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Home My WebLink AboutBuilding 3 - Unit #1 Generator Startup ReportForm B - Engine Generator Set Installation and Commissioning Instructions This report must be completed and signed by an MTU certified commissioning technician in order to accomplish all requirements of the MTU Limited Warranty. This report includes the physical installation checkups and commissioning procedures for all control versions, as well as open and enclosed generator sets. After completion, a signed copy must be provided to each of the following: 1.Distributor/Dealer 2.Owner 3.MTU Regional Warranty Department Applicant Contact Details Distributor/Company: Name: Telephone: Email: Project Details Project Name: Project Number: Site Address: Start‐Up and Commissioning Start Date: Start‐Up and Commissioning Completion Date: Engine Generator Set Nameplate Model Number: Serial Number: Rating: Hz:kW: kVA:Volts: Phase:Amps: Engine Model Number: Serial Number: Power: RPM: Fuel Type: Diesel  NG LP Vapor  Liquid LP  Other Generator Manufacturer: Model Number: Serial Number: AVR Type: kVA:Hz: Voltage: Current: Phase Rotation: Breaker (MTU Delivery  Yes  No) Manufacturer: Model Number: Serial Number: Voltage: Current: Poles: ATS ( Yes  No) Manufacturer: Model Number: Serial Number: Voltage: Current: Poles: Controller Manufacturer: Model Number: Serial Number: Firmware Version: Note: If this form does not appear with fillable fields, navigate to Edit > Preferences > Documents > PDF/A View Mode. 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Rolls-Royce Group www.mtu-solutions.com Form B - Engine Generator Set Installation and Commissioning 2 General Application:  3A Continuous  3B Prime  3D Standby  3F DCCP  ____________ Load test type on site:  Building load  Load bank  Grid parallel  None Load test not possible because: Engine Generator Set Application  Installed in building  Containerized  Enclosed Prestart Safety Checks/Environmental Check Yes No N/A Commissioning performed by an MTU certified commissioning technician       Personal protection equipment is available and functional       Access only for authorized personnel    Emergency escape routes are unobstructed (no loose materials, parts, or tools) and labeled       Danger spots are indicated (e.g. trip hazards, beams, pipes)       Control panel/engine area is unobstructed    All warning plates and instruction labels are properly in place       Genset room is free of debris, dirt, dust, loose materials, parts, and tools       Air ducts are free and clean    Engine generator set is leveled; mounting bolts secure    Shipping blocks are removed    For two‐bearing generators, check for proper alignment    Heat protection covers are installed    Engine Generator Set Room (Equipment) Yes No N/A Battery powered emergency light is installed    Fire extinguishers are in place    First aid kit is in place    Oil resistant floor coating    Spill containment system in place    Fire extinguishing system  Water  CO2  Chemical  None Engine Room Requirements (Open Power Units) Yes No N/A Engine room is located as close as practical to the main consumer       Space for maintenance is left around the engine generator set       Battery powered back‐up lights available    Engine Generator Set Room Ventilation Yes No N/A Intake and exhaust opening properly sized and louvers installed       Flexible duct section installed    Radiator duct properly sized to louver    Proper air flow direction past alternator and then the engine       Engine room inlet air filter in place    Weather/animal guard is fitted to intake and outlet     Self‐Contained Engine Generator Set Ventilation Yes No N/A Engine generator set intake positioned away from obstruction to airflow       Radiator discharge positioned away from prevailing winds       Sufficient clearance around self‐contained engine generator set for airflow        Air Inlet and Outlet Yes No N/A Air ducts are clean and clear    Ducts are installed properly    Weather protection guards are installed    Silencers are installed properly    Louvers open and close automatically    Manual operation of louvers is possible    Structure air flows are correct (no thermal short circuit)    Unrestricted airflow over the engine     Cooling System Yes No N/A Cooling system is free of leakages    Pipelines and connections undamaged    Radiator fan(s) are clear and clean    Venting pipes have gradient toward expansion tank    Overflow is free and spillage is avoided    System is filled to proper level    Filling cap is freely accessible    Coolant‐preheater is functional    Coolant type and concentration as specified in MTU manual:       Rolls-Royce Group www.mtu-solutions.com Form B - Engine Generator Set Installation and Commissioning 3 Frame‐Mounted Radiator Yes No N/A Check belt tension and alignment    Radiator clean and free from obstruction    Radiator air outlet connected to outlet duct    Check for possibility of hot air recirculation    Engine generator set vent pipes routed upward toward radiator expansion tank       Pipelines secure and undamaged    Overflow clear and routed to avoid spillage     Remote‐Mounted Cooling System Yes No N/A Pipelines cleaned and painted    Device(s) aligned and fixed properly    Pipelines fixed properly    Expansion tank is of adequate size    Pipelines isolated from generator set vibration    Static head pressure is within system capability    Auxiliary power supply is installed correctly    Potential equalization is installed properly    Fan rotational direction correct    Overflow clear and routed to avoid spillage    Engine generator set vent pipes routed upward toward radiator expansion tank       Avoid air locks in pipelines – air bleed valves provided    All proper electrical connections made    Heat Exchanger and Cooling Tower Yes No N/A Pipelines cleaned and painted    Device(s) aligned and fixed properly    Pipelines fixed properly    Expansion tank is of adequate size    Pipelines isolated from generator set vibration    Vent valves installed    Static head pressure is within system capability    Secondary circuit pump direction is accurate    Secondary circuit pump is functional    Potential equalization is functioning properly    Overflow lines are clear and routed to avoid spillage    Engine generator set vent pipes routed upward toward expansion tank       Air bleed valves installed    Cooling tower make up supply is complete    Auxiliary power supply to fans is correctly installed    All proper electrical connections made    Mounting/Foundation Yes No N/A Engine generator set is installed on proper mounts    Static deflection area of mounts not blocked by components       Surface is level    Support structure is adequate to support engine generator set weight       Engine generator set is supported at each mounting location       Lube Oil System Yes No N/A Engine is filled with oil to proper level    No oil leaks present    Flexible lines installed in make‐up lube‐oil system    Oil type as specified in MTU manual (record type):     Starting System Yes No N/A Battery and cables are free from damage    Battery and cables installed, mounted, and wired properly       Batteries filled up to appropriate level    Idle charging voltage min. 27.6 VDC for 24 V system or 13.7 VDC for 12 V system       Battery charger properly installed and wired  Battery is located near starter with shortest cable run as possible       Diesel Fuel System Yes No N/A Fuel system is free of leakages    Flexible lines installed at engine    Pipeline size adequate to system    Pipelines and connections undamaged    Flow and return lines connected correctly    Fuel lines free of tension, scuffing, or kinks    Potential equalization is installed properly    Adequate room is left for fuel tank inspections    Confirm proper rotation of auxiliary electric fuel lift pump    Tank is not overfilled    Tank is not in the vicinity of exhaust or other heat sources       For electric fan driven fuel coolers: Fuel cooler plumbed and wired correctly               Rolls-Royce Group www.mtu-solutions.com Form B - Engine Generator Set Installation and Commissioning 4 Diesel Fuel System (continued)  YesNoN/A Fuel returns to fuel tank without restriction, proper sized pipe       Fuel prefilter installed before engine inlet    Electronic day tank pump used from main storage to day tank       Day tank controls/pumps installed    Fuel transfer pump connected to emergency power    Level indicator used for checking tank contents    Leak sensors are in place    All proper control and sensor connections are made    Spill containment procedure in place per code     Diesel Fuel System (Main Storage Tank) Yes No N/A Isolating valves correctly positioned    Transfer pump and controls operational    Pipeline/tank heating system operational    Fuel level monitoring system operational    Check for leaks     Day Tank Yes No N/A Tank is fixed properly and mounted to substructure    Tank vent line is plumbed to safe area    Tank filling line is of adequate size    All unused fittings are plugged    Mechanical fuel level indicator installed    Electrical fuel level indicator installed and tested    Fuel level switches installed and adjusted    System pump(s) connected to emergency power    Potential equalization is installed properly    System pump(s) installed correctly (flow direction)    Refill function checked    Leakage sensor in place    Adequate space available for inspections    Isolating and solenoid valves checked    Tank filled    Check for leaks    Fire valves present     Gas Fuel System (Americas Only) Yes No N/A Dedicated gas supply line of proper size and material    Check for gas filter/screen    Check gas solenoid valve operation    Check supply lines for leaks    Check manual shut‐off valve operation    Solenoid valves correctly positioned    Regulator set to correct pressure    Gas leak detection equipment operational    Shut‐off devices operational    Specified gas pressure is available at fuel inlet     Exhaust System Yes No N/A Piping is installed and secured properly    Flexible connectors installed at engine exhaust outlet    Flexible connectors installed correctly    Exhaust line condensate trap with drain installed    Silencer is installed and secure    Exhaust thimble installed per local codes    Exhaust system below back pressure limit    Exhaust piping diameter properly sized for length of run    No diameter reductions downstream on exhaust pipes    All exhaust system weight is properly supported    Proper pipe wall thickness is maintained    Exhaust lines are properly insulated    Exhaust installed with a downward pitch to outlet    Exhaust line protected from natural elements (rain cap installed)       Exhaust gas prevented from re‐entry to building    Hot parts safety decals/guards are present     Fire Alarm/Suppression System Yes No N/A Fire alarm/suppression system present     Engine Management System (Engine Governor) Yes No N/A Engine Control Unit box is free of damage    Engine Control Unit box is securely mounted to engine    Electrical connections securely fastened     Grounding Yes No N/A Engine and generator are properly grounded     Electrical and Control System Yes No N/A Remote wiring connected correctly    Cables free of tension, scuffing, or kinks    All connections clean and secure    Bus bar phase sequence, voltage, and frequency checked    Control cables routed in separate conduits from phase leads       Engine generator set controls energized and functional    Software version of engine generator set controller recorded       All LEDs on panel illuminate when LED test is pressed    Emergency stop control operational    Test certificates available for all cables    Utility service breaker capacity verified    Small power and lighting circuits operational     Rolls-Royce Group www.mtu-solutions.com Form B - Engine Generator Set Installation and Commissioning 5 Switchgear/Transfer Switch Yes No N/A Cables installed to correct torque specification    Phase cables to switchgear/transfer switch are correctly sized and clearly identified       Switchgear protection settings checked    All other connections are clean and secure     Generator Circuit Breaker Yes No N/A ON/OFF function    Auxiliary contact    Adjust over‐current protection    Adjust the trip unit    Phase rotation checked     Preparation for Running Checks  Follow appropriate lockout/tagout procedure Running Checks Yes No N/A Engine generator set engine control switch in the RUN position. Start engine and verify whether there is sufficient oil pressure          Allow engine to run for five minutes    Check coolant level, add as necessary, and reinstall cap    Allow engine to run for at least 20 minutes and check engine operating temperature       Check the battery charger for proper operation    If the speed is unstable, adjust to specifications    Adjust the AC output voltage to match the utility voltage using the voltage adjusting control       Check for oil, coolant, and exhaust leaks/recirculation    Check temperature on city water‐cooled models and adjust the thermostatic valve as necessary       Engine generator set engine control switch in the OFF position       Permission must be obtained from the building authority before transfer switch test is performed       Test transfer switch    Record the current phase for the three phase systems A B C  Running Checks (continued) Yes No N/A Set the engine generator set exerciser with load to the customer’s required exercise period       Verify that all options on the transfer switch are adjusted and functional to the customer’s requirements       Record transfer switch delay settings: TDES (Time Delay to Engine Start) sec. TDNE (Time Delay Normal to Emergency) sec. TDN (Time Delay to Normal) min. TDEC (Time Delay Engine Cooldown) min.  Mains Failure Test Number of start trials: Duration between mains failure and generator circuit breaker (GCB) closed (until emergency power source supplies load) sec. Yes No N/A Dyn. Frequency drift within limit of ISO 8528‐5    Static voltage drift during operation within limit of ISO 8528‐5       Static frequency drift during operation within limit of ISO 8528‐5       Rolls-Royce Group www.mtu-solutions.com Form B - Engine Generator Set Installation and Commissioning 6 Running Checks (record on chart) Unless otherwise specified by local or state regulations, run the engine‐generator set at full expected system load in excess of 30% of the nameplate rating). Record data at 15 minute intervals. Shutdowns Yes No N/A Emergency stop (also external)    Overfrequency/overspeed    Underfrequency    Overvoltage    Undervoltage    Oil pressure Lo Lo    Engine temperature Hi Hi    Check and verify any additional protective devices and list: Additional Comments/Notes: Rolls-Royce Group www.mtu-solutions.com Form B - Engine Generator Set Installation and Commissioning 7 Customer Acknowledgement (Literature and Instructions) Verify that the customer has the appropriate engine/engine‐generator set and transfer switch (if provided by MTU) literature. Instruct the customer in the operation and maintenance of the power system. I, , received instructions on Please print name of person receiving instructions.Date Signature To be filled out by the commissioning technician only. Completed by (signature): Print Name: Company: Date: Note: Completion of this checklist does not relieve the installer of contract obligations. To be filled out by the customer/client. This signature acknowledges acceptance of unit and that all information on the start‐up is correct. The owner representative signature acknowledges review and understanding of this Form B – Engine Generator Set Installation and Commissioning. Witnessed by (signature): Print Name: Company: Location: Date: © MT U | Su b j e c t to ch a n g e . | 20 20 - 0 5 For generator sets built in the US: This form can be obtained from your MTU Distributor. When complete, please submit either via email or hard copy to: Email address: warrantyclaims-oed@mtu-online.com Hard copy: ATTN: Warranty Department MTU America Inc. 100 Power Drive Mankato, MN 56001