How to ensure successful PM shaft generator commissioning

Commissioning is the final handover of The Switch PM shaft generator to the system integrator at the shipyard.

Multiple stakeholders and many participants are involved in these projects. Typically, they include:

• The shipyard commissioning team and supervisors
• The shipowner’s inspector
• The classification society inspector or other representative
• The Switch service engineers
• The system integrator supervisors

Although we at The Switch contribute only one component, how we do our part affects many others.

Our focus from the beginning is to anticipate potential problems and eliminate them. This means our generators have been designed and built for easy installation, our team is highly skilled, and we are continuously working to devise the clearestinstallation instructions.

We do whatever it takes to ensure the day of commissioning proceeds smoothly.

What are the steps in commissioning? 

Successful commissioning relies on careful attention in three areas leading up to commissioning:

• Planning and documentation
• Pre-commissioning checks
• Team competence

And in three areas on the day of commissioning:

• Issue resolution
• Compliance with standards
• Handover and training

Commissioning engineersat The Switch consider all viewpoints and anticipate, discuss and respond to all questions. Commissioning checklists and documents continue to be adjusted to reflect the most up-to-date results of all discussions. And on the actual day of commissioning, The Switch personnel advise, train, supervise and troubleshoot as needed.

We at The Switch always work to develop a responsive and supportive relationship with every customer. This collaboration continues to be very important through commissioning. As we and the customer work through the details of each area,we focus on communicating clearly and promptly, collaborating creatively, finding quick, efficient solutions to any problems that arise and delivering an electrical component that runs exactly as promised.

A breakdown of the details involved gives an idea of the complexity of the process.

Planning and documentation   

Planning starts long before the actual day of commissioning.

1. We consider all the parties involved and identify what they’ll need to know to carry out their roles. This includes:  
2. Safety training, equipment requirements and instructions
3. Project-specific technical specifications for the delivery
4. The commissioning schedule, work phases of commissioning and the limits/tolerances for each phase
5. Areas of responsibility

• For each project, we prepare a technical customer documentation package specific to the project and pass it out early in the delivery phase. The package typically includes:
• User manual(s)
• Installation instructions
• Wiring diagrams
• Main dimension drawings
• Technical specifications
• Spare parts documents

We keep the customer updated on any engineering adjustments made after they receive the initial documentation package. We have recently added QR codes to installation instructions and user manuals to make access to the latest documents faster and simpler. Scanning the code brings up the latest approved version.

The customer passes all documents on to the other stakeholders, discusses specifics with them and orchestrates all details at the shipyard, including safety parameters, tools needed, the necessary documentation and any other essential issues. Areas of responsibility are clearly delineated in the installation document and the technical specifications.

We communicate regularly with the customer throughout this period to clarify details, answer questions and adjust the schedule as needed.

We encourage customers to ask questions any time. Communication is key.

Pre-commissioning checks and confirmations

The delivery period may take some time. So, it’s important to have all the specifications top of mind. As the commissioning day approaches, we check and recheck the details with the customer. Again, careful attention and smooth cooperation are key.

At this point, our list includes:  

• Ongoing communication with all stakeholders
• Confirmation that the necessary supervisors, skilled engineers and technicians will be present and a final review of their roles and responsibilities
• Confirmation that the customer and shipyard have the most up-to-date documents and that all shipyard questions have been addressed
• Final review of the commissioning schedule with the customer and confirmation that enough time and the right equipment is available
• Reiteration of the necessity of following The Switch instructions and manuals for a successful outcome
• Verification of machine quality at the factory
• Double-checking the list of tools provided by The Switch and by the shipyard and verifying they will be available in good condition on the day of commissioning
• Calibration of all tools and measuring devices
• Ensuring the availability of The Switch commissioning supervisors

Ensuring coordinated teamwork

Smooth cooperation and communication between the customer’s supervisor, The Switch service engineers and shipyard personnel on the day of commissioning is essential.

The shipyard site manager supervises the installation according to shipyard instructions and schedule and acts as the contact person between all the different people on site: service engineers, shipyard commissioning team, shipowners and classification society representatives.

Both the site manager and The Switch service engineers must have a clear idea of which technicians or engineers will be available and a clear understanding of each step of the training, installation, measurement, verification and handover stages.

The installation instructions in the customer document package explain these steps in clear and easy-to-understand language. The process and instructions are carefully reviewed with the customer before the actual day and any questions from the shipyard are resolved as early as possible.

Our commissioning report functions as both the day’s worklist and the collection point for records of the actual events. It creates order and a systematic way to proceed through the commissioning process. The report includes:

• Description of the commissioning work
• Work phases and status
• Measurement results
• Additional space to attach work phase images and comments

 It also serves as a template for the report of measurement results given after the event.

Day of commissioning

At last, the commissioning day arrives.

The day starts off with the shipyard’s safety training and hands-on training by The Switch service engineers. Thereafter, we supervise to ensure The Switch protocols are followed and careful attention is given to regulatory and safety standards. Adherence to industry standards is essential. Safety is paramount. Clear and consistent communication between all parties helps ensure an excellent outcome.

Once the intermediate shaft is installed to the machine, the machine is lifted inside the ship. After this, measurements related to shaft alignment are taken. These include:

• Preliminary air gap sanity check
  • Rotor axial position
  • Final adjustment of the eccentricity and air gap
  • Air gap sanity check

The most important measurement for shaft alignment is the final adjustment of the eccentricity and air gap. At this stage, the eccentricity of the rotor and stator is adjusted to within the tolerances given by The Switch to minimize unbalanced magnetic pull – the force between the stator and rotor due to the permanent magnets assembled on the rotor surface.

We also carefully monitor any jack-up tests done to make sure risks to the PM rotor are minimized and advise how to take the magnetic forces into account if the tests are executed with the rotor connected.

Throughout the day, our job is to ensure that the alignment process follows our instructions, the measurement results are within our tolerances and any issues are resolved promptly. We systematically log and track any issues, analyze them for root cause and make any needed adjustments. Remeasuring follows.

Once any issues have been resolved, the shaft alignment is complete. The Switch provides the customer with a report of the commissioning results and further updates in training or user manuals, if needed. 

After the commissioning day 

After every commissioning, we use the feedback from the customer, the shipyard and shipowner – and from within The Switch – to review and improve our procedures and refine our commissioning documents.

We value our customers and are continuously improving the process. Your successful commissioning is our goal!