SOP FOR DG SYNCHRONIZATION

ENGINE MAKE : CUMMINS (1500 KVA)

MODEL : KTA-50-G8-1
ALTERNATOR MAKE : STAMFORD

ENGINE MAKE : MITSUBISHI (1450 KVA)

MODEL : MGS1400B/C
ALTERNATOR MAKE : STAMFORD

PROCEDURE:

Before starting the engine, the following checks to be done

 Ensure for green flag in Vacuum Indicator.

 Ensure for Lube oil level is high.

 Ensure required coolant level is available and top up coolant if required.

 Ensure all the belt condition and tension is correct

 Ensure for required fuel level/availability in the Day tank (Above 80 %)

 Ensure No Fuel, Oil & Coolant leakages in the Engine.

 Ensure Emergency push button is in released condition.

 Ensure the 24V DC Control supply is available.

The procedure to “START” the DG set in “MANUAL MODE” (CUMMINS DG)

 Set the Synchronizing duty selector switch in Manual mode

 Put the Engine control Selector switch in ‘RUN’ Mode from ‘OFF’ Mode

 Ensure the voltage, Frequency & RPM are within the limits and record all no-load
parameters.

 Close the ACB by pressing the close push button manual and ensure the indication is
‘ON’.

 Ensure Neutral breaker is closed

 Ensure the supply is fed to the LT Panel.

To operate additional DG synchronization when the load is above 75 %

 Ensure the Synchronizing duty selector switch of Another DG in Manual mode

 Switch ‘ON’ the additional DG by selecting Engine control switch to ‘RUN’ Mode.

 Ensure the voltage, Frequency & RPM are within the limits and record all no-load
parameters.

 Close the ACB by pressing the push button manually when indicates * symbol and
ensure the indication is ‘ON’.

 Ensure the supply is fed to the LT Panel

The procedure to “START” the DG set in “MANUAL MODE” (MITSUBISHI DG)

 Set the key switch on “ACTIVE” at DG control panel.

 Set the controller to the auto mode in generator control panel and Manual mode in Woodward
control panel.

 To start the generator by press the start button manual at Woodward control, after start delay
timer elapses, the stop solenoid will be energized to start the starter motor.

 Ensure the voltage, Frequency & RPM are within the limits and record all no-load
parameters.

 Close the ACB by pressing the close push button manual in Woodward control and
ensure the indication is ‘ON’.

 Ensure Neutral breaker is closed

 Ensure the supply is fed to the LT Panel.

To operate additional DG synchronization when the load is above 75 %

 Ensure Another DG set key switch on “ACTIVE” at DG control panel.

 Ensure the controller to the auto mode in generator control panel and Manual mode in
Woodward control panel.

 To start the generator by press the start button manual at Woodward control, after start delay
timer elapses, the stop solenoid will be energized to start the starter motor.

 Ensure the voltage, Frequency & RPM are within the limits and record all no-load
parameters.

 Close the ACB by pressing the close push button manual in Woodward control it
become auto synchronized and ensure the indication is ‘ON’.
  Ensure the supply is fed to the LT Panel.

The following to be checked during DG set running

 DG Output Voltage, Load current, Frequency, Water Temp, Lube oil Pressure,
Battery Voltage, gauges, Exhaust gas inspection.
 Check for leaks, odd noises, or other signs of abnormal wear or operation.
 Note anything unusual and report it to the Shift Engineer / Technical Manager
immediately.
 Inspect day tank diesel level every 30 minutes and record once in every hour. If the
fuel level is at below half tank (or) at 400 Liters open fuel line valve and switch on
the fuel transfer pump to refilling the day tank.
 In case of emergency due to part failure, Isolate DG from the system by pressing
“Emergency push button”.
Procedure for Switching ‘OFF’ the DG set

 When the load is reduced to zero, Open the ACB by pressing the push button and
ensure the indication is on OFF position.

 Switch ‘OFF’ the DG sets after running the engine idle for 3 minutes by changing the
Engine control panel selector switch to ‘OFF’ Mode.

The procedure to “START” the DG set in “AUTO MODE” (CUMMINS DG)

 Set the Synchronizing duty selector switch in Auto mode

 Put the Engine control Selector switch in ‘AUTO’ Mode from ‘OFF’ Mode.

 In Auto mode the DG set starts automatically in case of mains failure.

 When the engine starts and alternator reaches the preset voltage, the DG contactor
closes and automatically restores the supply to the load.

 The auto-start system makes three attempts to start, in case it fails to start, the starting
system automatically disconnected and locked out.

 After the restoration of healthy mains voltage, the DG contactor opens and the main
supply extended to the load.

 However, the DG set continuous to run for 3 minutes and shut down after that if
mains supply remains stable.

 During the above mentioned 3 minutes, if the mains fail again, the DG shutdown
sequence discarded and the DG contactor closes again to restore the DG supply to the
load.
 The procedure to “START” the DG set in “AUTO MODE” (MITSUBISHI DG)

 Set the key switch on “ACTIVE” at DG control panel.

 Set the controller to the auto mode in generator control panel and Auto mode in Woodward
control panel.

 In Auto mode the DG set starts automatically in case of mains failure.

 When the engine starts and alternator reaches the preset voltage, the DG contactor closes and
automatically restores the supply to the load.

 The auto-start system makes three attempts to start, in case it fails to start, the starting system
automatically disconnected and locked out.

 After the restoration of healthy mains voltage, the DG contactor opens and the main supply
extended to the load.

 However, the DG set continuous to run for 3 minutes and shut down after that if mains supply
remains stable.

 During the above mentioned 3 minutes, if the mains fail again, the DG shutdown sequence
discarded and the DG contactor closes again to restore the DG supply to the load.

TRUTH TABLE FOR ELECTRICAL INTERLOCK

PHASE -1 DG SYNC PANEL CONDITIONS

CONDITIONS DG1 DG2 BUS-1 DG3 DG4 BUS-2 DG5 DG6

CONDITION ON ON OFF ON ON OFF ON ON
1
CONDITION ON ON ON OFF OFF ON OFF OFF
2
CONDITION OFF OFF ON ON ON ON OFF OFF
3
CONDITION OFF OFF ON OFF OFF ON ON ON
4

CONDITION DG DG BUS TIE DG DG BUS TIE DG DG DG TIE

S 7 8 1 1 9 10 2 2 11 12 13 3
CONDITION ON ON OFF OFF ON ON OFF OFF ON ON OFF OFF
1
CONDITION ON ON ON OFF OFF OFF ON OFF OFF OFF OFF OFF
2
CONDITION OFF OFF ON OFF ON ON ON OFF OFF OFF OFF OFF
3
CONDITION OFF OFF ON OFF OFF OFF ON OFF ON ON OFF OFF
4
CONDITION ON ON ON ON OFF OFF ON OFF OFF OFF ON OFF
5
CONDITION OFF OFF ON OFF ON ON ON ON OFF OFF ON OFF
6
CONDITION OFF OFF ON OFF OFF OFF ON OFF ON ON ON ON
7
CONDITION ON ON OFF ON ON ON OFF OFF ON ON ON OFF
8
CONDITION ON ON OFF OFF ON ON OFF ON ON ON ON OFF
9
CONDITION ON ON OFF OFF ON ON OFF OFF ON ON ON ON
10
CONDITION ON ON ON OFF ON ON ON OFF ON ON OFF OFF
11

PHASE -2 DG SYNC PANEL CONDITIONS