Operation Procedure of 1010 KVA DG Set

Standard Operating Procedure (SOP) for the operation of 1010 KVA Diesel Generating – DG Set installed for power backup in the pharmaceutical drug manufacturing plant.

Procedure for Operating of 1010 KVA DG Set

1.0   PURPOSE:

    • The purpose of this SOP is to define the procedure for the operation of the 1010 KVA DG set.

2.0   SCOPE:

    • This procedure is applicable for the operation of 1010 KVA DG Set installed for power backup in pharmaceuticals drug manufacturing plants.

3.0   REFERENCES:DG Set 1010 KVA

    • In House Procedure.
    • Operation and Maintenance Manual.

4.0   RESPONSIBILITY:

    • The technician shall be responsible for starting, stopping, and operation of equipment.
    • Maintenance Supervisor shall be responsible for periodically maintaining operation log, filter cleaning record, maintenance record, and status label.
    • Department Head shall be responsible to check performance and preventive maintenance of the equipment
    • Quality Head and Plant Head shall be responsible to review and approve the SOP.

5.0   ABBREVIATIONS USE IN SOP FOR DG SET:

    • AMF: Auto Main Failure
    • DG: Diesel Generating
    • GCU: Generator Controller Unit
    • KVA: Kilo Volt Ampere
    • MCB: Miniature Circuit Breaker
    • NA: Not Applicable
    • PCC: Power Control Centre
    • PLC: Programmable Logic Control
    • EB: Sikkim Electricity Board

6.0   PROCEDURE FOR OPERATION OF DG SET:

    • DG Set power to be restored within 3 minutes in case of SEB supply failure or any electrical power supply failure.
  • Pre Start Check Point of DG Set:
    • Check the following…
    • The fuel level is above minimum level marking (200 lit marking).
    • Engine oil level. It should be in-between L and H marking of the dipstick.
    • The coolant level above the heat exchanger should be full.

Related: SOP for Building Maintenance

    • Heat exchanger main and return line valve open or closed position, the valve should be kept in the open position for cooling.
    • Confirm the cooling tower fan with the pump running.
    • Open the supply and return lines of diesel.
    • Start the Lube oil circulation pump for 1 minute.
  • Starting of DG Set:

    • Stop the Lube oil circulation pump.
    • Release the emergency push button on the display panel.
    • Put the DG Set panel ON and put the switch position Manual/Auto.
    • Closed the breaker control switch, turn to the close position of AMF Panel.
    • Trip the SEB incomer ACB by opening the key.
    • Closed the PCC changeover panel’s ACB of DG set as per the logic diagram.
    • Closed the incomer ACB of the DG Set of PCC panel.
    • Ensure that the coolant temperature is below 90°C from the display panel.
    • Check that engine oil temperature is below 100°C from the display panel.
    • Check that current load is not more than 1250 Ampere
    • Take the reading from the display panel and maintain the record of diesel generating set operation log as per Annexure-1.
    • Inform maintenance Engineer in case of any problem.
  • Stopping of DG Set:

    • Trip the D.G incomer A.C.B by closing key and closed the ACB of SEB income.
    • Trip the PCC changeover panel’s ACB of DG set.
    • The AMF panel manually.
    • DG Set should be run 3-4 mins without load to bring down the Lubricant Oil temperature after then put the switch in OFF position.
    • Close the emergency push button off position
    • Close diesel supply and return line valve.
    • The heat exchanger valve of the cooling tower.
    • Confirm the cooling tower fan with pump closing.
  • Maintenance of DG Set:

    • Clean air filters of D.G. set monthly ±4 days by dry air pressure and maintain the record as per Annexure-2.
    • Clean fuel strainer/ mesh filter of D.G. set monthly ±4 days and maintain the record as per Annexure-2.
    • Check and maintain the filter cleaning status label as per Annexure-3
    • B-check maintenance should be done after 300 hrs run the engine or 6 months whichever comes earlier (i.e engine oil, lube oil filter, bypass filter, fuel filter, and coolant filter to be changed) and maintain the record as per Annexure-4.
    • Replacement of Air filters and fuel strainer/mesh filter to be done in case if the filters are found damaged or choked whichever comes earlier and maintain the record as per Annexure-5.

7.0   ANNEXURES – SOP FOR DG SET:

Annexure 1: Diesel Generating Set Operation Log

Capacity :__________________________  Equipment ID:___________________

Prepare the logbook by using following table contents…

    • Date
    • Start at
    • Stopped at
    • Running Hours
    • Energy Meter KWH
    • Load KVA
    • HSD Consumed
    • RPM
    • Frequency
    • Lube Oil Pressure
    • Lube Oil Temp.
    • Coolant Temp.
    • Voltage
      • RY
      • YB
      • BR
    • Current
      • R
      • Y
      • B
    • Battery Voltage
    • Battery Charging ON/OFF
    • Checked By
    • Remarks

Annexure 2: Air/Mesh Filter Cleaning Record

Area   Equipment Name  
Equipment Code  

Sr.No

Filter Cleaned On Next Cleaning Due On Cleaned By Checked By

Remarks

 

Annexure 3: Filter Cleaning Status Label

FILTER CLEANING STATUS LABEL

CLEANED ON : – _______________________________________

NEXT CLEANING DUE ON : – ___________________________

DONE BY :- ___________________________________________

CHECKED BY : – ______________________________________

 

Annexure 4: B- Check Maintenance

Area:_____________________ Equipment Name:____________________

Equipment Code:_______________

Prepare the table by using the following table contents.

    • Sr.No
    • Particular
    • Replacement
      • Date
      • Hours
    • Next Replacement
      • Date
      • Hours
    • Maintenance By
    • Checked By
    • Remarks

Note: Frequency for B-Check Maintenance should be done after 300 hrs run the engine or 6 months whichever comes earlier.

Annexure 5: Air Filter and Fuel Strainer Replacement Record

Area:_____________________ Equipment Name:____________________

Equipment Code:_______________

Prepare the table by using the following table contents.

    • Sr.No
    • Particular
    • Replacement
      • Date
      • Hours
    • Reasons for Replacement
    • Changed By
    • Checked By
    • Remarks

pharmabeginers

Janki Singh is experienced in Pharmaceuticals, author and founder of Pharma Beginners, an ultimate pharmaceutical blogging platform. Email: [email protected]

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