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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 3: Cylinder 4:
Cylinder 5: Cylinder 6:
Cylinder 7: Cylinder 8:
Cylinder 9: Cylinder 10:
Cylinder 11: Cylinder12:
Cylinder 13: Cylinder 14:
Cylinder 15: Cylinder 16:
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
26 to 30 (PM only) AC
No Load
28 to 30 (PM only) AC
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
26 to 28 (PM only) AC
26 to 30 (PM only) AC
Full Load
28 to 30 (PM only) AC
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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