Ramiro M. LeonJuly 2011

GMRC Engine Analyst Workshop:CAT Engines

A World of Energy Solutions Background Exterran offers a world of energy solutions through a comprehensive products

and services portfolio with operations worldwide. Exterran focuses on delivering a Total Solution for customers oil & gas production and processing facilities in every major hydrocarbon region around the globe. Our worldwide expertise includes:

Compression Technology Critical Process Equipment Gas Treatment Production Equipment Processed Water Technology Power Generation AMS

In 2007 the PdM Department was created in Exterran Bolivia as a means of monitoring our equipment and also providing service to customers

A World of Energy Solutions Typical Readings Typical readings collected on this type of

engines, 4-stroke, are: Power Cylinders:

Secondary Ignition; as long as the cable is accessible and not shielded Vibration Readings:

High Frequency Raw

Ultrasonic Readings

Main Bearings: Vibration Readings:

High Frequency Raw

Turbochargers: FFT Vibration Readings: acceleration, velocity & displacement

A World of Energy Solutions Case History #1 Caterpillar G3516:

High speed: 1200 rpm High Power Cylinder Temps

A World of Energy Solutions CAT 3516 One of the most common problems detected

on these engines has to do with valve lash regulation, on both exhaust and intake valves. This problem can be originated from: Not following the manufacturers procedure when

adjusting valve lashes Not using the proper tools as per the

manufacturers recommendations

A World of Energy Solutions Valve Lash Problems

Early closure events for both sets of valves

A World of Energy Solutions Valve Lash Problems

Early closure events for both sets of valves

A World of Energy Solutions Valve Lash Problems

Early closure events on both sets of valves

A World of Energy Solutions Valve Lash Problems

Early closure events on both sets of valves

A World of Energy Solutions Valve Lash Problems

Early closure events on both sets of valves

A World of Energy Solutions Valve Lash Problems

Early closure events on both sets of valves

A World of Energy Solutions Valve Lash Problems

Valve closure events detected while collecting Main Brg data

A World of Energy Solutions Recomendations Even Bank:

Check valve lash settings on both sets of valves in all cylinders due to differences on the closure event angles in regards to the manufacturers recommendations

Odd Bank: Check valve lash settings on both sets of valves

in all cylinders ASAP, due to the differences on the closure event angles in regards to the manufacturers recommendations

A World of Energy Solutions Actions Taken

Valve lash adjustment was done on all power cylinders the following day

The procedure and tools recommended on manufacturers instructive REH-50128 were followed

A World of Energy Solutions As Left Conditions

Improvements on the closure events for both sets of valves

A World of Energy Solutions As Left Conditions

Improvements on the closure events for both sets of valves

A World of Energy Solutions As Left Conditions

Improvements on the closure events for both sets of valves

A World of Energy Solutions Case History #2 Lack of lubrication

Another, not too common problem, found on CAT series 3500 engines is lack of lubrication on the cylinder heads

A World of Energy Solutions As Found Reading

Out of place events, and also loud audible knocks

A World of Energy Solutions Observations/Comments High temperature on the components of

the valve assembly, as well as the head cover

Completely dry head Turned bushing guide wasnt allowing

cylinder head lubrication

Bushing Guide Detail

Turned bushing guide, installedin the wrong position, didntallow lubrication of the cylinderhead components

Detail on the regulating bolt

Wear on the knob of theregulating bolt

A World of Energy Solutions As Left Readings

Events related to the wear seen on the knob of the regulating bolt

A World of Energy Solutions Case History #3 Caterpillar G3412

High Speed: 1800 rpm High Temperatures

A World of Energy Solutions Background Our customer has three CAT 3412 gensets at

one of their processing plants They have had many problems with these

engines since start-up Most of the problems had to do with burnt

valves, both exhaust and intake They also had high temperature problems

A World of Energy Solutions Background, 2 CAT rep suggested replacement of cylinder

heads for newer model that helped with cooling cylinders

Modifications were also made to the cooling system in order to bring down temperatures

..Problems continued to happen..

A World of Energy Solutions Background, 3 We were called to do an analysis on the

engine Collected the following data:

Secondary ignition traces Power Cylinders:

HF Vibration Raw Vibration Ultrasound

Main Bearings: HF Vibration Raw Vibration

A World of Energy Solutions As Found Readings, EB

Out of place events, and also loud audible knocks

A World of Energy Solutions As Found Readings, OB

Out of place events, and also loud audible knocks

A World of Energy Solutions Observations/Comments Early closure of both sets of valves, made

worst with exhaust valves not evacuating all burnt gases; this meant that the cylinder kept getting hotter and hotter

Which in turn affected intake valves Our early recommendations was to verify

the camshaft The customer wanted to wait until the

engine was due for overhaul, which was awarded to us

A World of Energy Solutions Findings During Disassembly

Gears alignedGears not aligned

A World of Energy Solutions As Left Conditions, EB

Improvements on the closure events for both sets of valves

A World of Energy Solutions As Left Conditions, OB

Improvements on the closure events for both sets of valves

A World of Energy Solutions Conclusions, Comments Customer got back to the EPC company to

find out about these engines, and some of the findings were: These engines were originally meant for Canada They were shipped to Ecuador and for some

reason were not accepted there Then they made it to Bolivia, and were installed

in a very warm location

Slide Number 1BackgroundTypical ReadingsCase History #1CAT 3516Valve Lash ProblemsValve Lash ProblemsValve Lash ProblemsValve Lash ProblemsValve Lash ProblemsValve Lash ProblemsValve Lash ProblemsRecomendationsActions TakenAs Left ConditionsAs Left ConditionsAs Left ConditionsCase History #2As Found ReadingObservations/CommentsBushing Guide DetailDetail on the regulating boltAs Left ReadingsCase History #3BackgroundBackground, 2Background, 3As Found Readings, EBAs Found Readings, OBObservations/CommentsFindings During DisassemblyAs Left Conditions, EBAs Left Conditions, OBConclusions, Comments