CAT D3516BHD 2275KVA M#539 GENERATOR TOP END

(OVERHAUL)

Replacement Critical Million PKR 50

BACKGROUND
Currently the Gen-Set of CAT D3516B HD2275 KVA Current Service Hours (11721) is Located at Sundar
Plant. These Gen-Set have been running since 2013.Caterpiller recommends Top end overhaul after
9,000 hours to ensure smooth Gen-set operation without any incidents.

The Need for a Top end (Overhaul) is determined by Several factors.

1. The Increase Service Hours of the Engine 9000.

2. An Increase in the levels of noise and vibration
3. An increase the Engine parts failure
 Left Side Turbo Chargers
 13 No Cylinder Head
 13 No Piston and Liner
 Oil Cooler
 Left and Right Temperature Difference
 We have observed decline in performance, with the Gen-Set showing signs of
wear and tear. Consequently, it poses a significant risk to Operation and Gen-Set
Safety. To avoid any potential disruptions or breakdowns, we urgently require
action for Gen-Set Top End overhauling.

Space:The vendor has the Gen-Set Top End Overhauling kit available 25 Days After PO Confirm. As
soon as the PO is issued, the vendor can start the Overhauling Kit Arrangement.

Cost: Approx 40 million PKR is required for this Top End Kit.
2 Million Cost is required For Parts Rebuild For Local Market.

Time Required: Total time required for this activity will be 15-18 days which include Top end removal
Engine Parts , Transportation to vendor workshop, Rebuild Engine Parts, Transportation back to site,
Reinstallation, Engine Start Up and Finally Load Test.

PICTORIAL EVIDENCE
Below are summarized view pictures that provide a clearer understanding of the
internal condition of Engine.
The Engine Turbo Charger
Compressor Wheel is starting to
damage.
It’s can Cause serious damages to its
blades.

It is clearly visible in this picture that

there is water in the rocker arm
assembly on cylinder head in engine.
It can cause lubricant parts are failure.

This engine Cylinder Head and head

gasket are damaged due to increase
Running Hours of top end.
They can Cause water dripped in
Engine oil and other failure.
The Exhaust port temperature are
good indication of condition of the
cylinders.Guttering of valve can be
diagnosed with the exhaust port
temperature.During normal operation
at rated load,the temp of the hottest
cylinder and the coldest clinder may
differs 5 C TO 30 C.
The engine fuel injectors Lack of
Servicing.

The engine Oil Coolar tubes are

damaged.
These tubes can cause water mix in
oil and other failure.

This engine Cylinder liner rings are

damaged due to high temperature
difference.
The Can Cause water dripped in
engine oil.