CAT-3412 TRIPPING PROBLEMS RECTIFICATION REPORT

Background:
Previously following problems were observed with CAT-3412:-
CAT-3412 had a frequency variation problem with sudden load changes, many power
shutdowns occurred due to said problem.
Load calibration was becoming more tedious and difficult from Governor and DeepSea
software as well.
CAT-3412 was having over speed/Under speed tripping after ESD-0 actuation.
Genset behavior was unpredictable
Frequency variations and Tripping were mostly observed in Rainy weather due to any
cable short circuiting and current leakages.
Keeping in view the above problems and Plant shutdowns, required spare parts were
arranged and M/S ASEA Lahore was called to rectify above problems.

Following jobs were performed by M/S ASEA Lahore to rectify the problem.
Day#1:-
CAT-3412 engine and Genset inspection carried out.
Day #2:-
Governor actuator serviced & Crank rod adjusted.
Woodward 2301A Governor Module replaced and Governor tuning carried out.
Governor Tuning carried out by DeepSea module.
All Spark plug replaced.
Engine Waste gate inspection carried out.
Day #3:-
Perkins Gas and Perkins Diesel Governors Tuning & adjustment carried out through
DeepSea software and from the governor.
All Gensets parameters checked by synchronizing all Gensets.
Gensets RMP inspection carried out on Sudden off load & on load by tripping utility
breakers (157 Amp Load was present on the breaker at the time of tripping).
All Gensets voltage adjustment, Gensets voltages increased from 400V to 410V (P-P) &
237V (P-N) to overcome voltage drop at residence area.
CAT G-3412 load/RPM inspection carried out on ESD-0 actuation.
Perkins Gas Genset load/Frequency inspection carried out on ESD-0 actuation.
Observations: -
Genset frequency variations observed from 01 Hz to 0.2 Hz on normal load, these variations
cannot be eliminated due to difference in Governor types installed at both Units.
Gensets made their frequencies stable within 1 second after sudden load of 157 Amp.
After ESD-0 actuation:
CAT-3412 was running on 644 Amp load but rpm fluctuations were observed from 49.3Hz
to 50.3 Hz as load was high, meanwhile Diesel Genset synchronized.
Perkins Gas was running on 550Amp load with minor frequency variation from 0.1 Hz to 0.3
Hz.
Result:
No power shutdown or load variations observed since rectification, even in heavy rains.


Pindori, Dated: August 13, 2014.

Muhammad Naeem
Instrument Engineer
POL Pindori.