CUS-812 Air Compressor Skid (Winterized) Operations Manual

CUS-812 Air Compressor Skid
(Winterized) Operations Manual

Reference: InTouch content ID# 4922979
Version: 1.0
Release Date: 16-Nov-2009
EDMS UID: 1652693470
Produced: 16-Nov-2009 07:30:59
Owner: IPC
Author: Svein Normann, Rao Zhiming, Sagar
Sundar Polley
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CUS-812 Air Compressor Skid
(Winterized) Operations Manual
Reference: InTouch content ID# 4922979
Version: 1.0
Release Date: 16-Nov-2009
EDMS UID: 1652693470
Published: 16-Nov-2009 07:30:59
Owner: IPC
Author: Svein Normann, Rao Zhiming, Sagar
Sundar Polley
Private
Copyright © 2009 Sophia, Unpublished Work. All rights reserved.

CUS-812 (Winterized) Operations Manual / Legal Information
Legal Information
IPC\Svein Normann, Rao Zhiming, Sagar Sundar Polley\InTouch content ID# 4922979 \1.0\Release Date:16-Nov-2009\EDMS UID: 1652693470\Produced: 16-Nov-2009 07:30:59
This work contains the confidential and proprietary trade secrets of Schlumberger
and may not be copied or stored in an information retrieval system, transferred,
used, distributed, translated or retransmitted in any form or by any means,
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Schlumberger, the Schlumberger logotype, and other words or symbols used

to identify the products and services described herein are either trademarks,
trade names or service marks of Schlumberger and its licensors, or are the
property of their respective owners. These marks may not be copied, imitated
or used, in whole or in part, without the express prior written permission of
Schlumberger. In addition, covers, page headers, custom graphics, icons, and
other design elements may be service marks, trademarks, and/or trade dress
of Schlumberger, and may not be copied, imitated, or used, in whole or in part,
without the express prior written permission of Schlumberger.
A complete list of Schlumberger marks may be viewed at the Schlumberger

Oilfield Services Marks page: http://markslist.slb.com
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CUS-812 (Winterized) Operations Manual / Document Control
Document Control
Owner: IPC
Author: Svein Normann, Rao Zhiming, Sagar Sundar Polley
Reviewer: Andy Sutherland,
Approver: Andy Sutherland
Contact Information
Name: IPC
LDAP Alias: ipc
Revision History
Version Date Description Prepared by
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CUS-812 (Winterized) Operations Manual / Document Control

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Regulatory Compliance
Waste management
IMPORTANT INFORMATION FOR CORRECT DISPOSAL OF THE EQUIPMENT
This symbol means that the equipment cannot be discarded in a rubbish-bin. At
its end of life, the equipment and/or its components must be treated, following
Schlumberger Environmental procedures, in compliance with Schlumberger QHSE
Policy and applicable laws and regulations on waste management.
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Foreword IPC,Well Services,WS,
New releases of this document supersede any other version. The most current
version of the document is in InTouchSupport.
If you have a printed copy, check the "Release Date" against the content in
InTouch to be sure you have the most current version.
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ix CUS-812 (Winterized) Operations Manual / Table of Contents ix
Table of Contents
Regulatory Compliance __________________________________________ v
Foreword ________________________________________________________ vii
1 Introduction ____________________________________________________ 1-1

1.1 Product History ______________________________________________ 1-1
1.2 Product Features ____________________________________________ 1-1
1.3 Product Application __________________________________________ 1-2
1.4 Documentation and Manuals _________________________________ 1-2
2 QHSE __________________________________________________________ 2-1

2.1 General Safety ______________________________________________ 2-1
2.2 OFS QHSE Standards _______________________________________ 2-1
2.3 Well Services Safety Standards _______________________________ 2-1
2.4 Personnel Safety ____________________________________________ 2-2
2.5 Equipment Safety ____________________________________________ 2-2
3 Specifications __________________________________________________ 3-1

3.1 General Specifications _______________________________________ 3-1
3.2 Engine ______________________________________________________ 3-3
3.3 Power take-off (PTO) _________________________________________ 3-4
3.4 Compressor _________________________________________________ 3-6
3.5 Air Heater ___________________________________________________ 3-6
3.6 Fluid and Filter Specifications _________________________________ 3-7
4 Unit Preparation ________________________________________________ 4-1

4.1 Pre-Job Checklist ____________________________________________ 4-1
4.2 Travel to Job Site ____________________________________________ 4-4
4.3 Job Site Pre-Start ____________________________________________ 4-5
5 Unit Operation _________________________________________________ 5-1

5.1 Unit Preheating ______________________________________________ 5-1
5.2 Start Up _____________________________________________________ 5-4
5.3 Operation ___________________________________________________ 5-7
5.4 Normal Shut Down ___________________________________________ 5-7
6 Troubleshooting ________________________________________________ 6-1

6.1 Engine ______________________________________________________ 6-1
6.2 Compressor _________________________________________________ 6-9
6.3 Control Console and J-Box __________________________________ 6-10
6.4 Air Heater __________________________________________________ 6-10
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Appendix
A Example STEM _________________________________________________ A-1
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List of Figures
3-1 CUS-812 Winterized Air Compressor Skid___________________________ 3-2

3-2 Deutz F6L 914 Diesel Engine_______________________________________ 3-3
3-3 Twin Disc Power Take-off from Engine to Pulley _____________________ 3-5
3-4 AirFlux 4LM 230 Compressor_______________________________________ 3-6
3-5 Eberspächer D8LC air heater_______________________________________ 3-7
3-6 SAE engine oil Specifications_______________________________________ 3-8
3-7 Fuel filter__________________________________________________________ 3-9
3-8 Engine oil filter ___________________________________________________ 3-10
3-9 Engine air filter ___________________________________________________ 3-11
3-10 Compressor air filter ______________________________________________ 3-11
3-11 Heated fuel filter __________________________________________________ 3-12
4-1 F6L914 engine components ________________________________________ 4-1
4-2 CUS–812 air filter__________________________________________________ 4-2
4-3 PTO lubrication point ______________________________________________ 4-2
4-4 Compressor fan guard _____________________________________________ 4-3
4-5 CUS 812 pressure gauge __________________________________________ 4-4
4-6 CUS 812 discharge butterfly valve __________________________________ 4-5
5-1 Air heater suction fan ______________________________________________ 5-2
5-2 Arctic heater fuel pump ____________________________________________ 5-2
5-3 Air heater fuel selector _____________________________________________ 5-3
5-4 Inline fuel heater schematic diagram ________________________________ 5-4
5-5 Engine control panel _______________________________________________ 5-6
5-6 Engine throttle_____________________________________________________ 5-6
6-1 Diagnosis Chart for the Engine _____________________________________ 6-3
6-2 Trouble Shooting for the AirFlux Compressor _______________________ 6-10
A-1 Example STEM____________________________________________________ A-1
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List of Tables
1-1 Basic Specifications _______________________________________________ 1-1

1-2 Unit Specifications _________________________________________________ 1-2
2-1 OFS QHSE Safety Standards ______________________________________ 2-1
2-2 Well Services Safety Standards ____________________________________ 2-1
3-1 General Specifications for CUS-812 Winterized______________________ 3-2
3-2 Deutz F6L914 Technical Data ______________________________________ 3-3
3-3 Specification for Twin Disc Power take-off, SP111-HP3 _______________ 3-5
3-4 Specification for Twin Disc Power take-off, SP311-P304 ______________ 3-5
3-5 Model description for 4LM 230 Compressor _________________________ 3-6
3-6 Model description for D8LC air heater _______________________________ 3-7
3-7 Unit Fluid Specifications____________________________________________ 3-7
3-8 Unit Filter Specifications ___________________________________________ 3-8
6-1 Engine Symptoms and Possible Remedies __________________________ 6-4
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1 Introduction
1.1 Product History ________________________________________________ 1-1

1.2 Product Features _______________________________________________ 1-1
1.3 Product Application ____________________________________________ 1-2
1.4 Documentation and Manuals ___________________________________ 1-2
1.4.1 Operations Manual ___________________________________________ 1-2
1.4.2 Maintenance Manual _________________________________________ 1-3
1.4.3 Vendor’s Manuals ____________________________________________ 1-3
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1 Introduction
This manual is applicable to the CUS-812 produced in 2008 or later by
IPCSingapore. The manufacturer can be found on the ID plate mounted on
the skid.
1.1 Product History

The CUS–812 winterized is a purpose built skid mounted unit designed to provide
compressed air for moving bulk cement. It is equipped with a AirFlux 4LM230
air compressor for fluidizing the bulk cement. The compressor is powered by a
Deutz F6L914 winterized engine. The unit is heated by an Eberspächer D8LC 24
Volts air heater for operation in sub-zero temperatures.
1.2 Product Features

The 440 cfm compressor operating at 30 psi (max) is driven by an air cooled
diesel engine through V-belt where the engine is started by an electrical starter.
The unit also comes with an 8 cubic feet air receiver that functions as both a
receiver and moisture separator. The Air Compressor Skid is designed to be
lightweight for ease of operation and maintenance.
Table 1-1: Basic Specifications
Skid Base for engine, compressor, fuel tank and air receiver
Engine Deutz F6L914 diesel engine, 63kw@1800rpm, electrical starter
Compressor AFP 4LM 230 Reciprocal Compressor
Power Take Off Twin Disc SP311-P304, Torque 171-227Lb-Ft
(PTO)
Heater Eberspächer D8LC air heater
Cooling System Air cooled
Air Receiver AIR 250PSI, 8CU FT, ABS 07 19928 SG4
Fuel Tank 35 US gal
Relief valve 30 psi
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Table 1-2: Unit Specifications

Model CUS-812 (Winterized)

Length 88 in (2,235mm)
Width 85 in (2,150mm)
Height 89 in (2,250mm)
Weight 6,820 lb (3,100 Kg)
Capacity 440 cfm @ 30 psi
Ambient Rating -40 degC to 42 degC
1.3 Product Application

The purpose of the CUS-812 Air Compressor Skid is to provide compressed air
to the Surge Tank and also used as a supplemental air supply to the bulk trailer
during cementing work.
1.4 Documentation and Manuals

The CUS-812 Air Compressor Skid manual set includes the following documents:
• CUS-812 Operations Manual (this volume)

• CUS-812 Maintenance Manual
• CUS-812 Vendor Manuals
The general structure and use of each of these volumes is described in the
following sections.
1.4.1 Operations Manual

The Operator’s Manual is designed to be used by an equipment operator to
learn how to safely and efficiently perform jobs and do routine maintenance on
the Air Compressor Skid. It should also be used by the maintenance technician
to become familiar with operation of the skid. By becoming knowledgeable
about the way the skid is used, maintenance personnel will be more effective
at servicing the equipment. A copy of this book should normally be kept with
the unit.
This Operations Manual is organized as follows:
• Introduction
• QHSE
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• Specifications
• Unit Preparation
• Unit Operation
• Troubleshooting
• Appendices
Do not use the Operations Manual to order parts. If parts or maintenance are
needed, see the CUS-812 Maintenance Manual or the appropriate component
supplier manual.
1.4.2 Maintenance Manual

The Maintenance Manual is designed to be used by electronic technicians and
mechanics to learn how to maintain the Air Compressor Skid. District personnel
will also find it useful when ordering spares or replacement parts. It can also
be used by advanced equipment operators to become familiar with some
maintenance operations on the skid. The Maintenance Manual should normally
be kept in the district office for reference.
The Maintenance Manual is organized as follows:
• Introduction
• QHSE
• Specifications
• Disassembly and Assembly
• Maintenance
• Troubleshooting
• Appendices
Maintenance Manual is required to repair or maintain this unit and must be kept
at the maintenance facility.
1.4.3 Vendor’s Manuals

The Vendor’s Manuals are designed to be used by electronic technicians and
mechanics to learn how to maintain the Air Compressor Skid. District personnel
will also find them useful when ordering spares or replacement parts. These
manuals document all the commercial systems used on the unit. The Vendor
Documentation Manuals should normally be kept in the district office for
reference.
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2 QHSE
2.1 General Safety _________________________________________________ 2-1

2.2 OFS QHSE Standards __________________________________________ 2-1
2.3 Well Services Safety Standards ________________________________ 2-1
2.4 Personnel Safety _______________________________________________ 2-2
2.5 Equipment Safety ______________________________________________ 2-2
2.5.1 Pre-Trip Inspection ___________________________________________ 2-2
2.5.2 Covers and Guards __________________________________________ 2-3
2.5.3 Pressure Relief Valves and Gauges (WS STD 4) _______________ 2-3
2.5.4 High-Pressure Liquid Jetting, Blasting, and Cleaning ___________ 2-4
2.5.5 Pre-Startup __________________________________________________ 2-4
2.5.6 Engine ______________________________________________________ 2-5
2.5.7 Engine Starting ______________________________________________ 2-5
2.5.8 Engine Stopping _____________________________________________ 2-6
2.5.9 Compressor _________________________________________________ 2-6
2.5.10 General Hazard Information __________________________________ 2-7
2.5.11 Pressurized Air and Water ____________________________________ 2-8
2.5.12 Fluid Penetration _____________________________________________ 2-8
2.5.13 Fluid Spillage ________________________________________________ 2-9
2.5.14 Lines, Tubes, and Hoses _____________________________________ 2-9
2.5.15 Burn Prevention _____________________________________________ 2-9
2.5.16 Oils ________________________________________________________ 2-10
2.5.17 Batteries ___________________________________________________ 2-10
2.5.18 Fire Prevention and Explosion Prevention ____________________ 2-10
2.5.19 Fire Extinguisher ____________________________________________ 2-11
2.5.20 Crushing and Cutting Prevention _____________________________ 2-11
2.5.21 Electrical System ___________________________________________ 2-11
2.5.22 Emergency Kill Switch _______________________________________ 2-12
2.5.23 Environmental Safety _______________________________________ 2-12
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2 QHSE
2.1 General Safety

Due to the many hazards involved in the oilfield industry, all Schlumberger
employees must be familiar with the relevant safety regulations and precautions.
The current Well Services Safety Standards are listed on the Well Services
Reference Page for Safety Standards, InTouch content ID# 4055049. Refer to
the appropriate sections as needed.
Anyone who feels an operation is unsafe has the right and duty to stop the
operation.
2.2 OFS QHSE Standards

All OFS QHSE Standards can be found at on the Hub at http://www.hub.slb.com/
display/index.do?id=id14651, or individually InTouch as shown in the table.
Table 2-1: OFS QHSE Safety Standards
Standard Name Location

OFS S002 SQ and PQ Event Reporting and InTouch content ID# 3571957
Management
OFS S003 Personal Protective Equipment (PPE) InTouch content ID# 3260259
OFS S013 Mechanical Lifting InTouch content ID# 3260276
2.3 Well Services Safety Standards

Every Schlumberger employee must be familiar with the following standards:
Table 2-2: Well Services Safety Standards
Standard Name Location

WSSS 4 Equipment InTouch content ID #3313678
WSSS 5 Pressure Pumping and Location Safety InTouch content ID #3313681
WSSS 12 Lockout -Tagout InTouch content ID #3313691
MB 625E Maintenance Bulletin No. 625E InTouch content ID #3998770
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2.4 Personnel Safety

Ensure that all relevant procedures and standards are followed at all times.
Ensure that PPE is always worn around the unit.
It is important to remember the dangers of the low pressure high volume

operations and heat this unit generates. As much as possible avoid the area
around the pneumatic pipes and the air receiver areas during operation. The
exhaust lines and parts of the engine become very hot while running and can
cause severe burns.
Be aware of all moving parts on the unit while it is running. All non-essential
personnel should stay away from the unit during operation.
2.5 Equipment Safety

Equipment should be maintained according to the regular Standard Equipment
Maintenance (STEM) system. An example of Schlumberger Preventive
Maintenance report and check sheets can be found in the appendix (see Figure
A-1 Example STEM).
2.5.1 Pre-Trip Inspection

Before leaving the yard, use the following guidelines to check all equipment
visually and note any potential problems to ensure equipment and road safety
during travel:
• Oil leaks
• Damaged hoses
• Loose or damaged components
• Inadequately secured loose equipment
• Fuel level
• Engine oil level
• Well Services Field Safety Handbook, (InTouch content ID# 3038407)
• If fuel will be added before leaving the district, refer to Safety Standard 5
section G02: Refueling (InTouch content ID# 3313681)
• Review deficiencies recorded on the unit from the previous job
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• Review all appropriate material safety data sheets (MSDS) and ensure they
are brought to the well site

• Properly store or tie down all loose equipment
• Ensure that a first-aid kit is present
• Check the capacity of the fire extinguisher
• Check the eye wash bottle and fill it if the level is low, or clean and refill
it if the water looks unsafe
2.5.2 Covers and Guards

Covers and guards are intended not only to protect against personal injury or
death, but also to protect the equipment from foreign object damage.
2.5.3 Pressure Relief Valves and Gauges (WS STD 4)

All bulk tanks (air receiver) operated with a pressure vacuum compressor must
have a vacuum relief valve to prevent damage to the tank when a vent valve is
blocked.
The pressure relief valve (PRV) equipment must comply with ASME Boiler and
Pressure Vessel Code or equivalent.
The PRV must have a lifting device, which causes the valve disk to lift from the
seat when the valve is at 75% of the calibrated opening pressure. The lifting
device must not lock or hold the disk in the open position when the pressure or
force is released.
All external adjustment devices must be locked so no one can change the
settings. Seals must be installed to prevent changes in the opening pressure
without breaking the seal. The manufacturer or an authorized person (not a
Schlumberger employee) must install the seals. No Schlumberger employee is
authorized to break the seal on the valve and make any adjustment or repairs.
At the end of each job, each PRV must be operated by the lift lever to allow
enough air to be released and to make sure there is no dry material in the PRV. If
a PRV is not used, each month, open the valve every 30 days with a lift lever.
Make sure there is no dry material in the PRV. If the valve does not open and
close correctly, replace the valve.
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All valves installed at remote locations must be removed and inspected if they
did not operate for more than 30 days before the bulk system is used. The seal
area must be inspected and any material removed. If the valve does not open
and close correctly, replace the valve.
Each vacuum relief valve must be checked by pushing the disk open from below
with a round wood dowel. The disc must open freely. If the disc does not open
freely, replace the vacuum relief valve.
All PRV equipment must have an identification number marked on the valve or
fastened with a wire tag. This identification number is used to verify the testing
date of the PRV.
The unloader valves are valves that have springs set to release overloads without
stopping the operation of the compressor. The unloader valve must be identified,
recorded and tested according to procedures according to Well Service Safety
Standard 4. Unloader valves can be adjusted and repaired at the facility.
2.5.4 High-Pressure Liquid Jetting, Blasting, and

Cleaning
After a cementing job the unit must be cleaned thoroughly with a water jet
blast to prevent any kind of blockage or build up of dirt on to the engine, the
compressor or to any part of the unit.
Due to the high pressure of the jet operation involved in the operation precaution
must be taken to avoid any kind of personnel injury or damage to the equipment.
During cleaning the operator must be equipped with proper PPE and the cleaning
area must be barricaded to prevent injury. Special care must be taken while
cleaning the valves and electronic components. For further information please
refer to WS QHSE STD 3: Maintenance.
2.5.5 Pre-Startup
Always be on the alert for emergency situations. Failure to spot an emergency
can result in equipment damage and personal injury.
You are responsible for constantly monitoring the control panel and the work
location for any and all hazards. Before starting the unit, be sure that all guards
are in place around moving parts, and that everyone is clear of the unit.
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2.5.6 Engine
Before starting the engine, make sure that everyone is clear of the engine area.
If working on the engine while it is shut down, place a lockout tag on the start
switch to ensure that no one starts the engine without your knowledge.
Be careful when touching any part of an operative engine because some parts
can be extremely hot.
Leaking fuel and most lubricants are flammable. A fire can result if any of these
fluids leak onto hot surfaces or electrical components.
Improper lift rigging can allow unit to tumble causing injury and damage.
If improper equipment is used to lift the engine, injury and damage can occur.
Use cables that are properly rated for the weight to be lifted. Use a spreader bar
and attach the cables according to the information on the warning label.
2.5.7 Engine Starting

If a warning tag is attached to the engine start switch or controls do not start the
engine or move the controls. Consult with the person who attached the warning
tag before starting the engine.
All protective guards and all protective covers must be installed if starting the
engine is necessary to perform service procedures. To help prevent accidents
caused by parts in rotation, work around the parts carefully.
Start the engine from the operator’s compartment or from the engine start switch.
Always start the engine according to the procedure described in the relative
sections in this manual. Knowing the correct procedure will help prevent major
damage to the engine components. Knowing the procedure will also help to
prevent personal injury.
Engine exhaust contains combustion products that can be harmful to your health.
Always start and operate the engine in a well-ventilated area. If the engine is
started in an enclosed area, vent the exhaust to the outside.
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2.5.8 Engine Stopping

To avoid overheating of the engine and accelerated wear of the engine
components, stop the engine according to the relative sections in this manual.
Use the emergency kill switch only in an emergency situation. Do not use the
emergency kill switch for normal engine stopping. After an emergency stop,
do not start the engine until the problem, that caused the emergency stop has
been corrected.
Upon initial start-up of a new engine or an engine that has been serviced, make
provisions to stop the engine if an over-speed condition occurs. This can be
done by shutting off the fuel supply or the air supply to the engine.
2.5.9 Compressor
Some critical precautions for operating the compressor are given below, and
more information on QHSE can be found in the vendor manual.
The foreman or person in charge must ensure that all instructions concerning the
handling and maintenance of the unit and its equipment are complied with at all
times. He/She must also ensure the equipment, accessories, safety devices,
vacuum and compression systems with their piping, valves, connections, hoses,
etc…and consumer units are all in good condition, with no abnormal wear, and
that they are treated correctly.
Before dismantling any pressurized component or performing any maintenance

or repair work, the unit must be cut off from all sources of pressure and fully
de-pressurized to atmospheric pressure. As a preventive measure, placing a
“work in progress-do not open” sign or standardized symbol on each valve is also
recommended. Personnel should be trained to recognize these symbols.
Critical ratings (pressure, temperature, speed, etc.) should be marked

adequately. Never run machines or components above the established levels of
pressure, temperature, speed, etc…
Pneumatic machinery must always be kept clean and as free as possible from
oil, dust, and other precipitates. Keep all regulating and safety devices in good
working order. These devices should never be out of service. Regularly check
the accuracy of pressure gauges, pressure switches and thermostats (if any) and
replace or calibrate them if they are not within acceptable tolerances.
Before performing any action on the machine which is likely to generate heat,
sparks or flames, cover the surrounding components with fireproof material.
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Moving parts are fitted with guards to prevent injury, and must be properly
signposted. Never start up the machine with guards off.
2.5.10 General Hazard Information

Attach a "Do Not Operate" or similar warning tag to the start switch or the
controls before the engine is serviced or repaired. Attach the warning tags to the
engine and to each operator control station. When it is appropriate, disconnect
the starting controls.
Do not allow unauthorized personnel on or around the engine when it is being

serviced.
Engine exhaust contains combustion products that may be harmful to your

health. Always start and operate the engine in a well-ventilated area. If the
engine is in an enclosed area, vent the exhaust to the outside.
Cautiously remove the following parts:
• filler caps
• grease fittings
• pressure taps
• breathers
• drain plugs
To help prevent spraying or splashing of pressurized fluids, hold a rag over the
part that is being removed.
Use caution when cover plates are removed. Gradually loosen but do not remove
the last two bolts or nuts that are located at opposite ends of the cover plate or
the device. Before removing the last two bolts or nuts, pry the cover loose in
order to relieve any spring pressure or other pressure.
• Wear a hard hat, protective glasses, and other protective equipment as

required.
• When work is performed around an engine that is operating, wear protective
devices for ears to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can snag on controls or on other
parts of the engine.
• Ensure that all protective guards and covers are secured in place on the
engine.
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• Never put maintenance fluids into glass containers. Glass containers can
break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under the
following conditions:
• The engine is stopped. Ensure that the engine cannot be started.

• Disconnect the batteries when maintenance is performed or when the
electrical system is serviced. Disconnect the battery ground leads. Tape the
leads in order to help prevent sparks.
• Do not attempt any repairs that are not understood. Use the proper tools.
Replace or repair any equipment that is damaged.
2.5.11 Pressurized Air and Water

Pressurized air and water can cause debris or hot water to be blown out. This
can result in personal injury.
When pressurized air is used for cleaning, wear a protective face shield,
protective clothing, and protective shoes.
The maximum air pressure for cleaning purposes must be below 205 kPa (30
psi). The maximum water pressure for cleaning purposes must be below 275
kPa (40 psi).
Always wear eye protection for cleaning the cooling system.
2.5.12 Fluid Penetration

Always use a metal plate or a similar tough surface when the engine components
are checked for leaks. Leaking fluid that is under pressure can cause serious
injury. This includes leaks as small as a pinhole.
If fluid is accidentally injected into the skin, seek treatment immediately from a
doctor who is familiar with this type of injury.
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2.5.13 Fluid Spillage

Care must be taken to ensure that fluids are contained during the inspection,
maintenance, testing, adjustment, and repair of the engine. Make provisions to
collect the fluid in a suitable container before any compartment is opened, or
before any component is disassembled. Dispose of fluids according to local
regulations.
2.5.14 Lines, Tubes, and Hoses

Do not bend or strike high-pressure lines. Do not install lines, tubes, or hoses
that are damaged. Repair any fuel lines, oil lines, tubes, or hoses that are loose
or damaged. Leaks can cause fires.
Inspect all lines, tubes and hoses carefully. Do not use bare hands to check for
leaks. Always use a board or cardboard for checking engine components for
leaks. Tighten all connections to the recommended torque.
Check for the following conditions:
• end fittings that are damaged or leaking

• outer covering that is chafed or cut
• wire that is exposed in reinforced hose
• outer covering that is ballooning locally
• flexible part of the hose that is kinked or crushed
• armoring that is embedded in the outer covering
Make sure that all the clamps, guards, and heat shields are installed correctly.
This will help to prevent:
• vibration
• rubbing against other parts
• excessive heat during operation
2.5.15 Burn Prevention

Do not touch any part of an operating engine. Allow the engine to cool before any
maintenance is performed on the engine. Relieve all pressure in the lubrication
system, fuel system, or cooling system before any lines, fittings, or related items
are disconnected.
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2.5.16 Oils
Hot oil and hot components can cause personal injury. Do not allow hot oil or
hot components to contact the skin.
Keep all the exhaust manifold and turbocharger shields in place in order to
protect components from oil spray if there is a failure of a line, tube, or seal.
2.5.17 Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow
electrolyte to touch the skin or the eyes. Always wear protective glasses when
servicing batteries. Wash hands after touching batteries and connectors. Use of
gloves is recommended.
Batteries emit combustible gases that can explode. Ensure proper ventilation
for batteries that are in an enclosure. Never disconnect any charging unit circuit
or battery circuit cable from the battery when the charging unit is operating. A
spark can cause the combustible gases to ignite. Do not smoke when batteries
are being serviced.
Always thaw a frozen battery before jump-starting the battery. Frozen batteries
can explode.
2.5.18 Fire Prevention and Explosion Prevention

Precautions must be taken at all times to prevent personal injury caused due
to fire and explosion. The following points must be kept in mind while handling
the unit.
• A flash fire may occur if the crankcase covers are opened within fifteen
minutes following an emergency shutdown.
• Fire may result from lubricating oil or fuel sprayed on hot surfaces.
• Engine being operated in a combustible gas environment could cause the
engine to over speed.
• Leaking fuel, or fuel spilled onto hot surfaces or electrical components, can
cause a fire.
• Do not smoke while the engine is refueled. Do not smoke in the refueling
area.
• Store all fuel and lubricants in properly marked containers. Store the
protective containers in a safe place.
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• Do not smoke in battery-charging areas. Batteries give off flammable fumes

that can explode.

• Do not smoke in areas that contain flammable material.
• Do not allow flammable materials to accumulate on the engine.
• Do not expose the engine to flames.
• Check the electrical wires that are loose or frayed. Before the engine is
operated, tighten all loose electrical wires. Repair all frayed electrical wires.
2.5.19 Fire Extinguisher

Make sure that fire extinguishers are readily available. Be familiar with their
operation. Inspect them regularly. Service the fire extinguishers according to the
recommendations on the instruction plate.
2.5.20 Crushing and Cutting Prevention

Unless other maintenance instructions are provided, never attempt adjustments
while the engine is running.
Stay clear of all rotating parts and moving parts. Leave the guards in place until
maintenance is performed. After the maintenance is performed, reinstall the
guards.
Keep objects away from moving fan blades (if provided). Fan blades can throw
and cut objects.
When objects are struck, wear protective glasses in order to avoid injury to the
eyes.
Chips or other debris may fly off objects when objects are struck. Before objects
are struck, ensure that flying debris will injure no one.
2.5.21 Electrical System

Never disconnect any charging unit circuit or battery circuit cable from the battery
when the charging unit is operating. A spark can cause the combustible gases
produced by some batteries to ignite. The CUS 812 Winterized has a 24-V
battery.
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2.5.22 Emergency Kill Switch

The emergency kill switch immediately shuts off the fuel and air supply to the
engine, resulting in system shutdown. The switch is located on the control panel.
2.5.23 Environmental Safety

Any chemical spill shall be contained and cleaned up according to local
procedures. Any spill shall also be reported according to local procedures.
When disposing of oils, filters, and batteries, ensure that these items are
disposed of in an environmentally acceptable way and in accordance with local
regulations.
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3-i CUS-812 (Winterized) Operations Manual / Specifications 3-i
3 Specifications
3.1 General Specifications _________________________________________ 3-1

3.2 Engine _________________________________________________________ 3-3
3.3 Power take-off (PTO) ___________________________________________ 3-4
3.4 Compressor ____________________________________________________ 3-6
3.5 Air Heater ______________________________________________________ 3-6
3.6 Fluid and Filter Specifications __________________________________ 3-7
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3 Specifications
3.1 General Specifications

The CUS-812 winterized skid mounted air compressor consists of a F6L914
Deutz air cooled diesel engine powering an AFP 4LM230 air compressor
capable of delivering 440 CFM @ 30 PSI. The unit is equipped with an 8 cubic
feet air receiver that functions as both a receiver and moisture separator. The
unit is heated by an Eberspächer D8LC 24 Volts air heater for operation up to
-40 degree Celsius. Figure 3-1 illustrates the typical features of the CUS-812
winterized Air Compressor Skid.
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Figure 3-1: CUS-812 Winterized Air Compressor Skid
Table 3-1: General Specifications for CUS-812 Winterized
Part Number 100506112

Length 88 in (2,235mm)
Width 85 in (2,150mm)
Height 89 in (2,250mm)
Dry Weight 2970 kg
Air Receiver 8 CU FT Capacity
Fuel Tank 35 US Gal Capacity
Relief Valve 30 PSI
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3-3 CUS-812 (Winterized) Operations Manual / Specifications 3-3
Engine Deutz F6L914 winterized Air Cooled, 63 KW

Compressor AFP 4LM 230 Reciprocal Compressor

Heater Eberspächer D8LC air heater
Capacity 440 CFM @30PSI
Ambient Rating -40 DegC to 42 DegC
3.2 Engine
The Deutz industrial Engine F6L914 is shown below.
Figure 3-2: Deutz F6L 914 Diesel Engine
Table 3-2: Deutz F6L914 Technical Data
Number of cylinders 6
Cylinder arrangement Vertical in line
Bore/stroke Mm 102/132
Total Displacement cm3 6472
Compression ratio 20
Engine speed min-1 1800
Power kW 63
Working cycle 4-stroke naturally aspirated diesel
engine
Combustion system Direct injection
Direction of rotation Counterclockwise
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Weight incl. cooling system as per DIN Kg 410

70020-A without starter or alternator

Lubrication Pressure lubrication
SAE oil 0W30
Oil temperature in oil pan oC 135
Min. oil pressure when warm (120 oC) Bar 0.4
and low idle
Oil change quantity without filter ca.ltr 14.5
Oil change quantity with filter ca.ltr 16.0
Injector opening pressure Bar 200+10
Firing order 1-5-3-6-2-4
V-belt tension Pre-tension/re-tension (15 minutes
after engine has been operated under
load)
Alternator fan N 450/300± 20
Compressor N 550/400± 20
3.3 Power take-off (PTO)

The CUS-812 Winterized is equipped with a Twin Disc SP111 HP3 or SP311
P304 (Heavy duty version) power take-off with hand lever drive clutch. This
device transfers power from the diesel engine to belt pulley.
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Figure 3-3: Twin Disc Power Take-off from Engine to Pulley
Table 3-3: Specification for Twin Disc Power take-off, SP111-HP3
Model SP-111-HP-3
Serial No. 1X2066
Input Torque (Min.) 107 Lb-Ft
Input Torque (Max.) 141Lb-Ft
Hand Lever Effort (Min.) 95 Lb
Hand Lever Effort (Max.) 125 Lb
Hand Lever Length (A) 13.6 In
Table 3-4: Specification for Twin Disc Power take-off, SP311-P304
Model SP311-P304
Serial No. P021766
Input Torque (Min.) 171 Lb-Ft
Input Torque (Max.) 227 Lb-Ft
Hand Lever Effort (Min.) 123 Lb
Hand Lever Effort (Max.) 163 Lb
Hand Lever Length (A) 21.3 In
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3.4 Compressor
The CUS-812 Winterized uses an air compressor from AirFlux. Table 3-5 Model
description for 4LM 230 Compressor describes the technical specifications for
the AFP 4LM 230 compressor.
Figure 3-4: AirFlux 4LM 230 Compressor
Table 3-5: Model description for 4LM 230 Compressor
Model 4LM 230

Working Pressure in Bar 2
Speed in rpm 1000
Free air flow delivered in m3/min 14.76
Air outlet flange connection DN 80
Oil in compressor circuit (liters) 5
Approx. Weight (kg) 850
Approx. Dimensions in mm 2005 x 1220 x 995
3.5 Air Heater

An Eberspächer D8LC 24 volt air heater is used to heat the inside of the CUS
812 Winterized unit.
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Figure 3-5: Eberspächer D8LC air heater
Table 3-6: Model description for D8LC air heater
Voltage (V) 24
Heating levels High Low
Heating capacity (watt) 8000 3500
Air Throughput (m3/h) 258 250
Power Requirements (watt) 115 115
Fuel comsumption (l/hr) 1.0 0.4
Dimensions (LxWxH) (mm) 653 x 260 x 250
Weight (Kg) 20
3.6 Fluid and Filter Specifications

Table 3-6 Model description for D8LC air heater lists the proper fluids used in the
various components of the CUS-812 Winterized. The capacities of fluids include
both the fluid to fill the component as well as the volume required for its filters
or coolers. Because of possible differences in hose routings, the capacities are
approximate. When changing fluids, always fill the system, and then circulate
fluid to fill the hoses and coolers, then re-check the levels. Table 3-8 Unit Filter
Specifications lists the filters required for each subsystem. The location of all
filters including Fuel filter, Engine oil filter, Engine Air filter, Compressor Air filter,
Compressor Air Intake Filter and heated fuel filters are shown in Figure 3-6
SAE engine oil Specifications, Figure 3-7 Fuel filter, Figure 3-8 Engine oil filter,
Figure 3-9 Engine air filter, Figure 3-10 Compressor air filter, and Figure 3-11
Heated fuel filter respectively.
Table 3-7: Unit Fluid Specifications
Component Temperature Range Capacity in

Gallons
-40 DegC < T < 30 DegC 30 DegC < T < 40 DegC
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Approved Deutz SAE0W-30 SAE10W-40 4.23 gal

Engine Oil: SAE0W-40 SAE5W-40

ACEA (E2-96, SAE5W-30 SAE10W-40
E3/96/E5-02, E4-99)
SAE5W-40 SAE15W-40
API (CF/CF-4,
CH-4/CG-4) SAE10W-30 SAE20W-50
DHD (DHD-1) SAE10W-40
SAE10W-30
SAE10W-40
SAE15W-40
Compressor oil ISO Viscosity Grade 68 ISO Viscosity Grade 100
(equal SAE20W) (equal SAE30)
Fuel #1 Diesel #2 Diesel 35 gal
1 Unit ambient rating: -40 DegC to 48 DegC
2 Should the temperature fall temporarily below the limits of the SAE grade selected, cold
starting may be affected but the engine will not be damaged.
3 In order to keep wear to a minimum, do not exceed application limits of engine oil for extended
periods of time.
Figure 3-6: SAE engine oil Specifications
Table 3-8: Unit Filter Specifications
Component Part No Supplier Part No Supplier Service
Fuel Filter - 01181917 Deutz Every STEM II
Engine Oil Filter - 01181749 Deutz
Engine Air Filter 100552422, P601437- fltr element Donaldson

100552423,
H000473- hood
100552424,
P004307- mnt band
100638638
X002278- srv indicator
Compressor oil filter - 401011 Air Flux Every STEM II
Compressor Air 545769000 4M0310F/AFP560 Precleaner/Air Every STEM II or as

Filter Donaldson indicated by gauge
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Component Part No Supplier Part No Supplier Service

Compressor Air 545769000 405012 & 405000 Air Flux Every STEM II or as
Intake filter indicated by gauge
Heated fuel filter N/A KT-4229-1276-1/4NPT Arctic Fox Every STEM II
Figure 3-7: Fuel filter
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Figure 3-8: Engine oil filter
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Figure 3-9: Engine air filter
Figure 3-10: Compressor air filter
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Figure 3-11: Heated fuel filter
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4-i CUS-812 (Winterized) Operations Manual / Unit Preparation 4-i
4 Unit Preparation
4.1 Pre-Job Checklist ______________________________________________ 4-1

4.2 Travel to Job Site _______________________________________________ 4-4
4.3 Job Site Pre-Start ______________________________________________ 4-5
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4 Unit Preparation
4.1 Pre-Job Checklist

Prior to traveling to job site, check the following:
• Engine oil level (Figure 4-1)
Figure 4-1: F6L914 engine components
• Air cleaner filter (Figure 4-2)
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Figure 4-2: CUS–812 air filter
• Diesel fuel level

• Power-take-over lubrication points
Figure 4-3: PTO lubrication point
• Check pop off of the pressure relief valve

• All guards secured in place
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Figure 4-4: Compressor fan guard
• Piping connections and caps. Make sure all piping is properly secured, caps
installed and manual valves are in closed position.
• Welds and frame are defect free.
• Panels are held securely and free of sharp edges.
• All hydraulic and air quick couplers have secured dust caps present.
• Paint finish conforms to Schlumberger requirement and is free of defects
and blemishes.
• Ensure all bolts and fasteners are secured.
• Compressor drive belts are tensioned and aligned. Use a straight edge to
align the belts and tension to allow approximately ½” of movement midway
between pulleys. Do not over-tension belts.
• Fill compressor sump to the full level on the dipstick, with SAE 30 compressor
oil that meets ISO Grade 100.
• Grease all fittings and butterfly valve with a Lithium type 2, general purpose
grease.
• Check gauges are filled with glycerin and free of moisture and leaks. (Figure
4-5).
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Figure 4-5: CUS 812 pressure gauge
• Check the hand operated clutch engages and disengages smoothly.

• Check all hoses and connections are secure.
• Look for any type of leak, loose bolts, and worn or frayed wires.
• Inspect the accessory drive belts for cracks, breaks or other damage, make
sure the belts are tight
• Make sure that First Aid Kit and Emergency eye wash bottle are enclosed.
• Make sure that other auxiliary equipments are properly secured for
transportation.
4.2 Travel to Job Site

• Follow all Schlumberger operating and safety procedures.
• Obey all state and local laws.
• Stop and check unit from time to time to make sure all items are properly
secured.
• Ensure the 3" hose connected to 8 Cu-Ft air tank is in good condition and
mounted correctly (Figure 4-6 CUS 812 discharge butterfly valve).
• Close 3" discharge butterfly valve.
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Figure 4-6: CUS 812 discharge butterfly valve
4.3 Job Site Pre-Start

• Upon arrival at job site, make sure the unit is placed on firm level ground
adequate to support the weight of the unit. Ensure the operator can see all
the hoses and that they reach the equipment they will be connected to.
• Inspect unit for any items that may have become loose or damaged in transit.
Tighten, repair, or replace as necessary.
• Make hose connections as appropriate for the planned operation. Make
sure all fittings are securely tightened.
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5-i CUS-812 (Winterized) Operations Manual / Unit Operation 5-i
5 Unit Operation
5.1 Unit Preheating ________________________________________________ 5-1

5.2 Start Up ________________________________________________________ 5-4
5.3 Operation ______________________________________________________ 5-7
5.4 Normal Shut Down _____________________________________________ 5-7
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5 Unit Operation
5.1 Unit Preheating

1. Go through the list in 4.1 Pre-Job Checklist again.
2. Switch on the circuit breaker.
3. Make sure the fuel selector is pointed towards the arctic fuel tank. (Figure
5-1 Air heater suction fan)
4. Switch on the Eberspächer heater from the winterized control panel. The
control lamp on the control panel would light up.
5. The glow plug is switched on and the fan starts at maximum speed. (Figure
5-1 Air heater suction fan)
6. Soon the heater fuel pump starts to pump winter fuel with a ‘ticking’ sound.
(Figure 5-2 Arctic heater fuel pump)
7. Select the heating capacity according to the ambient temperature.
8. Cover the unit with canvas on all sides.
9. Let the unit heat up for 30 mins.
10. Switch on the inline fuel heater (Figure 5-3 Air heater fuel selector) from
the winterized control panel.
11. Let it heat up the fuel for five minutes.
12. Start the engine as per normal operation.
13. Switch off the Inline fuel heater.
14. Use the air heater as per the ambient temperature inside the skid.
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Figure 5-1: Air heater suction fan
Figure 5-2: Arctic heater fuel pump
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Figure 5-3: Air heater fuel selector
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Figure 5-4: Inline fuel heater schematic diagram
5.2 Start Up
1. Check clutch is disengaged, then bleed diesel engine as required if there is
air traps in the engine fuel lines and hoses.
2. Start the engine.
3. Immediately check engine oil pressure gauge (see Figure 5-1 Air heater
suction fan) and ensure pressure comes up and remains. Ensure the engine
has oil pressure (if not, shut down the engine and resolve the problem before
continuing)
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5-5 CUS-812 (Winterized) Operations Manual / Unit Operation 5-5
4. Momentarily engage clutch and also check the compressor oil pressure rises.
If not, STOP engine immediately and rectify the problem.
Note
If either the compressor or the engine is run without sufficient oil pressure,
severe damage to the component will be the result within very short time.
5. Turn the throttle to adjust the engine speed (see Figure 5-2 Arctic heater fuel
pump) and make sure the engine idle speed at approximately 700-900rpm.
Check for any immediate problems, such as leaks or bad vibrations or
unusual noise.
6. After one minute stop engine, allow to stand for five minutes, then recheck oil
level and top up as required, to bring level back to upper mark on dipstick.
7. Allow engine to idle until engine temperature and oil pressures have reached
operating ranges.
Note
Typical oil pressure for an engine at idle with SAE 15W-40 is 2 to 5 bar {30 to 70
psi). Oil pressure and temperature can be monitored at the engine oil pressure
gauge located in the engine control panel (see Figure 5-3 Air heater fuel selector).
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Figure 5-5: Engine control panel
Figure 5-6: Engine throttle
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5.3 Operation
1. Push the handle to engage the PTO (see Figure 3-3 Twin Disc Power
Take-off from Engine to Pulley) at the idle speed.
2. Increase RPM to full speed (approximate 1800rpm).
3. Ensure there is no unusual noise or vibration.
4. Ensure pressure in air receiver and unloader valve is around 30psi on the
pressure gauge.
5. Open 3” valve slowly.
6. Watch and ensure that oil pressure of engine and compressor stay within
normal limits (see Table 3-2 Deutz F6L914 Technical Data and Table 3-5
Model description for 4LM 230 Compressor)
5.4 Normal Shut Down

1. Open discharge valve fully.
2. Bring engine to idle, disengage clutch and allow running for around two
minutes.
3. Stop Engine.
4. Re-check belt tension.
5. Wash unit down as required.
6. Clean and secure all hoses in place.
7. Shut all manual valves and secure piping caps.
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6-i CUS-812 (Winterized) Operations Manual / Troubleshooting 6-i
6 Troubleshooting
6.1 Engine _________________________________________________________ 6-1

6.1.1 Diagnostic Chart _____________________________________________ 6-1
6.1.2 Mechanical __________________________________________________ 6-4
6.1.3 Troubleshooting Guide _______________________________________ 6-5
6.2 Compressor ____________________________________________________ 6-9
6.3 Control Console and J-Box ____________________________________ 6-10
6.4 Air Heater _____________________________________________________ 6-10
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6 Troubleshooting
This troubleshooting guide is mainly for the operator in the field. It does not
cover all possible causes or remedies of problems. If you, as an operator,
encounter problems outside of what is covered in this chapter, please contact
your mechanic or electronic technician.
The three main areas covered are:
• Engine
• Compressor
• Junction Box
• Air Heater
6.1 Engine
6.1.1 Diagnostic Chart

The below diagnosis chart (Figure 6-1 Diagnosis Chart for the Engine) illustrates
a list of all the troubles and causes the engine might have during operation.
However, operating troubles are often due to improper operation or maintenance
of the engine. Thus, in the event of trouble, always check whether the operating
and maintenance instructions have been strictly followed.
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6-2
Figure 6-1: Diagnosis Chart for the Engine
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6.1.2 Mechanical
Some engine symptoms can be unrelated to the engine mechanical system. To
determine the problem, perform the following steps:
1. Gather information.
2. Verify that the problem is not due to normal engine operation.
3. Perform a visual inspection of the machine. Inspect the following items:
Table 6-1: Engine Symptoms and Possible Remedies
A) Fuel level Visually check fuel level. If necessary, add fuel.

and supply Check the fuel system if there is no smoke at the exhaust.
Check fuel lines for the following problems:
• Restrictions
• Collapse
• Pinched line
Repair or replace the lines.
Check the fuel tank for foreign objects, which may block the fuel supply. Check for water in the
fuel – drain some sample from the bottom of the tank. Check for air in the low-pressure fuel
supply system after you complete the following procedures:
• Replace the fuel filters

• Purge air from the low-pressure fuel supply circuit with the hand-priming pump and by
cranking the engine in 30-sec cycles. After you crank the engine, stop for two minutes. This
allows the starting motor to cool.
• Loosen the vent plug for the fuel return line. The plug is located on the rear upper left
side of the engine block.
• Hand-prime the engine again if there is still air in the fuel.
Check fuel quality. In temperatures below 0°C (32°F), check for solidified fuel (wax).
B) Air inlet
or exhaust 1. Ensure the emergency kill valve on the air inlet is open.
restriction
2. Check the air inlet and exhaust systems for the following problems:
• Restrictions
• Collapse
• Pinched line
Repair or replace the lines. Check for an air filter restriction indicator.
3. Replace plugged air filters or clean filters.
C) Oil Level Take out dip stick and check for correct engine oil level
D) Wiring Check for loose or burned wires
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6-5 CUS-812 (Winterized) Operations Manual / Troubleshooting 6-5
If these inspections do not reveal any problems, and you are still having trouble,
identify the symptom from the following list and try the remedy for that symptom.
6.1.3 Troubleshooting Guide

Engine will not crank
Cause Remedy
If there is power to If voltage is low (less than 23.5V with engine stopped), charge or replace batteries.
the Control Console,
check if there is correct
voltage on volt-meter.
Active emergency Ensure that the Emergency Shutdown switch is in the OFF position.
shutdown. Check that the air inlet flapper valve is locked in the open position.
If E-kill has been engaged, turn the main power on the Control Consol to the off position
for at least 15 seconds before you try to restart the engine.
RUN/KILL switch Check that the RUN/KILL switch is not in the KILL position.
Battery cables and/or
batteries Check the following for loose connections and corrosion:
• Battery posts
• Battery
• Battery cables
Clean the cables and/or connections if corrosion is found.

Load test the battery.
If necessary, charge the batteries.
Starting motor Test the operation of the starting motor.
Check the system wiring to the starting motor.
Engine cranks but will not start

Cause Remedy
Active engine If a shutdown is active, determine the reason. After you correct the problem, turn main
shutdown power on Control Console to the OFF position for at least 15 seconds before you try to
restart the engine.
Fuel level and supply See A) Fuel level and supply in Table 6-1 Engine Symptoms and Possible Remedies
Electrical power
supply Check the following for loose connections and corrosion:
• Battery posts
• Battery
• Battery cables

Load test the battery; if necessary, charge the batteries.
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Engine misfires, runs rough, or is unstable

Note
If the symptom cannot be repeated, see Low power/poor or no response to throttle. If the symptom can be
repeated, continue with this procedure.
Cause Remedy
Fuel supply See A) Fuel level and supply in Table 6-1 Engine Symptoms and Possible Remedies.
Air inlet restrictions See B) Air inlet or exhaust restriction in Table 6-1 Engine Symptoms and Possible
Remedies.
Low power/poor or no response to throttle

Cause Remedy
Fuel level See A) Fuel level and supply in Table 6-1 Engine Symptoms and Possible Remedies.
Electrical connectors
Check the following for loose connections and corrosion:
• Battery posts
• Battery
• Battery cables

Fuel consumption See A) Fuel level and supply in Table 6-1 Engine Symptoms and Possible Remedies.
Air inlet restriction See B) Air inlet or exhaust restriction in Table 6-1 Engine Symptoms and Possible
Remedies.
Intermittent engine shutdown

Cause Remedy
Faulty electrical Inspect the electrical connectors for proper installation.
connections Check cables to the J-box.
Check for loose wires or connectors inside the J-box.
Open and check inside the Control Console for loose connections.
Intermittent low power or power cutout

Cause Remedy
Remediesand verify that the turbocharger has not failed
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Excessive black smoke

Cause Remedy
Remedies.
Excessive white smoke
Note
Some white smoke may be present during cold start up conditions when the engine is operating normally.
Cause Remedy
Cannot reach top engine rpm
Note
If this problem occurs under load, see Low power/poor or no response to throttle.
Cause Remedy
Fuel Supply See A) Fuel level and supply in Table 6-1 Engine Symptoms and Possible Remedies.
Air inlet or exhaust See B) Air inlet or exhaust restriction in Table 6-1 Engine Symptoms and Possible
restriction Remedies.
Leaks in air system See B) Air inlet or exhaust restriction in Table 6-1 Engine Symptoms and Possible
Remedies.
Faulty accessory Check all accessory equipment.
equipment
Engine over speeds on

start
Cause Remedy
Injectors See Engine misfires, runs rough or is unstable.
Seal ring See A) Fuel level and supply in Table 6-1 Engine Symptoms and Possible Remedies.
Check for oil at the inlet manifold.
Ventilation Check the breathers for plugging.
Engine stalls at low rpm

Cause Remedy
Low fuel pressure See A) Fuel level and supply in Table 6-1 Engine Symptoms and Possible Remedies.
Faulty engine accessories Check all accessory equipment.
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Too much vibration

Cause Remedy
Vibration damper Check the vibration damper for damage. Tighten the bolts. Check the vibration
damper bolt holes for damage and wear
Loose engine supports
Run the engine. Check the engine for the following problems:
• Loose mounts
• Broken mounts
• Loose brackets
• Broken brackets
Tighten all mounting bolts.

Loose pulley and V-belts Adjust the engine position to tension the pulley and V-belts.
Noise coming from cylinder

Cause Remedy
Low quality fuel Check fuel quality.
Remove unsatisfactory fuel from the fuel tank.
Install new fuel filters. Use proper grade of clean fuel in the fuel tank.
Electrical connectors
Check the following for loose connections and corrosion:
• Battery posts
• Battery
• Battery cables

Low engine oil pressure
Note
Do not operate engine with low oil pressure. Engine damage will result. If measured oil pressure is low,
discontinue engine operation until the problem is corrected.
Cause Remedy
Low oil level Inspect the engine oil level. If engine oil is low, add engine oil
Dirty oil filters Check the operation of bypass valve for the filter. Inspect the oil filter. If the oil filter is
dirty, install a new oil filter.
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Excessive engine oil consumption

Cause Remedy
Oil leaks Inspect the engine for oil leaks.
Repair all oil leaks.
Crankcase breather Check the crankcase breathers for restrictions or debris.
If necessary, clean the crankcase breathers.
Oil level Inspect the oil level – verify that there is a correct mount of oil in the engine.
Remove any extra oil from the engine.
Oil cooler Check for blockage in the oil pump inlet screen.
Check for air leakage into the supply to the oil pump.
Breather element Check the breather element for debris.
If necessary, replace the breather element.
Check the crankcase breathers for restrictions and debris
If necessary, clean the crankcase breather.
6.2 Compressor
The table below illustrates a list of the most frequent compressor failures. The
engine is presumed to be in working order and all the materials correct. If any
other anomaly is observed, stop the unit, determine the extent of the trouble
and contact AIRFLUX NPA.
Private
Figure 6-2: Trouble Shooting for the AirFlux Compressor
6.3 Control Console and J-Box

A qualified technician should troubleshoot the control panel. Correct drawings
and schematics are required.
When troubleshooting the panel, always check for proper voltage (23.5V
minimum with engine stopped, if engine is running the voltage should be between
25.2V and 25.8V) at the panel. Mechanical integrity of the components should be
checked next. Broken components or loose terminations can cause problems.
Finally, a multimeter should be used to diagnose and troubleshoot more difficult

problems, such as continuity checks, current draw, etc.
6.4 Air Heater

If the air heater does not start after being switched on, please perform the
following operations. Switch the heater off and on again.
If the heater still does not start, check the following:
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• Level of fuel in the tank.

• The status of the fuse.

• The condition of the cables, connections etc.
• Possible clogging of the combustion air supply or exhaust system.
If the heater remains faulty even after these points have been checked or
another malfunction occurs in your heater please consult a qualified technician to
troubleshoot using correct drawings and schematics.
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IPC\Svein Normann, Rao Zhiming, Sagar Sundar Polley\InTouch content ID# 4922979 \1.0\Release Date:16-Nov-2009\EDMS UID: 1652693470\Produced: 16-Nov-2009 07:30:59 A-i
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Example STEM
CUS-812 (Winterized) Operations Manual / Example STEM

A-i
IPC\Svein Normann, Rao Zhiming, Sagar Sundar Polley\InTouch content ID# 4922979 \1.0\Release Date:16-Nov-2009\EDMS UID: 1652693470\Produced: 16-Nov-2009 07:30:59 A-ii
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Intentionally Blank
CUS-812 (Winterized) Operations Manual / Example STEM

A-ii
IPC\Svein Normann, Rao Zhiming, Sagar Sundar Polley\InTouch content ID# 4922979 \1.0\Release Date:16-Nov-2009\EDMS UID: 1652693470\Produced: 16-Nov-2009 07:30:59 A-1 CUS-812 (Winterized) Operations Manual / Example STEM A-1
A Example STEM
Figure A-1: Example STEM
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CUS-812 Air Compressor Skid (Winterized) Operations Manual

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CUS-812 Air Compressor Skid (Winterized) Operations Manual

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CUS-812 Air Compressor Skid

(Winterized) Operations Manual

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

REMOVE TWO (2) PAGES:

1. THIS PAGE and

Copyright © 2009 Sophia, Unpublished Work. All rights reserved.

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

Trademarks & Service marks

Schlumberger, the Schlumberger logotype, and other words or symbols used

A complete list of Schlumberger marks may be viewed at the Schlumberger

Author: Svein Normann, Rao Zhiming, Sagar Sundar Polley

Reviewer: Andy Sutherland,

Approver: Andy Sutherland

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

Foreword IPC,Well Services,WS,

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

Regulatory Compliance __________________________________________ v

Foreword ________________________________________________________ vii

1 Introduction ____________________________________________________ 1-1

2 QHSE __________________________________________________________ 2-1

3 Specifications __________________________________________________ 3-1

4 Unit Preparation ________________________________________________ 4-1

5 Unit Operation _________________________________________________ 5-1

6 Troubleshooting ________________________________________________ 6-1

A Example STEM _________________________________________________ A-1

3-1 CUS-812 Winterized Air Compressor Skid___________________________ 3-2

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

1-1 Basic Specifications _______________________________________________ 1-1

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

1.1 Product History ________________________________________________ 1-1

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

1.1 Product History

1.2 Product Features

Table 1-1: Basic Specifications

Table 1-2: Unit Specifications

Model CUS-812 (Winterized)

1.3 Product Application

1.4 Documentation and Manuals

• CUS-812 Operations Manual (this volume)

1.4.1 Operations Manual

This Operations Manual is organized as follows:

1.4.2 Maintenance Manual

The Maintenance Manual is organized as follows:

1.4.3 Vendor’s Manuals

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

2.1 General Safety _________________________________________________ 2-1

Copyright © 2009 Schlumberger, Unpublished Work. All rights reserved.

2.1 General Safety

2.2 OFS QHSE Standards

Table 2-1: OFS QHSE Safety Standards

Standard Name Location

2.3 Well Services Safety Standards

Table 2-2: Well Services Safety Standards

Standard Name Location

2.4 Personnel Safety

It is important to remember the dangers of the low pressure high volume

2.5 Equipment Safety

2.5.1 Pre-Trip Inspection

are brought to the well site

2.5.2 Covers and Guards

2.5.3 Pressure Relief Valves and Gauges (WS STD 4)

2.5.4 High-Pressure Liquid Jetting, Blasting, and