Emergency Stopping the Diesel Generator
Running a diesel generator on board can be dangerous if not handled correctly. Safety is paramount, and one crucial aspect is knowing precisely when and how to shut down the generator in an emergency.
To navigate the intricacies of using a diesel generator safely, it is imperative to be well-versed in the ten critical emergencies that necessitate an immediate generator shutdown. Failing to do so can have dire consequences, potentially resulting in severe damage or bodily harm. Operators must, therefore, possess a comprehensive understanding of the ten scenarios that mandate an immediate cessation of diesel generator operation. These encompass instances such as fuel leaks, overloads, overheating, and various other potentially hazardous situations. The ability to swiftly recognize these conditions and respond promptly is the linchpin of ensuring the safety of all on board.
This article will delve into the ten emergencies that demand an instantaneous shutdown of diesel generators on ships. It aims to offer valuable insights into the significance of being well-informed about these scenarios and taking decisive action when they come to the fore. By shedding light on these critical aspects of generator operation, we empower operators to navigate their responsibilities confidently and competently.
Abnormal/ Obnoxious Sound
A ship’s generator engine is a complex and robust system comprising numerous heavy oscillating and moving parts. Alongside, its attached auxiliaries, like turbochargers and pumps, are high-speed machines that inherently generate a certain noise level. However, there are instances when an unusual, obnoxious sound emanates from the engine, signaling a potential issue. These abnormal noises can stem from damage or wear on any part of the engine, and it is imperative to promptly identify and address them before they escalate into more severe problems.
The term “abnormal noise fault” pertains to irregular sounds produced during the regular operation of a diesel engine due to unusual damage, such as excessive part clearance or other abnormal conditions. These sounds can manifest in various forms, such as cylinder knocks, supercharger surges, or valve mechanism abnormalities, all indicating underlying mechanical faults in the diesel engine.
The abnormal noise is a warning sign, signifying a potential failure that may worsen if left unattended. In the daily operations and management of Marine Diesel Engines, vigilant monitoring by duty marine engineers is paramount. This entails keen observation, attentive listening, and even employing other senses like smell and touch. Among these, careful listening emerges as a practical and effective method. Every machine, during its operation, emits a characteristic frequency of sound. Any deviations in these sounds’ length, quality, intensity, or duration can signal abnormal noise.
Notably, even the slightest deviation from the norm should be noticed. In the event of abnormal noise, immediate action is imperative. This entails shutting down the engine and commencing a thorough troubleshooting process to identify and rectify the underlying issue. By heeding these principles and acting swiftly, marine engineers can ensure the ship’s generator engine’s continued safe and efficient operation.
Wrong Approach by Engineers
The engine room is equipped with hundreds of engine systems. Abnormal noise can be suppressed by noise from other machines during power plant operation. If you hear something strange coming from your generator, you might think it’s coming from a nearby machine or machine. Don’t ignore even the slightest noise. Get a second opinion and stop the engine for checking.
Smoke
When it comes to your ship’s generator, the appearance of smoke is a serious matter that requires immediate attention. Smoke near or coming from the generator signifies a problem that has reached a critical level of danger, and it’s crucial to act swiftly. You won’t need to go through the unloading of the generators because the situation has already escalated beyond that point. Instead, utilize the emergency stop button provided at the local or remote station to shut down the generator promptly.
The smoke could arise from various sources, such as friction between moving parts or overheating.
Abnormal smoke emanating from your ship’s engine serves as a red flag, indicating a potentially severe issue. Your response should be swift and precise. Begin by pinpointing the source of the smoke and assessing the problem’s magnitude. Depending on the severity, you may need to halt the engine and seek professional assistance. In cases where the issue appears minor, you can attempt troubleshooting independently and make the necessary adjustments.
In addition to addressing the immediate problem, it’s vital to conduct a visual inspection for any visible signs of damage or wear contributing to the smoke. This comprehensive approach to dealing with smoke issues ensures your safety and contributes to the smooth operation of your marine engine. Adhering to these steps and taking proactive measures can mitigate potential risks and keep your generator functioning optimally.
Wrong Approach by Engineers
Never panic in such situations. Use the remote start button on standby generators that charge near-instantaneously (usually on-site) and stop running generators in an emergency. Panic is the first thing that strikes you when you see smoke or fire. It reduces the engineer’s thought process and can ultimately slow down the approach.
Abnormal Lubricating Oil Parameters
Regarding your marine engine, abnormal lubricating oil parameters are a cause for concern that should be addressed. You must act immediately if you notice variations from standard operating conditions, like an increase in lubricating oil temperature or a decrease in oil pressure below acceptable levels. These deviations can indicate underlying issues, such as dirty lube coolers or clogged filters, requiring prompt attention.
Particular attention should be given to parameter changes such as high oil viscosity or low oil pressure. As soon as you notice these alterations, it is essential to respond swiftly. Proactive measures are crucial to ensuring your marine engine’s smooth and efficient operation. Ignoring abnormal lubricating oil parameters can lead to more severe problems down the line, potentially causing damage to critical engine components.
To address these issues effectively, the first step is to shut down the generator immediately. This action prevents further damage and lets you focus on identifying and resolving the problem. By taking these precautions and promptly addressing abnormal lubricating oil parameters, you can help safeguard the health of your marine engine and ensure its continued reliable performance.
Wrong Approach by Engineers
When you notice a pressure drop, the first thing that comes to mind is switching to the standby filter. Air pockets can seriously damage the bearings if the spare filter is not primed and does not come into working condition during operation. It is recommended to stop the machine and switch to the standby filter only after priming.
Higher Lube oil Differential Pressure
Monitoring higher differential lubricant pressure ensures marine engines’ safe and efficient functioning. This parameter helps assess the condition of lube filters by measuring the pressure difference across them. A pressure gauge provides readings for the pressure before and after the filter. If the differential pressure exceeds the norm, it’s vital to take immediate action by shutting down the generator and switching to the standby filter.
Maintaining appropriate lubricant pressure is paramount to prevent potential damage and ensure the continuous operation of the marine engine. When the differential pressure rises above the acceptable range, it indicates that the lube filters may be clogged or experiencing issues. Addressing this promptly by switching to the standby filter helps maintain uninterrupted engine operation and avoids potential damage to critical engine components. By staying vigilant and responsive to higher differential lubricant pressure, you contribute to the overall safety and reliability of the marine engine.
Wrong Approach by Engineers
Monitoring higher differential lubricant pressure ensures marine engines’ safe and efficient functioning. This parameter helps assess the condition of lube filters by measuring the pressure difference across them. A pressure gauge provides readings for the pressure before and after the filter. If the differential pressure exceeds the norm, it’s vital to take immediate action by shutting down the generator and switching to the standby filter.
Maintaining appropriate lubricant pressure is paramount to prevent potential damage and ensure the continuous operation of the marine engine. When the differential pressure rises above the acceptable range, it indicates that the lube filters may be clogged or experiencing issues. Addressing this promptly by switching to the standby filter helps maintain uninterrupted engine operation and avoids potential damage to critical engine components. By staying vigilant and responsive to higher differential lubricant pressure, you contribute to the overall safety and reliability of the marine engine.
Overspeed
Generators are high-speed machines, and the over-speeding of generator motors has historically caused explosions and consequences.
Generator over-speeding is mainly caused by fuel system problems, especially regulator malfunctions. If the generator runs above its rated speed but does not stop, the engineer should stop it immediately to avoid a severe accident. Then inspect the crankcase and replace the bottom end screw.
When a ship’s engine runs too quickly, neither the engine nor the passengers’ safety can be guaranteed. The engine breaks down and causes harm because the parts wear out too quickly. Therefore, it is crucial to make sure that every engine operates at the proper pace.
This helps the engines work well and keeps everyone safe.
Wrong Approach by Engineers
During the commissioning of the generator after overhaul, the governor droop is changed to achieve the desired RPM specified in the manual. Incorrect settings or stuck firing frames can cause the generator to overspeed during this time. Failure to inspect the crankcase and replace the bottom end bolt is a common cause of bearing failure..
Cooling Water Supply
Cooling water supply is an integral part of a marine engine as it helps it run smoothly and efficiently. Failure of the cooling water supply can have severe consequences for the engine. Cooling water starvation can cause the engine to overheat, damage components, or even fail. Insufficient cooling water supply due to prolonged exposure to high temperatures can also lead to corrosion of metal parts and other components within the engine. It is, therefore, crucial for ship technicians and operators to ensure that the cooling water supply system is always functioning correctly.
Wrong Approach by Engineers
If there is no cooling water pressure in the line, the engineer may try to bleed air from the bleeder cock near the generator expansion tank line. Suppose the water supply is unavailable (due to failure of the supply pump). In that case, this will further increase the temperature, and later, the generator will shut down, leading to the seizure of moving parts. Always stop the generator first before troubleshooting. To avoid seizing parts, the flywheel should be barred when the generator stops due to a lack of water.
Piping Leakage
Leaks in pipes within a marine engine are highly hazardous and must be addressed without delay. Repairs should only be attempted after shutting down the generator, whether a fuel, lubricant, or cooling water line leaks. The rationale is that these leaks can reduce system pressure, potentially damaging the engine and its components.
It is essential to recognize the gravity of leakage issues. Losing fuel, oil, or coolant because of leaks can harm how the engine works. It is crucial to constantly examine all the pipes for leaks and fix them as soon as you see any.
The most uncomplicated strategy to prevent leaks from occurring in the first place is to use the right plumbing supplies and adhere to the manufacturer’s instructions when installing and maintaining the pipes. These procedures ensure the engine runs safely and smoothly, which is essential for the ship and everyone on board.
Wrong Approach by Engineers
If there’s a minor fuel oil or water leak at a pipe joint, it’s often fixable by tightening the joint. But it’s important not to over-tighten it because it can worsen the leak and harm the pipe. So, fixing these leaks after shutting down the generator is best.
Loose Parts and vibrations
Vibration is one of the most common causes of wear on moving parts. Parts can come loose, reducing efficiency and performance. Loose bolts are also a significant source of vibration. To prevent this, it is essential to regularly inspect all moving parts for loose bolts and other signs of wear. Additionally, regular maintenance should ensure that all components are adequately lubricated and tightened to prevent excessive vibration while the engine runs. If the bolts loosen or vibrate excessively while the engine is running, immediately stop the generator motor, investigate the cause, and repair it.
Wrong Approach by Engineers
On board ships, it is not customary to check the tightness of generator foundation bolts and attached accessory units such as turbochargers. It turns out that PMS at many shipping companies do not incorporate foundation bolts and other bolt tightness checks into their routines.
Non-functional Alarms and Trips
Alarms and shutdowns are essential to your generator set’s safe and reliable operation. The generator should be shut down immediately whenever an alarm is detected due to a running generator not working. A non-functioning alarm can damage equipment and cause dangerous situations such as fire. Additionally, operational failures can occur, which can result in high costs. Therefore, checking alarms and trips regularly and replacing malfunctioning alarms as necessary is essential.
Wrong Approach by Engineers
Crews on many ships tend to ignore alarms they consider unimportant. Port State Control (PSC) often observes generator alarms and trips not functioning or set correctly. In such a situation, the generator cannot be saved from disaster. Check all alarms and trips weekly.
Lube oil Contaminated with water
Water leaking into the oil will reduce the capacity and damage the bearings. The generator should be stopped when the moisture content becomes too high. Find leaks immediately and change/clean the sump oil before operating the generator again..
Wrong Approach by Engineers
Several cases have been found where generator lubricant tests were not performed regularly, and generators were run with water in the oil. The effects of small amounts of water are not immediately noticeable, but in the long run, they corrode and damage critical parts of the crankshaft and bearings.
FAQ on “Emergency Stopping the Diesel Generator”
Q: What is the primary method to emergency stop a diesel generator?
A: Press the “Emergency Stop” button on the generator control panel.
Q: Will immediately stopping the diesel generator harm it?
A: Sudden stops can be stressful for the generator, but emergency stop mechanisms are designed for safety.
Q: How long should one wait before attempting to restart the generator after an emergency stop?
A: Wait at least 5 minutes, ensuring all issues are resolved, before attempting a restart.
Q: Why might someone need to emergency stop a diesel generator?
A: Situations like a detected fault, risk of fire, or uncontrolled operation necessitate an emergency stop.
Blog Conclusion
In conclusion, a ship’s generator’s safe and efficient operation is a critical responsibility that demands vigilance and proactive maintenance. We’ve explored various aspects of generator safety, from recognizing abnormal sounds to the need for swift action in the face of smoke or leaks. Understanding the potential risks and being prepared to address them promptly can prevent disasters and ensure the safety of both the vessel and its crew.
We’ve also emphasized the significance of adhering to specified RPM limits to prevent engine over-speeding, which can have catastrophic consequences. Additionally, we’ve underscored the importance of promptly addressing abnormal lubricating oil parameters to maintain engine health and longevity.
Moreover, we’ve highlighted the need for caution when dealing with leaking pipes, emphasizing that repairs should be conducted after the generator is shut down to avoid exacerbating the issue. Regular inspections and following proper installation and maintenance procedures are essential to minimize the occurrence of leaks and ensure the engine’s smooth operation.
Safety is paramount in marine engines; every precaution must be taken to protect the vessel and its crew. By staying informed, conducting routine checks, and taking immediate action when necessary, we can help ensure ship generators’ reliable and secure operation. The well-being of the ship and everyone on board depends on it.
