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This Policy is Under Development. If questions please contact Area Manger.
Purpose
Purpose
The purpose of this Help Guide 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
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 compressor unit 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.
Preventive Maintenance (GED) - Help Guide
Procedure link below
https://sites.google.com/a/flogistix.com/wiki/fieldservice/unit-policies-maintenance/pm-1/pm
Compressor Maintenance
Step 1: Upon your arrival to the compressor skid, observe the unit’s operating condition. First, check units alarm page to determine any existing issues. After checking alarm history move on to checking operating temperatures, compressor oil filter differential pressure, make-up/recycle valve operation, automatic dump control system, and oil levels during operation.
Step 2: Check switches on high scrubber level switch along with the low oil level switch and verify they are operating correctly. High scrubber switch should be up during normal operation, when switch is put in the down position unit should fault on high scrubber. Compressor oil level switch should be down during normal operation, when switch is put in the up position the unit should fault on Low compressor oil level.
Step 3: Check loading valve operation. Start by logging into the HMI by going to login page and login as mechanic. Return to home page and select the loading valve operation mode. Set to manual operation and then go to settings. Continue to the auto loading page and manually load all valves to ensure proper operation. After verifying their operation return them to the correct operating setting.
Before Shutting engine down check the Following
Check voltage from engine alternator 1.2. 3 Gas Engine Alternator/Charging System
Check current operating conditions (leaks, abnormal noise, temperatures, oil level, etc.)
Check engine governor response & stability
Check Engine Fuel Scrubber dump system. (if applicable)
Step 4: After making these checks it is now time to shut the unit down by following the Flogistix LOTO procedure.
Step 5: After shutting unit down and applying LOTO it is now time to continue with your PM. Depressurize vessels and verify zero energy on skid. Make repairs as needed if you found any issues with your initial inspection. If no issues were found during the initial inspection it is time to check your compressor oil level and viscosity. You want to check the compressor oil viscosity from the filter housing drain line to get a correct reading. Follow the procedure below to check the viscosity of the compressor oil.
1.05.001 Minimum Viscosity Limits for Poly Glycol Synthetic Screw Compressor Oil
After checking viscosity, determine whether oil is good for operating standards or needs to be changed.
Step 6: Next step is to change the compressor oil filters. Follow the procedure below.
After changing filters verify all drain lines are closed and ball valves for oil delivery on skid are open. Next, locate the thermocouplers and verify the red and yellow wires are terminated tightly and making a good connection. Verify all screws inside the cap are tight and holding everything in place. Next, verify all conduit is properly sealed and not exposed to the climate.
Step 7: Cooler items to check:
Check Cooler louvers (if applicable)
Check Cooler frame and fan supports for cracks
Check cooler grease lines (if applicable)
Engine Maintenance
Step 8: Start by closing the day-time engine oil tank. When possible, the engine oil should be drained while engine oil is still hot or warm. After draining, replace engine oil filter following the procedure below. After changing filter fill engine oil pan/sump with fresh engine oil to required level.
Step 9: (If applicable) Set valve lash by following the procedure below
Step 10: Next go through the ignition system and verifying all wiring connections and clips are tight and have enough wire loom to prevent weathering. Repair or replace any broken clips. After that remove all spark plugs by following the procedure below. During this process check the spark plug wires condition and add dielectric grease to the inside of the wire seat.
Step 11: Next check cylinder compression on all engine cylinders and record as required 1.3.04 Checking Engine Cylinder Compression. After checking compression re-install spark plugs. 1.3.11 GM 5.7 (350) Sparkplugs Installing/removing
NOTE* Installation of new (if needed) spark plugs (spark plugs must be gapped according to manufacturer specifications)
NOTE* Installation of used (if suitable) spark plugs (spark plugs must be cleaned and re-gapped according to manufacturer specifications)
Step 12: Next check & clean mag pick-up(s) (replace if needed). Reference 1.2. 4 Mag Pick Up (MPU)
Step 13: (If applicable) Check distributor cap & rotor (replace if needed), check distributor shaft side to side play (replace if needed), Check distributor ignition coil (corrosion, power / distributor wire connections, properly mounted)
Step 14: Check and clean engine air filter. (Replace if needed)
Step 15: Check engine cooler.
Check coolant level
Inspect all coolant hoses for cracks or wear (replace as needed)
Check engine belts (replace as needed)
Inspect engine fan belts(s) for wear or cracks
Step 16: Check batteries on skid
Inspect batteries by checking draw down on batteries (Load test)
Inspect electrical connections for Logix panel wiring (if applicable)
Inspect starter wires from battery to starter for wear to the wire insulation & cracks in wire insulation
Step 17: Before returning unit to service check panel for loose terminal connections. Return any loose wiring back into its cable tray and clean any trash left behind in the panel.
Step 18: Perform a walk around check on skid. Verify oil sump tank is open. After performing walk around it is now time to return unit to service by following the procedure below.
Step 19: After returning unit to service, check all set points and kills. Ensure all settings are set to the correct operating standards. If you are not sure of setpoints for your specific unit, the lead technician should be able to verify them with you.
Step 20: Check items after starting the unit
Check engine oil pressure gauge on the HMI.
Using a timing light, check / adjust / record ignition timing.
Check / adjust fuel gas pressure - 1st cut
Check / adjust fuel gas pressure - 2nd cut
Step 21: Check the screw compressor
Check Compressor Oil level
Adjust Scavenge Line needle valve for efficient flow 1.06.002 Scavenge Line Adjustment
Check spin on filter differential pressure 1.07.030 LOGIX panel - Setting up proper Compressor Oil Filter Differential Pressure
Check differential pressure between suction and discharge pressure for proper Delta P to maintain oil flow to compressor
Step 22: Check the Cooler while running
Grease Cooler bearings and Idler bearings
Check for air flow across cooler sections
Step 23: The final step to this PM is house keeping, wash the skid and clean environmental railings of trash. Clean around skid if any mess is apparent. After completing the clean up process check over the HMI and verify everything is operating back to normal conditions. Perform one last walk around to verify no leaks or operating issues. After completing this your PM will be completed.
Responsibilities
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 following requirements outlined in this procedure and ask for assistance
Scope
Scope
Hazards
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 compressor oil and possible production fluids
Safety
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
Spills and Disposal
All spills shall be handled immediately according to MSDS recommendations and the employee's level of training
Flogistix Service Technicians performing this task will properly dispose of any waste liquids or solids. 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 a compressor shaft seal change such as, oily rags, ETC, will be disposed of according to the local regulations regarding the disposal of oil soaked rags.
Training
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.
Oil viscosity gauge
Approvals
Field Service approved by:
Date:
Engineering approved by:
Date:
EHSS approved by:
Date:
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