1.02.002 GAC Governor set up guide for Gas Engines

This Policy is completed waiting on Engineering & Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for setting up a GAC throttle body actuator on a gas engine controlled by a LOGIX panel.

To ensure the proper high and low speed set points are set on the throttle body actuator to allow the LOGIX controller to have full range of RPM for smooth control of engine speed for operating conditions.

Also to ensure the ease of starting the engine.

Procedure

This procedure applies to all units that are currently in service in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the diagnostics and necessary adjustments as required to properly set up a GAC governor throttle body on a gas engine.

Before any work is performed a JSA needs to be done according to Flogistix procedure along with any Customer requirements before any work is started.

The governor throttle body on the engine needs to be set up properly.

If the throttle body has not been set up or if replacing the throttle body it will need to be properly set up.

If the throttle body has not been set up and the engine is started, it may have the following symptoms.

• Engine starts but only runs a second then dies.

• Engine will not slow down to an idle

• Engine will not speed up to Max set RPM

Follow these steps to set the high and low engine speed on the throttle body.

Setting the Low Idle set point

Step 1.

• • With the engine running to set the low Idle set point disconnect the wiring plug going to the throttle body as shown in photo #1.

Photo #1

Step 2.

• Using an Allen Wrench in the bottom hole remove the jamming Allen set screw. In most cases this screw has already been removed if the governor throttle body has been previously set. See photo #2

**It is not always needed but a good practice to remove the four Allen bolts on the side of the Governor actuator to view the throttle movement.

Photo #2

Step 3.

Start the engine.

• If the engine does not start or starts but dies you may have to screw in the lower Allen set screw, this will open the throttle body some.

• Once the engine starts and stays running look at the engine RPM on the LOGIX screen.

• Adjust the RPM to the desired idle or low RPM set point that the engine needs to run at.

• Minimum RPM on 5.7 engines is 1250 RPM unless otherwise approved by Engineering

• It is best to try to adjust the idle RPM while engine has a light load. See photo #3

Photo #3

Step 4.

• Plug the governor wiring harness back together as shown in photo #4.

Photo #4

Step 5.

• To set the high RPM set point with the newer version of the Logix PLC programs go to Diagnostic page, on the Diagnostic page there will be a Governor Set up Mode Enable switch in the middle right side of the screen see photo #5. This switch will be in the Off position change the switch to On.

photo #5

• If setting the high RPM speed set point on an older LOGIX panel that does not have the Governor Set up Mode Enable switch. Open the LOGIX Panel, at the bottom right of the LOGIX panel there are two small fuse holders by a large grey relay. see photo #6

photo #6

Step 6.

photo #7

• With the engine running flip up the left fuse holder as shown in the photo #7.

  • **Be aware that when the fuse holder is flipped up the engine RPM will speed up or will run to full RPM.

• In some cases the engine may shutdown on Engine overspeed.

Step 7.

With the fuse holder flipped up and engine running at high RPM look at the RPM showing on the LOGIX panel.

Adjust the small brass speed pod on the GAC governor box in LOGIX panel as shown in photo #8. Set the RPM to the desired high RPM set point for the engine, this will be the highest RPM that the engine will run at when controlled by the LOGIX PLC.

High RPM set point default is set at 2200 RPM on 5.7 engines. Running above 2200 RPM needs to have Engineering or Service Manager approval.

**The black plastic plug covering the Speed/Gain/Stability opening will most likely need to be removed to access the speed adjustment pod.

Photo #8

Step 8.

After setting the high speed RPM set point push the fuse holder back down to its normal position as shown in photo #9, The engine RPM should go to where the set point is in that the LOGIX panel is trying to run the engine speed at.

Photo #9

Step 9.

With the LOGIX panel controlling RPM, and if the side cover is still off the governor throttle body as shown in the photo #10.

It is a good practice to turn the shaft with your fingers to increase engine RPM’s and also turn shaft to reduce RPM’s to check governor response as shown in photo #11.

Photo #10

Photo #11

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 engines equipped with a GAC brand type Throttle body actuator controlled by a LOGIX panel and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of electrical sparks or electrical shock from DC voltage from electrical contacts or by grounding, this also could cause an ignition hazard. 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 or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• 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

• Small SAE Allen wrench set

• Small flat blade screw driver, recommended size 0.5x3.0

• Password level for Logix panel - Mechanic Level login

Approvals

Field Service approved by: Charles Crenshaw, VP Field Service

Date: 7/26/2017

Engineering approved by:

Date:

EHSS approved by:

Date