Ref No.

: I/RF/MGR/AMND/001
AMENDMENT SHEET Rev No.: 01
Eff Date: 01-12-2016

Document Name:
Sr. Effective
Document Reference No. Rev. No. Details of change
No Date
Change in organization
01 01/03/2010 Q/WI/MNT/DG/002 03
logo
Change in organization
02 01/07/2011 Q/WI/MNT/DG/002 04
logo
Change in organization
03 01/12/2016 I/WI/MNT/DG/002 01
logo

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 WORK INSTRUCTION FOR REF NO:I/WI/MNT/DG/002
STARTING AND STOPPING OF REV NO. : 01
EFF DATE : 11-10-2023
500 kva Cummins DG SET

PURPOSE:
To provide procedure for operating, Starting and stopping of Diesel Generating Set.

SCOPE:
Applicable to 500 KVA Diesel generator installed in the facility.

RESPONSIBILITY:
Technician

DEFINITION:
DIESEL GENERATOR: Electrical Power equipment capable of delivering rated Electrical
energy to energize equipments/machines safely, by converting rotary motion (Diesel Engine
as prime mover) into electrical energy

1.PROCEDURE:
1.1 PRE STARTING CHECKS (Daily A-Check)
1.1.1 Ensure diesel level is above minimum level.

1.1.2 Ensure valve from diesel tank to D.G. set is in open condition

1.1.3 Ensure D.G. set lubrication oil level is between L and H indicator mark of
Dipstick.

1.1.4 Ensure inner circuit coolant level is full.

1.1.5 Check and Ensure the 24 volts D.C. on ECP

1.1.6 Check for any loose connections, oil or water leakages in the DG set

1.1.7 Ensure toggle switch in idle mode

1.2 STARTING OF D.G SET (Change over from DG to EB Power)

1.2.1 Put ECP key in ON mode until scan all the parameters

1.2.2 Start(Crank) the Diesel engine by using key

1.2.3 Ensure the DG RPM is 1050 and then put the toggle switch in run mode

1.2.4 Ensure the Engine rpm is 1520 and 3 ph Voltage, should be 415 volts and
frequency should be 50 HZ in DG-1 (Bus coupler 1) Incoming panel

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 WORK INSTRUCTION FOR REF NO:I/WI/MNT/DG/002
STARTING AND STOPPING OF REV NO. : 01
EFF DATE : 01-12-2016
500 kva Cummins DG SET

1.2.5 Close Incomer ACB of DG-1 incomer at Main LT panel do the change over from
Transformer To Bus-1 using change over switch of Bus coupler-1 and ensure “I”
on isolation indicator with RED Flag

1.2.6 Put and confirm all the Feeders in Distribution panel are kept in Bus-1 mode,
and ensure the out put supply for all the feeders.

1.2.7 Check and ensure the power availability by seeing green LED lit on the
individual feeder for essential loads like UPS, Servers

1.3DURING RUNNING OF D.G.SET

1.3.1 Ensure total load in each phase is not more than 80% of full load current rating
of D.G set. Full load current of 500KVA DG = 690Amps.
1.3.2 Monitor and record the following parameters.
1.3.3 A).Radiator water temperature Should be less than 95°c
B).Lubrication oil pressure should be in between 3 kg/cm² to 6.5 kg/cm²
C).Load (Amps) below 690 Amps
D).Diesel Level should maintain above minimum level

1.4 STOPPING D.G SET

1.4.1 Inform the production department to switch OFF the machines to unload DG
where ever required

1.4.2 Ensure the EB power supply and check the 3 phase voltage ≈ 400 volts

1.4.3 Switch OFF the DG-1 Incomer ACB and confirm its isolation indicator on ACB is ”O”, “ACB
OFF” with green flag.

1.4.4 Do the change over from Bus-1 to transformer using change over switch of bus coupler-1

1.4.5 Put the D.G. selector toggle switch in the engine control panel to idle mode and run for minimum
two minutes.
1.4.6 Bring the start switch in the engine control panel from ON to Off position.
1.4.7 Enter final readings in the logbook.

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 WORK INSTRUCTION FOR REF NO:I/WI/MNT/DG/002
STARTING AND STOPPING OF REV NO. : 01
EFF DATE : 01-12-2016
500 kva Cummins DG SET

1.4.8 Ensure battery charger is changing accordingly (Should charge batteries only when government
supply is available) incoming 230 Volts A.C supply is ‘ON’ and it is charging Engine starting
Battery.

1.4.9 After stopping the engine for 20-30 minutes, please perform Pre start checks for next start up
operation.

1.5 EXTRA PRECAUTIONS :

1.5.1 Do not put Any part of the body in engine/set while running.

1.5.2 Do not touch Hot surface by Bare Hand.

1.5.3 Avoid loose clothing near Fans and belts

1.5.4 Do not open caps of Radiator when hot.

1.5.4 Use EAR MUFF when D.G.SET is in Operation.

1.5.6 No Flame, Hot work near D.G set.

1.5.7 Use Safety Goggles while Checking Battery sets and electrolyte level etc.

1.5.8 Do not spill any oil or fuel on the floor.

2. ABBREVIATIONS:
D.G.SET- Diesel generator set

E C P – Engine control panel

Kg/cm ² -Kilo gram per square centimeter

A.C - Alternating current.

D.C –Direct current

ACB –Air Circuit Breaker

KVA – Kilo volt ampere

3. REFERENCES:

4. ANNEXURES: D G Logbook – Q/RF/MNT/DG/001

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