Testing and Commissioning Procedure

of
FG Wilson Diesel Genset

Part 1 : Details of Project

1.1. Project title (with locati : PENGADAAN TEST UNIT FIELD SUBANG

1.2. Project No. : 002.GPS.I.15

1.3. Client : PT. BAHANA KARYA MANDIRI

1.4. Genset Model : P33-3

Part 2 : Items Inspected and Tested

Item Items
tested/check witnessed by
ed by GPS Customer

2.1. Daily service fuel tank

2.1.1. The daily service fuel tank has been fabricated and welded in *Yes/No *Yes/No
accordance with the specifications and drawings.

2.1.2. The pipework & socket connections (for filling, overflow, drainage, *Yes/No *Yes/No
return and
vent) have been properly installed at the fuel tank in accordance
with the
specifications and drawings.
2.1.3. One quick closing valve has been installed properly with all *Yes/No *Yes/No
necessary linkage for
operation from outside the building.
2.1.4. The fuel tank has been fitted with an approved content gauge unit *Yes/No *Yes/No
and level
sensing equipment.
2.1.5. The fuel tank has been subjected to hydraulic test to a pressure as *Yes/No *Yes/No
specified and
the results are satisfactory.

2.2. Visual inspection

2.2.1. The Generating Set has been properly fixed on a common steel *Yes/No *Yes/No
section base
frame.
2.2.2. Protection screen has been provided on all moving parts. *Yes/No *Yes/No

2.2.3. Protection guard has been provided on hot exhaust. *Yes/No *Yes/No

2.2.4. The fresh-water-cooled radiator has been properly fixed and there is *Yes/No *Yes/No
no water
leakage.
2.2.5. The radiator cooling fins and water tank are in good condition and pro *Yes/No *Yes/No

2.2.6. The water circulation pump with thermostatically controlled *Yes/No *Yes/No
temperature
regulator has been properly fixed.
2.2.7. The engine mounted instrument panel has been fixed properly and *Yes/No *Yes/No
c/w
lubrication oil temp. and cooling temp. gauges, tachometer and hour
meter.
2.2.8. The lubrication oil system with replaceable element types filter has *Yes/No *Yes/No
been properly
fixed.
2.2.9. The fuel oil system c/w filter, fuel transfer pumps has been properly *Yes/No *Yes/No
installed.
2.2.10. The fuel control solenoid c/w emergency shut off valve has been *Yes/No *Yes/No
provided and
properly installed.
2.2.11. The tubular exhaust silencer has been properly installed. *Yes/No *Yes/No

2.2.12 For remote radiator, if applicable, c/w break tank booster pump, heat *Yes/No *Yes/No
exchanger
etc. has been properly installed.
2.2.13. The enclosure to the alternator satisfy IP21 or as specified. *Yes/No *Yes/No

2.2.14. Anti-condensate heater for the alternator has been provided and *Yes/No *Yes/No
proper fixed.
2.2.15. Where specified, facilities for generation at 380/220V have been *Yes/No *Yes/No
provided. *
2.2.16. Starting batteries have been provided and properly installed. *Yes/No *Yes/No

2.3. Pre-commissioning inspection

2.3.1. Diesel engine

2.3.1.1. Radiator water is at right level. *Yes/No *Yes/No

2.3.1.2. Lubrication oil is at right level and with replaceable filter. *Yes/No *Yes/No

2.3.1.3. The engine exhaust has been properly fixed and covered with *Yes/No *Yes/No
asbestos-fee
insulation.
2.3.1.4. The engine anti-vibration mounting is effective. *Yes/No *Yes/No

2.3.1.5. Proper replaceable air filter has been installed. *Yes/No *Yes/No

Effective and adequate earth bonding have been provided for the *Yes/No *Yes/No
2.3.1.6. engine and
alternator.
2.3.2. Alternator

2.3.2.1. Batteries electrolyte is at right level. *Yes/No *Yes/No

2.3.2.2. Batteries output voltage is as specified. *Yes/No *Yes/No

2.3.2.3. The alternator output terminal is at correct phase sequence. *Yes/No *Yes/No

2.3.3. Control Cubicle

2.3.3.1. Permanent labels have been provided for all accessories *Yes/No *Yes/No

2.3.3.2. All control wirings are fitted with ferrules. *Yes/No *Yes/No

2.3.3.3. The following devices are provided in the control cubicle:

a) Voltmeter & selector switch *Yes/No *Yes/No

b) Ammeter & selector switch *Yes/No *Yes/No

c) Frequency meter *Yes/No *Yes/No

d) Wattmeter *Yes/No *Yes/No

e) Auto/off/manual selector switch *Yes/No *Yes/No

f) Start/stop push button *Yes/No *Yes/No

g) “Simulate main failure” key switch *Yes/No *Yes/No

h) “On-off” switch for generator anti-condensation element *Yes/No *Yes/No

i) Automatic 2 rate battery charging equipment c/w charging rat *Yes/No *Yes/No

2.3.3.4. Indicating lamp & reset button for:

a) Engine fault *Yes/No *Yes/No

 b) Failure to start *Yes/No *Yes/No

c) Generator supply available *Yes/No *Yes/No

2.3.3.5. Indication lamp for:

a) Mains available *Yes/No *Yes/No

b) Generator on load *Yes/No *Yes/No

c) Load supplied from mains *Yes/No *Yes/No

d) 7.5 hours fuel capacity *Yes/No *Yes/No

e) 6.5 hours fuel capacity *Yes/No *Yes/No

f) Low battery voltage *Yes/No *Yes/No

2.3.3.6. Generator output under voltage & over voltage protection devices *Yes/No *Yes/No

2.3.3.7. Approved type 4-pole withdraw-able air circuit breaker or 4 pole *Yes/No *Yes/No
MCCB c/w
overload & short cot. Protection
2.3.3.8. Mechanically & electrically interlocked 4-pole contactor for *Yes/No *Yes/No
automatic load
transfer & 4-pole manual by-pass

2.4. Comments :

Part 3 : Test Record attached to the Test Certificate

3.1. Equipment Details

3.1.1. Generating Set

a) Manufacturer : FG WILSON
b) Model : P33-3
c) Serial No. : FGWPEP37VJSA01828
d) Net Prime Rating : 30 KVA

3.1.2. Diesel Engine

 a) Make : PERKINS
b) Model : 1103A-33G1
c) Serial No. :
d) Rated Power (kW) : 28.2
e) Speed (rpm) : 1500
f) Governor : MECHANICAL
g) Turbocharger (type/model) : NOT EQUIPPED

3.1.3. Alternator

a) Make : LEROY SOMER

b) Model : LL1514F
c) Serial No. :
d) Rated kVA : 33
e) Voltage (V) : 400 / 230
f) Phase / Rated p.f. : 3 / 0.8
g) Insulation class : H

3.1.4. Starting Battery

a) Manufacturer :
b) Make / Model No. :
c) No. of battery / Voltage (V) :
d) Ampere hour :
e) Starting time (sec) :

3.1.5. Other Accessories

a) Name plate of manual bypass switch:

b) Name plate of auto-changeover swit:

3.2. Type of Control

Automatic/Manual
Starting
Automatic/Manual
Loading Transfer to Generating Set
Automatic/Manual
Stopping
Automatic/Manual
Load Transfer to Mains

3.3. Insulation Resistance Test (Temporarily open alternator star point)

1. Brown phase (L1) to earth Megaohm

2. Black phase (L2) to earth Megaohm

3. Grey phase (L3) to earth Megaohm

4. Brown phase (L1) to Black phase (L2) Megaohm

5. Black phase (L2) to Grey phase (L3) Megaohm

6. Grey phase (L3) to Brown phase (L1) Megaohm

Control Function Test Function Test Setting Remarks

1. Starting Manual
Simulate Test 1*
Mains Failure Test 2**
Delay Start Timer
Delay Repeat Start

2. Stopping Manual
Resumption of Mains***
Delay Stop Timer****
3. Engine Overload trip (MCCB)
Protection Engine HL
Overspeed LL
Lube Oil HL
Pressure (kPA) LL
High Water HL
Temperature LL
Under Voltage Trip
Over Voltager Trip
Underfrequency (Hz)
Response Time from
4. Others Mains Failure to
Changeover (sec)
Battery 3 Attemp Start
Quick Closing Mechanism
Governor Function
Voltage Regulator (346
V - 380 V)
Auto-starting of Vent Fan
Manual Override Facilities
Phase Sequence of
Alternator Output
Frequency Setting
Step-load Acceptance Test
Notes : * Refer to function test on capability to start and transfer load Generating Set automatically
** Refer to function test on capability to start but without load transfer if mains resume during engine starting.
*** Refer to function test on capability to automaic transfer load back to mains automatically
after a preset time delay and immediately back to generator if mains fails within the above
**** time
Referdelay period.test on capability to cool engine for a preset period after load is transferred to mains.
to function

Tested / Checked by : Signature : Post. :

Date :
( ) Telp. :
Witnessed by : Signature : Post. :
Date :
( ) Telp. :