The instruction of Gen set Start/Stop

MAN9L27/38
The starting procedure for MAN 9L27-38 gen set

1. First of all, check if any pressure available in the air bottle and the normal pressure is 20bar-
30bar. Please start the air compressor when you found the pressure is not enough.

2. Turn the change-over switch of lubrication oil pre-supply pump of power control box which
is beside the gen set to AUTO, and confirm if the lube.oil pre-supply pump start normally?
The lube.oil inlet pressure of engine should be bigger that 0.12 bar and engine starting would
be allowed in 15 mins at least after lube.oil pre-supply pump starting normally.

3. Confirm if the level of diesel daily tank, level of HT water expansion tank, level of cooling
tower and level of demineralized water tank are all in normal range.

4. Confirm the LFO/HFO change-over switch and indication light of control box console of
Fuel Oil Supply Module is on LFO position. Start 1# fuel oil transfer pump and 1# fuel oil
booster pump after confirmation. Then confirm the fuel oil pressure inlet engine should be 5-
6bar.

5. Start the LT water pump on MCC panel inside of control room. Check the LT water pump if
the suction is normal and the outlet pressure of pump is normal, and the normal pressure is 2-
3 bar .if the pressure too high. Please adjust the bypass-valve of pump outlet (PVC pipe).

6. Confirm the three way flapper valve is in the position of boiler and confirm the water level of
boiler is at the right position.

7. Open indicator valve of engine.

8. Check if the control power of all the panels inside of control room are normally input. And
check if all indication of control panels are normal. If no indication on the panels, please
check if the power switch inside of panels or the switch of DC distribution panels are closed
or not?

9. Start the PLC of computer to monitor the system and enter into the PLC monitoring screen,
select the screen of Gen set Start.
10. Eliminate the emergency stop alarm of Ready to Start Gen set on the control panel inside of
control room.(Press the EMERGENCY STOP)

11. Press the RESET button of local control box of engine, meanwhile you will hear the voice of
gas releasing from shutdown solenoid valve. And then switch the Local/Remote button to
Local.

12. Blow the gen set twice, and close indicator valve after blowing.

13. Confirm all Aux. equipment are normal, no alarm. Then switch the Local/Remote button on
the local control panel of engine to Remote.

14. When the operator inside of the control room get the Start Instructions from engine house,
press START button on the GCP-30 of PNL1 Control Panel. The display of GCP-30 will
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 indicate START and indication light READY TO START will be lighted. And then long press
REMOTE START on the control panel 3 second. Gen set will be started automatic in several
second.

15. Pay attention to all data for each system and gen set after starting successfully.
Lube. Oil pressure should be 4-5bar. Pre-supply lube. oil pump will be stopped after gen set
set up starting lube. oil pressure.

The main shaft temperature has to be lower than 95°C;

Oil pressure of TC should be bigger than 1bar;

HT water pressure should be 2-4bar, the temperature outlet engine should be lower than
85°C;

Diesel pressure inlet engine should be 4-6 bar, the temperature should be controlled at 40°C

Gen set RPM should be lower than 720rpm.

When gen set run up to rated RPM, TC RPM should be 8000 rpm.

16. When gen set reaches the below condition, inform the operator inside of control room to
SYNC.

Lube. oil temperature higher than 50°C;

HT water temperature higher that 60°C

Gen set has no abnormal sound and vibration;

17.
When gen set reaches the below condition, can be transferred from LFO to HFO.

The steam header pressure of main engine house should be 3bar and temperature should be higher
than 150°C.

The load of gen set cannot be lower than 35% of rated load,(i.e. 875kw)

After gen set transferred to HFO successfully, pay attention to the viscosity control, Should be 10-
14cst normally. Set the steam temperature controller at 130°C. The viscosity may be not met the
requirement at the beginning of transferring to HFO, so switch on the electrical heater inside of
module by manual operation according to the matter of fact.

MAN9L27-38 机组停机步骤：
STOP PROCEDURE FOR MAN9L27-38 GENSET

1. Plan to stop

When the load of gen set decreased to 50% of rated load, turn the LFO/HFO switch on
control box panel of fuel supply module to LFO position. And the light of LFO would
be lighted.
When the viscosity lowed to 6 CST, time to be estimated around 40 mins, the genset
decreased the load; When the load decreased to 300KW, start 3# Cummins gen set
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 (500KW),preheat the 3# gen set around 5 min..
Synchronous connection and step out the switch of MAN gen set.
Slow the gen set RPM to Idle speed (540rpm),the switch is inside of 0501 panel,
running 5-10 min.. Wait for the lube oil temperature and HT water temperature low
down, press the STOP. Please Note that before gen set fully stopped, it is strictly
forbidden to press the RESET button. When gen set fully stopped, turn the idle speed
switch to rated position.
Check if the pre-supply lube oil pump started automatic or not. If not turn to MANUAL
position to start manual.
Open the indicator valve for each cylinder.
Fit the turning machine, and turn engine more than 2 circumference.
Stop the relative Aux. equipment to the gen set.

2. Quick Stop

We can quick stop the gen set as below ways to avoid the HFO remained inside high-
pressure oil pump and nozzle, when the gen set running safety.
Inform the owner to decrease the load and explain the reason why we need decrease.
Start diesel supply pump.
Inform the operator inside of control room to turn the three way valve to LFO position
on PLC system which should be estimated around 5-10 min

3. Emergency Stop (Running on HFO)

When the gen set met the accident or emergency or protective action to stop automatic,
we cannot restart the gen set within half hour. We need flush the fuel supply module and
pipeline inside of engine.
Switch the three way valve of mixture oil tank to return the fuel back to drip tank.
Turn the LFO/HFO switch to LFO on the control box panel of Fuel supply module, and
LFO indication light bright.
Flushing time is around 5-10 min. But please pay attention on the fuel level of drip tank
and start the drip oil pump in time to avoid the oil leakage.

康明斯小机启机、并网步骤：
The procedure for starting and sync of Cummins gen set.

1. Confirm the local breaker of gen set is at the position of switching on. The remote outlet
breaker (AA01 LV panel of 3# gen set, AA07 LV panel off 4# gen set) is at the position of
switch off. Push the remote outlet breaker to the working position.

2. Press the START button on the 3# and 4# control panel inside of control room. Start the small
gen set locally when the display show COUNT DOWN, meanwhile which should display
voltage ,current ,frequency and etc.

3. 确认母线负载在 200KW 以下；

Confirm the load of bus should be lower than 200KW.

4. 将控制器面板上的合闸按钮按下，等待 5 秒，此时画面中出现一个同期画面，同期画
面上方左侧显示频率，右侧显示电压，如频率显示﹢0.1 表示你要在机组就地控制器上
将频率降低 0.1，如电压在﹣4V，表示你要在就地将电压升高 4V，就地控制器上调节
电 压 和 频 率 的 方 式 为 ： 按 Menu 键 进 入 主 画 面 ， 此 时 画 面 显 示 ENGINE （ 柴 油
机）/GEN（发电机）/ADJUST（设定）三个选项，每个选项的侧方都有一个按键，点
击进入 ADJUST（设定）画面，此时画面显示 VOLTAGE(电压)，左侧会出现可供你调
整的↑（加）↓（减）箭头，按相应的按键电压就会有响应。按右侧的》键进入下一页，
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 此时显示 FREQUENCY（频率）操作方法同上。切记要先调整电压，调整到规定位置
上方各数值的前面会有一个√显示出来，如果当两个√显示出来，移动的↓还没有走到
中间位置，只需要稍微调整一下频率就可以，只要↓开始移动就不要再调整了，当↓移
动到中间位置机组出口断路器会自动合闸，此时并网成功；
Press the sync button on the controller panel and wait for 5 seconds. The display will show the
sync. screen. On the left side of above it show frequency and on the right side of above it show
voltage. If the frequency display +0.1 that means you should low down the frequency 0.1 on the
local controller of genset. If the voltage display -4V,that means you should raise up 4V on the
local controller of genset. The way how to adjust voltage and frequency on the local controller is
press MENU and it will display ENGINE/GEN/ADJUST three-option.Each option should be have
the button on the side.Click ADJUST and it will display VOLTAGE. On the left side will display
↑（+）↓（-） and then please adjust as per the instruction of the operator inside of control room.
Press 》 button will enter into the next page and will display FREQUENCY. The operation way is
the same as above voltage. PLEASE NOTE that adjust the voltage first. It will display √ in front
of each data when adjust to the above of assigned position. If display two √ but the traveling ↓ do
not move to the middle position, we just make a little adjustment on Frequency should be okay. If
↓ is traveling, no need to adjust. When ↓ move to the middle position,the outlet breaker of genset
closed automatic that means sync.successfully.

5. 将网上其他机组的出口断路器分闸，因为还未实现负荷分配，所以转换过程尽量多人
配合速度要快，否则可能会造成逆功率保护动作，机组会跳机。如果出现跳开关或停
机，不要着急，先确认机组是否还在运转，如果还有机组在运转，请将除需要开机发
电机组以外的其他机组迅速停下（紧急停机），因为并网机组跳机后母线无电压，辅
机各电源都将中断，此时不紧急将大机停止非常危险，会造成大机损伤。确认故障原
因后，检查小机的出口断路器是否在分闸位置，检查厂变断路器是否在分闸位置，检
查小机有无其他保护动作，检查商场负载端的断路器是否在分闸位置（ 300A 以下的断
路器除外）检查无误后再将小机重新开启，因为是故障跳机，母线无压，此时小机可
不进行并网操作直接合出口断路器，合闸后注意观察涌流，因为 5000KVA 的变压器低
压侧直接与低压配电母线相连接，合闸后会产生励磁涌流。
Switch off the outlet breakers of other synchronous genset. As the reason that the synchronous
genset did not realize the load distribution yet, we need more staff to cooperative with and move
fast during this processing. Otherwise the genset will be tripped as reverse-power protecting of
genset. If the breaker tripped or genset stop, confirm genset are still running or not. If the genset
were still running, please emergency stop genset except the genset need power producing. It is
very dangerous to damage MAN genset if the MAN genset would not stop.Because the bus had no
voltage after synchronous genset tripped which will result in the power supply for all
aux.equipment broke off. After confirming the reason of failure, please check the outlet breaker of
Cummins genset if stayed at the switch-off position, check the breaker of station service
transformer if stayed at the switch-off position, check the other protection of Cummins genset still
active or not, check the load breakers of mall if stayed at the switch-off position (except the
breaker lower than 300A). After checking everything is okay, restart Cummins again. As failure
tripped and bus is dead, it is no need to sync. the Cummins genset and closed the breakers directly.
After breaker closed,please pay attention on the inrush current as the reason that LV side of
5000KVA transformer connected with LV distribution bus directly which will have exciting inrush
current after breaker closed.

6. 如一切正常，那机组操作完成，注意观察小机运行状态。
If everything is okay, that means operate genset successfully and pay attention on the status of
Cummins genset.
以上为 500KW 机组的启机、并网步骤，265KW 机组启机与并网的方法同上，不过小机属于
应急机组，发电机出线电缆安装在低压 MCC 母线段，如果要发电至商场需要经过厂变、主
变，由于主变容量很大，机组功率又太小，所以主变压器的断路器需要等待 30 分钟后才能
合闸，需要给变压器一个放电消磁的时间，否则小机将因为励磁涌流跳机。
Above it is the starting and sync. Procedure for 500KW, and it is same to do 265 kw genset. But
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the 265kw genset is for black-start using and the outlet cable of genset connected with LV MCC
bus. If we produce power to the mall ,the power need go through station service transformer and
main transformer. As the capacity of transformer is too big and the rate capacity of 265kw genset
is too small, we need wait for 30 mins at least to close the breakers of main transformer. The
reason is the transformer need time to Discharge degaussing, otherwise the 265kw genset will trip
as the reason of exciting inrush current.

康明斯小机脱网停机步骤：
The procedure of off-sync.for Cummins.
1. 计划停机：
Plan to Stop.
当大机具备并网条件完成并网后，立即将发电运行的小机组出口断路器断开，待机组
脱网运行 5 分钟后将机组停下，然后进行例行检查。将就地断路器分闸，将出口断路器
拉出至试验位置。
When MAN genset meet the requirement of sync. and carry out sync.successfully, open the
outlet breakers of Cummins. Wait for the genset off-sync running 5 mins and then stop it to
make routine inspection. Open the local breaker and pull the outlet breaker to TEST position.

2. 故障停机：
Failure stop.
小机组在发电运行时故障问题出现的停机或在机组并网时出现停机，此时全厂将整体
停电，此时要快速反应，确认原因解除故障后按上述启机方法将 500KW 机组立即开
启，如果 500KW 机组无法正常启动，那么就立即将 265KW 启动发电，开机前确认厂
变断路器及主变断路器在分闸位置，因机组功率太小，所以启机后只能暂时保证电厂
用电，要等待 30 分钟（变压器放电消磁时间）才能将主变断路器合闸给商场供电。在
230KW 机组启机发电后可以先将厂变断路器合闸。如果商场负载大于 200KW 而
500KW 机组又处于故障状态，那么就需要将大机开机、并网。
The small genset failure stop when the small genset is running or executing sync. which will
result into the entire power plant black out. Find out the failure and trouble shooting, then restart
the 500KW at once according to the above procedure. If can not start the 500KW genset, change
to start 265kw genset and produce power. Before starting,confirm the breakers of station service
transformer and main transformer stayed at the switch-off position. As the genset is too
small,which just can produce power for power plant temporary using. Wait 30 mins at least and
then close the main transformer breaker for offering the power to the mall.After 265kw genset
starting and producing power, we can close the break of station service transformer first. If the
load of the mall was bigger than 200KW and 500 kw genset can not be restarted, we just only can
start the MAN genset and sync.

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