Doc.

Type: Work Instructions

Doc. Title: GAM Installation Gas Area Operations

Scope: This work instruction applies to all power projects within Aggreko International that utilise Aggreko fleet of Gas Generators, QSK60G Doc. No. P06300012
This document describes the steps involved in installing the Generator Ancillary Module (GAM Unit). This work instruction is lead by the power work stream lead and is based around
Purpose: 1 Aggreko Technician and 2-man team of local labour, for clarity each step is broken down to Gen Tech (GT) and local labour. GT & LL must be trained in every step of this work Rev. No. A
instruction.

Related Docs. GAM Unit installation procedure Issue Date: 24/02/2013

Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)
Tools required for this Install: •
• ½ Inch ratchet set
• Side cutters
• 12 Inch Adjustable
• Cable ties
• Knife
• 6mm Allen key
• 2x 13mm Spanners
• Ladder
• 2x 24mm Spanners
• Battery impact driver
• 24mm ½” drive socket
• 17mm ½” drive socket
• 13mm ½” drive socket

• •
Fitting LTA elbows to Generator • Remove LTA elbows from inside rear of Generator
1
• Remove blank plates from LTA connection point on Generator
(GT)
• Fit LTA elbows to Generator (male at bottom, Female at top) see photos.

• Using battery powered with 17mm socket remove 20xM10 bolts from square cover to expose turbo
Removal of Generator roof covers outlets
2 • Remove left and right hand side circular covers to expose space fans using 13mm socket and ratchet
(LL)
• Re-fit bolts to secure protective metal grill
• Remove 3 fittings situated between radiator fans

Equipment Position: Key Points: Page 1 of 5

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

Inspection point: Ensure all covers have been removed and stored in the storage area of
the GAM unit when next step is complete
3 Removal of LP Gas train and other • Remove customs locks from rear door of the GAM unit
(LL) components. • Undo 8xM10 bolts that hold Gas train in position
• Remove box with rain cap etc
• Remove LTA hoses
• Remove long foam for noise cancellation

4 Fitting LTA hoses to GAM • Remove 10xM8 bolts at hose connections for access
(GT) • Remove transit plugs from hoses connections
• Fit shorter of the 2 LTA hoses to the top connection
• Fit Long LTA hose to the bottom connection
• Fit support bracket to GAM unit
• Secure CAM lock rings with cable ties

5 Fitting noise cancellation foam and • Use ladder to access Generator roof
(LL) twist locks • Cut foam to size and fit along appropriate edges
• Fit 4 twist locks at each corner

Equipment Position: Key Points: Page 2 of 5

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

Hold Point: This step is a hold point. Inspection required ensuring that all noise
cancellation foam has been installed and that twist locks are secured in
position of each corner before lifting operation.
6 Lifting GAM into position
(GT&LL) • Use 25 ton spread bar and slings with bottom lift container attachments Refer to: BOP21,22
• Lift GAM over Generator using Tag lines to steady
• Once in position lower GAM unit on top of Generator
• Once in place secure by locking twist locks
• Insert LTA hoses into LTA elbows and lock using CAM locks
• Secure CAM lock rings with cable ties

7 Hose connections inside GAM • Remove 6xM8 bolts from floor plates to expose hose connections and electrical socket
(GT&LL) • Loosen and re-position transit bracket for gate valve
• Loosen hose clamps and fit hose to Inlet on generator roof
• From the 5 hoses coiled inside GAM cross beam fit the red labeled hose to red inlet and blue labeled
hose to blue inlet
• Fit the 3 hoses remaining with no labeling to 3 inlets on generator roof
• Remove floor plate on the RHS of the GAM floor and connect gate valve hose as stated previously
• Connect electrical plug to inlet

• Open Gate valves to allow top fill from expansion tanks

• Re-fit floor plates
• Using the provided green jerry cans, top up LT and HT expansion tanks from the top

Inspection point: Check all hose connections are connected to their corresponding
points and secured

Equipment Position: Key Points: Page 3 of 5

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)
8 Exhaust silencer and bellows • Remove the bellows and gaskets from the rear of the Generator
(GT&LL) • Turn turbo outlets round so they are facing upwards
• Lift bellows up between turbo outlets and exhaust silencer and fit bellows to underside of silencer with
gaskets and fit loosely
• Using a 6mm Allen key, remove exhaust clamps from turbo outlets

Hold point: Ensure the bellows have been fitted loosely before silencer is lifted from
transit brackets and dropped in place, this will make for easy installation.

9a Dropping of exhaust silencer • On top of GAM remove metal grating surrounding silencer for crane access
(GT&LL) • Once back inside GAM unit and with crane still in position the silencer can be fitted
• Remove the floor plates
• Remove holding bolts fitted to silencer and transit brackets
• Lift exhaust up about 1 inch
• Remove transit brackets
• Lower exhaust and check whilst lowering inside the Generator to ensure the bellows mate with turbo
outlets
• Secure the silencer by fitting the mounting bolts
• Fit remaining bolts to bellows and tighten
• Fit exhaust clamp and tighten using 6mm Allen key
• Tighten band clamps to secure turbo outlets using deep 11mm socket and ratchet

9b Fitting exhaust Lagging • Remove lagging from rear of Generator

(LL) • Use 1 piece each for LH and RH bellows
• Pierce clips through lagging
• Wrap lagging around bellow and secure using wire provided
• Repeat step for remaining bellow

10 Fitting the Rain Cap • Remove rain cap from storage box that was removed from GAM unit
(GT) • Remove long M8 bolt and locking nuts and remove bolts from each side of the rain cap
• Place on top of silencer and line up bolt holes on either side of the cap with the holes on silencer
• Fit bolts, washers and nuts through sides and tighten so that wire rope is secured
• Fit long M8 bolt through front of rain cap to close the bracket
• Re-fit metal grating surrounding rain cap and silencer

Inspection point: Ensure all bolts have been fitted and that rain cap opens freely

Equipment Position: Key Points: Page 4 of 5

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side
 Step No. /
Main Steps Detailed Steps Key Points Photos / Comments
(Responsibility)

LP regulator Installation • Mount LP regulator on plastic blocks next to fuel inlet on Generator
11 • Remove 8 x M16 bolts from blank plate on site of Generator
(GT)
• Connect 1meter length 3” diameter flexible stainless steel Gas pipe to Generator with Gasket
• Connect open end to fuel output supply on LP Rig with Gasket
• Connect 1 meter length 4” diameter from inlet of LP Rig with Gasket and use stand to support and
cover open end
• Ensure that earth bonding is fitted at each flanged joint

Add Row Delete Row

REVISION HISTORY
Rev. No. Rev. Date Details of Changes Prepared By Reviewed By Approved By
1 11/12/2012 New Document David McLeish

Equipment Position: Key Points: Page 5 of 5

CP = Control Panel Safety
LH = Left Side Environmental
RH= Right Side