STANDARD OPERATING PROCEDURE

TITLE: DG SYNCHRONIZATION Page 1 of 3

SOP No. DG - 04 Revision: Issue Date: 01 Jun 2015 Next Revision: As &
Date: when requirement

Originated by Concurred by Approved by

________________ _________________ ________________

(Facility Manager) (Operation Manager) (Client)

OBJECTIVE:

To establish a procedure for Diesel Generator Synchronization

POLICY:

The operation of Diesel Generator should be safe, smooth and trouble free

RESPONSIBILITY:

MST and Sup. on duty

PROCEDURE:

PLC AUTO MODE

PLC MANUAL MODE

PLC AUTO MODE

A. WHEN LOAD MANAGEMENT SYSTEM (LMS) BYPASS

CONDITION:

MASTER DG

 Select The DG set to start in auto mode and make it master from the DG operating screen of
PC.

 When power fail master DG will start automatically, if DG is healthy condition. After achieving
the proper voltage and frequency (415V, 50 Hz) first it’s Neutral contactor will be closed and
then DG Breaker will be closed.

 If DG is not in healthy condition then go to respective DG Fault Status Screen and analyze
the fault, reset it and then DG will start immediately.

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SLAVE DG’S

 If Load Management system is Bypassed and next DG to be started, then just select that DG
in auto mode from DG operating screen of PC and press start key from its respective DG
operating screen. If DG is in healthy condition it will start, Auto synchronizing and load
sharing will be done through PLC.

 To stop any DG set, press the stop key from respective DG operating screen, load of that DG
will transfer to another running DG set. After transferring the load its Breaker will trip and the
engine will stop after a time delay of 3 minutes, if the operator desires to stop the DG without
idle run he should select the DG in manual mode or press emergency push button to stop the
engine immediately.

 B. WHEN LOAD MANAGEMENT SYSTEM (LMS) SELECTED IN AUTO AND GRID
FAILURE CONDITION:

MASTER DG

 Select all DG's in Auto mode and make any one DG as master from the DG operating screen
of PC.

 Press start key from DG OPERATING SCREEN of PC master DG will start automatically, if
DG is healthy condition. After achieving the proper voltage and frequency (415V, 50 Hz) first
it’s Neutral contactor will be closed and then DG Breaker will be closed.

SLAVE DG’S

DG’s STARTING CONDITION IN CASE OVER LOAD


 If load on master DG exceeds 80% of its full load then after 10 sec. of time delay in order to
check load consistency, the next DG which is in auto mode and healthy condition will start as
a second DG and gets synchronized with the master DG automatically. And load sharing will
be done through PLC automatically.

 If load on second DG exceeds 80% of its full load then after 10 sec. of time delay in order to
check load consistency, the next DG which is in auto mode and healthy condition will start as
a third DG and gets synchronized with the main bus automatically. And load sharing will be
done through PLC automatically.

DG,s STOPPING CONDITION IN CASE UNDER LOAD

 If N number of DG’s are running in parallel and the total load on the main bus bar is less than
60% of N-1 DG’s then last numbered DG Breaker will trip after time delay of 300 second after
load transfer, and engine will stop after an idle run of 3 minutes. If the operator desires to
stop the engine without any idle run, select the DG in test mode or press the stop button in
PC.

FAULT CONDITION:

 ENGINE FAULT:
 Emergency stop fault (PANEL)
 Over speed fault (ENGINE)
 Low lube oil pressure fault (ENGINE)

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  Water temp. High fault (ENGINE)
 DG failed to synchronized fault (PLC)

 If any engine faults occurred DG Engine and breaker shall be trip immediately

 ELECTRICAL FAULT:
 Over current fault (PLC)
 Over voltage/under voltage fault (PLC)
 Over freq./under freq. Fault (PLC)
 Reverse power fault (PLC)
 Reverse KVAR fault. (PLC)
 Over current & Earth Fault (RELAY)
 Reverse power fault relay (RELAY)
 Over voltage fault relay (RELAY)
 Breaker failed to close/ failed to trip (PLC)
 Neutral contactor failed to close/ failed to trip(PLC)

 If an electrical fault occurred only DG Breaker will trip and engine will be in running condition
 for 3 min. and then engine will also stop, if fault has been not rectified /reset within 3
minutes.
 If fault has been rectified / reset within 3 minutes the DG breaker will be closed again to cater
 the load.
PLC MANUAL MODE

 Manual operation is provided in PLC system for testing purpose only. If DG is in PLC manual
mode and start command has been given, engine will start but its Breaker and Neutral
contactor will not close, hence no synchronizing action takes place in this mode
automatically.
Note:

 Don’t select the DG set in manual mode directly, if it is running on load unless it’s Breaker
trips or is in OFF condition

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