ENGINEERING & OPERATION SOLUTIONS GROUP

Property Details:

Subject: Standard Operating Procedure for Diesel Generator

Released by: K. Magesh Kumar

Current Version /
Release Date: Version-1 / 25.08.2010

Document No: ISS/SOP/002

Approved by: Ganapathy M K

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Equipment History:

EQUIPMENT NAME: Diesel Generator

MAKE:

LOCATION:

CAPACITY:

TYPE:

MODEL:

SERIAL NUMBER:

MODE OF CONNECTIVITY:

DIESEL ENGINE:

An electrical generator is a device that converts kinetic energy to electrical energy, generally using electromagnetic
induction diesel engine is the source for mechanical energy in a Diesel generator.

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Diesel Generator:

Backup power supply for the Transformers in the event of Electricity Board power supply failure ( 440 V).

Details of the Redundancies: 100 %

Normal Operating procedures:

To operate Diesel Generator following checks to be done:

- Check for the fuel level in day tank

- Check the lubricating oil level in the sump
- Check the water level in the radiator tank
- Check the Battery condition and voltage
- Check air filter restriction status
- Check radiator fan belt

During the power failure all the generators start automatically and taken the load fully with the help of
synchronization panel. For auto operation, controls of all panels to be kept in AUTO mode.

OPERATING PROCEDURE

There are two modes of operation:

1. Auto mode
2. Manual mode

AUTO MODE

 Select ‘Auto’ mode in Auto / Manual switch in synchronization panel.

 Select ‘Auto’ mode in Auto / Manual switch in DG sets panel.
 Check PLC display for any alarms, press “Alarm event and Alarm clear’ then press enter and reset if any.
 All the DG sets synchronized in 15 to 20 sec and accepts the load.
 PLC will monitor all the DG sets running for 20 minutes.
 If load drops below the programmed limit (KW) one of the DG will go off and standby.
 When the EB power returns, DGs still run with load and PLC will monitor the condition of the EB power for 3
minutes.
 If the EB power is healthy and stable, load transfer will take place from DGs to EB.
 DG sets will run without load for 5 minutes to cool down.
 If EB power fails while DGs are in cool down mode, load transfer will take place without shutting down
synchronisation sequence will repeat.
 Operators intervention would only required if DGs trip due to some abnormal conditions, check and
manually reset master trip relays to bring DG back into normal operation after duly attending to the fault.

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Manual Mode Operation when auto synchronizing fails:

 1. Select ‘Manual’ mode in Auto / Manual switch in synchronization panel.

 Keep that particular DG in manual mode.
 Start the DG set.
 Observe the readings from the VOLTS AC meter and the FREQUENCY meter. The voltage readings should be
415/440 volts. meter will indicate the percent rated current (not more than 100 percent) between
generator line 2 and neutral. The FREQUENCY meter should indicate 50 hertz. The KILOWATTS meter should
indicate no more   than   100   percent   with   the   FREQUENCY meter showing 50 hertz.

 Observe the KILOWATTS meter. If the meter indicates that more than 60 % of load, start next DG set.

 Match the voltage, frequency bwt. 2 Dg sets and do the synchronization.

 DG sets get synchronized and accepts the load.

 When the EB power returns, DGs still run with load and operator monitor the condition of the EB power for
5 minutes.
 If the EB power is healthy and stable, do the load transfer from DGs to EB.

 DG sets will run without load for 5 minutes to cool down.

EMERGENCY OPERATING PROCEDURES:

Starting of Diesel Generator in Manual Emergency Mode:

- In case of an emergency normal inspection and preparation phase could be by – passed for manual
emergency start
- Rest all procedures are as per normal manual start.
- After taking the DG on Load do thorough inspection of the DG set and correct any deficiency such as
coolant, lubricating oil, fuel levels etc.,
- Ensure normal operation of DG and record parameters.

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Shut down of Diesel Generator in Emergency Mode:

- A manual emergency stop is attempted to avoid catastrophic failure of the DG engine, in case of major fire
incident in the vicinity or emergency situations. The aim is to save the equipment.
- Press the Engine STOP push button in the AMF panel or turning off the selector switch on the panel
mounted directly on the engine as convenient.

- Inform shift engineer about the emergency situation and wait for further instructions.
- Inspect the engine for any visible damage.
- Start other DG or restore power from the grid as per directions from shift Engineer.

Preventive Maintenance scheduling:

- Preventive Maintenance is carried out on equipment and systems so as to ensure maximum availability and
trouble free service during the life cycle.

- The PM scheduling is done as per the OEM’s recommendations

- PM should be carried out as per the relevant PM document generated separately.

- As far as possible the PM work should be scheduled so as not to disturb other activities and service
availability. In premises it is possible since enough redundancy of equipment and systems are provided.

- Trained and authorized personnel from the technical maintenance team, OEM or other vendors only should
carry out PM activities.

- Before taking up PM that would effect the availability of any other equipment or system the Facilities
Manager should be informed and permission should be obtained through e- mail. Effects of taking
equipment and systems OFFLINE should be brought out clearly in the mail.

- PM schedules should be well planned so as to ensure availability of competent personnel to carry out the
work, tools and tackles, spares and consumables.

- As a practice Electrical lock out Procedure should be in built in the PM work instructions. All the personnel
deputed to carry out PM schedules should be trained on Electrical Lock out Procedures.

Statutory requirements:

- Installation Certificate from Chief Electrical Inspectorate for Government as per the standard norms.
- Emission reports of exhaust smoke within the standard from Pollution control board during commissioning
of the DG sets
- Submission of Annual exhaust emission test certificates to State Pollution Control Board.

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A. SCOPE

This Procedure covers the instructions to be followed for DG Test Run (A – Check) and records to be maintained at
site.

B. OBJECTIVE

To Ensure 100 % Uptime of the Equipment.

C. PROCEDURE

 Put the Engine Control Switch in OFF Position.

 Check the water level in the radiator and top up if required.
 Check the lube oil level in the Engine and top up if required. (It should be between low and high markings).
 Check the radiator fan and battery charging alternator belts for any damage / crack.
 Switch ON the Engine Control Switch.
 Check the Battery voltage. (It should be greater than 24 V).
 Check for sufficient level of diesel in the fuel tank.
 Ensure all the fuel line valves are in open condition.
 Press the Manual button in the controller and press the Start button in the AMF Panel.
 Allow the DG Set to run on No Load for 5 minutes and record the parameters in the log sheet.
Coolant Temperature = < 80 Deg. C
Lube. Oil Pressure = > 300 KPa
Engine RPM = 1480 to 1520 RPM.
Voltage = 400 to 420 V
Frequency = 49.5 to 50.05 Hz.
 Then Stop the DG Set by pressing STOP button in the controller.

D. RECORDS:

1. DG – A Check
2. DG Log Book
3. History card to be maintained for each UPS.
4. Preventive Maintenance to be done as per the schedule given by the OEM.

E. AMC - CONTRACTOR DETAILS

M/s. _______________________________________ _ awarded the AMC contract for the maintenance

of the Diesel Generator after a thorough evaluation process. The contract includes labour for all the works
as mentioned in the scope of work, excluding any consumable material costs.

Mr. ______________________________________________ is their local representative. They will be

responsible for the execution of the contract. They are on call 24 hours 365 days at the following telephone
numbers: ______________________________________________.

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