TM-M001_R01

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AALLTTEER R AATTIIOO N NSS

PCM NO. DESCRIPTION AUTHOR. BY DATE

CHECK

Added owner’s approval date for Rev.0. Owner VIVEK 24th

Sept 09 Choong

REFERENCE PLANS

NO. TITLE PLAN NO. PLAN BY

This document and the information which it contains are confidential and are the property of Keppel-FELS Ltd. It is loaned to you for the limited purpose of

assisting you with operation and maintenance of the equipment which you have purchased from Keppel-FELS Ltd. It remains the property of Keppel-FELS Ltd. It

may not be reproduced in whole or in part without Keppel-FELS prior written consent. It may not be disclosed to persons not having need of disclosure for the loan

and it is to be returned to Keppel-FELS Ltd upon completion of the use for which it was loaned.

PRINT RECORD

JOB: DSS 38 - DP2 DRILLING

SEMI-SUBMERSIBLE

FOR 9000 FEET WATER DEPTH

DATE : 28th May 2009 SCALE : N.T.S TITLE:

DESIGNED BY : Keppel FELS HULL/JOB NO : B309 TEST MEMO FOR

DRAWN BY : JAI COST CODE NO: - MAIN GENERATOR

CHECKED BY : YANG APPROVED BY : CHOONG

APPROVED BY : DATE : SHEET 1 OF 46 SHEETS

OWNER QGOG 14-AUG-09 ALT. NO.

CLASS

K-FELS

DRAWING NO : TM-M001

OWNER

DRAWING NO : -

1

A4 (285 X 199)

Keppel FELS Limited

50, Gul Road

Singapore 629351Tel: ( 65) 68637200

Fax: (65) 68631739

11

11

29-Sep-09

Printed from GEMS

No Signature Required

DATE PRINTED

REVISION

Alpha Star Ltd

ABS Site

QA

PJS

PJS(C)

11/08

0

4

2

2

5

5

29/09

1

4

2

2

5

5

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Project: B309 Page 2 of 46

Doc. No. : TM-M001 Alt. 1

Title: Test Memo For Main Generator Date: 24-Sep-09

T T M M -- M M 000011 R R11 M M aaiinn GGeenneer r aat t oor r

1.0 REFERENCE

No. Description KFELS

Commissioning

Supervisor

1.1 Main specification for construction and outfitting of the DSS 38 - DP2, deep water of 9000

feet development Semi Submersible.1.2 ME 20-710G9B-T1Electro Motive Diesel engine - Operation and Maintenance Manual.

1.3 Keppel FELS drawing no. M101-10 Machinery Arrangement – Generator Room No.1

(Stbd/Lower & Tween Deck).

1.4 Keppel FELS drawing no. M101-11 Machinery Arrangement – Generator Room No.2

(Port/Lower & Tween Deck).

1.5 Keppel FELS drawing no. M201-05 Ventilation Arrangement and Details – Generator

Room No.1 (Stbd/Lower & Tween Deck).

1.6 Keppel FELS drawing no. M201-06 Ventilation Arrangement and Details – Generator

Room No.2 (Port/Lower & Tween Deck).

1.7 KEPPEL FELS drawing no. P107 Piping Diagram - Fuel Oil System

1.8 Keppel FELS drawing no. P113-1 Piping Diagram – Central Cooling System (Sea Water).1.9 Keppel FELS drawing no. P114 Piping Diagram – Engine Exhaust System.

1.10 Keppel FELS drawing no. P116-1 Piping Diagram – Rig Air System

1.11 Keppel FELS drawing no. P117 Piping Diagram – Starting Air System

1.12 Keppel FELS drawing no. P118-1 Piping Diagram – Lube Oil System

1.13 Keppel FELS drawing no. P118-2 Piping Diagram – Waste Oil System

1.14 Keppel FELS drawing no. E052, One Line Diagram 480VAC Main Switchboard A-B.

1.15 Keppel FELS drawing no.E059 One Line Diagram – 220 / 127 VAC Main Switchboard 1

- 2.

1.16 Keppel FELS drawing no. E051, One Line Diagram – 11 KVAC Main Switch board.1.17 Keppel FELS drawing no. E301, Schematic & Arrangement – Main Generator controls

2.0 PURPOSE

2.1 To ensure proper installation of main generators.

2.2 To demonstrate operational capabilities of main generators.

2.3 To demonstrate proper functioning of control and safety devices.

3.0 SYSTEM DESCRIPTION

3.1 System:

The purpose of the main generators is to supply power to the whole rig. The system consists of Ten

generator sets and a main switchboard. In order for the generator sets to function properly, the starting air

system, sea water cooling system, ventilation system inside engine room, fuel oil system and lube oil system

play an integral part.

3.2 Mechanical:

It consists of Ten (10) (ME 20-710G9B-T1) x EMD diesel engines with NOV Baylor generator ( Model no

855ZXT rated 3580 eKW ) as prime mover of the system, design output of each generator set is 3560 eKW

@ 900 rpm. The diesel engine and the alternator are coupled by flexible coupling.

3.3 Piping:

It consists of starting air piping, diesel piping, lube oil & waste oil piping, exhaust piping and cooling water

piping system.

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3.4 Electrical & Instrumentation:

The output power from generator is 4450 KVA, which is distributed throughout rig by 11 KVAC Main

Switchboard and 480VAC Main Switchboard A-B. The Generators are designed for a power factor of 0.8.

4.0 EQUIPMENT REQUIRED


Commissioning

Supervisor

4.1 Voltmeters*: 0-1500 volt, 0-1000 volt, 0-250 volt, 0-25 volt (2% accuracy)

4.2 Ammeter *

4.3 Ohmmeter *

4.4 Insulation resistance tester *

4.5 Thermometer *

4.6 Tachometer *

4.7 Stopwatch4.8 Load banks for load testing the generators ( 10680 KW, 13350 KVA)

4.9 Walkie Talkie

*NOTE: All test instruments shall bear certificate of calibration dated within 12 months of test.

5.0 PRE-OPERATIONAL CHECK


Commissioning

Supervisor5.1 Pre-operational checks shall be conducted by vendor service engineer as per manufacturer’s

standard.

Verify all major items listed on FAT PAIRS and Punch lists are closed by QGOG.

All necessary adjustments for alignment and crankshaft deflection of each generator have

completed and the readings are within tolerance of manufacturer recommended values and

accepted by QGOG/ABS and recorded by KFELS QA.

Crank case and alternator of each unit is inspected by QGOG, it is clean, no foreign materials

found and moisture free.

Crankshaft has been turned by turning device and found no mechanical interference.

Turbochargers have been checked.Record data found on the equipment nameplates in Table 1.0 and verify them against design

data.

5.2 Engine isolation height to be measured for all the engines before starting the test.

5.3 The main generators have been installed as per KFELS drawing no. M101-10 Machinery

Arrangement – Generator Room No.1 and M101-11 Machinery Arrangement – Generator

Room No 2. Mounting and alignment of generator sets are accepted by QGOG/ABS and

documented by KFELS QA.

5.5 Pipe works for cooling water system have been installed as per KFELS drawing P113-1

Piping Diagram – Central Cooling System (Sea water), hydro-tested, reinstalled, and accepted

by QGOG/ABS and documented by KFELS QA.

Jacket water with recommended additives for each engine is filled up to required level.

5.6 The fuel oil piping system from the service tank to generator and return line has been installedas per KFELS drawing no. P107 Piping Diagram - Fuel Oil System, hydro-tested, reinstalled,

accepted by QGOG/ABS and documented by KFELS QA.

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Commissioning

Supervisor

5.7 The lube oil piping system has been installed as per KFELS drawing no. P118-1 Piping

Diagram - Lube Oil System and P118-2 Piping Diagram – Waste Oil System, hydro-tested,

reinstalled, accepted by QGOG/ABS and documented by KFELS QA.

Lube oil sump low level alarm is tested before filling lube oil and documented by KFELSQA. Engine lube oil sump is filled up with manufacturer recommended lube oil.

Pre-lube oil pump is operated and checking has been done for leaks within the skid.

Lubrication NDE/DE Alternator shall be connected to 230 V UPS and 480 VAC Main.

5.8 Starting Air system test is installed as per KFELS drawing no P116-1 Rig Air System and

P117 Starting Air system, hydro tested, reinstated, accepted by QGOG/ABS and documented

by KFELS QA.

5.9 The electrical system has been installed as per KFELS drawing no. E051 One line diagram –

11KVAC Main Switchboard, E052, One line diagram - 480VAC Main Switchboard A-B,

E059, One line diagram - 220 / 127 VAC Main Switchboard 1-2., E301 Schematic &

Arrangement – Main Generator controls. Continuity checks and megger checks have been

done and the installation is accepted by QGOG/ABS and documented by KFELS QA.

Entire switchboard and transformers have been thoroughly cleaned and all foreign materials

removed. Commissioning team has completed the pre-commissioning of all AC modules.5.10 All preservation items such as silicon packages within engine and switchboard have been

removed. All non-essential items blocking the passages and equipment inside engine room

have been removed.

5.11 All penetrations for instruments, pipe works have completed before diesel filling into the FO

(day) tanks as per KFELS drawing no. H701-03 Settling & Day Tank Detail in Aux Mech

Room No-1 (Stbd). All fuel tanks and temporary tanks are cleaned and free from foreign

matters.

Permanent FO tanks to be properly treated and witness by QGOG.

5.12 Starting air system is ready and operational. Check air pressure on the receiver after charging

is 145 psi.

5.13 Portable fire extinguishers are readily available inside the engine room if C02 fire fighting

system is not ready.5.14 Insulation Resistance inspected and verified by vendor:

a) Stator insulation resistance not less than 1.6 M ohms, Actual value:

b) Rotor insulation resistance not less than 1.6 M ohms, Actual value:

c) Field insulation resistance not less than 1 M ohms, Actual value:

d) PMG Stator insulation resistance not less than 1.6 M ohms, Actual value:

e) PMG Rotor insulation resistance not less than 1.6 M ohms, Actual value:

f) Cable insulation resistance not less than 1000 M ohms, Actual value:

g) Insulation resistance between switchboard bus bars not less than 1.6 M ohms, Actual

value:h) Insulation resistance between transformer difference phases not less than 1.6 M ohms,

Actual value:

5.15 Filters and strainers are checked.

5.16 Generator space heaters should be powered for at least 24 hours prior to operation as per

manufacturer’s recommendation.

5.17 Important:

Confirmation of generator breaker setting and generator breaker operational test are to be

satisfactorily carried out including, but not limited to overload protection, prime mover

shutdown, under voltage protection and reverse power protection before start of item

6.3, 6.4.

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6.0 TEST PROCEDURE

All works are to be suspended on the Main Switchboard before the Engine start up.

All non-essential personnel need to vacate from the Main voltage switchboard room during the testing.

Note: Operation of the governor will comply to Part 4-3-4/ 3.19.1

Ensure generator being loaded / unloaded is on the opposite bus as load to allow the full amount of current to pass through the tie breaker.


Commissioning

Supervisor

QGOG

Representative

ABS (where

applicable)

6.1 Start-Up and Shut-Down

A brief start up and shut down will be demonstrated under this

test. Verify all the gauges, instruments on the control panel are

working.

N.A N.A

6.1.1 Start diesel engine according to manufacturer’s procedure(refer to Reference Document #1). Adjust it to rated speed of

900 rpm.

Note: Ensure breaker is in open position.

N.A N.A

6.1.2 Demonstrate the shut down by turning the engine control

switch to Off/Reset. Again restart the engine and demonstrate

the shut down by Emergency-stop switch at medium voltage

room and local engine panel.

N.A N.A

6.1.3 Check engine and all auxiliary equipment for signs of defects

and discrepancies (e.g. abnormal noise, vibration, leakage,

etc.). Record and rectify any inadequacies found.

N.A N.A

6.1.4 Lubrication of alternator bearings shall be continuously

checked during the commissioning test. N.A N.A

6.1.5 Repeat step 6.1.1 to 6.1.4 for all generator sets. N.A N.A

6.2 Shutdown and Alarm Setting Tests


Commissioning

Supervisor

QGOG

Representative

ABS (where

applicable)

6.2.1 Simulate over speed trip through generator control panel.

Verify the engine trip when over speed simulated. Record the

results. Repeat this at diesel generator local control panel andat EGCP-3.

6.2.2 Simulate low lube oil pressure by isolating the pressure

transducer from line pressure.

6.2.3 Simulate high jacket water temperature by removing

temperature sensor from the engine and exposing it to higher

temperature. 96.1C . Verify the alarm and record

the results.

6.2.4 Switchboard vendor to confirm all control panel

Configuration menus for all generators are set for correct

generator parameters.

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Commissioning

Supervisor

QGOG

Representative

ABS (where

applicable)

6.2.5 All switch board insulation tests and generators control panel

settings for both “Hard & Soft” shutdowns are set same for all

the generators and verified by vendor in the following

electrical test memo:11KVAC Main Switchboard Test Memo TM-E001, 480VAC

Switchboard Test Memo TM-E004, 480VAC Emergency

Switchboard Test Memo TM-E005 and 480VAC MCC Test

Memo TM-E006.

Also, check whether they comply with ABS requirements.

6.2.6 Repeat the steps 6.2.1 to 6.2.5 for all the 10 generators and

record the results in Table 2.1 to 2.10.

Alarm Test

6.2.7 Simulation of all alarm conditions shall be conducted by the

service engineer and recorded in the corresponding Table 2.1to 2.10 by KFELS QA. Verify each alarm circuit and alarm

indication on generator instrumentation panel.

6.3 Load Test and Endurance Trial


Commissioning

Supervisor

QGOG

Representative

ABS (where

applicable)

Carry out the following procedures and record data in Table 3.1 ~ 3.10.

Engine power = 3730 bKW, Generator design output = 3560 ekW.

Load bank = 3 x 3560= 10680 kW, (13350kVA), 11 KVA for parallel operation.

6.3.1 Start generator #1 with no load connected.

6.3.2 Preset the load at 10% full load. Start the unit and let the

controller warm up the engine at idle speed. Raise the

engine to full speed till we reach the operating

temperature.

6.3.3 Increase the load from 0% to 100% at 25% intervals and

run the generator for 15 min and till temperature settles at

each load setting before each 25% increase. For 100%

load, run the generator for 3 hrs.

Increase the load to 110% (or maximum fuel rack position)

and run the generator for 1 hr.

Record all results in Table 3.1 to 3.10.

6.3.4 Measure the diesel level in the Fuel Oil Tank before and

after the 100% load test to determine the specific fuel

consumption. Record the results in Table 1.0.

6.3.5 Check for tightness and integrity for all expansion joints,

silencers, pipe hangers of engine exhaust system.

6.3.6 Reduce the load in decrement and allow the engine to cool

down before shut down.

6.3.7 Repeat 6.3.1 to 6.3.6 for the rest of the generators.

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6.4 Parallel Tests

The following tests will demonstrate the capabilities of generator sets to share the load on the bus bar.

Carry out the following procedures and record data in Table 4.1 ~ Table 4.13.

Automatic synchronizing shall be function tested during the test.

Load on any generator is not to differ more than 15% of the rated output of the generator during these tests as per

ABS requirement:

1) Part 4-3-4 Section 3.21.2 on Steady State Condition

2) Part 4-3-4 Section 3.21.3 on Parallel Operation

3) Part 4-3-4 Section 3.21.3a on Reactive Load Sharing

Note: Load percentage described below is the percentage of rated output power of one generator unit.


Commissioning

Supervisor

QGOG

Representative

ABS

(Where

applicable)

6.4.

1

Run generator no. 1, close breaker to the main switch board bus

and increase load gradually to 100%.

6.4.

2

Start generator no. 2, synchronize and parallel with the bus. Load

up to 7120kW (2 generators running full load)

Observe the load sharing at 2x50% (7120/2=3560 kW).

Record load and current on each generator in Table 4.1 for

2x50% load.

6.4.

3

Start generator no. 3, synchronize and parallel with the bus.

Observe the load sharing at 3x33.33% (10680/3=3560 kW).


3x33.3% load.

6.4.

4


Observe the load sharing at 4x25% (10680/4= 2670 kW).

Record load and current on each generator in Table 4.3 for 4 x

25% load.

6.4.

5


Observe the load sharing at 5x20% (10680/5= 2136 kW).


5x20% load.

6.4.

6


Observe the load sharing at 6x16.67% (10680/6= 1780 kW).Record load and current on each generator in Table 4.5 for

6x16.67% load.

6.4.

7


Observe the load sharing at 7x 14.28% (10680/7= 1525.7 kW).

Record load and current on each generator in Table 4.6 for 7x

14.28% load.

6.4.

8


Observe the load sharing at 8x 12.5% (10680/8= 1335 kW).


12.5% load.

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Commissioning

Supervisor

QGOG

Representative

ABS

(Where

applicable)

6.4.

9


Observe the load sharing at 9x 11.11% (10680/9=1186.6 kW).

Record load and current on each generator in Table 4.8 for 9x11.11% load.

6.4.

10


Observe the load sharing at 10x 10% (10680/10= 1068 kW).


10% load.

6.4.

11

Remove load from generator no. 1 and disconnect it from the bus.


11.11% load.

6.4.

12Remove load from generator no. 2 and disconnect it from the bus.


12.5% load.

6.4.



14.28% load.

6.4.

14

Remove load from generator no. 4 and disconnect it from the bus.


6x16.67%.

6.4.


Record load and current on the remaining generator 4 in Table

4.14 for 5x20% load.

6.4.



25% load.

6.4.



3x33.3%.

6.4.


Record load and current on the remaining generator in Table 4.17

for 2x50% load.

6.4.

20

Remove the load from the generators slowly and shut down the

generators.

6.4.

21

During load test of Generator no. 4 and 5 in section 6.3,

observe the load sharing at 2x50% (each generator running at

max. load of 3560 kW, total 7120 KW).


2x50% load.

6.4.

22

During load test of Generator no. 6 and 7 in section 6.3,

observe the load sharing at 2x50% (each generator running at

max. load of 3560 kW, total 7120 KW).


2x50% load.

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Commissioning

Supervisor

QGOG

Representative

ABS

(Where

applicable)

6.4.

23

The reactive loads of the individual generating sets are not to

differ from their proportionate share of the combined reactive

load by more than 10% of the rated reactive output of the largest

generator, or 25% of the smallest generator, which ever is less.

6.5 Reverse Power Test


Commissioning

Supervisor

QGOG

Representative

ABS

(Where

applicable)

6.5.1 Carry out the following procedures and record data in

Table 5.1

6.5.2 Start generators 1 and 2 with no load connected.

6.5.3 Synchronize and parallel run these two generators.

6.5.4 Regulate the loading on generator 2 until a reverse power

of 10% is reached on generator 1. Verify that reverse

power relay is tripping-out before 10% reverse power.

Increase the relay setting if necessary.

6.5.5 Record time taken for circuit breaker to trip with 10%

reverse power (about 10 seconds).

6.5.6 Repeat steps 6.5.2 to 6.5.5 for remaining generators #6 to

#10. Record the result in Table 5.2.

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6.6 Block Load Test

These tests are to be recorded on a chart recorder.


CommissioningSupervisor

QGOG

Representative

ABS (where

applicable)

6.6.1 Start generator #1 with no load connected.

6.6.2 Increase load abruptly to 50% (of rated output). Verify that

momentary speed variation does not exceed 10% of engine

rated speed and the voltage variation are within the range of

minus (-) 15% to plus (+) 20% of rated voltage. The

Voltage is to be restored within plus or minus 3% of the

rated voltage in not more than 1.5 seconds.

Record data in Table 6.0.

6.6.3 Increase load abruptly from 50% to 100% (of rated output).

Verify that momentary speed variation does not exceed 10%of engine rated speed and the voltage variation are within

the range of minus (-) 15% to plus (+) 20% of rated voltage.

The Voltage is to be restored within plus or minus 3% of

the rated voltage in not more than 1.5 seconds.


6.6.4 Decrease load abruptly from 100% to 0% (of rated output).

Verify that momentary speed variation does not exceed 10%

of engine rated speed and the voltage variation are within

the range of minus (-) 15% to plus (+) 20% of rated voltage.

The Voltage is to be restored within plus or minus 3% of

the rated voltage in not more than 1.5 seconds.


6.6.5 Shutdown the generator.

6.6.6 Repeat steps 6.6.1 to 6.6.5 for the rest of the generator sets.

6.7 Post Test Check


Commissioning

Supervisor

QGOG

Representative

ABS (where

applicable)

6.7.1 Check whether the Engine vibration isolator height iswithin the allowable tolerance. Result shall be witnessed

by KFELS/QGOG/ABS.

6.7.2 Alignment of Engine and alternator to be checked after

engine test has been completed.

6.7.3 Post test check shall be conducted by service engineer as

per manufacturer’s standard. Record if any abnormalities.

6.7.4 Multilin settings shall be recorded by vendor and attached

to test memo results.

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DATA SHEET

Table 1.0 ENGINE DATA

Make/Model : EMD / ME 20-710G9B-T1

Engine rated power : 3730 bkW @ 900 rpm

Generator Model : 855ZXT

Generator rated power : 3580 ekW (11KVA/3ph/60Hz)

Generator set output : 3560 ekW (11KVA/3ph/60Hz)

Specific fuel consumption :

Description Gen.Set

No.1

Gen.Set

No.2

Gen.Set

No.3

Gen.Set

No.4

Gen.Set

No.5

Gen.Set

No.6

Gen.Set

No.7

Gen.Set

No.8

Gen.Set

No.9

Gen.Set

No.10

Tag No.

Engine S.No.

Alternator

S.No.

Output

Power (kW)

Specific Fuel

Consumption

(g/kWh)

Cooler No.

Governor

Alternator

lubricating

unit (Drive

End)

Alternator

lubricating

Unit(Non

Drive End)

Note: All engine/generator tests will be performed utilizing fuel conforming to Grade DF-2

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Table 2.1 SHUTDOWN AND ALARM TESTS FOR ENGINE/GENERATOR SET NO.1

Rated Speed - 900 rpm

Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set

point Alarm Shutdown Remarks

High Jacket Water Temperature 215 °F 190-212 °F X

Low Oil Pressure 27 PSIG 40-100 PSIG X

High Crankcase Pressure 1” H2O 0.8-1.3”

H2O X

Low Engine Coolant Level [switch] [switch] X

Low Oil Level (External Tank) [switch] [switch] X

High Oil Temperature 210 ºF 200–215 ºF 220 °F

Low Turbo soak back Oil Pressure 6 PSIG 8–30 PSIG X

Low Pre Lube Oil Pressure 10 PSIG 15-30 PSIG XHigh Intake Air Filter Restriction 14” H2O 6-10” H2O X

Emergency Stop [switch] [switch] X

Low Lube Oil Temperature 80 ºF 85-100 ºF X

Over speed Shutdown (RPM ) 990 899-902 X

Engine Over crank (Failed to Start) 3 attempts 3 attempts X

Intake Air Shut off Valve Tripped [switch] [switch] X

Engine Mode Selector Not in Remote

Auto [switch] [switch] X

Generator Lock-Out Relay Shutdown [switch] [switch] X

High Cylinder Temperature 1200 ºF 850–1100 ºF X

Low Oil Pressure 37 PSIG 40–100

PSIG X

High Jacket Water Temperature 205 ºF 190– 212 ºF X

Low Fuel Pressure 35 PSIG 40–60 PSIG X

Low Jacket Water Pressure, Right

Bank 25 PSIG 30-60 PSIG

X

Low Jacket Water Pressure, Left


X

High Lube Oil Filter Differential

Pressure 20 PSIG 5-15 PSIG

X

High Fuel Oil Filter Differential

Pressure 10 PSIG 4 -7 PSIG

X

High Engine Main Bearing

Temperature 270 °F 200-260 °F 290 °F

High Generator Stator Temperature 284 °F 270-280 °F X

High Generator Bearing Temperature 194 °F 180-190 °F X

Low Starting Air Pressure 70 PSIG 75-125 PSIG X

High Generator Air Inlet 140 °F 113-130 °F X

Generator Coolant leak [switch] X

Note: Observed set point should be +/- 5% of Design set point or +/-1 % unit whichever is greater.

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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X





Low Pre Lube Oil Pressure 10 PSIG 15-30 PSIG X

High Intake Air Filter Restriction 14” H2O 6-10” H2O X











PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F




High Generator Air Inlet 140 °F 113-130 °F

X



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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X

















PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F





X



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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X

















PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F





X



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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X

















PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F





X



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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X

















PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F





X



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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X

















PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F





X



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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X

















PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F





X



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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X
















PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F







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Description

Design

Trip Set

Point

Min – Max

Set Point

Observed Set





H2O X
















PSIG X





X



X



X



X


Temperature 270 °F 200-260 °F 290 °F







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Table 3.1 LOAD AND ENDURANCE TEST FOR ENGINE/GENERATOR NO 1

Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15

1. Engine Speed (rpm)

2. Engine Frequency (Hz)

3. Engine % load meter reading

4. Alternator voltage (V)

L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital

L3

Analogue6. Alternator

output

(kW) Digital

7. Alternator output (kVA)


output

(kVAR) Digital

9. Actuator (mA)

10. Field

excitation Current (A)

A1 (oC)

A4 (oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)

15. Lube oil pressure (Psig)

16. Lube oil temperature (°F)

17. Fuel Pressure (Psig)

18. Fuel oil temperature (°F)

19. Inlet air temperature (oF)

20. Fuel filter diff. pressure (Psig)

21. Jacket water outlet temperature (°F)

22. Jacket water pressure (Psig)

23. Post turbo exhaust temperature (°F)

24. Ambient temperature (o

C)

25. Exhaust gas color to check @ 100%

load for feel of proper combustion N/A N/A N/A N/A N/A

26. Fuel Rack setting @ 100% load N/A N/A N/A N/A N/A


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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital

L3


output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (

o

C)A4 (

oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)










24. Ambient temperature (oC)





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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital

L3


output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (o

C)A4 (

oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)















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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital

L3


output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (

o

C)A4 (

oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)














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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital

L3Analogue6. Alternator

output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (oC)

A4 (oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)











C)




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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital


output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (oC)

A4 (oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)











C)




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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital


output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (oC)

A4 (oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)











C)




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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital


output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (oC)

A4 (oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)











C)




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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital


output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (oC)

A4 (oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)











C)




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Load (%) 0 25 50 75 100 100 100 110

Power Factor 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8

Duration (min) 0 15 15 15 60 60 60 15





L1

L2Analogue

L3

L1

L2

5. Alternator

current (A)

Digital


output

(kW) Digital



output

(kVAR) Digital

9. Actuator (mA)

10. Field


A1 (oC)

A4 (oC)

B2 (oC)

B5 (oC)

B3 (oC)

11.

Winding temp.

(from swbd)

(max)

B6 (oC)

12. Bearing temp.

(max) Non-Drive (

oF)

13. Power (Kw)











C)




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Table 4.0 PARALLEL LOAD TEST

All Load Test are to be made with load bank set at 0.8 power factor.

Table 4.1 GEN NO.2 PARALLEL TO GEN NO. 1

Item Units Actual Load Remarks

Total Load On Line /

Actual Load (kW) 2x50% (7120 kW/8900 KVA Total)

Gen. Set No.1 (kW)

(50% of 7120=3560 kW) (A)

Gen. Set No.2 (kW)

(50% of 7120=3560 kW) (A)

Table 4.2 GEN NO.3 PARALLEL TO BUS



Actual Load (kW) 3x33.33% (10680 kW/13350 KVA Total)

Gen. Set No.1 (kW)

(33.33%x10680=3560 kW) (A)

Gen. Set No.2 (kW)

(33.33%x10680=3560 kW) (A)

Gen. Set No.3 (kW)

(33.33%x10680=3560 kW) (A)




Actual Load (kW) 4x25% (10680 kW /13350 KVA Total)

Gen. Set No.1 (kW)

(25%x10680=2670 kW) (A)

Gen. Set No.2 (kW)

(25%x10680=2670 kW) (A)

Gen. Set No.3 (kW)

(25%x10680=2670 kW) (A)

Gen. Set No.4 (kW)

(25%x10680=2670 kW) (A)

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Gen. Set No.1 (kW)

(20%x 10680 kW =2136 kW) (A)

Gen. Set No.2 (kW)

(20%x 10680 kW =2136 kW) (A)

Gen. Set No.3 (kW)

(20%x 10680 kW =2136 kW) (A)

(kW)Gen. Set No.4

(20%x 10680 kW =2136 kW) (A)

(kW)Gen. Set No.5

(20%x 10680 kW =2136 kW) (A)





Gen. Set No.1 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.2 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.3 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.4 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.5 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.6 (kW)

(16.67%x10680= 1780 kW) (A)

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Actual Load (kW) 7x 14.28% (10680 kW/13350 KVA Total)

Gen. Set No.1 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.2 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.3 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.4 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.5 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.6 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.7 (kW)

(14.28% x10680=1525.7 kW) (A)





Gen. Set No.1 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.2 (kW)

(12.5%x10680=1335 kW) (A)Gen. Set No.3 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.4 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.5 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.6 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.7 (kW)

(12.5%x10680=1335 kW) (A)

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Gen. Set No.8 (kW)

(12.5%x10680=1335 kW) (A)





Gen. Set No.1 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.2 (kW)

(11.11%x10680=1186.6 kW) (A)Gen. Set No.3 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.4 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.5 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.6 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.7 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.8 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.9 (kW)

(11.11%x10680=1186.6 kW) (A)

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Gen. Set No.6 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.7 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.8 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.9 (kW)

(11.11%x10680=1186.6 kW) (A)

Gen. Set No.10 (kW)

(11.11%x10680=1186.6 kW) (A)

Table 4.11 GEN NO.2 DISCONNECTED FROM BUS



Actual Load (kW) 8x 12.5% (10680 kW /13350 KVA Total)

Gen. Set No.3 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.4 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.5 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.6 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.7 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.8 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.9 (kW)

(12.5%x10680=1335 kW) (A)

Gen. Set No.10 (kW)

(12.5%x10680=1335 kW) (A)




Actual Load (kW) 7x 14.28% (10680 kW /13350 KVA Total)

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Gen. Set No.4 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.5 (kW)(14.28% x10680=1525.7 kW) (A)

Gen. Set No.6 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.7 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.8 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.9 (kW)

(14.28% x10680=1525.7 kW) (A)

Gen. Set No.10 (kW)

(14.28% x10680=1525.7 kW) (A)





Gen. Set No.5 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.6 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.7 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.8 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.9 (kW)

(16.67%x10680= 1780 kW) (A)

Gen. Set No.10 (kW)

(16.67%x10680= 1780 kW) (A)



Total Load On Line /Actual Load

(kW) 5x20% (10680 kW/13350 KVA Total)

Gen. Set No.6 (kW)

(20%x 10680 kW =2136 kW) (A)

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Gen. Set No.7 (kW)

(20%x 10680 kW =2136 kW) (A)

Gen. Set No.8 (kW)(20%x 10680 kW =2136 kW) (A)

Gen. Set No.9 (kW)

(20%x 10680 kW =2136 kW) (A)

Gen. Set No.10 (kW)

(20%x 10680 kW =2136 kW) (A)





Gen. Set No.7 (kW)

(25%x10680=2670 kW) (A)

Gen. Set No.8 (kW)

(25%x10680=2670 kW) (A)

Gen. Set No.9 (kW)

(25%x10680=2670 kW) (A)

Gen. Set No.10 (kW)

(25%x10680=2670 kW) (A)





Gen. Set No.8 (kW)

(33.33%x10680=3560 kW) (A)

Gen. Set No.9 (kW)

(33.33%x10680=3560 kW) (A)

Gen. Set No.10 (kW)

(33.33%x10680=3560 kW) (A)

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Gen. Set No.9 (kW)

(50% of 7120=3560 kW) (A)

Gen. Set No.10 (kW)

(50% of 7120=3560 kW) (A)


Note : This test can be performed during load test of Gen Set No.4 and No.5.




Gen. Set No.4 (kW)

(50% of 7120=3560 kW) (A)

Gen. Set No.5 (kW)

(50% of 7120=3560 kW) (A)


Note : This test can be performed during load test of Gen Set No. 6 and No.7.




Gen. Set No.6 (kW)

(50% of 7120=3560 kW) (A)Gen. Set No.7 (kW)

(50% of 7120=3560 kW) (A)

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Table 6.0 BLOCK LOAD TEST

Common Data

Engine Rated Speed : 900 rpm

Output Power (100%) : 3560 ekW (11KVA/3ph/60Hz)

Output Power (50%): 1780 ekW (11KVA/3ph/60Hz)

Load

Condition

Status Voltage

Control

Panel

(V)

Dev

(%)

Freq.

(Hz)

Analog

Panel

Meter

Dev

(%)

Time taken to Steady State

Condition (sec)

0% Initial

0% to 50% Momentary

50% Final

50% Initial

50% to 100% Momentary

100% Final

100% Initial

100% to 0%. Momentary

Generator No. 1

0% Final

0% Initial

0% to 50% Momentary

50% Final

50% Initial

50% to 100% Final

100% Final

100% Initial


Generator No.2

0% Final

0% Initial

0% to 50% Momentary

50% Final

50% Initial50% to 100% Momentary

100% Final

100% Initial


Generator

No.3

0% Final

0% Initial

0% to 50% Momentary

50% Final


100% Final

Generator

No.4

100% Initial

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Load

Condition

Status Voltage

Control

Panel

(V)

Dev

(%)

Freq.

(Hz)

Analog

Panel

Meter

Dev

(%)


Condition (sec)

100% to 0%. Momentary0% Final

0% Initial

0% to 50% Momentary

50% Final

50% Initial


100% Final

100% Initial


Generator

No.5

0% Final

0% Initial

0% to 50% Momentary

50% Final

50% Initial


100% Final

100% Initial


Generator

No.6

0% Final

0% Initial

0% to 50% Momentary

50% Final

50% Initial


100% Final

100% Initial


Generator

No.7

0% Final

0% Initial

0% to 50% Momentary

50% Final

50% Initial


100% Final

100% Initial


Generator

No.8

0% Final

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Load

Condition

Status Voltage

Control

Panel

(V)

Dev

(%)

Freq.

(Hz)

Analog

Panel

Meter

Dev

(%)


Condition (sec)


50% Final

50% Initial


100% Final

100% Initial


Generator

No.9

0% Final

0% Initial

0% to 50% Momentary

50% Final

50% Initial


100% Final

100% Initial


Generator

No.10

0% Final

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Table 7.0 Instrumentation (ALL WORKING CORRECTLY)

Results

Gen.

Set

No.1

Gen.

Set

No.2

Gen.

Set

No.3

Gen.

Set

No.4

Gen.

Set

No.5

Gen.

Set

No.6

Gen.

Set

No.7

Gen.

Set

No.8

Gen.

Set

No.9

Gen.

Set

No.10

KFELS

Comm.

Supervisor

Temperature

meter (0 - 100

C)

Ammeter

Kilowatt meter

Running Hour

timer

kVAR meter

Voltm

Date post:	05-Jul-2018
Category:	Documents
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