Professional Documents
Culture Documents
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 3000HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
Safety
2 Complete JSA before beginning job. ☐Completed ☐N/A
Safety • Be sure to list all people working on the job.
• Make sure all hazards and special requirements are addressed.
4
Complete Lock Out / Tag Out procedure (LOTO). Indicate number of Number of
Safety
points locked out Lock Outs
• List the number of points a lock was applied. Example; Suction=1,
Discharge=1, Scrubber Drain=1, Fuel Gas=1, Total would be 4.
• Record count of lock points where single or group LOTO applied.
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 1 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
Operating Parameters
10 Record unit RPM and Overspeed setting
Running Unit overspeed setting should be set no higher than 5% over the maximum RPM Current Overspeed
of compressor frame or 5% over the maximum RPM of engine, whichever is RPM Setting
lowest.
20 Record Compressor Flow Rate (MMCFD) and Percent Recycle Valve
Running open. Discharge Fuel Gas Recycle
Inlet Meter
If unavailable note N/A Record Meter Meter Open %
In
MMCFD
25 Record process gas system pressures – inlet and discharge of all stages.
Running Record Safety Setting Low (SSL), and Safety Setting High (SSH) for each
process gas panel gauge. Suction Disch. 1 Disch. 2 Disch. 3 Disch. 4 Disch. 5
• Process gas pressure safety settings should be set so that inlet pressure Pressure
cannot approach a vacuum, no system will approach max working
pressure, and that no stage can approach max rod load.
SSL
• Compressor performance programs would be an appropriate source for
determining process pressure safety settings. Special situations would SSH
require management approval.
30 Record process gas temperatures - inlet and discharge of all stages.
Running Record temperature safety settings. Cyl-1 Cyl-2 Cyl-3 Cyl-4 Cyl-5 Cyl-6
• Cylinder discharge temperature SSH's should be set at normal operating Inlet Temp
temperature plus 10%, with 350°F being the maximum allowable setting
unless approved by management. Disch. Temp
• Refer to the compressor performance program for calculated discharge
temperatures. SSH
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 2 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
40 Record all oil pressures and their SSL's. Record all available oil
Running temperatures and their SSH's, Record all filter ΔP's.
• Refer to current OEM publications for minimum and maximum oil PSI
SL Filter ∆ Temp SSH
pressure and temperature settings.
Engine Oil
• Record oil filter differential pressure (DP) if gauges are available, smaller
units are usually not equipped to read oil filter differential. Comp. Oil
• Normal oil filter DP 2-15 PSI, change oil filters if 15 psi differential
pressure.
50 Record all coolant temperatures and their SSH. Record all coolant
Running pressures and their SSL. PSI SSL Temp SSH
Refer to current OEM publications for min. and max. coolant temperatures and
safety settings Engine
Auxiliary
Exhaust Temp Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl 5 Cyl 6 Cyl 7 Cyl 8 Cyl SSH Turbo SSH
Left Bank
Right Bank
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 3 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
60 ESM Engine Controller; Verify that each cylinder is firing. Any Issues? ☐ Issues repaired ☐ Issue need to be addressed ☐ All OK
Running Record peak spark/firing number.
Record current ignition timing. Peak Spark/Firing Number Timing BTDC
Record current WKI or Methane number (as applicable) set in controller.
• Confirm cylinders are firing by viewing the ignition control panel diagnostics
screen, and via cylinder exhaust temperature. WKI / Methane Number
• A correct WKI value must be entered into ESM and timing will be managed
through the ESM system. Refer to Waukesha Form 6295, ESM Manual
and/or Waukesha SB 11-2558E, VHP Timing.
65 Record AFR controller data (If equipped). Record target value and sensor Stepper
Running value. Record stepper position(s). Record controller gain setting. Note if Target Actual Position Gain Tracking?
controller is “Tracking” or out of range. Review, analyze and correct any
faults. Right Bank
Become familiar with current local emissions regulations. Follow compliance
Left Bank
regulations when operating and maintaining emission control systems.
• Verify temperatures and trends are within limits and SSH are correctly
Engine Bearing
set. Comp. Bearing
• Maximum Main Bearing Temperature 250°F.
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 4 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
80 Record engine control screen shots. (ESM) Attach Screen Shots ☐Completed ☐N/A
Running
85 Review and analyze all safety settings for adequate equipment ☐Completed ☐N/A
Running protection limits.
Compare found settings to where they SHOULD be set at. Research current OEM
publications and the compressor performance program for correct settings.
90 Review and analyze alarm codes and fault history. Record any issues ☐Completed ☐N/A
Running that will need to be addressed.
100 Document all comments and issues found regarding parameters. Type comments or
issues found:
Running
199 Document all issues discovered during walk around inspection. Type comments or issues found:
Running
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 6 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
299 Document all issues discovered during temperature gun checks. Type comments or issues found:
Running
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 7 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
340 Any internal leakage at compressor recycle valve, dump valves, relief ☐Yes ☐No
Running valves?
Check the temperature difference between downstream vs upstream of a
particular valve to determine if leakage is occurring. Downstream side will be
cooler then upstream side.
350 Inspect scrubber dump valve controllers. Are scrubber level controllers ☐Yes ☐No
Running maintaining the appropriate level?
360 Are there any apparent worn or otherwise malfunctioning parts with ☐Yes ☐No
Running scrubber level controllers, dump valves, or site glasses?
370 Are all scrubber site glasses clean and valves are functioning? ☐Yes ☐No
Running
380 Verify correct instrument supply pressure and record reading.
Running Pressure
399 Document all discovered Cylinder lubrication and scrubber dump issues. Type comments or issues found:
Running
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 8 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
425 Adjust crankcase pressure to 0” to -2” H₂O (if adjustable). ☐Completed ☐N/A
Running
430 Record estimated hours on engine and/or compressor oil (if NOT
Running changing this service). Engine Oil Hours Comp Oil Hours
435 Indicate oil samples were collected? ☐Engine Oil Sample collected ☐Compressor oil Sample Collected
Running Did the previous oil analysis flag any issues? ☐Yes, Issues flagged ☐No issues flagged ☐Unknown
Sample at operating temperature, using a clean sample port located upstream of, ☐Not sampled
or prior to, filtering.
440 Collect coolant sample. ☐Sample collected ☐Not Sampled
Running Sample using a clean sample port (collected every 6 months).
445 Did the previous coolant analysis flag any issues? ☐Already addressed ☐Addressing this service
Running ☐Not sampled ☐No Issues ☐Unknown
450 Inspect coolant condition and color. Mark all that apply.
Running Perform freeze point test on coolant to verify sufficient protection. ☐Good Color ☐Clean ☐Not Freeze
☐ Weak Color ☐Dirty Checked Point
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 9 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
470 Drain fluid from fuel filter, fuel header, and supply gas regulators. ☐Filters Drained ☐N/A
Running Verify regulators are functioning properly. Pressure Setting
Verify start gas, fuel gas, and instrument supply pressures are set at Start Supply Left “A” Regulator
correct pressure. Record pressures
Item Recommended Maximum Fuel Supply Right “A” Regulator
IR Vane Starter 150 psi 150 psi Instrument Left Power Screw
TDI Turbine Starter 40 - 150 psi 150 psi
Fuel (2nd Cut)- L5794GSI; L7044GSI 24 – 50 psi 75 psi Pre Chamber Right Power Screw
Fuel (2nd Cut) - L5794LT; L5774LT 43 – 60 psi 75 psi
Fuel “A” Reg.- GSI 4” – 5” H2O 7” H2O
Fuel “A” Reg.- LT 5.5” – 6.5” H2O 7” H2O
Instrument Gas System dependent 30-45 psi
499 Document all discovered issues with the coolant, cooling system, Type comments or issues found:
Running governor and misc. items.
Electrical Systems
500 Record alternator AMP output (if equipped).
Running Record total battery voltage (if equipped). Amps Volts ☐N/A
599 Document all discovered issues with the electrical and charging system. Type comments or issues
found:
Running
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 10 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
630 Test all ESD switches and actuators prior to start-up. ☐ Completed ☐N/A
Running Note number of devices checked. No. Devices checked
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 11 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 12 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
Base 2L 2R
Current 2L 2R
Recession 2L 2R
Base 3L 3R
Current 3L 3R
Recession 3L 3R
Base 4L 4R
Current 4L 4R
Recession 4L 4R
Base 5L 5R
Current 5L 5R
Recession 5L 5R
Base 6L 6R
Current 6L 6R
Recession 6L 6R
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 13 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
1050 Set engine cylinder head valves (Per Cylinder Method – hydraulic lifters) ☐Completed ☐N/A
Shutdown
Clearances, Torques and Firing order
Valve Valve Setting Bridge Setting Firing Order
Intake 6 Cylinder 12
Cylinder 16 Cylinder(*)
0.000” + ½ turn CW 0.000” - Flat
Exhaust 1-5-2-4-3-6 1R 6L 5R 2L 3R 4L 6R 1L 2R 5L 4R 3L R1 L1 R3 L3 R7 L7 R5 L5 R8 L8 R6 L6 R2 L2 R4 L4
Mating Cylinder 6-2-5-3-4-1 6R 1L 2R 5L 4R 3L 1R 6L 5R 2L 3R 4L R8 L8 R6 L6 R2 L2 R4 L4 R1 L1 R3 L3 R7 L7 R5 L5
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 14 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
1070 Inspect valve cover gaskets, replace if needed (always replace on Top ☐OK- Reused ☐Replaced ☐N/A
Shutdown Ends and Overhauls when gaskets are provided in Head set).
1090 Inspect main and auxiliary water pumps (Rebuild or exchange if worn). ☐Rebuilt ☐Exchanged ☐OK – Reused ☐N/A
Shutdown
1099 Document comments and all issues found regarding Top End Task. Type comments or issues found:
Shutdown
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 15 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 16 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
2110 Clean (replace if needed) the following (AS APPLICABLE): ☐Completed ☐N/A
Shutdown • Engine crankcase breather element(s)
• Compressor crankcase breather element(s)
• Pre filter element(s)
• Air filter element(s)
Spark Plugs And Ignition System
2200 Inspect spark plugs. Clean, gap, and reuse or replace as needed. Standard
Gap Torque
Shutdown • Replace specific spark plug if defined fraught via exhaust temperatures, Plug
firing, etc. RB77CC 0.015" 35 ft. lbs.
• Clean spark plug with Actrel® 3338L dielectric solvent or compatible
solvent. Type Installed Replaced? Estimated hours if reused
• Install spark plug dry (no oil, anti-seize, or other lubricant).
• Note - Change spark plug gasket every time the plug is removed
☐Yes ☐No
2210 Address ignition system by fixing any found Magneto, wiring, or coil ☐All OK ☐Found Issues (see comments)
Shutdown issues found during running inspection
Also visually check ignition system by:
• Spot checking wiring harness for wear, nicks, cuts, & loose connections
• Spot checking high tension wiring, isolators, & caps for wear
• Spot checking coils corrosion & wear (no green stuff or cracks)
• Verifying “G” lead is attached and secure
• Address all found issues
2299 Document comments and issues found related to spark plugs and Type comments or issues found:
Shutdown ignition system.
2420 Is coolant analysis indicating flushing cooling system sooner than the ☐Yes – Flushed ☐Needs Flushing ☐Analysis states condition OK
Shutdown Top End/Overhaul schedule? If yes, complete the following:
• Flush system; ☐Unknown
• Inspect compressor cylinder water jackets (if applicable);
• Inspect coolant sides of oil coolers;
• Remove and inspect thermostats; replaced as required;
• Clean and check aftercooler;
• Clean & inspect cooler water sections internally;
• Charge with new fresh coolant.
2430 Check shutter condition each service Shutter Position
Shutdown > Note current position of shutters ☐Condition OK ☐N/A
2499 Document comments and all issues found regarding cooling systems. Type comments or i
sues found:
Shutdown
2800 Inspect applicable belt condition and tension, along with respective Replaced Adjusted Need N/A OK ☐
Shutdown drive sheaves, replace as needed. Alternator ☐ ☐ ☐ ☐ ☐
All Applicable - OK
Cooler Drive ☐ ☐ ☐ ☐ ☐
• Properly tensioned belts will feel alive springy. Belts too tight will not Fan/Radiator ☐ ☐ ☐ ☐ ☐
deflect, loose belts feel non-reactive.
Governor ☐ ☐ ☐ ☐ ☐
• Refer to Annex “Belt Tensions or service manual for tension information
• Mark what belt issues were addressed and how
PTO Drive ☐ ☐ ☐ ☐ ☐
• A single X in the “All applicable – OK” column represents all applicable WP – Aux. ☐ ☐ ☐ ☐ ☐
check and all OK WP - Main ☐ ☐ ☐ ☐ ☐
Sheaves ☐ ☐ ☐ ☐ ☐
2900 Grease all applicable points as defined below. Indicate number of points Item Amount No. Points
Shutdown greased.
• Use a Lithium based grease such as Hydrotex Parasyn 70, Lithoplex® Actuator Linkage ½ -1 Pump each joint
Grease No 2, or equivalent. Alternator Idler 1- 2 Pumps
• Use High Temperature Grease on Spill Port Valves and on Linage near Aux. Water Pump 1 Pump
waste gates. Cooler Bearings 3 – 5 Pumps
• Repair any broken grease lines. Control Linkage ½ -1 Pump each joint
• Replace any non-working grease fittings. Fan Bearing (Radiator) 1- 2 Pumps
• All points grease each down service except VVCP’s Fan Idler (Radiator) 1- 2 Pumps
• VVCP need only to greased annually VVCP’s 1 Pump annually
2999 Document all discovered issues with belts, sheaves, and grease points. Type comments or issues found:
Shutdown
Startup
3000 Check battery electrolyte levels. ☐Completed ☐N/A
Shutdown Not all "maintenance free" batteries are truly maintenance free.
SAFETY NOTE: Ensure eye protection is worn when working with batteries
3010 Prepare unit for restart. (Note multiple steps!) ☐Completed ☐N/A
Starting 1. Inspect all work, remove LOTO, check for leaks, purge, pressure test system,
and close out all safety permits.
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 19 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
MID
4. Additionally (R) | | | | | | (L) Inches
a. On dual carbureted Vee-Engines, verify banks are balanced OUT
mechanically. ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐
5. On turbocharged engines, verify that wastegate’s establish sufficient boost
(but not excessive boost) over manifold differential pressure.
6. Tune power screws (and sequentially A Regulator(s)) if needed to obtain LEFT BANK
lowest manifold pressure (Boost Method), then lean out ½” Hg per bank – Manifold Pressure
Stoichiometric setting “A” Regulator Setting
7. Record final Settings (as applicable)
Power Screw Position or Inches OUT
Load Screw
RPM
MID
(R) | | | | | | (L) Inches
Load (HP %) OUT
Bank Balance ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐
Fuel Supply PSI
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 20 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
3030 Verify fuel settings RIGHT BANK (Or Single Carbureted Engines)
Running RICH BURN WITH AFR CONTROLLER
Manifold Pressure
1. Verify Engine is loaded, running at a steady RPM, and fuel is at a steady state
2. Verify fuel pressure regulator settings are correct. “A” Regulator Setting
3. Verify ignition system is functioning properly - no miss-fires; engine timing Power Screw Position or Inches OUT
correct. Load Screw
MID
4. Additionally (R) | | | | | | (L) Inches
a. On dual carbureted Vee engines, verify banks are balanced OUT
mechanically. ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐ ☐
b. On turbocharged engines, verify wastegate’s establish sufficient Stepper Position Range H/L
boost (but not excessive boost) over manifold differential pressure. Current O2 Value O2 Target
c. On electronically controlled engines, verify A3, ESM, CEC, or other
controller is correctly programed. LEFT BANK
5. Verify stepper motors are functioning and near mid-range Manifold Pressure
a. IF NOT tune power screws (and sequentially A Regulator(s)) if
“A” Regulator Setting
needed to center range.
6. Verify emissions using an Exhaust Gas Analyzer, gradually adjust carburetor Power Screw Position or Inches OUT
power screw to obtain desired emissions- CO, NOx, O2. Load Screw
MID
7. Verify ARF controls can “swing” to handle Fuel BTU changes (R) | | | | | | (L) Inches
8. Record final Settings (as applicable) OUT
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 21 of 22
Operations & Maintenance Management System
PM Plan: PM-GC-3000HR-WAUK-VHP-S4
PM Description: PM Gas Comp 1500HR WAUK VHP-S4 6-16Cyl
PM Estimated Time: 6 Hours
PM-3000HR-WAUK-VHP-S4-R1-20161030 Page 22 of 22