Why commissioning deserves its own visit
New and relocated sets arrive with transport damage, loose terminations, shipping fluids and default settings. Installation adds its own risks: undersized cables, poor exhaust routing, blocked airflow and fuel lines that were never flushed. A commissioning technician treats the first start as a test of all of that, not as a formality before the contractor leaves site.
Pre-start checks
- Mechanical: mountings, anti-vibration pads, couplings, guards and clearances around the set.
- Fluids: correct oil grade and level, coolant mix and inhibitor, fuel supply clean and free of water.
- Air and exhaust: intake path clear, exhaust supported, flexible joints fitted and no leaks into occupied areas.
- Electrical: cable sizes and terminations, earthing, breaker ratings, control wiring and battery installation.
- Ventilation and fire safety: louvres, dampers and fuel shut-off devices working as designed.
First start and functional tests
With the set primed and the checks signed, the technician starts it off load and watches oil pressure, temperatures, frequency and voltage settle. Protection is then proven: low oil pressure, high coolant temperature, overspeed and emergency stop must each shut the set down as intended. Alarms are checked for the right wording and the right destination, whether that is a local panel, a building management system or a remote monitoring desk.
Load testing and transfer
A set that has only idled has not been commissioned. The technician applies load in steps, using the site load where it is safe and a load bank where it is not, and records recovery of voltage and frequency at each step. The automatic transfer switch is tested in both directions, with timers set to suit the site. Where several sets run in parallel, synchronising and load sharing are proven across the full range.
Handover records
The handover pack should include the settings as left, test sheets with readings, a list of any open items and the first service due date. That pack becomes the baseline for every later visit. On power stations the same discipline continues into power plant EPC projects, where commissioning of each set feeds the acceptance of the whole plant.
Commissioning FAQs
Who should be present during generator commissioning?
The commissioning technician, the installer, someone who can authorise switching on site and, where possible, the person who will own maintenance afterwards.
Is a load bank always needed for commissioning?
Not always. If the site load can be applied safely in steps it may be used, but a load bank gives controlled, repeatable steps and protects the site from a failed test.
Does a relocated generator need full commissioning?
Yes. Moving a set disturbs mountings, connections and settings, so it should be treated as a new installation.
Book a commissioning technician
Send the set details, the installation date and the site location, and we will plan the checks and tests.