Commissioning 3600c280

APPLICATION AND INSTALLATION GUIDE
DIESEL ENGINE
COMMISSIONING 3600/C280
Downloaded from www.Manualslib.com manuals search engine

Contents
Diesel Engine Commissioning 3600/C280.............................. 1

Design Review ................................................................... 3
Explanation of Design ..................................................... 3
Review Report ........................................................... 3
Caterpillar 3600/C280 Generator Set Design
Review Report ............................................................... 4
Design Review Results.................................................... 6
Construction Review ........................................................ 10
Explanation of Construction Review Report..................... 10
Caterpillar 3600/C280 Generator Set Construction
Audit Report ................................................................ 11
Construction Audit Results............................................ 13
Evaluation Guidelines........................................................ 17
Air Intake System Evaluation ......................................... 17
Combustion Air ........................................................ 18
Remote Mounted Air Cleaners ................................... 18
Air Inlet Ducting....................................................... 18
Filtered Engine Room Air ........................................... 19
Air Cleaner Provided by Others .................................. 19
Cooling System Evaluation ............................................ 19
Engine Cooling Circuits ............................................. 19
System Coolers........................................................ 20
Cooling System External Pressure Drop ...................... 20

Expansion Tank........................................................ 20
Cooling System Protection ........................................ 21
Central Cooling Systems ........................................... 22
External System Piping ............................................. 22
Corrosion Protection ................................................. 22
Heat Recovery ......................................................... 23
Cooling System Performance ..................................... 23
Starting System Evaluation ........................................... 23
Air Compressor ........................................................ 23
Air Receiver Tanks ................................................... 23
Air Supply Piping...................................................... 24
Engine Starters and Accessories ................................ 24
Alternate Forms of Starting ....................................... 24
Exhaust System Evaluation ........................................... 24
Exhaust System Warnings......................................... 25
Exhaust System Piping ............................................. 25
Distillate Fuel System Evaluation.................................... 26
Fuel Tanks............................................................... 26
Fuel Lines ................................................................ 26
Fuel Filters............................................................... 27
Fuel Coolers ............................................................ 27
Governors and/or Actuators .......................................... 27
Control System - ADEM III (C280 only) .......................... 28
Lubrication System Evaluation ....................................... 28
Engine Oil................................................................ 28

Engine Sump ........................................................... 28
Engine Prelube ......................................................... 29
Oil Pressure and Temperature .................................... 29
Mounting and Alignment Evaluation ............................... 29
Vibration Isolators .................................................... 29
Engine Base ............................................................. 30
Engine to Generator Alignment .................................. 30
Driven Equipment Evaluation ......................................... 30
Generator ................................................................ 30
Safety System Evaluation ............................................. 31
Engine Contactors .................................................... 31
Generator Safety Relays ........................................... 31
External Engine Support Systems............................... 31
Emergency Stops ..................................................... 31
Monitoring System ....................................................... 32
Generator Monitoring System (GMS) .......................... 32
Engine Operating Parameters ..................................... 32
Generator Operating Parameters ................................ 32
External Engine Support Systems............................... 32
Daily Log Sheet........................................................ 32
Ventilation System Evaluation ....................................... 33
Engine Room Ventilation ........................................... 33
Switchgear Room Ventilation..................................... 33
Serviceability Evaluation ............................................... 33
Engine Component Removal ...................................... 33

Engine Maintenance ................................................. 34
Reserved Work Area ................................................. 34
Spare Parts Storage.................................................. 34
Equipment Safety Evaluation ......................................... 34
Engine Room ........................................................... 34
Control Room .......................................................... 35
Generator Control Evaluation ......................................... 35
Generator Voltage Control......................................... 35
Generator Monitoring................................................ 35
Switchgear Evaluation .................................................. 36
Switchgear Cabinets................................................. 36
Current and Potential Transformers ............................ 36
Circuit Breakers........................................................ 36
Electrical Cables....................................................... 36
Generator Protective Relays ...................................... 36
Control Voltage........................................................ 36
Paralleling Operations ............................................... 37
Operation and Maintenance Evaluation ........................... 37
Engine Operation and Maintenance ............................ 37
Engine Support Equipment ........................................ 37
Mechanical Training.................................................. 37
Maintenance Contracts ............................................. 37
Crankcase Ventilation System Evaluation........................ 38
Crankcase Breathers ................................................. 38
Crankcase Ventilation Piping ..................................... 38

Startup & Shutdown Procedure ..................................... 38
Before Starting the Engine......................................... 38
Starting the Engine ................................................... 39
After Starting the Engine........................................... 39
Stopping the Engine ................................................. 39
Caterpillar 3600/C280 Generator Set Commissioning Report 41
Analysis of Test Data & Physical Systems ...................... 43
Engine Performance Data .............................................. 47
Engine Instrument Panel & Generator Control Panel
Instrument Readings ..................................................... 48

Foreword
This section of the Application and Installation Guide generally describes
the commissioning of the Caterpillar 3600/C280 engine. Additional engine
systems, components and dynamics are addressed in other sections of this
Application and Installation Guide.
Engine-specific information and data is available from a variety of sources.
Refer to the Introduction section of this guide for additional references.
Systems and components described in this guide may not be available or
applicable for every engine.
Information contained in this publication may be considered confidential.

Discretion is recommended when distributing. Materials and specifications
are subject to change without notice.
CAT, CATERPILLAR, ADEM, their respective logos and Caterpillar Yellow,

and the POWER EDGE trade dress, as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used without
permission.
2007 Caterpillar
All rights reserved.

Application and Installation Guide Diesel Engine Commissioning 3600/C280
Diesel Engine Commissioning 3600/C280

A well-planned engine installation will aid reliability, performance, and
serviceability. To be successful, the installation designer must be aware
of the application and installation requirements for Caterpillar 3600/C280
engines. As a first step, the designer should be aware of all pertinent
Caterpillar reference publications, including the additional sections of this
Application and Installation Guide, as well as other information available
from the Caterpillar 3600/C280 family of engines.
SECTION CONTENTS
Design Review .................... 3 Control System -

Explanation of ADEM III (C280 only)
Design Lubrication
Caterpillar System Evaluation
3600/C280 Generator Set Mounting
Design Review Report System Evaluation
Design Review Driven
Results Equipment Evaluation
Construction Review...........10 Safety System
Explanation of Evaluation
Construction Review Report
Ventilation
Caterpillar System Evaluation
3600/C280 Generator Set
Serviceability
Construction Audit Report
Evaluation
Construction
Equipment
Audit Results
Safety Evaluation
Evaluation Guidelines ..........17
Generator
Air Intake
Control Evaluation
System Evaluation
Operation &
Cooling System
Maintenance Evaluation
Evaluation
Crankcase
Starting System
Ventilation System Evaluation
Evaluation
Startup &
Exhaust System
Shutdown Procedure
Evaluation
Caterpillar 3600/C280
Distillate Fuel
Generator Set Commissioning
System Evaluation
Report.............................. 41
Governor and/or Analysis of Test
Actuators Data & Physical Systems
2007 Caterpillar
All rights reserved. Page 1

Engine Control Panel Instrument
Performance Data Readings
Engine
Instrument Panel & Generator

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

Diesel Engine Commissioning 3600/C280 Application and Installation Guide
Caterpillar 3600/C280 Generator Set Design Review Report

General:
Selling Dealer: ________________ District or Subsidiary: ___________________
Servicing Dealer ________________________________________________________
Equipment Suppliers and Contractors: ____________________________________
Customer: _____________________________________________________________
Address: _______________________________________________________________
Application: Prime Power: _______ Continuous: _______ @ ________% load
Peak Shaving: _______ Standby: _______
Expected Annual Operating Hours: _______________________________________
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: ________________________________________________
Engine Site Conditions: Elevation: _______________________________________
2007 Caterpillar
Page 4 All rights reserved.

Typical Ambient Temperature range for the year: ___________ to ___________

Types of Cooling: Radiator: ______________ Cooling Tower: _______________
Typical Powerhouse Temperature Range: _______________ to _______________
Atmospheric conditions: Typical Relative Humidity Level: ________________%
Air Quality: Salty: ____________ Dusty: ____________ Clean: _____________
Application Summary:___________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
The following parties have discussed and agreed to the results and required
action during the design review process.
Field Engineer Signature: ______________________________ Date: __________

Builder/Installer Signature: _____________________________ Date: __________
Owner Signature: _____________________________________ Date: __________
2007 Caterpillar

Design Review Results

Design Compliance with 3600/C280 Engine
System
Requirements
Air Intake
Satisfactory
Unsatisfactory
Cooling
Satisfactory
Unsatisfactory
Starting
Satisfactory
Unsatisfactory
Exhaust
Satisfactory
Unsatisfactory
Fuel
Satisfactory
Unsatisfactory
Lubrication
Satisfactory
Unsatisfactory
2007 Caterpillar


System
Requirements
Engine Mounting
Satisfactory
Unsatisfactory
Driven Equipment
Satisfactory
Unsatisfactory
Safety and Alarms
Satisfactory
Unsatisfactory
Engine Monitoring
Satisfactory
Unsatisfactory
Ventilation
Satisfactory
Unsatisfactory
2007 Caterpillar


System
Requirements
Serviceability
Satisfactory
Unsatisfactory
Equipment Safety
Satisfactory
Unsatisfactory
Generator
Controls
Satisfactory
Unsatisfactory
Switchgear
Satisfactory
Unsatisfactory
Operation and
Maintenance
Satisfactory
Unsatisfactory
2007 Caterpillar


System
Requirements
Crankcase Ventilation
Satisfactory
Unsatisfactory
Noise/Emissions
Satisfactory
Unsatisfactory
Auxiliary Cooling
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
2007 Caterpillar

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

Caterpillar 3600/C280 Generator Set Construction Audit Report

General:
Customer: _____________________________________________________________
Address: _______________________________________________________________
Application: Prime Power: _______ Continuous: _______ @ _________% load
Consist:
Rating: ______________ bhp: _______ bkW:_______ @ ____________________

Heinzmann: ____ 3161: ____ Other: _______________________
Describe: __________________________________________________
2007 Caterpillar


________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

2007 Caterpillar

Construction Audit Results

System
Requirements
Air Intake
Satisfactory
Unsatisfactory
Cooling
Satisfactory
Unsatisfactory
Starting
Satisfactory
Unsatisfactory
Exhaust
Satisfactory
Unsatisfactory
Fuel
Satisfactory
Unsatisfactory
Lubrication
Satisfactory
Unsatisfactory
2007 Caterpillar


System
Requirements
Engine Mounting
Satisfactory
Unsatisfactory
Driven Equipment
Satisfactory
Unsatisfactory
Safety and Alarms
Satisfactory
Unsatisfactory
Engine Monitoring
Satisfactory
Unsatisfactory
Ventilation
Satisfactory
Unsatisfactory
2007 Caterpillar


System
Requirements
Serviceability
Satisfactory
Unsatisfactory
Equipment Safety
Satisfactory
Unsatisfactory
Generator
Controls
Satisfactory
Unsatisfactory
Switchgear
Satisfactory
Unsatisfactory
Operation and
Maintenance
Satisfactory
Unsatisfactory
2007 Caterpillar


System
Requirements
Satisfactory
Unsatisfactory
Noise/Emissions
Satisfactory
Unsatisfactory
Auxiliary Cooling
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
Satisfactory
Unsatisfactory
2007 Caterpillar

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

Combustion Air to allow appropriate service intervals

Air inlet temperature to engine for the filter elements.
should not exceed 49C (120F). The air cleaner housing must be
Is the quantity of air available for mounted in a position that will not
combustion sufficient? This requires allow recirculating exhaust gases,
approximately 0.1 m/min/bkW crankcase fumes, rain or sea spray
(2.5 ft of air/min/bhp) for engines to mix with the combustion air.
using distillate fuel. Heavy fuel The air cleaners should draw
engines may require 30 to 40% outside air through the elements and
more for proper component use air ducting to the turbocharger
temperatures. inlet.
The engine room or enclosure In cold climates, the air cleaner
should not experience negative can be subjected to filter icing when
pressure if combustion air and mounted outside of the engine room.
ventilation air are from the same Consider the year-round conditions
source. at the site and insure provisions are
For extremely cold climates, an available for the engine to receive
alternate warm filtered air source filtered inlet air during all periods of
should be available for starting the engine operation.
engine.
Air Inlet Ducting
Remote Mounted Air Cleaners No rivets or mechanical fasteners
Air cleaner elements must be can be used in the construction of
accessible for periodic maintenance. the ducts. The intake air ducting
The air cleaner elements must be must be clean and free of any weld
mounted in the housing to assure slag, debris, rust or corrosion prior
the engine does not ingest foreign to operating the engine. This must
material due to incorrect positioning. be inspected prior to initial startup.
The air cleaner housing air outlet The interior surface of the intake
must have flexible transition attaching ducting must be protected from
the air inlet ducting. Double band future rust and corrosion due to
clamping at each end of the flex is intake air quality.
required to assure non-filtered air The intake air piping must have
does not enter the ducting. long gentle radius bends (2 x Dia =
The air cleaner housing must have Radius) and generous straight
surface protection when subjected lengths if a single straight length
to a harsh environment such as salty from the air cleaner housing is not
atmosphere. possible.
Air inlet restriction is The diameter of the intake ducting
recommended not to exceed must be the same or larger than the
381 mm H2O (15 in H2O). New, air cleaner housing outlet and the air
clean systems should be near inlet adapter for the turbocharger.
127 mm H2O (5 in H2O) restriction Any abrupt changes must be
2007 Caterpillar

avoided, see Air Intake System airflow and contamination

of the 3600 EPG Application & containment requirements to
Installation Guide for more protect the engine from shortened
information on air inlet ducting. component life. This requires prior
The air inlet restriction created factory approval.
by the ducting must be minimal
Cooling System Evaluation
to allow normal service intervals
A cooling system evaluation for
for the air cleaner elements.
the 3600/C280 engines must
Air inlet ducting must not be rigidly include engine operating parameters,
mounted to the air cleaner housing external system piping, water quality
or to the turbocharger inlet. Flexible and external cooling components. A
non-metallic connections must be properly controlled cooling system is
used between the ducting of both essential for satisfactory engine life
the air cleaner housing and the and performance. Defective cooling
turbocharger. The turbocharger systems and careless maintenance
must not support the weight of the are a direct cause of many engine
ducting. Also, there must be double failures. Consider the following
band clamping to insure non-filtered when evaluating the engine cooling
air does not enter the engine. system.
Observe the proximity of the Engine Cooling Circuits
exhaust piping and the air intake Water flow from the left side
ducting. Ensure there is no heat pump (viewed from the rear) is
transfer between the two sets of split between the aftercooler and
piping. If evident, insist either or oil cooler. Flow balance orifices
both are insulated to protect both are used on the outlet of both
air inlet temperature and the non- components. Ensure these orifices
metallic connections. are in place.
Air inlet ducting must be inspected The right-hand pump (viewed from
for leaks during engine operation. the rear) supplies water to the jacket
Filtered Engine Room Air water system. Ensure the orifice(s)
An air intake silencer can be are in place.
used at the turbocharger inlet The two-pump design can be
if combustion air supplied to the used as either a combined or
engine room is properly filtered. separate circuit cooling system.
If an intake silencer is remote The temperature of the water is
mounted, the same requirements always inlet controlled. During
apply for ducting to the turbocharger performance testing of the engine,
inlet as in the case of a remote ensure the appropriate inlet water
mounted air cleaner housing. temperature is being supplied to
both circuits and the temperature
Air Cleaner Provided by Others
rise of the water is within specified
Air cleaners not provided by
limits.
Caterpillar for the engine must meet
2007 Caterpillar

System Coolers Cooling System External Pressure

3600/C280 generator sets have Drop
the coolant water cooled by various Regardless of the type of cooler
means. The most common are used, the external system resistance
radiators. Others include heat in the piping and through the cooler
exchangers and cooling towers. must be adjusted to a specification
It is the user/installers based on the rated speed of the
responsibility to provide proper engine and full flow to the external
venting and isolation of the cooler system. Circuits with thermostats
for required maintenance or repair. must be replaced with blocked open
thermostats (for adjustment only) to
If an open cooling tower system
allow full flow.
is used, insure the water from the
cooling tower does not enter the The inlet and outlet pressure of the
engine. Debris collected by the coolant must be measured as close
water from the atmosphere can be to the engine as possible to obtain
detrimental to water pumps and be a correct external system resistance.
deposited in the engine. Consider Customer piping must have
the cooling tower water as raw monitoring ports added for this
water and configure the engine measurement.
cooling circuits as a closed-loop Ensure the flow control orifice is
system using a heat exchanger. positioned in the outlet line(s) from
It is the user/installers responsibility the engine to the cooler. A lockable
to ensure sufficient make up water plug valve is preferred, but a plate-
to the cooling tower. type orifice or other adjustable
Note: Raw water should be good valves are permitted. It is important
quality and treated with chemicals to maintain the external system
to prevent heat exchanger fouling. resistance at the specified value.
Refer to the Cooling System section
When not practical to route vent
of the 3600 Application &
lines long distances to a common
Installation Guide.
venting point, an APCO air release
valve, Model 200AB.3, or equivalent Expansion Tank
is recommended. It has a cast iron The water level in the expansion
body and stainless steel trim. The tank should be at the highest point
cover includes a 1/2 inch NPT plug in the cooling system to allow proper
that should be removed for venting during initial filling of the
installation of a nipple and ball system. This will also provide a
allowing rapid venting during initial single fill point for the cooling
fill of the system. The air release system.
valves internal diaphragm collects If the expansion tank is not the
entrained air and automatically highest point in the system, it is the
releases it to atmosphere during user/installers responsibility to
operation. provide an auxiliary expansion tank
at the highest point in the system.
2007 Caterpillar

The auxiliary tank must be temperature alarm and shutdown

interconnected with the expansion contactors according to atmospheric
tank to provide complete venting conditions to ensure adequate
of the system. engine protection.
Any other cooling system If a non-Caterpillar expansion tank
component should have vent lines or a shunt style cooling system is
run to the auxiliary tank or must be provided for the engine, a complete
vented independently. test must be done complying with
Initial filling of the system must requirements listed in LEKQ7235,
be done at a rate so that complete Cooling System Field Test, EDS
venting of the cooling system can 50.5.
occur. Always be ready to add a Cooling System Protection
supplemental volume of water to Protecting the engine from cooling
system at initial start-up in case air system problems is imperative.
has been trapped in the system. Ensure the engine is equipped with
The Caterpillar expansion tank is the following, and the projection
provided with a 48.3 kPa (7 psi) system functions according to
pressure cap. During testing and specification.
adjusting the external system
High jacket water
resistance, the pressure cap must
temperature alarm and
be removed. Install the pressure
shutdown
cap prior to the engine performance
testing under load. High oil
temperature alarm and
When altitude becomes a
shutdown
consideration for the boiling point
of water, ensure that the standard Jacket water
pressure cap is adequate to prevent pressure alarm and shutdown
coolant boiling below the alarm High air inlet
and/or shutdown protection settings. manifold temperature alarm
For example, a jacket water Low water level
temperature shutdown would require alarm
a 51.7 kPa (7.5 psi) cap at sea level
to maintain 104 C (219F) setting. It is the user/installers
responsibility to provide additional
At 3048 m (10,000 ft), the pressure
pressure and temperature gauges
cap would only provide the
and alarms in the external system
equivalent of 27.6 kPa (4 psi) and
the boiling point of water is reduced for the operators to monitor daily.
to approximately 93 C (200F). Detection of a developing cooling
The shutdown setting would not system problem can prevent an
unscheduled shutdown of the engine
protect the engine. A 96.5 kPa
or an operation alarm condition.
(14 psi) cap would be required.
If an expansion tank pressure cap
is not used, adjust water
2007 Caterpillar

Central Cooling Systems drop across the strainer can be

Cooling multiple engines from monitored. Excessive pressure
a common system is not drop can cause improper coolant
recommended. A devoted cooler flow to the engine. The same
for each engine is preferred. procedure should be followed for
If a central cooling system is permanent strainers as described
required for the installation, ensure for temporary strainers during initial
that the system performance is engine operation. At maximum flow
evaluated with the maximum heat condition, any clean strainer should
rejection possible from all engines have maximum capacity to create no
being cooled from the system. more than 10 - 14 kPa (1.5 -
Since every system, application 2.0 psi) pressure drop when clean.
and installation is unique, Caterpillar External piping must be isolated
approval is required. from the generator set. The
recommended flexible couplings are;
External System Piping
(4P5906) for 4 in. pipe, (4P5905)
The external system piping must
for 5 in. pipe and (4P5907) for
be clean and free of weld slag and
6 in. pipe. The couplings should be
other debris that can be detrimental
installed between the point of piping
to engine components.
support on the generator set and the
Inspect cooling system piping prior closest external piping support to
to the initial filling of the system. the engine.
If debris is found, insure the piping
is cleaned before filling the system. Corrosion Protection
Ensure Caterpillar guidelines
Install temporary strainers at the
established for water quality are
engine in the coolant inlet line(s)
followed precisely. These guidelines
prior to initial engine operation.
are published by Caterpillar and
Operate the engine at no-load and
available in the standard publication
rated speed for at least 15 minutes.
system. Two sources for information
Remove the strainers and check for
are:
debris. If debris is found, install the
strainers and repeat the operation. LEBV0915,
Continue this procedure until no Engine Installation and Service
debris is found in the screen. Do Handbook
not adjust external system SEBD0970,
resistance with the strainer installed. Coolant and Your Engine
The temporary strainers are available Ensure the proper quality of fresh
from Caterpillar for 4 in. (4C9045), water is installed in the system. Also
5 in. (4C9046) and 6 in. (4P9047) ensure that the water is properly
pipe. treated with corrosion inhibitor.
If a permanent strainer in the If ambient conditions require anti-
coolant inlet lines is provided by freeze to be used, ensure only low
the user/installer, ensure pressure silicate anti-freeze is installed.
2007 Caterpillar

Ensure that the Cooling System and producing a schematic of that

Test Kit (8T5296) is used to system. The schematic should
evaluate the concentration of indicate all the system flow paths,
corrosion inhibitor in the system. test and monitoring points, and
Excessive concentrations are as external system components.
detrimental to the engine as Include the system schematic as
insufficient concentrations. an attachment to the commissioning
Heat Recovery report.
Recovering heat from the engine Assign 900 series description
coolant can improve the efficiency numbers to each of the test and
of the operation, but can also be monitoring points and record on
detrimental to the engine if not the commissioning report test sheet.
designed and installed properly.
Ensure any external temperature Starting System Evaluation
regulators for the cooling system Air starting, either manual or
do not, in any way, inhibit operation automatic, is the typical starting
and temperature control of the system for 3600/C280 generator
engine temperature regulators. sets, but indeed not the only
system. The components of this
Ensure external heat recovery system or any other system can
components do not contribute have a significant affect on the
excessive resistance to the coolant life of the starters. Consider the
flow. following when evaluating a starting
Inlet temperature control at the system.
engine is many times misunderstood
Air Compressor
during the design of the system.
The air compressor must be sized
Ensure that the water temperature
to match the air receiver tank(s)
returning to the engine has been
make-up rate due to starting. Also
cooled sufficiently to achieve the
consider generator set site for
required coolant temperature at the
altitude and air density.
engine pump inlet(s). Very simply,
for the jacket water system, 1/3 of An air dryer on the compressor
the flow at 95C (203F) cannot be outlet is suggested to prevent water
mixed with 2/3 of the flow at 90C vapor in the air from freezing if
(194F) and achieve 90C (194F) expanded below 0C (32F).
coolant temperature into the engine Air Receiver Tanks
jacket water system. Ensure the air receiver tanks
Cooling System Performance are sized to provide the required
The complexity of the external consecutive engine starts without
cooling system, which may include depletion of air pressure below the
heat recovery and/or some other minimum starting pressure.
cooler, is best understood by Receiver tanks must have manual
reviewing the installed system or automatic drains to allow oil and
2007 Caterpillar

water condensate to be drained daily deposits or debris out of the pipe

to prevent damage to the starters. to prevent ingestion into starters.
Operators must be informed of this Engine Starters and Accessories
requirement. The starter lubricator should be
Receiver tanks should have manual adjusted during the initial starting
or automatic drains to allow oil and of the engine to limit slobber of
water deposits to be drained daily starter lubricant at the starter air
to prevent damage to the starters. outlet.
Operators must be informed of this Care should be taken when
requirement. starting the engine so the starter
Receiver tanks must meet silencer discharge does not endanger
specific characteristics, such as personnel safety. If the discharge is
the specifications of the American directed toward any potential
Society of Mechanical Engineers occupied area, provide shielding
(ASME). Ensure each receiver tank between the starter and the area
has been tested at 1.5 times the in question.
normal working pressure unless local
Alternate Forms of Starting
codes require some greater value.
There may be situations when
Set the tank relief valve pressure
electric starting or turbine air
at a level below the test pressure.
starters are provided on the engine.
Receiver tanks must be equipped Each should be treated in a similar
with a maximum pressure relief manner as the standard air starting
valve and a pressure gauge. These system.
should be monitored periodically
Electric starters must have enough
to assure proper operation.
battery potential to complete the
Air Supply Piping consecutive starts required without
Piping should be sized to provide overheating the cables or starters.
a minimal pressure drop of supply air Turbine air starters also require
from the receiver tank to the engine multiple start demonstration. Ensure
starters. Piping should not be smaller air capacity is available for this
than the connection at the engine. activity.
Piping should be routed so that
water vapor and oil deposits collect Exhaust System Evaluation
at a trap in the lowest point in the The exhaust system for
piping. The trap should be drained 3600/C280 engines must be
daily. Operators must be informed evaluated from the exit of exhaust
of this requirement. gases from the turbocharger to the
Prior to initial start-up of the atmospheric conditions existing at
engine, disconnect the air piping the muffler outlet. Fuel consumption
from the engine and allow controlled and engine component life are
air to blow any water vapor, oil affected by a non-designated or
incorrectly installed exhaust system.
2007 Caterpillar

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

between expansion joints and rigid condensation with temperature

supports. changes.
The exhaust piping routing must Fuel tanks vented to atmosphere
not interfere with the service of the must have some form of flame
engine. Pay particular attention to arrester in the vent opening to
the use of an overhead bridge crane. prevent possible flames from
A point for measuring exhaust entering or exiting the tank.
system backpressure should be in The outlet opening in the tank vents
a straight length of the exhaust pipe should have a fine mesh screen to
at least 3 to 5 pipe diameters away act as a flame arrester as a minimum
from the last size transition change precaution. Other forms of flame
from the turbocharger outlet. arresters may be used. Also ensure
System backpressure measurement that the vent opening is never left
is part of the engine performance totally open to the atmosphere.
testing. The fuel supply piping should draw
fuel from at least 50 mm (2 in.)
Distillate Fuel System above the bottom of the tank.
Evaluation The fuel return to the day tank
Clean fuel meeting Caterpillar should enter at the top and opposite
fuel recommendations provides the supply end of the tank.
outstanding engine service life and
performance; the use of lesser fuels The tank drain must be able to
is the users responsibility. To assure drain the complete contents of the
the engine is receiving good, clean tank as well as being used as a
sediment drain.
fuel, the entire system must be
evaluated from the fuel storage tank Fuel Lines
to the engine. In addition to the fuel Galvanized fittings or piping must
being consumed, the system is not be used in any portion of the
considered to include the controls lines.
for fuel to the engine. The governor Fuel line size and length must
control system should be described conform to the fuel transfer pump
along with pertinent information inlet restriction limit and the
concerning the governor interaction maximum fuel return restriction.
with the engine operation. Consider The inlet restriction must not exceed
the following when evaluating the 39 kPa (5.7 psi) and the fuel return
fuel system. line restriction must not exceed
Fuel Tanks 350 kPa (51 psi). These values
The fuel level in the tanks should should be measured and recorded.
be maintained as full as possible at Note that these requirements are
all times. The rise and fall of fuel independent of each other and
level can pull moist air into the tank should not be combined in any
through the vent, leading to water evaluation.
2007 Caterpillar

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 40C (100F), on the ball head can cause engine
with distillate fuel. overload if a paralleled unit goes
2007 Caterpillar

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

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 - 85C checking alignment of the engine
(180 - 185F). 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/installers
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 tanks 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

Adjust snubber bolt tightness Record the final alignment

during normal generator set measurements and include the
operation to ensure proper vibration measurements as an attachment
dampening to match the installation to the commissioning report.
site requirements. Check the crankshaft endplay and
Note: Tightening snubber bolts crankshaft deflection. Include the
greater than finger tight reduces measurements as an attachment
isolator efficiency. It is normal for to the commissioning report.
engine motion to increase during A vibration signature must be
startup and shutdown. Should this taken on each generator set.
motion be intolerable, tighten Record the readings and include
snubber bolts slightly; remember, as an attachment to the
for maximum durability of the commissioning report.
isolators, some clearance is required.
Note: System piping or any support Driven Equipment Evaluation
stands should not be located in front Driven equipment for the
of base-mounted vibration isolators; 3600/C280 engines have been
this will prevent access to isolators selected based on the particular load
for serviceability. profile of the site necessary to be
compatible with the total system.
Engine Base Driven equipment can be in many
If generator and/or engine have configurations, but each must be
been removed during shipment, evaluated according to the external
ensure engine, coupling and distribution system requirements.
generator mounting bolts are When more than one generator is
properly torqued prior to alignment involved in the driven equipment,
checks. each must be described in the
Ensure flexible connectors are commissioning findings report.
used between the generator set and Consider the following items while
external system components rigidly evaluating the driven equipment.
mounted off the package.
Generator
Engine to Generator Alignment Record the serial number of the
Ensure that the engine and generator and other appropriate data
generator are properly aligned by relating to the voltage and generator
taking bore and face dial indicator capacity.
readings. The engine must be
prelubed before the appropriate Ensure that the generator space
alignment procedure can begin heaters have been operational
for either single or two-bearing several days prior to the anticipated
generators. start-up date. To be effective in
many situations, covering the air
Make necessary adjustments to inlet and outlet screens on the
the alignment prior to starting the generator may be necessary.
engine.
2007 Caterpillar

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

The stop buttons must be guarded meter is required to monitor

from accidental personnel contact, operating time.
but accessible by trained personnel Generator Operating Parameters
in case of an emergency in the The user is responsible to ensure
engine room and the control room. that the generator output can be
Monitoring System properly monitored to allow
Monitoring the generator set correlation with other data and
requires periodic readings of gauges to monitor electrical production.
and readouts during a 24-hour The user is responsible for
period to ensure all the systems monitoring generator winding
are operating normally. Consider and bearing conditions.
the following when evaluating a External Engine Support Systems
system for monitoring generator The user is responsible for
set operation. providing gauges and/or
Generator Monitoring System (GMS) instrumentation to monitor operation
3600/C280 EPG packages of the external engine support
equipped with GMS should have systems. These should include but
sensors checked and calibrated are not exclusive to the following:
before the engine is put into service. Fuel day tank site
These sensors include transmitters, glass
resistive temperature devices,
Oil storage tank
thermocouples, jacket water
site glass.
detectors, oil mist detectors,
contactors and thermocouples. Water
Refer to RENR2491 for testing temperature to and from
and calibrating. external cooler. This may
include radiators, heat
Engine Operating Parameters exchangers or cooling towers.
Gauges and instrumentation,
whether on the engine gauge panel When strainers
or mounted by user/installer on the are permanently installed before
external systems, should give the pump inlets, monitor pump
accurate readings of operational inlet pressure for condition of
parameters for the oil, water, fuel, strainers.
air and exhaust systems for the Daily Log Sheet
engine. The user is responsible to provide
Periodic maintenance of oil, fuel a log sheet to record all gauge and
and air filters is based on differential instrumentation readings periodically
pressure as well as hours. Ensure by operators and/or automatic
differential pressure gauges or monitoring system.
restriction indicators are provided The user is responsible for
to monitor filter condition. An hour maintaining trained personnel
capable of recognizing operational
2007 Caterpillar

changes in a monitored parameter, dead air space for any detrimental

and be aware of the effect the effect from the temperature rise.
change may have on engine Require corrections if necessary.
operation. Engine room pressure should not
become excessively negative.
Ventilation System Evaluation
This would indicate a shortage
The heat radiated from generator
of ventilating air or excessive
sets and switchgear can cause the
ventilating fans if equipped.
site temperature to rise. This can
adversely affect personnel as well Switchgear Room Ventilation
as generator set and switchgear Cool, dry ventilating air should
performance. Ideally, clean, cool flow across the switchgear cabinets
air should be supplied to switchgear to remove the radiated heat created
rooms and engine rooms and flow during generator set operation.
across and around the equipment Switchgear room pressure should
to carry the radiant heat out of the not be negative. This would indicate
engine room. a shortage of ventilating air.
Consider the following when
evaluating the ventilation system. Serviceability Evaluation
Well-designed engine rooms
Engine Room Ventilation include features contributing to the
Ventilating air should enter near serviceability of the engine(s) and
the floor of the engine room and support equipment. These features
then flow upward around the engine can include an overhead lifting,
before exiting above the engine. push carts, component storage and
Building ventilation should be cleaning, and building equipment
designed to bring the coolest air to arrangement along with the required
the generators or driven equipment. tools.
If the building has a pitched roof, Consider the following for the
ventilating air should flow out at the evaluation of serviceability.
peak or near the top of the gable
Engine Component Removal
ends. The source of the air must be Overhead and side clearance must
low in the room and rise across the be provided around the engine for
engine or generator set and other major component removal and use
equipment. of necessary tools. Unfortunately,
For personnel comfort, maintain at the time of commissioning, it may
air velocity at 1.5 m/sec (5 ft/sec) be too late to change the
in areas of heat sources or areas configuration in some cases.
exceed 38C (100F). Overhead lifting equipment must
Potential dead air spaces should be be provided. Most all major engine
checked for temperature rise during components are heavier than one
engine operation. Check all electrical person can safely lift. Review the
and mechanical equipment in the overhead features for multi-direction
2007 Caterpillar

motion. Most engine component parts or tools that would impair

removal involves at least two- scheduled maintenance or repair.
direction motion for removal.
Equipment Safety Evaluation
Multiple engine installations should
The commissioning engineer must
be arranged to use the same
be able to recognize a safe operating
overhead lifting equipment without
environment. The entire system
major disassembly of piping or
operation must be reviewed to
ducting.
provide operator safety during any
Equipment should be available for normal or abnormal situation.
engine component movement to and
from the engine room.
evaluating the safety of operating
Engine Maintenance systems.
The generator set installer is
Engine Room
responsible for providing an engine
Hot engine water pipes should
service platform to perform all
be shielded or guarded to prevent
periodic maintenance functions.
operator contact.
This should consider all daily
inspections and activities including All generator drive components
an engine overhaul. and damper guards must be in place
prior to operating the engine.
Overhead and/or side clearance
and a platform must be provided for All floor openings in the engine
servicing all periodic maintenance room must be covered with plating
components. For example, changing or grating.
air, fuel or oil filters and setting Chains and hooks on overhead
valve lash. lifting equipment must not endanger
Reserved Work Area personnel.
A work area should be provided in Floors must be cleaned of any
the engine room for disassembly and debris or liquid spills.
cleaning of engine components and Engine heat shields must be in
other engine support equipment. place prior to operating the engine.
The area must have overhead
Remote emergency system stops
lifting capacity sized for the largest
must be guarded, but must operate
component to be placed in this area.
during a safety simulation.
Spare Parts Storage Test fire suppression systems prior
Reserve an area for storage to allowing normal operation. If this
of spare parts and tools for all has already been completed, verify
equipment in the engine room. a certificate of system operation
The parts and tools should be exists.
inventoried to insure ready access
during a repair. Ensure the area can Independently test all emergency
be locked to prevent the loss of stops for the engine while operating
at no load.
2007 Caterpillar

Check engine room noise levels specific application requirements

in normal operating areas and during the evaluation.
compare to general rules or local Generator Voltage Control
specifications. Include this data The voltage regulator must have
in the commissioning report. the voltage droop adjusted to be
Control Room compatible with the system and/or
Ensure that the control system with other generator sets being
meets local fire protection codes. paralleled to provide electrical power
Ensure that control room onto a distribution buss.
emergency stops are guarded For paralleled generator sets,
to prevent accidental contact. cross-current compensation is
Ensure that all high voltage necessary.
equipment and cabinets are Ensure automatic voltage control
inaccessible via locks and/or systems have manual control that
cages with locks. can be operated if problems develop
Ensure Kirk-Key interlocks with the automatic control.
are available for the appropriate Although not required, monitoring
switchgear cabinets. exciter DC voltage is a common
Check control room noise levels gauge to detect any diode or surge
and compare to general rules or local suppressor problem in the exciter.
specifications. Include this data in Ensure the gauge is operating
the commissioning report. properly, if provided.
Several different voltage regulators
Generator Control Evaluation are supplied for specific applications.
Control of generator output is Volts-per-Hertz, constant voltage
imperative to maintain the residential and the combination of both
and/or commercial customers during functions are available. Ensure that
prime power operations. The the regulator output to the generator
generator sets in severe climates are provides the correct system voltage
extremely important to provide life and voltage response to load
support power. Standby generator changes.
sets can also be applied in both of
If a constant voltage regulator is
the above situations. It is not
used, ensure that the excitation
typically the responsibility of the
circuit can be turned off before the
commissioning engineer to make
engine is started and ramped up to
these systems operate according to
speed, or is stopped and ramped
required specifications, but to ensure
down in speed. Operating at other
the systems are compatible with the
than synchronous speed can be very
design requirements.
detrimental to the voltage regulator.
Consider each of the following
items during the evaluation and the Generator Monitoring
Generators are supplied with either
10 Ohm or 100n Ohm RTDs
2007 Caterpillar

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 equipments 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

receiving voltage spikes or stray Engine Operation and Maintenance

currents from the battery charger. Ensure each operator is introduced
to the maintenance guide for the
Paralleling Operations
engine and each of the topics
Protect manual paralleling
explained. This may require the
operation against out-of-phase
presentation to be given several
engagement of the circuit breaker.
times to match the shift work of the
A synch check relay and SPM
operators. Coordinate the effort with
synchronizer are typical components
the appropriate operating supervisor.
to provide this protection.
Ensure instruction is given for
Auto paralleling is typically
starting and stopping the engine.
controlled by an SPM synchronizer;
Include a demonstration at the
both engine speed and generator
engine and allow each operator to
voltage, or just engine speed, can
observe and follow the directions
be controlled. If voltage control is
given. Follow the procedure outlined
not included, the system voltage
in the starting system evaluation
must not vary more than the voltage
section.
regulator compensation capability
with a closed circuit breaker. The servicing dealer is responsible
for providing appropriate forms and
Parallel generators must have the
records keeping information.
same pitch to prevent harmonics
creating current flow on the neutral Engine Support Equipment
side of the system. Use a neutral Review the list of equipment
ground resistor if neutral currents suppliers that will be on-site during
exist. commissioning. If the representative
is going to be on-site, ensure they
Operation and Maintenance are prepared to train operators.
Evaluation
Mechanical Training
Operation and maintenance
Operators and maintenance
training for operators designated
personnel should be trained to make
to be involved in the operation
minor repairs if needed; or provide
and/or maintenance of 3600/C280
assistance to the dealer mechanic
generator sets, and the associated
while making a repair.
support equipment, is an important
factor in achieving dependable Maintenance Contracts
generator set operation. The Review any maintenance contract
commissioning engineer should to ensure all maintenance and repair
be prepared to give this training responsibilities are defined for each
on the generator set. activity. Also, understand and record
Consider the following when the duration of the contract. Ensure
responsible personnel are properly
evaluating how well operation and
trained to perform their respective
maintenance will be completed.
functions. If a training deficiency is
found, take corrective action.
2007 Caterpillar

Crankcase Ventilation System The outlet should be configured

Evaluation to collect oil droplets prior to fumes
Normal combustion pressures of exiting the piping.
an internal combustion engine cause If piping rises from the engine, a
a certain amount of blow-by past trap must be installed to collect any
the piston rings into the crankcase. condensation or oil droplets before
These crankcase fumes must be they re-enter the breathers.
piped away from the engine to Crankcase fumes must never be
atmosphere. discharged in the engine room.
evaluating crankcase ventilation Startup & Shutdown Procedure
systems. The following procedure is
intended to serve as a guide for:
Crankcase Breathers
3600/C280
Crankcase breathers can be
arranged in several positions engine startup procedures
to match the best piping routing Design
away from the engine. Ensure consideration of the engine
that breather connections can be control systems
easily disconnected for scheduled Before Starting the Engine
maintenance. 1. Check coolant level in expansion
Crankcase Ventilation Piping tank site glass.
Generally, piping of the same 2. Check crankcase oil level using
size as the breather outlet is suitable the engine dipstick. Be sure to
unless the length and or bends use the side marked Engine
cause excessive restriction and Stopped Cold Oil.
a false crankcase pressure
3. Assure all protective guards are
measurement.
in place and the barring device
Note: See the Ventilation section disengaged.
of the 3600 EPG Application &
4. Open and close drain valve on
Installation Guide for additional
the bottom of the starting air
information on pipe sizing
tank and fuel day tank to drain
requirements. Consideration
condensation and sediment from
must be given to the blow-by
bottom of tanks.
requirements of a worn engine
when initially sizing the pipe. 5. Open starting air shutoff valve
at side of engine.
A separate ventilation piping
system must be installed for each 6. Check starting air pressure.
engine. Ensure maximum 1551 kPa
(225 psi) or minimum 862 kPa
Piping should slope away from the
(125 psi) air pressure for starting.
engine at a minimum of 13 mm per
300 mm, (1/2 in. per ft). 7. Check air starter lubricator oil
level. Check prelube motor
2007 Caterpillar

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
2007 Caterpillar

reduce jacket water temperature

to 85C (185F) and the average
cylinder exhaust temperature
(of all cylinders; when exhaust
pyrometer equipped) is reduced
to below 150C (300F). Fifteen
minutes will normally achieve the
cooler temperatures. Cool down
is best performed at or near rated
speed whenever possible.
3. Adjust other control systems
prior to engine shutoff; voltage
regulator, idle/rated switch,
raise/lower switch.
4. Turn the engine fuel ON/OFF
switch to the OFF position. The
engine will coast to a stop by
energizing the fuel shutoff
solenoid.
5. Check and put into shutdown
mode, all other non-engine
system components that have
been operating to support engine
operation.
2007 Caterpillar

Caterpillar 3600/C280 Generator Set Commissioning

Report
General:
Customer: _____________________________________________________________
Address: _______________________________________________________________
Application: Prime Power: _______ Continuous: _______ @ _________% load

Consist:
Rating: ______________ bhp: _______ bkW:_______ @ ____________________
Heinzmann: ____ 3161: ____ Other: _______________________
Describe: __________________________________________________
2007 Caterpillar


________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

2007 Caterpillar

Analysis of Test Data & Physical Systems

System Summary of Results
Air Intake
Satisfactory
Unsatisfactory
Not Complete
Cooling
Satisfactory
Unsatisfactory
Not Complete
Exhaust
Satisfactory
Unsatisfactory
Not Complete
Fuel
Satisfactory
Unsatisfactory
Not Complete
Lubrication
Satisfactory
Unsatisfactory
Not Complete
Monitoring System
Satisfactory
Unsatisfactory
Not Complete
Driven Equipment
Satisfactory
Unsatisfactory
Not Complete
2007 Caterpillar


Safety and Alarms
Satisfactory
Unsatisfactory
Not Complete
Engine Monitoring
Satisfactory
Unsatisfactory
Not Complete
Satisfactory
Unsatisfactory
Not Complete
Starting
Satisfactory
Unsatisfactory
Not Complete
Ventilation
Satisfactory
Unsatisfactory
Not Complete
Equipment Safety
Satisfactory
Unsatisfactory
Not Complete
2007 Caterpillar


Serviceability
Satisfactory
Unsatisfactory
Not Complete
Operation and
Maintenance
Satisfactory
Unsatisfactory
Not Complete
Generator Controls
Satisfactory
Unsatisfactory
Not Complete
Switchgear
Satisfactory
Unsatisfactory
Not Complete
Noise / Emissions
Satisfactory
Unsatisfactory
Not Complete
Auxiliary Cooling
Satisfactory
Unsatisfactory
Not Complete
2007 Caterpillar


___________________
Satisfactory
Unsatisfactory
Not Complete
___________________
Satisfactory
Unsatisfactory
Not Complete
___________________
Satisfactory
Unsatisfactory
Not Complete
___________________
Satisfactory
Unsatisfactory
Not Complete
___________________
Satisfactory
Unsatisfactory
Not Complete
2007 Caterpillar

Engine Performance Data

Record the following data using field test equipment while the engine is
being load tested under site conditions.
__________% Load
900
Actual
Series Description
Measured
Points
Comments: ____________________________________________________________
________________________________________________________________________
________________________________________________________________________
2007 Caterpillar

Engine Instrument Panel & Generator Control Panel

Instrument Readings
Engine S/N: ____________________ Generator Set
Description 0% 25% 50% 75% 100% 110%
Actual Load EMW
Voltage kV
Amperes A
Power Factor LAG 0. 0. 0. 0. 0. 0.
Gen Bearing Temp C
Gen Stator Temp C
Engine Coolant C
Air Inlet Man. Temp C
Air Inlet Restr. LH kPa
Air Inlet Restr. RH kPa
Oil Pressure kPa
Oil Temperature C
Oil Filter Press Diff kPa
Fuel Filter Press Diff kPa
Crankcase Pressure kPa
Air Inlet Man. Press kPa
Fuel Pressure kPa
Engine Hours
Stack Exh Temp RH C
Stack Exh Temp LH C
Cyl Exh Temp 1 C
Cyl Exh Temp 2 C
Cyl Exh Temp 3 C
Cyl Exh Temp 4 C
Cyl Exh Temp 5 C
Cyl Exh Temp 6 C
Cyl Exh Temp 7 C
Cyl Exh Temp 8 C
Cyl Exh Temp 9 C
Cyl Exh Temp 10 C
Cyl Exh Temp 11 C
Cyl Exh Temp 12 C
Cyl Exh Temp 13 C
Cyl Exh Temp 14 C
Cyl Exh Temp 15 C
Cyl Exh Temp 16 C
Comments: ____________________________________________________________
2007 Caterpillar

LEBW4985-01 2007 Caterpillar Printed in U.S.A.
All rights reserved.

Commissioning 3600c280

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Commissioning 3600c280

Uploaded by

Copyright:

Available Formats

APPLICATION AND INSTALLATION GUIDE

Downloaded from www.Manualslib.com manuals search engine

Diesel Engine Commissioning 3600/C280.............................. 1

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Information contained in this publication may be considered confidential.

CAT, CATERPILLAR, ADEM, their respective logos and Caterpillar Yellow,

Downloaded from www.Manualslib.com manuals search engine

Diesel Engine Commissioning 3600/C280

Design Review .................... 3 Control System -

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Caterpillar 3600/C280 Generator Set Design Review Report

Rating: ______________ bhp: _______ bkW:_______ @ ____________________

Downloaded from www.Manualslib.com manuals search engine

Typical Ambient Temperature range for the year: ___________ to ___________

Field Engineer Signature: ______________________________ Date: __________

Downloaded from www.Manualslib.com manuals search engine

Design Review Results

Downloaded from www.Manualslib.com manuals search engine

Design Compliance with 3600/C280 Engine

Downloaded from www.Manualslib.com manuals search engine

Design Compliance with 3600/C280 Engine

Downloaded from www.Manualslib.com manuals search engine

Design Compliance with 3600/C280 Engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Caterpillar 3600/C280 Generator Set Construction Audit Report

Rating: ______________ bhp: _______ bkW:_______ @ ____________________

Downloaded from www.Manualslib.com manuals search engine

Typical Ambient Temperature range for the year: ___________ to ___________

Field Engineer Signature: ______________________________ Date: __________

Downloaded from www.Manualslib.com manuals search engine

Construction Audit Results

Downloaded from www.Manualslib.com manuals search engine

Design Compliance with 3600/C280 Engine

Downloaded from www.Manualslib.com manuals search engine

Design Compliance with 3600/C280 Engine

Downloaded from www.Manualslib.com manuals search engine

Design Compliance with 3600/C280 Engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Combustion Air to allow appropriate service intervals

Downloaded from www.Manualslib.com manuals search engine

avoided, see Air Intake System airflow and contamination

Downloaded from www.Manualslib.com manuals search engine

System Coolers Cooling System External Pressure

Downloaded from www.Manualslib.com manuals search engine

The auxiliary tank must be temperature alarm and shutdown

Downloaded from www.Manualslib.com manuals search engine

Central Cooling Systems drop across the strainer can be

Downloaded from www.Manualslib.com manuals search engine

Ensure that the Cooling System and producing a schematic of that

Downloaded from www.Manualslib.com manuals search engine

water condensate to be drained daily deposits or debris out of the pipe

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

between expansion joints and rigid condensation with temperature

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Rating: __________ bhp: _ bkW:_ @ ________________

Typical Ambient Temperature range for the year: _ to _

Field Engineer Signature: ____________________ Date:

Rating: __________ bhp: _ bkW:_ @ ________________

Typical Ambient Temperature range for the year: _ to _

Field Engineer Signature: ____________________ Date:

Peak Shaving: _ Standby: _

Field Engineer Signature: ____________________ Date: