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    CMPAK-ZONG - 0193 (Flywheel Housing Damage)

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    Ammar Baig
    An engine flywheel housing was found cracked twice on a generator, initially at 1701 hours and again at 1999 hours. Vibration measurements and physical inspections were performed after replacing the housing with a cannibalized part. A technical service bulletin issued by the manufacturer recommended modifications to the flywheel housing design to resolve the issue. Measurements of the new housing found it was properly installed according to specifications.

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    © All Rights Reserved
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    CMPAK-ZONG - 0193 (Flywheel Housing Damage)

    Uploaded by

    Ammar Baig
    74 views6 pages
    An engine flywheel housing was found cracked twice on a generator, initially at 1701 hours and again at 1999 hours. Vibration measurements and physical inspections were performed after replacing the housing with a cannibalized part. A technical service bulletin issued by the manufacturer recommended modifications to the flywheel housing design to resolve the issue. Measurements of the new housing found it was properly installed according to specifications.

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    CMPAK-ZONG_0193 (Flywheel Housing Damage)

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    An engine flywheel housing was found cracked twice on a generator, initially at 1701 hours and again at 1999 hours. Vibration measurements and physical inspections were performed after replacing the housing with a cannibalized part. A technical service bulletin issued by the manufacturer recommended modifications to the flywheel housing design to resolve the issue. Measurements of the new housing found it was properly installed according to specifications.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    74 views6 pages

    CMPAK-ZONG - 0193 (Flywheel Housing Damage)

    Uploaded by

    Ammar Baig
    An engine flywheel housing was found cracked twice on a generator, initially at 1701 hours and again at 1999 hours. Vibration measurements and physical inspections were performed after replacing the housing with a cannibalized part. A technical service bulletin issued by the manufacturer recommended modifications to the flywheel housing design to resolve the issue. Measurements of the new housing found it was properly installed according to specifications.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 6

    CMPAK-ZONG (0193-LARKANA)

    FLYWHEEL HOUSING DAMAGE


    Equipment Details:
    Genset Model C28D5 Genset Sr. No G18R144156 Engine Model X2.5-G2 Engine Sr. No. H20416 Engine Hours 1999.0

    Complain:
    Customer complains that genset flywheel housing found damage once again.

    Site History:
    As per service team observation on site @ June 30 2019 (engine hours: 1701), flywheel housing found cracked from multiple points
    initially it is difficult to find out the reason behind that failure. We cannibalize the part from OES Yard (ESN: J95466) to rectify the issue
    on site and the issue resolved, but unfortunately on September 10, 2019 (engine hours: 1999.0) customer complains that genset flywheel
    housing damage once again along with oil leakages. Complete case reported to TSD for analysis and as the new modified flywheel housing
    is not available in stock (TSB190123) Service team once again cannibalize the flywheel housing (0104-2117) from OES Yard (J94624) and
    visit to the site on (October 12, 2019) measure all the readings which consider mandatory and replace flywheel housing once again.

    Troubleshooting:
    September 25, 2019
    Service team reached to the site and found that flywheel housing damage once again. Taken pictures to root cause failure identification
    October 12, 2019
    As per our diagnosis previously, service team cannibalize the Flywheel housing (0104-2117) from OES Yard (C22D5; X2.5-G2 / J94624)
    on October 11, 2019 (FSR #: 097677) and move with part on the next date to the effected site.

    Reached at site remove old flywheel housing and inspect it (completely cracked). Install new cannibalized flywheel housing (0104-2117)
    on October 12, 2019 and then run the genset on load, everything found normal and there is no additional abnormality observe on that
    time.

    Measure the readings as per TSB190123, record vibration data (off-load and on-load) and all dimensions which required at the time of
    flywheel housing.

    Conclusion:
    A TSB is launched from CUMMINS “TSB190123, Date: August 20, 2019” as some modification recommended by CUMMINS. A complete
    kit modified flywheel housing (0104-2117) and Allen Screw (Plate, Adaptor – A044Y202)] is required to resolve the issue as per TSB.

    Vibration Measurement Locations:

    Point No. Locations Point No. Locations


    1 Engine Cylinder Block Top- Flywheel Side 5 Engine Alternator Coupling Adaptor top location
    2 Engine Cylinder Block Top- Radiator Side 6 Alternator Non-Drive End
    3 Engine Mounting Bracket 7 Not Applicable
    4 Not Applicable 8 Alternator Mounting Bracket

    Orient Energy System (Pvt.) Ltd. Page |1


    CMPAK-ZONG (0193-LARKANA)
    FLYWHEEL HOUSING DAMAGE
    Location 1 & 2

    Location 3: Location 5:

    Location 6: Location 8:

    Orient Energy System (Pvt.) Ltd. Page |2


    CMPAK-ZONG (0193-LARKANA)
    FLYWHEEL HOUSING DAMAGE

    At 50% load At No Load


    Vibration Vibration
    Position Position
    Velocity (mm/s) Velocity (mm/s)
    1 19.0 1 17.0
    2 22.0 2 14.0
    LHS: 18.0 LHS: 20.0
    3 3
    RHS: 20.0 RHS: 18.0
    5 16.0 5 16.0
    6 55.0 6 54.0
    LHS: 29.0 LHS: 26.0
    8 8
    RHS: 29.0 RHS: 30.0

    Flywheel Housing measurement:


    FACE TIR OF FLYWHEEL HOUSING: FACE TIR OF FLYYWHEEL:
    S No. Locations mm S No. Locations Mm
    1. Location 12 o’clock 0.0 1. Location 12 o’clock 0.0
    1. Location 03 o’clock 0.10 2. Location 03 o’clock 0.19
    2. Location 06 o’clock 0.60 3. Location 06 o’clock 0.48
    3. Location 09 o’clock 0.36 4. Location 09 o’clock 0.23
    4. Minimum Observed 0.0 5. Minimum Observed 0.0
    5. Maximum Observed 0.60 6. Maximum Observed 0.48

    AVM MOUNTING SUBBASE PAD HEIGHTS AVM Compressed Height


    S No. Locations mm S No. Locations Mm
    1. AVM mounting Pad Height - Engine Right 30.0 1. Engine AVM Right Side 67.0
    2. AVM mounting Pad Height - Engine Left 30.0 2. Engine AVM Left Side 66.0
    3. AVM mounting Pad Height - Alternator Right 30.0 3. Alternator AVM Right Side 65.0
    4. AVM mounting Pad Height - Alternator Left 30.0 4. Alternator AVM Left Side 65.5

    Orient Energy System (Pvt.) Ltd. Page |3


    CMPAK-ZONG (0193-LARKANA)
    FLYWHEEL HOUSING DAMAGE
    Supporting Pictures:
    October 12, 2019

    Orient Energy System (Pvt.) Ltd. Page |4


    CMPAK-ZONG (0193-LARKANA)
    FLYWHEEL HOUSING DAMAGE

    Orient Energy System (Pvt.) Ltd. Page |5


    CMPAK-ZONG (0193-LARKANA)
    FLYWHEEL HOUSING DAMAGE

    Orient Energy System (Pvt.) Ltd. Page |6

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