1.02.003  Gas Engine Alternator/Charging System

This Policy is completed waiting on Engineering & Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for safely performing diagnostics on the charging system on Gas Engines with an Alternator.  Also to ensure Alternator is supplying proper amount of voltage to supply all required electrical components on a Flogistix unit as laid out in this procedure.

Procedure

This procedure applies to all units that are in currently in service in the field, Test Loop, at a repair shop, and or in storage yards.  Flogistix Service Technicians will perform the diagnostics as required according to the type of alternator being used on the gas engine type.  This procedure is to be used as a guide to the diagnosis of the gas engines with alternator charging systems on Flogistix packed units. 

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.

Pre-Check items for Alternator diagnosis on unit running before shutdown:

1. Engine:

   1. Check over running engine for abnormal noises or vibrations

   2. Check over alternator, alternator mounting brackets, and guards for excessive wear or damage

   3. Using a Volt Meter set to DC voltage place the black test lead from the Volt Meter to a good ground on the engine.  Then touch the Red test lead from the Volt meter to the positive post on the back of the Alternator(See Example “A”). Record what this voltage is on the positive post of the Alternator.  This single wire is the wire that supplies voltage and charges the battery(s).  Voltage should be a minimum constant voltage of no less than 12.6 volts on 12 volt systems, and a minimum constant voltage of no less than 25.2 volts on a 24 volt system. 

                        Example A 

If Alternator voltage is less than the listed minimum voltage, 

• 1. Disconnect the battery while unit is running(Make sure to place removed battery terminal in a position where it will not touch metal or come in contact with a grounded component causing an arc.  Check voltage at alternator with battery disconnected and see if voltage at alternator increases or decreases from previous reading.

  2. If voltage is still less than minimum voltage with battery disconnected the alternator needs replaced.  

  3. If voltage increases above the minimum voltage, the battery will need to be checked for conditions and wear, or other sources of a voltage draw. 

If Alternator Voltage is above the minimum voltage proceed with procedure   

1. Panel:

   1. Check voltage at the Control Panel it should match the voltage coming out of the alternator 

      1. Terminal Block LOGIX panel - TB1 - #1

      2. Murphy TTD/TTDJ Panel - DC Input Terminal

      3. Circuit Board LOGIX Panel - TB1 - #3

Before any work is performed all Safety precautions and LOTO must be in-place according to Flogistix policy for the unit type.  

Items to be done to check alternator voltage after alternator has been replaced and engine has been restarted:

1. Engine items:

   1.  Check over running engine for abnormal noises or vibrations

      1.  Check voltage with multimeter as in step 1, at the Engine Alternator, Voltage should be a minimum constant voltage of no less than 12.6 volts on 12 volt systems, and a minimum constant voltage of no less than 25.2 volts on a 24 volt system.   

   2.  Check voltage at the Control Panel, it should match the voltage coming out of the alternator.

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 an Alternator and are 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 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 any Customers safety practices.

Proper use of required tools 

Return Deposit or Disposal of faulted Alternator core 

Flogistix Service Technicians performing Procedure to remove and replace a faulted Alternator will return Alternator core to the purchasing warehouse of the replacement Alternator.  Disposal of any scrape parts will be disposed of properly according to Flogistix policy.  Disposal of any fluids will be done at an approved or designed waste location.  

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

• 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

• Multi-meter Volt meter

Approvals

Field Service approved by: Charles Crenshaw, VP Field Service

Date: 2/08/2023

Engineering approved by:

Date:

EHSS approved by:

Date: