Procedure For Starting Of The Procedure For Starting Of The Main GeneratorMain Generator

PRE-CHECKSPRE-CHECKSCheck lubricating oil level.Check lubricating oil level.

Check turning gear arrangement and Check turning gear arrangement and remove turning bar and other things such remove turning bar and other things such as spanners, etc from the vicinity as spanners, etc from the vicinity

Fill up the air bottles and remove Fill up the air bottles and remove moisture by opening the drain valve from moisture by opening the drain valve from the air cylinder.the air cylinder.

Open main air bottle valve and remove any Open main air bottle valve and remove any moisture present in the main air line by means moisture present in the main air line by means of drain valves provided in the air line.of drain valves provided in the air line.

Check cooling water level in the expansion Check cooling water level in the expansion tank.tank.

Check that all the valves are in open condition Check that all the valves are in open condition in the fresh water cooling system.in the fresh water cooling system.

Check lubricating oil level in the Check lubricating oil level in the governor. The grade of oil that is used is governor. The grade of oil that is used is T68T68

Check turbocharger lubricating oil level.Check turbocharger lubricating oil level.

Pre-start StepsPre-start Steps

Start the pre-lubricating oil pump.Start the pre-lubricating oil pump.

Keep indicator cocks opened.Keep indicator cocks opened.

Press the push valve in the main air line Press the push valve in the main air line for 5-6 seconds and make sure that only for 5-6 seconds and make sure that only air comes out of the indicator cocks. This air comes out of the indicator cocks. This process is called the “Blow Through” process is called the “Blow Through” processprocess

After blow through the generator is ready After blow through the generator is ready for startingfor starting

What is the purpose of blow What is the purpose of blow through?through?

In the cylinder jacket cooling water may leak In the cylinder jacket cooling water may leak out from the cracked liner which gets out from the cracked liner which gets accumulated on the piston.accumulated on the piston.

As water is incompressible fluid that may As water is incompressible fluid that may create the problem during the up movement create the problem during the up movement of the piston. of the piston.

This may result in banging of piston on head This may result in banging of piston on head & may lead to damage the cylinder head. & may lead to damage the cylinder head.

By blow passing we can assure that the By blow passing we can assure that the generator is safe to start and perform generator is safe to start and perform smoothly.smoothly.

NOTE:NOTE:

– After any overhaul start the generator and After any overhaul start the generator and check it. After starting check lubricating oil check it. After starting check lubricating oil pressure, abnormal noises and other defects.pressure, abnormal noises and other defects.

– Fuel line valves are kept opened.Fuel line valves are kept opened.

– Always keep a torch light with you during your Always keep a torch light with you during your watch.watch.

LINE DIAGRAM OF FUEL LINE DIAGRAM OF FUEL SYSTEMSYSTEM

DOUBLE

BOTTOM TANK

FO TRANSFER

PUMP

SETTLINGTANK

PURIFIER SERVICE TANK

AUXILLIARYENGINE # 1

AUXILLIARYENGINE # 2

AUXILLIARYENGINE # 3

After Start StepsAfter Start Steps

Feel the crank case doors. Check for Feel the crank case doors. Check for abnormal heating of any of the units.abnormal heating of any of the units.

Check for leakages in the fuel, Check for leakages in the fuel, lubrication, jacket cooling water system lubrication, jacket cooling water system and for other leakages.and for other leakages.

Open the cylinder cover and check the Open the cylinder cover and check the rocker arm lubrication system for rocker arm lubrication system for sufficient oil supply.sufficient oil supply.

Before putting the generator on load, run Before putting the generator on load, run the generator idle for 5-6 minutes to the generator idle for 5-6 minutes to warm up the engine and make sure that warm up the engine and make sure that the generator is running normally.the generator is running normally.

Check the pressure of the lub oil system, Check the pressure of the lub oil system, jacket cooling water system and the jacket cooling water system and the rocker arm lubrication systemrocker arm lubrication system

Pressure of different systems Pressure of different systems

Sl No. Sl No. System System Pressure Pressure

11 Lub Oil Pressure Lub Oil Pressure 3.8 – 5.0 bars 3.8 – 5.0 bars

22 Jacket cooling water Jacket cooling water system system

1.8 - 2.2 bars 1.8 - 2.2 bars

33 Rocker arm lub oil Rocker arm lub oil system system

0.8 – 1.2 bars 0.8 – 1.2 bars

Paralleling Of A GeneratorParalleling Of A GeneratorSwitch on the synchroscope. If the speed of Switch on the synchroscope. If the speed of the incoming generator is fast, the pointer of the incoming generator is fast, the pointer of the synchroscope will rotate in the fast the synchroscope will rotate in the fast direction and vice-versa.direction and vice-versa.

Adjust the speed of the incoming generator by Adjust the speed of the incoming generator by the help of the speed pot so that the rpm of the help of the speed pot so that the rpm of incoming generator is almost the same as that incoming generator is almost the same as that of the generator that is already on load.of the generator that is already on load.

When the needle of the synchroscope reaches When the needle of the synchroscope reaches the zero position, make the breaker of the the zero position, make the breaker of the incoming generator to put it on load. Now the incoming generator to put it on load. Now the load is shared.load is shared.

Check the exhaust temperature of each unit Check the exhaust temperature of each unit which varies between 3300 C - 3500 C which varies between 3300 C - 3500 C depending upon the engine type and make.depending upon the engine type and make.

Check the voltage, frequency, KWh meter.Check the voltage, frequency, KWh meter.

Stopping Of A GeneratorStopping Of A GeneratorTransfer the load of the generator to be Transfer the load of the generator to be stopped to the other generator by stopped to the other generator by adjusting the speed pot.adjusting the speed pot.

Drop the breaker.Drop the breaker.

Switch ‘off’ the generator.Switch ‘off’ the generator.

Start the pre-lubricating pump which Start the pre-lubricating pump which builds a pressure of about 1.2 – 1.5 bars.builds a pressure of about 1.2 – 1.5 bars.

Warning!!Warning!!

In case any of the parameter of the In case any of the parameter of the generator is abnormal, the respective generator is abnormal, the respective alarms will become active and the alarms will become active and the generator will trip resulting in a blackout generator will trip resulting in a blackout

Over speed TripOver speed Trip

This is caused by a sudden increase in the This is caused by a sudden increase in the engine speed or rpm resulting in the engine speed or rpm resulting in the tripping of the generator. This may be tripping of the generator. This may be because of the failure of the linkage to the because of the failure of the linkage to the fuel rack. The fuel rack then supplies more fuel rack. The fuel rack then supplies more fuel than required and as a result the fuel than required and as a result the engine speed increases.engine speed increases.

Lub Oil Filter ReplacementLub Oil Filter ReplacementClose the valve of the suction side.Close the valve of the suction side.

Close the valve on the discharge side.Close the valve on the discharge side.

Close the valve of the pressure switch.Close the valve of the pressure switch.

Replace the filter.Replace the filter.

Open the suction and discharge valves of the pump.Open the suction and discharge valves of the pump.

Drain the oil in the pressure switch line using the drain Drain the oil in the pressure switch line using the drain outlet at the bottom of the pressure valve.outlet at the bottom of the pressure valve.

NOTENOTE

When the valve of the lub oil pressure When the valve of the lub oil pressure switch is closed the “Low Lub Oil switch is closed the “Low Lub Oil Pressure” alarm will not ring.Pressure” alarm will not ring.

Lub Oil Low Pressure CutoutLub Oil Low Pressure Cutout

The pressure in the lub oil system during The pressure in the lub oil system during the normal running of engine is 3.8-5.0 the normal running of engine is 3.8-5.0 bars.bars.

This pressure keeps the pressure switch This pressure keeps the pressure switch de-energized and hence the “Low lub oil de-energized and hence the “Low lub oil pressure alarm is not activated when there pressure alarm is not activated when there is adequate pressure in the lub oil system.is adequate pressure in the lub oil system.

When the pressure in the lub oil system When the pressure in the lub oil system drops(say about 3.5 bars),the switch gets drops(say about 3.5 bars),the switch gets energized and the alarm start rings.energized and the alarm start rings.

At the same time, an electrical signal is At the same time, an electrical signal is also sent to the cutout and the generator also sent to the cutout and the generator trips.trips.

Jacket Cooling Water High Jacket Cooling Water High Temperature Cutout Temperature Cutout

The temperature of the lub oil during The temperature of the lub oil during normal running of the engine is maintained normal running of the engine is maintained at about 65at about 65oo-70-70ooCC

As the temperature of this water exceeds As the temperature of this water exceeds a certain limit (say 80oC) the “Jacket a certain limit (say 80oC) the “Jacket Cooling Water High Temperature Cutout” Cooling Water High Temperature Cutout” operates and the generator trips. At the operates and the generator trips. At the same time an alarm circuit is also same time an alarm circuit is also activated activated

NOTENOTE

When the valve of the lub oil pressure When the valve of the lub oil pressure switch is closed the “Low Lub Oil switch is closed the “Low Lub Oil Pressure” alarm will not ring Pressure” alarm will not ring

Pressing Of Air BottlesPressing Of Air BottlesOpen all valves between air compressor and Open all valves between air compressor and air bottle.air bottle.

Open the drain cocks of the air bottle and the Open the drain cocks of the air bottle and the main airline.main airline.

After about 5-6 seconds close the drain valves After about 5-6 seconds close the drain valves of the air bottle and the airline.of the air bottle and the airline.

Check the lubricating oil level.Check the lubricating oil level.

Check the jacket cooling water level.Check the jacket cooling water level.

Start the air compressor.Start the air compressor.

Before stopping the compressor open Before stopping the compressor open the drain valves of the air bottle and the the drain valves of the air bottle and the main airline for a short period.main airline for a short period.

Check the pressure in the air bottles. It Check the pressure in the air bottles. It varies from 25-30 bars depending on the varies from 25-30 bars depending on the ship.ship.

NOTENOTE

To run both compressors simultaneously, To run both compressors simultaneously, start both in the manual mode.start both in the manual mode.

A bursting disc/fusible plug is provided on A bursting disc/fusible plug is provided on the casing of the compressor to prevent the casing of the compressor to prevent the intercooler.the intercooler.

In auto solenoid valves whose timings are In auto solenoid valves whose timings are controlled by a timer relay do mode the controlled by a timer relay do mode the first and second stage draining.first and second stage draining.

Cylinder lubrication is required only in Cylinder lubrication is required only in case of large engines where the friction case of large engines where the friction between the cylinder liner and between the cylinder liner and compression rings is appreciable. This is compression rings is appreciable. This is applicable to both the generator and the applicable to both the generator and the compressor.compressor.

For cleaning and other purposes air For cleaning and other purposes air bottles can be accessed through bottles can be accessed through manholes.manholes.

MAKING THE PLANT READYMAKING THE PLANT READYThe bridge/wheel house gives notice The bridge/wheel house gives notice before 2 hours of the expected time of before 2 hours of the expected time of departure (ETD)departure (ETD)

All the settling tanks and purifiers are to All the settling tanks and purifiers are to be de-sludged.be de-sludged.

Check the temperature of both the diesel Check the temperature of both the diesel oil and the heavy oil settling and service oil and the heavy oil settling and service tanks (app 40tanks (app 4000C).C).

If the boiler is not running then start the If the boiler is not running then start the boiler.boiler.

Open steam to the diesel oil and heavy Open steam to the diesel oil and heavy oil settling and service tanks if required.oil settling and service tanks if required.

Check the level of the fuel in both the Check the level of the fuel in both the settling tanks. If required start fuel oil settling tanks. If required start fuel oil transfer pump to fill up the respective transfer pump to fill up the respective settling tanks.settling tanks.

Start the second auxiliary engine and Start the second auxiliary engine and synchronize it so that the load is shared. synchronize it so that the load is shared. This is done for two reasons- to prevent This is done for two reasons- to prevent a blackout in case one generator fails a blackout in case one generator fails and second –the load increases during and second –the load increases during maneuvering.maneuvering.

Start the lub oil, heavy oil and the diesel Start the lub oil, heavy oil and the diesel oil purifiers. Make sure the purifiers do oil purifiers. Make sure the purifiers do not overflow.not overflow.

Start the main engine lub oil pump.Start the main engine lub oil pump.

Start the jacket cooling water pump and Start the jacket cooling water pump and open steam to the circuit to warm up the open steam to the circuit to warm up the engine.engine.

Start the air compressors and press up Start the air compressors and press up the air bottles.the air bottles.

Check the engine room bilge level, which Check the engine room bilge level, which should be at least below the flywheel.should be at least below the flywheel.

MAIN ENGINE STARTING MAIN ENGINE STARTING PROCEDUREPROCEDURE

– Open the indicator cocks of the main engine.Open the indicator cocks of the main engine.

– Engage the turning gear and turn the engine Engage the turning gear and turn the engine for at least two rotations with the help of the for at least two rotations with the help of the turning gear motor.turning gear motor.

– Start the cylinder lubrication manually by Start the cylinder lubrication manually by hand. This is a separate lubrication system.hand. This is a separate lubrication system.

– Check that the scavenge drain valves are Check that the scavenge drain valves are closed.closed.

– Disengage the turning gear after turning the Disengage the turning gear after turning the engine.engine.

– Check the governor, turbo-charger oil level.Check the governor, turbo-charger oil level.

– If required grease the air starting valve.If required grease the air starting valve.

– Lubricate all the mechanical linkages.Lubricate all the mechanical linkages.

– Get a message cheat signed by the officer Get a message cheat signed by the officer on watch on the bridge stating that the on watch on the bridge stating that the propeller area is clear.propeller area is clear.

– Start the fuel oil booster pump.Start the fuel oil booster pump.

– Shut off all the indicator cocks.Shut off all the indicator cocks.

Bring the air-starting lever in the “engine Bring the air-starting lever in the “engine start” position for 2-3 seconds to start the start” position for 2-3 seconds to start the engine and make sure that the engine is engine and make sure that the engine is firing.firing.

Try out the steering gear system. Start the Try out the steering gear system. Start the steering gear motor and turn the lever to steering gear motor and turn the lever to turn the rudder from hard port (extreme turn the rudder from hard port (extreme port) to hard starboard (extreme port) to hard starboard (extreme starboard) and back.starboard) and back.

After starting the engine start the main After starting the engine start the main seawater pump.seawater pump.

Take a round and check the exhaust gas Take a round and check the exhaust gas temperature, lub oil pressure and temperature, lub oil pressure and temperature, fuel oil booster pump temperature, fuel oil booster pump pressure, jacket water pressure and pressure, jacket water pressure and temperature.temperature.

After getting full ahead order from the After getting full ahead order from the bridge change over to heavy oil by bridge change over to heavy oil by changing the 3-way cock located at the changing the 3-way cock located at the inlet of the mixing column. Before inlet of the mixing column. Before changing make sure that the temperature changing make sure that the temperature of heavy oil is at least 80-85of heavy oil is at least 80-85ooC.C.

NOTE-NOTE-

– Always start the engine in the ahead direction.Always start the engine in the ahead direction.In case the ETD is delayed put the engine in stand In case the ETD is delayed put the engine in stand by mode, open the indicator cocks.by mode, open the indicator cocks.

– Always make it a practice to blow down the Always make it a practice to blow down the engine when starting from the standby mode.engine when starting from the standby mode.

– As heavy oil is supplied to the engine, the As heavy oil is supplied to the engine, the speed increases for the same settings. This is speed increases for the same settings. This is because the pressure in the fuel line because the pressure in the fuel line increases and the engine receives more fuel.increases and the engine receives more fuel.

– Start the fresh water generator.Start the fresh water generator.