STANDARD OPERATING PROCEDURE

SOP No.: MNT/006-04 Issue date:

Supersedes : 03 Effective date:
DG SET OPERATION
Dept : Maintenance Review Date On
Or Before:
Area : Utility Page No.:1 of 3

1.  OBJECTIVE:
1.1 DG set (Diesel Generators) are used as emergency or stand by systems in the industries during
sudden cut off of electricity or its failure. Hence the objective of this SOP is to describe the
procedure for the operation of DG set.

2. SCOPE

2.1 This SOP is applicable to the Operation of DG Set at Vital Healthcare Pvt. Ltd. Nashik.

3. RESPONSIBILITY
3.1 Maintenance Supervisor: To follow the procedure correctly as per SOP.
3.2 Maintenance Incharge: To ensure that the procedure is followed correctly as per SOP.
3.3 QA Manager: To ensure that the procedure followed is correct and to review and
authorize the documents.

4. PROCEDURE:
Principle: D.G SET works on principle ELECTRO-MAGNETIC INDUCTION discovered by
MICHEL FARADAY in 1831-1832, which states “flow of electric charges induce
by moving on electrical conductor (such as electric wire that contains charge) in a
magnetic field”. This movement creates a voltage difference between two ends of
the conductor, which in turn cause the electric charge to flow, thus generating
electric current.
DG does not actually “ creates” electric energy, it uses the mechanical energy supplied to it
to force the movement electric charges presence in the conductor of its winding, trough and
external current supplied by the D.G
FREQUENCY: N.A.
4.1 START – UP PROCEDURE:
4.1.1 Check Hydraulic Governor, Air Connections and Engine Coolant supply.
4.1.2 Starting requires that clean air and fuel be supplied to the combustion chambers in
proper quantities at the correct time. While starting the engine do not touch the
throttle or throttle lever.
4.1.3 Before starting, check to make sure that everyone is away from of engine and equipment, to
prevent accident.

PREPARED BY REVIEWED BY APPROVED BY AUTHORIZED BY

Name
Designation/Dept.
Signature and
Date
 STANDARD OPERATING PROCEDURE
SOP No.: MNT/006-04 Issue date:
Supersedes : 03 Effective date:
DG SET OPERATION
Dept : Maintenance Review Date On
Or Before:
Area : Utility Page No.:2 of 3

4.1.4 If fuel system is equipped with overspeed, stop, push “Reset” button before
attempting to start the engine.
4.1.5 ON units equipped with air activated prelube device, open-air valve until oil pressure
is registered on oil pressure gauge to activate piston in prelube device, which will
lubricate all moving parts in engine.
4.1.6 ON engines equipped with an oil pressure safety switch, hold the fuel by-pass switch
in “start” position until engine oil pressure reaches 7 to 10 PSI then, move to ‘run”
position.
4.1.7 Set throttle for idle speed and disengage driven unit.
4.1.8 Protect the turbocharger during start-up by not opening throttle or accelerating above
1000, until idle speed oil pressure registers on gauge.
4.1.9 Open manual fuel shutdown valve, if so equipped. Electric shutdown valves operate s
as switch is turned on. A manual override knob provided on forward end of electric
shutdown valve allows valve to be opened in case of electric power failure. To use,
turn fully clockwise: return “run” position after electric repair.
4.1.10 Pull the compression release (if so equipped) and press starter button or turn switch
Key to “start” position. After three or four seconds of cranking, close compression
release (If so equipped) and continue to crank until engine fires.
4.1.11 To prevent permanent cranking motor damage, do not crank engine for more than
10 seconds continuously. If the engine does not start after about three repeated
attempts, with an interval of two minutes between successive starts then the starter
must not be operated and the fuel system has to be checked for any faults.
4.1.12 At the initial start or after oil or filter changes and after engine has run for a few
minutes, shut it down and wait for15 minutes for oil to drain back into pan. Check
engine oil levels again: add oil as necessary to bring oil level to “H” mark on dipstick.
The drop in oil level below the low-level mark or above the high level mark.

PREPARED BY REVIEWED BY APPROVED BY AUTHORIZED BY

Name
Designation/Dept.
Signature and
Date
 STANDARD OPERATING PROCEDURE
SOP No.: MNT/006-04 Issue date:
Supersedes : 03 Effective date:
DG SET OPERATION
Dept : Maintenance Review Date On
Or Before:
Area : Utility Page No.:3 of 3

5. ABBREVIATIONS
5.1 SOP  Standard Operating Procedure
5.2 IPQA  Inprocess Quality Assurance.
5.3 rpm  Revolutions per minute
5.4 PSI  Pressure per square inch

6. ANNEXURE: Nil

7. REFERENCE: In-House/Manufacturers Manual.

END OF THE DOCUMENT

PREPARED BY REVIEWED BY APPROVED BY AUTHORIZED BY

Name
Designation/Dept.
Signature and
Date