End-of-Line Assembly Test Cell for High-Horsepower Tier 4 Diesel Emissions Engines

Custom Facility Design and Integration for Advanced Tier 4 Emissions Compliance

When a leading high-horsepower engine manufacturer relocated its assembly operations to North Carolina, they partnered with ACS to design, construct, and commission a single-source end-of-line test facility. Discover how our team integrated custom test carts and blast-rated safety infrastructure to deliver full validation capabilities for complex engine lines while meeting strict tier 4 diesel emissions standards.

The Challenge

A leading manufacturer of heavy-duty engines for marine, drilling, power generation, and locomotive applications was relocating its engine assembly and testing operations from Illinois to North Carolina. As part of this major operational move, the manufacturer identified a critical need to upgrade and expand its heavy duty engine testing capabilities and end-of-line assembly workflows. The facility needed to accommodate a wide range of high-horsepower engine models (spanning 8, 12, 16, and 20 cylinders) featuring both clockwise and counterclockwise rotation configurations.

However, retrofitting the new site presented unique engineering and logistical hurdles. The chosen location was previously utilized to manufacture axle assemblies for large mining vehicles. To maintain production efficiency, the new testing workflow had to incorporate the legacy plant infrastructure, specifically the existing floor rails and large turntables used to transport the heavy machinery. Additionally, the infrastructure required extensive utility relocation before building construction could even begin. The company needed an expert partner capable of delivering specialized diesel engine testing facilities, complete with a blast-rated environment to safely test a massive new lineup while managing tier 4 diesel emissions and leaving structural provisions for future Natural Gas (NG) fuel testing capabilities.

The Solution

ACS accepted a single-source design/build contract to fully manage the building design, construction, and commissioning of a new 5,800 sq-ft, two-story addition dedicated to heavy duty engine testing. To address the physical challenges of the site, ACS designed and built custom test carts engineered to seamlessly interface with the plant’s existing rail and turntable system, ensuring a smooth transit path from assembly to the engine prep area and into the test cell.

The scope of the build included one diesel engine blast-rated test cell equipped with pressure relief walls for maximum structural safety, an operator control room featuring viewing monitors rather than traditional windows, a mechanical equipment support room, and an elevated mechanical platform. For the complex mechanical and electrical infrastructure, ACS designed, integrated, and built custom skidded systems, including an oil conditioning skid, fuel panel, jacket water and aftercooler water conditioning systems, an engine starting system, and a dedicated bottle gas and span gas room to support precise monitoring of tier 4 diesel emissions.

To streamline the timeline, owner-provided components were pre-integrated into ACS skid assemblies and subjected to rigorous Factory Acceptance Testing (FAT) before shipping, drastically reducing onsite installation and testing time. Additionally, ACS provided a facility Programmable Logic Controller (PLC) to manage crucial support infrastructure like test cell ventilation, hazardous gas detection, and fire suppression, while seamlessly interfacing with the primary data acquisition system to streamline overall operations within these advanced diesel engine testing facilities.

The Outcome

The ACS design, engineering, and construction teams successfully delivered a fully integrated End-of-Line (EOL) production assembly test cell, handing over an operational facility that completely satisfies the client’s strict validation requirements. Through meticulous pre-construction planning, site utilities were relocated without disrupting the broader project schedule, setting the stage for a smooth structural build.

During the final phase, ACS engineers executed individual equipment checkouts and facility startup, systematically commissioning all systems to prepare the cell for mule engine testing. During these initial runs, the team performed instrument calibration, finalized test cycle development, and completed detailed system tuning. A final validation engine test was executed and officially accepted by the client.

The completed facility successfully expands the manufacturer’s capacity for heavy duty engine testing, providing a safe, highly automated environment capable of running comprehensive compliance tests on their largest engine models, with the built-in structural flexibility to quickly upfit modern diesel engine testing facilities for natural gas testing when market demands shift.

Key Features

• Design, construction, and commissioning for a new 5,800 sq-ft, two-story production test facility addition
• High-horsepower diesel engine end-of-line assembly testing with advanced tier 4 emissions test capabilities
• Safety-engineered building construction featuring blast-rated pressure relief walls
• Integration of custom-designed ACS test carts utilizing pre-existing plant rail and turntable infrastructure
• Comprehensive facility PLC interfacing with test cell data acquisition and safety monitoring systems
• Structural provisions integrated into the initial footprint to allow for future natural gas fuel capability

ACS Services

• Turnkey building design and construction management under a single-source contract
• Relocation of site utilities prior to the start of building construction
• Engineering and integration of custom engine carts, docking stations, and fluid conditioning skids
• FAT on integrated skid assemblies to minimize on-site testing time
• Development and deployment of the facility PLC for automated ventilation, fuel delivery, and gas detection
• Comprehensive commissioning, instrument calibration, and final validation testing for high-horsepower tier 4 diesel engines