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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:

• • 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:

• • ACB: Air Circuit Breaker

• • 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

Annexure 3: Filter Cleaning Status Label

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