Mahindra & Mahindra Ltd.

Mahindra Powerol International Business

Check sheet - Installation and Commissioning

Distributor : Country Location :
Report No Site ID : Commissioning date: Hours:
Customer Name Location: Ground / Roof Top Segment :

Floor no. for roof top: Hospital / Hotel / Education / Real Estate / Textile /
Address :
Pharma / Chemical / Manufacturing / Process Ind / Bank
District: State / Province : Site Distance from Distributor / IT / Rental / Retail / Govt Sector / Telecom / other
mail id, contact Office in KM
DG Sr. No kVA / kW Single / Three Phase:
Engine Sr. No.: Engine Model: Avg. Running hour per day
Alternator Make: Alternator Frame: Alternator Sr. No.:
Panel Type:
Panel Sr. No. External ATS is used / not used
AMF / Manual / Synchronizing
Controller Make & Model: Controller Sr. No.: Controller Software Version:
DG Details
ECU Sr. No. ECU Software Version:
Fuel Pump Sr. No.:
(In case of CRDi engines only) (In case of CRDi engines only)
Fuel Pump Make: Fuel Pump Code: Battery Make
Starter Motor Make: Starter Motor Sr. No.: Battery AH rating
Charging Alternator Make: Charging Alternator Sr. No Battery Sr. No. (Battery 1)
Radiator Make: Radiator Sr. No Battery Sr. No. (Battery 2)

Critical Paramaters and Check points to capture during installation and commissioning
Sr No. Check points Ok / Not Ok Action Taken / Remarks
Levelling & Surface - Concerting (PCC)
1 Leveling foundation & Finishing.
Finishing
Recommended - Min. 04 nos earth pits from 82.5 to 500 kVA & Nos. of
Min 02 nos from 2.5 to 62.5 kVA Earthing Pits:
Earthing Resistance : (Value - less than 5 ohm for neutral and less than 1 ohm Earth
2 Earthing for body erthing). Proper earthing connections) Resistance :
Earthing Strip Size :
Earthing pits & earthing strip (refer Owner's Manual)
Copper / GI
Ensure Earthing on Engine / alternator / Control Panel / Radiator Body
Cable Size:
Power Cable size & cable Cable sizing as per kVA rating (refer Owner's Manual)
Copper / Alluminium
routing
3 Ensure use of Appropriate Glands
Ensure cable routing - not touching with any hot component / should not be
Control cable
under stress / not sharp bend or twisted
Suffiecient space for air
Check for sufficient space ( minimum 1 mtr from each side ) all around
4 ventilation & Service
enclosure for proper air ventilation & Maintenance. ( Photographs )
Accessibility
Refer Owner's Manual for proper dimensions Pipe Size:
Limit no. of bends to 3 or 4 maximum and avoid sharp bends Nos. of Bends:
Exhaust pipe connections and Piping to be supported with proper clamps No. of Bends :
5 To avoid rain water the tail pipe outlet should be 45 deg opening at the down
extension if required
side
Cladding on the silencer and the exhaust pipe is mandatory on all the
generators - 180 kVA and above
Check for External Damages / any other abnormilites
Check for Internal Damages / any other abnormilities
Overall conditon of Generator / Check Tightness of all mountings - Engine / alternator / radiator / silencer /
6 panel
Engine ( Photographs )
Check Condition of Engine & Alternator coupling
Check Canopy Doors for Proper Alignment, Rubber Gasket, Hinges & Locks
functioning.
Wiring harness - check and ensure tightness of terminals, proper crimping of
lugs and no loose connection.
Fuel tank - check breather condition & sealing of fuel sensor gasket to
7 General checkpoints
prevent external water entry. Tightness of inlet, outlet pipe connections to
fuel unit.
Check and ensure functioning of fuel sensor and float operation.
Check conditions of Fuel System hoses, gaskets & tigtheness for same.
Check Condition of air system hoses, Air Cleaner Assembly & vacuum
indicator
Check Exhaust Bellow alignment
Check proper assembly of Exhaust pipe (being supplied in loose in canopy)
Check Conditions of lube oil System hoses, gaskets & its tigtheness
Check Lube oil level & condition in the engine (Should be on "H" Mark).
8 Engine Checkpoints Check for any leakage on the engine, fuel tank or connections.
Check Breather pipe is routed properly outside canopy, No sharp bend
Check hoses condition & tighness of the clamps of Cooling System.
Check Radiator Condition for any External Damages.
Check Coolant level in the radiator (Full) and Recovery Bottle (High)
Check Radiator Pressure Cap is Tightened Properly.
Check Belt Condition and Tightness.
Check functioning of charging alternator Charging Volt (VDC) :
 Sr No. Check points Ok / Not Ok Action Taken / Remarks
Check tightness of terminal connections in alternator terminal box
9 Alternator Checkpoints
Ensure no sharp bend on the power cables going from alternator.
Check tightness of electrical connections, Controller terminal connections

Control Panel Checkpoints and Check all Fuse and MCB and contactors are ok and functioning
10
controller setting Check Battery charger functioning ok (if applicable)

Check Functioning of engine and alternator parameters on the controller

DG battery condition (Damage / Leakage / Specific Gravity /Electrolyte level )

11 DG Battery Check battery terminal connections are tight

Check Battery Voltage :
Cranking Volt (VDC):
Check DG Operation in Auto & Manual (Starting and Stopping)
(In case of AMF, changeover from Mains to DG and Vice Versa)
Check Operation of Remote Start / Stop operation (if applicable)
12 Operation checkpoints
Visual Check for Vibration and Abnormal Sound.
Check DG Saftety Operation - tripping with Engine Protection (LLOP, HWT,
RWL).
Load available % with respect to DG capacity (any future expansion in load)

13 Load on DG Sudden load in Amps (if any)

Thyristor load / non linear load (if any)
Unbalance load not more than 20%
Training on Operation & Maintenance of the DG
Explain warranty policy and do's & don'ts
Customer training on Operation Document Folder - check & ensure availability of test certificates, wiring
14
and Maintenance diagram, alternator manual & Keys. And hand over to customer.
Explain use of Genuine Filters / spares / recommended oil and coolant
Maintain Service record / log book on generator operations
Ensure that Exhaust bellow and silencer bolts are tight /
check for any exhaust leakages
Ensure Exhaust flange mounting is tight /
check for any leakage from the sealing gasket
Ensure oil cooler hose connections and clamps are tight and no coolant
leakage (30/40/50 kVA) (Photographs required)
Additional Check Points for
15 Ensure NRV Oil drain is working ok and there is no oil leakage
Telecom DG's
Ensure Murphy unit (Oil level Regulator) connections are tight / check for
leakages
Check distance between Radiator fan & cowl
Ensure Fuel Feed Pump is working correctly
Check RS485 communication / check slave ID (as per requirement)

Important Photos to Capture for Installation record

1) Installation Photographs from all the sides - Covering Foundation / cabeling / Power cable connections / earting - to be shared with Mahindra before the commissioning
2) Photos of - DG serial no. / Engine Serial no. / Alternator Serial no. / Controller & Control panel serial No. / radiator serial no / battery
3) Photos of controller terminal connectionis / Control Panel Inside view

DG PERFORMANCE PARAMETERS Any Other Work Done / Recommendation :-

Engine Oil Pressure on load RPM Bar
Engine Coolant temp on load RPM Degree Celsius
No Load Engine RPM RPM
No Load O/P Voltage VAC
No Load Alternator Excitation Voltage VDC Customer Remarks
On load Engine RPM RPM
On load Voltage VAC
Load Current - R/Y/B Amps
Frequency on Load Hz
Power Factor Lag / Lead Customer Feedback
Killo-Watt KW

Customer Name, contact no., Seal &

Distributor Service Eng. Name, No. & Sign
Sign (Mandatory)
Distributor Service Contact Details : FORMAT NO. 717/F/14/2/Rev-02