Project Engineering: Generator System Installation & Fuel System

This report details a project engineer's experience with Mech Power Generator PTE LTD, focusing on a generator and fuel system installation project for a Microsoft data center. The project involved installing 36 indoor canopy generators, underground storage tanks, and fuel pump systems across two phases. The engineer coordinated with design and production teams, managed drawing approvals, ensured quality control, and oversaw testing and commissioning. Key challenges included drawing changes, data recording during testing, and 3D modeling, which were resolved through collaboration, innovative solutions, and continuous learning. The successful completion of the project enhanced the company's reputation and profitability.

Career Episode 1:
Introduction
1.1 I worked with Mech Power Generator PTE LTD from 28th
September 2010 till date. Mech Power has a leading
manufacturer in design, assembly, testing, installation,
commissioning, sale and service of diesel power powered
generator sets in Singapore. It also supplies the power
generation industry in the Asia Pacific region. It has achieved
several key certifications.
In Mech Power Generator, I worked as a project engineer. My
job scope requires me to lead projects and coordinate it
accordingly until it is completed, and ready for the final
handover.
Background:
1.2 During my period of employment, I have completed many
projects. I want to highlight a particular project that involved
a well-established company – Microsoft Data Centre. For this
project we have 36 indoor canopy generators and
underground storage tank 12 numbers with the capacity of
75000 liters each tank with two transfer tanks with one
number of 1000 Liters service tank and fuel pump system.
This project was done in 2 phases. One phase consists of 24
generators including the 12 underground storage tank and
fuel pumps system. Second phase consists of another twelve
number of generators. I worked as a project engineer for this
project. We were worked as a team and get it done
according to the contract schedule, project duration from
2012 to 2015.

Organization Chart:

Personal Work Place Activity:
1.3 Starting stage of the project for our generator and fuel
system installation works, I coordinate with the design team
by getting the architectural drawings and concrete body plan
of the building according to the allocated location as per the
tender drawings. I spent a lot of time to study deeply in
order to understand about the scope of our work. PE 1.1
1.4 This project was fully dependent on the online paper work
submission so I had the hands-on experience in the
submission of drawings, catalogues and design calculations.
I am an ambitious in learning new technologies to improve
the efficiency of the project. PE 1.4 At the initial stage of the
project, I plan my work meticulously to ensure that I am able
to complete it within the deadline given.PE 2.4The project
management software was utilized, and this has helped me
to complete the project in time. PE 1.2 PE 3.4
1.5 I faced a major problem on getting the drawing approval due
to the changes in the architectural drawing. Time delays
were calculated earlier, so there was no delay on fabrication
of our generators and fuel storage tanks. PE 1.5, PE 2.1Followed
with the approval drawings issued to our production team.
1.6 Our manufacturing factory is located at the Malaysia, I travel
once in a week to check the quality of our production with
our QA/QC department. PE 2.3 In this project main technical
was synchronization system.
1.7 Tracking the materials and equipment shipment with
purchasing team. I coordinate with the production team
about the procurement and schedule the production to do an

internal testing. Proposed the date for factory acceptance
test dates and sequence of testing to get it approved from
the consultant and client. I have a knowledge about the
testing, commissioning of the generator system.
1.8 During the factory acceptance test, our generator system
complies with the Singapore standard SS535:2007 code of
practice of installation, operation, maintenance,
performance, construction requirements of mains failure
standby generator systems. PE 1.6 This role depends on the
knowledge of both the electrical and mechanical system. We
are prepared the temporary resistive load bank and
terminate the temporary power cables from generator to the
load bank. There were functional electrical protection tests
are carried out to check the performance of the engine. All
the testing was continuously recorded in the power analyzer
and history of testing are captured in the generator digital
controller. Generator controller plays an important role of
our entire system, it controls the entire generator. Testing
equipment we used are vibration meter, sound level meter,
infra-red thermometer to measure the temperature and
familiarized with the listed testing equipment. PE 2.2
1.9 We have two type of Generators outdoor and indoor
generator. In this project we have used the canopy
generator. During our design stage I calculated the air flow
rate according to the engine and size of the canopy, PE 1.3 so
there was no over heat and improve the efficiency of the
engine. PE 3.3

1.10 Each Generator has 1000 liters diesel storage tank and it
was located inside the generator canopy. 1000 liters storage
tank was tested before top up the fuel by engaged the
qualified radio graphic testing company and certified. Supply
tank was supported by the underground storage with
capacity of 75,000 liters. Automatic fuel system with two
pumps, filter and PLC logic systems to control the functions.
1.11 For this project we had 12 underground storage system with
75,000 liters capacity. Tanks were manufactured according
the approved drawings and thickness. Welding joints are
tested by the qualified government agencies and submitted
the test reports. Pressure test the tank by pneumatic and
check any leaks by using soap waters. Found there was no
leaks and it was passed. Thickness of the tank materials and
paints are measured with the thickness gauges. Inlet
flanges, outlet flanges, other provisions like level sensor
indicator, manual dip stick provision are inspected during the
fabrication stage according to the approved drawing.
1.12 Arrangement of transport from Malaysia factory to Singapore
site by coordinating with the site team and the production
team. PE 3.6Site walk and survived the site before delivery. For
this project faced the complicated-on delivery was our
Generator canopy are oversized it needs the escorts on the
Singapore road and only could delivered on night time. I
arranged the transport comply with the Land transport
authority of Singapore. Successfully delivered all our
Generator and Bulk fuel tanks according to the scheduled
dates.
1.13 Installation process played an important role in every
project. Planned the installation works by ordered the bill of
materials earlier to get it on time. Very helpful to me by

planned ahead the required materials. Manpower was also
calculated on the starting stage, so after our delivery of
generator we immediately mobilize the manpower to start
our installation work effectively and complete our project
according to the project schedule. Arranged our own
installation checklist to closely monitor the progress of the
project according to the planned schedule with the safety
concern.PE 3.1 Proper communication with the workers till the
managerial level. PE 3.2
1.14 Final completion of our installation, there was an as built
drawing according to the site installation. I checked on site
and update to the design department to capture the changes
on site. For this project requirement was to submit the
drawings in 3D modeling, I studied quickly manner with our
senior designer to get knowledge on study of 3D in viewing
the drawing. Our design team changed our 2D AutoCAD
drawing to 3D in timely manner.
Engineering Skills and Knowledge Applied in the Work
1.15 I have used my mechanical engineering skills and knowledge
for successful execution of this project. The first and the
foremost skill that I have applied here was structural
mechanics. Moreover, I have even used my skill of
assembling of project deliverables and analysis of test
results as well as adjustment of design if required. I have
even utilized my knowledge of AutoCAD software to
complete the 3D modelling of this project. I also had
executed few tests like protection tests for checking engine
performance PE 1.5. Problem solving skills and logical
reasoning were the next two skills applied in this particular
project.

Technical Difficulties Faced and Solutions
1.16 The first technical difficulty that I had faced in this project
was during getting approval for my drawings. Since, there
were changes in those drawings, the higher authority was
not giving permission and hence my project was getting
delayed. For resolving this issue, I arranged a meeting with
my project supervisor PE 2.1. I made him understand the
requirement of such changes in my drawing. I was finally
able to convince him and get approval for my drawings.
1.17 The second challenge in this project was while carrying out
the functional electrical protection tests for performance
checking of engine. I was unable to record the testing results
within the power analyzer and hence had to lose
experimental data in the primary stage PE 1.16. To solve this
issue, I considered the idea of capturing the data history in
generator digital controller. This helped me in controlling the
entire generator and thus I was able to check the
performance efficiently.
1.18 The next technical difficulty that I had faced here was during
usage of AutoCAD software for 3D modelling. As this was my
project with this particular software, I was not confident
enough and the output was erroneous as per my expected
outcome. However, with my engineering knowledge and
intellect, I was able to solve this issue. I checked for CAD
programs that run on the main frame computers or mini
computers and was able to understand the working principle
PE 2.3. Hence, the second time, when I took the readings, they
were accurate and error free. Regarding selection of
software version, I took the latest version.
Summary

1.19 As a project engineer, by working with this well-established
company, I earned a good knowledge of work experience.
This job scope allowed me to build a strong foundation in
project engineering. I was able to build my own reliable
network consisting of clients and vendors.
1.20 Upon successfully completion of this project, we gained a
good reputation and confident from our customers. It was
boosting our company business in the market. I have
successfully completed this project with good profit. . PE 3.5