CompressorTechTwo - 2010 (Sample)

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Foley Equipment’s gas compression engine rebuild history began in the late 1990s in the Hugoton Natural Gas Area in western Kansas. Foley had
an established irrigation gas engine service operation in that region, but the business grew significantly as the Hugoton field matured and pres-
sures declined, leading to the need for a large facility.

Rottler cylinder head machine model SG8 that is capable of rebuilding and testing engine cylinder heads.

Foley Rebuild also has a fleet of 25 to 30 exchange engines on-site at any given time, a combination of new and rebuilt models, allowing customers to switch out like-models. That size fleet can reduce downtime to only a day or two in some applications, Davis said.

After the engines are rebuilt they move to a separate test center with fireproof doors and its own foundation, isolating the dynamometer vibration from the rest of the building. The test operations center around a pair of Taylor water brake dynamometers, a 1500 hp (1118 kW) unit and a new

5000 hp (3728 kW) system, the latter being the first application of that model. As such, Davis said, Foley Rebuild was the first to dyno test a G3600 Cat engine outside of the factory. During testing, all rebuilt engines are brought up to load gradually, in steps, and then run at 100% load for a set period of time, depending on the engine being tested.

Foley is also capable of doing emissions tests on the rebuilt engines. “We can have an engine set to the original factory spec, emissions-wise,” Davis said, “and prove it. Neither we nor Caterpillar certify gas engines, because you can’t control the fuel gas quality going in, but we can bring it

back to what it was when it left the
factory as a new engine.”
In the assembly process, the techni-
cians follow a detailed quality control
process. The company is also evaluat-
ing all of its rebuilding processes us-
ing Caterpillar’s Six Sigma methodol-
ogy to further refine and improve its
operations.

Finally, paint is sometimes an overlooked part of a rebuilding operation. Foley has a 16 x 45 ft. ( 4. 9 x 13. 7 m) aluminum shot blasting booth and 16 x 45 ft. ( 4. 9 x 13. 7 m) and 20 x 75 ft. ( 6 x 23 m) paint bays.