2025.04.19 – Black Start Procedure – Emergency Generator (Caterpillar 3516-C)


Objective: Restore power after a total blackout using the emergency generator.


STEP 1 – Check if Emergency Shutdown (ESD) was activated

  • [ ] Press the red Reset button on the emergency shutdown panel.
  • [ ] Try starting the emergency generator.
      - If it does not start automatically, start it manually using the control panel.

STEP 2 – Make sure there is compressed air available

  • [ ] Open the air supply valves to the air receiver tank.
  • [ ] If there’s no pressure, start the air compressor by pulling the manual rope.
  • [ ] Wait until the pressure reaches at least 120 psi.

STEP 3 – Make sure control power is present (24VDC)

  • [ ] Check if the generator control panel has 24V power.
  • [ ] If not, go to the electrical panel and switch the 24V breaker ON.

STEP 4 – Send emergency power to the system

  • [ ] On the generator panel, check if the main breaker is closed.
  • [ ] If it’s open, close it manually.
      → This sends temporary power to the rest of the system.

STEP 5 – Start the main engine

  • [ ] Make sure the engine controls are in the correct position.
  • [ ] Check that the air intake flaps are open.
  • [ ] Confirm that the engine control panel also has 24V power.
  • [ ] Start the main engine using the panel.
  • [ ] Allow the engine to run for a few moments.
  • [ ] Close the engine breaker to connect it to the system.

STEP 6 – If the main engine fails to start

  • [ ] Check again that there is enough compressed air for starting.
  • [ ] WARNING: When closing any breaker, stand to the side to avoid injury in case of arc flash or fault.

STEP 7 – Restore general power to the facility

  • [ ] Make sure the breaker for the air compressor is closed.
  • [ ] Confirm that the main transformers are connected (breakers closed).
  • [ ] On the synchronization panel, turn the selector switch to ONLINE mode.
  • [ ] Close the breakers that send power to ventilation and cooling systems.
  • [ ] If you have a second generator, start it now.
  • [ ] Once power is stable, close all main distribution breakers.
  • [ ] You can now turn off the emergency generator.

STEP 8 – Shut down the emergency generator

  • [ ] Let the emergency generator engine shut down normally.
  • [ ] Switch the control panel to OFF and wait 20 seconds.
  • [ ] Switch it back to AUTO mode, ready for next use.

STEP 9 – Turn on ventilation in the engine room

  • [ ] Start the ventilation fans to keep the engine room cool.

STEP 10 – Start support systems

The mechanic should restart the following:

  • [ ] Drill and cutting systems
  • [ ] Wastewater and sewage systems
  • [ ] Fresh water pumps
  • [ ] Water pressure booster system
  • [ ] Hot water heaters
  • [ ] Air conditioning or fans in crew/work areas

STEP 11 – Final check

  • [ ] Restart any other essential systems that need to be running.
  • [ ] Check that all circuit breakers in secondary panels are in the correct position.

Published by Leonardo Tomás Cardillo

https://www.linkedin.com/in/leonardocardillo

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