Generator Commissioning Day - A real fact

November 2014 : As part of my work, i completed erection jobs for 2 no.s of 1500 KVA DG Sets at ABC Company situated in Hyderabad, India.

Finally day has come for commissioning of DG Sets, Commissioning engineer made his first attempt to crank the generator as part of trail run after making complete physical check of the generator. Here is where the issue noticed, generator set was junking every fraction of time while running. Engineer stopped the engine, started checking for presence of any defects in the diesel flow and bypass filters etc. Later he started the engine, found left with no solution as same problem of junking continued. Even though i had much experience in erection of different brands of DG Sets, i was asked to reduce the height of the diesel tank to a certain level, as part of my responsibility me & my team worked  almost 48 hours (day & night), reduced the height of the diesel tank stand supports. Though problem was not getting solved, situation was such worst that top technicians all around india belonging to that brand of generator came to the project site. Almost for three times i was asked to reduce the height of diesel tank stand & remodeling of fuel pipe line and so on. There was not even a single technician though with hands on experience, had clear clarity about the occurring problem to a brand new DG Set. 

At last the buyer lost his patience and asked them to replace the DG Set with new one. Here is where the commissioning team wanted to make their last attempt, and finally achieved success ...DG started running normal without showing any signs of errors. Readers eager to know what was that attempt made successful running of DG Set, it was nothing but replacing of injection pump with a alternate one. Yes, it was improper working of injection pump is the main reason for showing errors in the running DG Set. Few days later, a new injection pump was ordered and fitted to DG Set...

So beginners think of injection pump if there is any such problem occurs with DG Set.


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