Case StudiesCory Environmental Ltd

Following a Catastrophic failure of a LE bearing, GSE were contracted to carry out a crankshaft repair to a Caterpillar 3516 Landfill Gas powered engine for Cory Environmental Ltd.

Client:

Cory Environmental Ltd

Industry:

Green Energy

Key Parameters:

.Crankshaft Replacement of Caterpillar 3516 LFG engine.

Date:

August 2016

Project Desciption/Specification:

Following a Catastrophic failure of a LE bearing, GSE were contracted to carry out a crankshaft repair to a Caterpillar 3516 Landfill Gas powered engine for Cory Environmental Ltd.
The engine, complete with generator and skid was transported from site to GS Workshops in Wirral, to facilitate repair.

The engine was completely stripped to allow removal of damaged crankshaft, which was subsequently sent for repair at a specialist crankshaft repair facility.

However following an initial condition survey and proof grind of the damaged crankpin, the crankshaft was unfortunately deemed scrap, due to an excessive hardness variation of the crankpin, caused by the original bearing failure.

customer ‘Cory Environmental’ sourced a replacement OEM Crankshaft directly from Caterpillar UK, along with a complete engine set of rebuild parts.

original crankcase entablature and sump were thoroughly cleaned, inspected and re-certified for re-use, prior to fitment of replacement crankshaft.

Original connecting rods were re-worked and certified, with damaged rods replaced. New SE bushes were fitted to original connecting rods with all assemblies being recalibrated and certified, prior to being re-assembled and fitted new cylinder liners, pistons and ring packs.

Original cylinder heads were overhauled and refitted, along with both turbochargers and CA coolers.

Additionally during the main engine overhaul, the 1000kw generator was subsequently reconditioned locally by R J & Windsor and refitted on completion of rebuild.

Due to the nature of the original bearing failure, a full lubricating oil system flush was carried out at the workshop prior to transporting the engine back to site. GSE have developed a unique pumping rig, utilising a set of sacrificial oil filters. This procedure guarantees removal of all metal particles resulting for the preceding bearing failure.

Following re-installation on site, GSE engineers attended site to complete initial bearing runs and subsequent commissioning checks

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