Attachment_9_-_Generator_System_Operational_Test_WT_PM.docx

IMPROVED NAVY LIGHTERAGE SYSTEM (INLS)

CONTRACT NO.

CDRL DATA ITEM NO:

Revision:

Hull:

TEST PROCEDURE PREPARATION/APPROVAL

PREPARED BY:

K. Fischer

DATE:

JULY 2015

APPROVED BY:

DATE:

TEST PROCEDURE CONDUCTED

REVISION RECORD

PAGES

Original Issue

TEST OBJECTIVE:

The objective of this test is to demonstrate the no load, incremental and full load operation of the ships service diesel generators and to demonstrate that the manual features will control the generator within specific limits.

EQUIPMENT INVOLVED:

1. Starboard Ship Service Diesel Generator

2. Port Ship Service Diesel Generator

REFERENCES:

1. IEEE – 45, section 34.2.1, Ship Test, New Installations, Circuits

2. NAVFAC # 1600428 Electrical One Line Diagram

SAFETY PRECAUTIONS:

1. Test personnel shall strictly adhere to all shipyard safety precautions including, but not limited to all caution and warning notes contained in this test procedure and applicable documents.

2. All unauthorized personnel shall be kept clear of test areas for duration of test. Persons in adjacent areas shall be notified of testing being done.

3. Ensure all power sources are de-energized during insulation resistance tests.

4. A 500 Volt Megger shall be used only on the Generator Stator Circuit. A 50 Volt Megger shall be used on all other circuits, rotor, exciter field for a minimum of 60 seconds.

5. Observe Wattmeter and Ammeter during voltage adjustment demonstration to prevent overloading generator.

6. In the event of unusual noise or vibration, shut down the Generator.

PREREQUISITES:

1. Generator and Switchboard System Cable Test

2. Generator and Switchboard System Input Output Test

ADDITIONAL INSTRUCTIONS:

1. The test conductor will list on comment sheet, Section “H”, any discrepancies requiring corrective action, any unusual response observed while performing test or any significant events and observations occurring during performance of the test. If hazardous conditions exist, test is to be stopped until conditions are corrected.

2. Verify calibration of installed instruments and equipment to be used during test is complete.

3. All breakers on switchboard shall be secured during test. Vessel lighting electrical loads should be fed from a shore power supplied source the duration of the test.

4. Controls and indicators not specifically mentioned in this procedure shall be observed for proper operation.

5. Read the entire test procedure prior to initiating the tests described herein.

TEST EQUIPMENT REQUIRED TO ACCOMPLISH THIS TEST PROCEDURE:

(1) Stop Watch

(4) Slack Tube Manometer Inches of Water

PERSONNEL REQUIRED TO ACCOMPLISH THIS TEST PROCEDURE:

1. Two Qualified Electricians, One Qualified Machinery Installer

GOVERNMENT SUPPORT PERSONNEL:

1. Subject Matter Expert (SME): One SME, ISEA/SSA/PE or equivalent to witness and sign off on testing as Government Representative.

2. Ship’s Force personnel to stand by as safety watch, as necessary.

3. Ship’s Force engineer to align machinery as required.

4. Ship’s Force ET to support electrical checks and system alignment.

5. Contractor will require 4 hours of ISEA or SSA support. This support must be scheduled with the ISEA or SSA at least two weeks in advanced.

EQUIPMENT CONFIGURATION:

1. Ship Service Generators shall have all fluids checked and filled to their service levels.

2. Ensure starting batteries have been charged.

3. Align fuel oil system for normal operation.

4. Connect the variable resistive load bank to the bus work of the generator under test at the switchboard.

5. Align all auxiliary equipment to support the SSDG under full load conditions.

6. Attach a manometer to each SSDG exhaust and combustion air test port

TEST INSTRUCTIONS:

STEP 1: Ensure safety instructions paragraph are followed.

STEP 2: Measure the insulation resistance (cold) of the generator. Correct the insulation resistance readings to 25 degrees centigrade using the Nomograph on page 12. RECORD ON DATA SHEET

NO LOAD TEST

STEP 3: Bring engine up to speed with Generator Circuit Breaker open. Test is conducted at No Load as output power will be cut off. Check operation of over speed trips, manual trips, and all safety control and warning systems to ensure proper operation

STEP 4: Turn Auto/Manual switch to Manual. Line voltage should measure 460 VAC. Adjust manual Rheostat as necessary to obtain 460 VAC indication on AC Voltmeter. RECORD ON DATA SHEET

STEP 5: Adjust Automatic Voltage to minimum and maximum voltage. The Rheostat should be capable of adjusting the Generator Voltage between 432 and 510 Volts. RECORD ON DATA SHEET

STEP 6: Demonstrate operation of the speed control device in Manual Mode to control speed of the unit. Record the minimum and maximum values and the time to go from minimum to maximum on the Data Sheet. RECORD ON DATA SHEET

FULL LOAD TEST

STEP 7: Operate the Generator at full rated load for 30 minutes to bring it up to or near its operating temperature. During this period the general operation of the generator shall be monitored and any necessary adjustments shall be made.

STEP 8: Demonstrate that the generator Voltage can be adjusted over the minimum acceptable range of 436.5 to 481.5 volts under full load. RECORD ON DATA SHEET

STEP 9: After reaching operating temperature, the load shall be removed from the generator. At No Load and with Generator excitation under the control of the Voltage Regulator, set the generator to 100% of rated speed (1800 RPM). Note: Do not readjust speed during test.

110% LOAD TEST

STEP 11: Operate the unit at 110% rated load for 2 hours (minimum) to approximately 3 hours, until temperatures stabilize within 1 degree centigrade for 3 consecutive data points. Record Generator and Diesel Engine Data at 20 minute intervals as listed on the data sheets. RECORD ON DATA SHEET

SHUTDOWN

STEP 12: Secure the Diesel Generator and take hot insulation resistance readings. Correct the insulation resistance readings to 25 degrees centigrade using the Nomograph on page 11. RECORD ON DATA SHEET

STEP 13: Return all equipment to pretest conditions.

STEP 14: Perform a visual inspection of the generator set for oil for fuel leaks, loose connections and fittings.

COLD INSULATION RESISTANCE SSDG

STEP 2 MINIMUM EXPECTED RESULTS ACTUAL RESULTS

NO LOAD DATA SHEET

TEST TITLE: TEST NO: REV

Ships Service Diesel Generator Operational Test WT/PM

STEP 10 FULL LOAD DATA SHEET

Start Time

Date

40% LOAD

60% LOAD

80% LOAD

100% LOAD

Power (ekW)

Power Factor

Engine RPM

Frequency (Hz)

Voltage Phase A

Voltage Phase B

Voltage Phase C

Current Phase A

Current Phase B

Current Phase C

L.O. Pressure

Engine F.W. Temp Coolant/Out

Manifold Exhaust Temp

Exh Press (60” H2O max)

Air Intake Temp

Comb Air Press (32” H2O max)

STEP 11 110% LOAD DATA SHEET

Start Time

Date

40 Minutes

60 Minutes

80 Minutes

100 Minutes

120 Minutes

Power (ekW)

Power Factor

Engine RPM

Frequency (Hz)

Voltage Phase A

Voltage Phase B

Voltage Phase C

Current Phase A

Current Phase B

Current Phase C

L.O. Pressure

Eng F.W. Temp Coolant/Out

Manifold Exhaust Temp

Exh Press (60” H2O max)

Air Intake Temp

Comb Air Press (32” H2O max)

EQUIPMENT

NOT CLEANED

CLEANED IN PLACE

RECOND

NEW

STATOR

0.2 MEGOHMS

1.0 MEGOHMS

2.0 MEGOHMS

10.0 MEGOHMS

EXCITER FIELD

0.5 MEGOHMS

1.25 MEGOHMS

2.5 MEGOHMS

5.0 MEGOHMS

NOMOGRAPH FOR TEMPERATURE CORRECTION OF INSULATION RESISTANCE

TEST EQUIPMENT

NUMBER

SERIAL

NUMBER

CALIBRATION

DUE DATE

REMARKS/WITNESS

This test was conducted in accordance with this test procedure; no adjustments were made to equipment under test except as required by the test procedure, and the results of the test are as stated in this report.

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