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