Applications requirements – Liquid cooled generator sets

Generator set start-up checklist Coolant heater operational …

Leak check …
Open & enclosed generator sets
DCA dosing cartridges fitted & valves open …
This checklist should be used to validate the completion of
generator set start-up procedure. A check-list should be Remote mounted radiator systems
completed for each generator set of a multiple installation. Radiator, engine & pipework checked for leaks …
Project Details Coolant heater operational …
Project Name ...………………………………………………… Fans, pumps and controls checked …
………………………………………...…….…………………… Leak check …
Customer (End User).…………………………………..……... DCA dosing cartridges fitted & valves open …
Heat exchanger & cooling tower systems
…………………..………………………………………………..
System, engine & pipework checked for leaks …
Address……… …………………...…………………………….
Coolant heater operational …
……………………………………………………………………
Secondary cooling system checked …
…………………..……………………………………………….
Fans, pumps and controls checked …
Customer representative…………………..…………………..
DCA dosing cartridges fitted & valves open …
Tel. No ………………………..…………………………………
Legionnella dosing checked where applicable …
Email……………………………………………………………. Record dosing chemical & concentration.............................

Generator set details Diesel Fuel System

Generator set model………………….……………………….. Bulk storage facility
Generator set serial number………………….Set no………. Isolating valves correctly positioned …
Control type……………………………………………………... Transfer pump & controls operational …
Control serial number………………………………………….. Pipeline / tank heating system operational …
System control type (if applicable)…………………………… Fill point alarm operational …
Leaks check …
Generator set environment and services Storage facility secure …
Precommissioning work & checklist complete … Day tank
Surroundings clean & clear from obstruction … Isolating and solenoid valves checked …
Lighting / heating, etc., systems operational … Tank filled …
Observations………………………………………………….... Spillage containment & alarms operational …
…………………………………………………………………… Transfer pump operational …
Leak check …
Safety Checks Fire valves & release tested and operational …
Ensure starting is inhibited until start-up is required …
Set clean and fully assembled … Gas Fuel System
No loose materials near set … Isolating valves correctly positioned …
Air ducts clear and clean … Regulator set to correct pressure …
Access & egress routes unobstructed & labelled … Gas leak detection equipment operational …
Control & maintenance positions unobstructed … Double shut-off device operational …
Room secure – no unauthorised access … Leak test complete …
Personnel warned of start-up process … Purging complete …

Cooling System Fire alarm / suppression system

Set mounted radiator Fire alarm / suppression system operational …
Radiator, engine & pipework checked for leaks … Suppression system lock-off operational …
Belts & guards checked for security / slipping … Operator instructed in fire system operation …

Document Number: PGK FCD 04-0184 1 Start-up checklist V1.0

© 2004 Cummins Power Generation Ltd
 Applications requirements – Liquid cooled generator sets

Lubrication system Generator set voltage & frequency correct to order…

Engine oil pan filled to correct level … Control system calibrations checked …
Oil make up system operational … Phase rotation checked …
Paralleling sets phase coincidence check …
Starting system Generator set switchgear manual operation correct …
Battery starting Local stop / emergency stop control checked …
Batteries installed, filled and connected … Remote start / stop / emergency stop checked …
Battery charger commissioned …
Compressed air / hydraulic starting Generator set load test
Isolating valves correctly positioned … Note: Load test is carried out on customer’s site load
unless agreed in writing prior to start-up. Artificial load
Compressor operational … bank test will be performed using resistive load unless
HP & LP air / hydraulic pressures checked … otherwise specified.
Condensate drained … Load test completed using customer’s load …
Record load achieved……………………………………kW
Exhaust system Load bank test (if applicable)
Check security of pipework & muffler … Check load bank voltage & power capability …
Check cowl and/or rain cap are operational … Check cables installed correctly & tightened …
Check water drain pipework and valves correct … Energise auxiliary supplies and check functionality …
Leak check … Load test completed …
Check for exhaust gas recirculation … Result sheet completed …
Record load achieved……………………………………kW
Record power factor……………………………………………
Ventilation & attenuation
Check louvers are clear and operational …
System start-up completion
Forced ventilation system operational if applicable …
Generator set operational …
Check for hot air recirculation …
Changeover / transfer switch operational …
Paralleling switchgear operational …
Electrical system
Automatic operations checked …
Control systems
Master control operational …
Auxiliary supplies energised …
All safety shutdowns and warnings operational …
Generator set local controls checked …
Generator set remote controls checked … Electrical HV/MV/LV rules and procedures in place …
Generator set system controls checked … Comments on any item that may affect acceptance:
Customer remote indication / controls checked … ……………………………………………………………………
Changeover switchgear / transfer switch ……………………………………………………………………
Auxiliary supplies energised … ……………………………………………………………………
Utility supply energised … ……………………………………………………………………
Voltage / phase rotation checked … ……………………………………………………………………
Indications correct … ……………………………………………………………………
All covers in position … ……………………………………………………………………
Paralleling switchgear ……………………………………………………………………
Auxiliary supplies energised …
Indications correct … Checklist completed by ……………………………………….
All covers in position … Date……………………………………………………………...
Print Name………………………………………………………
Initial start-up Company………………………………………………………..
Manual start-up, idle & full speed checks complete … Note: Completion of this checklist does not relieve the installer of contract obligations.

Document Number: PGK FCD 04-0184 2 Start-up checklist V1.0

© 2004 Cummins Power Generation Ltd