DUAL FUEL GENERATOR - OPERATING

ENGINE START-UP REMOTE PROCEDURE (IN ECR)

1. Preparation
No. Place Operation Remark
 Cooling system Check T= 60 C
o

 MGO system Check

 LO system Check P= 1 bar
 Starting Air Check
 Control Air Check
 CONTROL LEVEL Put to ‘WORK’
 ENGINE MODE Put to REMOTE
2. Start
No. Place Operation Remark
 GEN MODE (GENERATOR PANEL) Put to DIESEL MGO MODE light
 GEN CONTROL (GENERATOR PANEL) Put to MANU
 ENG CONTROL (GENERATOR PANEL) Turn to START

3. Synchronization (Auto)
No. Place Operation Remark
 GEN CONTROL (GENERATOR PANEL) Change to AUTO Check Frequency, Volt.
 START (PMS) (GENERATOR PANEL) Press CB auto CLOSED
 GOVERNOR (SYNCHRO PANEL) LOWER or RAISE to share LOAD

4. Change over fuel

No. Place Operation Remark
 GEN MODE (GENERATOR PANEL) Put to GAS GAS MODE light
- Change to GAS when the Load: (10% - 50%) and stable/steady
- Gas trip: Auto change from GAS to DIESEL. After that, to reset at LOCAL, then GAS READY
light, then GAS MODE light and auto change to GAS MODE
 GEN MODE (GENERATOR PANEL) Put to DIESEL DIESEL MODE light

5. Manual Out load Engine

No. Place Operation Remark
 GEN CONTROL (GENERATOR PANEL) Switch to MANU Outloading engine
 GOVERNOR (SYNCHRO PANEL) LOWER Adjust until 50KW
 CB CONTROL (SYNCHRO PANEL) OPEN
 ENG CONTROL (GENERATOR PANEL) STOP Eng. stop after 5 min
 GEN CONTROL (GENERATOR PANEL) Put to AUTO
6. MANUAL SYNCHRONIZATION
No. Place Operation Remark
 GEN CONTROL (GENERATOR PANEL) Change to MANU Check Frequency, Volt.
 SYNCHRO SCOPE (SYNCHRO PANEL) Change to G1/2/3 to non-loading engine
 GOVERNOR (SYNCHRO PANEL) LOWER or RAISE Adjust frequency
Adjust frequency RAISE or LOW how the two engine frequency is equal
This will be demonstrated on the synchronize scope pointer that becomes to rotate very slowly
Check voltage, frequency (mentioned above) – they are OK
 CB CONTROL (SYNCHRO PANEL) CLOSE Close early than 12 point
 GOVERNOR (SYNCHRO PANEL) LOWER or RAISE to share LOAD
 GEN CONTROL (GENERATOR PANEL) Change to AUTO
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GENERATOR PANEL

PMS LIGHT

GEN CONTROL

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ENG CONTROL GEN MODE

GENERATOR PANEL

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CB CONTROL CB CONTROL

GOVERNOR GOVERNOR

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03 Start, stop and operation
Related topics
Note!

Keep an engine log book for every engine. Record to the log the starting and stopping times
of an engine, the loads, pressures and temperatures.

03.1 Engine start
The engine can be started:
Locally
Remotely
Remotely when emergency start mode is activated
For instructions on how to start the engine remotely, see the installation-specific documents.
Caution!

Before starting the engine, verify that the engine and the auxiliaries are in operating
condition. Before a trial run and after an overhaul or a prolonged stop, more extensive
checks and preparations are required.

03.1.1 Checking the engine before starting

The checklist applies to an engine which has been stopped for less than eight hours.
Warning!

Before starting the engine, check that all maintenance work on the engine or auxiliary
equipment is finished and all covers and shields have been replaced and firmly fastened.

Warning!

Avoid running the engine in gas mode without load. There is a risk of misfiring which may
lead to unburned gas entering the exhaust system and causing an explosion.

Check that the lubricating oil level is correct.

Check that the fuel system is in order.
Sufficient precirculation to heat the fuel injection pumps.
Correct preheating.
Correct pressure.
Check that both cooling water system circuits (LT and HT water circuits) are in
running order.
Correct pressures.
Circulating water preheated and circulated long enough to heat the engine.
Air is vented from the water system.
Check that the drain pipe of the air cooler casing is not blocked.
Check for leakage.
Check that the automation system indicates ready for start.
Check that the required coolers are in working order.
Check that the safety systems are tested and operational.
Check that the differential pressure alarms on filters are not activated.
Check that the prelubricating oil pump is running and the pressure is over the
minimum required prelubrication pressure.
Disengage the turning device.
Turn the stop lever in work position.
Check that the LFO system is in running order (correct pressure and fuel circulation)
and the gas fuel system is ready to start.
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Check that the instrument air pressure is correct.
03.1.2 Checking the engine when starting after a prolonged stop
If the engine has been stopped more than eight hours, additional checks are required before
starting the engine.
Warning!

Before starting the engine, check that all maintenance work on the engine or auxiliary
equipment is finished, and all covers and shields have been replaced and firmly fastened.

Check that enough fuel is available.

Reduced fuel level can cause air to enter the feed pump. Venting the air from the fuel
system could be troublesome.
Check the fuel oil pressure.
Check the lubricating oil pressure.
Check the lubricating oil level in the oil sump.
Check the cooling water level in the expansion tank.
Check that the raw water supply to heat exchangers is sufficient.
Check all parts of the control shaft system and the fuel injection pump racks move
freely. Otherwise, there is a risk of overspeed.
After starting the engine:
Run the engine at idle speed and make sure that it is running normally.
Caution!

If anything is suspected during the test run, stop the engine immediately.

Check that the exhaust gas temperature after each cylinder is low enough.
Ensure that all fuel injectors are operating.
03.1.3 Checking the engine before starting after an overhaul
If the engine has been overhauled, additional checks are required before starting the engine.
Warning!

Before starting the engine, check that all maintenance work on the engine or auxiliary
equipment is finished.

Note!

Operator should be informed about the results of the maintenance to be able to operate the
engine accordingly.

Check the gas system for leakage.

Clean the pipe systems between filters and the engine.
Test the safety devices regarding settings and functions, depending on the kind of
maintenance.
The connections between the speed governor and the injection pumps should be set
correctly and move freely. All connections should be properly locked and the fuel
racks should move freely in the pumps.Check especially the fuel rack position.
Push the emergency stop button on the local control panel.
Check that all fuel racks move less than 5 mm.
Check the injection timing if injection pumps, adjusting screws in the guide block or
camshaft or its driving mechanism have been overhauled.
If the camshaft or its driving mechanism has been overhauled, check the valve timing of at
least one cylinder.
Adjust the valve clearances.
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Check the cooling water system for leakage.
Check especially:
Water jackets and the cylinder heads.
Lower part of the cylinder liner.
Lubrication oil cooler.
Charge air cooler(s).
Check the fuel oil circulation.
Remove all rags and tools from the crankcase.
Check that there are no untensioned or unlocked screws, bolts or nuts.
Prelubricate the engine.
Start the prelubricating pump.
Vent the lubricating oil filter.
Check that lubricating oil appears from all bearings and lubricating nozzles, from the
piston cooling oil outlet and from the valve mechanism.
Check that there is no leakage from any of the pipe connections.
Note!

Turn the crankshaft to make oil pass through all the connecting rods.

03.1.4 Starting the engine locally

1 Start the prelubricating oil pump to obtain the required prelubricating oil
pressure.  If an external full flow lubricating oil pump is installed, adjust the
pump to nominal pressure.
Caution!

If a stand-by pump is used for prelubrication, stop continuous operation to avoid

fouling of the turbocharger.

2 Open the valve in the starting air supply system and drain the condensate via
the blow-off valve.  Close the blow-off valve when there is no more condensate.
3 If the engine is connected to a reduction gear, set the speed control to idle. 
Disconnect the propeller shaft.
Set the propeller blades to zero.
4 Turn the crankshaft two revolutions. Run the engine on starting air or use
the turning device. 
a) Keep the stop lever in the stop position (2). 
b) Push the button on the solenoid valve. 
5 Disengage the turning gear from the flywheel. 

6 Set the stop lever in work position (1). 

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figure: 03-1  Stop lever

1. Normal running position (work position)2. Stop position

7 Check that the automation system indicates ready for start (no start
blocking). 
8 Choose the mode of operation: 
Diesel mode with pilot injection.
Diesel mode without pilot injection (back-up mode).
Gas mode.
Warning!

Despite the safety systems, there is always a risk of explosion when dealing with
gas. Clear the engine room and the boiler room of people before engine start.

9 Switch the engine to the local control mode. 

figure: 03-2  Local control panel

1. Engine mode selector switch2. Start button3. Stop button4. Shutdown reset
button5. Emergency stop button

10 Push the start button on the local control panel. 

Note!

The engine can be restarted only after the ventilation sequence of the exhaust
system has finished. The exhaust system is equipped with automatic ventilation
that stays open for 5 min after the stop. At which time starting is blocked.

11 Check that the engine is running normally. 

1. Automation system indicates that the engine is running, and that the running
parameters are normal.
2. All cylinders are firing. The temperature of the exhaust gas should rise.
Note!

If all cylinders are not firing, stop the engine. Check the misfiring cylinders.

03.1.5 Starting the engine remotely

Starting an engine remotely requires same preparations as for a local start with the
exception of engines that are overhauled.
1 Start the prelubricating pump. 
The engine can be started when the lubrication oil pressure is approximately 0.5
bar.In automatically starting engines the prelubricating pump operates
continuously and keeps the engine in the start mode.

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2 Push the remote control button for 2-3 seconds to start the engine. 
If the engine does not start at the first attempt, ensure that the engine is stopped
completely before trying again. Limit the number of starting attempts to leave
some reserve capacity in the starting air bottles.The start is indicated by the
remote tachometer or by a signal lamp showing when the engine is running.
03.2 Engine stop
The engine can be stopped:
Locally
Remotely
With the emergency stop button
For instructions on remote stop of the engine, refer to the installation-specific documents.
If the engine has to be stopped for a long time, protective measures should be taken before
and after stopping the engine.
Warning!

Before overhauling the engine, check that the ready/blocked switch is in Blocked position
and the prelubricating pump is inoperative.

03.2.1 Preparing the engine for a prolonged stop

These instructions are valid for an engine which has been running but has to be stopped for
several months or longer.
Caution!

During a prolonged stop, cooling water and lubricating oil should remain in the engine and
systems.

Keep the cooling water additive dosage at least at the maximum recommended level
and preferably at 1.5 times the normal dosage.
A lower concentration may cause local corrosion, especially in cylinder liners and exhaust
valve seats.
If the water level in the system decreases during the stoppage, the leak must be located and
repaired.
Caution!

During the stop, do not keep the lubricating oil warm for example by running the separator
unless the engine is preheated to a normal preheating temperature.

If the lubricating oil is kept warm, any water in the oil in the engine oil sump evaporates and
condenses on the cold surfaces in the crankcase. The condensed water causes corrosion
damages on engine parts.
Add an antifreeze agent prior to the engine shutdown if the engine is stored in a cold
climate.Check if used cooling water anticorrosion inhibitor and antifreeze agent are
compatible.
Protect the turbocharger(s).
Remove the suction branch so that the rotor can be turned while the lubricating oil
priming pump is running.
Blind off the inlet(s) with a suitable plywood plate or equivalent.
Blind off or cover the exhaust gas pipe opening(s).
Protect the outside of the engine depending on how severe the ambient conditions are.
Protect unpainted surfaces in the hot box with a thin grease spray, for example, Tectyl
502 EH.
03.2.2 Stopping the engine locally
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1 Idle the engine. 
Note!

Idling not possible for gas mode.

2 Switch the engine to local control. 

figure: 03-3  Local control panel

1. Engine mode selector switch2. Start button3. Stop button4. Shutdown reset
button5. Emergency stop button
3 Push the stop button on the local control panel. 
Listen for any disturbing sounds while the engine is slowing down.
4 If the engine is provided with separate cooling water pumps, run the pumps
for 5 more minutes. 
Run the prelubricating oil pump for at least 10 minutes after the engine has stopped.
03.2.3 Stopping the engine with the stop lever
The engine can any time be stopped with the stop lever, independently of the remote control
or automation system.
1 Idle the engine. 
Note!

Idling is not possible in gas mode.

2 Stop the engine by turning the stop lever into stop position.  Listen for any
disturbing sounds while the engine is slowing down.
If the engine is provided with separate cooling water pumps, run the pumps
for 5 more minutes. 
Run the prelubricating oil pump for at least 10 minutes after the engine has stopped.
03.2.4 Stopping the engine remotely
Note!

Avoid idling for more than 3-5 minutes before stopping.

Push the remote control stop button.The stop solenoid operates until the engine stops.
During this time the engine cannot be restarted.
When the engine stops, the system for alarm, stop and speed remote control is disconnected.
If installed, the automatic prelubricating pump is started.
03.2.5 Emergency stopping
1 Push the local or remote Emergency stop button.  It latches in stop position.
The signal from the emergency stop button goes directly to the safety module of
the engine control system, which activates an instant shutdown.
After an emergency stop, the emergency stop mode in the engine control system

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remains, and the engine cannot be restarted until it is reset.

figure: 03-4  Local control panel

1. Engine mode selector switch2. Start button3. Stop button4. Shutdown reset
button5. Emergency stop button
2 Release the Emergency stop button by turning it. 
Note!

Check the reason for the automatic protective action before resetting or restarting.

3 Reset the system by pushing the Reset button for over 5 seconds. 
When the engine is stopped, pushing the Reset button resets the shutdown circuit.
In case of an automatic shutdown or an emergency stop, the shutdown circuit
latches. When a reset is necessary, a blue light turns on in the button.
03.2.6 Automatic shutdown
The engine control system activates an automatic shutdown if an abnormal engine condition
is detected by the sensors or measurement instruments, or an external shutdown command.
See the installation-specific documentation for shutdown reasons.
At an automatic shutdown, a stop signal activates the stop solenoid in the speed governor
and the pneumatic stop valve on the engine simultaneously. Through the pneumatic stop
valve, compressed air is fed to the pneumatic cylinders on the injection pumps, which drive
the pumps to stop position.
After an automatic shutdown, the engine cannot be restarted until it has been reset with the
Reset button. Before resetting the engine, the shutdown cause(s) must be cleared and
removed.
03.3 Running-in
A new engine must be run in according to the running-in program. Running-in ensures the
proper settling of the components into the assembly. Running-in is also recommended after
piston maintenance.
The running-in may be performed on gas, distillate or heavy fuel, using the normal
lubricating oil specified for the engine.
03.3.1 Running in after piston overhaul
Follow this programme as closely as possible for running in an engine after piston overhaul.
Caution!

If the running-in program cannot be followed, do not load the engine fully for at least 4 h.

1 Start the engine. 

2 Run the engine on 0% load for 5 min. 

3 Stop the engine. 

4 Check the big end bearing temperatures and inspect the cylinder liners and

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pistons from below. 
5 Load the engine according to the running-in programme. 
Caution!

Avoid running-in at a continuous low load.

It is important to vary the load several times. The piston ring groove tilts
differently at each load stage, and consequently, the line of contact between the
piston ring and the cylinder changes.

figure: 03-5  Running-in programme after piston overhaul

X = Operating hours

Y = Engine load

1 = Stop

2 = End of running-in programme

After completing the running-in programme, normal load can be put on the engine.
03.3.2 Running in after changing pistons, piston rings or cylinder liners
Follow this programme as closely as possible for running in an engine after:
changing pistons
changing piston rings and/or cylinder liners
honing cylinder liners.
Caution!

If the running-in program cannot be followed, do not load the engine fully for at least 10 h.

1 Start the engine. 

2 Run the engine on 0% load for 5 min. 

3 Stop the engine. 

4 Check the big end bearing temperatures and inspect the cylinder liners and
pistons from below. 
5 Load the engine according to the running-in programme. 
Caution!

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Avoid running-in at a continuous low load.

It is important to vary the load several times. The piston ring groove tilts
differently at each load stage, and consequently, the line of contact between the
piston ring and the cylinder changes.

figure: 03-6  Running-in programme

X = Operating hours

Y = Engine load

1 = Stop

2 = End of running-in programme

After completing the running-in programme, normal load can be put on the engine.
03.4 Operating the engine
03.4.1 Engine loading
Related topics
Start, stop and operation ....................................
[03]

Turbocharged engines cannot take a 100% load instantly because there is an air deficit in
the engine until the turbocharger has reached a steady state speed.
An engine has to be preheated to be ready to accept load.
Fuel must be of the correct viscosity in the internal engine system.
HT cooling water must be preheated with an external preheating system to min. 60°C or as
near as possible to the operating temperature.
Lubricating oil temperature should be min. 40°C.
Dual fuel engines operating in gas mode require precise control of the air/fuel ratio for
proper operation on gas fuel
The maximum load increase rates for engines operating at nominal speed are described by
the following graph:

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figure: 03-7  Maximum load increase rates for engines operating at nominal speed

X = Time (s)

Y = Engine load (%)

1. Emergency load (diesel mode)2. Max. loading capacity (gas mode)3. Load acceptance
with preheated engine in normal operation (gas and diesel mode)
The engine loading curve (3) is used as the default loading rate for a preheated engine in
both diesel and gas mode.
The engine loading curve (2) indicates the maximum loading capacity of an engine in gas
mode. Faster loading may result in alarms, knock and trips to diesel. This is also used as
normal loading rate in diesel mode once the engine has reached the normal operating
temperature.
The engine loading curve (1) indicates the maximum loading capacity of the engine in
emergency diesel mode.
Note!

The maximum loading rate for emergency diesel mode must not be used as normal loading
rate in diesel mode.

The load must always be applied gradually in normal operation. Load increments are
smaller in gas mode and at high loads than in diesel mode.
Note!

The time between load increments must not exceed the maximum loading rate. Sudden load
changes must be monitored carefully.

The electrical system is designed to manage tripping safely. The engine is protected from
load steps that exceed its maximum load acceptance limits. Fast load shedding is controlled
by a fast-acting signal that requests transfer to diesel mode.

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figure: 03-8  Instant load application in gas mode

X = Actual load (%)

Y = Max instant load step (%)

Description Values
Maximum step-wise load increase According to the instant load application
curve.
Steady-state frequency band ≤ 1.5%
Maximum speed drop 10%
Recovery time ≤ 10 s
Time between max. load steps ≥ 15 s
Maximum step-wise load 100 - 75 - 45 - 0%
reductions

Description Values
Maximum load step (example) 33% of MCR
Steady-state frequency band ≤ 1.0 %
Maximum speed increase 10%
Recovery time ≤5s
Time between max. load steps ≥8s

Starting mode Start-up to Restrictions

active nominal
speed
Normal start of a 50-70 s Start-up after pilot fuel injection check
stand-by generator completed.
Black-out start 25 s Pilot fuel injection disabled.
Gas mode start   Gas operation starts when pilot fuel
injection check completed and gas
supply system ready.
Start on HFO   No restrictions.
03.4.2 Operating at low loads and idling
Related topics
Start, stop and operation ....................................
[03]
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The engine can be started, stopped and operated on gas, heavy and light fuel oil under all
operating conditions.
When idling and operating at low loads, depending on the fuel quality and combustion,
more soot and sludge is formed than during higher loads. These combustion products
contaminate the engine internally. As a result, lubricating oil filters and separator are higher
loaded. Sticking of piston rings and valve stems can occur. Combustion products, not
sufficiently neutralised by the lubricating oil, can cause corrosion.
By reloading the engine, the concentration of all kind of combustion products reduces. This
is specially important if the engine is to be stopped.
Low load operation
Continuous operation on heavy fuel is preferred rather than changing over to diesel fuel at
low load operation and manoeuvring.
Operating continuously at low loads should be limited. After the maximum low load time is
accumulated, run the engine at high load (above 70% of the rated load) for one hour.
Continue with low load operation.
Operation Max time of continuous low load operation
Below 20 % load on HFO 100 h
Below 10 % load on LFO 100 h
No restrictions on operation above 20% load on HFO or above 10% load on LFO or gas
Caution!

Avoid idling, that is, running the engine while it is declutched or generator breaker open.

Operation Maximum idling time

Before loading 6h
Before stopping 10 min1)
1) (3-5 min is recommended)
Note!

Idling is performed at 1200 rpm. If the generator breaker is open and the engine is idling for
5 min, the alarm "Idle max time reached" is activated and the engine speed automatically
reduces to 1000 rpm. If the generator breaker is closed and the load is <5% for 5 min, the
alarm "Idle max time reached" is activated.

If the engine has been idling for more than five minutes, run it at high load (above 70% of
the rated load) for one hour.
03.4.3 Supervising engine operation
The engine operation and condition depend on the proper function of the auxiliary
equipment outside the engine. Supervise and maintain the equipment according to the
auxiliary system instructions.
For daily routine checks, see the daily maintenance tasks listed in the maintenance schedule.
Record and follow up operating data of the engine.
All temperatures
All pressures
Load
Speed of the engine
Speed of the turbocharger
Use the recommended forms to record the operating data. To be able to follow up the data,
take the readings at the same load (85% load recommended) and speed every time. When
comparing operating data with the data and curves in the Factory Acceptance Test (FAT)
report, always compare values read at corresponding load and speed.
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Note!

If the difference between exhaust gas temperatures of various cylinders is larger than 70°C
at loads higher than 25%, establish the cause. At loads higher than 80%, the charge air
temperature should be as low as possible, but not so low that it causes condensation. At
loads lower than 25% it is recommended to have the charge air temperature as high as
possible.

If engine-driven pumps are used, the cooling water pressures depend on the engine speed.
Check the indicator for pressure drop over the lubricating oil filter.
Too high pressure drop indicates clogged candles . It results in reduced oil filtration when
the by-pass valve is opened. Reduced oil filtration increases the wear of engine components
and risk of a damage.
Check the indicator for pressure drop over fuel filters.
When the pressure drop over the filters increases, the pressure in the system decreases. Very
low pressure (less than 5 bar) reduces the engine performance and may cause uneven load
distribution between the cylinders (risk of breakdown). Too high pressure drop can deform
the filter cartridges (risk of injection pump seizure).
Supervise strong blow-by past the pistons.
Warning!

Strong exhaust gas blow-by past the pistons can lead to a crankcase explosion.

If gas blow-by is suspected, for example, because of a sudden increase of the lubricating oil
consumption, check the crankcase pressure. If the pressure exceeds 30 mm H2O, check the
crankcase ventilation system. If the ventilation system is in order, the pistons must be
overhauled.
03.4.4 Alarm handling
Alarms are displayed on the local control panel of the engine.
In case of an alarm, an alarm switch is activated or an alarm limit is reached. The operating
situation of the engine is critical. Take all necessary measures to remove the abnormal
conditions and restore normal operating conditions.
If the abnormal conditions continue or get worse, the engine automatically shuts down.
Caution!

Abnormal operating conditions may damage the engine.

For alarm causes, see the installation-specific documents.

03.4.5 Supervising operation after overhaul
1 Start the engine and let it idle at normal speed. 
Caution!

If you suspect that something is wrong, stop the engine immediately.

2 After five minutes, stop the engine. 

3 Check: 
1. Temperatures of the main and big end bearing
2. Temperatures of all other bearings which have been opened
3. Visually from below the cylinder liners and piston skirts which have been
opened

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4 If everything is in order, restart the engine. 

5 Check the condition of the engine. 

1. Check for leakage of exhaust gas, water, fuel or lubricating oil.
2. Check the fuel lines, injection pumps and injection valves.
3. Check any increase of leak fuel.
4. Check pressures and temperatures.
5. Check automatic alarm and stop devices.
6. Check the pressure drop over the fuel filters.
7. Check the pressure drop over the lubricating oil automatic filter.
8. Check the oil level in the oil sump/oil tank and the condition of the oil.
9. Check the ventilation (de-aerating) of the engine cooling water system.
10. Check the telltale holes of the coolers.
11. Check the content of additives in the cooling water.
12. Check the crankcase pressure.
13. Listen for any jarring sounds.
14. Vent fuel filters before start with fuel feed pump running if cartridges or filter
candles have been renewed.
03.4.6 Operating standby engines
In a standby mode the engine is ready to accept load instantly.
Keep the prelubrication pump running.
Lubricating oil temperature should be at least 40°C.
Circulate the HT cooling water and keep its temperature at minimum 60°C.
Cooling water must flow in a reversed way through the engine for an optimum engine
preheating result.
Keep the LT water temperature of the charge air cooler at minimum 10°C.
Start the engine once a week to check that everything is in order.
©2012 Wärtsilä Finland Oy, all rights reserved

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