1.01.001 Gas Engine Drive PM

Purpose

The purpose of this procedure is to establish the minimum requirements for performing scheduled Preventative Maintenance (PM) on Flogistix units and to ensure compressor / driver longevity by maintaining Flogistix units as described in this procedure. This Preventative Maintenance Procedure is in compliance with EPA ruling 40 CFR Part 60 Subpart JJJJ and 40 CFR Part 63, Subpart ZZZZ where applicable. Maintenance intervals shall be based on run time hours of 1,440 running hours or driver manufacturer's recommended time intervals, whichever is less. Preventative Maintenance hours will be tracked automatically by Flogistix. Flogistix maintenance activities will vary depending on unit type, but will not exceed 1,440 run hours.

Procedure

This procedure applies to all units that are currently in service in the field, at a repair shop, and in storage yards. Flogistix Service Technicians will perform the scheduled PM as required according to the type of engine being maintained.

Before any work is performed, a JSA must be completed according to Flogistix procedure along with any Customer requirements before any work is started.

Preventative Maintenance Pre-Check items of unit before shutdown:

1. Compressor Skid

   1. Check over unit for leaks, abnormal noises, or vibrations

   2. Check Make-up / Recycle system for proper setting and operation (if applicable)

   3. Check all Pressure Relief Valves (PRV) for current / correct pressure tags and wire seals, see 1.1.3 Pressure Relief Valves (PRV)

   4. Control & Safety Shutdown Devices

      1. Test all Safety Shutdowns 1.02.005 Check Shutdown Devices

   5. Check Inlet Scrubber dump controls for proper operation

   6. Check all guards and brackets

   7. Check differential pressures on filters in Suction/Inlet Vessel and Discharge Vessel

   8. Check Telemetry (if applicable)

• • 1. Check antennas

    2. Check Cell modem for power and communication lights are all green - reference LED Status Lights from policy 1.7.21 LOGIX panel - Installation of Sierra Wireless RV50

2. Engine:

• 1. Check voltage from engine alternator 1.2. 3 Gas Engine Alternator/Charging System

  2. Check current operating conditions

  3. Check engine governor response & stability

  4. Check Engine Fuel Scrubber dump system.(if applicable)

  5. Take oil sample from engine and record sample information (if applicable)

3. Screw Compressor:

• 1. Check Scavenge Line & Needle valve for efficient flow 1.6.2 Scavenge Line Adjustment

  2. Check discharge temperature of compressor oil to make sure temperature is above gas dew point

  3. Check screw compressor oil level in Discharge Vessel while unit is running at operating conditions

  4. Take oil sample of compressor and record sample information (if applicable)

4. Reciprocating Compressor applications:

• 1. Check inter-stage pressures for failed compressor valves and/or piston rings

  2. Check cylinder discharge temperatures for failed compressor valves

  3. Check for warm suction valve caps on each cylinder

  4. Check lubricator box oil level

  5. Check lubricator pump for proper lubrication to cylinders

  6. Check packing vents for leaking gas vapors

Before any work is performed, all Safety precautions and LOTO must be in-place in accordance with Flogistix policy on the unit type for Preventative Maintenance.

Preventative Maintenance items to be performed after shutdown of unit

1. Engine items:

   1. When possible engine oil should be drained while engine oil is still hot or warm

   2. Fill engine oil pan/sump with fresh engine oil to required level

   3. Replace engine oil filter(s) 1.3.01 Engine Oil Filter change

   4. Remove all spark plugs 1.3.8 Sparkplugs Installing/removing GM 5.7 engine

   5. Check valve lash clearance and bridges (if applicable), reset to manufacturer specifications (if applicable) (**Ref Flogistix Field Service Wiki for valve lash setting for the engine type being serviced.)

   6. Check cylinder compression on all engine cylinders and record as required 1.3.04 Checking Engine Cylinder Compression

   7. Check valve recession (if applicable)

   8. Installation spark plugs 1.3.11 GM 5.7 (350) Sparkplugs Installing/removing

      1. Installation of new (if needed) spark plugs (spark plugs must be gapped according to manufacturer specifications)

      2. Installation of used (if suitable) spark plugs (spark plugs must be cleaned and re-gapped according to manufacturer specifications)

   9. Ignition System

• • 1. Distributor Type

       1. Check distributor cap & rotor (replace if needed)

       2. Check distributor shaft side to side play (replace if needed)

       3. Check distributor ignition coil - corrosion, power / distributor wire connections, properly mounted

       4. Spark plug wires - spark plug boots for corrosion, wires for cracks (replace if needed)

    2. Altronic Ignition

• • • 1. Check wiring plugs into Altronic ignition (replace if needed)

      2. Check primary wiring to coils (if applicable)

      3. Check ignition coils at each cylinder for corrosion and cracks (if applicable)

      4. Spark plug wires - spark plug boots for corrosion, wires for cracks (replace if needed)

1. 10. Check turbocharger (if applicable). Check for excessive wear, leaking oil seals

   11. Check / clean mag pick-up(s) (replace if needed). Reference 1.2. 4 Mag Pick Up (MPU)

   12. Service governor (if applicable) - check oil level in governor, check governor shafts for excessive wear and shaft movement

   13. Inspect throttle linkage from governor to carburetor (if applicable). Check for excessive wear

   14. Check air cleaner - replace if needed

   15. Engine coolant

• • 1. Check coolant level

    2. Check coolant mixture

    3. Check for DCA additive in coolant (if applicable)

1. 16. Inspect all coolant hoses for cracks or wear (replace as needed)

   17. Check engine belts (replace as needed)

• • 1. Inspect alternator belt(s) for wear or cracks

    2. Inspect water pump belt(s) for wear or cracks

    3. Inspect engine fan belts(s) for wear or cracks

1. 18. Check batteries on skid (replace as needed)

• • 1. Inspect batteries

    2. Check draw down on batteries

    3. Inspect electrical connections for Logix panel wiring (if applicable)

    4. Inspect starter wires from battery to starter for wear to the wire insulation & cracks in wire insulation

2. Screw Compressor items:

• 1. Change compressor oil spin on filter(s). Reference 1.04.001 Compressor Oil Filter Change

  2. Check compressor oil for dilution or mixing with condensate

  3. Check compressor oil viscosity 1.05.001 Minimum Viscosity Limits for Poly Glycol Synthetic Screw Compressor Oil

  4. Add or replace compressor oil to proper level in discharge vessel.

  5. Clean scavenge line sight glass if needed

3. Reciprocating Compressor items:

• 1. Change compressor oil spin on filter

  2. Check piston rod(s) for wear

  3. Visually check packing glands and packing tubing lines

  4. Visually check drive coupling for cracked shims or wear

4. Cooler items:

• 1. Check fan belts and / or electric motor driver (if applicable) (replace as needed)

  2. Check cooler louvers (if applicable)

  3. Check cooler frame and fan supports for cracks

  4. Check cooler grease lines (if applicable)

5. Panel items:

• 1. Check panel for loose terminal & wire connections

  2. Ensure all conduit entries, antennas, etc. are fully tightened and no weather leaks are present

Preventative Maintenance items to be done after Re-Starting the Engine.

1. Engine

   1. Check engine oil pressure

   2. Check / adjust / record ignition timing

   3. Check / adjust fuel gas pressure - 1st cut

   4. Check / adjust fuel gas pressure - 2nd cut

2. Screw Compressor

• 1. Check compressor oil level

  2. Adjust scavenge line needle valve for efficient flow 1.6.2 Scavenge Line Adjustment

  3. Check spin on filter differential pressure at full operating temperature 1.07.030 LOGIX panel - Setting up proper Compressor Oil Filter Differential Pressure

  4. Check differential pressure between suction and discharge pressure for proper Delta P to maintain oil flow to compressor

3. Cooler

• 1. Grease cooler bearings and idler bearings

  2. Check for air flow across cooler sections

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all engine driven compressor units and are applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees should be aware that units could contain flammable and toxic gasses. Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids, rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes. Environmental spill of engine waste oil and production fluids

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure. Four Gas Monitor, which is outlined in the Flogistix EHSS Manual, PPE Section 8, Procedure 8.3 This procedure applies to all units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification as required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools

Spills and Disposal

All spills shall be handled immediately according to MSDS recommendations and the employee's level of training

Flogistix Service Technicians performing PM's will properly dispose of waste either liquids or solids from the required PM. Disposal of any fluids or solid waste will be disposed of properly according to Flogistix policy. Disposal of any fluids will be done at an approved or designed waste location. Disposal of solid waste from the PM such as oil filters, oily rags, ETC, will be disposed according to the local regulations regarding the disposal of used oil filters and oil soaked rags.

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• MSDS Online System

• Emergency and First Aid procedures

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing Preventative Maintenance shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out LOTO items to properly perform LOTO procedure according to Flogistix policy

• Basic hand tools

• Oil filter wrench

• Drain pan

• Means of waste oil evacuation either by Sage or a pump system on service truck, or by containers to dispose of waste oil.

• Compression gauge tester

• Hand held remote push button starter (recommended not required)

• Oil viscosity gauge

• Spark plug gapping tool

• Feeler gauges

Revision History

Revised 7/27/2017

• Rain caps on PRV tailpipes no longer utilized. Drain holes on tailpipes remain. Inspection of PRVs no longer includes verification of tailpipe rain cap

• Clarifying verbiage

• Tool requirement additions

Approvals

Field Service approved by: Charles Crenshaw

Date: 4/11/17

Engineering approved by: Aaron Baker

Date: 7/27/17

EHSS approved by: Mike Southard

Date: 08-03-17