1.07.002 LOGIX panel - Gas Engine Drive LOGIX panel Battery voltage and Relay Diagnosis (LOGIX Panel with dual Relays)

This Policy is completed waiting on Engineering & Safety approval.

Purpose

The purpose of this procedure is to establish the minimum requirements for performing diagnostics on the Batteries and Relays in control panels on gas engine drive compressor packages. Also to ensure Batteries are supplying proper amount of voltage to restart gas engines and 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 currently in service in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the diagnostics as required according to the type and amount of batteries being used on the 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.

A new or fully charged automotive type battery referred to as a 12 volt battery should have close to 12.6 volts DC. 12 volt automotive batteries are composed internally of 6 individual cells that are designed to hold a charge of 2.1 volts DC each. If all the internal cells in a battery are fully charged at 2.1 volts DC the voltage measured on a batteries positive and negative post should be at 12.6 volts DC. If possible it would be good to use a draw/load tester to check the condition of the battery. This is a good practice when using used or recharged batteries. Using a draw tester will determine if the battery has enough reserve or cranking Amps. A weak battery with the draw test may have proper voltage but may not have enough reserve or cranking amps.

Flogistix skids that have the LOGIX type control panel will be equipped with two automotive batteries. The battery that is connected with the large cables going to the engine starter is referred to as the Main Battery. This is the only battery that supplies voltage to the engine starter.

The battery that supplies the LOGIX panel with voltage during the engine cranking cycle is referred to as the "B" Battery. During the engine start mode or cycle is the only time the main battery and the "B" battery circuits are interrupted. During normal operation when not in the start cycle the batteries will be charged through a common circuit. During the start cycle the batteries charging circuit are separated or interrupted by a relay controlled by the LOGIX panel.

With the unit not running check to make sure the Main battery and the “B” battery voltage is close to the same voltage as each other. The voltage should be no more than a 1 Volt difference of each other. If the voltage difference is more than 1 volt you need to change the battery with the lower voltage. Each battery should be close to what the voltage of a fully charged battery is. If the voltage is less than a fully charged battery is than it is recommend that both batteries be changed out with fully charged batteries.

After Starting a Unit back up that has had the batteries changes the following needs to be done:

Step 1: Using a Volt Meter set to DC voltage touch and hold 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 charges both the Main battery and the “B” battery.

Example "A"

Step 2: The battery voltage will need to be checked inside the LOGIX panel. Inside the LOGIX panel look on the left side of the panel, then go to the bottom wire terminal strip. Find the wires that will be labeled “B-Batt +” and “M-Batt +”. Using the Volt Meter touch the Red test lead from the Voltage Meter to the “M-Batt+” terminal. Then touch the Black test lead to the terminal “M-Batt –“. This terminal can be found just to the right of the positive terminals. (see example "B") Record what the voltage is on “M-Batt +” terminal. Keep the Black test lead on the “M-Batt –“ terminal then touch the Red test lead to the “B-Batt +” terminal and record that voltage.

Example "B"

Step 3: The Voltage readings from “M-Batt +” and “B-Batt +” and the voltage from the Alternator should be reading the same voltage. The voltage on the alternator may be a one decimal point difference. Example Alternator voltage is 13.8 and the “M-Batt +” & “B-Batt +” voltage may be 13.7 volts. Remember that once the Engine is running and the Alternator is charging it will be a higher voltage than what the Battery voltage was before the engine was started. If all voltages are reading the same voltage then the Starter relay in the Logix panel is operating correctly.

If the voltage on “M-Batt + is different than “B-Batt +” then proceed to the section Trouble Shooting M-Batt + & B-Batt +.

Trouble Shooting M-Batt + and B-Batt + Voltage Terminals:

If the Voltage on “M-Batt +” is reading Alternator Voltage but the voltage on “B-Batt +” voltage is reading battery voltage (**) then the B-Relay or B-Relay Base has faulted.

** Battery voltage as described is what the battery voltage was before the engine was started.

Step 1: If a good or spare Relay is available try changing out the B-Relay (see example “C”). After replacing B-Relay check both “M-Batt +” and “B-Batt +” terminals to see if both are reading Alternator voltage.

Example "C"

Step 2: After changing the B-Relay and the voltage on “M-Batt +” and “B-Batt +” still does not read the same then change the B-Relay Base. After the Relay Base has been removed look at the bottom of the base. In most cases the bottom of the base will show signs that the base has gotten hot. After changing B-Relay Base and installing relay back in base check voltage again on “M-Batt +” & “B-Batt +” and check to see if both are reading Alternator voltage.

Step 3: If voltage still does not read the Alternator voltage the wires going from the Relay Base to the M-Batt+ & B-Batt + terminals need to be checked for continuity or make sure they are connected correctly in the Relay Base. (see Example "D")

Example "D"

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 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

Return Deposit or Disposal of failed Battery core

Flogistix Service Technicians performing the procedure to remove and replace a failed or installing new battery will return the Battery core to the purchasing warehouse of the replacement Battery or placed for recharging. Disposal of any failed Battery will be done at an approved or designed Battery disposal site or recycle 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

• Battery Draw/Load Tester

Approvals

Field Service approved by: Charles Crenshaw, VP Field Service

Date: 7/26/2017

Engineering approved by:

Date:

EHSS approved by:

Date: