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STARTING PROCEDURE
The below instructions are to be followed whenever starting a diesel generator under normal circumstances. The remote starting must also be frequently tested to ensure that it is in order. The generator engines will normally be set for automatic starting and must be in this position before the engine room operates in an unmanned mode.
Set generator start control from remote to local.
• Check lube oil levels.
• Open engine indicator cocks.
• Turn engine manually at least one revolution while observing the indicator cocks.
• Replace flywheel turning and starting protection devices to their normal machine operating position.
• Turn the engine by normal start system without fuel and observe the indicator cocks.
• If all is in order, close the indicator cocks.
• Start the engine from the local position.
• Check round the engine and ensure that there are no leaks and that the engine is operating normally.
• When satisfied that all is in order, return the engine controls to remote and take the generator on load by paralleling with the running generator.
• All alarms and trips are to be tested as per maker’s guidelines.
• Over speed trip to be tested under supervision of Chief Engineer.
• Where disposable paper cartridges are used as the discharge filter, sufficient stock for at least one change of all engines is to be maintained on board. Under no circumstances should these filters be washed and reused.
• Functioning of the rotocaps at the inlet and outlet valves must be ensured. Non-rotating rotocaps cause increased deposits at the valve seat, constant one-sided bending stresses and involve the risk of spindle failure. Worn-out and non-rotating rotocaps must be exchanged or the worn-out parts replaced (spring cap, ball race ring, balls, and tangential springs).
• Proper valve clearances must be maintained at all times. Excessive clearance causes contact of the valve cone at the cage to become too heavy during dropping. The seat surface then becomes too hardened and brittle, resulting in cracks.
• The camshaft inspection must be carried out regularly at recommended intervals. The rollers of both Exhaust valve and Fuel pump driving gear must be inspected for rotation. The sliding of these without rotation may damage both roller and cam surface and cause heavy wear. The roller guides must be withdrawn periodically to clean the accumulated sludge, more particularly on engines run on IFO or Blend oil.
• The seal leakage tell-tale holes on the engine driven F.O booster pumps or tandem pumps must always be kept clear and checked daily for leakage. The lip seals separating F.O from the L.O system must be examined once a year.
• Unless starting on auto standby mode or emergency, the engine is to be started locally, after barring and blowing through the engine. Starting and stopping from remote control also to be tested at least once a week.
• When the engine is operated on Heavy Oil, low load operation may lead to unburned hard and adhesive carbon residue that may hinder piston ring seal function. It must therefore be ensured that: 1) Low load running is avoided as far as possible to reduce unburned residue on the combustion chamber. 2) Air intake temperature is maintained on higher side of the recommended value, ensuring the exhaust gas temperature at each cylinder outlet is within limits. 3) Fuel injectors are maintained in good order. 4) Before stopping, the engine is run at least 30 minutes over specified low load limit plus 5%.
• Turbo Charger turbine side, whenever possible and recommended by the maker, is to be water washed every 250 hours of operation, when the engine is run on Heavy Oil.
• The peak pressures are to be recorded at full load every 1000 hrs. In addition these are also to be recorded before and after the piston and/or cylinder head decarb, and Fuel pump overhauls and/ or timing adjustments to monitor the changes.
• During manoeuvring or passage through restricted waters, rough weather, poor visibility etc enough standby power to be maintained by running second generator as situation demands.
• Any accidental over speed, overheating, blackout or major failure must be notified to office.
• Regular checks should be made by an Engineer Officer to ensure that the cylinders of these engines are clear of water or fuel. Diesel engines should be barred or turned over by hand once a day. Serious damage may be caused by water leaking from defective turbo-blower casings into the cylinders via the exhaust manifolds. Water accumulation may also occur from leaking cylinder heads or cylinder liners. Fuel may also accumulate from leaking fuel combustion equipment. Drain cocks in exhaust and inlet manifolds are to remain open when machines are at rest and should be regularly tested and proved clear of blockages, especially prior to stopping machines.
• Each type of engine is designed to operate at specified limits. These limits are to be found in the manufacturer’s instructions. Exhaust temperatures are the best guide to cylinder output. It is important to maintain a near equal power output from each cylinder and this should be checked every month by taking peak pressures and by balancing individual cylinder loads, or cylinder banks in “V” type engines.

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