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Gas Engine Commissioning

The document discusses the process of commissioning a gas engine installation. It defines commissioning and outlines the key stages: design review, construction review, and commissioning. It emphasizes planning reviews in advance and documenting findings in a report. The remainder provides a system-by-system guide for evaluating installations, covering areas like air intake, cooling, fuel, lubrication, and more.

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530 views21 pages

Gas Engine Commissioning

The document discusses the process of commissioning a gas engine installation. It defines commissioning and outlines the key stages: design review, construction review, and commissioning. It emphasizes planning reviews in advance and documenting findings in a report. The remainder provides a system-by-system guide for evaluating installations, covering areas like air intake, cooling, fuel, lubrication, and more.

Uploaded by

aaakengyahoo.com
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Gas Engine Commissioning

Gas Engine Commissioning

• Definitions of commissioning
– A systematic process of reviewing the design and
execution of an installation to provide the best chance it
will perform as designed and will meet operational
needs when put into service.
– The phase during which the capabilities of the system
are demonstrated in the final operational configuration
under defined operating conditions. During
commissioning, both verification and validation tests are
performed on the complete system.
Stages of Commissioning

• Design Review
– Examine the installation design with the help of a
qualified technical expert to identify any areas that
should be revised before beginning construction
• Construction Review
– At least two site visits are recommended during
construction to ensure that the design is being followed
• Commissioning
– Final evaluation of the engine installation, proper
function of all engine systems, and overall engine
operation.
Design Review

• Planning for and scheduling the design review is


the responsibility of the project manager.
• “Best practice” recommendations:
– Conduct a design review to identify design problem
areas before they become part of the actual constructed
installation
– Arrange for qualified expert help to participate in the
review to benefit from their experience; this service may
be arranged with Caterpillar, the dealer, or outside
engineering firms, but qualifications and experience are
key
Construction Review

• Planning for and scheduling the construction


review is the responsibility of the project manager.
• “Best practice” recommendations:
– Conduct a construction review to identify and correct
design deviations that will otherwise have to be
addressed during final commissioning
– Arrange for qualified expert help to participate in the
review to benefit from their experience; this service may
be arranged with Caterpillar, the dealer, or outside
engineering firms, but qualifications and experience are
key
Commissioning

• Planning for and scheduling final commissioning is


the responsibility of the project manager.
• Commissioning facts:
– Commissioning is the required final review of the
installation before putting it into regular service
– Qualified expert commissioning services may be
available for a fee from Caterpillar, the dealer, or
outside engineering firms
– A thorough, detailed commissioning report must be
created to document all findings; this documentation
forms an important reference for warranty claims made
later
System Evaluations
• Installation reviews can be done in an orderly fashion if
a system-by-system approach is used.
• Understanding the standards established for each
system and the specifications accompanying those
standards is critical to proper completion of the review
• The Commissioning Guide sections of the A&I Guide
include a systems guide, a short description of items
that should be reviewed and documented during
commissioning.
System Guide Topics

• Air Intake System


– Combustion Air
• Temperature/Pressure
– Air Cleaners
• Type
• Location/Mounting
– Intake Air Ducts
• Flow Capacity
• Restriction
• Flexible Connections
System Guide Topics

• Cooling System
– Cooling Circuit
• Coolant Type
• Corrosion Protection
• System Pressure Drop
– Radiators/Coolers
– Expansion Tanks
– Protection Systems
• Alarms/Shutdowns
– Heat Recovery
– System Performance
System Guide Topics

• Starting System
– Air Compressors
– Receiver Tanks
– Starter Supply Piping
– Starters/Starter Accessories
– Electric Starters
• Batteries
• Battery Chargers
• Wiring/Cabling
• Cold Ambient Capability
System Guide Topics

• Exhaust System
– Hazard Warning
Labeling
• Hot Surfaces
– System Piping
• Piping Material
• Flow Capacity
• System Back
Pressure
• Flexible Connections
• Expansion Joints
• Supports
System Guide Topics

• Exhaust System
– Emissions
• Applicable
Regulations
• Permitting
Procedures
• Compliance
Requirements
• Crankcase
Ventilation
System
– Crankcase Breathers
– Crankcase
Ventilation Piping
System Guide Topics

• Fuel System (Gas)


– Fuel Type
• Heat Value (LHV)
• Methane Number
• Contaminants
– Supply Pressure
– Fuel Lines
• System Restriction
– Fuel Filters
System Guide Topics

• Governing System
– Governor Set-Up
– Programming
– Actuators
• Electrical
• Hydraulic (Hydrax)
– System Oil
– System
Condition
System Guide Topics

• Lubrication System
– Lubricating Oil
– Oil Sump
– Prelube / Postlube
• Pumps
• Connections
• Logic / Programming
– Protection Systems
• Alarms / Shutdowns
System Guide Topics

• Engine Protection System


– Sensors
– Connections (Wiring, etc.)
– Set Points / Programming
– Function
– Annunciation
• Engine Monitoring System
– Gauges / Display Panels
– Remote Display Systems
System Guide Topics

• Mounting & Alignment


– Vibration Isolators
– Engine Base / Mounting
• Mounting Bolt Torque
• Chocks / Shims
– Driveline Alignment
System Guide Topics

• Driven Equipment
– Torsional Analysis
• Coupling
• Damping
– Equipment
• Type
• Condition
• Mounting
System Guide Topics

• Ventilation System
– Engine Room Ventilation
• Air Flow
• Air Source
• Temperature
• Differential Pressure
(to Atmosphere)
System Guide Topics

• Serviceability Considerations
• Equipment Safety Evaluations
• Operation & Maintenance Considerations
• Customer Controls
Summary

• Read the A&I Guides


• Review the Commissioning Guides when planning
reviews
• Plan the review prior to conducting it
• Document and report findings

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