Chapter 8

Checklists

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 Application Manual – Liquid Cooled Generator Sets

CHAPTER 8 CHECKLISTS

8 – PROJECT & INSTALLATION QUESTIONNAIRE .................... 8–2

INSTALLATION CHECKLIST – OPEN ..................................... 8–6
INSTALLATION CHECKLIST – ENCLOSED ........................... 8–8
PRE-START-UP CHECKLIST ................................................... 8–10
START-UP CHECKLIST............................................................ 8–12

8 – CHECKLISTS 8–1
 Application Manual – Liquid Cooled Generator Sets

Project & Installation Questionnaire Load Characteristics:

In order to accurately estimate the labour, materials and Total load to be supported kW …………kVA………….
equipment costs for any project, it is essential that all Load primary constituents:
available data relating to the generator and its environment Misc. loads kW…………kVA………….
are itemised and documented before contacting the UPS loads kW…………kVA………….
supplier. This service may alternatively be provided by
Motor starting kW…………kVA………….
your local distributor.
Regenerative loads kW…………kVA………….
* - Delete where not applicable IT equipment kW…………kVA………….
Discharge lighting kW…………kVA………….
Project details Medical equipment kW…………kVA………….
Project name ...………………………………………………… Welding kW…………kVA………….
………………………………………...…….…………………… RF Transmission kW…………kVA………….
Traction kW…………kVA………….
Customer (end user) ..………………………………………...
Power factor correction kVAr……………………….
…………………..……………………………………………….
Other…………………………………...………………………..
Address of site …………………...…………………………….
Special load characteristics…………………………………...
……………………………………………………………………
……………………………………………………………………
…………………..……………………………………………….
Number of generators in parallel….………………………….
Tel. No ………………………..…………………………………
Number of utility supplies to control………………………….
Email…………………………………………………………….
Load shedding control required………………………………
Consultant / specifier / achitect ...…………...………………..
Redundancy requirement…………………………No of sets
Address …………………………………………………..……..
……………………………...…………………………………….
Site details
……………………………...……………………………………. Position of set(s):
Tel No ......………………………………………………………. Ground level Basement
Intermediate Roof top
Email……………………………………………………………..
Site drawing nos...…………………………………..………… Height above ground level………………...…........…....m/ft*
Site Access limitations………………………………………...

Application ……………………………………………….…………………..

Prime power Standby Underground / Overhead services checked………………...

Continuous Co-generation Crane reach required.……..………………….…….……m/ft*
Rental Overload required
Crane height required……………………………………m/ft*
Fuel: Diesel Bio-diesel
Road access to site: Asphalt
Mains gas Bio-gas
Road closures/ transport escort………………………………
Other fuel………………………………………………………...
Site ground conditions…..…………………………………….
Voltage………………….. Frequency……………………...
Language for instructions……………………………………..
No. of phases………….. Rated Power Factor…………..
o o
Site maximum temperature..……………………......... C/ F*
o o
Generator accommodation
Site minimum temperature...………….…………..…... C/ F*
Housing: Room Enclosure
Site altitude ……………….….…metres/ft* above sea level
Set mounting:
Distance from coast…………………………..…….km/miles* Concrete floor Concrete plinth
Site hazardous classification level (if any)………………….. Steel Rails Concrete rails
Pollution level: Other……………………...………………..……………………
Clean Normal
……………………………………………………………………
Dusty Mine / Quarry
Saline Corrosive Special vibration isolation requirements: Yes / No*
Oil / Petroleum Flammable gas
Cooling system
Type of Pollutant………………..…………………………...…
Set mounted: Radiator Heat exchanger
Emissions requirements…….…………………..………...…..

8–2 8 – CHECKLISTS
 Application Manual – Liquid Cooled Generator Sets

Remote cooling installations: Head of fuel at engine inlet - Max…………Min….…….m/ft*

Remote radiator Heat exchanger
Tank construction: Thickness ……...…mm/in*
Cooling tower - open Closed
Construction standards……………………………………….
Heat exchanger & cooling tower: secondary circuit coolant
Spillage containment: Yes / No*
…………………………………………………………………… Double skinned Bund
Special radiator requirements: Tank vent: Local Remote
Tinned cores Coated cores
Alarm contacts:
Static head at engine for remote installations:….…...…m/ft* Low level High Level
Spillage
Pipe route length……………………………………….....m/ft*
Number of bends………………………………………………. Type of pipe connection……...…..…………………………...

Standard coolant is ethylene glycol 25% concentration. Route overflow to bulk tank: Yes / No*
Dump valve & line to main tank: Yes / No*
State any special coolant requirements:…………………….. Fire valve: Yes / No* Electrical / Mechanical*
…………………………………………………………………… Standard paint
Special paint…………………………………………………..
Pipework: Painted Galvanised
Welded Screwed/flanged Fuel pipework:
Lagged Pipeline heating
Route length between fill point and bulk tank……….…m/ft*
Flange type……………………………………………………..
Number of bends……………………….
Route length between bulk & service tanks.…….…….m/ft*
Fuel system
Number of bends……………………….
Fuel bulk storage
Route length between service tank & engine………….m/ft*
Type of tank: cylindrical Rectangular
Number of bends……………………….(Remote tanks only)
Underground Above ground
Wall thickness…………mm/in*
Tank capacity……….……………….litres/gallons/hours run*
Route: Above ground Below ground
Height of top of tank above ground……………...………m/ft*
Single skinned Double skinned
Height of bottom of tank above ground.………...………m/ft* Pipeline heated Wrapped* / lagged*
Tank construction: Thickness …………mm/in* Welded Flanged
Fuel pre-filters Duplex filters
Construction standards……………………………………….
Automatic fuel transfer system
Spillage containment: Yes / No*
Double skinned tank Bunded Pump voltage……............V Frequency…………....Hz
Tank vent: Local Remote Single pump Duplex pumps
Type of pipe connection……………………………………... Gravity feed with solenoid valve: Yes / No*
Tank contents gauge: Double shut-off requirement: Yes / No*
Hydrostatic Electronic Special requirements…………………………………………..
Mechanical Dipstick
……………………………………………………………………
Contents gauge position……………………………………..
Fill point cabinet Yes / No*
Overfill alarm Yes / No*
Lubrication oil system
Duplex lube oil filters
Tank alarm contacts:
Oil pan evacuation pump: Hand Electric
Low level High Level
Spillage alarm Lubrication oil make-up tank Yes / No*
Standard paint Capacity…………………….litres/gallons*
Special paint………………………………………………….. Double skinned pipework Yes / No*
Fuel day service storage Route length between tank & engine………………......m/ft*
Base tank Free standing Alarm contacts: Low level High Level
Day tank capacity………….………litres/gallons/hours run* Fill pump: Hand Electric
Height of top of tank above ground………….....………m/ft* Special requirements…………………………………………..
Height of bottom of tank above ground….……..………m/ft* ……………………………………………………………………

8 – CHECKLISTS 8–3
 Application Manual – Liquid Cooled Generator Sets

2 2
Starting system Length ………………..m/ft* Area………….…......m /ft *
Battery Electric Compressed air No. of bends……………… Fan assistance: Yes / No*
Hydraulic Fire damper Inlet louver
Dual start method required: Yes / No* Attenuator Canvas duct
Number of start attempts required…………………………… Louver type:
Fixed blade Gravity
Battery type:
Motorised Spring return
Std Lead Acid Sealed Lead Acid Gas retention Sand-trap
NiCad Duct position: Low level High level
Battery charger: Normal Heavy Duty Outlet duct:
2 2
Special requirements………………………………………….. Length………………..m/ft* Area………..……. m /ft *
…………………………………………………………………… No. of bends……………… Fan assistance: Yes / No*
Fire damper Outlet louver
Exhaust system Attenuator Canvas duct
Muffler Louver type:
Fixed blade Gravity
Noise level……………dB(A) @ …………………………m/ft*
Motorised Spring return
Material: Steel Stainless steel Gas retention
Floor mounted Wall mounted
Ceiling mounted Other………………………. Duct position: Low level High level
Condensate drainage pipework: Yes / No* Design duct restriction…………………………..mm/in* H2O

Lagging: Rockwool Other ………………...........

Cladding: Aluminium Stainless steel Generator enclosure
Pipework Acoustic enclosure Weather enclosure

Flue material: Steel Stainless steel ISO Container Drop-over

Prefabricated flue Twin wall Walk-around Close-fit
Internal muffler Internal lighting
Type/Manufacturer…………………………………..…………
Internal power Emergency lighting
Overall length of exhaust: Horiz……….m/ft* Vert……..m/ft* Outboard attenuators
Number of bends: ……………………………………………... Internal tanks:
Number of expansion bellows………………………………... Internal fuel tank Lub. oil tank
Spillage containment Spill alarm
Flanged connections Butt-welded
Supports: Roller Spring Capacity………....litres/galls Capacity...…....litres/galls
Weathering in: Wall Roof Fire suppression system………………………………………
Termination: Tailpipe Cowl / rain-flap
……………………………………………………………………
Spark arrestor
Paint finish: Black Silver Noise limitation……………………dB(A) @...................m/ft*

Length of pipe to be lagged and clad………………..….m/ft* Special lifting arrangements…………………………………..

Lagging type…………………thickness………………..mm/in ……………………………………………………………………

Cladding: Aluminium Stainless steel Load cable termination internal* / external*
Explosion relief valve: Yes / No* Paint finish: Standard Special
Emission control system (e.g. SCR)…………………………. Specify paint colour & finish..…………………………………
…………………………………………………………………… ……………………………………………………………………

Ventilation and attenuation Electrical installation

Noise level…………….…dB(A) @................................m/ft* Control systems
Noise survey required: Yes / No*
Single generator Parallel generators
Colour of inlet & outlet termination…………………………. Base load Standby
Parallel with utility Short term <5 mins
Inlet duct:
Utility sensing Remote contact start

8–4 8 – CHECKLISTS
 Application Manual – Liquid Cooled Generator Sets

Additional features Cross sectional area………………….…….……….mm2/in2*

Break transfer No-break transfer Number of cables per phase………………………………….

Soft transfer Peak lopping Number of cables per neutral…………………………………
Utility export limit………………………………………………. Free-standing load box (no circuit breaker): Yes / No*
No. of generator circuit breakers controlled.…...……. ……. Route length of load cables…………………...………...m/ft*
No. of utility circuit breakers controlled…...……...….……… Special cabling requirements:………………………………...
Master control Type……………………….. ……………………………………………………………………
Network controls Type………………………..
Earthing systems (grounded neutral assumed)
Control wiring:
Ungrounded neutral Neutral switchgear
PVC/SWA/PVC EPR/CSP Grounding resistor Ground fault prot’n
Tri-rated LSF
Method of installation: On tray
Factory tests / documentation
Wall mounted Floor mounted
Suspended from ceiling In sunlight Standard tests Witnessed tests
In open trench Enclosed trench Special tests………………………………………………….
Buried direct In conduit
Rec. spare parts lists Parts catalogue
Special wiring requirements:…………………………………. Hard copy manuals Electronic manuals
Interface requirements No. of copies…………….. Format……………………
Clean contacts for interface to: BMS………………………... Language………………………………………………………
Remote control……………. Remote switchgear……….
SCADA system……………. Telemetry ………………….
Network interface to BMS
Start-up services
Remote control Remote switchgear Pre-start-up first fills
SCADA system Telemetry
Coolant Quantity………………….
Special interface requirements……………………………….. Lubrication oil Quantity………………….
Fuel – service tank Quantity………………….
Switchgear
Fuel – bulk tank Quantity………………….
Fitted on set: Circuit breaker
Special pre-start-up tests:…………………..…………………
Switch-disconnector None
……………………………………………………………………
Load Terminal Box: Circuit breaker
Switch-disconnector None ……………………………………………………………………

Remote switchgear: Circuit breaker

Start-up tests
Switch-disconnector Changeover Provide fuel for tests Witnessed testing
Transfer switch Paralleling s/board
Load bank required Rating………….……..kW
Incoming utility fault level………………….…………MVA/kA Resistive only Resistive / Reactive
Breaking capacity specified…………………………….…..kA Distance from generator……………………..…………..m/ft*
Making capacity specified…………………………………..kA Special start-up tests:…………………………......................
Special protection requirements……………………………… ……………………………………………………………………
…………………………………………………………………… ……………………………………………………………………
Generator systems
Special handover requirements………………………………
Type of load cables
……………………………………………………………………
PVC/SWA/PVC EPR/CSP
……………………………………………………………………
Tri-rated LSF
Maintenance contract No of visits / year…………
Method of installation: On tray
Wall mounted Floor mounted Extended warranty Extension period…...years
Suspended from ceiling In sunlight
In open trench Enclosed trench
Buried direct In single-way ducts
Other…………………………………………….…………….. Compiled…………………………………Date………………..

8 – CHECKLISTS 8–5
 Application Manual – Liquid Cooled Generator Sets

Generator set installation checklist Cooling System

Set mounted radiator
Open generator set installed in building
Radiator clean, free from obstruction
This checklist should be used to validate the completion of
a generator set installation, prior to commissioning. A Radiator air outlet connected to outlet duct
check-list should be completed for each generator set of a Check for possibility of hot air recirculation
multiple installation.
Access to coolant top-up clear
Project Details Engine vent pipes inclined toward radiator / header
Project Name ...………………………………………………… Pipework secure and undamaged
………………………………………...…….…………………… Overflow clear and routed to avoid spillage
Customer (End User).…………………………………..……... Remote mounted radiator systems
…………………..……………………………………………….. Header tank is of adequate size

Address of Site …………………...……………………………. Overflow is clear and routed to avoid spillage

Static/friction head is within engine/system capability
……………………………………………………………………
Engine vent pipes inclined toward radiator / header
…………………..……………………………………………….
Fuel cooler installed if required
Tel. No ………………………..…………………………………
Pipework avoids air locks – air bleed valves provided
Email…………………………………………………………….
Pipework isolated from generator set vibration
Pipework complete, cleaned, tested & painted
Generator set details Auxiliary supply to fans correctly installed
Generator set model……….………………………………….. Electrical bonding completed
Generator set serial number………………….Set no………. Heat exchanger & cooling tower systems
Control type……………………………………………………... Header tank is of adequate size
Control serial number………………………………………….. Overflow is clear and routed to avoid spillage
System control type (if applicable)…………………………… Static/friction head is within engine/system capability
Engine vent pipes inclined toward header tank
Generator set building and services Fuel cooler installed if required
Building & installation work complete Pipework avoids air locks – air bleed valves provided
Site clean & access clear from obstruction Pipework isolated from generator set vibration
Building services complete & commissioned Pipework complete, cleaned, tested & painted
(lightning, lighting, electrical auxiliary supplies, water, etc.) Secondary cooling system is complete
Observations………………………………………………….... Cooling tower make up supply is complete
…………………………………………………………………… Auxiliary supply to fans correctly installed
Electrical bonding completed
Room general
Generator set clean with all guards in place Liquid fuel system
No loose materials near to generator set Bulk storage facility
Air ducts clear and clean Bulk storage tank installation complete
Access & egress routes unobstructed & labelled Bulk tank incorporates water trap
Control & maintenance positions unobstructed Spillage containment complete
Room secure – no unauthorised access Isolating valves correctly positioned
Generator set is level – holding down bolts secure Tank contents gauge installed
Pipework and cables are secure with no trip hazards Content alarm contacts fitted & wired
Overhead obstructions clearly marked and labelled Transfer pump installed and connected
All key components are labelled Solenoid & pre-filter between bulk & service tank
Pipework and services colour coded & labelled Pipework correct material, cleaned tested & painted
Electrical bonding complete Vent installed, piped to safe area and open
Electrical bonding complete

8–6 8 – CHECKLISTS
 Application Manual – Liquid Cooled Generator Sets

Insulation & pipeline heating installed Joints welded or flanges secure with correct gaskets
Fill point installed & alarm fitted Stack/tail pipe prevents rain/snow ingress
Storage facility secure Flues are not combined in stack
Day tank (if none, complete check for bulk supply) Condensate drain provided
Positive head at engine for critical applications Exit directed away from buildings / personnel
Fuel inlet head/restriction within engine limits System is lagged & clad as required
Fuel return head/restriction within engine limits Building penetration & weathering complete & sealed
Isolating and solenoid valves fitted Flammable materials properly protected
Check for no valves in spill return
Flexible connections to engine Ventilation & attenuation
Connection to fill, overflow & vent lines completed Air intake is at least 150% area of air outlet
Overflow head of fuel within tank pressure limits Design prevents hot air recirculation & rain ingress
Tank contents gauge installed Design accounts for prevailing wind
Contents alarm contacts fitted & wired Air flow direction is from alternator to radiator
Electrical bonding complete Radiator outlet is ducted to attenuator / louver
Spillage containment complete & alarms wired Attenuator / louvers complete & sealed to building
Fire valves & contacts installed & wired Louver mechanisms complete & wired as required
Electrical bonding completed
Gaseous fuel system Forced ventilation provided for remote cooled sets
Pipework complete, material and construction correct Bird guard is fitted to intake & outlet
Regulator and shut off valves in correct locations
Leak test and certification complete Electrical system
Control system
Fire alarm / suppression system
Field wiring to set mounted control complete
Fire alarm / suppression system complete
Customer wiring to set mounted control complete
Sensors protected from radiant heat
Interconnection to remote control complete
Labelling and lock off system complete
Emergency stop controls wired
Set / Switchgear / Changeover / Transfer
Starting system
Means of disconnection / isolation provided
Battery starting
Switchgear installation & pre-testing completed
Starting batteries correct & installed on tray or stand
Cables installed correctly, marked, allow movement
Battery cables routed correctly
Power connections complete & torque-marked
Battery charger installed & wired
Cable tests complete & certificates available
Compressed air / hydraulic starting Electrical general
Compressor set installed and wired
All electrical boxes clean & covers replaced
Compressed air pipework correctly rated & installed
Auxiliary electrical supply complete
Isolating valves correctly positioned & labelled
Grounding system complete & tested
Pipework tested, painted & labelled
Electrical bonding of services / assemblies complete
Correct pressure regulator & HP/LP safety valves
Utility supply available as required
Flexible connection to engine fitted
Small power & lighting circuits tested & certificated

Exhaust system
Installation design prevents exhaust recirculation Checklist completed by ……………………………………….

Flexible connection to engine Date……………………………………………………………...

Support prevents load on turbocharger/manifold Print Name………………………………………………………
Installation allows for pipework expansion Company………………………………………………………..
Note: Completion of this checklist does not relieve the installer of contract obligations.
Pipework / muffler supported at required intervals

8 – CHECKLISTS 8–7
 Application Manual – Liquid Cooled Generator Sets

Generator set installation checklist Cooling System

Set mounted radiator
Enclosed or containerized generator
Radiator air outlet clean, free from obstruction
This checklist should be used to validate the completion of
a generator set installation, prior to commissioning. A Coolant overflow clear and routed to avoid pollution
check-list should be completed for each generator of a Check for possibility of hot air recirculation
multiple installation.
Remote / roof mounted radiator systems
Project Details Header tank is of adequate size
Project Name ...………………………………………………… Overflow is clear and routed to avoid spillage
………………………………………...…….…………………… Static/friction head is within engine/system capability
Customer (End User).…………………………………..……... Engine vent pipes inclined toward radiator / header
…………………..……………………………………………….. Fuel cooler installed if required
Address of Site …………………...……………………………. Pipework avoids air locks – air bleed valves provided
…………………………………………………………………… Pipework isolated from generator set vibration
…………………..………………………………………………. Pipework complete, cleaned, tested & painted

Tel. No ………………………..………………………………… Enclosure penetrations properly sealed

Auxiliary supply to fans correctly installed
Email…………………………………………………………….
Electrical bonding completed
Heat exchanger & cooling tower systems
Generator set details
Header tank is of adequate size
Generator set model.…………………………………………..
Overflow is clear and routed to avoid spillage
Generator set serial number………………….Set no……….
Static/friction head is within engine/system capability
Control type……………………………………………………...
Engine vent pipes inclined toward radiator / header
Control serial number…………………………………………..
Fuel cooler installed if required
System control type (if applicable)……………………………
Pipework avoids air locks – air bleed valves provided
Pipework isolated from generator set vibration
Generator site and services Pipework complete, cleaned, tested & painted
Installation work complete Enclosure penetrations properly sealed
Site clean & clear from obstruction & secure Secondary cooling system is complete
Site services complete & commissioned Cooling tower make-up supply is complete
(lightning, electrical auxiliary supplies, water, etc.)
Auxiliary supply to fans correctly installed
Observations…………………………………………………....
Electrical bonding completed
……………………………………………………………………

Fuel System
Site general
Bulk storage facility
Enclosure sited in open air on level, firm ground
No loose materials near to generator set Bulk storage tank installation complete
Air intake / exit paths clear and clean Bulk tank incorporates water trap
Access & egress routes unobstructed Spillage containment complete
Soil / sand covered to prevent dust (gravel, etc) Isolating valves correctly positioned
Site drainage adequate Tank contents gauge installed
Pipework and cables are secure with no trip hazards Content alarm contacts fitted & wired
Electrical bonding complete Transfer pump installed and connected
All key components are labelled Solenoid & pre-filter between bulk & service tank
Pipework and services colour coded & labelled Pipework correct material, cleaned, tested & painted
External spillage control adequate for fluid capacity Vent installed, piped to safe area and open
Electrical bonding completed
Insulation & pipeline heating installed
Fill point installed & alarm fitted

8–8 8 – CHECKLISTS
 Application Manual – Liquid Cooled Generator Sets

Storage facility secure Joints welded or flanges secure with correct gaskets
Installation with day tank (within / near enclosure) Muffler correctly supported
Positive head at engine for critical applications Stack/tail pipe prevents rain/snow ingress
Connection to fill, overflow & vent lines completed Condensate drain provided
Overflow head of fuel within tank pressure limits Exit directed away from buildings / personnel
Enclosure penetrations properly sealed System is lagged & clad as required
Fire valves & contacts installed & wired Enclosure weathering complete & sealed
Installations without day tank Flammable materials properly protected

Positive head at engine for critical applications

Fuel inlet head/restriction within engine limits Ventilation & attenuation
Fuel return head/restriction within engine limits Installation design prevents hot air recirculation
Isolating and solenoid valves fitted Installation design accounts for prevailing wind
Check for no valves in spill return Air exit directed away from buildings / personnel
Flexible connections to engine Forced ventilation systems wired
Electrical bonding complete Louver mechanisms complete & wired as required
Enclosure penetrations properly sealed Bird guard is fitted to intake & outlet
Spillage containment complete & alarms wired
Fire valves & contacts installed & wired
Electrical system
Control system
Gaseous fuel system
Field wiring to set mounted control complete
Pipework complete, material and construction correct
Customer wiring to set mounted control complete
Regulator and shut-off valves in correct locations
Interconnection to remote control complete
Enclosure penetrations properly sealed
Remote emergency stop controls wired
Leak test and certification complete
Generator / Switchgear / Changeover / Transfer
Means of disconnection / isolation provided
Fire alarm / suppression system Switchgear installation & pre-testing completed
System installation + remote alarms complete Cables installed correctly, marked, allow movement
Sensors protected from radiant heat Enclosure penetrations properly sealed
Labelling and lock off system complete Power connections complete & torque-marked
Cable tests complete & certificates available
Starting system Enclosure
Battery starting All electrical boxes clean & covers replaced
Starting batteries correct & installed on tray or stand Auxiliary electrical supply complete
Battery cables to engine routed correctly Grounding system complete & tested
Battery charger installed & wired Electrical bonding of services / assemblies complete
Compressed air / hydraulic starting Utility supply available as required
Compressor set installed and wired Small power & lighting circuits tested & certificated
Compressed air pipework correctly rated & installed
Isolating valves correctly positioned & labelled
Pipework tested, painted & labelled
Correct pressure regulator & LP safety valve
Flexible connection to engine fitted
Checklist completed by ……………………………………….
Date……………………………………………………………...
Exhaust system Print Name………………………………………………………
Installation design prevents exhaust recirculation Company………………………………………………………..
Installation allows for pipework expansion Note: Completion of this checklist does not relieve the installer of contractual
obligations.

8 – CHECKLISTS 8–9
 Application Manual – Liquid Cooled Generator Sets

Generator set pre-start-up checklist Cooling System

Coolant type………………………………………………….
Open & enclosed generator sets
Mix ratio……………………….….or factory installed
This checklist should be used to validate the completion of
generator set pre-commissioning. A check-list should be Set mounted radiator
completed for each generator set of a multiple installation. Radiator clean, free from obstruction
Project Details Overflow clear and routed to avoid pollution
Project Name ...………………………………………………… Radiator filled with correct coolant & cap replaced

………………………………………...…….…………………… Radiator, engine & pipework checked for leaks

Customer (End User).…………………………………..……... Belts checked for alignment, tension and damage
Guards in place & secure
…………………..………………………………………………..
Energise coolant heater supplies & check function
Address……….…………………...…………………………….
Remote mounted radiator systems
……………………………………………………………………
Radiator clean, free from obstruction
…………………..………………………………………………..
Overflow clear and routed to avoid pollution
Customer representative……………………………………….
Header tank filled with coolant & cap replaced
Tel. No ………………………..…………………………………
System & auxiliary tank (if fitted) filled
Email……………………………………………………………..
Radiator, engine & pipework checked for leaks
Air bled from system
Generator set details
Energise coolant heater supplies
Generator set model……………………………………………
Auxiliary supply to fans, pumps correctly installed
Generator set serial number………………….Set no………. Auxiliary supplies phase rotation / voltage check
Control type……………………………………………………... Heat exchanger & cooling tower systems
Control serial number………………………………………….. Header tank filled with coolant & cap replaced
System control type (if applicable)…………………………… Auxiliary tank (if fitted) commissioned
System, engine & pipework checked for leaks
Generator set environment and services Air bled from system
Installation work & checklist complete Energise coolant heater supplies
Surroundings clean & clear from obstruction Secondary cooling system is complete & filled
Services to generator set complete Secondary cooling systems pumps commissioned
Observations………………………………………………….... Cooling tower make up supply commissioned
…………………………………………………………………… Auxiliary supply to fans, pumps correctly installed
Auxiliary supply to fans etc., phase / voltage check
Safety Checks Record coolant concentration used………….......................
Ensure starting is inhibited
Set clean and fully assembled Fuel System
No loose materials near generator set Bulk storage facility
Air ducts clear and clean Bulk storage tank filled
Access & egress routes unobstructed & labelled Isolating valves correctly positioned
Control & maintenance positions unobstructed Tank contents gauge and alarm contacts checked
Room secure – no unauthorised access Transfer pump & controls tested
Generator set is level – holding down bolts secure Electrical bonding complete
Pipework and cables are secure with no trip hazards Pipeline/tank heating system tested & commissioned
Overhead obstructions clearly marked and labelled Fill point installed & alarm tested & commissioned
Electrical bonding complete Bulk system checked for leaks
Warn personnel of impending equipment start-up Vent and overflow pipes open
Storage facility secure

8–10 8 – CHECKLISTS
 Application Manual – Liquid Cooled Generator Sets

Day tank Louver mechanisms checked and supply energised

Isolating and solenoid valves checked for operation Commission forced ventilation system if applicable
Engine fuel return open
Day tank filled Electrical system
Air purged from system Control systems
Tank contents gauge and alarm contacts checked Visual check completed
Spillage containment alarms checked Energise set control and check functionality
Transfer pump functions checked Energise system controls and check functionality
Fire valves & contacts installed & wired Check software versions and upload as required
Select set parameters on set/system control
Gas fuel System Check remote control signals to set control
Visual check completed & test certificates present Check set control signals to remote control
Gas present at shut off valves Check signals to system control and switchgear
Check emergency stop controls
Fire alarm / suppression system
Enter / verify engine & alternator protection settings
Fire alarm / suppression system commissioned
Set / Switchgear / Changeover / Transfer
Fire wire & solenoid quick release commissioned
Visual check completed
Suppression system lock off commissioned
Check cables installed correctly & torque marked
Verify cable flexibility at generator set
Lubrication system Energise auxiliary supplies and check functionality
Engine oil pan filled to correct level
Enter switchgear protection settings and record
Level alarms checked
Utility sensing commissioned
Pre-lubrication system commissioned
Electrical general
Oil make up system filled & commissioned
Test certificates available for all cables
Check auxiliary supply protection settings
Starting system Check auxiliary electrical supplies voltage & phase
Battery starting Commission auxiliary supplies
Batteries filled, installed and connected
Check utility supply protection settings
Battery charger commissioned
Check utility supply for voltage & phase
Boost / float controls & instruments checked
Commission utility supplies
Compressed air / hydraulic starting Small power & lighting circuits test & commissioned
Isolating valves correctly positioned & labelled
Pressure regulator & LP safety valve checked Comments on any item that may affect commissioning
Compressor commissioned ……………………………………………………………………
HP & LP air / hydraulic pressures checked ……………………………………………………………………
Condensate drained ……………………………………………………………………
……………………………………………………………………
Exhaust system ……………………………………………………………………
Check security of bellows, pipework & muffler
……………………………………………………………………
Check all flanges, joints & welds
……………………………………………………………………
Check stack/tail pipe and rain cap are clear
Drain water from system
Checklist completed by ……………………………………….
Pre-lubricate turbo charger if required
Date……………………………………………………………...
Print Name………………………………………………………
Ventilation & attenuation
Company………………………………………………………..
Check louvers are clear and free to operate
Note: Completion of this checklist does not relieve the installer of contract obligations.

8 – CHECKLISTS 8–11
 Application Manual – Liquid Cooled Generator Sets

Generator set start-up checklist Coolant heater operational U

Leak check U
Open & enclosed generator sets
DCA dosing cartridges fitted & valves open U
This checklist should be used to validate the completion of
generator set start-up procedure. A check-list should be Remote mounted radiator systems
completed for each generator set of a multiple installation. Radiator, engine & pipework checked for leaks U
Project Details Coolant heater operational U
Project Name ...………………………………………………… Fans, pumps and controls checked U
………………………………………...…….…………………… Leak check U
Customer (End User).…………………………………..……... DCA dosing cartridges fitted & valves open U
Heat exchanger & cooling tower systems
…………………..………………………………………………..
System, engine & pipework checked for leaks U
Address……… …………………...…………………………….
Coolant heater operational U
……………………………………………………………………
Secondary cooling system checked U
…………………..……………………………………………….
Fans, pumps and controls checked U
Customer representative…………………..…………………..
DCA dosing cartridges fitted & valves open U
Tel. No ………………………..…………………………………
Legionnella dosing checked where applicable U
Email……………………………………………………………. Record dosing chemical & concentration.............................

Generator set details Diesel Fuel System

Generator set model………………….……………………….. Bulk storage facility
Generator set serial number………………….Set no………. Isolating valves correctly positioned U
Control type……………………………………………………... Transfer pump & controls operational U
Control serial number………………………………………….. Pipeline / tank heating system operational U
System control type (if applicable)…………………………… Fill point alarm operational U
Leaks check U
Generator set environment and services Storage facility secure U
Precommissioning work & checklist complete U Day tank
Surroundings clean & clear from obstruction U Isolating and solenoid valves checked U
Lighting / heating, etc., systems operational U Tank filled U
Observations………………………………………………….... Spillage containment & alarms operational U
…………………………………………………………………… Transfer pump operational U
Leak check U
Safety Checks Fire valves & release tested and operational U
Ensure starting is inhibited until start-up is required U
Set clean and fully assembled U Gas Fuel System
No loose materials near set U Isolating valves correctly positioned U
Air ducts clear and clean U Regulator set to correct pressure U
Access & egress routes unobstructed & labelled U Gas leak detection equipment operational U
Control & maintenance positions unobstructed U Double shut-off device operational U
Room secure – no unauthorised access U Leak test complete U
Personnel warned of start-up process U Purging complete U

Cooling System Fire alarm / suppression system

Set mounted radiator Fire alarm / suppression system operational U
Radiator, engine & pipework checked for leaks U Suppression system lock-off operational U
Belts & guards checked for security / slipping U Operator instructed in fire system operation U

8–12 8 – CHECKLISTS
 Application Manual – Liquid Cooled Generator Sets

Lubrication system Generator set voltage & frequency correct to orderU

Engine oil pan filled to correct level U Control system calibrations checked U
Oil make up system operational U Phase rotation checked U
Paralleling sets phase coincidence check U
Starting system Generator set switchgear manual operation correct U
Battery starting Local stop / emergency stop control checked U
Batteries installed, filled and connected U Remote start / stop / emergency stop checked U
Battery charger commissioned U
Compressed air / hydraulic starting Generator set load test
Isolating valves correctly positioned U Note: Load test is carried out on customer’s site load
unless agreed in writing prior to start-up. Artificial load
Compressor operational U bank test will be performed using resistive load unless
HP & LP air / hydraulic pressures checked U otherwise specified.
Condensate drained U Load test completed using customer’s load U
Record load achieved……………………………………kW
Exhaust system Load bank test (if applicable)
Check security of pipework & muffler U Check load bank voltage & power capability U
Check cowl and/or rain cap are operational U Check cables installed correctly & tightened U
Check water drain pipework and valves correct U Energise auxiliary supplies and check functionality U
Leak check U Load test completed U
Check for exhaust gas recirculation U Result sheet completed U
Record load achieved……………………………………kW
Record power factor……………………………………………
Ventilation & attenuation
Check louvers are clear and operational U
System start-up completion
Forced ventilation system operational if applicable U
Generator set operational U
Check for hot air recirculation U
Changeover / transfer switch operational U
Paralleling switchgear operational U
Electrical system
Automatic operations checked U
Control systems
Master control operational U
Auxiliary supplies energised U
All safety shutdowns and warnings operational U
Generator set local controls checked U
Generator set remote controls checked U Electrical HV/MV/LV rules and procedures in place U
Generator set system controls checked U Comments on any item that may affect acceptance:
Customer remote indication / controls checked U ……………………………………………………………………
Changeover switchgear / transfer switch ……………………………………………………………………
Auxiliary supplies energised U ……………………………………………………………………
Utility supply energised U ……………………………………………………………………
Voltage / phase rotation checked U ……………………………………………………………………
Indications correct U ……………………………………………………………………
All covers in position U ……………………………………………………………………
Paralleling switchgear ……………………………………………………………………
Auxiliary supplies energised U
Indications correct U Checklist completed by ……………………………………….
All covers in position U Date……………………………………………………………...
Print Name………………………………………………………
Initial start-up Company………………………………………………………..
Manual start-up, idle & full speed checks complete U Note: Completion of this checklist does not relieve the installer of contract obligations.

8 – CHECKLISTS 8–13