This Policy is Currently Under Development.

Purpose

The purpose of this procedure is to establish the minimum requirements for determining the correct Fuel Pressure on Gas Engine Drive units and the correct Supply Gas Pressure for Gas and Electric Drive units.

Incorrect Fuel Supply pressures either that are too Low of a Pressure or being Over Pressured can lead to multiple issues from Hard to Start, Low Horsepower, Low RPM, Fail Emissions Compliance, just to name a few.  

The Fuel Supply Pressure being set to the correct pressures is vital to keeping the engine operating correctly.

There are two Fuel Pressure settings that need to be set correctly.

The Primary Fuel Pressure

The Secondary Fuel Pressure also referenced as the Ounce Pressure going to the engine Carburetor.

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 assistanceFor the next step a flex-able measuring tape will be needed to measure and mark where the desired ignition timing mark is needed to be marked at on the Balnacer.  The engine turns counterclockwise when standing behind the engine looking at the flywheel.  

Scope

This procedure applies to all Gas Engine Drive units and is applicable to all Flogistix employees, contractors, and temporary employees.

1.  What is the fuel source for the compressor? Is it customer supplied or supplied from the discharge of the compressor itself?

A. If the customer is supplying the fuel source we need to verify there is a little joe regulator installed on the incoming supply line.  If no regulator has been installed the fuel system could potentially over pressure and cause other issues with failing to start or hard starting.  A regulator that is good for a minimum of 20 PSI should be used here. The little joes that are supplied on the package are good for 10-95 PSI. Big joes that customers sometimes use will also work but could cause a hard start issue if they do not maintain pressure properly. Little joes are suggested here

B. Supplied pressure on skid, ensure that the little joe regulator on the incoming fuel line adjusts pressure properly.  If it doesn't seem to change the fuel  pressure, then it will need to be inspected for damage, it will need to be repaired or replaced.

• Be sure to have a spare 0-100 psi liquid filled gauge on your truck, in case the gauge on the vessel needs to be replaced 

• 004-050-046 - REGULATOR. SENSUS 046, 1" NPT DUCTILE, 046-1-.375-10-95 

• The fuel gas "Primary Pressure" should be set to 20 psig minimum pressure with the maximum pressure set no higher than 30 psig maximum pressure.   Any pressure higher than 30 psig could result in premature failure of the fuel Ounce Regulator going to the engine.  This could also result in hard starts or failed starts.

1. If the ounce regulator is venting gas out of the vent of the regulator bonnet or does not seem to be dropping pressure, inspection of the ounce regulator will need to be done to ensure the diaphragm is not damaged.  If the diaphragm is damaged or the connecting rods inside of the upper housing are worn or broken it needs to be replaced.  

2. 004-050-002 - REGULATOR, SENSUS, OUNCE 1", 3/8 ORIF 6-14WC 143-80-2  

• The "Primary Pressure" should be high enough to maintain control of the engine and also supply pneumatic pressure to the recycle valve pilot and blow case controls during activation. 

• After setting the fuel Primary Pressure, the vessel will collect fluids from both sides, the Fuel Vessel dump system needs to be verified that it is working properly and efficiently.  If the fuel vessel is equipped with the Welmark style Dump valve, it should be replaced with a "No-Freeze dump valve" and plumbed in to the existing dump line. 

a. For the one inch supply port on the vessel use part number 004-025-002 - VALVE, "NO-FREEZE" DUMP, 1800 PSI, 1" X 1/2", KDV-P18-1-05

b. For the two inch supply port on the vessel use part number 004-025-001 - VALVE, "NO-FREEZE" DUMP, 500 PSI, 2" X 1", KDV-P05-2-1 

• Close valves to the fuel vessel to isolate any additional pressure from entering system

• Ensure the needle valve supplying pressure to the two Peter Paul valves are open

• Ensure the discharge side of the blow case is open 

• Log in to the PLC using the temporary password and follow these steps to ensure the dump valve is working properly prior to starting the unit.

• Go to Diagnostics Page of the Logix panel

• Then go to Digital Output Test feature

• Scroll down to Discharge Blow Down in the option list (discharge blow down and fuel vessel dump are ran by the same circuit)

• Turn switch On and verify that the Peter Paul valve has activated and the no freeze dump valve has opened.

• Verify the pressure in the fuel vessel is dropping properly, if the fuel pressure does not drop, additional diagnostics of the supply pressure or the dump system needs to be performed

After checking all of the above, power up the Logix panel to open the Asco Fuel Valve and check the pressure supply going to the engine through the ounce regulator.  The ounce regulator should have a green spring in the body, this is good for 6"-14" Water column pressure and should also have a 3/8" orifice in the body of the regulator. 

• To check the spring in the ounce regulator using a flat head or allen wrench screw the spring plate from the ounce regulator top section, verify the tension of the spring and color is proper. Also make sure the spring has not been stretched out

• To check the orifice loosen the nut on top of the body of the regulator and remove top section. Orifice is screwed into the body of the valve. 

• If when the panel is powered up and there is no fuel gas to the carburetor diagnostics of the asco valve need to be performed.  

Power points for Asco valves are as follows.

Older terminal block panels - TB-2 Terminal 7 and 8 also relay CR-3

PCB style panels - PWR/DO PCB or right hand board is  TB7  CR5 NO and TB7  PS1-

UL listed panels - TB2 Terminal 75 and 76 also relay CR16

Check termination at the valve itself to ensure it is wired properly. 

• If the power to the Asco valves check out but the valve still does not open there is a possibility that the coil to the                    Asco is bad and not picking the diaphragm up properly. If the unit is equipped with an older asco valve you can inspect the coil for damage, with the panel esd unscrew the top of the asco valve and remove the coil. Inspect the coil for breaks and cracks, if it is cracked replace the asco valve with the updated valve. A crack will cause a short to ground and create other issues in the panel. The tops will inner change so there is no reason to rebuild the fuel line. 

004-015-004 - VALVE, GAS SHUTOFF 1", 8214G251 12/DC 

004-015-003 - VALVE, GAS SHUTOFF, 1", 24VDC, CSA APPROVED 8214050-24/DC 

004-015-005 - VALVE, GAS SHUTOFF 2" 24VDC CSA APPROVED 8214280CSA-7 

• To set the water column to the engine use your flat head or allen and rotate the spring plate in to increase the pressure and out to reduce the pressure. All fuel regulators should be set between 4-6 ounces for proper starting. 

• The BTU of the gas may effect these settings and will vary from location to location.

a. For lower BTU gas it may be necessary to change the orifice and the spring in the fuel regulator to increase the volume to         the carburetor.

b. It may also be necessary to adjust the home position of the fuel valve for start up as well on the AFR setup page in the              HMI, have found 20-40% for start up works the best.

If everything checks out properly its time to start the compressor, if the compressor roles over and fails to start need to check the ignition power, spark and carburetor are functioning properly. 

• Remove air cleaner and watch the diaphragm in the carburetor while rolling the engine over. If the diaphragm does not move then there is possibly a tear on the diaphragm itself. Remove the screws from the top of the carburetor and removed the diaphragm. Inspect for rips or tears and make sure the gasket on the edge is good. If there is a tear replace the diaphragm. 

A. Impco 225 - 5.7L GM diaphragm -  D1-16-2

B. Impco 200 - 8.3 Cummins diaphragm - D1-16-2

C. Impco 425 - 855 Cummins, 8.0L GM and 8.1L GM  diaphragm - D1-25

• Check firing order on 5.7L and 8.0L engines 

    A. 5.7L - 18436572

          B. 8.0L - 18726543

• Check to ensure the ignition is powered up. 

A. Old terminal block panels - TB2 - 3

PCB board panels - TB5 - CR1 NO 

UL listed panels - TB2 - 72

• It is possible that the fuel gas vessel will need to be purged of oxygen prior to start up of the engine. If all above has been checked completely and engine has spark then there is a great chance the idle screw of the governor actuator has not been set correctly. 

• To adjust the idle properly on the GAC actuators you will need a 2MM allen wrench and phillips screw driver.

A. Remove the bottom cover screw on the side of the GAC and using your 2MM allen adjust the idle set screw in until the engine will fire and check RPM settings on HMI. 

B. If the engine is running faster then 1250 RPM additional adjustments will need to be made, Log into the HMI with a temporary password and enter the diagnostics screen.

C. On this screen there is a governor setup mode switch, turning this switch on will stop the plc from controlling the governor and actuator for 300 seconds. 

D. While the governor setup mode is enabled return to the actuator and adjust the bottom screw for idle set point to desired idle settings 1000-1250 rpm, after idle has been set return the cover screw to actuator and turn off the governor set up mode on the HMI. 

• Compressor should be running now and further adjustments of the fuel supply should be made at this point for load on the compressor or max rpms of the engine. Adjusting the spring plate on the ounce regulator in gives engine more fuel and screwing plate out reduces fuel supply. While adjusting the spring plate watch the AFR valve postion on the HMI and try to set AFR valve at 70-80% at full load of compressor. This should give AFR valve plenty of room to move when engine is at an idle. 

If the AFR valve is not controlling properly please reference 7.13.001 AFR (trouble shooting guide) in the wiki

• If spring is adjusted out completely and oxygen sensor still says it is rich it is possible that the orifice in the ounce regulator will need to be changed, there is also a power valve on the carburator where the fuel supply goes in on the bottom side. Turning this valve to the right will lean the engine out and turning to the left will richen the engine for a little more added control of fuel supply. 

Hazards

Employees need to be aware of the possibility of extremely hot exhaust pipe surfaces, potential exposure and the inhalation of engine exhaust.  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.  

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure.  

Four Gas Monitor, which is outlined in the Flogistix EHS 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)

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

• 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 this procedure 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

• Small Flex-able measuring tape

Approvals

Field Service approved by:

Date:

Engineering approved by: 

Date: 

EHS approved by:

Date: