Senior Engine & Generator Commissioning Engineer

The Senior Engine & Generator Commissioning Engineer is the technical authority responsible for the on-site start-up, testing, commissioning, and troubleshooting of diesel/gas engine-generator sets, generator control systems, and paralleling switchgear across industrial, data center, utility, marine, and prime/standby power installations. The role owns the technical integrity of the commissioning scope from mechanical completion through customer acceptance, ensuring every genset and switchgear system performs to OEM specification, code, and contract requirements before handover.

KEY RESPONSILIBITIES

• Commissioning Execution: Execute and lead pre-commissioning inspections, cold/hot commissioning, load bank testing, and performance verification of single and multiple engine-generator sets.
• Genset Controls: Configure, program, and commission generator control units (DSE, ComAp, DEIF, Woodward, or equivalent) including engine protection parameters, AVR settings, governor tuning, and alarm/shutdown logic.
• Paralleling & Switchgear: Commission and functionally test automatic synchronizing and load-sharing systems, closed/open transition transfer schemes, peak shaving, load shedding/adding, mains (utility) paralleling, and multi-set paralleling switchgear (LV/MV) in coordination with switchgear OEMs.
• Industrial Networks & Controls Integration: Configure and troubleshoot industrial communication networks between engine ECMs, generator controllers, switchgear PLCs, SCADA/BMS, and remote monitoring platforms using J1939, CAN bus, Modbus RTU (serial), and Modbus TCP/IP; support integration over Ethernet/IP, Profibus, or BACnet where applicable.
• Troubleshooting: Diagnose and resolve complex electrical faults (control wiring, protection relays, AVR/exciter circuits, CT/PT wiring, earthing/grounding, harmonics) and mechanical faults (fuel, air, cooling, lubrication, exhaust, vibration, alignment) down to root cause, using OEM service tools, wiring diagrams, and structured RCA methods.
• Test & Measurement: Use and interpret data from insulation resistance (IR) testers, clamp meters, digital multimeters, power quality/harmonic analyzers, oscilloscopes, primary injection/relay test sets, and thermal imaging cameras to validate system integrity and diagnose faults.
• Service Tools & Software: Operate OEM diagnostic and configuration software (e.g., INSITE/PowerCommand/InPower, DSE Configuration Suite, ComAp GenConfig/InteliMonitor/WebSupervisor, DEIF Utility Suite/USW, Woodward ToolKit) to commission, calibrate, flash, and troubleshoot controllers.
• Documentation: Prepare and execute Method of Procedure (MOP) / commissioning test scripts, complete redlines and as-built markups, and generate factory/site acceptance test (FAT/SAT) reports, punch lists, and commissioning certificates.
• Customer Interface: Act as the primary technical point of contact for the customer, EPC, and OEM during commissioning; provide clear progress updates, technical explanations, and issue resolution paths.
• Training & Handover: Deliver on-the-job training and knowledge transfer to customer O&M staff and junior commissioning engineers on genset operation, controls, and basic troubleshooting.
• Safety & Compliance: Enforce Lock-Out/Tag-Out (LOTO), arc-flash, confined space, and working-at-height protocols; complete job safety analyses (JSAs) and comply with client and company HSE requirements at all times.

TECHNICAL REQUIREMENTS

1. Generator Control Systems

• Hands-on configuration, calibration, and fault-finding experience on Deep Sea Electronics (DSE), ComAp (InteliGen / InteliSys / InteliNeo), and DEIF (AGC/AGC-4/Multi-line 2) generator control platforms; exposure to Woodward and Basler control/protection platforms is a strong plus.
• Working knowledge of AVR/exciter systems, governor and speed control, engine protection curves, and control system parameterization for both mechanical and electronic engines.

2. Paralleling & Switchgear

• Demonstrated experience commissioning generator paralleling switchgear — automatic synchronizing, load sharing (isochronous/droop), closed and open transition, utility paralleling, peak shave/load shed, and N+1/N+2 redundant configurations.
• Familiarity with LV/MV switchgear, automatic transfer switches (ATS), static transfer switches (STS), protective relaying (e.g., SEL, Woodward, GE Multilin), breaker coordination, and basic short-circuit/arc-flash awareness.

3. Industrial Networks & Communication Protocols

• Proficient with J1939 (SAE) engine data bus, CAN bus diagnostics and wiring, Modbus RTU (serial RS-232/RS-485), and Modbus TCP/IP for controller-to-SCADA/BMS/remote monitoring integration.
• Ability to read CAN/Modbus register maps, use bus analyzers/sniffers, and resolve network wiring, addressing, and termination issues; exposure to Ethernet/IP, Profibus, or BACnet is beneficial for data center and BMS-integrated projects.

4. Test & Measurement Equipment

• Insulation resistance testers (Meggers), clamp meters, digital multimeters, power quality/harmonics analyzers, oscilloscopes, and secondary/primary injection relay test sets, plus infrared thermography for connection and thermal fault checks.

5. Service Tools & Software

• Proficient with OEM commissioning/diagnostic software such as Cummins INSITE, PowerCommand Toolkit, and InPower; DSE Configuration Suite; ComAp GenConfig, InteliMonitor and WebSupervisor; DEIF Utility Software (USW); and equivalent Woodward/Caterpillar/MTU/Perkins service tools.

6. Troubleshooting — Electrical & Mechanical

• Structured fault-finding across control wiring, protection and metering circuits, alternator/AVR systems, and grounding/bonding, alongside mechanical systems — fuel injection, turbocharging/air intake, cooling, lubrication, exhaust after-treatment, and vibration/alignment — on diesel and gas engine platforms.

QUALIFICATIONS & EXPERIENCE

• Bachelor's degree in Electrical, Mechanical, Power/Automotive, or Mechatronics Engineering, or equivalent extensive field experience in lieu of degree.
• Minimum 7–10 years of hands-on field experience in engine-generator commissioning, startup, or field service, including at least 3–5 years leading commissioning on multi-set/paralleled installations.
• OEM factory training/certification on one or more major genset or controls brands (e.g., Cummins, Caterpillar, MTU/Rolls-Royce, Perkins, DSE, ComAp, DEIF) strongly preferred.
• Experience commissioning in mission-critical (data center), oil & gas, marine, utility, or industrial power environments is highly valued.
• Valid electrical safety / LOTO / arc-flash training (e.g., NFPA 70E or regional equivalent); NETA-related testing exposure is a plus.
• Willingness and ability to travel extensively, including internationally, and to work variable hours to meet project schedules.
• Strong written and verbal communication skills in English; additional languages relevant to the operating region are an advantage.

KEY COMPETENCIES

• Analytical, methodical fault-diagnosis mindset with the ability to work independently under time and safety pressure on live electrical systems.
• Strong customer-facing presence — able to explain technical issues clearly to clients, EPCs, and OEM partners.
• Meticulous documentation habits and ownership of quality and safety outcomes.
• Mentoring orientation — willing and able to transfer knowledge to junior engineers, technicians, and customer O&M teams.