Data Center Diesel Generator System Test Plan

Ⅰ.Test Objectives

1. Basic Compliance Verification: Confirm that the construction quality of the unit and auxiliary systems meets design specifications and is free of installation defects.
2. Individual Unit Performance Compliance: Verify the unit’s steady-state output, transient response, alarm protection, and long-term load-bearing capacity to meet rated operating conditions.
3. System Interconnection Reliability Assurance: Ensure the normal operation of the interconnection logic between the unit and the mains power, UPS, computer room load, and cooling system, and ensure stable power supply in the event of mains power failure.

Ⅱ.Prerequisites for Testing

1.Construction verification closed loop (key item list)

The following key items must be 100% satisfied:

2. System and personnel ready

• Equipment Status: Engine and generator are fault-free; controller firmware version is compliant; fuel/cooling/battery systems are operating normally; linkage circuit connections are correct.
• Pre-testing: Each unit has completed 4 hours of full-load hot operation, with complete and anomaly-free data.
• Personnel Safety: All participating parties (testing agency, supplier, contractor, etc.) personnel are in place; warning signs are posted in the testing area, personnel are equipped with protective equipment (safety helmets, earplugs, etc.), and emergency shutdown procedures have been trained.

III. Test Scope (Integrating the core coverage items of the three documents)

Ⅳ.Test Preparation (Detailed Requirements for Personnel, Equipment, and Documentation)

1.Staffing and Division of Responsibilities

2. List of testing equipment and tools (including specifications/purposes)

3.Document preparation checklist (must be archived in advance)

• Signed construction inspection checklist, including closed-loop records of rectification items;
• Test process table (including blank “Status Alarm Confirmation Record Form,” “Heat Operation Test Data Sheet,” and “Steady-State Data Sheet”);
• Joint test execution form (including steps and result record columns for mains power switching and cooling linkage);
• Manufacturer’s technical documents (installation manual, startup manual, factory test data, controller parameter setting table);
• Data center electrical schematic diagram (mains power – generator – UPS linkage circuit, high-voltage cabinet/low-voltage cabinet wiring diagram, marked with key node numbers);
• Emergency operation card (including manual start/stop steps, EPO switch location, and fault contact person’s phone number).

Ⅴ.Detailed Testing Process (divided into three interconnected stages)

Phase 1: Pre-test verification (removing prerequisite obstacles)

The core of this phase is to verify the construction quality and the condition of the equipment foundation, laying the groundwork for subsequent testing.

1. Equipment model and parameter verification

2.Installation quality review (subsystem verification)

• Mechanical Installation Verification: Use a level to check the unit’s levelness (deviation ≤0.1%), and use a torque wrench to randomly check the fixing bolts (e.g., M16 → 60 N·m), confirming no damage or debris accumulation.
• Electrical Installation Verification: Open the electrical cabinet, visually and with a torque wrench check the wiring tightness; use a grounding resistance tester to measure the grounding resistance (direct grounding ≤4Ω); clean the dust inside the cabinet, and confirm that the neutral ground binding point is unique.
• Auxiliary System Verification:

◦ Oil Supply: Check oil level ≥80%, close the oil outlet valve and maintain pressure for 30 minutes (no pressure drop), valve labels are clear (“Oil Supply Valve”, “Oil Return Valve”);

◦ Exhaust: Insulation layer intact, rain cap not tilted, start exhaust fan (normal ventilation, no backflow);

◦ Cooling: Coolant level between “MIN-MAX”, start cooling fan (no abnormal noise).

3.Control and Communication Testing

• Connect the local controller (EMCP) power supply and switch the “Auto – Run – Stop” switch. The indicator lights should change normally (Run → green light on, Stop → red light on);
• Simulate a “low oil pressure alarm” (adjust the sensor threshold to ≤15PSI) and confirm that the EMCP terminal (audible and visual), control room terminal (audible and visual), and BMS terminal (data display) are triggered synchronously;
• Send a “Start” command through the remote control cabinet. The unit should start within 6 seconds (reaching rated voltage/frequency).

Phase Two: Functional Testing of a Single Diesel Generator (Core Performance Verification)

This phase focuses on the functions of a single unit and is executed in the following order: “basic inspection → alarm protection → long-term load → steady state → transient state”.

1. Visual inspection and basic function check

2.Alarm and protection function test (simulate 28 alarms, with 5 key alarms)

• Recording requirements: For each test, fill out the “Status Alarm Confirmation Record Form” and mark “EMCP / Control Room / BMS Confirmation Result” and “Engine / Circuit Breaker Action”.

3.Long-term operation heat generation test

• Loading Preparation: Connect the load box and load at 0%→25%→50%→75%→100% (5 minutes per step) until 100% rated power is reached;
• Data Recording:

◦ First 30 minutes: Record data every 15 minutes (fill out the “Heat Test Data Sheet”), including engine (exhaust temperature/oil pressure/coolant temperature), output (phase voltage/current/frequency), and infrared data (engine head/turbine/connector temperature);

◦ After 30 minutes: Record data every hour, simultaneously scanning key areas with an infrared camera (save thermal images);

• Acceptance Criteria:

◦ No shutdowns/alarms for 4 hours, power terminal temperature ≤75℃, cylinder head temperature deviation ≤5℃, turbine temperature deviation ≤10℃;

◦ Noise at 1 meter ≤107dB(A), voltage fluctuation ≤±1%.

4.Steady-state performance testing

• Data logging: Fill in the “Steady-state data table” and save the voltage-time curve for 1 minute.

5.Transient response test

1. Test Preparation: Initial load 0%, power analyzer set to “Transient Recording Mode”;
2. Step Execution: Perform a step test “0%→50%→100%→50%→0%” (stabilize for 2 minutes per step), recording voltage/frequency peak values ​​and recovery times;
3. Acceptance Criteria:

Phase 3: System Integration Testing

This phase verifies the linkage logic between the core verification unit and other systems in the data center, simulating actual mains power failure scenarios.

1. Load testing of data center modules

2.Mains power switching linkage test (single-path/dual-path scenarios)

2.1 Single-circuit mains power failure and restoration

2.2 Power Loss and Restoration from Dual-Circuit Mains Power

3. Integration test with the refrigeration system (simulating fault scenarios)

Ⅵ.Test Data Recording and Analysis (Standardized Process)

1. Data Recording Standards

• Categorization and Archiving: Records are categorized into “Verification Records,” “Functional Test Records,” and “Linkage Test Records.” Each record requires signature confirmation (by the tester and supervisor).
• Supporting Materials: Infrared thermal images, load snapshots, and transient curves must be named according to specifications and attached to the corresponding record sheets.

2. Deviation Analysis and Rectification (Closed-Loop Management)

3. Report Preparation

The test report must include:

• Core content: Test overview (objectives/scope/time), precondition verification results, test data summary (presented in stages), deviation and rectification records, and conclusions;
• Attachments: All record sheets, supporting materials, and copies of manufacturer documents.

VII. Risk Control Measures (Targeted Prevention and Control)

VIII. Determination of Test Results (Clearly Define Pass/Fail Standards)

1.Judgment Criteria

◦ Construction verification items: 100% qualified, no unresolved rectification items;

◦ Single unit functional tests (visual inspection/alarm/heating/steady-state/transient): 100% compliant;

◦ Interlocking tests (machine room load/mains power switching/cooling linkage): No major faults (e.g., load power failure).

 2.Conclusion Classification

◦ Qualified: Meets all the above standards, the unit can be put into standby power supply;

◦ Qualified (with deviation): Minor deviations (e.g., BMS display delay of 1.5 seconds) have been rectified and retested successfully, not affecting reliability;

◦ Unqualified: There are unrectified major deviations (e.g., the unit cannot be paralleled), and a new test plan needs to be developed.

Ⅸ.List of deliverables (completely archived)