Testing Amp Commissioning Procedure Generator
Testing Amp Commissioning Procedure Generator
:
CL35-130-PRO-EL-SWI-001
PROCEDURE
Rev. No.: 00
20. Be very careful while using certain test equipment such as insulation resistance test sets and
charging, discharging test sets. If a cable is being tested, ensure that the other end has been secured,
and that a responsible person has been stationed there.
21. Apply LOTO to relevant Feeders/Sections at the time of testing and charging (power up trial) in
presence of HSSE department authorized person.
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TESTING & COMMISSIONING Document No.:
CL35-130-PRO-EL-SWI-001
PROCEDURE
Rev. No.: 00
a General Checks
b Operational and functional checks
c Battery Voltage measurement Test
d DG operational interlock/auto changeover test with LVAC/LT panel
Electronic Governor
• The low idle speed, rated speed, start fuel limit and ramp time shall be measured & recorded against
setting value
• The actuator compensation, gain, reset, droop, load gain and overspeed settings shall be recorded
against the setting value. All setting values shall be as per manufacturer’s guidelines
• The system shall be filled with portable water with rust inhibitor & the air shall be purged.
• The water level shall be checked and any leakage in the system shall be checked.
• The engine shall be run at no load & the circuit shall be checked for any leakage.
• The operation of the low coolant level sensor shall be checked as per manufacturers guidelines
• The jacket water temperature high alarm and shut down simulation shall be checked as per
manufacturers guidelines.
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TESTING & COMMISSIONING Document No.:
CL35-130-PRO-EL-SWI-001
PROCEDURE
Rev. No.: 00
• Fuel oil system with fire valve,2port, motorized valve, pressure switch &level sensor shall be
checked for proper installation with alignment.
• The tank shall be filled & the system shall be checked for leakage.
• In case of a leak, the leak will be detected by a drip tray mounted float switch which shall be
connected to sound alarm.
• The engine shall be run at no load & the circuit shall be checked for any leakage.
• The fuel oil high level and low-level alarm switch shall be checked
• The fuel oil high level and low-level pump stop switch shall be checked.
• The system shall be filled with the oil recommended by the manufacture.
• The oil level shall be checked & it shall be ensured that there are no leaks in sump & drain.
• The engine shall be started & the oil pressure shall be observed as per manufacturers guidelines.
• The engine shall be stopped & the oil level shall be checked again.
• The lube oil high temperature alarm and shut down shall be checked as per manufacturers
guidelines
• The lube oil low pressure alarm & shut down shall be checked.
Equipment Required
• 415 Volt PLC based resistive load bank at Unity power factor.
The load test on the generator shall be carried out @ following loads and durations
Following parameters need to be note down while performing load test at every load condition and
duration
Speed in RPM, Load in KW, Current in AMPS, Voltage, Frequency (Hz), Fuel consumption, Lube oil pressure,
Water temperature, Speed in RPM and Battery Voltage, Vibration
• During simulation test check that the appropriate annunciation windows/alarm LEDs in the
generator sensing panel illuminated.
• Check ON & OFF function of the generator from the sensing panel by simulation
• Check the OFF function of the generator by the emergency stop push button.
• Check crank cooling time for initial start-up of generator before starting as per setting or not.
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TESTING & COMMISSIONING Document No.:
CL35-130-PRO-EL-SWI-001
PROCEDURE
Rev. No.: 00
• Check the voltage availability in the line side of the ATS. If the voltage is available, the changeover
switch remains unchanged.
• When the voltage is not available in the line side, check for signal from the ATS to the generator
sensing panel to start generator
• Once the generator full voltage is available at the ATS emergency terminals, check the ATS change
over to generator supply.
Interface test
• Prior to auto operation test, it will be checked that all power and control interconnection between
generator and ATS panel are done and ATS is ready to energize.
• For automatic operation set selector switch should be auto position, mains fail to be simulated at
ATS panel, in turn ATS will initiate start/run command (close contact) generator will start with a
delay of 2-3 seconds and will accept load within 10 seconds. Upon removal of start/run command
(open contact) generator will cool down for 3-5 minutes will come to rest and will be ready for next
command.
Check battery voltage before connecting to ATS in Voc and check polarity for same at ATS input terminal
• This procedure checks the Electrical Operation of Automatic Transfer Switch Operation form grid to
Emergency Diesel Generator.
• Be sure to close enclose door before proceeding to prevent personal injury in case of electrical
system fault.
• The ATS (Automatic transfer switch) should still be bypassed.
• Both normal and emergency sources must be available, and the emergency source generator must
be capable of being started.
• Put generator starting control in automatic position the transfer switch connected to normal light
and the Normal source accepted light should be on
• Turn the Normal source handle Off position. The transfer switch connected from Normal Source to
Emergency generator source. And same time send start comment to Emergency generator
• The emergency source accepted lights blink until the generator starts and runs.
• The emergency source accepted lights should come on After Generator Turn on and normal
Operation
• Transfer switch will operate to the emergency light should come ON and the transfer switch Normal
light goes off
• Now Turn on the Normal source, The Transfer switch sense the voltage from Normal source
• The transfer switch change from Emergency source to Normal source.
• Transfer switch emergency light should go off
• The generator will stop after some time delay (unloaded running engine cool down) The emergency
source accepted light should go off.
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TESTING & COMMISSIONING Document No.:
CL35-130-PRO-EL-SWI-001
PROCEDURE
Rev. No.: 00
SCOPE
This procedure covers the Pre commissioning Test for Battery bank unit and float cum boost charger which
is getting AC source LT AC main switchboard.
PURPOSE
This procedure is prepared to define the step-by-step method to implement the correct practices for the
pre-Commissioning & commissioning of battery bank system through the guidelines contained herein so as
to ensure that the job execution complies with the project requirements and serves the intended function
to satisfactory level
11. HSSE Team will require inspecting items of commissioning & technical personnel’s paperwork
relating to health and safety.
12. HSSE Supervisor must be present at site verifying all the activities.
13. Ensure to operate with permit-to-work system
14. Always consider equipment energized if not grounded.
15. Remove your watch and any rings or metallic ornaments that you might be wearing before testing
on battery terminals.
16. Emergency response procedures should be in place before the commencement of any
commissioning activity and before the introduction of any fissile material into the facility.
17. Whenever work is done on power circuits (AC/DC), all power sources must be isolated by opening
and withdrawing the circuit breakers. Earthing switches should be closed, or if not available, local
Earthing should be done.
18. Ensure proper grounding of the panel and testing kit is done
19. Ensure the auxiliary supply given to the relay is proper and is according to the manual.
20. Availability of tester and other tools is ensured.
21. Commissioning engineer should get familiarized with local menu control and the software of the
battery charger unit.
22. Be very careful while using certain test equipment such as insulation resistance test sets and
charging, discharging test sets. If a cable is being tested, ensure that the other end has been secured,
and that a responsible person has been stationed there.
23. Apply LOTO to relevant Feeders/Sections at the time of testing and charging (power up trial) in
presence of HSSE department authorized person.
a General Checks
b All auxiliary power cable continuity and IR test
c Operation of Charger without battery.
d Test of manual, float as well as boost mode.
e Rectifier as well as other all parameter Setting Check.
f Single Battery Voc/Polarity test and Battery bank Voc/Polarity test
g Battery bank charging and discharging test with appropriate set (at least 8 hours).
1. Ensure that the battery bank system is completely installed, and mechanical completion is
approved and all comments on the installation inspections are incorporated.
2. Ensure that no damage to whole system and properly tagged and identified.
3. Ensure that the wiring termination to the panels are complete.
4. Ensure that cables are tested for continuity & insulation resistance before termination.
5. Ensure that the earthing of the battery bank and charger unit has been completed.
6. Ensure the cables are secured well on to the connections to avoid system misbehavior due to any
loose connection.
7. Check for Charging voltage, Current and time set as per battery requirement.
8. Check for the correct Polarity of Charger and Battery terminations before switching isolator ON, in
Battery Fuse Box with the use of Digital Multimeter.
9. Check and record Open Circuit Voltage, specific gravity, and electrolyte temperature of all cells
before charging.
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TESTING & COMMISSIONING Document No.:
CL35-130-PRO-EL-SWI-001
PROCEDURE
Rev. No.: 00
10. Check and record Voltage & polarity of all battery/cells and ambient temperature for every hour of
charge.
11. Check and record Specific gravity if applicable and electrolyte temperature of pilot cell for every
hour of charge.
12. Check all other parameters are set as per OEM recommendation or not.
OBJECTIVE
To find out the cable insulation by testing its IR limit in order to avoid system fault with respect to polarity
or earth.
EQUIPMENT’S REQUIRED:
All the auxiliary power cable IR and continuity check can be performed with the following equipment’s,
• Insulation resistance Tester.
• Specific size of spanner.
TEST PROCEDURE
i. Check the continuity of Cable with the help of Multimeter as mentioned in cable schedule and SLD
(Aux. SLD for MCR Building) in following ways.
• Short another core with other core plus neutral and apply multimeter between the core to be tested
and other shorted core.
ii. Check the insulation resistance of Cable with the help of IR tester at 500 V to 1 KV DC (as per rating
of cable) for 1 min as mentioned in cable schedule and (Aux. SLD for MCR Building)
IR to be done for following points of connections at 500V to 1000V DC for 1 Min.
• Between Core to core (i.e. Phase to phase) short two or other cores with sheath and
shielding/armor
• Between Core to earth (i.e. phase to earth) short other two spare cores with each other and
Figure 13.1 Insulation Resistance test for AC/DC auxiliary supply power cable
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