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STARTING A PLANT

CHECK:

1. Fuel level, supply, drain filters and prime system.

2. Fill engine jackets with water, expansion tank ¾ full.

3. Vent cooling water pumps and start pumps. Close vents when primed.

4. Drain scavenging air box of condensate and blowers.

5. Oil level and prime until oil appears at rocker levers. Fill governor.

6. Pour oil over rockers and valve mechanisms and fill air maze loop.

7. Fuel supply free of condensate.

8. Exhaust line open and drained.

9. Cylinder test valve or vent open.

10. Engine lever in injector stop position.

11. Turn engine with turning gear. No fuel or water at cylinder vents. Check for binding

and disengage turning gear.

12. Close cylinder test valves.

13. Place operating lever to injector full with latch connected to injector linkage.

14. Open air starting valve, 10 second should start, then throttle speed to idle.

15. Check oil pressure and warm up slowly raising Rpm’s.

16. Disengage engine operating lever from injector linkage and latch into governor run

position.

17. When up to speed, close air starting valves and bleed lines.

18. Add load slowly.


STOPPING A PLANT

1. Reduce load slowly.

2. Run under governor control.

3. Engage operating lever to injector lever and move to injector stop position slowly

(bring speed down gradually).

4. Open drains when engine stops.

5. Rotate engine in turning gear.

Once a diesel engine is setup it will normally run trouble-free for many years only

requiring routine oil changes, injector timing, fuel, oil and air filter changes. The greatest

danger is overspeeding, overloading, and running out of lubricating oil. These engines

will explode unmercifully throwing metal fragments like a bomb. Keep crankcase vents

open and clear to prevent fuel vapor accumulating in the crankcase as this too can cause

the case to burst. However, most large diesels have explosion doors such as inspection

plates that will burst. Nevertheless, any burst is dangerous. Never be complacent when

running a large diesel. Always be aware of rotating elements and never take any safety

guards off an engine without tagging and locking-out the starting control panel.
COMMISSSIONING AND TESTING OF THE PLANT

The future contractor of the plant must have a specific process of commissioning

the plant. Commissioning is a process that ensures that a component, subsystem, or

system will meet the intent of the designer and the user. The contractor must also conduct

commissioning test, a test conducted when the equipment is installed to verify correct

operation. Furthermore, he should also tests of correct function of the complete system

with all equipment connected and live.

Testing Types

 Construction Testing

Performing required inspections and tests to ensure that completed installations

are in accordance with contract requirements and the latest engineering and

design information.

 Operational Testing

All testing required verifying system operation in accordance with design

requirements after the major component is energized or operated.

 Performance Testing

Testing conducted to evaluate the compliance of a system or component with

specified performance.

 Preoperational Testing

All testing required for system components prior to energizing or operating the

major system component.

 Prestart up Testing

All testing required prior to rotating the generating unit under power (hydraulic or

electrical) which is unique to the unit and not associated with system testing.

 Startup Testing/ Wet Testing

Operation testing of the generating unit from initial powered rotation to verify

suitability for operation.


Construction:

a. Construction test

 The construction contractor usually performs required inspections and

tests to ensure that completed installations are in accordance with contract

requirements and the latest engineering and design information.

 The results of construction testing should be documented by the

construction contractor and turned over with release of equipment to the

preoperational testing group.

b. Electrical

 Insulation resistance testing

 Continuity test

 Initial operation of motors uncoupled

 Inspection and testing of motor control centers

 Verification of cable terminations

c. Mechanical

 Hydrostatic testing

 Mechanical equipment alignment

 Initial lubrication

 Tank and pipe cleaning

 Mechanical equipment inspection

 Mechanical test implementation

d. Instrumentation

 Pneumatic instrumentation lines testing

 Verification of proper grounding of cables

 Installation of instrumentations

 Continuity test of cable routing

 Verification of cable terminations

 Implementation of instrument test


e. Preoperational tests

 Checkout of motors

 Electrical relays and meters calibration

 Mechanical systems flushing

 Blowdown of station

 Loop calibration

f. Operational tests

 Nozzle alignment

 Speed trip test

 Governor control setting verification

 Final Setting

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