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Guide to Proper Loading of Marine Diesel Gensets

Diesel generators are designed to work demanding hours to supply electrical power under challenging conditions with exceptional reliability and a long lifespan, but even the toughest machines will fail if they are not managed correctly. Here’s how to load a marine generator correctly and why it matters. 

Load Matters to Lifespan and Performance in Diesel Generators 
In diesel generators, working them gently isn’t good for the machine itself, contrary to what you may think. In fact, regularly running diesel generators under the recommended 60-75% maximum rated load can lead to lasting damage. 

What happens is that operation under low load conditions causes low pressure in the marine generator cylinders, which compromises the performance of the piston ring seal. This seal relies on a high combustion gas pressure to force the piston rings against the cylinder bore and without it, the engine doesn’t achieve an optimal temperature to burn fuel efficiently. This leads to a build-up of soot and residue from unburned fuel, which clogs and can permanently damage the cylinder bore.

Another issue that arises from running marine generators at low loads is cylinder glazing, which occurs then the hot combustion gasses escape through the poor seal and ignite the engine’s lubricating oil to create a hard glaze that smooths the bore and affects performance further.
If your marine generator is emitting blue smoke, the low load use has allowed carbon – a highly abrasive substance – to build up on the bores and wear down the honing marks. That leads to higher oil consumption which causes blue smoke. Black smoke can also occur as the residue from poor fuel consumption clogs the injector tips.
Running your marine generator on a light load therefore effectively shortens its lifespan, increases maintenance cost and creates environmental hazards that may incur complaints and penalties from nearby vessels and port authorities.
How to Avoid Running a Marine Generator at Light Load for Electrical Power
 
Firstly, it is important that your marine generator is correctly sized for your vessel’s power needs. This should be assessed by an experienced technical team on your behalf to ensure you are not buying oversized diesel generators.
 
Secondly, only run your marine generator for electrical power on low load when it is unavoidable and bring it up to optimal load for around 20 minutes on a regular basis to give the engine a proper run and prevent damage in the long-term.
Need a World-Class Electrical Power Solution for Your Vessel?
If you’d like assistance in purchasing a new marine generator for your vessel, speak to the specialists at Energy Power Systems Australia – the authorised CAT engine dealers for Australia, the Solomon Islands and Papua New Guinea. Our team can assist you with every aspect of your purchase, from technical advice and sizing to installation and maintenance. 
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