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DG Operation and Maintenance SOP

This Standard Operating Procedure (SOP) outlines the guidelines for the safe and efficient operation and maintenance of diesel generators (DG). It details responsibilities of personnel, safety precautions, pre-startup checks, operational procedures, routine maintenance schedules, and emergency handling protocols. Record keeping is emphasized to ensure proper documentation of DG operations and maintenance activities.

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सुशील कुमार कुशवाहा
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68 views3 pages

DG Operation and Maintenance SOP

This Standard Operating Procedure (SOP) outlines the guidelines for the safe and efficient operation and maintenance of diesel generators (DG). It details responsibilities of personnel, safety precautions, pre-startup checks, operational procedures, routine maintenance schedules, and emergency handling protocols. Record keeping is emphasized to ensure proper documentation of DG operations and maintenance activities.

Uploaded by

सुशील कुमार कुशवाहा
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Standard Operating Procedure (SOP)

Diesel Generator (DG) Operation and Maintenance

1. Purpose
To provide standardized guidelines for the safe and efficient operation and maintenance of
diesel generator (DG) sets to ensure uninterrupted power supply and long service life.

2. Scope
Applicable to all personnel responsible for the operation and maintenance of DG sets
installed at the facility.

3. Responsibilities
 - DG Operator: Responsible for daily checks, routine operation, and logging.
 - Maintenance Technician: Conducts scheduled preventive maintenance.
 - Facility Manager: Ensures SOP implementation and availability of resources.

4. Safety Precautions
 - Always wear appropriate PPE (gloves, ear protection, safety shoes).
 - Ensure proper ventilation before starting the DG.
 - Never refuel while the DG is running or hot.
 - Keep fire extinguishers nearby.
 - Avoid loose clothing near rotating parts.

5. Pre-Startup Checklist
 - Fuel level – ensure it is sufficient.
 - Engine oil level – check and top up if necessary.
 - Coolant level – verify and refill if low.
 - Battery voltage and terminals – clean and tight.
 - Air filter – clean and service regularly.
 - Check for oil/fuel leaks.
 - Remove any load from the DG before starting.

6. Starting Procedure
1. Ensure main circuit breaker is OFF.

2. Turn the control key to “ON” or “AUTO” position.

3. Press the START button (manual mode) or ensure auto-start settings are functional.

4. Let the engine idle for 2–5 minutes to stabilize.


7. During Operation
 - Monitor the following parameters:
 - Oil pressure
 - Coolant temperature
 - Voltage, current, and frequency
 - Battery charging status
 - Listen for abnormal noises or vibrations.
 - Ensure the exhaust is not blocked.
 - Do not overload the DG set.

8. Shutdown Procedure
1. Remove the load or switch off the breaker.

2. Let the engine run idle for 2–3 minutes to cool down.

3. Press the STOP button or turn the key to OFF.

4. Turn off the fuel supply valve (if applicable).

9. Routine Maintenance Schedule


Task Frequency

Check fuel, oil, coolant Daily

Clean air filter Weekly

Check battery and terminals Weekly

Change engine oil Every 250 hours

Replace oil filter Every 250 hours

Replace fuel filter Every 250 hours

Check radiator coolant Monthly

Overhaul engine As per OEM

10. Record Keeping


Maintain a DG Logbook with the following entries:

 - Date and time of operation


 - Running hours
 - Fuel added
 - Oil changes
 - Observations and faults
 - Maintenance done
11. Emergency Handling
 - In case of fire, use CO₂ or dry powder extinguishers.
 - Shut down the DG immediately in case of:
 - Low oil pressure
 - High engine temperature
 - Excessive vibration or noise

12. References
 - Manufacturer’s operation manual
 - OEM maintenance guidelines
 - Safety datasheets for diesel and lubricants

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