Diesel 3500 Commissioning Check Lists

8/17/2019 Diesel 3500 Commissioning Check Lists

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3500 DIESEL EPGCOMMISSIONING - FIELDDATA RECODING SHEETS


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ECM Parameter Settings Record:

For EUI engines list all the programmed parameters. Keep a record of any changes byrecoding the settings before and after a change.

Engine Serial Number

ECM Serial Number

Rated Fuel Position

Low Idle Speed

Acceleration Delay Time

Acceleration Ramp Rate

Cooldown Time

Cooldown Speed

Prelube Time

Crank Duration

Total Number of Crank Cycles

Air ShutoffFuel Control

Direct Fuel Control Mode

Record the following information from the engineinformation plate.Engine serial numberRecord the following information from the enginemonitoring system.ECM Voltage

Warning Trip Point

Warning Delay Time

Engine Oil Pressure

Warning Trip Point

Warning Delay Time

Shutdown Trip Point

Shutdown Delay Time

High Coolant Temperature

Warning Trip Point

Warning Delay Time

Derate Trip Point

Derate Delay Time

Shutdown Trip Point

Shutdown Delay Time

Low Coolant Temperature

Warning Trip Point

Warning Delay Time

Engine Overspeed

Warning Trip Point

Warning Delay Time

Shutdown Trip Point

Shutdown Delay Time

Air Inlet Restriction

Warning Trip Point

Warning Delay Time

Derate Trip Point

Derate Delay Time

Altitude

Derate Trip Point

High Exhaust Temperature

Warning Trip Point

Warning Delay Time

Derate Trip Point

Delay Time

Engine Oil Filter Differential Pressure

Warning Trip Point

Warning Delay Time

Fuel Filter Differential Pressure

Warning Trip Point

Warning Delay Time

Crankcase Pressure

Warning Trip Point

Warning Delay Time

Shutdown Trip Point

Shutdown Delay Time

Aftercooler Temperature

Warning Trip Point

Warning Delay Time

Derate Trip Point

Derate Delay Time

Shutdown Trip Point

Shutdown Delay Time

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Customer Data:

Name Start up date

Contact Time

Telephone

SiteType of Installation

Application: PP Continuous Peak Shave Standby Marine Industrial Other

Engine Data: Generator Data:

Engine Model Serial Number

Serial Number Arrangement

Arrangement Rating

TMI Spec Voltage

Rating BHP BkW Amperage

Environment:

Ambient Temperature Room Temperature

Elevationr Relative Humidity

Atmospheric Condition Salty Dusty Wet Clean Other:

Safety:

Heat Shields on Engine OK - Not OK - N/A All Guards in place OK - Not OK - N/A

Emergency Stop Operates OK - Not OK - N/A Floor Openings Covered OK - Not OK - N/A

Engine Room Noise Level OK - Not OK - N/A Floors Clean OK - Not OK - N/A

Warning Decals in Place OK - Not OK - N/A Hot Pipes Wrapped OK - Not OK - N/A

Fire Extinguisher OK - Not OK - N/A Wiring Secure OK - Not OK - N/A

Fire Suppression System OK - Not OK - N/A Piping and Hoses Secure OK - Not OK - N/A

Access to Fluid Fill Areas OK - Not OK - N/A OK - Not OK - N/

Serviceability:

Overhead Clearance Gauges Accurate

Side Clearance Oil OK - Not OK - N/A

Air Filters Accessible OK - Not OK - N/A Water OK - Not OK - N/A

Oil Filter Accessible OK - Not OK - N/A Fuel OK - Not OK - N/A

Fuel Filter Accessible OK - Not OK - N/A Air OK - Not OK - N/A

Site Glass Visible OK - Not OK - N/A Exhaust OK - Not OK - N/A

Level Indicators OK - Not OK - N/A

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Customer Orientation

Safety practices (Refer to OMM) OK - Not OK - N/A

Manuals OK - Not OK - N/A

Operation and Maintenance Manual delivered and explained OK - Not OK - N/A

Reviewed start up procedure OK - Not OK - N/A

Pre-delivery Report OK - Not OK - N/A

Service manual delivered and explained OK - Not OK - N/A

Parts manual delivered and explained OK - Not OK - N/A

Proper levels OK - Not OK - N/A

Proper fluids OK - Not OK - N/A

Delivery Service Completed OK - Not OK - N/A

Warranty information explained OK - Not OK - N/A

SOS service explained and offered OK - Not OK - N/A

Maintenance contract advantages explained and offered. OK - Not OK - N/A

Load Test Report Presented OK - Not OK - N/A

As Built Drawings Delivered OK - Not OK - N/A

Customer Acceptance Test OK - Not OK - N/A

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Engine Commissioning Checklist:

Governor:

Governor / Actuator type

Linkage free OK - Not OK - N/A

Oil Level OK - Not OK - N/A

Fuel System Information:

High Idle Setting: Specification

Low Idle Setting Specification

Fuel Type: Fuel Treatment OK - Not OK - N/A

Fuel API: Fuel Line Isolated OK - Not OK - N/A

Fuel Filter Pressure Differential: Fuel Tanks Full & lines Open OK - Not OK - N/A

Fuel Pressure: Specification: Check for Fuel Leaks OK - Not OK - N/A

Anti Siphon Valves Fitted OK - Not OK - N/A Day Tank operation OK - Not OK - N/A

(1)Day Tank Elevation OK - Not OK - N/A (2)Day tank Distance to Engine OK - Not OK - N/A

(1) The full level of the day tank should be lower than the injector height of the engine(2) The day tank should be no more than 15m away.

Cooling System:

+JW Inlet Temp: +JW Outlet Temp

+SCAC Water Inlet Temp +SCAC Water Outlet Temp

*Fill Test OK - Not OK Full Load Temperature OK - Not OK - N/A

*Draw Down Test OK - Not OK Antifreeze OK - Not OK - N/A

*Cavitation Test OK - Not OK Radiator Temp Differential OK - Not OK - N/A

*Air Venting Test OK - Not OK Coolant Level Check OK - Not OK - N/A

*Ambient Capability Value Check for Leaks OK - Not OK - N/A

+ At Rated Load* Refer to EDS 50.5

Lubrication System:

Oil Filter pressure Differential OK - Not OK - N/A Oil Level Check OK - Not OK - N/A

Oil Pressure Level OK - Not OK - N/A Check for Oil Leaks OK - Not OK - N/A

Combustion Air:

Temperature in Duct Isolation OK - Not OK - N/A

Temperature AC Check for Leaks OK - Not OK - N/A

+Air Filter Pressure Diff +Intake Manifold Pressure

+Total Inlet Restriction +Intake Manifold Temperature

+ At Rated Load

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Exhaust System-*

Exhaust Back Pressure Exhaust Pipe Isolation

Exhaust Temperature Before Turbo Check for Leaks

Exhaust Stack temperature

Port Temperatures

Right Bank Left Bank

Cylinder 1: Cylinder 2:





Cylinder 11: Cylinder12:



Average Right Bank: Average Left Bank:

Total Average: Maximum difference from Average:

Hottest to coldest Differential: All Figures OK / NOT OK

* All to be done at Rated load

Mechanical:

Loose Bolts OK - Not OK - N/A Attachments OK - Not OK - N/A

Inspect Belts OK - Not OK - N/A Alternator OK - Not OK - N/A

Inspect fan OK - Not OK - N/A Air Shut-off OK - Not OK - N/A

Hoses and Connections OK - Not OK - N/A Check for Leaks OK - Not OK - N/A

Inspect Supports OK - Not OK - N/A Unusual Noises OK - Not OK - N/A

Lubrication Points OK - Not OK - N/A Cleanliness OK - Not OK - N/A

Vibration Isolator Type Vibration Isolator Adjustment OK - Not OK - N/A

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Vibration Levels:

Order of Vibration – Measured in mm

Overall m/s ½ 1st

1 ½ 2nd

2 ½ 3rd

EFV(1)

EFH(2)

ERV(3)

ERH(4)

GFV(5)

GFH(6)

GRV(7)

GRH(8)

GRA(9)

ERR(10)

BASE(11)

Limits are as follows.Peak to Peak Half Order - 0.13mmPeak to Peak First Order - 0.13mmOverall Displacement - 0.22 mmOverall Velocity - 34.3 mm/s

Batteries

Charged OK - Not OK - N/A Trickle Charger OK - Not OK - N/A

Electrolyte OK - Not OK - N/A Charge rate OK - Not OK - N/A

Isolated from floor OK - Not OK - N/A Leads well secured OK - Not OK - N/A

Jacket Water Heaters

Temperature Setting Wired Correctly OK - Not OK - N/A

Correct Orientation OK - Not OK - N/A Power on OK - Not OK - N/A

Starter

Type Inspect wirings OK - Not OK - N/A

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Crankcase Ventilation

Type of Fumes Disposal Ingestive – Y / N Number of Breathers

Filter Y / N Liquid Discharge Trap Y / N

Location of Discharge Leaks OK - Not OK - N/A

*Crankcase pressure Separate system per Engine OK - Not OK - N/A

* Limits on Crankcase pressure:For an injestive system the minimum crankcase pressure allowed is 25mm H 2O Vacuum.For a non-injestive system the maximum crankcase pressure allowed is 13mm H2O Positive.

Protection System Accuracy & Functional Tests.

High Water Temp OK - Not OK - N/A Low Water OK - Not OK - N/A

Low Oil Pressure OK - Not OK - N/A Shutdown Devices OK - Not OK - N/A

High Oil temperature OK - Not OK - N/A High Air Inlet Temperature OK - Not OK - N/A

Over Speed OK - Not OK - N/A

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Generator Startup Checklist:

RATING INFORMATION

Engine Serial Number:

___________________________________

Arrangement Number: ___________________

Generator Serial Number: _________________________________

Arrangement Number: ___________________

GENERATOR NAME PLATE INFORMATION

Voltage: ___________________ Package (prime, continuous, standby): _________________

Amperage: _________________ Kilowatts: ________________________________________

Storage Location:

Crankshaft Deflection:

Generator Alignment:

Main Stator MegohmmeterReading:

Before Storage: After Storage:

Generator dried for 24 hours prior to startup? (Y/N) Drying method:

SPACE HEATERS Yes No Comments

Space heaters operating properly?

Space heater operated 48 hrs.before startup?

MEGOHMMETER TEST(SEHS9124)

30 sec.reading

60 sec.reading

30 sec.corrected

60 sec.corrected

Ambienttemp.

Comments

Main Stator

Main Rotor

Exciter Stator

Exciter Rotor

Beginning ofStorage

PMG Stator

Main Stator

Main Rotor

Exciter Stator

Exciter Rotor

Start-up

PMG Stator

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Regulator Voltage Amps Comments

F1 to F2 DC

20 to 22 AC

20 to 24 AC

22 to 24 AC24 to 30 (SE only) AC

26 to 28 (PM only) AC


No Load


GeneratorExcitation NamePlate Information:

DC Compare with F1 to F2

F1 to F2 DC

20 to 22 AC

20 to 24 AC

22 to 24 AC

24 to 30 (SE only) AC



Full Load


ELECTRICAL Yes No Comments

Unit properly grounded

Check diodes

Over current protection

Over voltage protection

Check for loose wiring

Adjust voltage

Adjust frequency

MECHANICAL Data Comments

Bearing temperature readings at full load Front __________ Rear ___________

Stator temperature readings at full load A0 _______ B0 _______ C0 _______

Air gap on main stator Top __________ Bottom __________

Air gap on exciter stator Top __________ Bottom __________

Air gap of PMG Top __________ Bottom __________

Ambient air to generator at full load Temperature ____________________

Supplier air opening to generator Size of Opening _________________

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SWITCH GEAR/PARALLEL OPERATION

Manufacturer:

Utility Grade:

PLC Manufacturer:

Software:Busbar Current Rating:

Circuit Breaker Manufacturer:

Data Communication: SCADA

Communication OK - Not OK - N/A

Setting 1 Setting 2 Setting 3 Comments

Circuit breaker type

Overload setting

Reverse power relay

VAR/PF Controller

Load share

INSTALLATION & LOAD INFORMATION

Neutral grounding system UPS

Enclosure type - Size

Motor: Other loads:

- Total SKVA - Lighting

- Total HP - Computers

- Welding

- Non-linear

- Other

AC Functional Tests

AC Protection Function Test OK - Not OK - N/A

Reverse Power Protection OK - Not OK - N/A

Under Frequency Protection OK - Not OK - N/A

Over Frequency Protection OK - Not OK - N/A

Over Voltage Protection OK - Not OK - N/A

Cable Installation

Cable Entry Location Top / Bottom

Cable Size

Number of Cores OK - Not OK - N/A

Cable Try OK - Not OK - N/A

Cable Ladder OK - Not OK - N/A

Cable Lay Out OK - Not OK - N/A

FULL LOAD DATA

Voltage Amps KW KVARS P.F.

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Statement of Completion:

The following section I to be completed and signed off by the authorizedmechanic, or mechanics, that have carried out the works to verify that thenumbers contained in this report are an accurate reflection of the readingstaken during the commissioning of the Generator Set / Engine.

The Caterpillar authorized selling dealer is to also sign off that all works havebeen completed to their satisfaction and the customer to sign off as havingreceived a coy of this document for their records.

Installation Mechanic:

Name:

Title:

Signature:

Date:

Additional Mechanic:

Name:

Title:

Signature:

Date:

Selling Dealer:

Name:

Title:

Signature:

Date:

Customer:

Name:

Title:

Signature:

Date:

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Diesel 3500 Commissioning Check Lists

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