PROCEDURE FOR LOAD TESTING OF DIESEL GENERATOR Doc No : UES/MSLT

METHOD STATEMENT Rev No : 0

PROCEDURE FOR LOAD TESTING

OF DIESEL GENERATOR

FOR STANDBY POWER

CUMMINS GENERATOR

Prepared by Reviewed by Approved by

REV No DATE
MT / UES

Reviewed by
Consultants :

Date:

Rev no and date Reasons for revision

Rev 0 dated 15.9.2016 As submitted

 PROCEDURE FOR LOAD TESTING OF DIESEL GENERATOR Doc No : UES/MSLT
METHOD STATEMENT Rev No : 0

INDEX

SR.NO DESCRIPTION PAGE NO.

01 SCOPE / OBJECTIVE 03

02 REFERENCE 03

03 GENERAL INSTRUCTIONS 03

04 SAFETY REQUIREMENTS 03

05 RESPONSIBILITIES 04

06 INSPECTION AND TEST PROCEDURE 04

07 TESTING INSTRUMENTS 05

08 RECORDS 05
 PROCEDURE FOR LOAD TESTING OF DIESEL GENERATOR Doc No : UES/MSLT
METHOD STATEMENT Rev No : 0

1 Scope / Objective

This method statement explains the procedure for Load test on Diesel Generators Using
Resistive Load Bank at Unity Power Factor.

2 Reference

a. Load Test Format

3 General Instructions

a. The Testing of the Generator will be carried out at UES Facility

b. The testing of Generator will commence only after a proper walk around
inspection by the Testing Engineer.
c. Access to area / equipment under test shall be restricted to authorized personnel
only.

4 Safety Requirements

Health and safety procedure as followed by UES/BEC will be implemented for this job.
The responsible safety officer as per procedure will conduct routine inspection.

4.1 Safety Rules during testing

In order to ensure safe condition during testing the following rules have to be followed:

4.1.1 Persons engaged with inspection and testing have to be Skilled and have received
proper and adequate training related to procedures and test equipment utilized for the
particular testing activity.
4.1.2 Test Instrument should be maintained in a safe condition and the test method not
to create danger for the operator or for other persons.

4.2 Safety Lighting

Safety lighting will be used in cease of power failure ensuring adequate illumination of
the working area to aid evacuation when necessary.

4.3 Task Lighting

Adequate lighting shall be provided to ensure illumination within the working area.
 PROCEDURE FOR LOAD TESTING OF DIESEL GENERATOR Doc No : UES/MSLT
METHOD STATEMENT Rev No : 0

4.4 Emergency Arrangement

4.4.1 General safety procedure will be followed in case of emergency the most senior
employee present will stop the works and make the necessary emergency arrangements
and report to the assembly points.

4.4.2 Fire Protection: No significant fire risks associated with this activity but general
fire protection measures will be taken as per main contractor instruction.

4.4.3 Communication from site areas to site officer via mobile phones issued to
engineer.

5 Responsibilities

UES Testing Engineer will have the overall responsibility for the Generator for
commissioning Quality and Safety.

6 Test Procedure

Inspection and Test Procedure

6.1 Inspection prior to starting the Diesel Generator Set

• Generator set details

Cummins DG set

• Generator set Environment and services

Surrounding clean and clear from obstruction

• Safety Checks

Ensure starting is inhabited until start up is required

Set clean and fully assembled
No loose material near the set
Air duct clear and clean

• Cooling System

Check coolant level in radiator

Radiator, engine and pipe work check for leaks
Belt and Guard check for safety / slipping
Leak Check

• Fuel System

Tank Filled
Leak check
 PROCEDURE FOR LOAD TESTING OF DIESEL GENERATOR Doc No : UES/MSLT
METHOD STATEMENT Rev No : 0

• Lubrication System

Engine oil filled to correct level in the oil pan

• Starting System

Batteries installed, filled and connected

• Exhaust System

Check Leaks

• Electrical System

All wiring checks for any loose connection

6.2. Test Procedure

The set is run on no load for 5 minutes.

Genset will be tested with Unity Power Factor Load from a Resistive load bank for
a duration of 2 hour in the gradual loading pattern, i.e. 25%, 50%, 75% & 100% of
standby rating capacity of the Genset. The following Parameters will be noted

Time of Start
KW
Frequency
Voltage - per phase
Load Ampere AC - per phase
Engine Oil Pressure
Engine Coolant Temperature
Engine Speed
Battery V - DC
Hour meter read

6.3. Following Fault simulations for the Generator Protections will be demonstrated
1. High Coolant temperature - Warning & Shutdown
2. Low Lub Oil pressure - Warning & Shutdown
3. Failed to start / failed to crank - Shutdown
4. Over Voltage - Shutdown
5. Under Voltage - Shutdown
6. Emergency stop - Shutdown

7 Testing Equipment

2000 KW Resistive load bank with Unity Power Factor

8 Records
Load Test Report.