Power Generation: Site Design, Installation, and Connection

[EPGAlbanCat_MD]

We currently have several brand new 3516B 2250 kw 60 hz tier 2 gensets and would like to convert them to 50 Hz for overseas use. We are not concerned about achieving the same power output and would like to do this at minimal cost and labor. What modifications are required to create a reliable genset without changing the injectors, camshaft or any other internal engine components. Any input would be greatly appreciated.

[Rajiv57]

Dear Sir,

We are the manufacturers of Alternators up to 100 Mega Watt capacity, 415Volts to 17000Volts, 115.3RPM to 3000RPM, 2 Poles to 52 Poles, 50Hz. To 400 Hz., 0.8 to 0.85PF, 98% Efficiency, with over temp., over speed & ground fault protection system. Extended shaft provided on request.

You do not need to make any changes in the Engine. Changes have to be made in the winding of the Alternator. Our e-mail is rajeev.mkt@bijendra.com. Ph. Mob.: 91 976 196 8622 Land Line:91 121 252 5557.

Address is Bijendra Heavy Electricals Pvt.Ltd., Opposite Ramlila Ground, Delhi Road, Meerut City-250 002, Uttar Pradesh, India. You may contact us as and when required.

Regards

Rajiv Mohan

[EPGAlbanCat_MD]

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Rajiv57 wrote:

Dear Sir,

We are the manufacturers of Alternators up to 100 Mega Watt capacity, 415Volts to 17000Volts, 115.3RPM to 3000RPM, 2 Poles to 52 Poles, 50Hz. To 400 Hz., 0.8 to 0.85PF, 98% Efficiency, with over temp., over speed & ground fault protection system. Extended shaft provided on request.

You do not need to make any changes in the Engine. Changes have to be made in the winding of the Alternator. Our e-mail is rajeev.mkt@bijendra.com. Ph. Mob.: 91 976 196 8622 Land Line:91 121 252 5557.

Address is Bijendra Heavy Electricals Pvt.Ltd., Opposite Ramlila Ground, Delhi Road, Meerut City-250 002, Uttar Pradesh, India. You may contact us as and when required.

Regards

Rajiv Mohan

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Thankyou for the advice. We already have appropriate alternators, I'm 99% sure the engine speed needs to be reduced from 1800 to 1500 rpm, in order to achieve 50 Hz. My question is what else besides a reflash of the engine management, and maybe changing the turbos. I am looking for an example where someone has successfully completed the conversion with minimal modifications and high reliability.

[eugyno]

first and foremost is for you to send me the serial number of the genset and the type of EMCP that it has, but know that this services is for a token

[CCOOK]

We also have looked at this before. The first hurdle is that you will not be able to programme the top engine limit (TEL) down to 1500 rpm. This will require flashing a 50Hz rating flash file into the ECM but the factory password system (FPS)  may not give passwords due to the rating / flash file mismatch. The only way then to get around that problem is a new ECM. Then you may have possible iron changes etc 

[EPGAlbanCat_MD]

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CCOOK wrote:
We also have looked at this before. The first hurdle is that you will not be able to programme the top engine limit (TEL) down to 1500 rpm. This will require flashing a 50Hz rating flash file into the ECM but the factory password system (FPS)  may not give passwords due to the rating / flash file mismatch. The only way then to get around that problem is a new ECM. Then you may have possible iron changes etc 

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Thankyou for the information, from what I understand CAT will provide these level 3 passwords for a charge. In the case of derating an engine such as this situation it will be significantly cheaper than when increasing the BHP.

[CCOOK]

Thats correct, you go into the FPS and go to "estimate rerate" then enter your engine serial number and the interlock codes for the file in your engine and the file you want to flash into the ecm.It will then give you what charge would be applied from cat. You can obtain the new flash file number from the flash file cross reference listing then go to TMI to obtain the interlock code for the new flash file.

in saying this i have assumed from your ID you are from Alban cat dealer.

[Gary]

Apart from ECM, the tubo do need to be replaced?

[hbutt]

well, i have been involved in frequency coversion dilema. Found it fairly easy, but it needs a bit of workout. My proposal is that when you will convert that same genset to 50hz, its kW will become its kVA. For conversion procedure, you would need the flash file. But you need to see and study which flash file can do the conversion without changing any iron. You need to find the exact arrangement number which is used with the 50hz flash file. To make sure if there is any iron change required for the new genset, goto TMI and compare your current arrangement number with the new arrangement number. That will show u all what u need to change. If u succeed in finding that number which gives u no change except the flash file, you have almost won the game. goto TMI and put that arrangement number, get the respective test spec number and get the flash file number. Flash your ECM with the same flash file and send the information given by ECM (at the end of flashing) to CATERPILLAR for factory passwords. Simple, it is really

Regards

Hussan butt

Application Engr.

K.S.A

[h374jah]

We did a conversion to 50Hz,380volts last year. We took a 1500kw power module with a 1GZ serial number. It was 1500kw at 1800rpm"60Hz,"standby rating we put a new 50Hz flashfile in it,which changed the test spec . Next we had to put turbos on the engine. finally it took a set of injectors. The out come was a 1120Kw standby rating at 380 volts @ 50Hz. I

had to get the DSN involved to come up with the test spec to order the correct parts.Im pretty sure you should be able to do something simalar .Just a note, this wasnt as easy as that.

We had issues with loading the flashfile. It took a special factory password to be generated manually. It couldnt be done through the normal password screen.

Hope this helped.