Repairs, overhauls, and rebuilds by a team of specialists
Get to know the workshop of Pon Power
Over fifty overhauls per year! Fifty engine blocks, gas or diesel, some of which arrive looking like scrap but are reconditioned to the strictest specifications of Caterpillar to start a new life. Shining in a freshly painted yellow coat. This is the workshop of Pon Power in Papendrecht.
A full team of specialists
Whether it's individual components or complete engine blocks—everything is welcome in the Pon Power workshop. However, the majority of the work involves overhauling complete engine blocks. Teus Hartog, workshop manager, explains: “An engine block usually comes in as a whole. At first glance, they often look old or worn out. But we already know at that point that such a gas or diesel engine still has a full life ahead of it. If the foundation is solid, we’ll restore it to like-new condition. That’s not only more cost-effective for the customer, but also more sustainable.”
“The journey an engine block takes through our facility involves many specialists and highly specialized tools. From the wash bay to the injector test bench, and from the boring mill to our test stand. The goal is to assess the condition of every component, and repair or replace parts where necessary—to values that match those of a brand-new engine, as specified in the Caterpillar Reusable Guidelines. That’s how we guarantee them a second life.”
In al die specialistische hoeken worden ook veel losse onderdelen geserviced, die niet afkomstig zijn uit een revisie-blok. Teus: “Onder andere van Caterpillar Marine Service Providers krijgen we veel losse onderdelen en componenten opgestuurd, net zoals van onze eigen buitendienst en vanuit andere vestigingen. Die onderdelen krijgen dezelfde focus en maken we tip-top in orde. Is er haast bij, dan kan een klant kiezen voor ruil-onderdelen. Die hebben we vrijwel altijd op voorraad.”
The general workshop
The largest floor area in the workshop is occupied by the general workshop. Here, the engine block is mainly disassembled and then reassembled afterward. The technicians who disassemble the engine block are the first to see the condition and any damage to the engine. It's great work, as the complete engine block passes through their hands.
David Ellis, service technician, seen working in the photo: “From the smallest bolts to the crankcase: we see everything. And it’s not just a matter of disassembling; simultaneously, you are also analyzing: what does the block look like, and why do I see what I see? Ultimately, the entire engine block passes through our hands and we get to see the comprehensive technology of a gas or diesel engine. It's amazing, and rebuilding the block—like new—provides a great sense of satisfaction.”
Wash tunnel
Everything needs to be clean! Not for the appearance, but to optimally inspect and test each component. The wash tunnel includes, among other things, three ultrasonic cleaners. To give you an idea: the largest one can fit a disassembled Cat 3516 in its entirety!
These tanks create countless sound waves that cause imploding water vapor bubbles. These bubbles produce currents in the ultrasonic liquid, resulting in perfectly clean parts.
Diederik: “Unlike the specialized sections, we don’t have a fixed crew in this wash tunnel. In other words, everyone uses the wash tunnel for their own parts. Everything goes in, from cylinder heads to turbos. Afterward, it's a pleasure to work with—clean material allows us to perform an optimal inspection of the part.”
In 2024, the workshop will get a new ultrasonic tank, replacing the largest one that is gradually becoming due for replacement. Teus: “You wouldn’t say it, but such an ultrasonic tank is very important to us. Clean work delivers the best analysis. And that's what it's all about for us; we need to be able to see the wear on a block, but also trace its origins.”
The cylinder head section
Informally, it’s called ‘the cylinder head section,’ but what we see is an ultra-clean and tidy workspace where a few specialists work on cylinder heads. Dik van Wingerden, service technician in the workshop: “In this workspace, the cylinder head is visually inspected, all components are measured one by one and replaced if necessary, and the head is pressure tested to check for cracks or other ‘leaks.’ If a head is not perfectly flat—and we’re talking about the smallest tolerances here—it needs to be resurfaced. We do that in-house; on the surface grinder that automatically shaves the head to the hundredth of a millimeter.”
A cylinder head not only seals the engine block but also houses the camshaft and valves. Our own boring machine plays an important role in ensuring everything fits perfectly here as well. Nico van der Pol: “On the boring machine, we rework the valve seats so that a valve fits optimally on the seat. We’re dealing with tolerances that we can't see with the naked eye—real precision work. That actually applies to everything we do here: the right tools, high-quality machines, and clean and organized work are essential.”
The components section
A bit further on, we find the components section, where various specialists, among other things, bring turbos and water pumps back to like-new condition. Marien van der Want is one such specialist: “Here, it's really about balance. A turbo must be fully balanced, and over the years a turbo blade always accumulates dirt and slight damage from exhaust gases and intake air. We ensure new balance on our two balancing machines and renew the bearings, seals, etc.”
Marien on working with components: “It's nice precise work in a clean, organized workspace with all the tools and machines we need. Moreover, I’m flexibly deployable; for example, sometimes I also do overhauls in the general workshop; this allows me to be involved in all stages of overhauls and remain versatile.”
The fuel pump section
A space as clean and organized as a laboratory; we are in the domain of service technician Wim van den Berg. A nice enclosed space where all fuel pumps and injectors are put to the test. Are any parts defective, or do they no longer fall within the tolerances? Everything is inspected, replaced if necessary, and the injectors are tested on two test benches.
On the test benches, we see if the injectors deliver enough output. In other words: does the cylinder receive sufficient output? That, of course, has to be extremely precise, and we check if the performance meets Caterpillar's specifications. We also test injectors and regulators against these Cat standards. If they fail, we overhaul them. For injectors, if they fail, we supply them new or re-man.
This is truly specialized work, work that has a significant impact on how an engine runs. The smallest tolerances have the greatest consequences. That's why we have equipment like a Hartridge test bench: quality gear for the best results.
The planning team
With a view of the Ketelhaven, behind a multitude of large screens, sit Gerben, Benny, and Teus Batenburg; the planning and work preparation team. Without them, work simply comes to a halt. They not only organize the parts but also plan the work of the twenty-five technicians. The reason their phone is constantly ringing is clear, especially considering they also handle all customer contacts.
That customer contact makes the planning even more complicated than it already is. Not every engine block or part has the same priority. If there's an engine block in the workshop and the ship is in the harbor, there is obviously urgency. Other engine blocks have more time, especially when an exchange block is available.
The test stand
We’ve never seen our test rooms this empty before! For good reason, as we recently received two new test stands replacing the old ones after twenty years of loyal service. All engines and generator sets that leave our workshop are extensively tested here. Is everything functioning correctly, and do they achieve their power and emissions? We can test up to 3,500 kWe electrically and up to 3,300 kW mechanically.
More to come soon, as we will delve into our new test stand in detail in another article!
Closing
And then? The journey of an engine block is complete. The block is ready, as good as new! Well, except for a fresh yellow coat of paint; that happens outside the workshop. So, the block is not only new on the inside, it also looks new on the outside.
Teus: “When we ship an engine block back to the customer after test-running it, we see what it’s truly about: keeping our customers’ operations running smoothly. As technology enthusiasts, we enjoy tinkering, analyzing, and improving, but ultimately, we are a service-oriented organization. Many trouble-free operating hours—that’s what it’s all about. An engine block that the customer doesn’t have to worry about, whether it’s in a locomotive, a CHP, a ship, an industrial machine, a hospital, or on an oil rig. That’s Caterpillar, that’s Pon Power.”
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