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April 13, 2012
MEMORANDUM
To: Caterpillar Owners Group:
M. Skeete (WRB Enterprises), C. Ince (Grenada Electricity Services), C. Francis (Bahamas Electricity Corporation), M. Polonio (Provo Power Company), F. Williams (Turks & Caicos Utilities), M. Riddle (Dominica Electricity Services), D. Parsons (Caribbean Utilities Company), M. Sturr (BMT / U.S. Coast Guard), W. Wah (American Electric Power), J. Ren (Caterpillar)
From: G. Thompson (MPR Associates)
Subject: Meeting Report for Caterpillar Owners Group (COG) Meeting on November 15-16, 2011
Enclosed is the report for the Caterpillar Owners Group meeting held November 15-16, 2011 in San Juan, Puerto Rico. This report documents the discussions held during the meeting. It also documents action items that were identified and assigned during the meeting. Please take a moment to review Appendix C and complete any open action items assigned to you.
Enclosure
320 KING STREET ALEXANDRIA, VA 22314-3230 703-519-0200 FAX: 703-519-0224 http:\\www.mpr.com
Caterpillar Owners Group (COG) Meeting Report
November 15-16, 2011 San Juan, PR
Page 2 of 17
Contents
1. Purpose ........................................... ...................................................................... 4
2. Adminstrative Details ................................ ........................................................... 4
3. Operating Experience ............................... ............................................................ 4
3.1 3608 Fuel Injector Failures Due to Cavitation .............................................................5
3.2 3616 Overhaul ..............................................................................................................6
3.3 Fuel-Related Issues .......................................................................................................7
4. Parts and Vendor Issues ........................... ........................................................... 9
4.1 Service Letters - Continued Product Improvements (CPI) ...........................................9
4.2 CPI Issues from Recent TC Conference .......................................................................9
4.3 Update on Tier 4 Engine Components and Retro-Fit Options .....................................9
4.4 Caterpillar Acquisition of Motoren-Werke Mannheim ..............................................10
4.5 SpecSizer Tool for Generating Sets ............................................................................10
5. Condition Monitoring / Preventive Maintenance ..... ......................................... 10
5.1 USCG Lube Oil Analysis Program .............................................................................10
5.2 Caterpillar SOS Oil Analysis ......................................................................................11
6. Training .......................................... ..................................................................... 11
6.1 Training by Caterpillar and/or Its Dealers ..................................................................11
6.2 Tour of RIMCO Caterpillar ........................................................................................14
7. COG Budget, Planned / Proposed Tasks and Group Statu s ........................... 15
7.1 Budget Status ..............................................................................................................15
7.2 Planned / Proposed Tasks ...........................................................................................15
7.3 Status of COG .............................................................................................................15
8. Closing Items ...................................... ................................................................ 15
8.1 Review of Action Items ..............................................................................................15
8.2 COG Email Signature .................................................................................................15
8.3 Deadlines for Issue of Meeting Agenda and Minutes ................................................15
Page 3 of 17
8.4 Frequency of Meetings ...............................................................................................16
8.5 Next Meeting Date and Location ................................................................................16
8.6 Election of New COG Chairman ................................................................................16
Page 4 of 17
April 13, 2012
MEETING REPORT
Date: November 15-16, 2011 Place: Carib Hilton, San Juan, Puerto Rico Subject: Caterpillar Owners Group (COG) Meeting Attendees: See Appendix A
1. PURPOSE
The purpose of the meeting was to discuss technical issues pertaining to Caterpillar 3500 and 3600-series engines and diesel generators. Summaries of discussions that occurred are presented in the following sections. Appendix B contains a copy of the meeting agenda.
2. ADMINSTRATIVE DETAILS
The meeting was called to order at 8:25 a.m. on November 15th. Mr. William Wah (AEP), the current chairman of the COG, welcomed attendees. The attendees introduced themselves. Dr. Gary Thompson (MPR) updated attendees on the condition of Mr. Mark OConnell (MPR), the project manager of the COG, who could not attend the meeting for health reasons. A list of the meeting attendees is included as Appendix A.
Mr. Wah reviewed the agenda for the meeting. He also indicated that the minutes for the previous COG meeting in May 2011 had been drafted, but not issued. The approval of the minutes was deferred to allow members to review the draft and provide comments.
Mr. Wah reviewed the status of action items assigned during previous COG meetings. These actions, along with the person/organization assigned responsibility for completing them and their current status, are summarized in Appendix C.
Mr. Wah stated that he has continued to work on increasing membership in the COG. He stated that the Catawba Nuclear Power Plant was a potential new member, and that he would like to reach out to the plant and invite personnel to attend a future meeting. Mr. Wah asked the meeting attendees if it was OK for him to invite Catawba personnel to a meeting. The attendees were unanimously in favor of Mr. Wah doing so.
3. OPERATING EXPERIENCE
Members discussed failures that have occurred since the last COG meeting, including troubleshooting, cause determination and compensatory and corrective actions.
Page 5 of 17
3.1 3608 FUEL INJECTOR FAILURES DUE TO CAVITATION
Mr. Matthew Sturr presented information regarding recent failures of fuel injectors on the Caterpillar 3608 Main Diesel Engines (MDEs) of 225 buoy tenders, including the USCGC ELM, USCGC HOLLYHOCK and other ships. A copy of Mr. Sturrs presentation is included in Appendix D.
Mr. Sturr reported that on one of the USCGC ELM MDEs, the Cylinder #2 injector failed in the compressed position. This resulted in excessive rocker arm to push rod clearance and caused damage to the push rod and rocker arm button. Mr. Chris Francis asked about the condition of the camshaft lobe for the affected fuel injection pump. Mr. Sturr responded that the cam survived; however, part of the rocker arm assembly was "mushroomed" by the push rod, and the pushrod and rocker arm assembly had to be replaced. Mr. Justin Providence asked how long the engine ran with the stuck injector. Mr. Tim Cotton responded that he was not sure and that he would have to ask. Mr. Providence added that the individual exhaust temperature probes should have picked up the stuck injector. Mr. Dale Jacobs responded that the injector could have been stuck for a few minutes before the ship realized there was a problem. He added that a similar problem also occurred on another USCG ship and the entire cylinder suffered damage.
The cause of the injector failures was first thought to be the result of water contamination in fuel tanks. The USCG investigated this cause, and considered cleaning fuel tanks as a potential solution. Mr. Sturr reported that the injector from the USCGC ELM was sent to Mr. Bob Hall (Caterpillar) for inspection. Mr. Hall determined that the injector failure was due to cavitation damage from insufficient fuel pressure and fuel aeration. During the meeting, Mr. Hall added that 3500-series engines are less sensitive to fuel pressure variations than 3600-series engines due to difference in injector design.
The USCG is working closely with Caterpillar to determine a solution for the problem. Specifically, Mr. Sturr asked Mr. Hall if Caterpillar wanted a platform to study the cavitation issue. Mr. Hall stated that Caterpillar would like to identify an engine where cavitation is a recurring problem, and then use that engine for testing. He added that they would like to make adjustments to the engine to make cavitation occur and stop, and take fuel pressure readings at various places during both. Mr. Hall presented a check sheet showing the locations where fuel pressure readings would be taken, and the recommended fuel pressures at each location. A copy of Mr. Halls presentation is included as Appendix E. Mr. Sturr stated that the USCGC ELM and/or HOLLYHOCK may be available for Caterpillar to use for fuel pressure testing. Mr. Hall requested that Mr. Sturr provide the injector failure rate for these two ships, as well as any available reports related to the failures. Messrs. Sturr, Hall and Mike Weiland (Caterpillar) discussed what gauges would be required to make the fuel pressure measurements on the USCG engines. Mr. Sturr asked for the part number for a gauge that could be used. Mr. Weiland replied that he would provide the part number. Finally, Mr. Sturr stated that the USCG would be interested in a booster pump option for the fuel system as a potential way of mitigating the injector failures. He added that Caterpillar might be able to learn something from Mustique since they have booster pumps (but on a C175 engine, not a 3600-series engine).
Mr. Michael Polonio stated that he is also interested in the cavitation issue, and that he planned to collect fuel pressure data for all of the 3600-series engines at Fortis TCI to send to Caterpillar.
Page 6 of 17
Mr. Hall asked Mr. Polonio if Fortis TCI was experiencing fuel injector seizures, to which Mr. Polonio answered "Yes."
Mr. Robert Gruszkowski (USCG) stated that the USCG is having more problems with remanufactured injectors than new injectors. Mr. Hall replied that remanufactured injectors use a new plunger and barrel set; however, this may have been a valid concern in the past because the remanufacturing procedure was not strictly followed. He also reminded attendees that all 3600-series injectors experience some level of cavitation.
3.2 3616 OVERHAUL
Mr. Francis presented information regarding the recent overhaul of one of the two Caterpillar 3616 engines at Bahamas Electricity Corporations (BEC) Marsh Harbour power plant on the Great Abaco Island. A copy of Mr. Francis presentation is included in Appendix F.
Mr. Francis stated that BEC has two Caterpillar 3616 generating units. The units were installed in 2001 and are rated at 4.4 MW each. Mr. Francis stated that the engines have had a number of problems recently, including (1) that they would not start (fuel coolers needed to be added), (2) their turbochargers needed to be remanufactured, (3) lube oil was found in the cooling system (due to faulty oil coolers), and (4) high lube oil consumption. He added that BEC is currently in the process of completing the second major overhaul of the engines.
Mr. Francis stated that BEC is currently concerned with high lube oil consumption on the MH#9 3616 engine. He stated that the unit had to be de-rated to 4.2 MW due to the oil consumption. Mr. Francis stated that no unusual wear of engine components that could lead to excessive oil consumption was found when the engine was disassembled for overhaul. He asked the group for possible reasons for the excessive lube oil consumption.
Mr. Hall stated that Caterpillar recommends cylinder heads with 30 valve seats in high ambient temperature applications (such as in the Caribbean) rather than heads with 20 valve seats.Mr. Polonio stated that Fortis TCI had problems with excessive lube oil consumption when using heads with 20 valve seats on their Caterpillar engines. He added that the plant is now using heads with 30 valve seats on the engines and the excessive lube oil consumption has stopped.Mr. Polonio stated that excessive lube oil consumption can occur if the oil mister is not properly adjusted and that it was very important for BEC to verify this. Mr. Osorio stated that he knows that BEC is using heads with 30 valve seats on the engine. Mr. Hall responded that the cause of the excessive lube oil consumption was probably not the type of cylinder head used.
Mr. Osorio stated that the MH#9 engine at BEC had an oil consumption of 0.724 gal/hr at 100% load, which is a normal value. Mr. Osorio provided information for estimating lube oil consumption, as well as the data for BECs lube oil consumption. These are provided in Appendix G. Mr. Providence stated that data from before and after the recent overhaul was needed to determine if there was, and continues to be, a lube oil consumption problem. Mr. Polonio stated that unless the level of wear is significant and visible, you cannot simply check the running surface of cylinder liners and make a conclusion about their contribution to excessive oil consumption.
Page 7 of 17
Mr. Francis stated that he wondered if the problem was related to the oil mister pump. Mr. Sturr stated that there is a procedure for properly calibrating the pump. Mr. Hall stated that the oil mister pump can be disconnected when using cylinder heads with 20 valve seats. He added that if this is done when using cylinder heads with 30 valve seats, then you need to check for valve recession. Mr. Polonio stated that if oil misters are adjusted and operating properly, then there is no need to disconnect them, regardless of which heads are being used. Mr. Hall responded that this was correct. Mr. Sturr stated that the USCG would like to disconnect the oil misters on the main engines of 225 buoy tenders. He added that he thought these engines would be good candidates for having the misters disconnected. Mr. Hall agreed.
Mr. Francis asked Mr. Hall if excessive oil consumption could occur for some other reason. Mr. Hall responded that he learned from his experience with engines on Turks & Caicos that valve guttering will occur when using cylinder heads with 20 valve seats in high ambient conditions. He added that engines will automatically come with 20 valve seat heads unless a customer specifically requests heads with 30 valve seats.
Mr. Francis asked what BEC should do if excessive lube oil consumption continues after the engine overhaul. Mr. Osorio stated that BEC first needed data to support that there really is high oil consumption. Mr. Hall stated that it is not recommended to operate engines at a constant, steady load when using cyclic heads. He added that if this is done, then inspections should be performed to confirm that valve recession is not occurring.
3.3 FUEL-RELATED ISSUES
Mr. Polonio presented information regarding Fortis TCIs experience with dirty fuel and the importance of fuel tank monitoring and maintenance. A copy of Mr. Polonios presentation is included in Appendix H.
Mr. Polonio stated that Fortis TCIs power plant is in Providenciales, which is the largest city in the Turks & Caicos Islands. For a long time, the plant used Caterpillar 3612 and 3616 generator sets for baseload power, supplemented by 3500-series trailer units. Recently the plant added an 8.7 MW Wrtsil generating unit.
Mr. Polonio stated that the power plant in Providenciales has experienced fuel-related problems for some time. The problems included a high rate of fuel filter blockages and need for replacement, and a high rate of injector failures. Prior to the addition of the Wrtsil unit, Fortis TCI blamed Caterpillar for the fuel problems. However, when the fuel problems also affected the new Wrtsil unit, the plant realized that Caterpillar was not the problem.
Mr. Polonio stated that the plant recently added a new 400,000 gal fuel tank, which provides fuel for approximately 10 days of continuous operation (~40,000 gal used per day). The old tank farm at the plant consisted of four 25,000 gal day tanks, which together only allowed for 2.5 days of continuous operation.
Page 8 of 17
Mr. Polonio stated that he asked plant personnel when was the last time the old tanks were cleaned. He added that no one could remember when they were last cleaned. Mr. Polonio stated that one of the tanks was isolated for cleaning and it was found to be full of sludge, etc. He added that since the volume of the day tanks was small (emptied every 2.5 days), the sludge in the tanks was constantly being stirred up and fed to the fuel filters.
Mr. Polonio stated that fuel had been consistently sampled from the tanks and sent out for analysis. However, the samples were taken from a convenient location that was not near the bottom of the tank. Mr. Polonio stated that the results for all fuel samples came back as good, which was not surprising because the samples were not representative of the tank contents. Mr. Polonio stated that he now uses a thief sampler to sample fuel from tanks. The thief sampler allows representative samples to be taken from anywhere in the volume of fuel.
Mr. Polonio stated that fuel sampled from the day tanks was much cleaner (lighter) after the tanks were cleaned. He added that he later noticed that the fuel sampled from the tanks began to get dirtier/darker again. Mr. Polonio stated that he suspected his fuel suppliers tanks were also dirty. To test this theory, he used the thief sampler to sample fuel from the suppliers tanks. These fuel samples were tested and were confirmed to be dirty.
Mr. Ed Guevara (USCG) noted that there must be a stability issue with the fuel. Mr. Polonio stated that the plant was trusting that the fuel going into and coming out of the tanks was OK. It now knows that proper fuel sampling and periodic tank cleaning is critical.
Mr. Cotton noted problems with the tank setup at Fortis TCI (shown in photos in the presentation in Appendix G), specifically that the tanks have a small volume and are above ground. As a result, they may be subject to temperature drops at night and condensation inside the tanks. Mr. Polonio stated that the Shell now deposits fuel into the 400,000 gal tank, and that there is a pipeline to the four 25,000 gal tanks, which are now used as day tanks. The fuel delivered by Shell originates in the Bahamas. Mr. Polonio stated that he has requested a profile of the supplier tanks.
Mr. Providence stated that Mustique has a 10,000 gal tank, which contains enough fuel for 4.5 days of operation. He added that when fuel deliveries are made, three representatives (one from each involved party) are present and three fuel samples are taken. Mr. Polonio stated that it is important to take control of the entire fuel delivery process.
Mr. Cotton stated that fuel stability and contamination is a big problem with marine fuel supplies on USCG ships. Mr. Vlez stated that he is aware of large fuel tanks in Puerto Rico that are simply refilled after the level drops to a set point. He added that sludge may have been at the bottom of these tanks for 10-15 years.
Mr. Guevara provided the group with information on fuel stability. He stated that it is important to perform a fuel stability test if storing fuel for a long period of time, as well as if paraffinic and naphlalenic fuels are mixed. He added that fuel stability guidance is provided in ISO 8217 DMA (Distillate Marine Grade A). Mr. Guevara accepted an action to upload ISO 8217 DMA information to the COG Projectview site.
Page 9 of 17
Mr. Sturr stated that the USCG is constantly having fuel issues. He added that the USCG now has a dedicated fuel expert who used to be with U.S. Navy.
Mr. Wah stated that D.C. Cook has 60,000 gal fuel tanks. The tanks are very clean because of checks that are imposed on the fuel supplier. Mr. Wah also stated that a reason that the fuel in AEPs tanks are very clean is that it turns fuel deliveries away. He added he realizes that plants on the Caribbean islands may not have this option. Mr. Wah showed to the group tables containing AEPs fuel specification requirements. A copy of these tables is included in Appendix I.
4. PARTS AND VENDOR ISSUES
Members discussed parts obsolescence, quality and availability issues, etc. This discussion included presentations by Caterpillar.
4.1 SERVICE LETTERS - CONTINUED PRODUCT IMPROVEMENTS (CPI)
Mr. Ren stated that service letters come from the CPI process. He added that he had prepared a list of service letters for the 2010-2011 time period. Mr. Wah asked if customers have access to service letter via sis.cat.com. Mr. Osorio replied that they do not. Mr. Ren stated that he would provide the list of service letters to the group.
4.2 CPI ISSUES FROM RECENT TC CONFERENCE
Mr. Ren provided feedback from a recent TC conference regarding how Caterpillar approaches and resolves CPI issues. He stated that each CPI issue includes a problem statement, a root cause investigation, and preparation of a Permanent Corrective Action (PCA). He added that CPI issues sometimes also include other things, for example, a field support plan.
Mr. Ren used the new factory torque setting for the fuel injector case-to-body (to eliminate overstressing and cracking in the threads of the body) as an example of a successful CPI process. Mr. Wah stated that the example helps illustrate that Caterpillar has a rigorous process for addressing and correcting problems. Mr. Ren responded that Caterpillar takes all failures seriously, and that customer satisfaction was the most important part of their business.
Mr. Ren stated that he would provide the new factory torque setting for the fuel injector case-to-body to the group.
4.3 UPDATE ON TIER 4 ENGINE COMPONENTS AND RETRO-FIT OPTIONS
Mr. Ren provided a brief update on engine components and retro-fit options related to new Tier 4 emissions standards. He stated that he had put together a list of website links containing information on various Caterpillar-related topics, and that one of the links covers emission reduction. A copy of the list generated by Mr. Ren is provided in Attachment J.
Page 10 of 17
4.4 CATERPILLAR ACQUISITION OF M OTOREN -WERKE M ANNHEIM
Mr. Ren provided information on Caterpillars recent acquisition of Motoren-Werke Mannheim (MWM). He stated that MWM produces gas engines, which is the main reason why Caterpillar wanted to acquire it. He added that Caterpillar would like MWM to maintain its identity and that at first Caterpillar and MWM will be run as two separate companies. Eventually, Caterpillar wants MWM to sell products through the Caterpillar dealer network; however, it does not want that addition to overwhelm the network. A copy of the Caterpillar press release regarding the acquisition is included in Appendix K.
4.5 SPECSIZER TOOL FOR GENERATING SETS
Mr. Ren provided information on Caterpillars SpecSizer software for determining the "best fit" generator set based on various input criteria. Files provided by Mr. Ren related to SpecSizer are included in Appendix L. Also, an interactive Microsoft Excel-based "Help" file has been uploaded to the COG ProjectView web site.
5. CONDITION MONITORING / PREVENTIVE MAINTENANCE
Members discussed reliability improvements, planned maintenance changes and asset management strategy updates, including parameters monitored, preventive maintenance frequency optimization and critical spare parts strategy.
5.1 USCG LUBE OIL ANALYSIS PROGRAM
Mr. Guevara presented information on the USCGs lube oil analysis program. A copy of Mr. Guevaras presentation is included in Appendix M.
Mr. Guevara stated that he would like to improve the USCGs lube oil analysis program. He stated that an effective program can detect engine problems early and reduce the extent and cost of failures. He added that the potential cost savings from an effective program are large.
Mr. Guevara reported that the USCG currently only performs on-shore testing of lube oil. Three different laboratories are used. There is no consistency in the results provided by the labs, and there is currently no central database for storing test results. Mr. Guevara stated that an effective program required the use of both ship-board testing using hand-held equipment and on-shore testing at a commercial laboratory (preferably ISO certified).
Mr. Cotton stated that in 20 years of oil analysis, the USCG has never caught a single-point catastrophic failure. Based on this, he stated he did not understand why the USCG was looking to spend $500,000 per year on oil analysis. Mr. Polonio stated that in his experience, oil analysis can be beneficial if it is done right. He stated that Fortis TCI has used oil analysis results to identify engine problems in an early stage of development. He added that lube oil samples need to be collected consistently and labeled well, and the analysis results analyzed in detail. Mr. Jacobs stated that implementing an effective lube oil analysis program on ships is difficult.Specifically, samples are taken once per week; however, three samples can go out for analysis at
Page 11 of 17
the same time because of how infrequently mail is sent out from the ship. Mr. Gruszkowski stated that the benefits of oil analysis are also negated by the high frequency of lube oil changes on the ships (every 500 hours).
Mr. Guevara stated that the above points illustrate the importance of having good on-board oil analysis capabilities. He added that lube oil analysis, even with the best program implementation and results, will not identify every catastrophic failure before it occurs.
5.2 CATERPILLAR SOS OIL ANALYSIS
Mr. Wah initiated a discussion about Caterpillars SOS oil analysis program. He stated that he wanted to have a lube oil sample analyzed in the program; however, this did not occur because a Caterpillar representative was not permitted to collect the sample due to plant security. Instead, the sample was collected by AEP personnel and sent to Herguth Laboratories for analysis.Mr. Wah showed Herguths analysis results to the group (the results are included in Appendix N).
Mr. Weiland stated that Caterpillar does not need to collect a sample for it to be analyzed by the SOS program. He added that AEP can collect the sample and send it to Caterpillar. Mr. Weiland also noted that wear metal parameters that are quantified in an SOS oil analysis are based on Caterpillars global experience and are proprietary. He also stated that some important wear metals are not listed in the Herguth reports.
Mr. Wah stated that he would pursue SOS analysis of lube oil from D.C. Cooks Caterpillar engine with his local dealer.
6. TRAINING
6.1 TRAINING BY CATERPILLAR AND /OR ITS DEALERS
In response to a request for an update to Action Item #13 from the December 2010 COG meeting, Mr. Vlez stated the RIMCO provides training within its territory as requested by utilities. Mr. Wah asked if he would have to contact his local dealer for training. Mr. Vlez responded "Yes." Mr. Polonio stated that some dealers are too small to offer training, and asked if training could be coordinated for multiple groups at the same time. e.g., a regional course. Mr. Vlez stated that RIMCO could handle 4-8 people for training in their facility. Training could also be held at a remote site, e.g., the recent 3600-series training that RIMCO held at DOMLEC for two people.
Mr. Polonio stated that Fortis TCI is interested in sending employees for training, and that he needed to know when training classes would be held. Mr. Vlez stated that Mr. Polonio should make a training request, and RIMCO will work with M&E Ltd. to arrange the training. Mr. Vlez added that if RIMCO has space available in upcoming training classes, he can pass on the number of available spaces to Mr. Osorio so he can announce the openings to utilities in the M&E Ltd. region. Mr. Vlez stated that 3600-series training would be held in April 2012. Mr. Wah stated that it would be nice to know when training spots are open.
Page 12 of 17
Mr. Ren asked Mr. Vlez how extensive is the training provided by RIMCO. He stated that he asked because Caterpillar does not want end users doing hardcore internal work on engines. Mr. Vlez responded that RIMCO does whatever training a utility asks for. He added that RIMCO has a core training program, but can also provide information and training for additional items, as requested. Mr. Ren stated that Caterpillar does not want customers performing work for which they do not have expertise or the proper tools. He added that this is especially critical if a product is still covered under warranty. Mr. Providence stated that all customers should be given the same information. He added that knowledge is power, and all customers should know what is OK and not OK to do. Mr. Sturr stated that for the USCG, only CAT-certified technicians should be working on engines since Caterpillar may not honor a warranty if a non-certified person performs the work. He added that when subcontracting out the work, it is often difficult getting certified personnel. The USCG usually chooses the cheapest option, which could end up being someone like "Mom & Pop Katerpillar."
Mr. Guevara stated that he expects there are different levels of certification. He asked Mr. Vlez if RIMCO provides training and issues different levels of certification. In response, Mr. Vlez showed an example of a training agenda prepared for a St. Maarten utility, which was conducted over a period of four days at RIMCO. He added that after this training was completed, the utility asked for a "second level" of training as a follow-up. He stated that the cost of the training was US$4500.
Mr. Francis asked about RIMCO providing training for BEC. Mr. Vlez stated that the BEC personnel could travel to RIMCO or that RIMCO could travel to the Bahamas. He added that for either option, BEC would need to coordinate the training through M&E Ltd. since they are BECs local dealer. Mr. Osorio stated that M&E Ltd. does not have all of the special tools required for 3600-series training (e.g., for a major overhaul) and typically will use a utilitys tools.
Mr. Wah stated that at AEP, a factory representative will come in and direct/supervise AEP personnel, who will perform the work on the engine. He added that for work on Cooper Bessemer engines, two factory representatives would be dispatched, one for the day shift and one for the night shift. Mr. Vlez stated that training styles and information would be different for each utility. Mr. Osorio stated that for recent overhauls at BEC, M&E Ltd used BEC personnel for some labor, cleaning, etc. He added that when performing overhauls, one lead technician is needed to perform work, as well as to supervise what other personnel are doing. He stated that M&E Ltd. does not have the facilities and resources to perform extended training; however, he can work with RIMCO to coordinate the training, if requested.
Mr. Francis asked about training for fuel injectors. Mr. Vlez stated that RIMCO does not provide training for injectors for liability reasons. Mr. Ren asked Mr. Vlez if RIMCO provides training for overhauls. Mr. Vlez responded "Yes."
Mr. Providence asked why there is a need for extensive training. He stated that engine design has not changed much, and utilities should already have a core of trained staff (engineers, mechanics, fitters) to perform most work. He added that training should only normally be
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required for new updates. If a utility has an engineer (or engineers) on staff with an extensive fundamental knowledge of engines and significant experience, then only the additional knowledge of specifics and what tools to use should be needed. He asked why training does not cover only the specifics. Mr. Ren stated that Caterpillar is a world-wide organization and does not have the resources to provide training to customers themselves. He added that because of a lack of resources, Caterpillar even finds it difficult to provide all of the necessary training to its own dealers.
Mr. Gruszkowski stated that the USCGs approach to training/maintenance is to provide specific training to support organic resources. He added that technicians needed to be qualified and current. He stated that for post-warranty issues, if specific information can be pushed to these organic resources, then this frees up resources for Caterpillar to work on bigger issues.Otherwise, the Caterpillar resources are always tied up with smaller, less important issues. For warranty issues, Caterpillar should be involved with everything, no matter how small.
Mr. Polonio stated that training is viewed as a win-win scenario at Fortis TCI. He stated that Caterpillar used to handle certification programs in Peoria. This was preferred since Caterpillar knows what level of training people need. He added that the problem now is that the training of the next generation of personnel is being performed by the older generation, who are no longer certified. He stated that a training program is needed, and the program should state what training is needed to be certified to a certain level. He added that there is a need to get employees up to a consistent level of training/knowledge.
Mr. Vlez stated that RIMCO likes to perform training for utility personnel; however, it needs to train its own personnel and there is not much time left to train others. He added that the needs of each utility are different, which is also a problem when trying to provide training. Mr. Osorio stated that M&E Ltd. cannot issue a "certification" with training due to liability issues. He added that if a certification is desired, then Caterpillar should provide the training. Mr. Ren stated that Caterpillar also will not issue a training certification due to liability issues. Mr. Polonio stated that he was not focused on certifications, but rather was focused on knowledge. He added that any training should include a testing aspect.
Mr. Guevara stated that general knowledge/training is needed before specific training is provided. He stated that many people go out on USCG ships without any general knowledge or training. He added that engineers, etc. need to know the basics first, or specifics will not help out much. Mr. Ren stated that the USCG needs to talk to dealers in the U.S. regarding training.Dealers in the Caribbean do not have enough resources to support the USCG, except maybe for the USCG assets in Puerto Rico. He added that for Caribbean utilities, only RIMCO (no offense to M&E Ltd.) is set up to provide the level of training needed.
Mr. Jacobs stated that training for the USCG can differ depending on what a specific dealer can and does provide. He stated that there needs to be a standard within Caterpillar, e.g., training for 3500-series engines includes the following ... . Mr. Ren stated that Caterpillar pushes responsibility for training to its dealers. To receive a standardized level of training, an organization should choose one dealer for all training. Mr. Jacobs stated that this can be difficult for the USCG since ships often cross regional dealer boundaries. Mr. Ren stated that training
Page 14 of 17
cannot be exactly the same at different dealers. Messrs. Jacobs and Providence stated that the core fundamentals of any training should be the same at different dealers, though. Mr. Ren stated that RIMCO has a training course structure set up. Each organization needs to go to its local dealer to discuss what their own training program contains.
Mr. Wah stated that personnel used to be able to go directly to Caterpillar for training. Mr. Ren responded that Caterpillar no longer has the resources to provide training. There are now too many products in numerous regions of the world, and as a result, Caterpillar has to rely heavily on its dealer network. Mr. Sturr stated that the USCG developed "CAT 101" in conjunction with Caterpillar, and that it is available on the COG Projectview site. Mr. Jacobs discussed additional issues regarding the Defense Products group of the USCG. He stated that some engines are restricted because they are defense-related, and dealers cannot look up information/parts for restricted engine serial numbers. Mr. Gruszkowski asked Mr. Ren if Caterpillar still maintains the training materials that it used in the 1970s and 1980s.
Mr. Francis stated that personnel no longer receive certification for training by Caterpillar. He asked the USCG members what they receive when they get training from dealers. Mr. Cotton responded that they receive a "certificate of analysis." Mr. Francis asked if Caterpillar recognizes this certificate. Mr. Ren responded "No" and asked Mr. Francis why having a training certification is necessary. He added that Caterpillar will not honor training certificates issued to a 2nd party (the dealer providing the training is the 1st party) due to liability concerns.Mr. Francis responded that certification may be important within an organization for promotions, raises, etc. Mr. Ren stated that training (or a training certificate) does not really mean anything. If an engine is under warranty, then Caterpillar should be performing the work. If the engine is out of warranty, then it is the customers engine to work on and repair or damage.
Mr. Ren stated that he has prepared a list of core training topics for Caterpillar dealers. To become "certified," it would take 3-5 years to complete all of the recommended courses on the list. He stated that there is not one single training class that you can take to become certified. Mr. Ren stated that Caterpillar not only does not have the resources to provide training to customers, it does not have resources to provide training to all of its dealers technicians. As a result, Caterpillar has to tell dealers that some of technicians are not authorized to go out to customers and provide service. Mr. Ren stated that not all people who have been trained to train are good teachers. He stated that Caterpillar has "trainer trainers" whose mission is to train the dealers trainers to be good teachers.
6.2 TOUR OF RIMCO CATERPILLAR
Members participated in a tour of the RIMCO Caterpillar facility on the morning of Wednesday, November 16, 2011. Members were able to see the wide range of products and services that RIMCO is able to offer Caterpillar clients in Puerto Rico and the surrounding Caribbean area.
Page 15 of 17
7. COG BUDGET, PLANNED / PROPOSED TASKS AND GROUP STATUS
7.1 BUDGET STATUS
Dr. Thompson stated that as of the meeting, only two members had paid the COG dues for 2011.
Timely payment of dues by all members is key to the effectiveness and longevity of the owners group. Please work to have outstanding dues paid as soon as possible.
7.2 PLANNED / PROPOSED TASKS
Mr. Wah stated that it would be helpful for the group to review minimum training standards recommended by Caterpillar and used at each utility. Mr. Wah recommended that the group contract with MPR to perform the review. Dr. Thompson accepted an action for MPR to provide a proposal for the review by the next meeting.
7.3 STATUS OF COG
Mr. Wah stated that he thought the status of the group was good. He apologized for MPR and himself being behind schedule on preparing the minutes from the previous meeting and the agenda for the current meeting. He stated that he was pleased with the groups discussion and thought that it had good technical content.
8. CLOSING ITEMS
8.1 REVIEW OF ACTION ITEMS
Dr. Thompson reviewed the list of action items assigned during the meeting. The list of items is included in Appendix C.
8.2 COG EMAIL SIGNATURE
Mr. Wah requested that "www.cog.mpr.com" be added to the signature of COG-related emails.
8.3 DEADLINES FOR ISSUE OF M EETING AGENDA AND M INUTES
Mr. Wah requested that the COG and MPR set deadlines for the issuing of meeting minutes, solicitation of meeting topics for an upcoming meeting, and the issuing of a draft meeting agenda. The following deadlines were agreed to:
x Meeting minutes - Issued within 60 days after the meeting ends
Page 16 of 17
x Agenda topics - Email request sent out 45 days prior to start of next meeting; members/attendees to respond with topics during next 15 days
x Draft agenda - Emailed to members 30 days prior to start of next meeting
8.4 FREQUENCY OF M EETINGS
Mr. Wah asked members if meeting twice per year was too frequent. Most members replied that having two meetings per year was acceptable, and that the round table discussion should be more efficient and preferably limited to one day. Mr. Ren stated that he questioned the value of semi-annual meetings because many members did not submit questions or concerns for discussion at the meeting. He added that it would be valuable to have members prepare presentations describing operating experiences, best practices and other topics.
8.5 NEXT M EETING DATE AND LOCATION
The group agreed that the next meeting of the Caterpillar Owners Group will be held in Lafayette, Indiana. The target schedule for the meeting is May 15-16, 2012. Mr. Ren stated that it should be OK to schedule the meeting for this week. He added that a concern was scheduling the meeting around the Indianapolis 500 race, during which hotel vacancies are scarce. A tour of Caterpillars 3516 production facility may be conducted on the morning of Wednesday, May 16th.
8.6 ELECTION OF NEW COG CHAIRMAN
Mr. Wah asked for volunteers to be considered for election as the new COG chairman. Mr. Polonio also suggested, for continuity sake, that an assistant chairman be elected no later than one year prior to the current chairman stepping down and that the assistant chair automatically move in to the chairman role (i.e., a chair-in-waiting). Mr. Wah indicated that a charter revision would be required to define the role of the assistant chairman and the rules of succession. He stated that he would revise the charter and send out a draft for review and signatures.
The COG selected Messrs. Sturr and Providence as the new chairman and assistant chairman, respectively.
Page 17 of 17
List of Appendices
A List of Attendees
B Meeting Agenda
C Action Items
D USCG Presentation - 3608 Fuel Injector Failures Due to Cavitation
E Caterpillar - Typical Diesel System Pressure Check Sheet
F BEC Presentation- 3616 Overhaul
G Caterpillar - Estimating Lube Oil Consumption - General Information and BEC Data
H Fortis TCI Presentation - Effect of Dirty Fuel and Importance of Fuel Tank Monitoring and
Maintenance
I AEP - Fuel Specification Requirements
J List of Caterpillar Website Links
K Caterpillar - Press Release for Acquisition of MWM
L Caterpillar - SpecSizer Software Information
M USCG Presentation - Lube Oil Analysis Program
N Herguth Laboratory Reports - D.C. Cook Lube Oil Samples
A-1
A List of Attendees
A-2
CA
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RP
ILLA
R O
WN
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U
SC
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FLC
Nor
folk
75
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Noe
l.Cab
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@us
cg.m
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Tim
Cot
ton
US
CG
SF
LC N
orfo
lk
757-
628-
4359
T
imot
hy.H
.Cot
ton@
uscg
.mil
John
DiF
ranc
esco
U
SC
GC
WA
ES
CH
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510-
437-
5902
Jo
hn.D
iFra
nces
co@
uscg
.mil
Chr
is F
ranc
is
Bah
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Ele
ctric
ity C
orp
242-
302-
1245
C
MF
ranc
is@
Bah
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Ele
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ity.c
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Rob
ert G
rusz
kow
ski
US
CG
SF
LC A
lam
eda
510-
437-
5951
R
ober
t.J.G
rusz
kow
ski@
uscg
.mil
Ed
Gue
vara
U
SC
G B
altim
ore
SF
LC/E
SD
/MP
M
410-
762-
6616
E
dgar
do.S
.Gue
vara
@us
cg.m
il
Bob
Hal
l (b
y ph
one)
C
ater
pilla
r 76
5-44
8-53
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Hal
lRJ@
cat.c
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Tim
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D.C
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Dal
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U
SC
G S
FLC
Ass
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757-
628-
4545
D
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T.J
acob
s@us
cg.m
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Juan
Oso
rio
Mac
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ry &
Ene
rgy
Ltd.
24
2-37
6-57
01
joso
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me-
ltd.c
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Mic
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Pol
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F
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784-
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ju
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Jay
Ren
Cat
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713-
895-
4531
R
eneJ
C@
cat.c
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Gar
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ponh
olz
US
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Bal
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FLC
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Gar
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Mat
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US
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LC M
ain
Pro
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410-
762-
6364
M
atth
ew.P
.Stu
rr@
uscg
.mil
Gar
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hom
pson
M
PR
Ass
ocia
tes
703-
519-
0431
gt
hom
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@m
pr.c
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Mig
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le
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, Inc
. 78
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Will
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B-1
B Meeting Agenda
10 November 2011
CATERPILLAR OWNERS GROUP MEETING AGENDA
Dates: Tuesday - Wednesday 15-16 November 2011 8 am - 5 pm (Tuesday) 9:30 am - 11 am (Wednesday)
Location: Caribe Hilton (Tuesday) 1 San Geronimo Street, San Juan, Puerto Rico 00901
RIMCO (Cat), Inc. (Wednesday) John F. Kennedy Ave, Km 3.7, San Juan, Puerto Rico
Subject: Caterpillar Owners Group Semi-Annual Meeting
Attendees: COG Members, Caterpillar / Dealer Representatives, and Project Manager
Purpose: Discuss technical issues associated with Caterpillar Engines / Electrical Generation and discuss 2011 COG tasks.
Objectives: 1. Review operating experience to improve COG diesel engine / generator reliability.
2. Identify and assign projects that will benefit CAT equipment reliability. 3. Provide technical reports and/or evaluations to facilitate technical exchanges. 4. Conduct technical training or plant tour as scheduled.
Note to Members:If possible, please develop a PowerPoint presentation using the below agenda item numbers, discussing developments at your facility(s).
AGENDA:
1. Opening and Administrative Details
Topic Discussion Leader a) Introductions Chairman b) Agenda Review MPR c) Review & Approve Previous COG Meeting Minutes MPR d) Updates on COG Action Items MPR e) COG e-mail List Processor Update MPR f) Potential New COG Members Chairman
2. Operating Experience (OE) Discuss any significant failures since last meeting. Areas for discussion consideration include identification of problem (troubleshooting), cause determination, compensatory actions, and corrective actions.
Topic Discussion Leader a) 3608 Fuel Injector Failures Due to Cavitation USCG b) 3616 Overhaul BEC
2
3. Parts and Vendor Issues Areas for discussion consideration include fuel oil developments, parts obsolescence, parts quality, parts availability, etc.
Topic Discussion Leader a) Caterpillar / Dealer Presentations CAT / RIMCO b) Continuous Product Improvements Released Serv ice Letters CAT / RIMCO c) Update on Tier 4 Engine Components and Retro-Fit Options CAT / RIMCO d) Impact of CAT Acquisition of Motoren-Werke Mannheim CAT e) SpecSizer Tool for Generating Sets CAT / RIMCO f) Caterpillar Updates from Last TC Conference R. Hall CAT
4. Condition Monitoring / Preventive Maintenance Discuss reliability improvements, planned maintenance changes, asset management strategy updates, etc. Areas for discussion consideration include parameters monitored, PM frequency optimization, critical spares strategy, etc.
Topic Discussion Leader a) USCG Lube Oil Analysis Program USCG b) Oil Analysis DC Cook vs. CAT SOS Parameters A EP c) Generator Bearings Configuration, Alarm Setti ngs and
MaintenanceUSCG
5. Other Technical Topics Discuss topics such as designed upgrades, regulatory issues, operating limits, etc.
Topic Discussion Leader a) Plant Response to Extreme Weather Situations All b) How Members Use Their Equipment AEP AEP c) How Members Use Their Equipment U.S. Coast Gu ard USCG d) Plant Equipment List (e.g., Model, S/N) Updat e Needed? All e) SIS Access and Questions All f) Use of Electronic Meeting Technology for Future Meetings. USCG g) Use of COG Website Messages, e-mail Signature s, etc. All
6. Training Areas for consideration include guidance report developments, classroom training, working meetings to develop maintenance guides, etc.
Topic Discussion Leader a) Dealer Solution Network and a Data Entry and Processing
Demonstration (during Tour?) RIMCO
7. COG Budget
Topic Discussion Leader a) Budget Status MPR b) Planned / Proposed Tasks MPR c) Status of COG Chairman
3
8. Closing
Topic Discussion Leader a) Review & Assignment of Meeting Commitments / Action Items Chairman / MPR b) Addition of www.cog.mpr.com in Signature of COG e-mails All c) Deadlines for Completion of Meeting Agenda and Minutes All d) Frequency of Meetings All e) Next Meeting Dates, Locations & Subjects
x Lafayette in Summer of 2012? x Please be prepared to submit items for discussion at the
next meeting.
All
f) Election of New COG Chairman All g) Adjourn Meeting Chairman h) Tour of RIMCO (Wednesday) All
C-1
C Action Items
C-2
ACTION ITEMS FROM DECEMBER 2010 CATERPILLAR OWNERS GROUP MEETING
# Action Assigned to Status
1 Provide Service Information System Q&A session at next meeting Caterpillar Incomplete
2 Add DSN spreadsheet to COG website OConnell
Complete; Mr. Sturr asked that Mr. OConnell was given a new action to send the location of the spreadsheet on the website to members. Mr. Sturr accepted a new action to investigate better way to access newly post information on the Projectview site.
3 Bring table name cards to next meeting OConnell Complete
4 Coordinate Google search for public COG website OConnell Complete; Mr. Wah stated that the group is now recognized by the Google search engine.
5 Determine options for COG message board OConnell
Incomplete; Mr. Sturr stated that the group needed to determine how it wants to use the GOC website and design a new site around what is wanted. Members stated that a message forum style would be preferred, and that forum subgroups and alert messages would be helpful. Mr. Sturr accepted a new action to take the lead on developing a new site with assistance from Mr. Cotton and MPR.
6Provide update on 3516 high exhaust temperature issue at next meeting
Francis Complete
7 Post configuration data on website OConnell
Incomplete; Mr. Wah stated that he believed the action had been completed. Dr. Thompson will confirm with Mr. OConnell that the action has been completed. Mr. OConnell was given a new action to add an "Update Date" column to Equipment Data Sheet.
8 Provide information on aftercooler cleaning Happe / Williams Complete
9Change generator arrangement number field to generator model number on configuration data sheet
OConnell Incomplete
10 Develop plan for organizing documents on COG website Sturr Incomplete
C-3
# Action Assigned to Status
11 Add new attendees to COG email list and website OConnell Complete
12 Provide presentation on issues raised by members to COG Hall Complete
13 Arranging 3600 training for technicians Vlez / Osorio
Complete; RIMCO will try to notify group of open seats when they are available. Max is 8 per session. The group discussed at length opportunities for training by Caterpillar and/or its dealers at the November 2011 meeting - see Section 6.1 for a summary of the discussion.
14 Send configuration data for USCG engines Sturr Complete
15 Remove Wes Fassnacht from email list and website OConnell Complete
16 Send 2011 task statement letters to members OConnell Complete
C-4
ACTION ITEMS FROM MAY 2011 CATERPILLAR OWNERS GROUP MEETING
# Action Assigned to Status
1 Supply Serial Number to CAT to see if turbo adapter can be applied Francis / BEC Complete
2Status of 3500 remanufactured head availability / turn around - BEC had noted long lead times
CAT / M&E Ltd.
Complete; Mr. Osorio stated that M&E is having problems getting cylinder heads on time, in particular for the new C175 engine. Mr. Ren stated that members need to be proactive when the time for an overhaul is approaching and make a "reservation" with their dealer. Mr. Ren also stated that he needed specific dates to figure out what happened with the delay in the delivery of heads to BEC.
3 Send copy of U.S.A. EPA rules (40 CFR 63 ) to RIMCO Wah / AEP
Complete; Mr. Vlez stated that he had contacted Mr. Tim Cresswell, the head of emissions for Caterpillar, and received a response email from him. Mr. Wah stated that he had a copy of the email and would provide it to members.
4Provide copy of 2011 Global Power Systems Technical Communicator Conference agenda to members
Ren / CAT
Complete; Mr. Ren provided a summary of the conference to members at the current meeting.
C-5
ACTION ITEMS FROM NOVEMBER 2011 CATERPILLAR OWNERS GROUP MEETING
# Action Assigned to Status
1 Send location of DSN reporting form on ProjectView site to members MPR Complete
2 Investigate better way to access newly post information on ProjectView site Sturr Incomplete
3 Investigate development of new COG website / discussion forum Sturr / Cotton / MPR Incomplete
4 Add "Update Date" column to Equipment Data Sheet MPR Incomplete
5 Provide access to ProjectView site to Jay Ren MPR Complete
6 Upload ISO 8217 DMA information to ProjectView site Guevara Incomplete
7
Provide injector failure rates, failure reports and completed fuel pressure data sheets for USCGC ELM and HOLLYHOCK to Bob Hall
Sturr Incomplete
8 Provide completed fuel pressure data sheet to Bob Hall Polonio Incomplete
9 Provide part number for appropriate fuel pressure gauge to Matt Sturr Weiland Incomplete
10 Share MWM acquisition press release with group Ren Incomplete
11 Provide list of web link resources (from presentation) to group Ren Incomplete
12 Provide list of 2010-2011 service letters to group Ren Incomplete
13 Provide new factory fuel injector case-to-body torque value to group Ren Incomplete
14 Provide proposal for review of minimum training standards to group by next meeting
MPR Incomplete
C-6
# Action Assigned to Status
15 Revise charter to reflect new election procedure and succession rule(s) for vice-chairman/chairman
Wah Incomplete
16 Add new attendees to email list server and ProjectView site MPR Complete
17
For future meetings, add new attendees (who have indicated they will attend the meeting) to email list server and ProjectView site prior to the meeting
MPR Incomplete
18 Issue draft of meeting minutes within 60 days of meeting adjournment MPR Complete
19 Submit proposed agenda topics to MPR no later than 45 days prior to start of meeting
All members Incomplete
20 Issue draft meeting agenda for comments no longer than 30 days prior to start of meeting
MPR Incomplete
D-1
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ansf
er/P
rimin
gPum
p
Filt
erO
utle
tE
ngin
eFue
lPS
IF
ilter
Out
let
Diff
eren
tialP
SI
Gau
ge
Sup
plyf
rom
f
/i
i
Out
toIn
ject
ors
xfer
/prim
ing
pum
ps
Sec
onda
ryFilt
erB
ankS
elec
tor
We
alw
aysr
uno
nbo
th
ToF
uelS
uppl
yIn
ject
orR
ail
ToF
uelS
uppl
yInj
ecto
rRai
l
Fro
mIn
ject
orR
etur
nR
ail
Fue
lPre
ssur
eReg
ulat
or?
Sec
onda
ryF
ilter
lS
econ
daryF
ilter
D
iffer
entia
lE
ngin
eFue
lPre
ssur
e
#2
MD
ER
acor
Ban
ks#
1M
DE
Rac
orB
ank
New
Vac
uum
Gau
ge
Wat
erIn
dica
torG
auge
#2M
DE
Str
aine
rVac
uum
ga
uges
OLD
OO
CVac
uum
Gau
ge
#2M
DE
Str
aine
rs
Wat
erIn
dica
tor
sens
or
Wat
erin
dica
torg
auge
just
wire
d
and
test
ed.
Vac
uum
gaug
eOO
C,
inst
alle
dne
wva
cuum
gaug
eson
inst
alle
dne
wv
acuu
mga
uges
on
fil
ter
outle
tpip
ing.
NV
GN
ewV
acuu
mG
auge
New
cab
les,
110
VA
C.
Wat
erin
dica
torf
rom
th
ega
uge/
light
just
term
inat
edin
the
junc
tion
bo
x.
E-1
E Caterpillar - Typical Diesel System Pressure Check Sheet
Typ
ical
Die
selS
yste
mP
ress
ure
Typ
ical
Die
selS
yste
mP
ress
ure
Che
ck S
heet
Mea
sure
men
t Loc
atio
nsI
f a fi
lter
or s
epar
ator
is u
sed
betw
een
the
mai
n ta
nk a
nd d
ay ta
nk ta
ke in
let a
nd o
ut
pres
sure
of t
he fi
lter
or
sepa
rato
r.
If a
filte
r or
sep
arat
or is
use
d be
twee
n th
e da
y t
ank
and
the
engi
ne tr
ansf
er p
ump
take
in
let a
nd o
utle
t pre
ssur
e m
easu
rem
ents
at t
hat f
ilter
.
Tak
e in
let p
ress
ure
and
tem
pera
ture
at t
he e
ngin
e in
let.
Ref
eren
ce S
EB
D93
07
Tak
e in
let a
nd o
utle
t pre
ssur
e at
the
seco
ndar
y fi
lters
that
are
mou
nted
on
the
engi
ne.
Thi
s is
typi
cally
sta
ndar
d m
easu
rem
ents
take
n on
Ca
t eng
ine
mon
itorin
g sy
stem
s.
Tak
e pr
essu
re a
t pre
ssur
e re
gula
tor
port
. S
ee a
ttac
hed
Dia
gram
.
Tak
e re
turn
pre
ssur
e af
ter
the
regu
lato
r.
If
afu
elco
oler
isus
edin
the
retu
rnfu
ellin
eta
kea
pres
sure
mea
sure
men
tbef
ore
and
If
afu
elco
oler
isus
edin
the
retu
rnfu
ellin
eta
kea
pres
sure
mea
sure
men
tbef
ore
and
afte
r th
e co
oler
.
Fue
l Pre
ssur
e R
ecom
men
datio
ns
In
let F
uel P
ress
ure
to th
e P
rimar
y F
ilter
(at
rat
ed s
peed
and
load
).
N
ot le
ss th
an -
20 k
Pa
(-3
psi)
gaug
e &
no
grea
ter
tha
n 10
0 kP
a (1
4.5
psi)
gaug
e; 5
0 kP
a (7
.25
psi)
gaug
e if
the
prim
ing pu
mp
is u
sed.
P
rimar
y an
d S
econ
dary
Diff
eren
tial P
ress
ure.
75 k
Pa
(10.
8 ps
i)
M
UI F
uel S
yste
m P
ress
ure
(set
@ r
ated
spe
ed a
nd lo
ad).
550
kPa
+/-
50 k
Pa
(80
psi +
/-7
psi)
R
etur
n F
uel L
ine
Res
tric
tion
Pre
ssur
eS
houl
d no
t exc
eed
350
kPa (5
1ps
i) at
rat
ed s
peed
and
load
(p
)p
Ei
Che
ck S
heet
Mai
nS
tora
ge T
ank
Eng
ine
Inje
ctor
s
on e
ngin
e tr
ansf
erpu
mp
iI
ltP
Inle
t Pre
ssur
ekP
a
Out
let
Pre
ssur
e__
____
___
kP
aP
ress
ure
at R
egul
ator
____
__ k
Pa on
eng
ine
pres
sure
regu
lato
r
filte
r /
sepa
rato
r
on e
ngin
e se
cond
ary
filte
r
Inle
tPre
ssur
e__
____
kP
aIn
let P
ress
ure
____
__ k
Pa
____
___
kPa
Otl
tP
Inle
t Tem
pera
ture
____
__ d
eg C
sepa
rato
r
Out
let
Pre
ssur
e__
____
___
kP
a
Out
let
Pres
sure
____
____
_ k
Pa
Out
let
Pre
ssur
e__
____
___
kP
a
DT
k
prim
ary
filte
r /
sepa
rato
r
Inle
t Pre
ssur
e__
____
kP
a
Ret
urn
to (c
ircle
one
)fu
elco
oler
Day
Tank
Inle
t Pre
ssur
e__
____
kP
aO
utle
t P
ress
ure
____
____
_ k
Pa
()
1) m
ain
tank
2) d
ay ta
nk
F-1
F BEC Presentation- 3616 Overhaul
2* 3616MACHINES
RATEDFOR4.4MW S
INSTALLED2001
ENGINESWOULDNOTSTART/FUELCOOLERSADDED
TURBOCHARGERS!REMANED"
LUBEOILINCOOLINGSYSTEM/FAULTYOILCOOLERS
HIGHOILCONSUMPTION
INPROCESSOFCOMPLETING2ND,MAJOROVERHAULS
CONCERN
(1) PRESENTLYMH#93616ISCONSUMINGEXCESSAMOUTOFLUBEOIL,ONDISASSEMBLYDIDNOTSEEANYNOTICABLEFAULTOREXCESSIVEWEARONCOMPONENTS.
G-1
G Caterpillar - Estimating Lube Oil Consumption - General Information and BEC Data
0.00
08N
OR
MA
L:0.0
008
MA
XIM
UM
:0.00
367.
5N
OR
MA
LFO
RCA
TOIL
:7.5
UN
ITM
OD
EL
SN
EN
GIN
EB
HP
LOA
DF
AC
TO
R(%
)G
AL/
HR
HO
UR
ST
OC
ALC
ULA
TE
ES
TIM
AT
E O
ILG
ALL
ON
S
G9
3616
1PD
0036
86,
786
100%
0.72
41
0.72
G10
3616
1PD
0036
96,
786
100%
0.72
41
0.72
CH
AR
T F
OR
CA
LCU
LAT
E E
ST
IMA
TE
D O
IL C
ON
SU
MP
TIO
N/H
OU
RS
WIT
H L
OA
D F
AC
TO
R
BR
AK
E S
PE
CIF
IC O
IL C
ON
SU
MP
TIO
N B
SO
C (
LB/B
HP
-HR
)
DE
NS
ITY
OF
OIL
(LB
/GA
L)
inpu
tLoa
dF
acto
rH
ours
inpu
tLo
adF
acto
rH
ours
H-1
H Fortis TCI Presentation - Effect of Dirty Fuel and Importance of Fuel Tank Monitoring and Maintenance
Ene
rgy
for
Goo
dE
nerg
y fo
r G
ood
FO
RT
IS T
CI
CO
G P
rese
ntat
ion
on E
ffect
of
CO
G P
rese
ntat
ion
on E
ffect
of
Dirt
y F
uel a
nd im
port
ance
of
Fue
l Tan
k M
onito
ring
&
Mai
nten
ance
ntat
ion
title
]M
aint
enan
cent
atio
n tit
le]
[t
ti ti
tl]
Ene
rgy
for
Goo
dE
nerg
y fo
r G
ood
[pre
sen
tatio
n ti
tle
]
FO
RT
IS T
CI
CO
G P
rese
ntat
ion
on E
ffect
of D
irty
CO
G P
rese
ntat
ion
on E
ffect
of D
irty
Fue
l and
impo
rtan
ce o
f Fue
l Tan
k M
onito
ring
& M
aint
enan
ce
Npv
embe
r 20
11
3
Bk
d T
Pbl
Bac
kgr
oun
d To
Pro
blem
Con
sist
ently
Hig
h fu
el fi
lter
blo
ckag
e
Con
sist
ently
Hig
h fu
el fi
lter
blo
ckag
e an
d re
plac
emen
t rat
e
H
igh
fuel
inje
ctor
failu
re r
ate.
4
[t
ti ti
tl]
Ene
rgy
for
Goo
dE
nerg
y fo
r G
ood
[pre
sen
tatio
n ti
tle
]
6
7
8
9
10
11
12
13
Roo
t Cau
se &
Pro
blem
R
oot C
ause
& P
robl
em
Res
olut
ion
Dirt
acc
umul
atio
n in
fuel
tank
s du
e to
Dirt
acc
umul
atio
n in
fuel
tank
s du
e to
in
freq
uent
and
irre
gula
r cl
eani
ng
whi
ch fl
ows
thru
to e
ngin
esw
hich
flow
s th
ru to
eng
ines
In
corr
ect t
ools
and
tech
niqu
es fo
r st
orag
e ta
nk s
ampl
ing
and
stor
age
tank
sam
plin
g an
d m
aint
enan
ce
Lk
f i
ifit f
l t
t
La
ck
of
sign
ifica
nt f
uels
tora
gea
tpl
ant s
ite a
nd in
suffi
cien
t tim
e fo
r fu
el
settl
emen
tse
ttlem
ent
D
irt a
ccum
ulat
ion
and
infr
eque
nt
li
f
t t
k
t li
14
Roo
t Cau
se &
Pro
blem
R
oot C
ause
& P
robl
em
Res
olut
ion
Incr
ease
aw
aren
ess
of
In
crea
se a
war
enes
s of
im
port
ance
& im
pact
of f
uel o
n en
gine
per
form
ance
engi
ne p
erfo
rman
ce.
Im
prov
e kn
owle
dge
and
co
mm
itmen
t to
stor
age
tank
com
mitm
ent t
o st
orag
e ta
nkm
onito
ring
and
mai
nten
ance
.
15
Btif
l B N
tB
eau
tifu
l By
Na
ture
16
I-1
I AEP - Fuel Specification Requirements
Information 12-THP-6020-CHM-307 Rev. 16 Page 9 of 88
EMERGENCY DIESEL FUEL OIL
5 ACCEPTANCE CRITERIA
Table 1 - Emergency Diesel Fuel Oil Tanker Truck Parameters
PARAMETER ASTM # SAMPLE FREQUENCY LIMIT ATT # Clear & Bright Appearance (1) (4) [TS SR 3.8.3.2 & 5.5.11.a.3]
D4176-82 Method A
Prior to adding new fuel to the storage tanks
Pass 11
Color [TS SR 3.8.3.2 & 5.5.11.a.3] [Ref. 8.2.1o]
D 1500 Prior to adding new fuel to the storage tanks
d #5 16
Specific Gravity [TS SR 3.8.3.2 & 5.5.11.a.1]
D1298-80 Prior to adding the new fuel to the storage tanks
0.82 ! 0.88 60/60qF 10
Flash Point [TS SR 3.8.3.2 & 5.5.11.a.2]
D93 Prior to adding new fuel to the storage tanks
t 51.67qC or t 125qF 13
Kinematic Viscosity [TS SR 3.8.3.2 & 5.5.11.a.2]
D445 Prior to adding new fuel to the storage tanks
1.9 ! 4.1 cSt @ 40qC 14 OR 19
Water & Sediment [TS SR 3.8.3.2 & 5.5.11.b]
D1796 Within 31 days after new fuel is added to the
storage tanks
d 0.05 Vol.% 15
Cloud Point [TS SR 3.8.3.2 & 5.5.11.b]
D2500 Within 31 days after new fuel is added to the
storage tanks
d -6.7qC or d 20qF
Carbon Residue on 10% Residuum [TS SR 3.8.3.2 & 5.5.11.b]
D524 Within 31 days after new fuel is added to the
storage tanks
d 0.35%
Ash Weight [TS SR 3.8.3.2 & 5.5.11.b]
D482 Within 31 days after new fuel is added to the
storage tanks
d 0.01%
Distillation Temperature 90% Point [TS SR 3.8.3.2 & 5.5.11.b]
D86 Within 31 days after new fuel is added to the
storage tanks
282.2 ! 338qC or 540 - 640qF
Sulfur Weight [TS SR 3.8.3.2 & 5.5.11.b]
D129 or D2622-82
Within 31 days after new fuel is added to the
storage tanks
d 0.5% [TS 5.5.11.a.2] d 0.3% (2)
Copper Strip Corrosion [TS SR 3.8.3.2 & 5.5.11.b]
D130 Within 31 days after new fuel is added to the
storage tanks
d 3
Cetane Number (3) [TS SR 3.8.3.2 & 5.5.11.b]
D976 Within 31 days after new fuel is added to the
storage tanks
t 40
(1) A condition in which the fuel contains no visible water drops or particles and is free of haze or cloudiness. (2) Department of Natural Resources Permit limit. Typical Sulfur % content of Cook fuel oil is < 0.05%. (3) Where cetane number by Method D613 is not available, D976 may be used as an approximation. Where there is
a disagreement, Method D613 shall be the preferred method. (4) Ensure fuel oil is color #5 or less to validate Clear & Bright results. [Ref. 8.2.1g]
Information 12-THP-6020-CHM-307 Rev. 16 Page 10 of 88
EMERGENCY DIESEL FUEL OIL
Table 2 ! Emergency Diesel Fuel Oil Sample Parameters
PARAMETER ASTM # SAMPLE FREQUENCY
LIMIT ATT #
Particulate Contamination [TS 5.5.11.c, SR 3.8.3.2]
D2276-83 Method A
1 / 31 Days < 10 mg/L 12
Particulate Contamination (1) [TRM TSR 8.8.2.1]
D2276-83 1 / 10 years < 10 mg/L 12
(1) TRS 8.8.2.1 reads: !Clean each fuel oil storage tank by: a. Draining fuel oil storage tank, removing the accumulated sediment, and cleaning the tank; OR b. Agitate the fuel oil in the storage tank while pumping the oil from the bottom of the tank through a 5-micron filter, and back to the opposite end of the tank. Three consecutive samples shall be taken and analyzed in accordance with ASTM D2276-83. If the contaminant level in any of the samples is greater than 10 mg per liter, the agitation, filtration, and sampling processes shall be repeated. If the contaminant level remains above 10 mg per liter after 3 iterations, the draining, and cleaning method described in TRS 8.8.2.1.a." Therefore the particulate contamination surveillance requirement every 10 years is performed only if option !b" is being performed.
Table 3 - Emergency Diesel Fuel Oil Tank Dip Sample Parameters
PARAMETER ASTM # SAMPLE FREQUENCY
LIMIT ATT #
Visible Accumulated Water [TS SR 3.8.3.3]
--- 1 / 31 Days PASS
Table 4 - Diesel Driven Fire Pump Fuel Oil Tank Parameters
PARAMETER ASTM # SAMPLE FREQUENCY
LIMITS ATT #
Kinematic Viscosity [TRM TRS 8.7.5.8]
D445 1 / 92 Days 1.9 # 4.1 cSt @ 40qC
14 OR 19
Visible Accumulated Water (1) --- 1 / 92 Days PASS --- Water & Sediment [TRM TRS 8.7.5.8]
D1796 1 / 92 Days d 0.05 Vol.% 15
(1) Remove any visible water found and obtain an additional sample for water and sediment
Information 12-THP-6020-CHM-307 Rev. 16 Page 11 of 88
EMERGENCY DIESEL FUEL OIL
Table 5 ! Security Diesel Fuel Oil Tank Parameters
PARAMETER ASTM # SAMPLE FREQUENCY
LIMITS ATT #
Visible Accumulated Water (1)
--- 1 / 92 Days PASS ---
Water & Sediment D1796 1 / 92 Days d 0.05 Vol.% 15
(1) Remove any found.
Table 6 ! Supplemental Emergency Diesel Fuel Oil Tanker Truck Parameters
PARAMETER ASTM # SAMPLE FREQUENCY
LIMIT ATT #
Clear & Bright Appearance
D4176-82 Method A
Prior to adding new fuel to the storage
tanks
Pass 11
Color D 1500 Prior to adding new fuel to the storage
tanks
d #5 16
Specific Gravity
D1298-80 Prior to adding the new fuel to the storage tanks
0.82 ! 0.88 60/60qF 10
Flash Point
D93 Prior to adding new fuel to the storage
tanks
t 51.67qC or t 125qF 13
Kinematic Viscosity D445 Prior to adding new fuel to the storage
tanks
1.9 ! 4.1 cSt @ 40qC 14 OR 19
Table 7 ! Supplemental Emergency Diesel Fuel Oil Tank Dip Sample Parameters
PARAMETER ASTM # SAMPLE FREQUENCY
LIMIT ATT #
Visible Accumulated Water
--- 1 / 31 Days PASS
Water & Sediment D1796 Diagnostic < 0.05 % Vol. 15
Information 12-THP-6020-CHM-307 Rev. 16 Page 12 of 88
EMERGENCY DIESEL FUEL OIL
Table 8 - Emergency Diesel Fuel Oil Tank Annual Test Parameters
PARAMETER ASTM # SAMPLE FREQUENCY ATT # Clear & Bright Appearance D4176-82
Method A Annually from each EDG storage tank transfer pump. 11
Color D 1500 Annually from each EDG storage tank transfer pump
16
Specific Gravity D1298-80 Annually from each EDG storage tank transfer pump
10
Flash Point
D93 Annually from each EDG storage tank transfer pump
13
Kinematic Viscosity
D445 Annually from each EDG storage tank transfer pump
14 OR 19
Water & Sediment
D1796 Annually from each EDG storage tank transfer pump
15
Cloud Point
D2500 Annually from each EDG storage tank transfer pump Offsite
Carbon Residue on 10% Residue
D524 Annually from each EDG storage tank transfer pump Offsite
Ash Weight D482 Annually from each EDG storage tank transfer pump Offsite
Distillation Temperature 90% Point
D86 Annually from each EDG storage tank transfer pump Offsite
Sulfur Weight D129 or D2622-82
Annually from each EDG storage tank transfer pump Offsite
Copper Strip Corrosion D130 Annually from each EDG storage tank transfer pump Offsite
Cetane Number D976 Annually from each EDG storage tank transfer pump Offsite
Lubricity Annually from each EDG storage tank transfer pump Offsite
Biodiesel Annually from each EDG storage tank transfer pump Offsite
Oxidation Stability Annually from each EDG storage tank transfer pump Offsite
Calorific Value Annually from each EDG storage tank transfer pump Offsite
Density Annually from each EDG storage tank transfer pump Offsite
Hydrocarbon types [% volume] aromatics, olefins, lubricates
Annually from each EDG storage tank transfer pump Offsite
J-1
J List of Caterpillar Website Links
http://www.cat.com/ November15, 2011
2011 Cat Owners Group Meeting
Caterpillar Power Generation Resource Center www.catelectricpowerinfo.com/pr
Power Generation http://www.cat.com/power-generation
Emissions Reduction http://www.cat.com/power-generation/generator-sets/emissions
Emission Retrofits http://www.cat.com/engines/emissions-solutions
Electric Power SpecSizer http://www.cat.com/powergeneration/specsizer
Registration Form Free Copy https://specsizerrequest.csesoftware.com/spec