Remerciez-le!

Remerciez @Admin pour avoir partagé cet document gratuitement, de la manière la plus simple, en partageant sur les réseaux sociaux.

CAT MARINE AIRLESS AFTERTREATMENT BECOME EPA TIER 4 / IMO III COMPLIANT WITH CA

CAT MARINE AIRLESS AFTERTREATMENT BECOME EPA TIER 4 / IMO III COMPLIANT WITH CAT’S SCR SOLUTION A SIMPLE SOLUTION, DELIVERING RESULTS A&I GUIDE Airless Aftertreatment U.S. EPA Tier 4 / IMO III Applicable for Cat C7.1, C9.3 & C18 Page 1 of 90 Warning: Paper copies of this document are uncontrolled. Page 2 of 90 Caterpillar: Confidential Green Table of Contents 1.1 Purpose ............................................................................................................................ 4 1.2 Scope ............................................................................................................................... 4 1.3 Requirements and Agreements (DFA) .............................................................................. 4 Terminology and Definitions .................................................................................... 5 1.4 IMO III Fluid Requirements ............................................................................................... 5 1.5 Oil Renewal System ......................................................................................................... 6 1.6 Rating Reference ............................................................................................................. 6 1.7 IMOIII / EPA Tier Notes ................................................................................................... 6 1.8 Basic SCR System Function ............................................................................................. 6 1.9 Airless Solutions and Variations ....................................................................................... 8 2. Mechanical Requirements ...................................................................................................... 9 2.1 Clean Emissions Module (CEM) ....................................................................................... 9 Weight and Dimensions –C7.1, C9.3 and C18 ....................................................... 11 Mounting – Airless CEM ........................................................................................ 11 Service Access and Clearance – C7.1, C9.3 and C18 ........................................... 14 Connections on CEM ............................................................................................. 14 Sensor Connections on CEM ................................................................................. 16 CEM Exhaust Mounting Flange ............................................................................. 16 Thermal Growth ..................................................................................................... 17 CEM Thermal Protection ....................................................................................... 17 2.2 CEM Inlet and Outlet Electrical Connection Boxes ......................................................... 18 CEM Electrical Boxes ............................................................................................ 18 Outlet Side Electrical Box ...................................................................................... 19 Inlet Side Electrical Box ......................................................................................... 20 Sensor Temperature Limits.................................................................................... 21 2.3 Phase Tank .................................................................................................................... 22 2.4 Cooling Line Connections for DEF Injector ..................................................................... 23 Cooling Line Connections ...................................................................................... 23 Engine Cooling Connection Locations ................................................................... 23 2.5 Dosing Cabinet ............................................................................................................... 30 Connections .......................................................................................................... 31 Weight and Dimensions ......................................................................................... 31 Mounting Orientation ............................................................................................. 31 Lifting ..................................................................................................................... 32 Service Access and Clearance .............................................................................. 32 Installation and Venting ......................................................................................... 33 Schematic .............................................................................................................. 35 2.6 Optional CAT® Supplied Transfer Pump ......................................................................... 35 Cat® Transfer Pump Schematic ............................................................................. 38 2.7 Exhaust System ............................................................................................................. 39 Overview ............................................................................................................... 39 Exhaust flange connection details .......................................................................... 40 Exhaust Backpressure Requirements .................................................................... 40 Joint Loading ......................................................................................................... 43 Thermal Management and Protection .................................................................... 43 Sound Attenuation ................................................................................................. 44 2.8 Diesel Exhaust Fluid (DEF) System ................................................................................ 44 Overview ............................................................................................................... 44 DEF Selection........................................................................................................ 44 Material Selection for DEF ..................................................................................... 46 DEF Handling Procedure, Transport & Cleanliness ............................................... 46 Vessel DEF Tank ................................................................................................... 47 DEF Flow ............................................................................................................... 48 Caterpillar® Marine Airless Aftertreatment A&I Guide LEBM0103-01 Warning: Paper copies of this document are uncontrolled. Page 3 of 90 Caterpillar: Confidential Green DEF Flow Schematic ............................................................................................. 50 2.9 Overall System Considerations ...................................................................................... 51 Overview and Schematic ....................................................................................... 51 Welding ................................................................................................................. 51 Painting ................................................................................................................. 52 Multiple Engine Installations .................................................................................. 52 3. Electrical Systems ................................................................................................................ 53 3.1 Overall System Considerations ...................................................................................... 53 3.2 Wiring Diagrams, Connectors and Pinouts ..................................................................... 55 Wiring Diagrams .................................................................................................... 55 3.3 Connectors ..................................................................................................................... 56 Dosing Cabinet Connectors .................................................................................. 56 CEM Connections .................................................................................................. 57 Pinouts .................................................................................................................. 57 3.4 CDL and J1939 Control Wiring ....................................................................................... 61 J1939 Architecture ................................................................................................. 61 C9.3 Installation ..................................................................................................... 61 C18 Installation ...................................................................................................... 63 J1939 Parameters ................................................................................................ 64 3.5 24V Power Supply .......................................................................................................... 65 Customer Supplied ................................................................................................ 65 3.6 DEF Transfer Pump Control ........................................................................................... 66 DEF Transfer Pump Control with Multiple Dosing Cabinets ................................... 67 3.7 Main DEF Tank Level Switches ...................................................................................... 68 3.8 Commissioning ............................................................................................................... 69 Commissioning ...................................................................................................... 69 Verifying Current Software revision ........................................................................ 69 Enabling the Aftertreatment System ...................................................................... 70 Labeling Dosing Cabinets (C18s Only) .................................................................. 70 Changing Aftertreatment System Number ............................................................. 70 Labeling Dosing Cabinet Disconnect Switches ...................................................... 71 ECM ID and Serial Numbers .................................................................................. 71 Program Engine ECM Serial Number .................................................................... 72 Aftertreatment ID ................................................................................................... 72 Program Dosing Cabinet ID ............................................................................ 72 Program Engine Location ............................................................................... 73 Control Panel Configuration ............................................................................ 73 4. Service and Maintenance Considerations ........................................................................... 86 4.1 Cleaning ......................................................................................................................... 86 High Pressure Wash .............................................................................................. 86 Spills & Basic Cleaning .......................................................................................... 86 5. Startup and Commissioning ................................................................................................ 87 5.1 Initial Startup .................................................................................................................. 87 5.2 Commissioning ............................................................................................................... 87 Delegated Final Assembly (DFA) ........................................................................... 87 6. References ............................................................................................................................ 88 6.1 Links ............................................................................................................................... 88 6.2 A&I Literature ................................................................................................................. 88 6.3 A&I Newsletters .............................................................................................................. 88 6.4 Product News ................................................................................................................. 89 6.5 Miscellaneous ................................................................................................................. 89 Caterpillar® Marine Airless Aftertreatment A&I Guide LEBM0103-01 Warning: Paper copies of this document are uncontrolled. Page 4 of 90 Caterpillar: Confidential Green Introduction 1.1 Purpose This document is a reference and guide for the installation of a CatP® P Airless Selective Catalytic Reduction (SCR) system. UNote: The information in this document is subject to change as the aftertreatment system is revised and improved or as required for emission regulation standards. CatP engines are designed and built to provide superior value, however, achieving the end user’s value expectations depends greatly on the performance of the complete installation to assure proper function and design life. Proper installation will allow the engine to produce rated power, expected fuel consumption, and meet emissions standards. Caterpillar®P does not guarantee or approve the validity or correctness of any installation. CaterpillarP’s obligation with respect to any product is as set forth in the applicable Cat P warranty statement. It is the installer’s responsibility to consider and avoid possible hazardous conditions, which could develop from the systems involved in the installation. The suggestions provided in this guide should be considered general examples only and are in no way intended to cover every possible hazard in every installation. The information in this document is the property of Caterpillar Inc. and/or its subsidiaries. Without written permission, any copying, transmissions to others, and any use except that for which it is intended is prohibited. Contact the appropriate application support group for the latest information on Cat P Airless SCR guidelines. 1.2 Scope The scope of this document covers the CatP Airless Aftertreatment system for the C7.1, C9.3, C18 (below 599bkw) Marine products. This system is considered the “Airless” system as compressed air is NOT required to meet IMO III engine solutions. 1.3 Requirements and Agreements (DFA) (1) The installer is required to follow CaterpillarP’s Application and Installation requirements for proper CatP CEM integration with the engine. (2) A full sea trial, as described in the marine commissioning procedure (LEBM0025), and utilizing CAMPAR, is required on all engines equipped with an aftertreatment system. The completed sea trial data must be uploaded by the authorized CatP dealer in Service Interlink. The following forms must also be completed and uploaded into Service Interlink: a. Design and Construction Review Form (SEHS8716) b. Start Up checklist for the Engine: i. LEBM0038 for C7-C32 Prop ii. LEBM0053 for C7-C32 Aux Note: If the available Cat aftertreatment options do not meet the application/installation requirements, the installer must contact his or her respective CatP A&I Representative. Caterpillar® Marine Airless Aftertreatment A&I Guide LEBM0103-01 Warning: Paper copies of this document are uncontrolled. Page 5 of 90 Caterpillar: Confidential Green Terminology and Definitions Acronyms ASTM American Society for Testing and Materials AT Aftertreatment AUS Aqueous Urea Solution CEM Clean Emissions Module DEF Diesel Exhaust Fluid DFA Delegated Final Assembly DPF Diesel Particulate Filter ECM Engine Control Module EDDC Engine Drawing Design Center EPA U.S. Environmental Protection Agency IMO International Maritime Organization ISO International Organization for Standardization JIC Joint Industry Council NORx Nitrogen Oxides (NO & NOR2 R) MCS Marine Certification Soceity OEM Original Equipment Manufacturer OMM Operation and Maintenance Manual ORS Oil Renewal System P&ID Piping and Instrumentation Diagram PETU Pump Electronic Tank Unit (also referred to as Dosing Pump Unit) PI Pressure Indicator PM Particulate Matter PS Pressure Sensor SAE Society of Automotive Engineers SCR Selective Catalytic Reduction STOR Straight Thread O-Ring T4 Tier 4 TMI Technical Marketing Information ULSD Ultra Low Sultur Diesel 1.4 IMO III Fluid Requirements IMO III Fluid Requirements This Installation Guide is intended for use with engines that must comply with and be certified to IMO III emission requirements. Proper fluids must be used to meet these requirements. Refer to the specific Operation and Maintenance Manual (OMM) for the CatP engine model being installed for the proper fuel, lubricants, and coolants that are to be used. The proper fluids enable the engine to produce its published rated power, fuel consumption, and emissions regulations. JP8 fuel is not compatible with CatP IMO III systems. IMO III requires fuel sulfur levels below 1,000 ppm. Caterpillar® Marine Airless Aftertreatment A&I Guide LEBM0103-01 Warning: Paper copies of this document are uncontrolled. Page 6 of 90 Caterpillar: Confidential Green Engine Operating Fluids Fuel Tolerance – Sulfur (ppm) IMO III = 1,000 or less Fuel Tolerance – biofuels (ASTM 6751-075 B100) B20 or less Oil Tolerance (ash content) CJ-4 or better Table 1: Tier 4 & IMO III Engine Operating Fluid Requirements Oils that have more than 1% total sulfated ash should not be used in aftertreatment device equipped engines. In order to achieve expected ash service intervals, performance, and life, these engines require the use of CatP DEO-ULS or oils meeting the CatP ECF-3 specification and the API CJ-4 oil category. Oils that meet the CatP ECF-2 specification and that have a maximum sulfated ash level of 1% are also acceptable for use in most aftertreatment equipped engines. Use of oils with more than 1% total sulfated ash in aftertreatment device equipped engines will cause the need for more frequent ash service intervals, and/or cause loss of performance. Refer to your uploads/s1/ guide-src.pdf