Standard Generator Testing

[KenAlmon]

We bought a 500 kW diesel powered brushless generator to serve in a standby capacity specified under ANSI/IEEE standards. Our spec had testing requirements including heat run, no load and full load loss measurements, as well as insulation testing, resistance measurements, and open circuit and short circuit curve test.

The vendor has just about finished manufacturing and is late. They are claiming that the tests that we state in the spec that we want they had not planned to do because they are "type" tests.

While we feel that the spec is clear in what we had requested, I am looking for some input on what minimum testing should be performed. I am aware that MG1 32.20.2 has "Routine Factory Tests" that just call for resistance, voltage checks and hi-pot tests, but wanted to see if there was consensus for more testing despite MG1's limited scope in this regard.

 

[JohnHamburger]

While some of the tests you have outlined may be "type" tests, you have specified that the tests be run as part of the factory testing. We typically ask for all the tests you have indicated and ask for measurements of fuel consumption, vibration analysis, coolant temperature and pressure, lube oil temperature and exhaust gas temperature to be recorded in 15 minute intervals during the heat run. We also ask for verification of alarms and shutdown circuitry, as well as transient response to load steps. On multi-generator installations, we will witness at least one engine test from start to finish. The generator vendor includes these tests in the cost of providing the machine. In addition to the factory tests, we specify site testing which verifies the proper installation of the equipment, and we witness that as well.

 

[dpc]

Contractor should have taken exception to the tests at bid time.

It doesn't matter if they are normally done or not - if they are in the spec, he owes them to you.

Ask him how much the tests would cost, then offer to deduct that from his final payment request.

 

[bru]

JohnHamburger is correct, you want to see response in load reaction including full load rejection, these are very importantfor complete units. Also, you may also request a "surge test" if the results of this normally factory provided test are not available. Especially since the supplier is on the defensive already.

 

[Tuas]

You may like to note that there is a difference in testing standards between a standby set and a continuous one. The requirements for a standby set is not as stringent, in terms of stability and response, as compared to a continuous genset. So, that'll alleviate you from some of your concerns on the stringent tests. However, you may like to focus on emergency start and step loading tests, which is a major requirement if your genset is to function as a standby.