Power Generation: Product Operation and Maintenance

[drkosamia]

Hello Everybody, My CAT G3520C has crossed almost 25000 running hours of operation but I am not able to figure out reason of slightly black & yellowish colour of smoke at chimney outlet(since commissioning) which is clearally feasibale rom distance. We have other CAT Gas Engines also running since 1997 (24X7) but never had this problem.While contacting dealer I was informed that it is a unique problem with G35 series Gas Engine and nothing to worry. I also have visited these installations and found same type of smoke.

What could be the reason ?

Some technicle information,
1. SOC - 0.3 gms/kwh
2. O2 in exhaust - 8%
3. SPM,NOx & SO datas are all within limit.
4. Water level remains constant at expansion tank.

Kindly give your inputs.

Message Edited by woodag on 09-24-2009 03:03 PM

[APG1981]

What are the emmissions N0x in ppm or Mg/M3, Have you checked the inlet side of the the turbo chargers,we have a 3520 with over 40000 running hrs now and have experienced problems with the turbo Chargers.

[drkosamia]

Nox datas are in range of 0.01 to 0.56 ppm for last 6 moths.

Once Turbo failed in April -2009 due to oil cocking in supply line. Than its working OK.

But facing the problem since starting.

[APG1981]

What is the oil consumption of the engine between servicing.

Have you bore scoped the engine and checked the liners etc.

what type of oil are you running on.

Was the engine run off load for long periods during commissioning.

Is the pre lube set to run continuous during down time.

Have you checked the end float of the turbo chargers.

have you got any blow by readings from new.

have you checked the exhaust back pressure.

Does the engine run at full load 1950kw.

Has the engine had new Turbo chargers sine commissioning.

Sorry about the tons of questions.

Regards Adam.

[drkosamia]

 Hope I have reply to all your querries,

What is the oil consumption of the engine between servicing.

SOC REMAIN IN RANGE OF 0.1 TO 0.2 GMS/KWH.

Have you bore scoped the engine and checked the liners etc.

NO

what type of oil are you running on.

CAT NGEO EL 350

Was the engine run off load for long periods during commissioning.

WHAT DO YOU MEAN BY RUN OFF ? SINCE COMMISIONING IT IS RUNNNG ON AROUND 50 TO 70 LOAD

Is the pre lube set to run continuous during down time.

NO

Have you checked the end float of the turbo chargers.

YES

have you got any blow by readings from new.

DEALER HAS NOT TAKEN

have you checked the exhaust back pressure.

NO

Does the engine run at full load 1950kw.

NO

Has the engine had new Turbo chargers sine commissioning.

YES

[Plantpro]

Running off load means running without generator load. Cats (as do most other diesels) tend to slobber fuel and oil when run without load or at low loads for extended periods times. That's why he wants to know what load you do run at. In my opinion one should avoid loads below 80% of rated if at alll possible. Do you notice blow by or signs of leakage around exhaust couplings/flanges?

Good Luck

[mikel]

With the low NOx numbers you listed, are you using an SCR exhaust aftertreatment?  If so can you post details on it, such as what you're dosing with (ammonia or urea), dosing rates, etc?

I have seen a yellow haze from the exhaust when the SCR is over dosed, and you get a reform effect.

[elod490]

Is this G3520C a natural gas, landfill or bio-gas? I know it's not diesel engine.

[bigmeany]

What kind of comming problems due you incounter with G3520C landfill gas gen set?

[drkosamia]

Its an Natrual Gas application.