Method Statement Title: Testing and Commissioning of Generator and ATS

Method Statement Title: Testing and Commissioning of Generator and ATS

1.0       Scope

1.1       This method statement details the Testing and Commissioning of Generator and ATS  according to the specification section 16402.

Note:   A separate method statement is submitted for installation of Generator

and ATS. (Ref. ETA /MS/E-022)

2.0       Material

• All the materials shall be as per approved material submittals.

• Size and number of Generator and ATS shall be as per approved shop drawing and load schedule.

• Identifications and labels.

3.0       Applicable Location

• Generator : East & West Podium – Ground floor.

• ATS : Tower E1,E2,E3 & W1,W2,W3 – LV Rooms.

4.0       Instruments.

• Generator :
• Resistive Load bank – UPF.
• Controller for the Load bank.
  • ATS :
• Insulation Resistance tester ( Megger ) with VariableVoltage selections.
• Phase Sequence meter.
• Multimeter.

Note : The calibration certificates of testing instruments shall be verified prior to usage and copies shall be included in the test reports.

4.2       Installation

• Testing & Commissioning procedure for Generator :

• Overall Inspection:

• Batteries, fuel & auxiliary power must be isolated before carrying out initial inspection.
• Ensure that the control switch is in the OFF position and emergency switched is pressed.
• Ensure that the panel has the correct fascia and labels.
• All round check of the genset to ensure that no loose items e.g. nuts, bolts, washers etc are lying in, or around the equipment. Such items are to be removed as they pose a hazard to safety.
• A careful check of the interior of the alternator terminal box to ensure that no loose objects are lying within.
• Ensure the load circuit breaker is in open position (if fitted )
• A careful check of the interior of the control panel to confirm that wiring termination is correct and that no loose clippings, cable lengths, nuts etc remain in the control panel from manufacturer.
• A careful check of the engine exhaust manifold to ensure that no unplugged apparatuses exist.
• Ensure the lubricating oil to the full mark on the dipstick.
• Fill the engine with required coolant mixture i.e. anti freeze, rust inhibitor. Ensure all coolant systems are properly bled during filling.
• Check engine air intake and exhaust system for blockage.
• Ensure that sufficient unrestricted air circulation is available in the genset room without recirculation.
• Ensure that sufficient space is available around the genset for easy maintenance of the genset and easy access of the control switches and control panel reading.
• Fuel piping shall be with minimum bends so that the suction head shall be within the manufacturers recommended limit.
• Check for lube oil level, coolant and fuel.

• Position of wiring loom relative to any moving part or hot surfaces, especially exhaust.
• Carry out a random check on control wiring connections both on the engine and within the control panel for tightness and suitability.
• Ensure all defects/damages found are logged.
• Fill up the Commissioning sheetsupplied with operation and maintenance manual, and ensure that the rating matches with the specification.

• Genset Functional Test :

• Check that load cables are suitably rated for the calculated full load current.
• If required megger the alternator winding and load cable for insulation testing.
• Ensure that all control and low voltage devices are disconnected while insulation test.
• Connect the load cables, neutral to the load bank.
• Set the load to correct voltage, frequency and power factor.
• Connect the genset to the earth with sufficiently rated earth cable.
• Ensure that all the equipments are earthed satisfactorily.
• Check for earth resistance and ensure that the resistance is well within the limit.
• Remove the alternator terminal box top plate and check terminal for tigthness.
• Remove the AVR cover and securely attach to the genset.
• Check the link is set at correct frequency.
• Ensure all units are rated for operating voltage of genset both AC and DC.
• Manually close and open the circuit breaker to ensure smooth operation.
• Check all electrical connection and tightness.
• Calculate the full load current of the generator and calculate current rating at 110%, 100%, 75%, 50%, 25% and 0%.
• Fuel lines are now to be connected.

• Check any leakage in the fuel Line.
• Ensure that control switch is in ‘OFF’ mode, emergency switch is pressed and the circuit breaker is in open position.
• Connect the battery to the starter motor with correct polarity (negative of the battery shall be connected to last)
• Check all electrical connections.
• Power-up the Access 4000 series control panel.

• Start-up Tests :

Note : The genset shall not be started unless it is clean and dirty.

• Test results should be in accordance with the values stated in the operating manual. Test results should be recorded into the test format.
• Ensure that breaker is in open position.
• Release the emergency push button.
• Star engine using the RUN position on the control switch.
• Check operation of emergency stop button .
• Re-start generator set by clearing emergency stop fault and control switch in RUN position..
• Check RPMreading on the screen with the value on the rating plate.
• Adjust output voltage at AVR to specified voltage.
• Verify operation of the volts raise/lower switches if applicable.
• Verify operation of the speed raise/lower switches if applicable.
• Check the phase sequence and ensure correct phase sequence.
• Close the circuit breaker.
• Apply a small load (approx 25%) to the generating set.
• Check CT polarity by observing current readouts in the screen.
• Release the load.
• Ensure all protection devices are installed are the correct type/setting and are operating satisfactorily.
• Check operation of all shutdowns and alarms.
• Where fitted check the operation of all auxiliary chargers, heaters, pumps etc. The control cabling protection circuits and equipment for all auxiliary items should be of correct size and rating.
• Turn control switch to OFF.

• Verify that the generator set shuts down correctly.
• Fit the AVR cover.
• Open the circuit breaker.
• To ensure auto start of genset, link the control terminals for auto start in the control panel.
• Turn the control switch to AUTO mode.
• After a while switch off the genset.

• Genset Load Test :

Note : Genset do not leave unattended until satisfactory testing.

Load test on the genset is not recommended if start up test is not

 satisfactory.

• Start the genset.
• Once the genset is reached to rated speed and voltage close the circuit breaker.
• Load up generator set smoothly as per site load testing specified.
• Observe and tabulate all necessary reading for every interval as specified in the specification.
• Observe for any leakage, undue noise or vibration.
• After completion of the test, remove load smoothly and allow the genset to run for cool down.
• After cool down time (approx 10 minutes) switch off the genset using control switch to OFF position.

• Post Test Checks :

Note : Press the Emergency button before doing any inspection on the genset.

• On completion of all the test rewiring and re cabling the genset is to be properly swept clean of all loose debris e.g nuts, bolts, washers and cable clipping etc.
• Ensure generator set are left in a clean and fit condition, and ready for use.
• Check for leak in fuel, oil and coolant system.

• Check for oil level, coolant level and fuel level, top up if necessary.
• Check for any damage.
• Remove the load cable to the ATS and ensure bolts are fastened to securely to bus bars.
• Ensure that the ATS panel is set for proper voltage and suitable timings are programmed.
• Connect all the auxiliary power supply for the heater etc if applicable.
• Ensure that control switch is in ‘OFF’ mode.
• Connect the auto start signal cable to genset control to genset control panel from the ATS.
• Release the emergency push button.
• Turn the control switch to auto mode.

• Procedure for  Auto Transfer Switch (ATS) :

• Insulation Resistance Test  using 500V Megger:

• Check the tightness of connections.
• Clean all the supporting insulators.
• Isolate the cables on incoming and outgoing side.
• Apply a megger voltage of 500Volts DC between Phase ‘R’ to earth for 1 min with Phase ‘Y’,’B’ & ‘N’ shorted and earthed and record the values.
• Similarly continue the test and record the values for the other phases.

• Operational Checks:

• Connect the required control supply as per the schematic.
• Check the operation of the switchgear i.e. closing / tripping of switchgear from local and control points.
• Check the operation of protective relays.
• Check the operation of interlocks, alarms and indications circuits as per the approved schematic

•       Safety :

• Only experienced and skilled personnel shall be engaged for testing.
• Safety guards shall be in place and secured prior to start-up.
• Warning signs and tapes shall be placed during start-up and commissioning as required.
• All safety procedures shall be followed in accordance with the project health and safety plan.
• Safety officer shall check and ensure all safety precautions as followed.

6.0       Records

• Site Test Reports.
• Calibration certificates of testing instruments

7.0       Attachment

• Inspection Check List for ATS .
• Insulation Resistance Test for ATS.
• Generator Load Test Sheet.