repair and maintenance history of anoud power 10 mw

Repair and Maintenance History of

Anoud Power 10 MW

P a g e 2 | 37

Contents 1. General Product Overview ........................................................................................... 3

1.1. Gensets ............................................................................................................... 3

1.2. Model View Illustration ......................................................................................... 4

1.3. Product Description .............................................................................................. 5

1.4. Specifications ....................................................................................................... 7

1.5. Benefits & Features ............................................................................................. 8

2. Repair and Maintenance ............................................................................................... 9

2.1. Overview .............................................................................................................. 9

2.2. Fluids Maintenance .............................................................................................. 9

2.3. Repair/rebuild/replacement history ..................................................................... 10

2.3.1. Generator Set # 01 ....................................................................................... 10

2.3.2. Generator Set # 02 ....................................................................................... 11

2.3.3. Generator Set # 03 ....................................................................................... 12

2.3.4. Generator Set # 04 ....................................................................................... 14

2.3.5. Generator Set # 05 ....................................................................................... 16

2.3.6. Generator Set # 06 ....................................................................................... 17

3. Valve Data .................................................................................................................... 18

3.1. Generator Set # 01 ............................................................................................ 18

3.2. Generator Set # 02 ............................................................................................ 19

3.3. Generator Set # 03 ............................................................................................ 20

3.4. Generator Set # 04 ............................................................................................ 21

3.5. Generator Set # 05 ............................................................................................ 22

3.6. Generator Set # 06 ............................................................................................ 23

4. Operational Considerations ........................................................................................ 24

Appendix A: CAT® Maintenance Recommendations ..................................................... 26

Appendix B: CAT® Cylinder Pressure Recommendations ............................................ 32

Appendix C: CAT® Valve Stem Projection Recommendations ...................................... 34

Appendix D: Glossary of Terms ....................................................................................... 36

P a g e 3 | 37

1. General Product Overview

1.1. Gensets

Genset 1 2 3 4 5 6

Engine Serial GZN00788 GZN00789 GZN00790 GZN00794 GZN00793 GZN00792

Gen Serial PCP00553 PCP00554 PCP00555 PCP00559 PCP00558 PCP00557

Arr Number 260-3693 260-3693 260-3693 260-3693 260-3693 260-3693

Model G3520C G3520C G3520C G3520C G3520C G3520C

Rating 1,950 ekW 1,950 ekW 1,950 ekW 1,950 ekW 1,950 ekW 1,950 ekW

Full load rpm 1,500 rpm 1,500 rpm 1,500 rpm 1,500 rpm 1,500 rpm 1,500 rpm

Built Date 11-Oct-10 11-Oct-10 11-Oct-10 11-Oct-10 11-Oct-10 11-Oct-10

Tested Date 28-Oct-10 28-Oct-10 28-Oct-10 28-Oct-10 28-Oct-10 28-Oct-10

Shipped Date 11-Nov-10 11-Nov-10 11-Nov-10 11-Nov-10 11-Nov-10 11-Nov-10

Plant Lafayette Lafayette Lafayette Lafayette Lafayette Lafayette

Comissioned 4-Jun-11 4-Jun-11 4-Jun-11 4-Jun-11 4-Jun-11 4-Jun-11

Current SMU1 32,626 32,871 32,125 32,288 32,542 32,723

1 As at 14

th of June, 2015 (Sunday)

P a g e 4 | 37

1.2. Model View Illustration

The illustration above shows various typical features of G3520C Generator Set. These

illustrations do not, however, show all of the options that are available.

(1) Oil filler

(2) Engine control module

(3) Jacket water outlet

(4) Lifting eyes

(5) Aftercooler

(6) Throttle

(7) Aftercooler drains

(8) Oil filters

(9) Oil level gauge

(dipstick)

(10) Jacket water inlet

(11) Fuel inlet

(12) Fuel metering valve

(13) Air inlet

(14) Exhaust stack

(15) Oil drain

P a g e 5 | 37

1.3. Product Description

Product Description

The Generator Set consists of an engine, a generator, and a control system.

Intended Use

This Power Generator is intended to be used to generate electrical power.

Engine Description

Fuel System (Air/Fuel Ratio Control)

The fuel system includes these components:

Fuel metering valve

Engine control module (ECM)

Inlet Manifold Pressure Sensor

Load Signal

Inlet manifold temperature sensor

The fuel metering valve controls the flow of fuel to the engine. The ECM determines the

requirement for the mixture of air and fuel. The ECM sends a signal to the fuel metering valve.

The fuel metering valve controls the volume of the gas flow to the engine.

The fuel flows through the fuel metering valve into the air inlet elbow. The mixture of air and fuel

flows through the turbocharger compressor. The air/fuel mixture is cooled in the aftercooler. The

mixture enters the manifold through a throttle which is electronically controlled.

The ECM sends an electronic throttle signal to the electronic actuator. The throttle is controlled

by the actuator.

Ignition System

The engine is equipped with an electronic ignition system. The system provides dependable

firing and low maintenance. The system provides precise control of the spark and the ignition

timing for each cylinder.

The system also provides diagnostic capability that enhances troubleshooting.

The engines are equipped with protection from detonation. A detonation sensor is located

between every two cylinders. The ignition timing is retarded for a cylinder when excessive

detonation is sensed in that cylinder. If the maximum retarded position is attained and

detonation continues to occur, the ECM shuts down the engine.

P a g e 6 | 37

The engines are equipped with flame arresters. The flame arresters are located at the entrance

of each inlet port. If the engine backfires, the flame arresters prevent the fire from entering the

air/fuel mixture.

Lubrication System

The engine lubrication oil is circulated by a gear-driven pump. The oil is cooled and filtered. A

bypass valve provides unrestricted flow of lubrication oil to the engine parts if the oil filter

elements become plugged.

Cooling System

The cooling system uses a water pump. The cooling system has temperature regulators that

regulate the temperature of the coolant. The temperature depends on the application.

The turbocharged engine has a Separate Circuit Aftercooler (SCAC). The temperature depends

on the engine rating and the application.

The circuit for the aftercooler may be combined or the circuit for the aftercooler may be separate

circuits. In the combined system, a pump circulates water through both the aftercooler and oil

cooler cores. The combined system uses a thermostatic control to regulate the oil temperature.

This prevents overcooling.

Description of the Generator

The SR4B brushless generator can be used with the following loads: mixed loads of motors and

lights, SCR-controlled equipment, computer centers and petroleum drilling applications.

The generator set packages can be utilized for prime power generation or standby power

generation.

SR4B generators are utilized in three-phase full-wave excitation and regulation. The generators

are either four pole or six pole design. The generators have six lead configuration or twelve lead

configuration. The generators are capable of producing electrical power in either 50 Hz or 60 Hz

applications.

P a g e 7 | 37

1.4. Specifications

Cylinder and valve location

(A) Inlet valve

(B) Exhaust valve

Number and arrangement of cylinders ... 60 degree V-20

Valves per cylinder ... 4

Displacement ... 86 L (5263 cu in)

Bore ... 170 mm (6.7 inch)

Stroke ... 190 mm (7.5 inch)

Combustion ... Spark ignited

When the crankshaft is viewed from the flywheel end, the crankshaft rotates in the following

direction. ... Counterclockwise

Firing order

Standard rotation CCW ... 1, 2, 11, 12, 3, 4, 15, 16, 7, 8, 19, 20, 9, 10, 17, 18, 5, 6, 13, 14

Note: The front end of the engine is opposite the flywheel end of the engine. The left and the

right side of the engine are seen from the flywheel end. The number 1 cylinder is the front

cylinder on the right side. The number 2 cylinder is the front cylinder on the left side.

P a g e 8 | 37

1.5. Benefits & Features

WORLD WIDE PRODUCT SUPPORT

Cat Dealers provide extensive post sale support including maintenance and repair agreements.

Cat dealers have over 1,800 dealer branch stores operating in 200 countries.The Cat® S•O•S

program cost effectively detects internal engine component condition, even the presence of

unwanted fluids and combustion by-products.

PROVEN SYSTEM

FIELD PROVEN IN A WIDE RANGE OF APLLICATIONS WORLDWIDE

FULLY PROTYPE TESTED

CERTIFIED TORSIONAL VIBRATION ANALYSIS AVAILABLE

CAT SR4B GENERATOR

Designed to match performance and output characteristics of Caterpillar gas engines. Industry

leading mechanical and electrical design. High efficiency

CAT ELECTRONIC CONTROL SYSTEM

Simple user friendly interface and navigation. Digital monitoring, metering and protection setting.

Fully-featured power metering and protective relaying. Remote control and monitor capability

options

EMISSIONS

Meets most worldwide emissions requirements down to 0.5 g/bhp-hr Nox level without

aftertreatment

FULL RANGE OF ATTACHMENTS

Wide range of bolt-on system expansion attachments, factory designed and tested

CAT® G3520C GAS ENGINE

Robust high speed block design provides prolonged life and lower owning operationg costs.

Designed for maximum performance on low pressure pipeline natural gas. Simple open hamber

combustion system for reliability and fuel flexibility. Leading edge technology in ignition system

and air/fuel ratio control for lower emission and engine efficiency. One electronic control module

handles all engine functions: ignition, governing, air/fuel ratio control and engine protection

P a g e 9 | 37

2. Repair and Maintenance

2.1. Overview

All Caterpillar recommended standard maintenance intervals have been fully complied2. Walk-

around inspections and 1000 hr basic preventive maintenance procedures have been carried

out ever since the plant’s inception. Detailed logs of all maintenance activities are available at

Anoud Power.

2.2. Fluids Maintenance

Only ORIGINAL Caterpillar fluids have been used in refill and maintenance of gensets3. These

have been regularly monitored as per OEM recommendations, details of which are as below:

Lubricant Usage

Brand of lube oil Cat NGEO (Natural Gas Engine Oil)

Grade of Viscocity SAE 40

Approximate Refill Capacity 423 liters

Monitoring technique CAT SOS (Scheduled Oil Sampling)

Coolant Usage

Brand of coolant Water and CAT® SCA (Supplemental Coolant Additive)

Refill Capacity 344 L in Jacket Water Circuit, 47.5 L in Aftercooler Circuit

Monitoring technique CAT® Coolant Conditioner Test Kit

Grease Usage

Brand of grease CAT® Ball Bearing Grease

Refill Area Generator Bearings

2 Check Appendix A: Maintenance Interval Recommendation for CAT® G3520C

3 As per SEBU6400: CAT Gas Engine Lubricant, Fuel, and Coolant Recommendations.

Link: https://parts.cat.com/wcs-static/pdfs/SEBU6400-05-secure.pdf

https://parts.cat.com/wcs-static/pdfs/SEBU6400-05-secure.pdf

P a g e 10 | 37

2.3. Repair/rebuild history

2.3.1. Generator Set # 1 -

History: Consumable Items

Component Activity Undertaken Of last change

R/H4

CAT® Recommended R/H

5 Date SMU

Engine Oil & Filters

Replaced with new 21-05-15 32,130 496 1,000 hours

Air filters Replaced with new 07-06-15 32,486 140 3,000 hours

Spark plugs Replaced with new 11-01-15 29,420 3,206 3,000 hours

History: Miscellaneous repairs/rebuilds/overhauls

Component Nature of work Date & SMU R/H CAT®

Recommended R/H

Topend Overhaul

1st Topend 15-03-14 22,669 9,957

Between 10,000 and 20,000 hours

Turbocharger 1

st ABB Certified Rebuild 10-03-13 14,674

2,453 Inspection every

8,000 hours 2

nd ABB Certified Rebuild 15-02-15 30,173

Generator Bearing

1st CAT® Certified Rebuild 15-03-14 22,669


10,000 hours 2

nd CAT® Certified Rebuild 31-05-14 24,334

Throttle Replaced with spare 30-03-15 31,001 1,625 As per requirement Damper CAT® Certified Rebuild 20-10-14 27,570 5,056

Inspection every 1,000 hours

Flexible Coupling

Replaced with new 15-03-14 22,669 9,957 Inspection every

1,500 hours Fuel metering

valve Repaired 20-07-14 25,441 7,185 As per requirement

Compressor bypass valve

- - - - Checked every

2,000 hours

History: Replacement of Heads

Date SMU R/H Qty Head No. Reason

15-03-14 22,669 22,669 20 All Topend Overhaul

21-09-14 26,896 4,227 1 12 Leakage

19-04-15 31,420 8,751 2 4 &18 Leakage

07-06-15 32,486 9,817 4 6,7,10, & 19 CAT® Reman head # 6

4 R/H = Running Hours = Current SMU – SMU. Current SMU is as in page 3.

5 CAT recommended R/H as per Maintenance Schedule. Refer to Appendix A. A indicates that the component is

currently maintained/rebuilt as per CAT® standards. A , on the other hand, indicates that maintenance activity is pending on that particular component.

P a g e 11 | 37

2.3.2. Generator Set # 02

History: Replacement of Consumables


R/H CAT®

Recommended R/H Date SMU



Air filters Replaced with new 07-12-14 28,823 4,048 3,000 hours


Miscellaneous major repairs/rebuilds/replacements


Recommended R/H

Topend Overhaul

1st Topend 19-09-13 18,943 13,928

Between 10,000 and 20,000 hours

Turbocharger 1

st ABB Certified Rebuild 03-03-13 14,571 - Inspection every

8,000 hours 2

nd ABB Certified Rebuild 15-02-15 30,359 2,512

Generator Bearing

1st CAT® Certified Rebuild 19-09-13 18,943 13,928


Throttle 1

st repair 20-07-14 25,278

1,928 As per

requirement 2

nd repair 15-03-15 30,943

Damper CAT® Certified Rebuild 16-01-15 29,727 3,144 Inspection every

1,000 hours Flexible

Coupling Replaced with new 01-08-14 25,844 7,027


Fuel metering valve

- - - - As per

requirement Compressor bypass valve


2,000 hours

Head Replacement Detail


17-09-12 10,773 10,773 2 14 & 16 Water Leakage

04-11-12 11,855 11,855 1 2 (New Head) Water Leakage

20-02-13 14,333 3,560 1 16 High valve recession.

19-09-13 18,943 - 20 All T.E.O

07-12-14 28,823 9,880 1 19 leakage

14-12-14 28,980 10,037 2 5 & 13 leakage

25-01-15 29,932 10,989 1 18 leakage (used gasket)

01-02-15 30,079 11,136 1 20 leakage (new spacer plate)

22-03-15 31,100 12,157 1 10 leakage

07-06-15 32,720 13,777 1 14 leakage

P a g e 12 | 37




R/H CAT®






Miscellaneous repairs/rebuilds/replacements


Recommended R/H

Topend Overhaul

1st Topend 03-12-13 20,644

8,769 Between 10,000 and 20,000 hours

2nd

Topend 23-04-14 23,356

Turbocharger 1



8,000 hours 2


Generator Bearing



10,000 hours 2nd

CAT® Certified Rebuild 28-03-14 22,927

3rd


Throttle Replaced by CAT® under

warranty 05-01-12 4,854 27,271

As per requirement

Damper - - - - Inspection every


Coupling Replaced with new 28-03-14 22,927 9,198


Fuel metering valve

Replaced with spare 22-03-15 30,454

1,178 As per

requirement Old valve repaired and re-installed

19-04-15 30,947


Repaired 10-03-14 22,927 9,198 Checked every

2,000 hours

P a g e 13 | 37



16-05-13 16,267 16,267 1 13 High valve recession

03-12-13 20,644 20,644 20 All Topend overhaul

17-04-14 23,356 2,712 20 All Due to water leakage

30-05-14 24,203 8,47 1 4 Due to water leakage




31-08-14 26,265 2,909 3 6,12,15 Due to water leakage

07-09-14 26,408 3,052 2 3,5 Due to water leakage


05-10-14 27,038 3,682 2 10 & 20 Due to water leakage




28-12-14 28,730 5,374 3 8,9,17 Due to water leakage

04-01-15 28,896 - 1 3 Head gasket replaced (external leak)


18-01-15 29,189 2,781 1 3 With used Gasket

18-01-15 29,189 4,986 1 4 Gasket new


08-03-15 30,153 4,208 1 16 with new accessories


P a g e 14 | 37




R/H CAT®





Spark plugs Replaced with new 30-04-15 31,309 979 3,000 hours



Recommended R/H

Topend Overhaul

1st Topend 07-03-14 22,262

5,819 Between 10,000 and 20,000 hours

2nd

Topend 11-09-14 26,469

Turbocharger 1



8,000 hours 2


Generator Bearing



10,000 hours 2

nd CAT® Certified Rebuild 11-09-14 26,469

Throttle Repaired 23-04-15 31,600 688 As per requirement Damper - - - -


Flexible Coupling



valve - - - - As per requirement



2,000 hours

P a g e 15 | 37



04-11-11 3,458 3,458 2 8 & 9 Exhaust side bridge damage.

10-04-13 15,140 15,140 1 18 Water Leakage

01-05-13 15,619 15,619 1 11 Water leakage

07-03-14 22,262 - 20 All Topend Overhaul

07-09-14 26,374 4,112 1 12 Spring break

11-09-14 26,469 4,207 20 All Water Leakage

04-01-15 28,981 2,512 1 5 Water Leakage

26-04-15 31,221 4,847 3 12,14,17 Water Leakage

03-05-15 31373 4,904 2 13,06 Water Leakage

03-05-15 31,373 2,392 1 5 Water Leakage

24-05-15 31,833 5,364 1 4 Water Leakage

11-06-15 32,214 5,745 4 2,9,10,16 Water Leakage

P a g e 16 | 37




R/H CAT®



Replaced with new 25-03-15 30,976 1,566 1,000 hours





Recommended R/H

Topend Overhaul

Topend 10-01-14 21,344 11,198 Between 10,000

and 20,000 hours

Turbocharger 1



8,000 hours 2

nd ABB Certified Rebuild

6 22-02-15 30,354

Generator Bearing


0 Inspection every

10,000 hours 2nd


3rd


Throttle Replaced 16-12-13 20,969 11,573 As per

requirement Damper CAT® Certified Rebuild 25-01-15 29,784 2,758


Flexible Coupling



valve Repaired 26-10-14 27,834 4,708

As per requirement



2,000 hours

Head replacement detail


06-03-13 14,623 14,623 1 8 (New Head) High valve recession.

10-01-14 21,344 21,344 20 All T.E.O

01-01-15 29,257 7,913 3 7,9,10 Leakage

11-01-15 29,471 8,127 1 11 leakage (used gasket)

08-02-15 30,095 8,751 2 4 & 20 with used Gasket

05-04-15 31,172 9,828 2 16 & 18 leakage (used gasket)

6 ABB Service Report recommended replacement of bladed shaft, which has been ordered. It will be replaced upon

arrival of consignment.

P a g e 17 | 37




R/H CAT®



Replaced with new 19-04-15 31,518 1,205 1,000 hours





Recommended R/H

Topend Overhaul

Topend 10-10-13 19,413 13,310 Between 10,000

and 20,000 hours

Turbocharger 1



8,000 hours 2


Generator Bearing

1st CAT® Certified Rebuild 10-10-13 19,413 13,310


Throttle 1

st repair 06-07-14 25,286

1,518 As per

requirement 2

nd repair 05-04-15 31,205

Damper CAT® Certified Rebuild 11-12-13 20,706 12,017 Inspection every


Coupling

Replaced with new 06-10-13 19,462 6,138


Replaced with new 01-09-14 26,585

Fuel metering valve

- - - - As per

requirement Compressor bypass valve

Replaced with spare 22-03-15 30,943 1,780 Checked every

2,000 hours

Head replacement detail


10-10-13 19,413 19,413 20 All T.E.O

30-11-14 28,542 9,129 1 7 leakage

01-02-15 29,955 10,542 2 14 & 4 leakage

08-02-15 30,108 10,695 1 1 with used gasket

22-02-15 30,375 10,962 1 17 17 low comp pressure

22-02-15 30,375 10,962 1 13 13 water leakage.

15-03-15 30,802 11,389 1 10 leakage/used gasket

10-05-15 31,958 12,545 2 18 & 19 Leakage

P a g e 18 | 37

3. Valve Data

3.1. Generator Set # 01

Cylinder Valve

Location

Valve Recession

(mm)

CAT® Recommended

Valve Recession (mm)

7

Cylinder Pressure

(psi)

CAT® Recommended cylinder pressure

(psi)8

1 Pushrod Side 1.03

< 2.3 250 250 – 290 Inlet Manifold 0.83

2 Pushrod Side 0.80

< 2.3 250 250 – 290 Inlet Manifold 0.90

3 Pushrod Side 0.90

< 2.3 255 250 – 290 Inlet Manifold 0.62

4 Pushrod Side 0.66

< 2.3 250 250 – 290 Inlet Manifold 0.80

5 Pushrod Side 0.70

< 2.3 260 250 – 290 Inlet Manifold 1.09

6 Pushrod Side 0.58

< 2.3 260 250 – 290 Inlet Manifold 1.04

7 Pushrod Side 0.78

< 2.3 250 250 – 290 Inlet Manifold 0.96

8 Pushrod Side 1.18

< 2.3 240 250 – 290 Inlet Manifold 0.74

9 Pushrod Side 0.67

< 2.3 250 250 – 290 Inlet Manifold 0.87

10 Pushrod Side 0.80

< 2.3 260 250 – 290 Inlet Manifold 0.64


< 2.3 250 250 – 290 Inlet Manifold 0.75


< 2.3 250 250 – 290 Inlet Manifold 1.03


< 2.3 250 250 – 290 Inlet Manifold 0.73


< 2.3 250 250 – 290 Inlet Manifold 0.90


< 2.3 250 250 – 290 Inlet Manifold 0.86


< 2.3 250 250 – 290 Inlet Manifold 0.79


< 2.3 260 250 – 290 Inlet Manifold 0.84


< 2.3 260 250 – 290 Inlet Manifold 0.54


< 2.3 250 250 – 290 Inlet Manifold 0.60


< 2.3 255 250 – 290 Inlet Manifold 0.78

7 As per SEBU7681-18: Operation and Maintenance Manual – G3500C and G3500E Generator Sets, Maintenance

Section, Valve Stem Projection – Measure/Record 8 Same as

6. Refer to Maintenance Section, Cylinder Pressure – Measure/Record

P a g e 19 | 37


Cylinder Valve

Location

Valve Recession

(mm)

CAT® Recommended


Cylinder Pressure

(psi)


(psi)

1 Pushrod Side 0.56

< 2.3 250 250 – 290 Inlet Manifold 0.90

2 Pushrod Side 0.64

< 2.3 250 250 – 290 Inlet Manifold 0.88

3 Pushrod Side 0.74

< 2.3 260 250 – 290 Inlet Manifold 0.92

4 Pushrod Side 1.11

< 2.3 260 250 – 290 Inlet Manifold 0.94

5 Pushrod Side 0.65

< 2.3 250 250 – 290 Inlet Manifold 0.83

6 Pushrod Side 0.90

< 2.3 260 250 – 290 Inlet Manifold 0.68

7 Pushrod Side 0.99

< 2.3 265 250 – 290 Inlet Manifold 0.72

8 Pushrod Side 0.79

< 2.3 272 250 – 290 Inlet Manifold 0.97

9 Pushrod Side 0.95

< 2.3 255 250 – 290 Inlet Manifold 0.68


< 2.3 260 250 – 290 Inlet Manifold 0.87


< 2.3 265 250 – 290 Inlet Manifold 0.77


< 2.3 270 250 – 290 Inlet Manifold 0.72


< 2.3 256 250 – 290 Inlet Manifold 0.88


< 2.3 266 250 – 290 Inlet Manifold 0.58


< 2.3 250 250 – 290 Inlet Manifold 0.55


< 2.3 276 250 – 290 Inlet Manifold 0.85


< 2.3 255 250 – 290 Inlet Manifold 0.58


< 2.3 262 250 – 290 Inlet Manifold 0.66


< 2.3 275 250 – 290 Inlet Manifold 0.54


< 2.3 255 250 – 290 Inlet Manifold 0.69

P a g e 20 | 37


Cylinder Valve

Location

Valve Recession

(mm)

CAT® Recommended


Cylinder Pressure

(psi)


(psi)

1 Pushrod Side 0.91

< 2.3 250 250 – 290 Inlet Manifold 1.07

2 Pushrod Side 1.10

< 2.3 258 250 – 290 Inlet Manifold 0.98

3 Pushrod Side 1.08

< 2.3 265 250 – 290 Inlet Manifold 0.90

4 Pushrod Side 0.95

< 2.3 272 250 – 290 Inlet Manifold 1.06

5 Pushrod Side 1.16

< 2.3 250 250 – 290 Inlet Manifold 0.72

6 Pushrod Side 1.18

< 2.3 259 250 – 290 Inlet Manifold 0.91

7 Pushrod Side 0.95

< 2.3 268 250 – 290 Inlet Manifold 1.02

8 Pushrod Side 0.99

< 2.3 255 250 – 290 Inlet Manifold 0.75

9 Pushrod Side 1.05

< 2.3 257 250 – 290 Inlet Manifold 0.86


< 2.3 259 250 – 290 Inlet Manifold 0.99


< 2.3 260 250 – 290 Inlet Manifold 0.74


< 2.3 257 250 – 290 Inlet Manifold 0.53


< 2.3 258 250 – 290 Inlet Manifold 0.72


< 2.3 251 250 – 290 Inlet Manifold 0.79


< 2.3 275 250 – 290 Inlet Manifold 1.02


< 2.3 251 250 – 290 Inlet Manifold 0.68


< 2.3 265 250 – 290 Inlet Manifold 0.76


< 2.3 250 250 – 290 Inlet Manifold 0.88


< 2.3 252 250 – 290 Inlet Manifold 0.95


< 2.3 255 250 – 290 Inlet Manifold 0.84

P a g e 21 | 37


Cylinder Valve

Location

Valve Recession

(mm)

CAT® Recommended


Cylinder Pressure

(psi)


(psi)

1 Pushrod Side 0.92

< 2.3 265 250 – 290 Inlet Manifold 0.79

2 Pushrod Side 0.90

< 2.3 270 250 – 290 Inlet Manifold 0.50

3 Pushrod Side 0.73

< 2.3 255 250 – 290 Inlet Manifold 0.51

4 Pushrod Side 0.91

< 2.3 250 250 – 290 Inlet Manifold 0.79

5 Pushrod Side 0.65

< 2.3 280 250 – 290 Inlet Manifold 0.89

6 Pushrod Side 0.89

< 2.3 250 250 – 290 Inlet Manifold 0.70

7 Pushrod Side 0.50

< 2.3 265 250 – 290 Inlet Manifold 0.60

8 Pushrod Side 0.52

< 2.3 260 250 – 290 Inlet Manifold 0.68

9 Pushrod Side 0.66

< 2.3 250 250 – 290 Inlet Manifold 0.82


< 2.3 260 250 – 290 Inlet Manifold 0.91


< 2.3 250 250 – 290 Inlet Manifold 0.95


< 2.3 265 250 – 290 Inlet Manifold 0.81


< 2.3 270 250 – 290 Inlet Manifold 0.86


< 2.3 265 250 – 290 Inlet Manifold 1.03


< 2.3 250 250 – 290 Inlet Manifold 0.70


< 2.3 260 250 – 290 Inlet Manifold 1.02


< 2.3 270 250 – 290 Inlet Manifold 0.73


< 2.3 240 250 – 290 Inlet Manifold 0.90


< 2.3 265 250 – 290 Inlet Manifold 1.03


< 2.3 250 250 – 290 Inlet Manifold 1.02

P a g e 22 | 37


Cylinder Valve

Location

Valve Recession

(mm)

CAT® Recommended


Cylinder Pressure

(psi)


(psi)

1 Pushrod Side 0.67

< 2.3 252 250 – 290 Inlet Manifold 0.71

2 Pushrod Side 0.71

< 2.3 250 250 – 290 Inlet Manifold 0.81

3 Pushrod Side 0.69

< 2.3 260 250 – 290 Inlet Manifold 0.59

4 Pushrod Side 0.59

< 2.3 250 250 – 290 Inlet Manifold 0.88

5 Pushrod Side 0.67

< 2.3 252 250 – 290 Inlet Manifold 0.90

6 Pushrod Side 0.70

< 2.3 266 250 – 290 Inlet Manifold 0.62

7 Pushrod Side 0.82

< 2.3 265 250 – 290 Inlet Manifold 0.60

8 Pushrod Side 0.88

< 2.3 272 250 – 290 Inlet Manifold 0.59

9 Pushrod Side 0.77

< 2.3 255 250 – 290 Inlet Manifold 0.63


< 2.3 260 250 – 290 Inlet Manifold 0.80


< 2.3 250 250 – 290 Inlet Manifold 0.95


< 2.3 265 250 – 290 Inlet Manifold 0.83


< 2.3 257 250 – 290 Inlet Manifold 0.72


< 2.3 268 250 – 290 Inlet Manifold 0.69


< 2.3 263 250 – 290 Inlet Manifold 0.84


< 2.3 273 250 – 290 Inlet Manifold 0.99


< 2.3 273 250 – 290 Inlet Manifold 1.02


< 2.3 267 250 – 290 Inlet Manifold 0.81


< 2.3 250 250 – 290 Inlet Manifold 0.67


< 2.3 250 250 – 290 Inlet Manifold 0.75

P a g e 23 | 37


Cylinder Valve

Location

Valve Recession

(mm)

CAT® Recommended


Cylinder Pressure

(psi)


(psi)

1 Pushrod Side 0.63

< 2.3 251 250 – 290 Inlet Manifold 0.52

2 Pushrod Side 0.85

< 2.3 259 250 – 290 Inlet Manifold 0.71

3 Pushrod Side 0.98

< 2.3 265 250 – 290 Inlet Manifold 0.60

4 Pushrod Side 0.70

< 2.3 268 250 – 290 Inlet Manifold 0.54

5 Pushrod Side 0.59

< 2.3 269 250 – 290 Inlet Manifold 0.52

6 Pushrod Side 0.54

< 2.3 266 250 – 290 Inlet Manifold 0.74

7 Pushrod Side 1.04

< 2.3 250 250 – 290 Inlet Manifold 0.60

8 Pushrod Side 0.85

< 2.3 255 250 – 290 Inlet Manifold 0.58

9 Pushrod Side 0.72

< 2.3 260 250 – 290 Inlet Manifold 0.55


< 2.3 271 250 – 290 Inlet Manifold 0.60


< 2.3 265 250 – 290 Inlet Manifold 0.66


< 2.3 252 250 – 290 Inlet Manifold 0.78


< 2.3 260 250 – 290 Inlet Manifold 0.66


< 2.3 271 250 – 290 Inlet Manifold 0.90


< 2.3 269 250 – 290 Inlet Manifold 0.68


< 2.3 269 250 – 290 Inlet Manifold 0.63


< 2.3 253 250 – 290 Inlet Manifold 0.60


< 2.3 265 250 – 290 Inlet Manifold 0.82


< 2.3 265 250 – 290 Inlet Manifold 0.71


< 2.3 275 250 – 290 Inlet Manifold 0.64

P a g e 24 | 37

4. Operational Considerations

During the course of operations at Anoud Power, a number of challenges were encountered by

ARM Operations Team which are summarily described as follows:

Cooling (Radiator) System

Cooling system of plant was designed using radiators. Radiator cooling provides a closed, self –

contained system that is both simple and practical for most installations. The system in Anoud

has saved a tremendous amount of water in its last four years of operation. In addition to

delivering savings in terms of cost of water, possibility of unscheduled downtime due to

unavailability of water was also eliminated, due to nature of this system. At the time of plant

commissioning, it was mutually agreed that the area (where the radiators are installed) will be

kept open and no construction would be made. Furthermore, planting of grass/vegetation would

also be undertaken to ensure circulation of clean, fresh air around the radiator system.

However, to comply with SSGC directives, complete waste heat recovery system was installed

around the radiators. Currently, three boilers, steam turbine and pump room have surrounded

the radiator.

Construction of WHR system has affected the radiator in following ways:

1. Supply of fresh air to radiators is now restricted.

2. Induction of cement, sand and gravel during construction has affected the internal core

of radiators, thereby affecting cooling performance.

3. Boilers are directly adjacent to the radiators. Consequently, heated air from the boilers is

directed towards the radiator intake which affects the cooling capability of radiators.

The above – mentioned factors, coupled with high ambient temperature have led to increased

coolant temperatures (above 95 C). This high temperature is the main reason of leakages of

cylinder heads, and problems encountered in throttle and compressor bypass valve.

Back Pressure and Reverse Exhaust Flow

ARM Team has observed problem of back pressure and reversing of exhaust flow (from WHR

boilers to the gensets). At the time of installation of WHR system, no proper operational or

design scheme was followed. CAT® Application and Installation Guidelines were also not

complied with. Upon ARM complaint and repeated follow-ups for a year, an operational

philosophy consisting of damper and shut – off valve was developed and implemented at site.

This problem has also contributed to failure of cylinder heads.

SSGC Weekly Curtailment

After the announcement of SSGC weekly full/partial curtailment of gas, plant was operated on

full load to meet production targets. Being connected to HESCO, this plant has always been

P a g e 25 | 37

subjected to frequent ‘hot’ shutdowns. Black shutdowns from 95% load have affected genset

mounted components such as ball-bearings, flexible coupling and damper.

Power Source of Auxiliaries

For most of the time, this plant remained the sole source of power on site. During black

shutdown due to HESCO, radiators and ventilation systems also stopped immediately. This in

turn led to sudden spikes in engine room and coolant temperatures. This high temperature has

also affected electronic components and cylinder heads.

P a g e 26 | 37

APPENDIX A:

CAT® Maintenance Recommendations9

9 Excerpted from Operation and Maintenance Manual: G3500E and G3500C Generator Sets,

Media Number: SEBU7681-18 || Publication Date: 01/06/2013 Link: https://safety.cat.com/cda/files/2450417/7/SEBU7681-15%20M.pdf

P a g e 27 | 37

Maintenance Interval Schedule - Prime

SMCS - 1000; 4450; 7500

Ensure that all safety information, warnings, and instructions are read and understood before

any operation or any maintenance procedures are performed.

An authorized operator may perform the maintenance items with daily intervals. An authorized

operator may perform the maintenance items with intervals of every week. The maintenance

that is recommended for all other maintenance intervals must be performed by an authorized

service technician or by your Cat dealer.

The user is responsible for the performance of all maintenance which includes the following

items: performing all adjustments, using proper lubricants, fluids, and filters and replacing old

components with new components due to normal wear and aging.

Failure to adhere to proper maintenance intervals and procedures may result in diminished

performance of the product and/or accelerated wear of components.

Before each consecutive interval is performed, all maintenance from the previous intervals must

be performed.

Choose the interval that occurs first in order to determine the correct maintenance interval: fuel

consumption, service hours and calendar time. Products that operate in severe operating

conditions may require more frequent maintenance.

All of the following will affect the oil change interval: operating conditions, fuel type, oil type and

size of the oil sump. Scheduled oil sampling analyzes used oil in order to determine if the oil

change interval is suitable for your specific engine.

Refer to this Operation and Maintenance Manual, "Engine Oil and Filter - Change" in order to

determine the oil change interval that is suitable for your specific engine.

To determine the maintenance intervals for the overhauls, refer to this Operation and

Maintenance Manual, "Maintenance Recommendations".

Unless other instructions are provided, perform maintenance and perform repairs under the

following conditions:

The starting system is disabled.

The engine is stopped.

The generator does not pose an electrical shock hazard.

The generator is disconnected from the load.

When Required

Battery - Recycle(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Battery - Replace(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

P a g e 28 | 37

Battery or Battery Cable - Disconnect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Coolant Sample (Level 2) - Obtain(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Fuel Metering Valve - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Generator - Dry(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Generator Lead - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Generator Set - Test(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Generator Set Alignment - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Generator Winding - Test(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Overhaul Considerations(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Space Heater - Test(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Stator Winding Temperature - Test(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Throttle Control Valve - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Daily

Air Tank Moisture and Sediment - Drain(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Coolant Level - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Engine Air Cleaner Service Indicator - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-

Up)

Engine Oil Level - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Fuel Filter Differential Pressure - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Fumes Disposal Filter Differential Pressure - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-

UpDKR1-

Up)

Generator Bearing Temperature - Test/Record(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-

Up)

Generator Load - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Jacket Water Heater - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Power Factor - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Voltage and Frequency - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Walk-Around Inspection(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

P a g e 29 | 37

Initial 250 Service Hours

Cylinder Pressure - Test/Record(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Every 250 Service Hours

Battery Electrolyte Level - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Coolant Sample (Level 1) - Obtain(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Cooling System Supplemental Coolant Additive (SCA) - Test/Add(RWA1-UpGDB1-UpGHC1-

UpGHE1-UpDKR1-Up)

Engine Oil Sample - Obtain(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Fumes Disposal Filter - Drain(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)


Aftercooler Condensation - Drain(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Alternator - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Belts - Inspect/Adjust/Replace(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Crankcase Pressure - Measure(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Crankshaft Vibration Damper - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Crankshaft Vibration Damper - Inspect

Engine Crankcase Breather - Clean(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Engine Oil - Change(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Engine Oil Filter - Change(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Engine Speed/Timing Sensor - Clean/Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Engine Valve Lash and Bridge - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Flexible Coupling - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Gas Pressure Regulator Condensation - Drain(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-

Up)

Generator Winding Insulation - Test(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Hoses and Clamps - Inspect/Replace(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Inlet Air System - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Radiator - Clean(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

P a g e 30 | 37

Valve Stem Projection - Measure/Record(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Water Pump - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)


Carburetor Air/Fuel Ratio - Check/Adjust(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Compressor Bypass - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Generator - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Generator Bearing - Lubricate(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Generator Set Vibration - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Stator Lead - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)


Spark Plugs - Inspect/Replace(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)


Crankcase Blowby - Test/Record(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Cylinder Pressure - Test/Record(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Engine Mounts - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Engine Protective Devices - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Ignition System Timing - Check/Adjust(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Starting Motor - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)


Fumes Disposal Filter Element - Replace(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Rotating Rectifier - Check(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Turbocharger - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Between 10 000 and 20 000 Service Hours

Engine Oil Temperature Regulator - Replace(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Overhaul (Top End)(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

P a g e 31 | 37

Every 10 000 Service Hours

Generator Bearing - Inspect(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)


Overhaul (In-Frame)(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

Every 24 000 Service Hours or 3 Years

Coolant (NGEC) - Change(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)


Overhaul (Major)(RWA1-UpGDB1-UpGHC1-UpGHE1-UpDKR1-Up)

P a g e 32 | 37

Appendix B:

CAT® Cylinder Pressure

Recommendations10

10

Excerpted from Operation and Maintenance Manual: G3500E and G3500C Generator Sets, Media Number: SEBU7681-18 || Publication Date: 01/06/2013 Maintenance Section, Cylinder Pressure: Test/Record

P a g e 33 | 37

Cylinder Pressure

P a g e 34 | 37

Appendix C:

CAT® Valve Stem Projection

Recommendations11

11

Excerpted from Operation and Maintenance Manual: G3500E and G3500C Generator Sets, Media Number: SEBU7681-18 || Publication Date: 01/06/2013 Maintenance Section, Valve Stem Projection, Test/Record

P a g e 35 | 37

Valve Stem Projection

P a g e 36 | 37

Appendix D:

Glossary of Terms

P a g e 37 | 37

ABB Certified Rebuild

Rebuild undertaken at ABB Workshop located in Korangi Industrial Area. Parts and labor are

procured from ABB (OEM for turbochargers) hence the rebuild are covered under ABB’s

warranty policy.

CAT® Certified Rebuild

Rebuild undertaken at AESL Workshop (sole authorized dealer of CAT® in Pakistan and

Afghanistan). Parts are procured from CAT® directly (OEM for G3520C) whereas labor is CAT®

certified. Rebuilds are therefore, covered under warranty policy of CAT®.

Inspect

Inspect the components according to the instructions that are in Caterpillar reusability

publications. Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8029,

“Index of Publications on Reusability or Salvage of Used Parts”. The guidelines were developed

in order to help Caterpillar dealers and customers to avoid unnecessary expenditures. New

parts are not required if the existing parts can still be used, reconditioned, or repaired. If the

components are not in the reusability guidelines, refer to the Service Manual, “Specifications”

module.

PIP

Product Improvement Program

PSP

Product Support Program

Service Letter

Caterpillar issues service letters to its dealers to address potential issues in product. Dealer

assesses equipment condition and implements service letters, which subject to CAT® specified

conditions.

Rebuild

The component can be reconditioned in order to comply with reusability guidelines.

Replace The service life of the part is exhausted. The part may fail before the next maintenance interval. The part must be replaced with a part that meets functional specifications. The replacement part may be a new part, a CAT remanufactured part, a rebuilt part, or a used part. Some worn components may be exchanged with your Caterpillar dealer. Consult your Caterpillar dealer about repair options for your engine.

R/H

Running Hours

SMU

Service Meter Units (Miles/Hours)

repair and maintenance history of anoud power 10 mw

Documents

generator set

fluids maintenance

appendix c

appendix b

cat valve stem pr

general product overview

valve data

product description