End-of-Line (EOL) Large Engine Assembly Test Cell with Tier 4 Emissions Capability

Project Overview

Our client, a manufacturer of engines for marine, drilling, power generation and locomotive applications was relocating engine assembly and testing from Illinois to North Carolina. As part of the engine assembly move, they identified a need to upgrade and expand their Tier 4 Emissions Test capabilities and end-of-line assembly testing of a wide range of high horsepower engine models (8,12,16, 20 – cylinder), with clockwise and counterclockwise rotation, used in locomotive, marine, and industrial applications.

The new location was previously used to manufacture axle assemblies for large mining vehicles. The floor rails and several large turntables from that manufacturing process remained and were used to transport engines through assembly and test.

Key Features

• Test cell for high horsepower diesel engine production assembly testing, Tier 4 emissions test capability
• Building construction included pressure relief walls for safety
• Relocation of site utilities prior to start of building construction
• In-floor rail system in cell and engine prep area
• Test carts, designed and built by ACS, use existing plant rail and turntable system
• Mechanical/electrical including bottle gas room, span gas equipment, engine exhaust, test cell ventilation
• Control room with viewing monitors, no windows to test cell
• Structural provision for future Natural Gas (NG) fuel capability

ACS Services

Building Design, Construction, Commissioning

ACS held a single source design/build contract to manage the design and construction of the 5,800 sq-ft two-story addition to an existing production facility.

The project included one diesel engine blast-rated test cell constructed to accommodate the addition of future natural gas testing, an operator control room, mechanical equipment support room, and mechanical platform.

Skidded Systems, Test Cell Equipment

ACS designed, engineered, integrated and built engine carts, the docking station and alternator riser, oil conditioning skid, fuel panel, jacket water and aftercooler water conditioning systems, engine starting system and drive shaft with engine interface, engine exhaust, combustion air and engine wetted component rigging. Owner-provided components were incorporated into equipment skid and panel assemblies and used to prove functional performance during Factory Acceptance Tested (FAT) prior to shipping to minimize test time on site.

Controls and Data Acquisition

ACS provided a facility Programmable Logic Controller (PLC) used to control systems such as test cell ventilation, fuel delivery, pre-lube, jacket water, engine oil, cooling tower water, pump room and tank farm, fire suppression interface, and hazardous gas detection. The PLC facility controller also interfaces with the test cell data acquisition and engine control system for monitoring and set point data transfer.

Commissioning and Site Acceptance Testing (SAT)

ACS engineers performed individual equipment checkout and facility system startup. Upon facility system startup, test cell systems were commissioned and made ready for mule engine start up. During mule engine operation, instrument calibration, test cycle development and system tuning occurred. Validation engine test was performed and accepted.

The End of Line (EOL) production assembly test cell with capability for Tier 4 Emissions Test was turned over to the customer.