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 Section (7)

7.9.2 Electrical
7.9.2.1Generator :
Generator test general check.
Generator air gap test.

7.9.2.2Generator control panel (GCP).

Protection function (Alarm and Trip function) according to the type of equipment
(injection or other)
7.9.2.3Common control panel (CCP)¬
7.9.2.4Engine auxiliary drive panel (EA)
7.9.2.5Protection Relays.
Generator protection:
Differential protection.
Negative phase sequence.
Over current ANSI (51) and short circuit ANSI (50)
Earth fault voltage indicated (ANSI code (46) & earth fault current).
Exciter over / under current ANSI (40)
Over / under voltage
7.9.2.6Transformer test.
Earth fault, Over current, short circuit protection, buchloz, temp. rise……etc.
7.9.2.7 11KV busbar.
High voltage and current test.
7.9.2.8Current transformer:
Ratio and directional test & primary injection
7.9.2.9Voltage transformer Test.
7.9.2.10 24V battery charger test.
7.9.2.11 11KV switchgear test.
7.9.2.12 Cable test (High pressure & Continuity test)
7.9.2.13 Motor test (by meager) & Load test.
7.9.2.14 Over speed test.

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