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Diesel Engine COMMISSIONING - 3600/C280
Diesel Engine COMMISSIONING - 3600/C280
Diesel Engine COMMISSIONING - 3600/C280
DIESEL ENGINE
COMMISSIONING – 3600/C280
Contents
©2007 Caterpillar®
All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
©2007 Caterpillar®
All rights reserved. Page 1
• Engine Control Panel Instrument
Performance Data Readings
• Engine
Instrument Panel & Generator
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Design Review
The engine and generator only, and is available from
installation should be designed to Caterpillar.
give efficient and reliable operation. It is a checklist to determine if
A poorly designed installation can sufficient information has been
hinder serviceability, and make provided to the installation designer
routine maintenance and repairs for completion of initial layouts in
difficult. The neglect of specific compliance with requirements in the
design requirements for mounting, 3600 EPG Application and
alignment and support systems can Installation Guide.
lead to poor performance and
The form should be completed
increased cost of operation.
with general information about the
When the installation designer has owner, power station, and
completed a review of the Caterpillar builder/installer using design criteria
application and installation of the power station, record specific
requirements, a discussion should data concerning physical features of
take place with Caterpillar dealer the site as well as the engine and
personnel to cover concerns he may generator support systems.
have about specific areas of the
There is provision to record
design. This will establish ground
Caterpillar reference materials
rules for further working
provided to the designer as well as
relationships in the design phase.
a checklist for results of the design
After the initial installation drawings
and serviceability review.
have been completed, follow-up
Compliance with Caterpillar
discussions should take place with
requirements is noted by placing an
the designer to make sure the
“X” in the box next to the system
drawings meet application and
reviewed, indicating satisfactory or
installation guide requirements. As
unsatisfactory compliance. If the
an aid in the review of the design,
design of a system does not comply,
use the 3600/C280 Generator Set
space is provided to record action
Design Review Report on page 4 of
required to follow-up and correct the
this guide or the 3500 Industrial
problem areas.
Engine Design Review Report.
After completion of the design
Explanation of Design review and design review form, and
Review Report after reaching agreement on required
The design review reports in this corrective action, it is recommended
guide provide a checklist for dealer that all concerned parties sign the
or Caterpillar representative use form at the designated location.
©2007 Caterpillar®
All rights reserved. Page 3
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
Address: _______________________________________________________________
Application: Prime Power: _______ Continuous: _______ @ ________% load
Peak Shaving: _______ Standby: _______
Expected Annual Operating Hours: _______________________________________
Consist:
Engine Model: _____________ Engine Arrangement No.: ___________________
OT Specification No.: ______________ Serial No.: _________________________
©2007 Caterpillar®
Page 4 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
The following parties have discussed and agreed to the results and required
action during the design review process.
©2007 Caterpillar®
All rights reserved. Page 5
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
Satisfactory
Unsatisfactory
Cooling
Satisfactory
Unsatisfactory
Starting
Satisfactory
Unsatisfactory
Exhaust
Satisfactory
Unsatisfactory
Fuel
Satisfactory
Unsatisfactory
Lubrication
Satisfactory
Unsatisfactory
©2007 Caterpillar®
Page 6 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Satisfactory
Unsatisfactory
Driven Equipment
Satisfactory
Unsatisfactory
Safety and Alarms
Satisfactory
Unsatisfactory
Engine Monitoring
Satisfactory
Unsatisfactory
Ventilation
Satisfactory
Unsatisfactory
©2007 Caterpillar®
All rights reserved. Page 7
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
Satisfactory
Unsatisfactory
Equipment Safety
Satisfactory
Unsatisfactory
Generator
Controls
Satisfactory
Unsatisfactory
Switchgear
Satisfactory
Unsatisfactory
Operation and
Maintenance
Satisfactory
Unsatisfactory
©2007 Caterpillar®
Page 8 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Satisfactory
Unsatisfactory
Noise/Emissions
Satisfactory
Unsatisfactory
Auxiliary Cooling
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
©2007 Caterpillar®
All rights reserved. Page 9
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
Construction Review
After the design review is dealer use only, and is available from
satisfactorily completed, the next Caterpillar. The report is a simple
step is the construction of the checklist used to determine if the
installation site. During this phase, previously agreed on design is being
visit the construction site at least successfully implemented during the
twice to perform a review of construction process.
systems installation progress. Fill out the report with general
The first visit should follow information about the owner,
installation of the Caterpillar installation site and builder/installer,
3600/C280 generator set units. including the power station physical
Additional visits may be necessary, features. Provisions are made for
depending on the difficulty of the recording the generator set systems’
installation, and the stage of descriptions, including serial
completion. Make the final visit numbers, and manufacturer, where
before the commissioning process applicable.
begins. When the construction and
The objective of these visits is to installation are in compliance with
determine if the previously approved Caterpillar requirements, indicate
design is being followed. These this by placing an “X” in the box
visits not only continue to produce a next to the system reviewed for
better understanding of Caterpillar satisfactory or unsatisfactory
requirements, but also provide a compliance to requirements. If a
more reliable installation. system does not comply, there is
Experienced construction builders space to record the necessary
will make necessary changes as corrective action.
soon as possible, to avoid costly After the construction review and
delays and eventual customer the construction review form are
downtime. completed, and any corrective action
is agreed to, it is recommended that
Explanation of Construction
all concerned parties sign the
Review Report construction review form at the
The Caterpillar 3600/C280 designated locations on the report.
generator set construction review is
intended to provide a checklist for
©2007 Caterpillar®
Page 10 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Consist:
Engine Model: _____________ Engine Arrangement No.: ___________________
OT Specification No.: ______________ Serial No.: _________________________
Describe: __________________________________________________
High Idle: Specified: ______________ OT Specification: _________________
Low Idle: Specified: ______________ % Droop Specified: _______________
Fuel Used: Distillate: _________ Blended: _________ Residual: __________
Fuel (API): _______ Corrected Density: ______ (kg/L): _____ (lb/gal): _____
Fuel Treatment: Coalescing Filter:___ Centrifuge:___ Viscosity Control:___
Engine Coolant: Antifreeze: _____________ Corrosion Inhibitor: ____________
Oil to be used in engine: ________________________________________________
Engine Site Conditions: Elevation: _______________________________________
©2007 Caterpillar®
All rights reserved. Page 11
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
The following parties have discussed and agreed to the results and required
action during the design review process.
©2007 Caterpillar®
Page 12 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Satisfactory
Unsatisfactory
Cooling
Satisfactory
Unsatisfactory
Starting
Satisfactory
Unsatisfactory
Exhaust
Satisfactory
Unsatisfactory
Fuel
Satisfactory
Unsatisfactory
Lubrication
Satisfactory
Unsatisfactory
©2007 Caterpillar®
All rights reserved. Page 13
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
Satisfactory
Unsatisfactory
Driven Equipment
Satisfactory
Unsatisfactory
Safety and Alarms
Satisfactory
Unsatisfactory
Engine Monitoring
Satisfactory
Unsatisfactory
Ventilation
Satisfactory
Unsatisfactory
©2007 Caterpillar®
Page 14 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Satisfactory
Unsatisfactory
Equipment Safety
Satisfactory
Unsatisfactory
Generator
Controls
Satisfactory
Unsatisfactory
Switchgear
Satisfactory
Unsatisfactory
Operation and
Maintenance
Satisfactory
Unsatisfactory
©2007 Caterpillar®
All rights reserved. Page 15
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
Satisfactory
Unsatisfactory
Noise/Emissions
Satisfactory
Unsatisfactory
Auxiliary Cooling
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
©2007 Caterpillar®
Page 16 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Evaluation Guidelines
Note: The project manager should operation of systems can cause
insure proper systems integration deterioration in their performance
between all disciplines before the over their expected life. Starting
start of commissioning. with deviated standards and
This document gives guidance to specifications will only shorten the
personnel commissioning Caterpillar expected life.
3600/C280 Generator Sets. The The items included in the system
included information should be used guides are intended to assist in the
to prepare the final commissioning documentation of facts to be
report and documentation of included in the final commissioning
performance of each engine as it report. Pictures and other
goes into full service. Any deletion schematics or visual aids as
of information can cause confusion attachments to the commissioning
during future maintenance or report are valuable to help others
warranty activity. Each of the items understand the descriptions given
included in each discussion should in the report.
be documented in the final report It is to be understood that
that establishes the initial condition Caterpillar personnel are available
of engine operation. to commission 3600/C280 generator
Commissioning has many activities sets for a nominal fee described in
associated with its definition. the “3600 Quoter.” If this is not
The field engineer responsible for done, the responsibility of system
commissioning must be prepared evaluations and full commissioning
to give guidance to all areas of the is that of the described party
project as well as being the final designated by the project manager
evaluator of operating systems and for any project.
engine performance. This guide is
intended to assist in this activity and Air Intake System Evaluation
to complement the existing 3600 To evaluate the engine air intake
EPG Application and Installation system for the 3600/C280 engines,
Guide. the total system must be evaluated
from the air source for the engine
It is important to understand
to the inlet to the turbocharger. This
the standards established for each
may include engine room air or the
system and the specifications
air cleaner may be mounted outside
accompanying those standards
the engine room. Whichever the
to give the Caterpillar 3600/C280
case, consider the following items
generator set the highest reliability
when evaluating the air intake
and customer satisfaction possible.
system.
Any deviation from the standards
or specifications can be detrimental
to the life of the product. Normal
©2007 Caterpillar®
All rights reserved. Page 17
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
Page 18 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
©2007 Caterpillar®
All rights reserved. Page 19
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
Page 20 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
©2007 Caterpillar®
All rights reserved. Page 21
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
Page 22 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
©2007 Caterpillar®
All rights reserved. Page 23
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
Page 24 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Consider the following items when piping from the muffler and piping
evaluating the exhaust system. degradation during the life of the
engine. Fuel consumption and
Exhaust System Warnings
component life will be affected
The engine installer must protect
if the backpressure is beyond the
engine room equipment and
recommend value of 254 mm H2O
personnel from the heat of exhaust
(10 in H2O).
system piping.
The exhaust backpressure on each
The engine installer must provide
bank of the twin turbocharged
appropriate drains and/or rain caps
3612/C280-12 and 3616/C280-16
to protect the engine from rainwater
(vee) engines must be balanced;
entering the engine through the
even when the dual pipes exiting the
exhaust piping. The last few feet
turbochargers are transitioned into
of the exhaust outlet should be
one larger pipe going to the muffler.
installed to prohibit rainwater entry
Do not allow gas flow to turn at a
without inducing excessive exhaust
right angle during a transition. Do
backpressure.
not allow the exhaust system piping
The use of a common exhaust for a vee engine to be routed
system between engines is to be vertically from each turbocharger
strictly avoided. and then be blended horizontally.
The turbocharger must be This will cause excessive
protected from debris entering the backpressure on one bank. Blend the
exhaust outlet during construction exhaust gases into a common pipe
of the exhaust piping. A properly before the direction change is made
tagged blanking plate is or during a long radius bend in the
recommended. The tagged plate directional change.
must be removed prior to initial Exhaust piping should not be
engine operation. The debris supported from the engine package.
collected on the plate must not
There must be expansion joints
go into the turbocharger.
and vertical supports in the
Exhaust System Piping appropriate positions to assure free
The exhaust system piping must movement of the exhaust piping
be made of a material to withstand during thermal expansion.
the effects of exhaust gas
The exhaust piping should be
temperature, pressure, velocity and
rigidly supported, (with off-engine
thermal expansion. Ensure that any
supports) near the engine to
insulation added to exhaust piping
minimize compression and offset
does not deteriorate the piping since
of the engine exhaust bellows.
the pipe temperature will be higher
Exhaust pipe expansion must be in
than if uninsulated.
the direction away from the engine.
The backpressure of the total Rollers are strongly recommended
piping system must be minimal to when vertical supports are required
allow for muffler restriction, outlet
©2007 Caterpillar®
All rights reserved. Page 25
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
Page 26 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Fuel lines must be treated (pickled) Note: Refer to the Fuel System
and coated inside with lube oil prior section of the 3600 EPG Application
to final assembly. “Refer to & Installation Guide for additional
Caterpillar Flushing and Pickling information on fuel temperature
Guidlines.” requirements.
Fuel lines must never be smaller An air-to-fuel cooler is preferred.
than the engine connections of A water-to-fuel cooler is allowable,
31.7 mm (1.25 in.) pipe for supply but there must be an awareness that
and 25.4 mm (1 in.) pipe on return. a cooler failure can result in water
Customer fuel piping to the engine entering the fuel supply, leading to
should not be smaller that the inside subsequent, possible, fuel injector
diameter of the engine mounted inlet failures.
and return fuel piping. Flexible
connections must be used at both Governors and/or Actuators
the fuel inlet and return, connecting The type of governor being used,
the customer piping to the engine and its operating characteristics,
mounted piping. must be described on the
Fuel Filters commissioning report.
Initial fuel filter differential should If a hydra-mechanical governor is
be monitored to eliminate premature used, ensure that compensation is
plugging of engine filters. adjusted to provide engine stability
The user and/or installer are for synchronizing and load changes.
responsible for providing primary If an electronic governor and
filtering of fuel supplied to the hydra-mechanical ball head backup
engine. Water separation is of actuator is being used, ensure proper
prime concern. Water separators engine operation with both
or coalescing filters should be governing systems. Refer to the
installed. If fuel does not meet the Starting System Evaluation section
required recommendations, a fuel of this guide for the appropriate
centrifuge/purifier should be used. starting and stopping procedure
An initial stock of engine fuel for the engine.
filters should be on-site prior to The high idle of the engine, (for
initial starting of the engine. each governor system used) must
agree with the droop setting if the
Fuel Coolers
engine is to operate in droop mode.
A fuel cooler may be required
when the return fuel is not returned Caution: With an electronic governor
to the main tank and the day tank and a backup ball head actuator, the
is not large enough to handle the ball head governor speed must be
heat transfer from the injection set above the electronic governor
pumps. The fuel cooler should be speed by a minimum of 15 rpm,
sized to cool fuel returning to the (plus any droop). Excessive speed
day tank below 40°C (100°F), on the ball head can cause engine
with distillate fuel. overload if a paralleled unit goes
©2007 Caterpillar®
All rights reserved. Page 27
Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
off-line during parallel and ball head the oil sump. Record the oil brand
operation. and type.
Ensure stability for synchronizing Note: Refer to the Lubrication
and load changes when using total section of the 3600 EPG Application
electric governor systems. & Installation Guide for additional
information.
Control System - ADEM III
A system must be in place to
(C280 only) properly handle the waste oil from
Verify the loaded flash file in the engine oil changes.
ECM is correct for the application.
Oil samples should be scheduled
Ensure the governing control system
every 250 engine hours with
is on the correct setting for the
application, using Caterpillar appropriate transportation to provide
Electronic Technician. If the ADEM adequate turn around time for
III is being used to control the engine results. Submit a sample of new oil
for testing prior to the first interval
speed, refer to Caterpillar media
sample. If transportation is a serious
number RENR5083 for instructions
on governor adjusting. If Direct Rack problem, ensure the minimum oil
setting is used, setup governor using change period is communicated.
manufacturers recommendations. Only after several sampling periods
during this mode of operation, can
Lubrication System Evaluation the engine be allowed to go beyond
The lubrication system supplies the minimum change period. Ensure
a constant oil flow to engine the appropriate oil information is
components. Oil is filtered, cooled provided to the operating personnel
and pressure regulated throughout and other appropriate personnel to
the engine operating range. Bearing enforce this. Instruct the personnel
failure, piston ring sticking and on trending the results of the oil
excessive oil consumption are analysis. Refer to the appropriate
classic symptoms of oil related manuals for further description:
engine failures. Maintaining the • SEBU6121,
lubrication system, scheduled oil Operation and Maintenance
sampling and quality oil can mean Manual for 3606 and 3608
the difference between repeated oil engines
related failures and satisfactory • SEBU6122,
engine life. Consider the following Operation and Maintenance
when evaluating the Caterpillar Manual for 3612 and 3616
3600/C280 engine lubrication engines
system.
Engine Sump
Engine Oil The oil sump must be filled through
The oil to be used in the engine the coil filler tube. Do not remove
must meet Caterpillar 3600/C280 the engine crankcase cover to fill the
engine oil requirements prior to filling sump.
©2007 Caterpillar®
Page 28 All rights reserved.
Application and Installation Guide Diesel Engine Commissioning – 3600/C280
The user must connect oil sump Oil Pressure and Temperature
drain valves to external piping for Safety shutdowns and alarms
draining oil during an oil change. should be provided for these engine
Additionally, a flexible connector operating parameters.
should be provided between the
external piping and the drain valve. Mounting and Alignment
A dedicated pump should be used Evaluation
if oil is to be pumped into and out The 3600/C280 generator set
of the oil sump. This helps eliminate packages using the Caterpillar rigid
the chance of foreign material or base are self-supporting structures.
debris entering the oil sump. The package will maintain alignment
if the floor is true (flat). The
Ensure cold engine oil level is Caterpillar spring vibration isolators
correct and check the oil level can be adjusted to minimize forces
several times during initial engine transmitted to the floor. Consider
operation. Allow engine oil the following when evaluating the
temperature to reach normal proper mounting of the package and
operating temperature 82 - 85°C checking alignment of the engine
(180 - 185°F). The dipstick must and generator or engine and drive
be marked for proper operating level equipment on-site.
at rated speed and load.
Vibration Isolators
Engine Prelube It is the user/installer’s
If equipped, ensure the air prelube responsibility to provide adequate
motor is properly lubricated prior to number of anchor bolts between the
operation. floor and the bottom of the isolator
Check the air receiver tank’s sizing if the generator set is to be
for the required starting paralleled with one or more other
requirements. Consider air prelubing generator sets.
requirements if so equipped. The snubber bolts on the isolators
Is the time for prelubing within the should be tightened hand-tight and
required time for starting the engine? locked in that position prior to
Electric prelube systems must have starting the engine. Refer to the
motor starters sized for current draw Vibration section of the 3600 EPG
to maintain pump operation until Application & Installation Guide for
prelubing is complete. further instruction of isolator
adjustment.
Continuous prelube systems must
have the Caterpillar spill-tube system The leveling nuts should be
to prevent oil collecting in cylinders adjusted if the isolators are not level.
resulting in hydraulic lock and Ensure the dampening blocks
damage to cylinder components between the snubber push plate
upon start-up. and the inner spring cage plate are
installed properly.
©2007 Caterpillar®
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Ensure that the generator space The alarm or shutdown fault signal
heaters are controlled to be off must be wired to remote
during generator set operation and annunciation points to alert
on during shutdown periods. There operators.
are contacts available in the engine Ensure contactor capillary tubes
electrical system to control this or have not been damaged.
an alternate arrangement may be
An emergency stop button must
considered.
be available at the engine.
Ensure that the generator windings
have been meggered prior to initial Generator Safety Relays
excitation. In addition, the cables Ensure Resistive Temperature
between the generator and first Devices (RTD)s for generator
circuit breaker should be meggered. winding and bearing(s) temperatures
are connected to instrumentation
Ensure the generator mounting, to monitor and alarm temperature
alignment and connections are faults found in the bearings or the
correct based on the contents of the windings of the generator.
3600 EPG Application & Installation
Guide. Confirm a relay coordination study
has been completed for proper
Safety System Evaluation setting of protective relays in the
The safety system on the engine switchgear.
gives early alert to operators of a External Engine Support Systems
pending problem or shutdown to the The user must provide alarms
engine to protect the engine and/or and/or shutdowns on external
generator from imminent danger or system components that can
limit contingent damage due to adversely affect engine operation in
failure. Proper maintenance of the a fault condition. These components
system is imperative for constant may include fuel day tanks, primary
protection. Consider the following fuel filters and/or centrifuges,
when evaluating the generator set radiator fans and similar devices.
safety system.
The user must provide both audible
Engine Contactors and visual annunciation of faults
Ensure minimum shutdown and in both the engine room and the
alarms are supplied for the engine. control room. This should include
For the requirements of generator horns, rotating beacons or any other
set engines refer to the Equipment form of audible or visual alert.
Selection section of the 3600 EPG
Application & Installation Guide. Emergency Stops
The user must provide remote,
The contactors at the engine must emergency stop buttons allowing
demonstrate trip settings according an operator to safely shutdown the
to specifications for alarm and system without endangering
shutdown requirements. personnel.
©2007 Caterpillar®
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
©2007 Caterpillar®
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
©2007 Caterpillar®
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
mounted in the windings and the to ensure they are installed properly
bearing housing(s). Ensure the before energizing the voltage control
temperatures can be monitored circuit. This is imperative for proper
daily. Several types of alarms and or monitoring of engine operation.
shutdowns are optional. If included,
Circuit Breakers
ensure they function properly. Ensure the circuit breaker has been
Ensure generator voltage, manually tested before installing in
amperage, power factor and kW load the test position.
are gauges in the control panel and Ensure the circuit breaker is in the
are monitored on a daily basis. test position during any testing of
Initial readings should be compared the generator controls and/or engine
to engine operating parameters to safety system.
ensure proper wiring.
Initial energizing of the electrical
Switchgear Evaluation system with the circuit breaker
Switchgear is a necessary part should be coordinated with all on-
of distributing generated electrical site personnel.
power, as well as providing input Electrical Cables
to monitoring and control systems. Electrical cables between the
This equipment’s interaction and generator and the switchgear
possible detrimental effect on engine cabinets must be high-pot tested
and generator operation makes it prior to terminating. Review data
necessary to ensure that the system from tests and include in the
functions according to commissioning report.
specifications.
Ensure terminations have shielding
Consider the following when removed from ends prior to
evaluating switchgear systems. connecting.
Switchgear Cabinets Generator Protective Relays
Ensure that switchgear cabinets Ensure the generator protective
are properly vented and ventilation relay setting for both the
air is available. instantaneous and time-delay
Switches and controls not involved agree with the results of the relay
in daily operations should be coordination study of the system.
mounted inside the cabinets.
Control Voltage
Ensure that any high voltage A mixture of control voltages may
cabinet has Kirk-Key interlocks (or require multiple banks of batteries.
equivalent) to lock the cabinet and Ensure the appropriate charging
prevent accidental personnel method for the batteries is
contact. maintained.
Current and Potential Transformers Ensure the batteries are placed
Inspect the mounting and wiring of between the charger and the
all current and potential transformers controls to prevent the controls from
©2007 Caterpillar®
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
©2007 Caterpillar®
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
©2007 Caterpillar®
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
lubricator oil level (if air prelube 150 rpm is achieved, the
equipped). START/PRELUBE switch can
8. Ensure that the engine control be released from the start
system allows engine starting position. If not, the starters will
from the engine starting panel automatically disengage when
(local/remote) and the engine the engine reaches 170 rpm.
starting speed is at idle. 4. The engine should stabilize speed
9. Other engine support systems at low idle; typically 350 rpm.
or control systems must be Ensure gauge panel oil and fuel
prepared for the start of the pressure reach normal levels.
engine. This includes items 5. Inspect engine for any leaks
such as reduction gear prelube, and/or abnormal noises.
injector tip cooling, cooling 6. After assured of proper engine
systems, voltage regulator operation, adjust engine and
ON/OFF switch, idle/rated switch other control systems to increase
and external piping system valve engine speed/load to achieve
position check. normal operation.
10. Customer fuel piping to the
After Starting the Engine
engine should not be smaller that 1. Close the starting air shutoff
the inside diameter of the engine valve.
mounted inlet and return fuel
piping. Flexible connections must 2. After engine is started and
be used at both the fuel inlet and at rated speed and load, fuel
return, connecting the customer pressure should be between
piping to the engine mounted 800 to 840 kPa (116 to
piping. 121.8 psi). Fuel pressure
should be adjusted if not
Starting the Engine within tolerance using the
1. Put the engine fuel ON/OFF engine mounted fuel regulator.
switch to the ON position.
3. Monitor engine operating
2. Put the engine START/PRELUBE parameters every hour and record
switch in the PRELUBE position. on an appropriate log sheet.
The green indicator will be
4. Compare operating parameters
observed when prelube oil
recorded to specifications for
pressure reaches 7 kPa (1 psi).
normal engine operation on a
The engine can not be started.
daily basis. Monitor operating
It is a good idea to verify oil
parameter trends and take action
pressure on the gauge if time
when discrepancies are found.
is not a critical factor.
3. Move engine START/PRELUBE Stopping the Engine
switch to the START position 1. Reduce load on engine to zero.
while viewing the engine 2. Allow engine to operate for the
tachometer. When 130 to period of time necessary to
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Consist:
Engine Model: _____________ Engine Arrangement No.: ___________________
OT Specification No.: ______________ Serial No.: _________________________
Rating: ______________ bhp: _______ bkW:_______ @ ____________________
Engine Cooling System: Separate Circuit: ______ Combined Circuit: _______
Governor/Actuator: ______ Forward Acting: ______ Reverse Acting: ______
Heinzmann: ____ 3161: ____ Other: _______________________
Describe: __________________________________________________
High Idle: Specified: ______________ OT Specification: _________________
Low Idle: Specified: ______________ % Droop Specified: _______________
Fuel Used: Distillate: _________ Blended: _________ Residual: __________
Fuel (API): _______ Corrected Density: ______ (kg/L): _____ (lb/gal): _____
Fuel Treatment: Coalescing Filter:___ Centrifuge:___ Viscosity Control:___
Engine Coolant: Antifreeze: _____________ Corrosion Inhibitor: ____________
Oil to be used in engine: ________________________________________________
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
The following parties have discussed and agreed to the results and required
action during the design review process.
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
Noise / Emissions
Satisfactory
Unsatisfactory
Not Complete
Auxiliary Cooling
Satisfactory
Unsatisfactory
Not Complete
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
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Application and Installation Guide Diesel Engine Commissioning – 3600/C280
__________% Load
900
Actual
Series Description
Measured
Points
Comments: ____________________________________________________________
________________________________________________________________________
________________________________________________________________________
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Diesel Engine Commissioning – 3600/C280 Application and Installation Guide
Comments: ____________________________________________________________
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LEBW4985-01 ©2007 Caterpillar Printed in U.S.A.
All rights reserved.