Application Manual – Liquid Cooled Generator Sets
Generator set installation checklist Cooling System
Set mounted radiator
Open generator set installed in building
Radiator clean, free from obstruction
This checklist should be used to validate the completion of
a generator set installation, prior to commissioning. A Radiator air outlet connected to outlet duct
check-list should be completed for each generator set of a Check for possibility of hot air recirculation
multiple installation.
Access to coolant top-up clear
Project Details Engine vent pipes inclined toward radiator / header
Project Name ...………………………………………………… Pipework secure and undamaged
………………………………………...…….…………………… Overflow clear and routed to avoid spillage
Customer (End User).…………………………………..……... Remote mounted radiator systems
…………………..……………………………………………….. Header tank is of adequate size
Address of Site …………………...……………………………. Overflow is clear and routed to avoid spillage
Static/friction head is within engine/system capability
……………………………………………………………………
Engine vent pipes inclined toward radiator / header
…………………..……………………………………………….
Fuel cooler installed if required
Tel. No ………………………..…………………………………
Pipework avoids air locks – air bleed valves provided
Email…………………………………………………………….
Pipework isolated from generator set vibration
Pipework complete, cleaned, tested & painted
Generator set details Auxiliary supply to fans correctly installed
Generator set model……….………………………………….. Electrical bonding completed
Generator set serial number………………….Set no………. Heat exchanger & cooling tower systems
Control type……………………………………………………... Header tank is of adequate size
Control serial number………………………………………….. Overflow is clear and routed to avoid spillage
System control type (if applicable)…………………………… Static/friction head is within engine/system capability
Engine vent pipes inclined toward header tank
Generator set building and services Fuel cooler installed if required
Building & installation work complete
Pipework avoids air locks – air bleed valves provided
Site clean & access clear from obstruction
Pipework isolated from generator set vibration
Building services complete & commissioned
Pipework complete, cleaned, tested & painted
(lightning, lighting, electrical auxiliary supplies, water, etc.) Secondary cooling system is complete
Observations………………………………………………….... Cooling tower make up supply is complete
…………………………………………………………………… Auxiliary supply to fans correctly installed
Electrical bonding completed
Room general
Generator set clean with all guards in place
Liquid fuel system
No loose materials near to generator set
Bulk storage facility
Air ducts clear and clean
Bulk storage tank installation complete
Access & egress routes unobstructed & labelled
Bulk tank incorporates water trap
Control & maintenance positions unobstructed
Spillage containment complete
Room secure – no unauthorised access
Isolating valves correctly positioned
Generator set is level – holding down bolts secure
Tank contents gauge installed
Pipework and cables are secure with no trip hazards
Content alarm contacts fitted & wired
Overhead obstructions clearly marked and labelled
Transfer pump installed and connected
All key components are labelled
Solenoid & pre-filter between bulk & service tank
Pipework and services colour coded & labelled
Pipework correct material, cleaned tested & painted
Electrical bonding complete
Vent installed, piped to safe area and open
Electrical bonding complete
8–6 8 – CHECKLISTS
Application Manual – Liquid Cooled Generator Sets
Insulation & pipeline heating installed
Joints welded or flanges secure with correct gaskets
Fill point installed & alarm fitted
Stack/tail pipe prevents rain/snow ingress
Storage facility secure
Flues are not combined in stack
Day tank (if none, complete check for bulk supply) Condensate drain provided
Positive head at engine for critical applications
Exit directed away from buildings / personnel
Fuel inlet head/restriction within engine limits
System is lagged & clad as required
Fuel return head/restriction within engine limits
Building penetration & weathering complete & sealed
Isolating and solenoid valves fitted
Flammable materials properly protected
Check for no valves in spill return
Flexible connections to engine
Ventilation & attenuation
Connection to fill, overflow & vent lines completed
Air intake is at least 150% area of air outlet
Overflow head of fuel within tank pressure limits
Design prevents hot air recirculation & rain ingress
Tank contents gauge installed
Design accounts for prevailing wind
Contents alarm contacts fitted & wired
Air flow direction is from alternator to radiator
Electrical bonding complete
Radiator outlet is ducted to attenuator / louver
Spillage containment complete & alarms wired
Attenuator / louvers complete & sealed to building
Fire valves & contacts installed & wired
Louver mechanisms complete & wired as required
Electrical bonding completed
Gaseous fuel system Forced ventilation provided for remote cooled sets
Pipework complete, material and construction correct
Bird guard is fitted to intake & outlet
Regulator and shut off valves in correct locations
Leak test and certification complete
Electrical system
Control system
Fire alarm / suppression system
Field wiring to set mounted control complete
Fire alarm / suppression system complete
Customer wiring to set mounted control complete
Sensors protected from radiant heat
Interconnection to remote control complete
Labelling and lock off system complete
Emergency stop controls wired
Set / Switchgear / Changeover / Transfer
Starting system
Means of disconnection / isolation provided
Battery starting
Switchgear installation & pre-testing completed
Starting batteries correct & installed on tray or stand
Cables installed correctly, marked, allow movement
Battery cables routed correctly
Power connections complete & torque-marked
Battery charger installed & wired
Cable tests complete & certificates available
Compressed air / hydraulic starting Electrical general
Compressor set installed and wired
All electrical boxes clean & covers replaced
Compressed air pipework correctly rated & installed
Auxiliary electrical supply complete
Isolating valves correctly positioned & labelled
Grounding system complete & tested
Pipework tested, painted & labelled
Electrical bonding of services / assemblies complete
Correct pressure regulator & HP/LP safety valves
Utility supply available as required
Flexible connection to engine fitted
Small power & lighting circuits tested & certificated
Exhaust system
Installation design prevents exhaust recirculation
Checklist completed by ……………………………………….
Flexible connection to engine
Date……………………………………………………………...
Support prevents load on turbocharger/manifold
Print Name………………………………………………………
Installation allows for pipework expansion
Company………………………………………………………..
Pipework / muffler supported at required intervals
Note: Completion of this checklist does not relieve the installer of contract obligations.
8 – CHECKLISTS 8–7
