- Marine Engine
- C18 MARINE ENG (S/N: T2P1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
This document outlines the procedures required to be followed to change the intake and exhaust systems on the Caterpillar C18 twin cementer CPS 678.
This work instruction must be complimented by Pyrobans Offshore Installation Manual OG003 for more guidance, safety notes, and fastener torque tables. Refer to product Material Safety Data Sheets (MSDS) as required.
During the unit build, the latest versions of drawings P0578, Pyroban 300829477/1 (Insulated Charge Air Pipe Kit), and Pyroban 300829478 (Exhaust Gas Cooler Kit) shall be consulted in association with this document. Refer to WI403 for instructions on HCTB application for the turbocharger recesses.
Appropriate care when handling must be taken to avoid any damage to the component parts or personal injury. Some items are heavy and require appropriate lifting equipment during the process of handling and installation. Prior to installation, ensure that all packing material is removed and also ensure that the engine is rigidly installed and level.
During installation, refer to the appropriate installation drawing.
For torque specifications, refer to the Pyroban Offshore Installation Manual OG003.
Do NOT modify any parts without authorization from Pyroban. Failure to observe any instructions in this manual may invalidate any warranty agreement.
Only genuine Pyroban parts should be used for replacements
Safety Section
The installation will be conducted by suitably trained personnel. All persons supporting / working on the installation must be inducted into the safety requirements before work commences.
The safety requirements for the specific location where the system is installed must be adhered to, and any necessary risk assessments conducted.
The person in authority for the specific location has full authority regarding safety and requests in relation to safety are final.
Safety equipment:
- Gloves
- Safety glasses
- Coveralls
- Dust masks
- Ear defenders
PPE must be worn always.
Ear defenders, must be worn when the engine is running.
Hard hats must be worn if engaged in activities where there is a risk of head injury (overhead lifting, working within the package space).
Overalls must be worn when conducting the rework to minimize the risk of injury.
Required Parts
Note: All part numbers in this Special Instruction are Pyroban part number and not Caterpillar.
There are two upgrade kits available. One for the inlet upgrade and one for the exhaust upgrade. Refer to drawings Pyroban 300829477 (Insulated Charge Air Pipe Kit) and Pyroban 300829478 (Exhaust Gas Cooler Kit). For each twin cementer package, the appropriate quantity of inlet and exhaust kits will be provided, assigned to each engine serial number. All engines will require the inlet upgrade, some engines do not require the exhaust upgrade.
The charge air cooler covers of the engines to be upgraded are made from either aluminum. As new charge air covers are supplied with the upgrade kits, the specific version of the inlet kit will be provided to match the engines cover type. Drawing 300829477 shows the parts which are specific to the Aluminum and cast iron cover versions. Replacement turbochargers are also included in each kit.
Kit Supply:
Primary contact: Ricky Clark
Oil & Gas /Materials Handling (After Sales)Pyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456 800
Direct : + 44 (0) 1273 456 837
Ricky.Clark@pyroban.com
parts@pyroban.com
Secondary contact: Keith Brown
Parts Co-ordinator (After Sales)Pyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456800
Direct: +44 (0) 1273 456860
Keith.brown@pyroban.com
parts@pyroban.com
Tertiary contact: Marlon Parbery
Offshore Service CoordinatorPyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456800
Direct : + 44 (0) 1273 456900
Mobile: +44 (0) 7786550588
Marlon.parbery@pyroban.com
parts@pyroban.com
Kit Supply Escalation: Darren Boiling
Global After Sales ManagerPyroban Group
23 South, 23 Dolphin Road, W. Sussex, Shoreham by Sea, BN43 6QG, UK
Direct: + 44 (0) 1273 456831
Mobile: + 44 (0) 7803 500 396
darren.boiling@pyroban.com
Technical Support:
Primary Contact: Marlon Parbery
Offshore Service CoordinatorPyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456800
Direct : + 44 (0) 1273 456900
Mobile: +44 (0) 7786550588
Marlon.parbery@pyroban.com
parts@pyroban.com
Secondary Contact: Steven Keeley
Service Engineer Offshore Oil & GasPyroban Group Ltd
Dolphin Road, Shoreham-by-Sea, W. Sussex, BN43 6QG, United Kingdom
Main: + 44 (0) 1273 456 800
Direct: + 44 (0) 1273 456 845
Mobile: + 44 (0) 7557 938 084
steven.keeley@pyroban.com
Technical Support Escalation: Steve Noakes
Engineering ManagerPyroban Group
23 South, 23 Dolphin Road, Shoreham by Sea, BN43 6QG, United Kingdom
Direct: + 44 (0)1273 456823
Mobile: + 44 (0)7803 500171
steve.noakes@pyroban.com
As part of the upgrade kit process, the original aluminum charge air cover and turbo charger must be returned to Pyroban.
Illustration 1 | g06091488 |
Aluminum charge air cover and turbo charger |
Disassembly of Engine Components
Before the engine conversion can take place, several of engine components must be removed to allow unobstructed working access to the turbo compressor shell.
A good practice is to "bag and tag" all removed components along with plugging all apertures to aid a quicker and easier reassembly process.
The photographs below show the components that are requiredto be removedand in the preferred order.
Note: The new coated turbochargers will have been supplied with a 5 ° downward rotation to align with the new charge air pipes.
The photos below illustrate the various stages of removal of the old cross over pipes.
- Removal of left-hand bolt securing compressor outlet to charge air pipes.
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Illustration 3 g06082018 - Removal of right-hand bolt securing compressor outlet to charge air pipe.
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Illustration 4 g06082025 - Removal of bolts securing first charge air pipe to second charge air pipe.
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Illustration 5 g06082029 - Removal of bolts securing charge air pipe to charge air cooler.
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Illustration 6 g06082032 - Separation of charge air pipes.
Remove the old cross over pipes with SCTB installed.
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Illustration 2 | g06081924 |
Installation of the New Turbocharger Procedure
The turbocharger replaced with a new turbocharger that has Pyrobans SCTB coating on the entire compressor shell with a 5 ° rotation incorporated.
The existing turbocharger removed and replaced with the new supplied turbocharger 300827837-0.
The photos below illustrate the various stages of the removal and installation process.
- Remove the clamps on the rubber cuff on the compressor shell and air intake.
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Illustration 9 g06082063 Clamps removed from compressor air intake Show/hide tableIllustration 10 g06082072 Turbo band clamp - Remove or loosen the clamps on the side of the turbo.
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Illustration 11 g06082320 Turbo oil connections - Disconnect the oil feed and drain connections to the flexible hoses.
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Illustration 12 g06082325 Air intake pipe assembly - Remove the nuts and bolts on the round flange on the intake pipe.
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Illustration 13 g06082336 Air intake pipe bracket - Loosen off the bracket nuts and bolts on the air intake pipe, but do not remove completely to hold in place.
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Illustration 14 g06082341 Air intake pipe connection to turbo - Remove the nuts and bolts on the round flange on the intake rubber cuff.
- Lift off the air intake pipe, using the correct procedure for lifting.
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Illustration 15 g06082350 Compressor air intake pipe and hose connection - Once the air intake is removed, remove the round intake flange, the rubber cuff, and the compressor shell.
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Illustration 16 g06082358 Old turbo with band clamp and inside compressor shell uncoated - Unbolt the existing turbocharger from the connection to the flexible exhaust pipe and install the new turbocharger. The pictures above illustrate the appearance of the turbocharger before and after the rework.
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Illustration 17 g06082391 New turbo with inside compressor shell coated - (300827837/0) - After installations of the turbocharger refer to WI403 for installation of hard compound thermal barrier in the turbocharger bolt recesses.
Note: The hard compound thermal barrier must be done on all four bolts securing the turbine housing to the exhaust manifold.
Illustration 8 | g06082052 |
Compressor intake pipe with clamps removed |
Replacement Charge Air Cover
The charge air covers are replaced with units modified with thermal barrier material on the outer surface.
The charge air cover is further protected by a stainless steel cover plate attached to four standoff bolts.
Refer to Caterpillar service manuals for the process to remove and install charge air covers. Four standoff bolts are replaced with stud-bolts to provide fixing for the stainless steel plate.
Illustration 18 | g06082402 |
Illustration 19 | g06090607 |
Typical standoff (1) Bolt (2) (3) Cover (4) Standoff - (5) Charge air cover (6) Stud bolt - For aluminum cover 1W-1038 |
Illustration 20 | g06082409 |
Replacement of Cross-Over Pipes
Illustration 21 | g06082442 |
Old cross over pipes |
Illustration 22 | g06082455 |
New cross over pipes (Note: the pipes in the picture have been painted for test purposes. The pipes used in this installation will have an uncoated stainless steel appearance). |
Installation Of New Cross Over Pipes
The photos below illustrate the various stages of the installation process. Refer to the latest version of drawing Pyroban kit part number 300829477/1 for this stage of the installation process.
- Clean all surface flanges on the charge air cooler cover.
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Illustration 23 g06082491 Aftercooler cover with sleeve inserted - Place the rectangle sleeve (part number 300829430/1) inside the charge air cooler cover flange, and using 2 gaskets (part number 300814750), 1 on the charge air cooler cover flange and another on the outside of the sleeve.
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Illustration 24 g06082493 SCTB coated adapter - Install the SCTB coated adapter onto the charge air cooler cover.
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Illustration 25 g06082500 O-ring installation onto crossover pipe - Inspect the new cross over pipes and install the O-rings 300461017 on the first flange that installs into the turbo compressor shell.
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Illustration 26 g06082502 Gaskets - Install the gasket 300829506 on the first flange. Two gaskets are supplied to compensate for variations in casting tolerances. Install both gaskets if required to give full contact surface between the flange and turbo compressor scroll.
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Illustration 27 g06082510 300828227 Installed - Install the new first cross over pipe 300828227.
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Illustration 28 g06082520 300828224 Installed - Ensure a suitable distance between the new cross over pipe and the frame.
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Illustration 29 g06082526 Crossover pipes viewed from the top - Install the second new cross over pipe 300828224. Ensure the square and round gaskets (part numbers 300828233 and 800261/13) are installed.
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Illustration 30 g06082527 Cross over pipes viewed from the rear/side - After installing the new cross over pipes, tighten up all nuts and bolts to correct torque while checking the alignment of the inlet system assembly.
Exhaust System Rework
This section describes the necessary steps required to replace the heat exchanger / cooler for the C18 exhaust systems on the front and rear engines of the C18 twin cementer system CPS679.
Illustration 31 | g06082533 |
Replacement exhaust heat exchanger and gasket (Pyroban kit part number 300829478) |
Tools required:
- Socket set 10mm, 14mm, 17mm, 22mm, and 30mm
- Open ended wrenches 10mm, 14mm, 17mm, 22mm, and 30mm
- Flat end screw driver
- Small scraper (gasket cleaner)
- Knife
- Straight edge rule
- Sand paper
- Clean rags
- Brush for cleaning out plenum
- Gloves
Lifting equipment required:
- Overhead crane. If there is no overhead crane available, scaffolding will need to be erected over the heat exchangers to make removal possible.
- Chain blocks
- Lifting shackles
- Slings
- Overhead crane. If there is no overhead crane available, scaffolding will need to be erected over the heat exchangers to make removal possible.
Consumable required:
- Copper grease
Parts Required for Rework (Pyroban 300829478)
Part Numbers Required for Exhaust System Rework | ||
---|---|---|
QTY | Pyroban Part Numbers | Description |
1 | 300814510 | Exhaust gas heat exchanger |
1 | 300813174 | Gasket : Plenum to heat exchanger |
1 | 300500874 | Gasket : Outlet box to spark arrestor |
Rework Procedure
- Isolate the batteries in the stainless steel enclosures and lock out the isolator switch using local lock out tag out procedures.
- The heat exchangers must be drained of coolant prior to removal.
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Illustration 32 g06082605 Battery location - Drain the coolant from the engine.
Take care when removing the coolant as not to get over electrical equipment and use the correct method of disposal.
Show/hide tableIllustration 33 g06082607 Silicon hose on coolant bonnet - Remove the clamps on the blue silicone 4” pipes.
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Illustration 34 g06082612 Silicon hose on heat exchanger - Remove the 4” stainless steel pipes from the heat exchanger to the engine bonnets, 1 pipe each side of the heat exchanger.
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Illustration 35 g06082634 Coolant pipe work with U-Clamps - Remove the U-Clamps.
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Illustration 36 g06082636 Sensors in outlet box - Remove the temperature sensors on top of the exhaust outlet box.
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Illustration 37 g06082653 Remove the temperature sensors on top of the exhaust outlet box. - Support the weight of the spark arrestor with appropriate lifting equipment. Remove the M20 nuts and bolts from the exhaust outlet flange onto the dry exhaust flexible flange. Remove the round green 8” gasket.
- At this stage, install the lifting equipment (shackles and slings) onto the lifting eyes on the heat exchanger.
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Illustration 38 g06082656 Heat exchanger to plenum bolts - Remove the nuts and bolts around the plenum.
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Illustration 39 g06082658 Heat exchanger support bracket bolts - Remove the nuts and bolts on the upper bracket on the heat exchanger.
- Loosen the bolts on the bottom of the bracket.
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Illustration 40 g06082662 Heat exchanger assembly removed from system - Lift off the exhaust heat exchanger and outlet box using the lifting eyes.
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Illustration 41 g06082665 Plenum after removal of heat exchanger assembly - Clean off the old gaskets on flange surface and clean out the plenum after cleaning. Refer to offshore installation manual OG003 for guidance on cleaning.
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Illustration 42 g06082668 Covered plenum - Cover up the plenum, exhaust, and piping so no objects fall inside.
- Write down the old serial numbers and the new serial numbers from the heat exchangers in the serial number records Table 2 and attach to SIMSi entry.
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Illustration 43 g06082670 - Remove the exhaust outlet box and flame arrestors from the heat exchanger.
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Illustration 44 g06082672 - Reinstall the exhaust outlet box on to the new heat exchanger along with the flame arrestors. Use copper grease provided on the new heat exchanger for the flame arrestors.
- Install the new heat exchanger assembly by following the steps taken to remove the old heat exchanger in reverse order.
Post - Rework Activities
After installing the new heat exchanger assembly, follow the following steps to prepare the engine for running.
- Tidy the work area and clear any tools, scrap equipment, and debris from the area surrounding the engine.
- Clean the engines as far as practicable.
- Run engine for 15 mins and check for coolant leaks.
- Fill the coolant system with 50% water and 50% glycol anti-freeze.
- Carry out a test run on engine, and checking around engine at the same time.
- While the engine is running, the coolant system needs to be bled to remove trapped air using butterfly valves on engine coolant pipes. Follow instructions in the SLB engine maintenance service book for bleeding coolant system.
Cleaning And Inspection For Dispatch
Once all work is completed. The surrounding areas should be cleaned thoroughly to remove any excess material and then photographed to proved evidence of the parts condition prior to leaving work site. These photographs should be attached to the SIMSi entry.
Returning turbo charger and aluminum charge air cover
The original turbo charger and aluminum charge air cover from both engines are to be returned to Pyroban for upgrade and subsequent use in PCA kits.
The replacement turbocharger is supplied in a bespoke shipping box which is to be used for the return of the original turbocharger.
Pack the turbocharger and aluminum charge air cover and return to Pyroban at the following address :
For attention of goods in
Pyroban LtdEndeavor Works
Dolphin Road
Shoreham by Sea
West Sussex
BN43 6QG
Serial Number Records Table
Engine Serial # | Package Serial # | Old Intake Pipe Serial # | New Intake Pipe Serial # | Old Turbo Serial # | New Turbo Serial # | Old Cooler Serial # | New Cooler Serial # |
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