7.05.002 Low Compressor Oil Level (Trouble Shooting Guide)

This Policy is Under Development. If questions please contact Area Manger.

Purpose

The purpose of this trouble-shooting guide is to assist you in diagnosing a Low Compressor Oil fault.

Procedure

This procedure applies to all units that are currently in service in the field, at a repair shop, and in storage yards.

Before any work is performed a JSA must be completed according to Flogistix procedure along with any customer requirements before any work is started.

Help guide to trouble shooting a Low Compressor Oil fault.

Diagnosing Low Compressor Oil Level

Are you having oil loss issues? Here is a trouble shooting guide on how to find the root cause of the oil loss.

Step 1: First, lets start by checking the amount of oil that is going through the scavenge line while the unit is running. If there is excessive oil in the scavenge line this could indicate a ruptured discharge filter causing compressor oil to enter the filter excessively and continue down the discharge line. Another quick sign of a discharge filter going out is when there is oil blowing out of the blow down ball valves on the discharge vessel when opened. Refer to the link below on replacing the Discharge filter. Now this could also indicate foamy oil, you will have to distinguish between the two. Ensure the Scavenge line in Properly set by following the procedure in the link below.

1.06.002 Scavenge Line Adjustment

Did the discharge filter correct your issue or seem to be the root cause of the oil loss? If not, continue to step 2.

Step 2: Lets continue by checking the wafer check valve located above the compressor. A quick indicator that the check valve has failed is that when you turn the unit off the oil level drops rapidly. The suction pressure will go up due to the blow by of discharge pressure flowing back up through the suction piping. Feel the suction piping for a drastic temperature change and this will indicate a faulty check valve. To verify this, blow the unit down and remove the tubing line used to read the suction pressure, there will be sign of oil in the line caused by the blow by.

Did you find any of these signs above? If so, the wafer check valve needs to be replaced. If not continue to step 3

Step 3: A potential cause of oil loss could be motor valves being stuck in the open position. Check the recycle motor valve for proper operation and verify it is seating properly. Do the same with the motor valves used for the automatic dump system. If these valves a stuck open it will cause a drastic change in pressure causing the oil loss.

Did you have any valves hanging open? If so, make repairs or adjustments as needed to return to proper operating standards. If not continue to step 4.

Step 4: Check operating temperatures and cooling fan settings. Not reaching desired operating temperatures will cause the oil to become foamy and lose viscosity making it easier to flow through the discharge line. Operating temperatures should reach at least 230 degrees on compressor oil temperature and between 250-260 degrees on discharge temperature. Being able to control these temperatures by the thermostats and even cooling fan control in the electric drive packages. If the unit is not getting up to the correct operating temperature verify that there is a 230-degree thermostat being used. On a package where cooling fan control is enabled select the fan control for compressor oil temperature. Set the cooling fan to turn on when the compressor oil reaches 230-235 degrees. After making these changes you want to watch your discharge temperature to verify it is not going to overheat.

Did making these changes correct the oil loss issue? If not, continue to the next step.

Step 5: Check and verify all regulators are working properly and are set to desired operating standards. Having a failed regulator can cause a drastic change in the pressure causing it to sweep the vessel of oil.

If issues continue after using this diagnostic sheet, contact your area lead for further instruction.

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

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

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

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

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

• 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: