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2010 Caterpillar
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Application and Installation Guide Diesel Engine Commissioning - 3500
SECTION CONTENTS
2010 Caterpillar
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Diesel Engine Commissioning - 3500 Application and Installation Guide
Design Review
The engine installation should be during the final commissioning audit
designed to give efficient and and is also useful in earlier stages of
reliable operation. A poorly designed the project.
installation can hinder serviceability,
and make routine maintenance and Explanation of Design
repairs difficult. The neglect of Installation Audit Form
specific design requirements for The Installation Audit form can be
mounting, alignment and support used during the design review as a
systems can lead to poor checklist to determine if sufficient
performance and increased cost of information has been provided to the
operation. installation designer for completion
When the installation designer has of initial layouts in compliance with
completed a review of the Caterpillar requirements in this and additional
application and installation sections of the Application and
requirements, a discussion should Installation Guide.
take place with Cat dealer personnel The form should be completed
to cover concerns he may have with general information about the
about specific areas of the design. owner, application, and
This will establish ground rules for builder/installer. Using design criteria
further working relationships in the of the installation, record specific
design phase. After the initial data concerning physical features of
installation drawings have been the site as well as the engine, driven
completed, follow-up discussions equipment, and support systems.
should take place with the designer
After completion of the design
to make sure the drawings meet
review, and after reaching
application and installation guide
agreement on required corrective
requirements. As an aid in the
action, it is recommended that all
review of the design, use the 3500
concerned parties sign the form at
Engine Installation Audit Form
the designated location.
provided on Pages 24 through 29 of
this guide. This form will be used
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Application and Installation Guide Diesel Engine Commissioning - 3500
Construction Review
After the Design Review is
satisfactorily completed, the next
step is the construction of the
installation site. During this phase,
visit the construction site at least
twice to perform a review of
systems installation progress.
The first visit should follow
installation of the engine(s).
Additional visits may be necessary,
depending on the difficulty of the
installation, and the stage of
completion. Make the final visit
before the commissioning process
begins.
The objective of these visits is to
determine if the previously approved
design is being followed. These
visits not only continue to produce a
better understanding of Caterpillar
requirements, but also provide a
more reliable installation.
Experienced construction builders
will make necessary changes as
soon as possible to avoid costly
delays and eventual customer
downtime.
As with the Design Review, the
Construction Review can use the
Installation Audit form provided on
Pages 24 through 29 of this guide
as a checklist. The form can help
determine if the previously agreed on
design is being successfully
implemented during the construction
process.
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Diesel Engine Commissioning - 3500 Application and Installation Guide
Evaluation Guidelines
This document gives guidance to The items included in the system
personnel commissioning Cat 3500 guides are intended to assist in the
Engines. The included information documentation of facts to be
should be used to prepare the final included in the final commissioning
commissioning report and report. Pictures and other
documentation of performance of schematics or visual aids as
each engine as it goes into full attachments to the commissioning
service. Any deletion of information report are valuable to help others
can cause confusion during future understand the descriptions given in
maintenance or warranty activity. the report.
Each of the items included in each The responsibility of system
discussion should be documented in evaluations and full commissioning is
the final report that establishes the that of the described party
initial condition of engine operation. designated by the project manager
Commissioning has many activities for any project.
associated with its definition. The
field engineer responsible for Air Intake System Evaluation
commissioning must be prepared to To evaluate the engine air intake
give guidance to all areas of the system for the 3500 Engines, the
project as well as being the final total system must be evaluated from
evaluator of operating systems and the air source for the engine to the
engine performance. inlet to the turbocharger. This may
include engine room air or the air
Note: This guide is intended to assist
cleaner may be mounted outside the
in this activity and to complement
engine room. Whichever the case,
the other sections of the Application
consider the following items when
and Installation Guide.
evaluating the air intake system.
It is important to understand the
standards established for each Combustion Air
system and the specifications Air inlet temperature to engine
accompanying those standards to should not exceed 49C (120F).
give the Cat 3500 engine the Is the quantity of air available for
highest reliability and customer combustion sufficient? This requires
satisfaction possible. Any deviation approximately 0.1 m/min/bkW (2.5
from the standards or specifications ft of air/min/bhp) for engines using
can be detrimental to the life of the distillate fuel.
product. Normal operation of The engine room or enclosure
systems can cause deterioration in should not experience negative
their performance over their pressure if combustion air and
expected life. Starting with deviated ventilation air are from the same
standards and specifications will source.
only shorten the expected life.
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Application and Installation Guide Diesel Engine Commissioning - 3500
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Application and Installation Guide Diesel Engine Commissioning - 3500
exhaust piping. The last few feet of There must be expansion joints
the exhaust outlet should be and vertical supports in the
installed to prohibit rainwater entry appropriate positions to assure free
without inducing excessive exhaust movement of the exhaust piping
backpressure. during thermal expansion.
Note: The use of a common exhaust The exhaust piping should be
system between engines is to be rigidly supported, (with off-engine
strictly avoided. supports) near the engine to
The turbocharger must be minimize compression and offset of
protected from debris entering the the engine exhaust bellows. Exhaust
exhaust outlet during construction of pipe expansion must be in the
the exhaust piping. A properly direction away from the engine.
tagged blanking plate is Rollers are strongly recommended
recommended. The tagged plate when vertical supports are required
must be removed prior to initial between expansion joints and rigid
engine operation. The debris supports.
collected on the plate must not go The exhaust piping routing must
into the turbocharger. not interfere with the service of the
engine. Pay particular attention to
Exhaust System Piping
the use of an overhead bridge crane.
The exhaust system piping must
be made of a material to withstand A point for measuring exhaust
the effects of exhaust gas system backpressure should be in a
temperature, pressure, velocity and straight length of the exhaust pipe at
thermal expansion. Ensure that any least 3 to 5 pipe diameters away
insulation added to exhaust piping from the last size transition change
does not deteriorate the piping since from the turbocharger outlet.
the pipe temperature will be higher System backpressure measurement
than if uninsulated. is part of the engine performance
testing.
The backpressure of the total
piping system must be minimal to Distillate Fuel System
allow for muffler restriction, outlet
Evaluation
piping from the muffler and piping
Clean fuel meeting Caterpillar fuel
degradation during the life of the
recommendations provides
engine. Fuel consumption and
outstanding engine service life and
component life will be affected if the
performance; the use of lesser fuels
backpressure is beyond the
is the users responsibility. To assure
recommend value of 254 mm H2O
the engine is receiving good, clean
(10 in H2O).
fuel, the entire system must be
Do not allow gas flow to turn at a evaluated from the fuel storage tank
right angle during a transition. to the engine. In addition to the fuel
Exhaust piping should not be being consumed, the system is
supported from the engine package. considered to include the controls
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Diesel Engine Commissioning - 3500 Application and Installation Guide
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. The
with the engine operation. Consider inlet restriction must not exceed 39
the following when evaluating the kPa (5.7 psi) and the fuel return line
fuel system. restriction must not exceed 350 kPa
(51 psi). These values should be
Fuel Tanks
measured and recorded. Note that
The fuel level in the tanks should
these requirements are independent
be maintained as full as possible at
of each other and should not be
all times. The rise and fall of fuel
combined in any evaluation.
level can pull moist air into the tank
through the vent, leading to water Fuel lines must be treated (pickled)
condensation with temperature and coated inside with lube oil prior
changes. to final assembly.
Fuel tanks vented to atmosphere Fuel lines must never be smaller
must have some form of flame than the engine connections.
arrester in the vent opening to Fuel Filters
prevent possible flames from Initial fuel filter differential should
entering or exiting the tank. The be monitored to eliminate premature
outlet opening in the tank vents plugging of engine filters.
should have a fine mesh screen to
The user and/or installer are
act as a flame arrester as a minimum
responsible for providing primary
precaution. Other forms of flame
filtering of fuel supplied to the
arresters may be used, but ensure
engine. Water separation is of prime
that the vent opening is never left
concern. Water separators or
totally open to the atmosphere.
coalescing filters should be installed.
The fuel supply piping should draw If fuel does not meet the required
fuel from at least 50 mm (2 in.) recommendations, a fuel
above the bottom of the tank. centrifuge/purifier should be used.
The fuel return to the day tank An initial stock of engine fuel
should enter at the top and opposite filters should be on-site prior to
the supply end of the tank. initial starting of the engine.
The tank drain must be able to Fuel Coolers
drain the complete contents of the A fuel cooler may be required
tank as well as being used as a when the return fuel is not returned
sediment drain. to the main tank and the day tank is
Fuel Lines not large enough to handle the heat
Galvanized fittings or piping must transfer from the injection pumps.
not be used in any portion of the The fuel cooler should be sized to
lines. cool fuel returning to the day tank
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Application and Installation Guide Diesel Engine Commissioning - 3500
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Diesel Engine Commissioning - 3500 Application and Installation Guide
the appropriate oil information is Is the time for prelubing within the
provided to the operating personnel required time for starting the engine?
and other appropriate personnel to Electric prelube systems must have
enforce this. Instruct the personnel motor starters sized for current draw
on trending the results of the oil to maintain pump operation until
analysis. Refer to the appropriate prelubing is complete.
Operation and Maintenance manual
Continuous prelube systems must
for further description.
have the Cat spill-tube system to
Engine Sump prevent oil collecting in cylinders
The oil sump must be filled through resulting in hydraulic lock and
the filler tube. Do not remove the damage to cylinder components
engine crankcase cover to fill the upon start-up.
sump.
Oil Pressure and Temperature
The user must connect oil sump Safety shutdowns and alarms
drain valves to external piping for should be provided for oil pressure.
draining oil during an oil change. Oil temperature monitoring is
Additionally, a flexible connector optional for 3500 series engines.
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 of The 3500 generator set package
the oil sump. This helps eliminate using the Cat rigid base is a self-
the chance of foreign material or supporting structure. The package
debris entering the oil sump. will maintain alignment if the floor is
Ensure cold engine oil level is true (flat).
correct and check the oil level
Driven Equipment Evaluation
several times during initial engine
Record the serial number and other
operation. Allow engine oil
appropriate data of the driven
temperature to reach normal
equipment.
operating temperature 82 to 85C
(180 to 185F). The dipstick must Ensure generator space heaters
be marked for proper operating level have been operational for at least 24
at rated speed and load. hours prior to the anticipated start-
up date. To be effective in many
Engine Prelube situations, covering the air inlet and
If equipped, ensure the air prelube outlet screens on the generator may
motor is properly lubricated prior to be necessary.
operation.
Ensure generator space heaters are
Check the air receiver tanks sizing controlled to be off during generator
for the required starting set operation and on during
requirements. Consider air prelubing shutdown periods. There are
requirements if so equipped. contacts available in the engine
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Diesel Engine Commissioning - 3500 Application and Installation Guide
air, fuel or oil filters and setting Chains and hooks on overhead
valve lash. lifting equipment must not endanger
personnel.
Reserved Work Area
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. The place prior to operating the engine.
area must have overhead lifting Remote emergency system stops
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 of to allowing normal operation. If this
spare parts and tools for all has already been completed, verify a
equipment in the engine room. The certificate of system operation
parts and tools should be inventoried exists.
to insure ready access during a
Independently test all emergency
repair. Ensure the area can be locked
stops for the engine while operating
to prevent the loss of parts or tools
at no load.
that would impair scheduled
maintenance or repair. Check engine room noise levels in
normal operating areas and compare
Equipment Safety Evaluation to general rules or local
The commissioning engineer must specifications. Include this data in
be able to recognize a safe operating the commissioning report.
environment. The entire system
Control Room
operation must be reviewed to
Ensure that the control system
provide operator safety during any
meets local fire protection codes.
normal or abnormal situation.
Ensure that control room
Consider the following when
emergency stops are guarded to
evaluating the safety of operating
prevent accidental contact.
systems.
Ensure that all high voltage
Engine Room equipment and cabinets are
Hot engine water pipes should be inaccessible via locks and/or cages
shielded or guarded to prevent with locks.
operator contact.
Ensure Kirk-Key interlocks (or
All generator drive components equivalent) are available for the
and damper guards must be in place appropriate switchgear cabinets.
prior to operating the engine.
Check control room noise levels
All floor openings in the engine and compare to general rules or local
room must be covered with plating specifications. Include this data in
or grating. the commissioning report.
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Diesel Engine Commissioning - 3500 Application and Installation Guide
match the best piping routing away a worn engine when initially sizing
from the engine. Ensure that the pipe.
breather connections can be easily A separate ventilation piping
disconnected for scheduled system must be installed for each
maintenance. engine.
Crankcase Ventilation Piping Piping should slope away from the
Generally, piping of the same size engine at a minimum of 41.7 mm/m
as the breather outlet is suitable (0.5 in. per ft).
unless the length and or bends The outlet should be configured to
cause excessive restriction and a collect oil droplets prior to fumes
false crankcase pressure exiting the piping.
measurement.
If piping rises from the engine, a
Note: See the Engine Room trap must be installed to collect any
Ventilation section of the Application condensation or oil droplets before
& Installation Guide for additional they re-enter the breathers.
information on pipe sizing
requirements. Consideration must be Crankcase fumes must never be
given to the blow-by requirements of discharged in the engine room.
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Diesel Engine Commissioning - 3500 Application and Installation Guide
__________% Load
900
Actual
Series Description
Measured
Points
Comments: ____________________________________________________________
________________________________________________________________________
________________________________________________________________________
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Comments: ____________________________________________________________
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LEBW4986-00 2010 Caterpillar Printed in U.S.A.
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