Diesel Generator (DG Set) Weekly Auto Mains Failure (AMF) Run Test

1. Purpose & Scope

Standard weekly inspection and on-load testing of emergency diesel generators to guarantee compliance with NFPA 110 Level 1 emergency power standards and ISO 8528.

2. Personal Protective Equipment (PPE) & Hazards

• Hearing Protection (Ear Muffs) & Safety Shoes
• Hot exhaust manifold (> 500°C) & high pressure diesel fuel injection leaks

3. Sequential Execution Steps

1. Perform Pre-Start Physical Walkaround: Check for any oil, water, or diesel fuel leaks beneath engine bed. Ensure intake louvers are unobstructed and exhaust flap is free to open.
2. Initiate Manual Test Run (No-Load Mode): Turn selector switch on Deep Sea / ComAp controller to MANUAL and press START. Engine must crank, fire, and reach 1500 RPM (50 Hz) or 1800 RPM (60 Hz) within 6 seconds.
3. Verify Alternator Voltage & Lube Oil Pressure: Confirm generated voltage stabilizes at 415V ± 1%. Confirm lube oil pressure builds rapidly to 4.5 – 6.0 bar (65 – 85 PSI).
4. Simulate Grid Power Failure (On-Load AMF Test): Open mains incomer breaker. Confirm ATS transfers essential emergency load to DG within 10 seconds. Run under load for minimum 30 minutes.
5. Restore Grid & Cool-Down Sequence: Re-close mains utility power. Confirm ATS transfers load back to grid seamlessly. Allow DG engine to idle at no-load for 5 minutes cool-down before automatic shutdown.
6. Return Controller to AUTO Ready Mode: Set mode selector switch back to “AUTO”. Log run hours, fuel consumption, battery voltage, and oil pressure in DG Plant Log Book.