Generator commissioning is a critical process that ensures the safe, efficient, and reliable operation of a diesel generator (DG) before it is put into service. A properly commissioned generator minimizes the risk of electrical faults, mechanical failures, and operational inefficiencies.
This blog outlines the step-by-step commissioning process, including pre-commissioning inspections, electrical and mechanical tests, safety checks, and load testing.
1. Pre-Commissioning Checks
Before starting the generator, the following pre-installation inspections must be conducted:
1.1 Physical Inspection
✔ Ensure the generator is installed on a level foundation.
✔ Check for any physical damage or loose connections.
✔ Verify the alignment of the alternator and engine.
1.2 Fuel System Inspection
✔ Ensure fuel lines are free from leaks.
✔ Verify that the fuel tank is properly vented and secured.
✔ Check the fuel filter and injectors for blockages.
1.3 Cooling System Inspection
✔ Check the radiator coolant levels.
✔ Inspect cooling fan belts for proper tension.
✔ Ensure the heat exchanger is clean and free from obstructions.
1.4 Battery & Electrical System Check
✔ Ensure the battery is fully charged and connections are secure.
✔ Check the Automatic Voltage Regulator (AVR) settings.
✔ Verify that the earthing system is properly installed.
2. Electrical Testing
Once the pre-commissioning checks are completed, electrical tests ensure the generator operates at the correct voltage, frequency, and load capacity.
2.1 Insulation Resistance Test
✔ Measures the insulation strength of generator windings.
✔ Conducted using a megger to check for insulation breakdown.
2.2 Voltage & Frequency Stability Test
✔ Ensures the generator maintains stable voltage (400V/230V) and frequency (50Hz or 60Hz) under different load conditions.
2.3 Phase Sequence Test
✔ Verifies that the generator’s phase sequence matches the connected load.
2.4 Grounding & Earthing Resistance Test
✔ Measures the neutral and body grounding resistance to ensure safe operation.
✔ Recommended earthing resistance: <1 ohm.
3. Mechanical Testing
Mechanical tests ensure the engine, alternator, and exhaust system function correctly.
3.1 Engine Performance Check
✔ Start the generator and check for abnormal vibrations or noises.
✔ Monitor oil pressure, coolant temperature, and exhaust temperature.
3.2 Fuel Consumption Test
✔ Records fuel efficiency at different load levels.
✔ Ensures fuel injection timing is properly adjusted.
4. Load Testing & Synchronization
Before putting the generator into full operation, it must undergo load testing to verify its ability to supply power without interruptions.
4.1 Load Bank Testing
✔ Simulates real-world conditions by gradually applying incremental loads.
✔ Ensures the generator can handle 100% rated load without voltage/frequency fluctuations.
4.2 Synchronization Check (For Multiple DG Sets)
✔ Verifies that multiple generators can operate in parallel.
✔ Ensures proper load sharing and phase synchronization.
5. Final Safety & Compliance Checks
Before handing over the generator for full operation, final safety checks must be performed.
✔ Ensure compliance with CPCB IV+ emission norms.
✔ Verify that the acoustic enclosure meets noise regulations.
✔ Check the Automatic Transfer Switch (ATS) functionality for seamless power switching.
6. Generator Commissioning Checklist
✅ Physical & mechanical inspection completed
✅ Fuel, lubrication, and cooling systems verified
✅ Voltage, frequency, and insulation resistance tested
✅ Load test conducted at full capacity
✅ Earthing resistance checked
✅ CPCB IV+ and IEC compliance verified
Wrapping Up
Proper generator commissioning ensures long-term efficiency, reliability, and compliance with industry standards. Following a structured commissioning procedure and checklist minimizes the risk of failures and ensures seamless power generation.
In the next blog, we will explore Generator Maintenance: Preventive, Predictive & Corrective Approaches. Stay tuned!
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