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100 586 GSX 00028 00A Performance Test Procedure EDG U331
100 586 GSX 00028 00A Performance Test Procedure EDG U331
: 26071-100-586-GSX-00028
REVISION LOG
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Doc. No. : 26071-100-586-GSX-00028
HOLD LIST
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TABLE OF CONTENTS
1 PURPOSE ........................................................................................................................................... 6
2 DEFINITION AND ABBREVIATION ............................................................................................... 6
2.1 Definition .................................................................................................................................................. 6
2.2 Abbreviation ............................................................................................................................................ 6
3 REFERENCE........................................................................................................................................ 7
4 SAFETY PRECAUTIONS ................................................................................................................... 8
4.1 General Safety Precaution ..................................................................................................................... 8
4.2 Safety Notes, Caution and Warning ................................................................................................... 9
5 GENERAL ........................................................................................................................................... 9
5.1 Testing Conditions .................................................................................................................................. 9
5.2 Instrument/Equipment Required during Test ................................................................................... 9
5.3 Pre-test Inspection ................................................................................................................................. 10
5.4 Post Work................................................................................................................................................. 11
6 FIRST START, ALARM AND SHUTDOWN TEST AND SYNCHRONIZATION TEST ............. 11
6.1 FIRST START UP ...................................................................................................................................... 11
6.1.1 MCP/DMC Energization and Generator Communication Checks ................................................................11
6.1.2 Generator First Start ..........................................................................................................................................................11
6.1.3 Acceptance Criteria ............................................................................................................................................................14
6.2 SYNCHRONIZATION TEST ..................................................................................................................... 14
6.2.1 Pre-start Checks ...................................................................................................................................................................14
6.2.2 Synchronization Test – Close CB for 1st EDG only, Phasing Check for other EDG ............................16
6.2.3 Synchronization Test – Close CB for 1st & 2nd EDG only..............................................................................18
6.2.4 Synchronization Test – Close CB for all EDG.........................................................................................................20
6.2.5 Acceptance Criteria ............................................................................................................................................................22
6.3 ALARM AND SHUTDOWN TEST .......................................................................................................... 22
6.3.1 Pre-start Checks ...................................................................................................................................................................23
6.3.2 Emergency Stop from LCP ..............................................................................................................................................24
6.3.3 Coolant Temperature High Alarm Test .....................................................................................................................25
6.3.4 Coolant Temperature High Shutdown Test ............................................................................................................27
6.3.5 Lube Oil Pressure Low Shutdown Test .....................................................................................................................28
6.3.6 Engine Fail to Start Shutdown Test ............................................................................................................................29
6.3.7 Battery DC Voltage Low Alarm Test ..........................................................................................................................30
6.3.8 Battery DC Voltage High Alarm Test .........................................................................................................................32
6.3.9 Overspeed Shutdown Test..............................................................................................................................................33
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1 PURPOSE
The purpose of this document is to provide an inclusive procedure for performance test for
Emergency Diesel Generator (A-331-05A/B/C) in Refinery Development Master Plan
(RDMP) Project RU V Balikpapan.
This document shall consider normal condition of performance test, if in any case deviation
occurs before or during the execution of this procedure, all parties shall be in an agreement
regarding the best course of action.
Terms Definition
Terms Definition
CB Circuit Breaker
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3 REFERENCE
This document has been prepared with reference to following documents:
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4 SAFETY PRECAUTIONS
4.1 General Safety Precaution
The following requirement shall be complied prior execution of EDG performance test
activities:
1 Permit to Work and SIKA shall be applied and are obtained prior
to proceeding with the work in the area
5 Ensure the fire fighting facility is presented near the EDG when
hydrocarbon or highly flammable material is involved in the
activity.
- Fire Hydrant 333-FHF-020 & 333-FHF-030 to cover all EDGs
- Fire Extinguisher – Portable Dry Chemical in each EDG
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7 Evacuation/escape plan
2 Moving Parts
3 Toxic Hazards
5 Combustible Liquid
7 Hot Surfaces
8 Fire Hazards
9 Fall Hazards
5 GENERAL
5.1 Testing Conditions
The testing will be carried out under ambient temperature condition in open area. The engine
coolant for the test shall be a VENDOR recommended pre-mixed coolant (Fleetguard – ES
Compleat™ Coolant PG Premix or equivalent). The test fuel shall be standard diesel fuel to
grade no. 2-D per ASTM D975 or equivalent with minimum cetane number of 40. The oil
used during the test shall be SAE 15W40, API class CD oil (Valvoline – Premium Blue™
SAE 15W-40 or equivalent).
5.2 Instrument/Equipment Required during Test
The following temporary equipment shall be available and ready on site to perform the
execution work of this procedure.
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3. Vibration meter 1 ea
4. Tachometer 1 ea
5. Temperature gun 1 ea
7. Digital Multimeter 1 ea
8. Clamp meter 1 ea
All measuring tools shall be calibrated and validly certified during testing.
5.3 Pre-test Inspection
Before performance test is conducted, pre-test inspection (installation checks) of the
package is carried out. In the case that switchgear energization is required in the steps,
switchgear commissioning shall be completed prior to generator start-up. General pre-test
inspection checklist is as follows.
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Ensure earth switch at generator incomer CBs open and generator NEC
3.
is closed
5. Ensure all CBs & Earth switch position is accurately showing at DMC
6. Verify that all engine and generator safety checks have been performed
to ensure the engine and generator are fit to run as below
- Operator to ensure mechanical valves are in position before start- up
such as Diesel, Lube oil, Cooling circuit line
- Operator to check & ensure no heavy fault occurred in the EDG
package such as FGS confirm fire, Emergency stop (UCP & LCP),
Engine protection system
- Battery healthy condition status
All the above are satisfied, engine will be started upon receiving of start
signal and will reach idle RPM immediately.
7. Ensure lube oil level, Coolant level, Fuel Level is enough for EDG run
test
Diesel Oil Storage Day Tank (D-331-01A/B) : __________%
Normal level : 8 – 93 %
Fuel Tank (A-331-05A/B/C-D1) : __________%
Normal level : 50 %
Lube Oil Tank (A-331-05A/B/C-D2) : __________%
Normal level : between L-H
Coolant Radiator (A-331-05A/B/C-E1) : __________%
Normal level : <2.5 cm from top
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12. Within less than 5 minutes, EDG will reach stability at idle speed, then Test duration
STOP Engine from LCP and confirm Engine stop. will be
confirmed by
After engine stop, reset system and ensure system ready to start
Cummins
during
execution
15. After more than 5 minutes, EDG will reach stability at rated speed &
voltage, then STOP Engine from LCP and confirm Engine stop.
Do not run the EDG for more than 15 minutes without load!
17. Once EDG startup completed, ensure start stop of EDG from MCP.
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Circuit Breaker Open/Close from LCP & MCP works properly, and CB
4.
indication position is correct
Verify that all engine and generator safety checks have been
4. performed to ensure the engine and generator are fit to run as below
- Operator to ensure mechanical valves are in position before
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Ensure lube oil level, Coolant level, Fuel Level is enough for EDG
synchronization test
- Diesel Oil Storage Day Tank (D-331-01A/B) : __________%
- Normal level : 8 – 93 %
- Fuel Tank (A-331-05A/B/C-D1) : __________%
5.
- Normal level : 50 %
- Lube Oil Tank (A-331-05A/B/C-D2) : __________%
- Normal level : between L-H
- Coolant Radiator (A-331-05A/B/C-E1) : __________%
- Normal level : <2.5 cm from top
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6.2.2 Synchronization Test – Close CB for 1st EDG only, Phasing Check for other EDG
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6.2.3 Synchronization Test – Close CB for 1st & 2nd EDG only
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5.
6.
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5.
6.
9.
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11. STOP the EDG A-331-05B, then repeat for EDG A-331-05A and EDG
A-331-05C.
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Check the engine lubrication oil level and ensure the correct level is
11.
always maintained
Check the coolant level and ensure the correct level is always
maintained
12.
Fill the cooling system to the bottom of the fill neck in the radiator fill
or expansion tank.
14. Make sure that the cooling air inlet/outlet are unobstructed
Make sure that all batteries are charged, and that all connections are
16. clean, correct and tight
Normal voltage : 24-27 V
Make sure that all auxiliary equipment is received the power from
17.
external source
18. Make sure that the Emergency Stop button is fully operational
Connect the PCC to the Laptop via RS485 port to communicate with Performed by
19.
the InPower software Cummins
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Verify that all engine and generator safety checks have been performed
to ensure the engine and generator are fit to run as below
- Operator to ensure mechanical valves are in position before start-
up such as Diesel, Lube oil, Cooling circuit line
- Operator to check & ensure no heavy fault occurred in the EDG
4.
package such as FGS confirm fire, Emergency stop (UCP & LCP),
Engine protection system
- Battery healthy condition status
All the above are satisfied, engine will be started upon receiving of start
signal.
Ensure lube oil level, Coolant level, Fuel Level is enough for EDG run
test
Diesel Oil Storage Day Tank (D-331-01A/B) : __________%
Normal level : 8 – 93 %
Fuel Tank (A-331-05A/B/C-D1) : __________%
5.
Normal level : 50 %
Lube Oil Tank (A-331-05A/B/C-D2) : __________%
Normal level : between L-H
Coolant Radiator (A-331-05A/B/C-E1) : __________%
Normal level : <2.5 cm from top
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Note:
The start button must be pressed within 10 seconds since switching to Manual mode.
Failure to do this results in the control mode defaulting, putting the generator set into the
Off mode
During running check condition of engine, Generator, Aux Equipment, Fuel Line, Coolant
line, and lube oil line, ensure the unit working properly and no leak.
Check vibration of Engine and Generator
After 5 minutes, STOP Engine by using E-Stop from LCP and confirm Test duration
Engine can stop by using E-Stop from LCP. will be
confirmed by
10. After engine stop by using E-Stop, reset system and ensure system
Cummins
ready to start
during
execution
START Engine from LCP and ensure both ventilation fan and radiator
fan are running.
Note:
4.
During running check condition of engine, Generator, Aux Equipment, Fuel Line,
Coolant line, and lube oil line, ensure the unit working properly and no leak.
Check vibration of Engine and Generator
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6. Access InPower and change High Coolant Temperature Alarm set Set point
point to be lower than original set point change as per
Cummins
recommendation
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START Engine from LCP and ensure both ventilation fan and radiator
fan are running.
Note:
4.
During running check condition of engine, Generator, Aux Equipment, Fuel Line,
Coolant line, and lube oil line, ensure the unit working properly and no leak.
Check vibration of Engine and Generator
5.
6. Access InPower and change High Coolant Temperature Shutdown set Set point
point to be lower than original set point change as per
Cummins
recommendation
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START Engine from LCP and ensure both ventilation fan and radiator
fan are running.
Note:
4.
During running check condition of engine, Generator, Aux Equipment, Fuel Line,
Coolant line, and lube oil line, ensure the unit working properly and no leak.
Check vibration of Engine and Generator
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6. Access InPower and change Lube Oil Pressure Low Shutdown set Set point
point to be higher than original set point change as per
Cummins
recommendation
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5. Wait for few minutes while the EDG tries to crank the engine
START Engine from LCP and ensure both ventilation fan and radiator
fan are running.
Note:
4.
During running check condition of engine, Generator, Aux Equipment, Fuel Line,
Coolant line, and lube oil line, ensure the unit working properly and no leak.
Check vibration of Engine and Generator
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6. Access InPower and change Battery DC Voltage Low Alarm set point Set point
to be higher than original set point change as per
Cummins
recommendation
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START Engine from LCP and ensure both ventilation fan and
radiator fan are running.
Note:
4.
During running check condition of engine, Generator, Aux Equipment, Fuel Line,
Coolant line, and lube oil line, ensure the unit working properly and no leak.
Check vibration of Engine and Generator
5.
6. Access InPower and change Battery DC Voltage High Alarm set Set point
point to be lower er than original set point change as per
Cummins
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START Engine from LCP and ensure both ventilation fan and radiator
fan are running.
Note:
4.
During running check condition of engine, Generator, Aux Equipment, Fuel Line,
Coolant line, and lube oil line, ensure the unit working properly and no leak.
Check vibration of Engine and Generator
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Check the engine lubrication oil level and ensure the correct level is
4.
always maintained
Check the coolant level and ensure the correct level is always
maintained
5.
Fill the cooling system to the bottom of the fill neck in the radiator fill
or expansion tank.
Make sure that all batteries are charged, and that all connections are
9.
clean, correct and tight
Make sure that all auxiliary equipment is received the power from
10.
external source
Make sure that the Emergency Stop button is fully operational Performed by
11.
Cummins
Verify that all engine and generator safety checks have been performed
to ensure the engine and generator are fit to run as below
- Operator to ensure mechanical valves are in position before start-
1. up such as Diesel, Lube oil, Cooling circuit line
- Operator to check & ensure no heavy fault occurred in the EDG
package such as FGS confirm fire, Emergency stop (GCP & LCP),
Engine protection system
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Ensure that no alarm in the PCC, protection relay, all faults to be cleared
2.
and/or logged before start.
Ensure Engine cranking and full speed no load (1500 RPM) and ensure
7.
aux equipment is running properly
Check the status of the engine after receive start command from LCP up
8.
to ready to load
All parameters for the EDG shall be recorded in the check sheet
11.
(Attachment-5, 6 and 8)
Check lube oil level, Coolant level and fuel level and ensure there is no
12.
leak.
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Ramp down the load to 0 % Load then let the generator run for 3 minutes
13. This allows This allows the lubricating oil and engine coolant to carry
heat away from the combustion chamber and bearings.
STOP EDG by pressing stop push button from LCP and Ensure EDG
14. shall normal stop (cool down runtime) sequence for complete stop of
EDG package
Generator Frequency 50 Hz
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Verify that all engine and generator safety checks have been
4.
performed to ensure the engine and generator are fit to run as below
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Ensure lube oil level, Coolant level, Fuel Level is enough for EDG
test
- Diesel Oil Storage Day Tank (D-331-01A/B) : __________%
- Normal level : 8 – 93 %
- Fuel Tank (A-331-05A/B/C-D1) : __________%
5. - Normal level : 50 %
- Lube Oil Tank (A-331-05A/B/C-D2) : __________%
- Normal level : between L-H
- Coolant Radiator (A-331-05A/B/C-E1) : __________%
- Normal level : <2.5 cm from
top
Make sure that all auxiliary equipment is received the power from
10.
external source
Make sure that the Emergency Stop button is fully operational Performed by
11.
Cummins
Connect the PCC to the Laptop via RS485 port to communicate with
12.
the InPower software
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STOP EDG by pressing stop push button from LCP and Ensure EDG
6. shall normal stop (cool down runtime) sequence for complete stop of
EDG package
Frequency -10% ; Hz
time 5 second
Voltage -20% ; V
time 6 second
1.
Decreasing Load:
Frequency +12% ; Hz
time 5 second
Voltage +25% ; V
time 6 second
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Verify that all engine and generator safety checks have been
performed to ensure the engine and generator are fit to run as below
- Operator to ensure mechanical valves are in position before
start- up such as diesel, lube oil, cooling circuit line
4.
- Operator to check & ensure no heavy fault occurred in the EDG
package such as FGS confirm fire, Emergency stop (UCP &
LCP), Engine protection system
- Battery healthy condition status
Ensure lube oil level, Coolant level, Fuel Level is enough for EDG
test
- Diesel Oil Storage Day Tank (D-331-01A/B) : __________%
- Normal level : 8 – 93 %
- Fuel Tank (A-331-05A/B/C-D1) : __________%
5. - Normal level : 50 %
- Lube Oil Tank (A-331-05A/B/C-D2) : __________%
- Normal level : between L-H
- Coolant Radiator (A-331-05A/B/C-E1) : __________%
- Normal level : <2.5 cm from
top
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Make sure that all auxiliary equipment is received the power from
10.
external source
Make sure that the Emergency Stop button is fully operational Performed by
11.
Cummins
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STOP EDG by pressing stop push button from LCP and Ensure EDG
11. shall normal stop (cool down runtime) sequence for complete stop of
EDG package
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8 ATTACHMENT
Attachment 1 - EDG First Start Checklist
Attachment 2 - Synchronization Test Report
Attachment 3 - Alarm & Shutdown Test Report
Attachment 4 - Load Sharing Verifying Test Report
Attachment 5 - Noise Measurement Test Report
Attachment 6 - Vibration Measurement Test Report
Attachment 7 – Transient Response Test Report
Attachment 8 – Load Test Report
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ATTACHMENT-1
26071‐V67‐331‐A‐105‐GEN1‐00074_Attachment #1
26071‐V67‐331‐A‐105‐GEN1‐00074_Attachment #1
Check for hot air recirculation Energise auxiliary supplies and check functionality
Load test completed
Electrical system
Result sheet completed
Control systems Record load achieved………………………kW
Auxiliary supplies energised Record power factor……………………………
Generator set local controls checked System start-up completion
Generator set remote controls checked Generator set operational
Generator set system controls checked Changeover / transfer switch operational
SYNCHRONIZATION TEST
G1 CB closed G1 G2 G3 G4 Bus VT
R-Y (volts)
Y-B (volts)
B-R (volts)
R-N (volts)
Y-N (volts)
B-N (volts)
R-E (volts)
Y-E (volts)
B-E (volts)
N-E (volts)
Phase Rot.
G3 CB closed G1 G2 G3 G4 Bus VT
R-Y (volts)
Y-B (volts)
B-R (volts)
R-N (volts)
Y-N (volts)
B-N (volts)
R-E (volts)
Y-E (volts)
B-E (volts)
N-E (volts)
Phase Rot.
R-R (volts) N/A N/A N/A N/A
Y-Y (volts) N/A N/A N/A N/A
B-B (volts) N/A N/A N/A N/A
G4 CB closed G1 G2 G3 G4 Bus VT
R-Y (volts)
Y-B (volts)
B-R (volts)
R-N (volts)
Y-N (volts)
B-N (volts)
R-E (volts)
Y-E (volts)
B-E (volts)
N-E (volts)
Phase Rot.
R-R (volts) N/A N/A N/A N/A
Y-Y (volts) N/A N/A N/A N/A
B-B (volts) N/A N/A N/A N/A
REMARKS
CONTRACTOR:
Name Signature Date
CUMMINS:
Name Signature Date
CLIENT:
Name Signature Date
ATTACHMENT-3
Cummins:
Contractor:
Client:
G-1
G-2
G-3
G-4
G-5
REMARKS
CONTRACTOR:
Name Signature Date
CUMMINS:
Name Signature Date
CLIENT:
Name Signature Date
ATTACHMENT-5
REMARKS
CONTRACTOR:
Name Signature Date
CUMMINS:
Name Signature Date
CLIENT:
Name Signature Date
ATTACHMENT-5
Load POS 1 POS 2 POS 3 POS 4 POS 5 POS 6 POS 7 POS 8 Remark
REMARKS
INSPECTOR:
Name Signature Date
CUMMINS:
Name Signature Date
CLIENT:
Name Signature Date
ATTACHMENT-6
SITE PRE-COMMISSIONING,
C
C Sale�and
Service
• Korea COMMISSIONING TEST PRECEDURE
Attachment #2. Genset Load Test Report
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55-57-15
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