W220 Start, Stop and running-in 03.

03. Start, Stop and running-in

03.1. Engine sequences
03.1.1. Wecs modes
Note : For details, see chap. 23;

Engine works under 6 modes from the WECS :

· Stop mode : engine is at stop.

· Start mode : engine is in starting progress, speed is under
250 rpm.
· Run mode, breaker open : speed is over 250 rpm.
· Run mode, breaker closed : engine is loaded.
· Shutdown mode : engine is going to be stopped.
· Emergency mode : engine is stopped because of a safety
trip, emergency stop.

Start mode

· V14 / V15 / V11 ventilation solenoid valves closure.

· Gas leak test between the 2 main solenoid valves V12 / V13
(P06).
· V12 opens, gas pressure test between V12 and V13.
· Air starter is energized.
· Engine rotations in order to ventilate cylinders and mani-
folds.
· V13 opens.
· If speed > 50 rpm, MCC and PCC valves open + ignition.
· Air starter disabled at 150 rpm (V12) or 180 rpm (V18).
· Some safety controls are activated over 250 rpm.

Run mode

· Active after 250 rpm.

· Safety control is active.

1117 Page 1
 03. Start, Stop and running-in W220

Shutdown mode
Active when :
– a stop is requested by the operator
– a fault comes out (see chap. 23).
The sequence of the shutdown is as follows :
· K2 (stop) relay switched off and Genset Circuit Breaker
will be tripped by the Genset Control Panel (GCP).
· Gas pressure control stops and gas line supply is closed.
· Engine gas injection stopped at 100 rpm.
· Ignition stopped at 50 rpm.
· The Gas will be burnt during engine deceleration.

Shutdown and alarm status is valid until the fault is resetted.

Shutdown and « Stop » request®engine stops.

Stop mode
· Active when the engine is totally stopped.
· Validated when Wecs checks no Shutdown or Emergency
modes.
· K2 relay will be energized again on Wecs cabinet.
Emergency mode
Active when :
· « Emergency Stop » button is pressed on GCP or WECS
panel.
· a fault has been detected (see chap. 23).

The sequence of the emergency mode is as follows :

Resulting effects :
· Stop relay and breaker trip
· Emergency stop relay trip
· Gas line supply closed (V12 / V13)
· Gas injection stopped
· Ignition powered off
· Gas pressure control stopped
· Ignition and gas injection no more possible
· Back to « Stop mode » after operator’s fault reset & ac-
knowledgment.

Page 2 1117
 W220 Start, Stop and running-in 03.

Engine and external protections are processed under 6 aspects :

· Startblock : stop mode,engine start prohibited.
· Alarms : only trouble display (GCP).
· Unloading : delayed stop , engine will derate before to be
stopped.
· Derating : engine derating until trouble disappears then re-
sume the load.
· Shutdown : breaker trip and engine stop through gas sup-
ply interruption.
Emergency : breaker trip and engine stop when all systems shut
down.

03.1.2. Preheating
See appendix 1.

The preheating function is activated when the engine is stopped

(Wecs Stop, Emergency or Shutdown modes).
The preheating function is stopped when the switch mode selection is
turned on Stop position or in case of following stops :
· Manual emergency stop (push buttons)
· Fire detection
· Gas detection
· Watchdog PLC activated
· High voltage locking.
An alarm function is also generated and will stop the preheating func-
tion if the water temperature has not reached a minimum in a certain
time 3h, in case of preheating security (TE440>98°C) or in case of wa-
ter leakage (PT401<180mBar).

03.1.3. Pre-lubricating
See appendix 2.
A W220 is allowed to start if the following condition is fulfilled :
PT271and PT201 > 100 mbar more than 5 seconds.

03.1.4. Gas line procedure

See appendix 3 for test gas line.
See appendix 3.1 for injection gas to the engine.

1117 Page 3
 03. Start, Stop and running-in W220

03.1.5. Gas Line Leakage Test:

This test is done to check the gastightness of the gas shut off valve, and
check if the pressure sensors are ok. If the test results are satisfying, a
Start impulsion is sent to the Wecs.
Genset Gas line Instrumentation :

Item Designation Signal Stand by status

P01 Differential filtre pressure sensor TOR NO
P02 Input line pressure sensor TOR NC
T01 Input line input temperature sensor TOR NC
V11 Shut off valve NC
V06 Pressure regul valve 4-20 mm
V12 Input valve NC
V14 Shut off valve NO
P06 Pressure sensor TOR NO
V13 output valve NC
V15 Shut off valve NO

V11 V14 V15

6

6
6

NC NO NO
6 6
PO6
Gas pipe feeder
to engine
P02 V06 V12 V13

Fig. 03-1

03.1.6. Ventilation procedure

See appendix 4.

03.1.7. Start procedure

See appendix 5.

03.1.8. Stop procedure

See appendix 6.

Page 4 1117
 W220 Start, Stop and running-in 03.

Appendix 1 : Preheating procedure

Engine stopped

Pump failure
Preheating or
pump ON Water HT presure
PT 401<180 mbar

Signal TE 402 SF TE 402

Preheating alarm
pump off

TE 402
< 45 ° C

Heaters ON Timer out 3h + TE 402<40 ° C

TE 402 TE 440>98 ° C+ pump ON Pump OFF & heater OFF

> 52 ° C

Heaters OFF Preheating alarm

Fig. 03-2

1117 Page 5
 03. Start, Stop and running-in W220

Appendix 2 : Prelubricating procedure

Start
prelubricating procedure

Engine
stopped End

Engine start not allowed

Prelubricating pump ON
during 3 min OR until
the engine passed in run mode Prelub pump fault (breaker down)

Prelubricating failure

PT201 & PT 271 Timer prelub

> 100 mbar > 3 min

Timer 5s Stop prelub pump

Timer 5s & Time prelub too long

PT201 & PT 271 (missed pressure)
> 100 mbar

Prelubricaring failure
Start allowed

Go to start procedure

fig. 03-3

Page 6 1117
 W220 Start, Stop and running-in 03.

Appendix 3 : Test gas line

Start
request OK

Valve V11, V14, V15 opened

valve V12, V13 closed

No pressure Gas leak test failed

on P06

End

Valve V11, V14, V15 closed

Pressure Gas leak test failed

on P06
Valve V12 opened

Valve V14 opened End

Timer 5s

Valve V11, V15 opened

Injection gas valve V12 closed

valve V12 closed

Timer 5s

Gastightness test between

V12 & V13

Fig. 03-4

1117 Page 7
 03. Start, Stop and running-in W220

Appendix 3.1 : Gas line

Start request OK

Valve V11, V14, V15 opened

valve V12, V13 closed

Valve V11, V14, V15 closed

Valve V12 opened

Injection gas

Ventilation
turns OK Start attempt failed
1 to 5 Rpm

End
Valve V13 opened

Injection gas to the engine

Fig. 03-5

Page 8 1117
 W220 Start, Stop and running-in 03.

Appendix 4 : Manual ventilation request

Stop mode

Ventilation request

Circuit breaker OFF Fan motor fault

Flow switch OFF Flow switch fault
Valve close valve fault

Ventilation failure alarm

Start ventilation
timer 3 to 8 min

Circuit breaker ON
Flow switch ON
Valve close

End ventilation
Fan circuit breaker OFF
Flow switch OFF
Valve close

Fig. 03-6

1117 Page 9
 03. Start, Stop and running-in W220

Appendix 5 : Sart sequence procedure

Start order

Starting conditons :
- Earthing disconnector open Start pre ventilation
- Tripping alarm not active See fig-03-6
- Shutdown alarm not active
- No remote startblock
- Starting air pressure>12 or 20 bar
- Wecs ready to start :
- Plc-wecs communication Pre ventilation
- Turning gear disengaged Ventilation failure
OK
- Ht water>40 °C
- Post ventilation exhaust gas line

Test gas line

See fig-03-4

Test gas line Test gas line failure

OK
Start not allowed

Start prelubriating
See fig-03-3

Start prelubricating Prelub. failure

OK

Start failure

Starter ON (CV321)
timer starter too long
End

Ventilation turns OK Starter attempt failed

Timer < 20s
1 to 5 turns

Injection gas in gas line Engine speed = 160/180 rpm

Starter OFF
Engine speed = 50 Rpm OK

Injection gas MCC/PCC

Ignition ON

Engine start

See next page

Fig. 03-7

Page 10 1117
 W220 Start, Stop and running-in 03.

Engine started

Run mode>250 Rpm

Idle running 800 Rpm

1 to 5 mn, speed ramp 36 Rpm/s

Loading 1MW/mn
AVR excitation rated
speed -200 Rpm

Normal operation

Timer AVR too long

Timer < 25s AVR excitation failure

Shutdown
Rated speed

Timer synchronizing too long

Timer < 180 to 300s Synchronisation failure

Shutdown

Breaker close

Fig. 03-8

1117 Page 11
 03. Start, Stop and running-in W220

Appendix 6 : Normal stop sequence procedure with post

ventilation and prelubricating

Stop order

Unloading 1MW/mn

Timer (unloading too long)

Power = 0
Unloading failure
Timer = 240S

Shutdown
Breaker open

Cooling run
Idle speed 800 Rpm 1 to 5 min

Stop injection gas MCC/PCC

at 400 rpm

Ignition OFF at 80 rpm

Stop engine

Prelubricating Ventilation Ventilation failure alarm

see fig-03-3 see fig-03-6

Engine stop mode

Prelubricating failure alarm

Fig. 03-9

If immediate stop = go to the step "open breaker " and " engine stop"
without completing the unloading and cooling run procedure.
If electrical stop = go to the step "open breaker" and follow the normal
procedure.
If delayed stop = go to the step "breaker open" and follow the normal
procedure.

Page 12 1117
 W220 Start, Stop and running-in 03.

03.2. Starting
Before starting the engine, check that :
1 The lubricating oil level is correct.
2 The gas circuit is in working order :
· Pressure relief unit in service (correct pressure)
· Gas circuit main valve open.
3 The low-temperature and high-temperature coolant circuits
are in working order (correct pressure, preheating and pre-circu-
lation of water sufficient to warm up the engine).
4 The starting air line pressure is open.
5 The starting air system contains no condensate.
6 The drain hole of the charge air cooler is open, no leakage
7 Check that the alarm and stop devices are in working order.

Caution : The shaft driven water pump must be degassed (manual bleed on
pump body) or the air pocket in the pump will prevent the coolant
from circulating.

Note 1 : All covers and protective panels must be fitted before starting the en-
gine. These covers may be occasionally removed for measurement
and checking purposes, but must be re-fitted immediately afterwards.

Note 2 : Before starting the engine, make sure that possible maintenance and
service operations have been finished and that all persons have left
the engine room and other risk areas.

Note 3 : Avoid running the engine on low loads. Misfiring may cause unburned
gas explosion in the exhaust system

Note 4 : It is possible to restart the engine is possible once the ventilation se-
quence of the exhaust system is finished. The exhaust system is
equipped with automatic ventilation and will stay open for a while af-
ter the stop. During this time, the start will be blocked.

Note 5: Despite the safety system, there is always a risk of gas explosion. To
avoid any possible accidents, no one must remain in the engine room
and boiler/silencer room during engine start.

1117 Page 13
 03. Start, Stop and running-in W220

Warning : Never attempt to re-start the engine before the flywheel has come to a
complete stop.

8 After starting, check immediately that pressure and tempera-

ture values are normal.
9 Check that all cylinders are firing, if not, the engine must be
stopped and the misfiring cylinders should be checked.

03.2.1. Automatic start

See installation specific documentation.

Page 14 1117
 W220 Start, Stop and running-in 03.

03.3. Stopping
03.3.1. General information

Caution : When overhauling the engine, make sure that the automatic starting
system and the pre-lubricating oil pump have been properly discon-
nected.

1 Every two days, the oil circuits of an engine that is stopped

for a relatively long period of time must be filled using the pre-lu-
bricating oil pump. At the same time, crank the crankshaft to a
new position. This reduces the risk of corrosion to bearing sur-
faces and bearings when the engine is exposed to vibrations.

03.3.2. Manual stop

Stop the engine by pushing the stop button. Normally when the stop
order is given, the engine starts to decrease the load automatically to
zero and do the cooling precedure after stop (see appendix 6).

1117 Page 15
 03. Start, Stop and running-in W220

03.4. Normal operation supervision

If an alarm has been activated, the engine condition is already critical.
Therefore, all necessary countermeasures must be taken to remove
this emergency condition and return to normal operating conditions.
Warning : do not wait for the engine automatic shutdown to reset the
fault.

03.4.1. Every day

· Read all temperatures and pressures as well as engine
load. All temperatures are more or less dependent on the
load, and the lubricating oil, cooling water pressures are
dependent on the speed. Therefore, always compare the
values read with those at corresponding load and speed
(see engine criteria chap.7).
· Check the indicator for pressure drop over gas filters.
When the pressure drop over the filters increases, the gas
feed pressure to the engine might become too low and the
output of the engine must be decreased. Too high of a pres-
sure drop may also result in deformation of filter car-
tridges.
· Check the oil pressure value before and after the filter, the
differences must be less than 1.5 bars. Too large of a pres-
sure drop indicates clogged filter, which results in re-
duced oil filtration. Reduced oil filtration results in
increased wear.
· Check the oil level in the oil sump/oil tank. Estimate the
appearance and consistency of the oil. A simple control of
the water content : A drop of oil on a hot surface (about
150°C), e.g. a hot-plate. If the drop keeps “quiet”, it does
not contain water; if it “frizzles” it contains water. Com-
pensate for oil consumption by adding max. 10 % fresh oil
at a time.
· Check that coolant circuit de-gassing (at the expansion
sump) is working correctly. Check there is no excessive
leakage from the tell-tale hole in the coolant circulation
pumps.
· Check that the tell-tale holes of the oil coolers are free.

Page 16 1117
 W220 Start, Stop and running-in 03.

Caution : In some situations, you can have condensation in charge air cooler. In
consequence, water leakage at charge air cooler telltale hole can ap-
pear. That doesn't mean that the charge air cooler is damaged.

Example : If the ambient air temperature is 35°C and the relative hu-
midity is 80 % the water content in the air can be read from the diagram
(0.029 kg water/kg dry air). If the air manifold pressure (receiver pres-
sure) under these conditions is 2.5 bar, i.e. absolute air pressure in the
air manifold is abt. 3.5 bar (ambient pressure + air manifold pressure),
the dew point will be 55°C ( from diag.). If the air temperature in the air
manifold is only 45°C, the air can only contain 0.018 kg/kg (from diag.).
The difference, 0.011 kg/kg (0.029-0.018) will appear as condensed
water.

Fig. 03-10

1117 Page 17
 03. Start, Stop and running-in W220

03.4.2. Operation supervision in connection with main-

tenance work
Record the following steps and the running hours in the engine log :
- Lubricating oil sampling (record also operating time of oil). Lubricat-
ing oil analyses without statement of operating time is of limited value
(“go - no go” only).
- Lubricating oil changes.
- Cleaning of centrifugal lubricating oil filters.
- Inspection, cleaning/change of the gas filter.
- Change of parts in connection with maintenance according to chap-
ter 04.

Note : Disconnect the electronic equipment, if any welding is performed on

the engine. Keep the return connection near the welding point.

Warning : Incorrectly performed welding may cause serious mechanical and

electrical damages.

03.4.3. General
· There is no automatic supervision or control arrange-
ment that can replace an experienced engineer’s observa-
tions. LOOK at and LISTEN to the engine !
· Strong gas blow-by past the pistons is one of the most dan-
gerous things that can occur in an engine. If gas blow-by is
suspected, check the crankcase pressure. If the pressure
exceeds 30 mm H2O, check the crankcase venting system,
if in order, do a boroscope liner inspection.

Page 18 1117
 W220 Start, Stop and running-in 03.

03.5. Start after a prolonged stop (more than 8 h)

03.5.1. Manual Start
a) Check :
- The lubricating oil level
- The cooling water level in the expansion tank
- The raw water supply to heat exchangers
- The starting air pressure is min. 18 bar.
b) Observe all points in chapter "MANUAL START".

1117 Page 19
 03. Start, Stop and running-in W220

03.6. Monthly test procedure (for stanby or black start applica-

tions)
In order to make sure the engine runs without any problem, it is neces-
sary to start it monthly. For that, you need to :
· Start the engine, according to the procedure described in
section 3.2.
· Load progressively the engine, until its full load.
· Keep the full load during one hour until all parameter
stabilization.
· Check all engine parameters to be sure that the engine
runs without any problems, see section 3.4.
· Stop the engine, according to the procedure described in
section 3.3.
The aim of this test is to validate the starting sequence and the good
running of the engine on-load. This test should be done every month.

Page 20 1117
 W220 Start, Stop and running-in 03.

03.7. Start after overhaul

1 Check gas system for leakage.
2 Check the cooling water system for leakage, especially :
· the lower part of the cylinder liners
· the oil cooler
· the charge air cooler.
3 Check/adjust the valve clearances.
4 Start the prelubricating pump manually (see electrical draw-
ing). Check that lubricating oil appears from all bearings and lubri-
cating nozzles, from the piston cooling oil outlet and from the
valve mechanism. Check that there is no leakage from the pipe
connections inside or outside the engine.

Note : Turn the crankshaft to feed oil to all connecting rods and valve rock-
ers.

Caution : Rags or tools left in the engine block, incorrectly tightened screws or
nuts, and worn self-locking nuts may cause total breakdown.

5 See instructions in section 03.2 and 03.5 when starting.

1117 Page 21
 03. Start, Stop and running-in W220

03.8. Operation supervision after overhaul

1 At the first start, listen carefully for possible jarring sounds.
If anything is suspected, immediately stop the engine. Check with
an infrared thermometer the temperatures of the main and big end
bearing and of all other bearings, and contact your Wärtsilä repre-
sentative for more analysis.
2 Check that there is no leakage of gas, water or lubricating oil.
Pay special attention to gas lines and valves.
3 After overhauling, the following instructions are especially
important :
· Check pressures and temperatures.
· Check the automatic alarm and stop devices.
· Check the pressure drop over the gas filter and lubricating
oil filter.
· Check the oil level in the oil sump/oil tank. Estimate the
condition of the oil.
· Check the ventilation (de-aerating) of the engine cooling
water system.
· Check the telltale holes of the coolers.
· Check the content of additives in the cooling water.
· Listen for jarring sounds.
· Check the crankcase pressure.
· Check the starting air pipes.

Page 22 1117
 W220 Start, Stop and running-in 03.

03.9. Running-in
The running programe below must be followed :
· After piston overhaul.
· After piston rings, pistons, liners, conrod bearing or main
bearing replacing.
This program is given for information only.

Warning : Contact your Wärtsilä representative as a special software is needed

for doing the running in program.

Note : Avoid continuous running-in under low load at rated speed.

The engine may be run-in with the normal lubricating oil specified for
the engine.

Note : If your engine nominal speed is 1200 rpm, never exceed this value dur-
ing engine running-in.

1117 Page 23
 03. Start, Stop and running-in W220

Fig. 03-11

Time Speed Load

0 0 0
2 0 0
3 800 0
8 800 0
9 0 0
20 0 0
21 800 0
23 800 0
24 1000 0
26 1000 0
27 1200 0
29 1200 0
33 0 0
50 0 0
51 800 0
53 800 0
54 1000 0
56 1000 0
57 1200 0
59 1200 0
60 1500 0
61 1500 0

Page 24 1117
 W220 Start, Stop and running-in 03.

* After the first step at 800 rpm during 5 minutes, you must stop the en-
gine. Open visiting doors and verify conrods, bearings, ….
Note the oil and the HT water temperatures. Check the conrods tem-
peratures. The conrods temperatures should be 50°C ± 5 after 5 min-
utes of engine running. Normally, the maximal temperature gap
between the conrods is 5°C. If there is a problem, don’t continue the
running-in without founding the reason (call your Wärtsilä France
Representative).
* You must stop the engine after the first step at 1200 rpm. Open visit-
ing doors and verify conrods, bearings, ….
Note the oil and the HT water temperatures. Verify the conrods tem-
peratures, typically, the conrods temperatures should be at 80°C ± 5.
Normally, the maximal temperatures gap is 5°C between the conrods.
If there is a problem, do not continue the running-in without finding
the reason (call your Wärtsilä France Representative).
* Restart the engine and go to Rated Speed (1200 rpm or 1500 rpm)
step by step (see picture above).
* When the engine is at Rated Speed, the load running-in can start.

Warning : Do not stay more than 1 minute at 1500 rpm without load. When you
increase or decrease the load, proceed in lots of steps.

* After the step at full load, the running-in sequence is finished. Stop
the engine and do the standard controls : rocker arm clearances, oil fil-
ters changing, fluids level checking. After that, you can use normally
the engine.

Fig. 03-12]

1117 Page 25
 03. Start, Stop and running-in W220

Time Speed Load

0 0 0
2 0 0
3 800 0
8 800 0
9 0 0
20 0 0
21 800 0
23 800 0
24 1000 0
26 1000 0
27 1200 0
29 1200 0
33 0 0
50 0 0
51 800 0
53 800 0
54 1000 0
56 1000 0
57 1200 0
59 1200 0
60 1500 0
61 1500 0
65 1500 25
95 1500 25
100 1500 50
140 1500 50
145 1500 25
150 1500 25
155 1500 50
160 1500 50
165 1500 75
200 1500 75
205 1500 50
210 1500 50
215 1500 25
220 1500 25
225 1500 50
230 1500 50
235 1500 75
240 1500 75
245 1500 100
290 1500 100
295 1500 75
300 1500 75
305 1500 50
310 1500 50
315 1500 25
320 1500 25

Page 26 1117
 W220 Start, Stop and running-in 03.

325 1500 0
326 1500 0

1117 Page 27