Mechanical 17 18

PRODUCTION MAINTENANCE
MECHANICAL GRADES 17-18
A program produced Operations Training Program

and published by: Development Team
Name: ____________________________________
Company Confidential
Copyright © 2004 Chevron Corporation
Employee Resource & Training Center (ERTC)
To be reproduced and used only in
accordance with written permission of ERTC.
TABLE OF CONTENTS
Page
Section I
Introduction ............................................................................................................................... i
Section II
Job Description ....................................................................................................................... xi
Section III
List of Skill Assessments ...................................................................................................... xix
Section IV
100 Safety, Policy,and Procedures .................................................................................... 01
200 Tools and Measurement Devices ................................................................................ 45
300 Natural Gas Engine (Four Cycle) ................................................................................. 59
400 Diesel Engine .............................................................................................................. 83
500 Gas Turbine Engine ....................................................................................................101
600 Ignition System ..........................................................................................................141
700 Cooling Systems ........................................................................................................151
900 Starter Systems .........................................................................................................167
1000 Governors ...................................................................................................................163
1100 Positive Displacement Pumps ....................................................................................169
1200 Centrifugal Pumps ......................................................................................................185
1300 Air Compressors .........................................................................................................203
1900 Clutches .....................................................................................................................209
2200 Alignment ....................................................................................................................211
2300 Gearboxes ..................................................................................................................235
2400 Couplings ....................................................................................................................239
6000 Computer Based Test .................................................................................................251
Section V
Appendices.............................................................................................................. Appendices
Section VI
Glossary .................................................................................................................................. 1
Section VII
List of Reference Materials ...................................................................................................... 1
Section VIII
Training Equipment and Equivalents List .................................................................................. 1
MECHANIC 17-18 I
REVISIONS
II MECHANIC 17-18
INTRODUCTION
Table of Contents
Page
1.0 Operations Training Program (OTP) .......................................................................... iii
2.0 Employee Feedback ................................................................................................... v
3.0 OSA Administration Guidelines ................................................................................... v
4.0 Documentation and Filing ............................................................................................ x
MECHANIC 17-18 i
ii MECHANIC 17-18
INTRODUCTION
The Operations Training Program (OTP) was developed for employees in the Operations and Maintenance
(O&M) classification. Each job classification has specific Operations Skill Assessments (OSAs) and
training that have been developed for all O&M employees. This program may be mandatory for newly hired
O&M employees and is voluntary for incumbent personnel who wish to advance in their career path.
Along with our current Performance Management Process (PMP), the Skill Assessments are intended to
identify individual employee training needs and ensure an acceptable skill level prior to promotion within
the O&M structure. Completion of the current level and next higher level Grade OSA’s must be completed
along with sustained job performance to be considered for promotion to the next Salary Grade.
Note: Employees who have successfully completed 100% of the required (JSA) Skill Assessments
under the old CAT Program will not be required to complete any of the new (OSA’s) for that Grade level or
below. If an employee has not achieved 100% completion of the required (JSA’s) under the old CAT
Program for their current grade level they are working in, then they will be required to begin the new
(OSA’s) for that current grade level. The Superintendent shall validate the successful completion of the
employee's grade level in the CAT program through the CAT training database or documented Supervisor
handbooks.
The Skill Assessments are based upon the current job description for each (O&M) classification and are
representative of the key job duties and skills that are common to each classification throughout the entire
Business Unit. The Skill Assessments are not intended to be a comprehensive list of duties or skills for a
specific classification or a specific location. OSA’s may be revised periodically to include new technology
or operating procedures.
1.0 OPERATIONS TRAINING PROGRAM MANUAL (OTP)
1.1 The OTP Manual may be used as a reference and guide by Qualifiers during training and
administration of the OSAs.
1.2 The OTP Manual may be used as a reference and guide by (O&M) employees for training prior
to attempting to qualify on OSAs.
1.3 Employees should utilize any formal or on the job training (OJT), referenced materials,
Company policies, CABGOC Standard Operating Procedures and/or manufacturer’s manuals
prior to attempting to qualify on a Skill Assessment.
1.4 Recommended safe practices and safety precautions are not always included in the
Skill Assessment. To satisfactorily complete a Skill Assessment that requires the
demonstration of a procedure, the employee shall adhere to and apply all applicable
laws and Company safety guidelines and procedures during the performance of each
Skill Assessment or the employee will not be given credit for that Assessment.
MECHANIC 17-18 iii

INTRODUCTION
Section I - Introduction
1.5 Section I describes the Skill Assessment format and provides guidelines for the administration
and documentation of the OSAs.
Section II - Job Description
1.6 Section II contains the description of the job duties for the particular classification.
Section III - List of Skill Assessments
1.7 Section III contains a list of all the Skill Assessments from the OSA Manual.
Section IV - Qualification In Operations Skill Assessments (OSAs)
1.8 Section IV assists the Qualifier and the employee in the qualification process and ensures the
uniform administration of the OSAs. (Section IV is subdivided into job-related subjects.)
1.9 Section IV defines the knowledge, skills, and abilities required for the successful completion
of each Skill Assessment in the OSA. It includes the basic information for each job skill.
1.10 The following is an example and an explanation of the Skill Assessment format:
SKILL ASSESSMENT
1) The exact Skill Assessment is stated.
ADMINISTRATION
1) Provides the Qualifier with a standard to follow, ensuring uniform administration of all Skill
Assessments.
2) Ensures that the (O&M) employee knows what to expect--no surprises
3) Specifies which of the two modes of Skill Assessment administration is acceptable:
a) DEMONSTRATE: The procedure shall be demonstrated (perform hands-on skills to complete

the Skill Assessment) by the employee.
b) EXPLAIN: The Skill Assessment shall be explained by the employee. The Qualifier has the
option to decide whether to complete this Skill Assessment at the equipment location (On-
Site) or in an office environment (Office). It is recommended that "Explain" Skill Assessments
be performed on the site of actual equipment when possible.
iv MECHANIC 17-18
INTRODUCTION
PROCEDURE
1) Lists step-by-step procedures
NOTE: For an identify and explain Skill Assessment, the wording in “bold” is to be identified and
the explanation follows. Example:
Station Bill - Indicates the location of the life saving and fire fighting equipment, and
lists the duties and emergency stations of the platform.
2) References support material if applicable

3) Notes in this section are for information only, and shall not be considered part of the skill
assessment.
Section V - Appendices
1.11 Section V contains additional material to complete various Skill Assessments.
Section VI - Glossary
1.12 Section VI contains a list of words and/or terms with their meanings.
Section VII - List of Reference Material
Section VIII - Training Equipment
2.0 EMPLOYEE FEEDBACK
2.1 O&M employees are encouraged to provide feedback (for example, suggestions for new Skill
Assessments, new or revised procedures, additional explanations, or reference material) to
their Supervisors. The Superintendent will then forward this information to the OTP
Administrator at CLDC for consideration in updates to the program.
3.0 ADMINISTRATION GUIDELINES
General Requirements
3.1 Guidelines have been established to ensure uniform Skill Assessment administration.
3.2 These guidelines shall not be revised, modified, or interpreted on a local or individual basis.
Any revisions or clarifications shall be addressed by the OTP Administrator at CLDC and the
OTP Administrator at ERTC in Lafayette, Louisiana.
MECHANIC 17-18 v
INTRODUCTION
3.3 Most of these guidelines are common to any Skill Assessment at any time in the employee’s
career. These guidelines are included in the OSA Manual for each classification.
3.4 Each Superintendent will be responsible for, or ensure appropriate controls are in place to
manage coordination and administration of the OSA's in their area of responsibility.
3.5 Each Superintendent will be responsible for, or ensure appropriate controls are in place to
assist employees in obtaining any training (including OJT) that is required to complete their
assigned OSA. A Development Plan along with PMP should be part of the employee's
evaluation process. It is the employee's responsibility to actively seek and retain the
knowledge and abilities required to complete any formal training and OSA's.
Skill Assessment Qualifiers
3.6 Operations Skill Assessments at or above the Salary Grade 14 classification shall only be
administered by the Superintendent, Supervisor, Field Training Coordinator, CLDC Trainer,
Mentors and / or Alternate Qualifiers (AQ). All Qualifiers selected shall be at least a salary
grade 20 or above and approved by the Superintendent. Selected Qualifiers and / or Mentors
shall have their names recorded in the Supervisor’s Documentation Copy of the OSAs and are
the only personnel allowed to administer Skill Assessments..
3.7 Mechanical related Skill Assessments in the OSA shall be administered by a person qualified
in mechanical skills at a salary grade 20 or above.
3.8 Electrical related Skill Assessments in the OSA shall be administered by a person qualified
in electrical skills at a salary grade 20 or above.
3.9 To ensure uniform administration of the OSAs in the (O&M) Structure, selected Skill
Assessments within each OSA shall only be administered by Alternate Qualifiers (AQs). An
Alternate Qualifier may include other approved Qualifiers from another field, Supervisors, Field
Training Coordinators, or CLDC Trainers. Alternate Qualifiers should be from another work
area or field and not regularly associated with the employee.
3.10 Selected Skill Assessments in Section III of applicable OSAs are designated "CLDC" or
"CLDC ONLY" Skill Assessments.
3.11 These selected Skill Assessments shall be administered as follows:
3.11.1 "CLDC" Skill Assessments may be completed at CLDC or at a field location if the
appropriate equipment is available. "CLDC ONLY" Skill Assessments must be
administered at CLDC. (Example: Computer Base Testing).
3.12 Any time an employee is scheduled to attend a course at CLDC, the employee can ask to
qualify on the "CLDC" Skill Assessments as well as any others, if a Trainer is available to
administer the assessment. Prior arrangements with CLDC should be made before coming to
the facility to qualify on a Skill Assessment.
3.13 O&M employees, including those relieving Supervisors, are not allowed to administer Skill
Assessments to employees without written permission from the Superintendent.
3.14 An Operations Manager (OM) shall not administer Skill Assessments.

vi MECHANIC 17-18
INTRODUCTION
Skill Assessment Administration
3.15 Employees shall not be required to attempt a Skill Assessment unless they feel confident
enough to successfully complete it.
3.16 When the employee requests to attempt a Skill Assessment that they did not satisfactorily
complete earlier or chose not to attempt, the Superintendent will be responsible for, or
ensure appropriate controls are in place to coordinate schedules as needed to ensure that
the employee has the opportunity to complete the Skill Assessment.
3.17 The Qualifier shall observe the skill being performed or explained during Skill Assessment
administration.
3.18 Employees who are unsure or do not fully understand the procedure or process shall not be
credited with completing the Skill Assessment.
3.19 Procedures given in the employee's own words are preferred. However, memorizing a
procedure is acceptable if an employee can answer Skill Assessment related questions that
indicate an understanding of the subject.
3.20 The Qualifier may ask an employee additional Skill Assessment related questions as needed
to ensure a complete understanding of each job skill.
3.21 Employees may not refer to written text, notes, training material or the OSA manual while
attempting to qualify on a Skill Assessment, except when specifically noted in the
Administration Statement of the Skill Assessment.
3.22 Employees may request formal or On the Job Training (OJT) training on a particular Skill
Assessment (or subject) prior to attempting to qualify on it for the first time.
3.23 Employees shall not be allowed to attempt to qualify on a Skill Assessment within a
minimum of eight calendar days of receiving formal training (including OJT and/or self-study
books) on that subject. This allows time for an employee to increase their knowledge level
in a particular skill. The minimum eight-day waiting period does not apply to any informal
training. However, the minimum eight-day waiting period may be waived for "CLDC" Skill
Assessments that are administered at CLDC with approval of the CLDC Training Coordinator.
3.24 Employees shall attempt to qualify individually on each Skill Assessment. A group of
employees attempting to qualify on the same Skill Assessment, at the same time, is not
allowed.
3.25 Skill Assessments within an OSA may be completed in any order or sequence except the
Computer Based Test (CBT). The CBT may be taken once all other Skill Assessments
have been completed.
3.26 Most Skill Assessments will be administered on actual equipment. If the Skill Assessment
requires an identification and explanation, the employee shall identify the component(s) while
explaining the process or procedure.
MECHANIC 17-18 vii

INTRODUCTION
3.27 Certain Skill Assessments require calculations, forms, etc. The Qualifier shall witness the
calculations being made and the forms being completed, etc. The completed forms shall be
included with the Supervisors Documentation Copy of the OSAs.
3.28 Employees will be required to complete each Skill Assessment in their assigned OSA Manual.
If a particular type of equipment or process is not available for training or for the employees to
attempt to qualify on, they shall be temporarily assigned to a location having the required
equipment or process. “NOT APPLICABLE” (NA) will not be acceptable for any Skill
Assessment, unless approved by the POMT PDC
3.29 Recommended safe practices and safety precautions are not always included in the
Skill Assessment. To satisfactorily complete a Skill Assessment that requires the
demonstration of a procedure, the employee shall adhere to and apply all applicable
laws and company safety guidelines and procedures during the performance of each
Skill Assessment or the employee will not be given credit for that Assessment.
3.30 The criteria and procedures specified in the OSA shall not be altered without the approval of
the OTP administrator at CLDC and the OTP Coordinator at ERTC in Lafayette, Louisiana.
3.31 When an employee is issued an OSA Manual, the employee will receive the latest edition.
The employee will be considered "started" in an OSA upon attempting to qualify on any Skill
Assessment within that OSA Manual. If a newer edition of the OSA is released, the
employee will not be required to qualify on the newer OSA version.
3.32 Employees who begin qualifying on an OSA within their career path shall be required to
complete that OSA before beginning another OSA within their career path. After completion of
a lower level OSA, the employee may begin qualifying on an OSA one level higher than his or
her current job classification with the approval of the Superintendent.
3.33 Employees will be permitted to complete the OSAs in any career path to the highest level
they can attain or wish to pursue. (For example, an Operator Salary Grade 14 can complete
the OSA for the Operator Salary Grade 15 and Operator Salary Grade 16 level without a
promotion or change in job classification). Formal training prior to attempting Skill Assessment
qualification in a OSA higher than one level above their current Salary Grade shall be decided
by their Superintendent. Other considerations for promotion shall include sustained job
performance, (PMP), Superintendent recommendation, POPDC approval. Other related issues
may also be included as part of the promotion plan such as time in place.
3.34 Employees who wish to qualify in a job classification outside of their career path shall be
required to complete that Operations Skill Assessment (OSA) before beginning another OSA
outside their career path.
3.35 After an employee successfully completes the OSA's there may be some time restrictions for
qualifying on higher classification OSA's.
viii MECHANIC 17-18

INTRODUCTION
Repeating Skill Assessments
3.36 Employees will not be required to repeat previously completed Skill Assessments. However,
Skill Assessment content may be repeated in a higher level OSA or through Computer Based
Testing (CBT) as part of a progressive training program to ensure employee knowledge.
3.37 Employees who have previously completed an OSA for a specific job classification shall not
be administered these Skill Assessments again if transferred to another location.
Substitute Equipment
3.38 Equivalent equipment will be acceptable only if the equipment stated in the Skill Assessment
is unavailable or not part of CABGOC’s normal operations. The Qualifier has the option of
selecting substitute equipment if the substitute equipment meets the requirements and intent
of the Skill Assessment. Substitute equipment and procedures must be approved by the
POMT PDC as an acceptable substitute before a Qualifier is allowed to qualify an employee
on that Skill Assessment. Placing Non Applicable (NA) on the Skill Assessment is not
acceptable.
Unsatisfactory Attempt of a Skill Assessment - After Qualifying Period
3.39 First Attempt - Employees not satisfactorily completing a Skill Assessment on the first
attempt shall be given training on the Skill Assessment subject. The employee's immediate
Supervisor shall be notified after an employee's unsatisfactory first attempt. The employee's
training requirements shall be reviewed at this time by their assigned Superintendent or
approved substitute. The employee shall be required to wait a minimum of eight calendar days
after any training before attempting to qualify on that particular Skill Assessment again.
3.40 Second Attempt - Employees not satisfactorily completing the Skill Assessment on the
second attempt shall be given additional training on the Skill Assessment subject. The
employee's immediate Superintendent and the OTP Coordinator shall be notified after an
employee's unsatisfactory second attempt. The training requirements for the employee shall
be reviewed at this time by their assigned Superintendent or approved substitute. The employee
shall be required to wait a minimum of eight calendar days after any training before attempting
to qualify on that particular Skill Assessment again. The employee's immediate Superintendent
or approved substitute shall assign a different Qualifier to administer the employee's second
attempt on that Skill Assessment.
3.41 Third Attempt - No employee shall have the second and third attempts on the same Skill
Assessment administered by the same Qualifier. An employee not satisfactorily completing a
Skill Assessment on the third attempt shall be given additional training on the Skill Assessment
subject. The employee shall be required to wait a minimum of 90 calendar days before
attempting to qualify on that Skill Assessment again. However, they may continue to qualify
on other Skill Assessments in the same OSA. After waiting the required minimum 90 calendar
days, the employee may attempt to qualify on the Skill Assessment again. All unsuccessful
attempts shall be reported to the employee's immediate Superintendent and the OTP
Coordinator for review and assessment.
MECHANIC 17-18 ix
3.42 Second attempts on "CLDC" Skill Assessments shall only be administered with the
Superintendent's or approved substitute's approval.
3.43 Third attempts on "CLDC" Skill Assessments shall only be administered with the approval of
the Superintendent and the OTP Coordinator. Third attempt "CLDC" failures shall be reviewed
by the Superintendent and the OTP Coordinator.
4.0 DOCUMENTATION AND FILING
4.1 The Supervisor’s Documentation Copy of the OSAs shall be used by the Superintendent as
the “official” copy to document the employee's progress on each Skill Assessment and
document the satisfactory completion of an OSA. Skill Assessments signed in the employee’s
OSA manual are for reference only and may not be considered “official” until transferred into
the Supervisor’s Documentation Copy of the OSA’s. The Supervisor’s Documentation Copy of
the OSAs shall be updated to include any changes to the OSA.
4.1.1 The Supervisor’s Documentation Copy of the OSAs are to be completed in black ink.
Any corrections are to be initialed by the Qualifier and the employee.
4.1.2 When a Skill Assessment is administered or training is given, the appropriate sections
of the Supervisor’s Documentation Copy of the OSAs shall be completed the same
day (if possible) that the Skill Assessment or training was administered.
4.1.3 When an employee attempts to qualify on Skill Assessments at CLDC, documentation

will be forwarded by the Trainer to the employee's Supervisor. The Superintendent will
document it in the appropriate section of the Supervisor's Documentation Copy of the
OSAs and retain the document on file.
4.1.4 Supervisors and O&M employees who provide OJT or verify the skills in an OSA shall
print their full name and sign their initials in the space provided in the Supervisor’s
Documentation Copy of the OSAs.
4.2 When an employee has satisfactorily completed all of the Skill Assessments within an OSA,
the Supervisor’s Documentation Copy of the OSAs and any other associated documentation
shall be signed by the Superintendent and then forwarded to the CABGOC Operations Manager
for review. It shall then be forwarded to CLDC. CLDC will then enter the information from the
Supervisor’s Documentation Copy of the OSAs on the employee's permanent training record
in KnowledgePlanet. The Supervisor’s Documentation Copy of the OSAs and all pertinent
documentation will be permanently retained.
4.3 If an employee is transferred, any incomplete Supervisor’s Documentation Copy of the OSAs
in an employee's field file shall be forwarded to the new Superintendent.
4.4 After an employee completes any formal training and the required OSA for one classification
above their present position in their career path, a new or current performance evaluation (one
within 12 months) shall be submitted to the CABGOC Operations Manager with the completed
Supervisor’s Documentation Copy of the OSAs.
x MECHANIC 17-18
JOB DESCRIPTION
MAINTENANCE TECHNICIAN GRADE 17
I. WORK PERFORMED: A. Summary: Brief overall picture of the job and its objectives. B. Scope: Size, area, or similar
measure of job in specific terms such as sales, throughput, equipment, organizations served, etc., include typical assignments
where pertinent. C. Functions: In terms of what, how, and why. Show % of time spent on each function.
A. SUMMARY: A fully qualified Maintenance Technician Grade 17 diagnoses problems and performs
repair and maintenance work on a wide variety of oil field or plant mechanical equipment. Actively
supports Incident Free Operation (IFO) through their actions.
NOTE: Has been verified in all skills necessary for the Maintenance Technician Grade 17
classification. Must successfully complete the Maintenance Technician Grade 18 Operations Skill
Assessments to be eligible for future promotion to the Maintenance Technician Grade 18 level.
B. SCOPE: Equipment may include, but is not limited to, internal combustion engines, air
compressors, centrifugal pumps, chemical pumps, water makers, filteration equipment, hoisting
equipment, turbine generators, ignition and safety control systems.
C. FUNCTIONS: Examples of work performed and job assignments may include, but are not limited
to, the following:
1. Inspects equipment, diagnoses mechanical problems, establishes baseline performance and

either recommends to Supervisor or makes repairs within authority.
2. Performs highly skilled mechanical work such as aligning drivers with driven equipment,
installing crankshafts, camshafts and main and connecting rod bearings and bushings,
installing, aligning, and leveling engines, pumps, gearboxes and turbines and checking
crankshaft angles. Using precision measurement tools (inside and outside micrometers, dial
indicators, deflection gauges, and protractors). May disassemble and assemble power
turbines.
3. May perform detailed analyses of engines, turbines, speed reducers and increasers, pumps
etc. Using state-of-the-art techniques and equipment. Detailed work includes collecting and
interpreting operating and downtime data, preparing recommendations for corrective action,
educating Company personnel in the efficiencies and capabilities of their equipment, and
documenting equipment performance characteristics and maintenance histories for comparative
and interpretive analyses.
4. Plans and performs and / or directs lower classification Mechanics and Trainees in routine
installation, repair and maintenance work on mechanical equipment such as replacing power
pistons, timing engines, repairing pumps and gearboxes and repairing automatic engine shut-
down systems. Plans and directs or performs preventative maintenance work.
5. Performs and /or directs Mechanics in more complex repair work such as running crankshaft
deflections, checking thrust on bearings and backlash on gears.
6. Prepares necessary records and reports of overhauls, repair and maintenance work performed
for submittal to Supervisor.
7. Reviews work insuring that it is performed according to instructions, specifications and limits
of tolerance. Keeps accurate and concise reports.
MECHANIC 17- 18 xi
JOB DESCRIPTION
8. Assists in training lower classification Mechanics and Trainees. Provides guidance to contract
Mechanics.
9. Observes safety rules and regulations and continually practices good housekeeping and
actively supports IFO. Reports or corrects any unsafe conditions or practices.
10. Maintains an adequate inventory of mechanical supplies and spare parts and prepares
requisitions utilizing IMREX material ordering system for Supervisor's approval as items are
needed.
11. May assist other Company personnel in the performance of their normal duties. Performs or
directs housekeeping as required to maintain a safe working environment.
12. Supports ongoing initiatives that include safety training, compliance reviews, near miss
incidents, investigation / reporting emergency preparedness, spill reporting / response, safety
/ communications meetings and process improvement initiatives
13. Takes a proactive role in observing and reinforcing health, safety and environmental standards
and requirements in support of Operational Excellence in all aspects of the operations
consistent with Chevron management processes, Policy 530, SASBU Standard
Operating Procedures, API guidelines and other approved industry standards and
environmental practices.
II. SUPERVISION RECEIVED: A. Immediate Supervisor: Title and number of positions reporting directly to the supervisor.
B. Nature: Frequency and detail with which assignments are given, assistance and guidance provided, and extent to which
work is reviewed. C. Functional Assistance: Guidance or help from written materials or persons other than immediate
supervisor where significant.
A. IMMEDIATE SUPERVISOR: Mechanical or offshore Foreman depending on assigned area. May

receive periodic work directions from Maintenance Supervisor or Engineer..
B. NATURE: Instructions normally consist of a general out line of work to be done. Detailed
instructions and / or assistance may be given for complex assignments. Position usually
determines method of procedure. Work is evaluated by the accuracy of mechanical trouble,
determinations, the quality and speed of the repair work, and the manner in which reports are
prepared.
C. FUNCTIONAL ASSISTANCE: Company and equipment manufacturer manuals, division

construction engineering staff, and service representatives.
III. RESPONSIBILITY AND AUTHORITY: Define significant responsibilities and authorities (latitude for independent action)
regarding: A. Personnel: Number and levels of employees supervised or given work direction . B. Materials or Products.
C. Operations or Functions. D. Equipment. E. Money. F. Contacts.
xii MECHANIC 17 - 18
JOB DESCRIPTION
A. PERSONNEL: Provides work direction to Mechanics, Trainees and contract personnel. Must
have a good understanding of the English language.
B. MATERIALS OR PRODUCTS: Prepares spare parts and material requisitions utilizing IMREX
material ordering system for Supervisor's approval.
C. OPERATIONS OR FUNCTIONS: May be temporally assigned to jobs of equal or lower

classification or lesser scope for operations needs or training purposes.
IV. REMARKS: State any factors not covered above which are essential to the evaluation of this job.
NOTE: Excerpted from: Job Description (GO-400)

Titled: “Maintenance Technician Grade 17"
Date Approved: October 1, 2003
The above information is not quoted word-for-word from the GO-400. The GO-400 will take precedence
over this job description outline.
MECHANIC 17- 18 xiii

JOB DESCRIPTION
xiv MECHANIC 17 - 18
JOB DESCRIPTION
MAINTENANCE TECHNICIAN GRADE 18
I. WORK PERFORMED: A. Summary: Brief overall picture of the job and its objectives. B. Scope: Size, area, or similar
measure of job in specific terms such as sales, throughput, equipment, organizations served, etc., include typical assignments
where pertinent. C. Functions: In terms of what, how, and why. Show % of time spent on each function.
A. SUMMARY: A fully qualified Maintenance Technician Grade 18 diagnoses problems and performs
repair and maintenance work on a wide variety of oil field or plant mechanical equipment. Actively
supports Incident Free Operation (IFO) through their actions.
NOTE: Has been verified in all skills necessary for the Maintenance Tecnnician Grade 18
classification. Must successfully complete the Maintenance Technician Grade 19 Operations Skill
Assessments to be eligible for future promotion to the Maintenance Technician Grade 19 level.
B. SCOPE: Equipment may include, but is not limited to, internal combustion engines, generators,
centrifugal pumps, chemical pumps, water makers, filteration equipment, hoisting equipment,
turbine engines, ignition and safety control systems.
C. FUNCTIONS: Examples of work performed and job assignments may include, but are not limited
to, the following:
1. Inspects equipment, diagnoses mechanical problems, establishes baseline performance and

either recommends to Supervisor or makes repairs within authority.
2. Performs highly skilled mechanical work such as aligning drivers with driven equipment,
installing crankshafts, camshafts and main and connecting rod bearings and bushings,
installing, aligning, and leveling engines, pumps, gearboxes and turbines and checking
crankshaft angles. Using precision measurement tools (inside and outside micrometers, dial
indicators, deflection gauges, and protractors). May disassemble and assemble power
turbines.
3. May perform detailed analyses of engines, turbines, speed reducers and increasers, pumps
etc. Using state-of-the-art techniques and equipment. Detailed work includes collecting and
interpreting operating and downtime data, preparing recommendations for corrective action,
educating Company personnel in the efficiencies and capabilities of their equipment, and
documenting equipment performance characteristics and maintenance histories for comparative
and interpretive analyses.
4. Plans and performs and / or directs lower classification Mechanics and Trainees in routine
installation, repair and maintenance work on mechanical equipment such as replacing power
pistons, timing engines, repairing pumps and gearboxes and repairing automatic engine shut-
down systems. Plans and directs or performs preventative maintenance work.
5. Performs and /or directs Mechanics in more complex repair work such as running crankshaft
deflections, checking thrust on bearings and backlash on gears.
6. Prepares necessary records and reports of overhauls, repair and maintenance work performed
for submittal to Supervisor.
MECHANIC 17- 18 xv
JOB DESCRIPTION
7. Reviews work insuring that it is performed according to instructions, specifications and limits
of tolerance. Keeps accurate and concise reports.
8. Assists in training lower classification Mechanics and Trainees. Provides guidance to contract
Mechanics.
9. Observes safety rules and regulations and continually practices good housekeeping and
actively supports IFO. Reports or corrects any unsafe conditions or practices.
10. Maintains an adequate inventory of mechanical supplies and spare parts and prepares
requisitions utilizing IMREX material ordering system for Supervisor's approval as items are
needed.
11. May assist other Company personnel in the performance of their normal duties. Performs or
directs housekeeping as required to maintain a safe working environment.
12. Supports ongoing initiatives that include safety training, compliance reviews, near miss
incidents, investigation / reporting emergency preparedness, spill reporting / response, safety
/ communications meetings and process improvement initiatives
13. Takes a proactive role in observing and reinforcing health, safety and environmental standards
and requirements in support of Operational Excellence in all aspects of the operations
consistent with Chevron management processes, Policy 530, SASBU Standard
Operating Procedures, API guidelines and other approved industry standards and
environmental practices.
II. SUPERVISION RECEIVED: A. Immediate Supervisor: Title and number of positions reporting directly to the supervisor.
B. Nature: Frequency and detail with which assignments are given, assistance and guidance provided, and extent to which
work is reviewed. C. Functional Assistance: Guidance or help from written materials or persons other than immediate
supervisor where significant.
A. IMMEDIATE SUPERVISOR: Mechanical or offshore Foreman depending on assigned area. May

receive periodic work directions from Maintenance Supervisor or Engineer..
B. NATURE: Instructions normally consist of a general out line of work to be done. Detailed
instructions and / or assistance may be given for complex assignments. Position usually
determines method of procedure. Work is evaluated by the accuracy of mechanical trouble,
determinations, the quality and speed of the repair work, and the manner in which reports are
prepared.
C. FUNCTIONAL ASSISTANCE: Most Jobs performed with little guidance. When required, a
Maintenance Technician Grade 18 competently refers to manufactures and other manuals to
perform work assignments.
III. RESPONSIBILITY AND AUTHORITY: Define significant responsibilities and authorities (latitude for independent action)
regarding: A. Personnel: Number and levels of employees supervised or given work direction . B. Materials or Products.
C. Operations or Functions. D. Equipment. E. Money. F. Contacts.
xvi MECHANIC 17 - 18
JOB DESCRIPTION
A. PERSONNEL: Provides assistance to Operations when it comes to making decisions about

mechanical problems. May assist with work priorities dealing with mechanical issues. Has a good
working knowledge of the Operations, Mechanical, and Electrical disciplines. Must be capable of
writing concise reports in English.
B. MATERIALS OR PRODUCTS: Prepares spare parts and material requisitions utilizing IMREX
material ordering system for Supervisor's approval.
C. OPERATIONS OR FUNCTIONS: May be temporally assigned to jobs of equal or lower

classification or lesser scope for operations needs or training purposes.
D. EQUIPMENT: May make modifications to mechanical / rotating equipment to improve the process
as approved by the Maintenance Supervisor. Utilizes the "Management of Change" process.
E. CONTACTS: Company or other regulatory agencies.
F. SKILL ENHANCEMENT: It is recommended that the Maintenance Technician Grade 18 receive

additional training with the following disciplines: Turbine Mechanic, Field Training Coordinator, HES
Coordinator, Maintenance Foreman, Mechanical Engineers, I&E Reps, or any others that may
enhance their career advancement.
IV. REMARKS: State any factors not covered above which are essential to the evaluation of this job.
NOTE: Excerpted from: Job Description (GO-400)

Titled: “Maintenance Technician Grade 18"
Date Approved: October 1, 2003
The above information is not quoted word-for-word from the GO-400. The GO-400 will take precedence
over this job description outline.
MECHANIC 17- 18 xvii

JOB DESCRIPTION
xviii MECHANIC 17 - 18
LIST OF COMPETENCIES
100. SAFETY, POLICY, EQUIPMENT, AND PROCEDURES
Completed:
Initials/Date
_____/_____ 17 OSA 101 State the lock colors used in Lockout/Tagout procedures.
_____/_____ 18 OSA 102 Participate in a Root Cause Analysis (RCA) on a recent incident.
_____/_____ 17 (AQ) OSA 103 Explain Zero Mechanical State (ZMS)
_____/_____ 17 OSA 104 Acquire and fill out a General "Permit To Work".
_____/_____ 17 OSA 105 Lockout and tagout a turbine package.
_____/_____ 17 OSA 106 Lockout and tagout an electric motor.
_____/_____ 17 (AQ) OSA 107 Return a locked out and tagged out piece of equipment to the in-
service position.
_____/_____ 17 OSA 108 Acquire and fill out a “Hot Work” permit
_____/_____ 17 OSA 109 Acquire and fill out a “Bypass Approval” permit.
_____/_____ 18 OSA 110 Acquire and complete a "Management of Change" (MOC) for
surface equipment.
_____/_____ 17 OSA 111 Explain when and why to use a “Confined Space Entry Permit”.
_____/_____ 17 OSA 112 Complete a Job Safety Analysis (JSA) for a maintenance task.
_____/_____ 17 OSA 113 Demonstrate the procedure to open a “Work Order” in JDE.
_____/_____ 17 OSA 114 Demonstrate the procedure to locate and requisition material
against a “Work Order”.
_____/_____ 17 OSA 115 Demonstrate the procedure to close a “Work Order” including
proper Reason for Work(RFW) codes in JDE.
_____/_____ 18 OSA 116 Demonstrate the procedure to purchase material against an

“Order Requisition” (OR).
MECHANIC 17-18 xvii

200. TOOLS AND MEASUREMENT DEVICES
Completed:
Initials/Date
_____/_____ 17 (AQ) OSA 201 Explain using a cylinder liner puller.
_____/_____ 17 OSA 202 Explain the use of a thermographic camera in performing a

thermal survey and state some of the advantages of it's use.
_____/_____ 17 OSA 203 Demonstrate the proper use of a Digital multi-meter.
_____/_____ 17 OSA 204 Demonstrate the use of a photo tachometer.
_____/_____ 18 OSA 205 Measure and record a centrifugal pump's wear ring dimensions.
_____/_____ 18 (AQ) OSA 206 Explain the use of a Bore Scope.
_____/_____ 18 OSA 207 Demonstrate the proper use of a torque multiplier
300. NATURAL GAS ENGINE (FOUR-CYCLE)
Completed:
Initials/Date
_____/_____ 18 (AQ) OSA 301 Explain the steps to troubleshoot an engine that has coolant in
the crankcase.
_____/_____ 17 OSA 302 Explain the steps to troubleshoot an engine that has excessive
pressure in the crankcase.
_____/_____ 17 OSA 303 Explain the steps to troubleshoot an engine that shuts down on
high oil temperature.
_____/_____ 17 (AQ) OSA 304 Explain the steps to troubleshoot an engine that shuts down on
low oil pressure.
_____/_____ 17 OSA 305 Explain the principle of operation of a carburetor.
_____/_____ 18 OSA 306 Balance the load on a naturally aspirated "V" block engine.
_____/_____ 18 OSA 307 Remove and install a power cylinder head on a natural gas.
_____/_____ 18 OSA 308 Remove, inspect, and install a piston and rod assembly on a
natural gas engine.
xviii MECHANIC 17-18

Completed:
Initials/Date
_____/_____ 18 OSA 309 Remove, inspect, and install a power cylinder liner on a
natural gas engine.
_____/_____ 18 OSA 310 Explain the main bearing torqing procedures for a Waukesha
VHP Series engine.
400. DIESEL ENGINE
Completed:
Initials/Date
_____/_____ 18 OSA 401 Remove and install a fuel injection pump on a 4-cycle diesel.
_____/_____ 18 OSA 402 Remove and install a blower on a Detroit Diesel inline engine.
_____/_____ 17 OSA 403 Adjust the valves on a four-valve head diesel engine.
_____/_____ 18 OSA 404 Remove, install and adjust a fuel injector control tube assembly
(rack) on a Detroit Diesel engine.
_____/_____ 18 (AQ) OSA 405 Inspect a turbo charger on a diesel engine.
_____/_____ 17 OSA 406 Explain the procedure to perform an annual Preventive

Maintenance (PM) task on a diesel engine.
500. GAS TURBINE ENGINE
Completed:
Initials/Date
_____/_____ 17 OSA 501 Disassemble, inspect, and reassemble the combustor assembly
on a Solar Saturn Gas producer.
_____/_____ 18 (AQ) OSA 502 Explain the possible causes of high exhaust gas temperature.
(EGT)
_____/_____ 18 OSA 503 Explain the purpose and principle operation of a variable guide
vane system on a gas turbine engine.
_____/_____ 17 (AQ) OSA 504 Explain the principle of operations of the secondary gas fuel
valve of a gas turbine engine.
MECHANIC 17-18 xix

Completed:
Initials/Date
_____/_____ 17 OSA 505 Explain the principle of operation of the gas fuel control valve on
a gas turbine engine.
_____/_____ 18 OSA 506 Explain the adjustment procedure for the number one loader on
the gas fuel control valve.
_____/_____ 18 OSA 507 Remove, inspect and install the filter element and poppet valve
in a gas fuel control valve of a Solar gas turbine engine.
_____/_____ 17 (AQ) OSA 508 Check the backup post-lube pump of a gas turbine engine for
proper operation.
_____/_____ 17 OSA 509 Explain the start-up procedure from the control panel/console of
a Solar turbine compressor.
_____/_____ 17 OSA 510 Change the lube oil filters of a Solar gas turbine engine.
_____/_____ 18 OSA 511 Remove and install the diffuser O-Ring tube on a Solar gas
turbine engine.
_____/_____ 17 (AQ) OSA 512 Disassemble, inspect and reassemble a spare or removed bleed
valve on a Solar gas turbine engine.
_____/_____ 17 OSA 513 Detergent wash a gas turbine engine.
_____/_____ 17 OSA 514 Explain the flow of the seal oil system of a gas turbine engine.
_____/_____ 18 (AQ) OSA 515 Explain the function of a dry gas seal in a turbine compressor.
_____/_____ 18 OSA 516 Start, synchronize and load a turbine generator.
_____/_____ 18 OSA 517 Trace the gas flow through and explain the functions of the major
components of a turbine driven centrifugal compressor including
surge control.
600. IGNITION SYSTEMS
Completed:
Initials/Date
_____/_____ 17 OSA 601 Check the output voltage on a spare or removed Altronic III
ignition unit.
_____/_____ 17(AQ) OSA 602 Explain the term and probable causes of an engine backfiring.
xx MECHANIC 17-18
Completed:
Initials/Date
_____/_____ 18 (AQ) OSA 603 Explain the probably causes of an misfiring ignition.
_____/_____ 18 OSA 604 Identify and explain the function of an Altronic CPU 95 ignition
system.
700. COOLING SYSTEMS
Completed:
Initials/Date
_____/_____ 18 (AQ) OSA 701 Explain what effect fan pitch has on horsepower or amps.
_____/_____ 17 OSA 702 Explain steps to troubleshoot a unit that is shutting down on high
water temperature.
_____/_____ 18 OSA 703 Remove and install a water pump on an engine.
900. STARTER SYSTEMS
Completed:
Initials/Date
_____/_____ 17 OSA 901 Explain the principle of operation of a typical turbine type starter.
_____/_____ 17 OSA 902 Explain the principle of operation of a direct AC type starter
system.
_____/_____ 17 OSA 903 Explain the principle of operation of a vane-type pneumatic

starter system.
1000. GOVERNERS
Completed:
Initials/Date
_____/_____ 17 OSA 1001 Remove, inspect and reinstall a magnetic pickup.
_____/_____ 18 OSA 1002 Adjust the compensating needle valve in a Woodward EP2
hydraulic governor.
MECHANIC 17-18 xxi

Completed:
Initials/Date
_____/_____ 18 (AQ) OSA 1003 Adjust the governor linkage on a hydro mechanical governor.
_____/_____ 18 OSA 1004 Explain the principle of operation of a Woodward 2301 governor.
1100. POSITIVE DISPLACEMENT PUMPS
Completed:
Initials/Date
_____/_____ 17 (AQ) OSA 1101 Explain the possible causes of knocking in the fluid end in a
positive displacement pump.
_____/_____ 18 OSA 1102 Replace a valve and seat in a positive displacement pump.
_____/_____ 17 OSA 1103 Replace a plunger and seal in a positive displacement pump.
_____/_____ 17 OSA 1104 Disassemble and reassemble a double diaphragm pump.
_____/_____ 18 OSA 1105 Explain the function of the major components of a progressive
cavity type pump.
_____/_____ 17 OSA 1106 Explain the principle of operation of a gear type pump.
1200. CENTRIFUGAL PUMPS
Completed:
Initials/Date
_____/_____ 18 OSA 1201 Disassemble, inspect, set the impeller clearance and reassemble
a single-stage horizontal pump.
_____/_____ 18 OSA 1202 Disassemble, inspect, set the impeller clearance and reassemble
a single-stage vertical pump.
xxii MECHANIC 17-18

1300. AIR COMPRESSORS
Completed:
Initials/Date
_____/_____ 18 (AQ) OSA 1301 Explain the steps to troubleshoot an air compressor that runs but
does not compress air.
_____/_____ 17 OSA 1302 Trace the flow of air through a rotary (screw) air compressor
system.
_____/_____ 17 OSA 1303 Explain the function of an inlet control valve on a rotary (screw)
air compressor.
_____/_____ 17 (AQ) OSA 1304 Explain the function of the lubricating system on a rotary (screw)
air compressor system.
1900. CLUTCHES
Completed:
Initials/Date
_____/_____ 17 (AQ) OSA 1901 Explain the purpose of a clutch.
_____/_____ 17 OSA 1902 Explain the principle operation of a Sprague type clutch.
2200. ALIGNMENT
Completed:
Initials/Date
_____/_____ 17 OSA 2201 Define soft foot and explain the method used to check and
correct it.
_____/_____ 17 OSA 2202 Define indicator arm sag and explain the method used to check
and compensate for it.
_____/_____ 17 OSA 2203 Explain the items that should be checked prior to aligning a unit.
MECHANIC 17-18 xxiii

Completed:
Initials/Date
_____/_____ 17 OSA 2204 Perform a face (angular) and rim (parallel) alignment.
_____/_____ 18 OSA 2205 Demonstrate the procedure to perform a reverse alignment on a

pump.
_____/_____ 18 OSA 2206 Demonstrate the procedure to perform a laser alignment on a

pump.
_____/_____ 18 OSA 2207 Explain thermal growth and it's effect on alignment.
2300. GEARBOXES
Completed:
Initials/Date
_____/_____ 18 OSA 2301 Explain how to adjust the thrust on a gearbox shaft equipped with
tapered roller bearings.
_____/_____ 18 (AQ) OSA 2302 Explain the items that could cause unusual vibration and noise
in a gearbox.
2400. COUPLINGS
Completed:
Initials/Date
_____/_____ 17 (AQ) OSA 2401 Explain the purpose of a flexible coupling
_____/_____ 17 OSA 2402 Explain the types of couplings used in offshore applications.
_____/_____ 18 OSA 2403 Remove, inspect, and reinstall a grid coupling.
_____/_____ 17 OSA 2404 Explain the importance of determining the magnetic center of a
sleeve bearing type motor.
xxiv MECHANIC 17-18

6000. COMPUTER BASED TEST
Completed:
Initials/Date
_____/_____ 18 OSA 6001 Complete a randomly selected Production Maintenance computer

(CLDC base test (CBT) for the Maintenance Technician Pay Salary
ONLY) Grade 18 level.
MECHANIC 17-18 xxv

xxvi MECHANIC 17-18

SAFETY, POLICY, EQUIPMENT AND PROCEDURES
SAFETY, POLICY, EQUIPMENT AND
PROCEDURES
OSA 101
COMPETENCY
State the lock colors used in Lockout / Tagout procedures.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee state the lock colors used in Lockout / Tagout procedures.
PROCEDURE
'The employee will explain as follows: (Appendix 1)
1. Locks should be color coded as follows:
Group Color Code Warehouses Symbol No.
Operators Yellow 555355790
Mechanics Blue 555355792
Electricians Red 555355794
Instrument Technicians Green 555355796
Facilities Engineering White 555355798
General None 555355000
MECHANIC 17-18 1
OSA 102
COMPETENCY
Participate in a Root Cause Analysis (RCA) on a recent incident.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee participate in a Root Cause Analysis (RCA) on a
recent incident. The Qualifier will select a recent incident and have the employee participate in the Root
Cause Analysis. The employee will assist in completing (Appendix 2), providing full details about the
incident. Employee will submit the completed RCA to the Qualifier for review and approval for completion
of this Assessment.
PROCEDURE
The employee will demonstrate as follows:(Appendix 2)
Note:The following basic SASBU Root Cause Categories have been developed as a guide for putting
root causes into a database. In any incident, several of these basic causes may play a role. The table is
broken down into Basic Cause Category - Explanation - Example
1. Risk Assessment:
Were the risks perceived correctly? Were the risk management processes used correctly? Was there
a failure in the PHA process? ( I.e. risk ranking not used / required or JSA not completed).
2. Procedures & Safe Work Practices:

Are plant specific and / or general procedures in place? Were they used correctly? Were safe work
practices such as hot work, Lockout / Tagout and confined space entry employed? (I.e. no Lockout /
Tagout procedure used, procedure not adequate, or use of procedure not emphasized / supported).
3. Procedure not adequate:

Use of procedure not emphasized/ supported
4. Design:
Was there a design review? Were codes and standards followed? Was human / behavior engineering
considered? Does design incorporate the principles of inherent safety? (I.e. no design review required,
design did not consider human factors, CPDEP not used).
2 MECHANIC 17-18
5. Pre-Startup Safety Reviews :

Was the PSSR procedure established and followed? Was the PSSR adequate? (I.e. no PSSR
conducted prior to startup, not emphasized by management).
6. Inspection / Quality Control :

Were the appropriate inspections requested and made? Were the proper materials used? Were they
installed correctly? Is there an inspection schedule and was it followed? (I.e. wrong material installed
- no positive material identification process).
7. Preventive Maintenance / Repeat Failure:

Was recommended maintenance carried out, either scheduled or due to prior failure? (I.e. no preventive
maintenance program).
8. Human Factors:
This includes confusion, fatigue, substance abuse, and all causes where human factors are not due
to failure of other systems such as training deficiencies or scheduling of work. (I.e. alarms not prioritized
because human factors review not included in design process (this could also fall under design or
training).
9. Management of Change :
Was there an MOC system in place? Did the MOC system fail? Was it followed? (I.e. no MOC process,
MOC not used-commonly viewed as not worthwhile).
10. Training :
Did a training deficiency in any way contribute to this incident? (I.e. employee missed training session
and no system to ensure all training carried out).
11. Contractor Safety ;

Is there a process that ensures that all contractors hired, meet the standards for company systems?
(I.e. contractor safety records not audited by Company).
12. Communications :
Have instructions been conveyed clearly? Have recommendations been passed on and confirmed? Are
turnover logs used as a communication tool? What systems ensure correct interpretation of
communication? (I.e. no end of shift written turnover required, Instructions not understood and no
process to confirm understanding).
13. Supervision :
Was there adequate oversight to understand the “big picture”? Did supervisors and management hold
employees accountable for their actions? Did they audit the process? Did they foster teamwork? (I.e.
job planning was less then adequate, Supervisor was not aware of the activity).
14. Incident & Near Miss Investigation :

Did a previous incident or near miss recommend action that would have prevented this incident? Did
lack of investigating a previous incident contribute to this incident? (I.e. near miss reporting and
investigation not required).
MECHANIC 17-18 3
15. Emergency Response:

Did emergency response in any way contribute to the magnitude of this incident? Could better
emergency response have mitigated or terminated this incident sooner? (I.e. no system to ensure Local
Fire Department trained in hydrocarbon fire fighting techniques).
16. Natural Phenomenon:

This includes items out of our control (I.e. flood, earthquake, tornado, hurricane, etc.).
4 MECHANIC 17-18
OSA 103 (AQ)
COMPETENCY
Explain Zero Mechanical State (ZMS).
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain Zero Mechanical State (ZMS).
PROCEDURE
The employee will explain as follows:
1. Zero Mechanical State represents the maximum protection against one of the following when
maintenance or repair is required.
a. Unexpected movement or activation of equipment or machinery.

b. Release of stored pressure.
c. Flow of liquid or gas.
MECHANIC 17-18 5
OSA 104
COMPETENCY
Acquire and fill out a "General Permit to Work".
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee acquire and fill out a "General Permit to Work". The
Qualifier will select a task that requires completion of a "General Permit to Work". Employee will submit the
completed permit to the Qualifier for review and approval for completion of this Assessment.
PROCEDURE
The employee will demonstrate as follows: (Figure 1)
1. Secure a General Permit to Work form and complete for the task assigned.
2. Except as noted, a “ General Permit to Work” must be completed before work can begin in any
operating area.
3. Exceptions may be granted at the discretion of the Person In Charge (PIC) under the following
circumstances:
a) Repairs, adjustments, and replacements within the scope of on-site Craft personnel are
conducted without the assistance of off-site mechanics, technicians, or other personnel.
b) Routine services crafts work, supervised by a services craftsman, within the scope of his/
her job duties, and using only services personnel (i.e. plumbing repairs, lamp replacement,
etc.).
c) Work is to be performed under a separate plan that addresses the safety requirements listed
on the Permit to Work.
4. Additional permits are required when specialized work activities such as hot work, confined space
entry, excavations, etc. are performed. Permitting requirements for specialized work may be found
in the SASBU SOP publications.
5. A General Permit to Work should be applied for no later than twelve (12) hours prior to the initiation
of the work.
6 MECHANIC 17-18
Figure 1: General Work Permit
MECHANIC 17-18 7
OSA 105
COMPETENCY
Lockout and tagout a turbine package.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee lockout and tagout a turbine package. The
Qualifier will select a stand-by turbine package and have the employee conduct a lockout / tagout
procedure to ensure the unit is safe for a routine maintenance task. Employee will be allowed to use
(Appendix 1).
PROCEDURE
The employee will demonstrate as follows: (Appendix 1).
NOTE: The steps listed below outline a generic procedure. Always follow facility shutdown and start-
up standard operating procedures.
1. Conduct a JSA and notify all affected personnel.
2. Shut down the turbine if applicable by normal stopping procedures.
3. Open the manually-operated electrical circuit breaker feeding the control panel.
4. Install a lockout device on the locking mechanism of the main circuit breaker.
5. Fill out a "Danger" tag and place it on the locking mechanism on the main circuit breaker.
6. Close the fuel gas block valves or blind flange as needed.
7. Bleed down any pressure trapped between the block valves.
8. Install a lockout device on each closed valve.
8 MECHANIC 17-18
9. Fill out a “Danger” tag and place it on the locking mechanism on each closed valve.
10. Attempt to activate the motor control and ensure that the turbine does not start.
11. Return turbine back to stand-by staus by:
a. Removing locks, tags and return all fuel gas valves to normal position.
b. Removing locks, tags and return main circuit breaker to normal position.
MECHANIC 17-18 9
OSA 106
COMPETENCY
Lockout and tagout an electric motor.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee lockout and tagout an electric motor. The
Qualifier will select a stand-by electric motor and have the employee conduct a lockout / tagout
procedure to ensure the motor is safe for a routine maintenance task. Employee will be allowed to use
(Appendix 1).
PROCEDURE
The employee will demonstrate as follows: (Appendix 1).
NOTE: The steps listed below outline a generic procedure. Always follow shutdown and
start-up standard operating procedures.
1. Conduct a JSA and notify all affected personnel.
2. Shut down the machine or equipment by normal stopping procedures
3. Open the manually operated electrical circuit breaker.
4. Install a lockout device on the locking mechanism of the main circuit breaker. Ensure to check for
alternate power sources and lockout if applicable.
5. Fill out a "Danger" tag and place it on the locking mechanism on the main circuit breaker.
6. Attempt to activate the motor control and ensure that the motor does not start.
7. Return the motor back to stand-by status by:
a. Removing locks, tags and return main circuit breaker to normal position.
10 MECHANIC 17-18
OSA 107 (AQ)
COMPETENCY
Return a locked out and tagged out piece of equipment to the in-service position.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee return a locked out and tagged out piece of
equipment to the in-service position. The Qualifier will select a locked out piece of equipment and have
the employee follow the procedure to return to the in-service position. Employee will be allowed to use
(Appendix 1).
PROCEDURE
The employee will demonstrate as follows:(Appendix 1).
NOTE: The steps listed below outline a generic procedure. Always follow facility shutdown and start-
up standard operating procedures.
1. Inspect the work area to ensure nonessential items have been removed and that the machine or
equipment are operationally intact.
2. Inspect the work area to ensure that all affected personnel are safely positioned.
3. Ensure all safety devices, guards, etc., are properly installed.
4. Notify all affected personnel that the lockout and tagout devices will be removed.
5. Remove all lockout and tagout devices.
6. Return all valves, switches, circuit breakers, etc., that were locked out and tagged out to the in-service
position.
MECHANIC 17-18 11
OSA 108
COMPETENCY
Acquire and fill out a “Hot Work” permit.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee acquire and fill out a “Hot Work” permit. The
Qualifier will select a task that requires completion of a "Hot Work" permit. Employee will submit the
completed permit to the Qualifier for review and approval for completion of this Assessment. Employee
will be allowed to use the Standard Operating Procedure for "Hot Work"
PROCEDURE
Employee will demonstrate as follows: (Figures 2 and 3)
1 Secure a "Hot Work" permit and complete for the task assigned.
2. Except as noted in the Standard Operating Procedures, a "Hot Work" permit must be completed before
work can begin in any operating area.
Hot Work
1. Any work activities that introduce a potential ignition source of any kind to the job site, including but not
limited to, activities such as welding, cutting, brazing, burning, grit-blasting, use of electrical power tools
(drill, sander, grinder, etc.), use of matches or lighters, operation of portable internal combustion engines
(that are not a properly designed and permanently installed part of the facility), driving vehicles into an
electrically classified area, i.e., tank impounding basins, etc.
2. Before hot work is authorized and started, there shall be thorough communication among all employees
and contractors involved. The meetings will be conducted by the PIC and recorded in the job logbook.
All personnel shall be instructed on the job to be performed, permit restrictions, potential work site
hazards, and the need to be on the alert for changing conditions that might increase the fire hazard.
12 MECHANIC 17-18
3. A "Hot Work Permit" for a specific job is valid for only that day or that shift. If the work is not
completed, a new permit must be issued before hot work may resume. The permit shall be
approved only after the original permit precautions plus any additional precautions are verified.
If work has been interrupted for more than 30 minutes for any reason, gas testing shall be
repeated before hot work resumes. If the hot work is stopped as a precautionary measure
because of hazardous (yet normal) operating conditions or activities, i.e., pigging, hot-oiling,
generator shutdown, etc., it may be resumed under the existing permit provided the PIC verifies
that:
a) Current operating conditions are essentially the same as those that existed when the
permit was originally issued.
b) Gas testing proves the area is still safe.
Responsibilities for Hot Work in Restricted Areas
1. Supervisor
a) The first-line Supervisor of the PIC, and/or of the facility or job in question, is responsible
for requesting the hot work to be done and for obtaining the Area Superintendent's
approval of the "Hot Work Permit". The Supervisor, in consultation with those involved
in the work,shall identify the permit restrictions that apply to the job. When the
Supervisor is satisfied with the permit, he/she should sign it and recommend to the Area
Superintendent that the permit be approved. The Supervisor shall sign the permit before
the permit is valid.
2. Person-In-Charge (PIC)
a) The PIC is responsible for completing the "Hot Work Permit", for inspecting the hot work
area to ensure the conditions of the permit are fully met, and for determining if there are
any planned activities (pigging, hot oiling, etc.) that may affect the hot work.
3. Person Performing the Hot Work (PPW)
The Person Performing Work shall:
a) Assist the PIC in inspecting the work area for potential fire and explosion hazards
before hot work begins.
b) Sign the Hot Work Permit (see "WORK MAY SAFELY BEGIN") and ensure that the
hot work is performed in accordance with the permit restrictions and conditions.
c) Be on alert for changing conditions in the hot work area, or on decks above or below
the area, that may increase the fire hazard, and report these changes to the PIC
or shut down the hot work if warranted.
MECHANIC 17-18 13
4. Permitting and Recordkeeping
a) During planning of any hot work, the first-line Supervisor shall obtain the necessary
approval from the Area Superintendent (or equivalent level of management), or from a
supervisor delegated this responsibility in the Area Superintendent's absence, for
conducting hot work.
b) The originals of "Hot Work Permits" shall be retained for one year at a location designated
by the Area Superintendent or equivalent level of management.
c) All required records or logs shall be kept for one year from the date of the work. If a permit
was approved via verbal authorization, upon completion of the work a copy of the "Hot Work
Permit", showing the unique control number, shall be sent by the PIC to the Area
Superintendent (or equivalent level of management) so it can be filed with the log.
d) The PPW shall retain a copy of the permit while at the job and shall comply with its
conditions. Upon completion, stoppage, or shutdown of the work, the PPW shall return his/
her copy to the PIC.
e) "Hot Work Permits" are only valid for the date of issue. If the nature of the job changes, the
job extends to the next day, or permit conditions can no longer be followed, the permit shall
be suspended and a new permit shall be issued.
14 MECHANIC 17-18
Figure 2: Hot Work Permit
MECHANIC 17-18 15
Figure 3: Hot Work Permitting Flowchart
16 MECHANIC 17-18
OSA 109
COMPETENCY
Acquire and fill out a “Bypass Approval” permit.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee acquire and fill out a “Bypass Approval”
permit. The Qualifier will select a piece of equipment that has safety devices associated with it and
have the employee complete a "Bypass Approval" permit to place the equipment in bypass for routine
maintenance. Employee will submit the completed permit to the Qualifier for review and approval for
completion of this Assessment.
PROCEDURE
Responsibilities and Requirements for Bypassing or Isolating Safety System Devices

1. Functional and operational Safety devices are a critical component of our safety systems. They
ensure safe, reliable, and environmentally sound operations consistent with the “Company Policy”.
This approach is in alignment with the 3rd Tenet of Operational Excellence; “Ensure safety devices
are in place and functional”.
2. All operations, maintenance, and contractor personnel that may for any reason need to bypass a
Safety device during normal work routines must understand and follow this procedure. Operational
Foremen and Supervisors must be aware of the risks associated with bypassing safety devices
and help to mitigate these risks by following this procedure.
3. For the purpose of this procedure, the words “bypass”, “isolate”, “override”, “inhibit”, “jumper”,
“block”, “disable” or any other term used to describe the temporary act of disabling a safety device
or system should be considered synonymous.
4. Verbal approvals to bypass, isolate, or remove safety system devices are not allowed.
5. Bypassing, isolating, or removing safety devices during upset/abnormal operating conditions in

order to maintain production is forbidden.
6. Facility Supervisors must pre-approve all actions to bypass, isolate, or remove safety system
devices using the "Permit to Work" system, and a "Safety Device Bypass Permit". The individual
seeking to bypass, isolate, or remove a safety system device shall have an approved
"General Work Permit" before doing so.
MECHANIC 17-18 17
Exceptions:
1. During planned/scheduled testing of the device.
2. During equipment start-up or shutdown when bypass or isolation is specified in written facility or
manufacturer operating procedures, or is a normal operating constraint dictated by the equipment
design.
3. In the cases above, the device will be taken out of service for the minimum amount of time required
to complete the activity. A qualified Operator will be posted in the best possible location, either
control room or field, in order to monitor and control the system during the time a device is out of
service.
4. Violation of the permitting system may result in disciplinary action up to and including termination,
according to HR policy.
18 MECHANIC 17-18
CAB-54, Autorização para Desvio de Dispositivos de

Segurança
Date of Bypass Time of Bypass

Data do desvio: Hora do desvio:
Device to be bypassed
Dispositivo a ser desviado:
Tag Number of Device

No. de etiqueta do dispositivo:
Operator on Duty
O operador de serviço:
Reason for Bypass

Razões do desvio:
Steps to be taken to reduce risk during device bypass or out of service.

Passos a seguir para a redução de riscos enquanto se desvia ou se interrompe o funcionamento do
dispositivo.
Approved By
Aprovado Por:
Date Back in Service Time Back in Service

Data da reposição em serviço: Hora da reposição em Serviço:
Operator on Duty
O operador de serviço:
Figure 4: Bypass Approval Permit
MECHANIC 17-18 19
OSA 110
COMPETENCY
Acquire and complete a "Management of Change" (MOC) for surface equipment.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee acquire and complete a "Management of
Change" (MOC) for surface equipment. The Qualifier will select an existing pump and have the
employee complete a "Management of Change" for a pump capacity upgrade. The employee will
submit the completed form to the Qualifier for review and approval for completion of this Assessment.
PROCEDURE
The employee will demonstrate as follows: (Figures 5 and 6)
1. The MOC applies to all changes to processes and equipment, feed streams, and chemicals in
production or services functions that should be evaluated, documented and communicated.
2. This MOC applies to all SASBU production facilities that involve producing, handling, or storing large
quantities of crude oil, natural gas, associated flammable petroleum products, or produced/injection
water.
a) Covered facilities include production lines and equipment, from the wellhead, through separation
and treating/processing (both onshore and offshore), to storage, and onto (but not including) export
vessels, inclusive of all utilities. Power generation and distribution systems under the management
of the Production Department are also covered by this procedure.
3. The MOC may be initiated by any SASBU employee. Any work that results in a “Change” to a covered
production facility or utility system requires completion of a MOC form. The originator must fill in his
or her name, the production or operating area where the “Change” is planned, and the current date. The
originator completes Part 1, Description of Change, on the MOC form. The originator is responsible for
providing sufficient information to clearly and completely describe the “Change”, and the personnel (if
any)
4. The originator completes Part 1, Description of Change, on the MOC form. The originator is responsible
for providing sufficient information to clearly and completely describe the “Change”, and the personnel
(if any) affected by that “Change”. If the description is extensive, attach separate documents, or
continue in Section 0 “Additional comments.” A clearly marked, red lined drawing, preferably a P&ID,
should be attached to the MOC form to detail the exact requirements of the “Change”.
20 MECHANIC 17-18
5. The originator completes Part 2, Reason for Change, on the MOC form. The originator is responsible
for providing sufficient information to clearly and completely justify the “Change”. The originator should
explain if the “Change” would improve Safety, environmental, or operational conditions (i.e., productivity
or economic improvement) within the facility.
6. The MOC process should be used on any not in kind change including, but not limited to, the following
examples:
a) Installation of new platform or processing or utilities equipment
b) Removal from service or abandonment of processing facilities or equipment
c) The utilization of new chemicals or stimulation practices
d) Changes in fluids, pressures or temperatures in existing systems
e) Changes in operating parameters (pressure, temperature, flow rates, chemistry) outside of

the defined limits of the existing process
f) Addition or deletion of a process chemical
g) Electrical upgrades, removal, or reclassification
h) SCADA control changes outside of established operating procedures or limits, and program
sequence changes
i) Movement or installation of surface process pumping systems for the purpose of capacity
upgrades
j) New facility installations (compressors, generators, panel boards, …)
k) Changing a safety valve size or type
l) Any movement of buildings or other significant weights on facilities
Examples of when the MOC process does not need to be used:
1) In kind changes where the manufacturer or capacity or the operation limits of the new
equipment do not cause an HES risk
2) Change in liquid level, temperature or pressure set points within established operating ranges
3) Minor facility modifications or maintenance activities which do not affect process safety
information, operating procedures, facility safety or environmental risk.
MECHANIC 17-18 21
Figure 5: Management Of Change Form
22 MECHANIC 17-18
Figure 6: Management Of Change Workflow
MECHANIC 17-18 23
OSA 111
COMPETENCY
Explain when and why to use a “Confined Space Entry" permit.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain when and why to use a “Confined Space
Entry" permit.
PROCEDURE
The employee will explain as follows: (Figures 7 and 8)
1. Confined space operations should be avoided if possible (for example, waiting until a tank roof is
raised before entering onto the roof). When a confined space operation is necessary, an approved
"Confined Space Entry" permit shall be prepared before the confined space entry is started.
2. Work involving entry into confined spaces can introduce suffocation, physical entrapment, and
chemical exposure hazards into the workplace. The procedure is designed to help Supervisors
manage the risks associated with confined space entry by establishing minimum requirements for
confined space operations.
3. Supervisors may, at their discretion, establish more restrictive requirements based on their
knowledge and assessment of the hazards associated with work conducted in confined spaces.
4. Any variance from this procedure shall be specified on the "Confined Space Entry" permit and
authorized by the Area Superintendent or equivalent level of management responsible for the
facility.
5. Confined spaces include all areas or pieces of equipment where:
a. The space is large enough and designed to allow an employee to enter and perform work
and;
b. One or both of the following also apply:
1. The interior atmosphere is hazardous (or has the potential to become hazardous) or
the interior contains electrical or mechanical hazards capable of causing serious
injury.
2. Entry or egress is difficult, impaired or restricted.
6. Examples of confined spaces are: pipelines, tunnels, tanks, vessels, roofs of floating roof tanks
(when the roof is 5 feet or more below the top of the shell), heaters, compartments, ducts,
sewers, pits, cellars, or any similar locations.
24 MECHANIC 17-18
Figure 7: Confined Space Entry Permit
MECHANIC 17-18 25
Figure 8: Confined Space Entry Permit
26 MECHANIC 17-18
OSA 112
COMPETENCY
Complete a Job Safety Analysis (JSA) for a maintenance task.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee complete a Job Safety Analysis (JSA) for a
maintenance task. The Qualifier will select a piece of equipment with a mechanical problem and have
the employee complete a JSA for the repair work. The employee will submit the completed form to the
Qualifier for review and approval for completion of this Assessment.
PROCEDURE

1. The Job Safety Analysis form addresses four (4) key sections:
a. Precondition to isolate equipment.
b. Hazard Identification / Mitigation and Waste Disposal.
c. Lockout/Tagout/ Blinding.
d. Precondition to Activate Equipment.
2. The JSA is used to identify what steps must be taken to ensure continued safe operation of the facility
when equipment is taken out of service. It is intended to provide information regarding any equipment
that could be affected by the isolation of a critical piece of equipment, and any additional or unusual
steps that must be completed during isolation. The purpose is to inform the Operator of any potential
impacts to upstream or downstream equipment, and the “preconditions” that must be met in order to
safely isolate the equipment or process.
MECHANIC 17-18 27
3. The JSA must be reviewed even in cases where total facility shutdowns occur. During shutdown
/ turnaround operations many simultaneous operations are performed and each activity must
be reviewed to see what potential impact, if any, the isolation of equipment or work to be
performed may have on each other.
4. The JSA must be written for all designated job tasks and all new job tasks defined as: a)
Involving a sequence of events (more than one step) and, b) Has identifiable (specific) hazards
associated with those events.
5. The JSA will be used as an onsite tool to engage all workers involved in the work.
Each JSA shall include:
a. Document work location.
b. Be dated (using the actual date work is performed).
c. Specifically describe work to be performed.
d. Define, by documentation, the sequence of events or basic steps involved with

the specific task to be performed.
e. Identify, by documentation, potential hazards associated with each event and/or

step to be performed.
f. Identify, by documentation, the mitigation intended to eliminate and/or reduce the

potential hazard identified.
Note: Identifying associated procedures (when/ where applicable) is a viable

mitigation when incorporated by review and thorough understanding of all
individuals involved in job task planning.
g. Identify by documentation workers associated with work described in the specific

JSA.
h. Identify potential spill sources or items lost overboard, along with preventive and/
or backup containment plans.
i. Utilize "Think Incident Free" (TIF) Worksheet (incorporated with Long Form) as a
checklist tool to ensure potential hazards, controls and emergency/contingency
plans, and safety equipment required have all been addressed in the JSA.
j. Be adaptable to changing conditions by following what’s written (documented)

and, if not written, the job shall be stopped to discuss and document changes
accordingly.
28 MECHANIC 17-18
SASBU
Cabinda Gulf Oil Company, Inc.

“THINK INCIDENT FREE!”
Job Safety Analysis Worksheet
Work Location: Date:
Describe Work to be Done:
Owner:
Sequence of basic steps Potential Accidents or Hazards Actions to eliminate/reduce hazards
Zero Discharge Analysis

Potential Spill Sources or Items That Could Be Recommendations to Prevent Discharge and Backup
Dropped Overboard Containment Procedures
Figure 9: Job Safety Analysis
MECHANIC 17-18 29
SASBU
Cabinda Gulf Oil Company, Inc.

“THINK INCIDENT FREE!”
Job Safety Analysis Worksheet
Potential Hazards
Chemical Exposure Ignition Sources Fire/Explosion

Hazardous Atmosphere Pressure Spills
Confined Spaces Lifting Slips/Trips
Noise Overhead Chips/Slivers
Working/Walking Surfaces Falls Pinch Points
Environment/Weather Machinery Hot Surfaces
Arc/Flash Heat Stress Simultaneous Operations
Open Hole Power & Hand Tools Other- Describe:
Hazard Controls and Emergency/Contingency Plans
Personal Protective Equipment Spill Control / Contingency Plans

Physical Barriers Fire Fighting
Safety Equipment Emergency Evacuation Procedures
Ignition Source Controls Eyewash / Safety Shower Locations
Lock Out / Tag Out Material Safety Data Sheets
Required Work Permits Simultaneous Operations Plan
Fall Protection / Open Hole Policy Hot Bolting Policy
Other – Describe:
Safety Equipment Required
Hard Hats Work Vests/Life Jackets Respirator

Safety Shoes Full Body Harness Fire Extinguisher
Safety Glasses Double Lanyard w/ Shock Absorber Fire Retardant Tarps
Face Shield Life Line Lock Out / Tag Out
Goggles Safety Cable Gas Detector
Cotton Gloves Safety Barricade Hearing Protection
Leather Gloves Caution Tape Adsorbent Pads
Rubber/Chemical gloves Clothing Containment Pans
Chemical Apron Work Permit Proper Tools
“Think Incident Free is a state of mind. This worksheet is a tool to help ensure that we have the right
mindset, that we have planned the job with the safety of our people and protection of the environment as a
priority. It is also designed to ensure that we have communicated all of the potential hazards to all of the
affected parties. This process will also ensure that we have taken steps to eliminate or mitigate the hazards
identified.
Job Safety Analysis cont.

30 MECHANIC 17-18
OSA 113
COMPETENCY
Demonstrate the procedure to open a “Work Order” in JDE.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee demonstrate the procedure to open a “Work Order”in
JDE. The Qualifier will select an upcoming maintenance task and have the employee complete a "Work
Order" using JDE. The employee will submitt the completed "Work Order" to the Qualifier for review and
approval for completion of this Assessment.
PROCEDURE
The employee will demonstrate as follows:
1. Open the "Work Order" form using JDE.
2. Action Code:
a) Enter [A] to add code.
3. Parent Work Order Number:
a) Enter the "Parent Work Order" number, if required, to link this "Work Order" to an existing "Work
Order".
4. Description:
a) Enter a brief description of the work requested. Do NOT enter a description of the equipment.
5. Unit Number:
a) Enter the Unit number of the equipment requiring attention.
6. Priority:
a) Check the priority of the "Work Order", change if required.
1. Enter [1] where one of the following apply:
MECHANIC 17-18 31
a. Production has stopped.
b. Production is about to be stopped.
c. The faulty equipment may cause an injury.
d. The faulty equipment is causing a loss to capital equipment.
e. There is an environmental hazard.
f. Enter [2] where work must be started as promptly as possible, i.e., no later than the next
working day.
g. Enter [3] where work must be started within 2 to 7 working days.
h. Enter [4] where work must be started within the next month.
i. Enter [5] where there is no deadline.
7. Originator:
a) Enter the Personal Address Book number of the person requesting the work.
8. Foreman/Coordinator:
a) Enter the Positional Address Book number of the Foreman responsible for the "Work Order", if the
"Work Order" is to be updated in order to attach parts.
Note: B&C operators must complete this field.
9. Group Code:
a) Enter the applicable Group Code number for the "Work Order", if the "Work Order" is to be updated
in order to attach parts.
Note: B&C operators must complete this field.
10. Extended Description:
a) Enter a detailed explanation of the problem and the requirements of the Work request.
11. Press [F5] to display the Status Date and Time
a) Do NOT press [F3].
12. Press [ENTER] to confirm the Work Request.
32 MECHANIC 17-18
OSA 114
COMPETENCY
Demonstrate the procedure to locate and requisition material against a "Work Order".
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee demonstrate the procedure to locate and
requisition material against a "Work Order".The Qualifier will select an upcoming maintenance task and
have the employee requisition extra material against a "Work Order". The employee will submitt the
completed "Work Order" to the Qualifier for review and approval for completion of this Assessment.
PROCEDURE
Work Order Inquiry
1. Retrieve a current "Work Order" that needs to have parts attached to it.
2. Action Code:
a) Enter [I] to inquire.
3. "Parent Work Order" Number:
a) Enter the "Work Order" number, if this is unknown, use the "Work Order" Inquiry On-line Help to
find the "Work Order" number.
4. Press [ENTER] to display the "Work Order" header.
5. OP:
a) Enter [1] next to the "Work Order" header.
6. Press [ENTER] to access the Equipment "Work Order" Entry.
MECHANIC 17-18 33
Equipment Work Order entry
1. Access the Parts List for the selected "Work Order". Press [F12] to access the "Work Order" Parts
List.
Adding Parts to direct "Work Order"
1. Action Code:
a) Defaults to [I] for inquire, change to [C] for change.
Note: If the Order Number is highlighted in red, then there are no parts attached to the "Work Order".
2. Part:
a) Press [F8] on the first available line item to access the Item Search – and add parts
to the parts list.
b) Enter [STOCK] in the Business Unit field.
c) Enter the search name of the item in the Search Text field.
d) To display the extended description of the item, place the cursor on the item and press [F14].
Remember to press [F3] to return to the Item Search Screen.
e) Check that there is quantity available in the Warehouse.
f) Enter [4] in the OP field to select the item to be added to the list.
g) Press [ENTER] to return to the Add Parts to "Work Order"
h) Repeat process for each part.
3. Quanty Ordered:
a) Enter the quantity of the item required for the "Work Order".
4. Press [F5] to update the parts list.
Note: The Action Code changes to [I] for inquire and the new parts are displayed at the top of the Parts
List.
5. If the number in the Quantity field turns red, there is not enough stock in the Warehouse.
a) Change the quantity to the available stock in the Warehouse.
b) Press [F5].
34 MECHANIC 17-18
Note: If there is not enough stock in the Warehouse, complete all the steps, and then follow the steps
in the Note.
6. OP:
a) Enter [11] to add special instructions to the order.
b) Press [ENTER] to go to the Additional Part Information.
c) Enter the special instructions for the order.
d) Press [ENTER].
e) Press [F3].
Note: You return to the Add Parts to Direct "Work Order" – The OP field is highlighted to indicate that
the comment is attached.
7. OP:
a) Enter [14] next to each line item that does not have the QTY Ordered field highlighted in yellow.
8. Press [F5] to requisition the order and print the pickslip in the Warehouse.
Note: The number in the QTY Ordered field will highlight in yellow to indicate that the parts have been
requisitioned from the Warehouse. If there are not enough items in the Warehouse and the material
needs to be requested:
9. Part:
a) Enter the Symbol number of the item on the next available line item.
Note: Only do this once the available items have been ordered.
10. Quanity Ordered:

a) Enter the quantity of unavailable stock.
Note: The amount will turn red as there is no stock in the Warehouse.
11. Press [F5] to update the "Work Order".
12. OP:
a) Enter [7] next to the item.
13. Press [ENTER] to access the Buyer Advisory.
14. User ID:

a) Enter your CAI.
15. Press [F3] and Buyer advised displays in the quanity field.
16. Press [F5] to update the "Work Order".
MECHANIC 17-18 35
OSA 115
COMPETENCY
Demonstrate the proper way to close a "Work Order" including proper Reason for Work (RFW) codes in JDE.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee demonstrate the procedure to close a "Work
Order" including the proper Reason for Work (RFW) codes in JDE.The Qualifier will select a completed
maintenance task and have the employee close a "WorkOrder" using the proper (RFW) codes. The
employee will submitt the completed "Work Order" to the Qualifier for review and approval for completion
of this Assessment.
PROCEDURE
Note : Use this system task to complete "Work Orders", i.e., detail the work done only once the work
has been completed. A Work Order can only be closed once it has been through a status [60], i.e.,
Work in Progress. Preventative Maintenance "Work Orders" (PM’s) are closed in the same way as
corrective "Work Orders". Once PM’s are closed then the JDE system automatically resets the timer
for the PM.
Work Order Inquiries
1. Open the JDE screen to display all "Work Order" requests that are work in progress.
2. Action Code:
a) Enter [I] to inquire.
3. Status From / Thru:

a) Enter status from [60] to [60].
4. Mentor:
a) Enter the Address Book number of the "Work Order" Mentor.
5. Press [ENTER] to display the "Work Orders" attached to this position.
36 MECHANIC 17-18
Note: If an error is displayed, there are no "Work Orders" attached to this position.
6. OP:
a) Enter [1] next to all "Work Orders" to be closed.
7. Press [ENTER] to go to the Equipment "Work Order" Entry.
Equipment Work Order Entry
1. To change the status and to enter the details of the work that has been completed.
2. Action Code:
a) Enter [C] to change.
3. Status:
a) Enter [65] to indicate that the "Work Order" has been completed.
4. Completed:
a) Enter the date (DD/MM/YY) the work was completed.
5. Primary RFW:
a) Enter the code that explains the primary reason for the work done. Press [F1] to access the
User Defined Codes Window and enter one of the following in the Skip
To Code field:
b) Enter [E] for electric work
c) Enter [G] for general maintenance
d) Enter [I] for work on instruments
e) Enter [M] for mechanical work
f) Enter [S] for SCADA (i.e., work on computers)
g) Press [ENTER].
h) Select the code that describes the reason for the "Work Order".
i) Press [ENTER].
6. Seconday RFW:
a) Enter the code that further describes the reason for the work done.
b) Press [F1] to access the User Defined Codes Window and enter the Primary RFW
code in the Skip To Code field.
c) Press [ENTER].
d) Select the code that further describes the Primary RFW selected.
e) Press [ENTER].
MECHANIC 17-18 37
7. Extended Description:
a) Press [F15] to enter the full details of the work that was completed.
8. To perform a specific screen function, press the following Function key:

a) To print the "Work Order" press [F21].
Record Type Review
1. To select the extended description screen, to enter further details on the "Work Order".
2. OP:
a) Enter [1] next to [B "Work Order" Closing Remarks].
3. Press [ENTER] to go to "Work Order" Detail Entry.
W.O. Detail Entry
1. To enter an extended description on the details of the "Work Order".
2. Action Code:
a) Enter [C] to change.
3. Description:
a) Enter the full details of the work that was completed.
4. Press [ENTER].
5. Press [F3] to return to the Record Type Review.
Note: The OP field will highlight to indicate that there is a text message attached.
6. Press [F3] to return to the Equipment "Work Order".
38 MECHANIC 17-18
Equipment Work Order
1. To finish updating the "Work Order".
2. Press [F5] to save and update your entries and display the Status Change Date and Time.
3. Press [ENTER] to complete the transaction.
4. To perform a specific screen function, press the following Function key:
a) To print the "Work Order" press [F21].
5. End of transaction
MECHANIC 17-18 39
OSA 116
COMPETENCY
Demonstrate the procedure to purchase material against an “Order Requisition” (OR).
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee demonstrate the procedure to purchase
material against an "Order Requisition" (OR). The Qualifier will select a maintenance task and have the
employee purchase material against a "Order Requisition". The employee will submitt the completed "Order
Requisition" to the Qualifier for review and approval for completion of this Assessment.
PROCEDURE
Note: Use this system task to request nonstock items. Nonstock items are items that are not
stocked in the Warehouse. If the material to be ordered is a stock item, but is needed for a project
and you do not want to deplete the Warehouse supplies, then this system task can also be used
to enter a request for items, which are in stock.
1. Before purchasing materials:
a) Have the actual or estimated unit cost of the nonstock item

b) Know the Business Unit (Cost Center) or AFE to which the item is to be charged
2. Menu Path forGeneral Users:
a) MMR & POR Processing >> POR Processing >> Enter NONSTOCK Requisitions
3. Production User:
a) MMR & POR Processing >> POR Processing >> Enter NONSTOCK Requisitions
4. Materials Users:
a) Ordering Materials >> POR Processing >> Enter NONSTOCK Requisitions
5. Other Users:
a) Enter NONSTOCK Requisitions
40 MECHANIC 17-18
Enter a Non Stock Requisition
1. To enter the details of the individual or department requesting an item.
2. Action Code:
a) Defaults [A] for add.
3. Branch/Plant:
a) Enter [NONSTOCK].
4. Supplier:
a) Enter the Procurement Supervisor’s Address Book number [308539]. If the Supplier is known,
enter the Supplier's Address Book number.
5. Ship To:
a) Enter the CABGOC Address Book number [307828].
6. Buyer:
a) Enter the Procurement Supervisor’s Address Book number [308539].
7. OR Originated By:
a) Enter the Address Book number of the individual requesting the material.
8. R.O.S Malongo:
a) Enter the date (DD/MM/YY) on which the item is required on site.
Note: Remember to take into consideration the 3 months required for the item to be shipped.
9. Transportation:
a) Enter the code for the mode of transportation.
10. Order Priority:

a) Enter the priority of the order.
11. Classification:
a) Enter one of the following:
b) Enter [DIR] for items charged to a Cost Center.
c) Enter [EXD] for exchange items charged to a Cost Center.
d) Enter [AFE] for items charged to an AFE.
e) Enter [EXA] for exchange items charged to an AFE.
12. Press [ENTER] to validate the information.
13. Press [ENTER] to process the requisition and access the Purchase Order Detail.
MECHANIC 17-18 41
Purchase Order Detail
1. To enter the order details of the item(s) being requested.
2. Account Number:
a) Enter the Account number against which the item will be charged.
Note: If you are entering a number of items with different Account numbers, enter the account
number next to the relevant line item.
3. Work Order #:
a) Enter the "Work Order" number, followed by [W] if the items are to be used for a "Work Order".
4. Symbol Number:
a) Enter [.] to order an item that is not kept in the Warehouse or:
b) Press [F1] to find the nonstock symbol number for an item to be used for a special project.
c) Enter [NONSTOCK] in the Branch/Plant field.
d) Enter the name of the item in the Search Text field.
e) Press [ENTER] to display all nonstock items for the search text.
f) To display the extended description of the item, place the cursor on the item and press [F14].
Remember to press [F3] to return to the Item Search Screen.
g) Enter [4] and press [ENTER] to select the Symbol number for the nonstock item.
5. Quantity:
a) Enter the quantity of the item required.
6. Unit Cost:
a) Enter the cost, if known, or an estimated value.
7. If a [.] was entered in the Symbol Number field go to step 8.

a) If a Symbol number was entered in the Symbol Number field, go to step 14.
8. Press [F4] to display the Fold Area.
Note: If the Fold Area is open, do not press [F4].
9. Description 1 - Enter a description of the item, of no more than 30 characters.
10. Description 2 - Continue the description if necessary.
42 MECHANIC 17-18
11. To add text of more than 60 characters to the description of the item, complete the following steps:
a) Enter [3] in the O field and press [ENTER] to access the Associated Text Window.
b) Complete the description of the item.
c) Press [ENTER] to process the description.
d) Press [F3] to exit this screen and return to Purchase Order Details.
12. UOM:
a) Enter the code for a valid Unit of Measure.
13. UOM:
a) Enter the code for a valid Unit of Measure; this must be the same as the Unit of Measure in
step 11.
14. To add another line item to the POR.

a) Press [Page Down] and return to step 1.
15. Press [F14] to enter special instructions to the Buyer, relating to the whole order, if applicable.
a) Enter the instruction for the order.
b) Press [ENTER].
c) Press [F3].
Note: The message: “See Memo” will display in the top left-hand corner of the screen, to
indicate that there is an instruction attached to the order.
16. Press [ENTER] to validate the information and to display the “Enter ‘Y’ to Record Order” message.
17. Enter ‘Y’ to Record Order

a) Enter [Y] to accept the order or:
b) Enter [N] to change the order and add further information to the screen.
18. Press [ENTER] to record the order.
Note: You will return to the Enter Non-Stock Requisitions. The "Purchase Order
Requisition" number is displayed in the Previous Order field. Record this number for future use.
a) You are ready to process a new requisition.
19. End of transaction
MECHANIC 17-18 43
44 MECHANIC 17-18
T M
TOOLS ANDD
OOLS AND EASUREMENT EVICES
MEASUREMENT DEVICES
OSA 201 (AQ)
COMPETENCY
Explain using a cylinder liner puller.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain using a cylinder liner puller.
PROCEDURE
The employee will explain as follows: (Figure 1)
NOTE: The steps listed below outline a generic procedure.
1. Place the top bracket on top of the block with the feet of the bracket facing down. Ensure the top bracket
is centered over the liner and the feet are not contacting the adjoining liners.
2. Screw the torque nut onto the stud until it is flush with the stud.
3. Place the stud through the center of the top bracket.
4. Place the bottom bracket against the lower area of the cylinder liner. Ensure the machined grooves on
the bottom bracket are facing up.
5. Screw the holding nut onto the stud finger tight. Ensure the lower area of the liner fits into the machined
grooves on the bottom bracket.
6. Tighten the torquing nut until the o-ring seal is broken and the liner is free.
NOTE: It may be necessary to tap the liner puller with a hammer or allow torque to remain on the
puller before the liner can be removed. If the liner puller torquing nut is overtightened,
damage to the liner can result.
MECHANIC 17-18 45
TOOLS AND MEASUREMENT DEVICES
Figure 1: Typical Liner Puller
46 MECHANIC 17-18
OSA 202
COMPETENCY
Explain the use of a thermographic camera in performing a thermal survey and state some of the
advantages of it's use.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the use of a thermographic camera in
performing a thermal survey and state some of the advantages of it's use.
PROCEDURE
1. Thermography is the use of an infrared imaging and measurement camera to "See" and "measure"
thermal energy eitted from an object. Nearly everything that uses or transmits power gets hot before
it fails. Maintaining electrical and mechanical reliability is critical to our business.
2. Infrared thermography is the most cost effective, proven, predictive maintenance technology available
today. It allows you to quickly, accurately and most importnatly, safely locate problems prior to failure.
The versatility of the camera is amazing. It allows for troubleshooting in all facets of our business.
3. Advantages of it's use includes:
a. Operations:
1) Sand in separators
2) Fluid levels in vessels
3) Interface level in chem-elec
4) Leaking valves
5) Flow problems
MECHANIC 17-18 47
b. Electrical:
1) Loose wiring connections
2) Faulty breakers
3) Bad motor windings
4) Faulty buss bar connections
c. Mechanical:
1) Bad valves in compressors
2) Bad bearings
3) Pump / Motor misalignment
4) Gear boxes
d. Automation:
1) Loose wire connections
2) Faulty Interpak breakers
3) Bad PLC equipment
4) Faulty DC buss connections.
48 MECHANIC 17-18
OSA 203
COMPETENCY
Demonstrate the proper use of a digital multi-meter.
ADMINISTRATION
DEMONSTRATE: Qualifier will have the employee demonstrate the proper use of a digital multi-meter. The
Qualifier will have the employee test a 12/24 DC voltage system and a 4 to 20 mA output from a transmitter.
The employee will be allowed to use the procedure section and (Figures 2 and 3). The employee will be
required to complete a JSA for this Assessment.
PROCEDURE
The employee will demonstrate as follows: (Figure 2 and 3)
1. Meter Check:
a. Verify the operation of the multi-meter by checking it against a known value (resistor).
b. Perform a meter check by placing the meter selector switch in the ohms position and touch the ends
of the two leads together. If the reading is at or near zero, then the meter is good.
c. Apply the leads across the ends of the resistor and observe the reading on the meter display. The
reading should be at or near the known ohm value of the resistor.
2. Checking 12/24 DC voltage: (Figure 2)
a. Switch the meter selector switch to the DC position.
b. Apply the leads to the positive and negative posts of the battery.
NOTE: Hold the leads in such a manner to be sufficiently clear of the bare metal tips to avoid a possible
shock.
c. Observe the reading on the meter display. For a 12-volt battery, the reading should be at or near
12 volts. For a 24-volt battery system, the voltage should be at or near 24 volts.
MECHANIC 17-18 49
3. Checking 4 to 20 mA output. (Figure 3)
a. Switch the meter selector switch to the mA position.
b. Apply the leads to the Viatran or equivalent circuit. The positive lead should be connected to the
transmitter side and the negative lead should be connected to the grounded side.
c. Bleed the pressure off the unit and observe the reading. With no pressure, the reading should be
at or near 4 mA.
NOTE: Consult with an I&C Technician to determine the latest range setting of the transmitter.
d. Apply full system pressure to the transmitter. Depending on the range of the unit, the reading on
the display can vary from 4 mA up to 20 mA.
e. If full range pressure can be applied to the transmitter, the reading on the display should be at or
near 20 mA.
50 MECHANIC 17-18
Figure 2: Fluke meter battery check
MECHANIC 17-18 51
Figure 3: Fluke meter, Viatran check
52 MECHANIC 17-18
OSA 204
COMPETENCY
Demonstrate the use of a photo tachometer.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee demonstrate the use of a photo tachometer. The
Qualifier will select an engine and have the employee determine the RPM's using a photo tachometer.
PROCEDURE
1. A reference point on the rotating device must be established before the photo tachometer can be used.
After the reference point is established, the photo tachometer must be turned on and aimed at the
reference point.
2. Turn the strobe light rheostat to adjust the strobe light speed so the reference point on the rotating device
appears to stop turning, at this point the display should illustrate the RPM of the rotating device.
MECHANIC 17-18 53
OSA 205
COMPETENCY
Measure and record a centrifugal pump's wear ring dimensions.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee measure and record a centrifugal pump's wear ring
dimensions.The Qualifier will select a centrifugal pump and have the employee demonstrate using outside
and inside micrometers to measure the thickness and diameter of the selected pump's impeller wear rings
according to the manufacturer's specifications. The employee will be allowed to use the manufacturer's
manual for the pump selected.
PROCEDURE
The employee will demonstrate as follows: (Figure 4 and 5)
1. Take the diameter reading using the inside micrometer.
2. Measure the thickness using the outside micrometer.
3. Record readings and compare with manufacturers technical manual to determine if readings are
within specifications.
Figure 4: 0" to 1" Outside Micrometer
54 MECHANIC 17-18
9
8
MECHANIC 17-18
7-8
;;
;;
8
6-7
9 6
8
5-6
3
9
;;
;;
4-5
8 ;;
;;
1
;;
;;
8
;;
3-4
4
2
;;
;;
;;;;
5
;; ;;;;;;;
;; ;;;;;;
;
;;;;;
;
Figure 5: Inside Micrometer

;
;
;
;
;
;;;
7
INSIDE MICROMETER
1 MICROMETER 5 EXTENSION HANDLE CONNECTION
2 THIMBLE 6 .500 SPACING COLLAR
3 LOCKING SCREW 7 KNURLED EXTENSION HANDLE
4 SLEEVE 8 MEASURING ROD
9 ROD LENGTH ADJUSTMENTS
55
OSA 206 (AQ)
COMPETENCY
Explain the use of a Bore Scope.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the use of a Bore Scope.
PROCEDURE
1. A Bore Scope is an illuminated rigid or flexible light shaft with a lens mounted at the end of shaft or tube.
The diameter and length of this instrument may vary depending on its uses. The Bore Scope is used
to view internal components which cannot be seen under normal external conditions. Some examples
are:
a) Cylinder liner through the spark plug hole.
b) Turbine blades from the air inlet housing.
56 MECHANIC 17-18
OSA 207
COMPETENCY
Demonstrate the proper use of a torque multiplier.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee demonstrate the proper use of a torque
multiplier.The Qualifier will select any ratio torque multiplier and any fastener to be torqued.The employee
will then calculate the torque setting for the torque wrench through the selected torque multiplier. Employee
will be allowed to use (Figure 6)
PROCEDURE
1. Select the correct wrenches
2. Calcualate the torque setting through the selected torque multiplier.
Example:
Fastener torque limit is 600 ft. lbs.
Torque multiplier is ½ inch drive input and ¾ drive output with a 4:1 ratio.
Torque wrench is ½ drive 0 to 250 ft. lbs. range.
600ft. lbs. divided by ratio of 4 = 150 ft. lbs.
MECHANIC 17-18 57
TABLE 1: X-4 MULTIPLIERS
Theoretical Actual
Mechanical Mechanical Maximum
Input Size Output Size Advantage Advantage ft-lbs
1. 1/2 inch 3/4 inch 4 to 1 3.6 to 1 1250
2. 3/4 inch 1 inch 4 to 1 3.6 to 1 2000
3. 1 inch 1-1/2 inch 4.33 to 1 3.897 to 1 4000
TABLE 2: MULTIPLIER COMBINATIONS

Actual
Mechanical
Combination Advantage
1&2 12.96 to 1
2&3 14.03 to 1
1, 2 & 3 50.5 to 1
TABLE 3: FORMULA
Formula for Determining Torque: Example (ft-lbs):
t= T 360 ft-lbs is the required torque for
AMA a nut.
Where:
t = Torque in ft-lbs indicated 360 ft-lbs = 360 ft-lbs = 100 ft-lbs
at wrench. AMA 3.6
T = Effective torque in ft-lbs Therefore, 100 ft-lbs is the required
on fastener. torque wrench reading when used with
AMA = Actual Mechanical Advantage one of these two multipliers.
from Table 1 or 2.
TABLE 4:
Stacking Holders Torque Wrench
Anti-Backlash Ratchet
Torque Multipliers
Figure 6: Torque Multipliers
58 MECHANIC 17-18
G E (F C )
GAS
AS
ENGINE
NGINE OUR YCLE
(FOUR-CYCLE)
OSA 301 (AQ)
COMPETENCY
Explain steps to troubleshoot an engine that has coolant in the crankcase.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain steps to troubleshoot an engine that has coolant in
the crankcase.
PROCEDURE
1. Inspect the area between each cylinder liner and the engine block for leaking coolant. If leaking coolant
is noted, the probable causes are defective liner o-rings or a damaged engine block.
2. Remove the spark plugs from each cylinder. Roll the engine over, blowing out any coolant that has
accumulated on top of the pistons. Wait approximately five minutes, then roll the engine over again. If
coolant is blown out of the same cylinder, the probable causes are a cracked head, a damaged head
gasket, or a cracked cylinder liner. If coolant is blown out of a different cylinder, the probable causes
are a cracked exhaust manifold, damaged exhaust manifold gasket(s), leaking turbocharger, or a
leaking innercooler. If coolant is blown out of the same cylinder, the head, head gasket, and cylinder
liner will have to be removed and inspected individually to determine the source of the leak.
a. If coolant is blown out of a different cylinder, the piping connected to the intake and exhaust manifolds
should be disconnected. Inspect the piping in an attempt to determine if the turbocharger or
innercooler is leaking. If no leaks are noted, the exhaust manifold should be removed and the exhaust
manifold gaskets inspected for damage. If the exhaust manifold gaskets are not damaged, the
exhaust manifold should be pressure tested.
b. If the exhaust manifold is positioned above the heads, the coolant level can be drained below the
manifold to isolate it from the system during troubleshooting.
3. On engines equipped with gear driven water pumps, inspect the pump shaft seal, ensuring it is not
damaged. A damaged shaft seal can allow coolant to leak into the crankcase.
4. On engines equipped with a water cooled oil cooler, inspect the cooler, ensuring the tubes are not
damaged. Damaged tubes can allow coolant to enter the lubrication system.
MECHANIC 17-18 59
GAS ENGINE (FOUR CYCLE)
OSA 302
COMPETENCY
Explain steps to troubleshoot an engine that has excessive pressure in the crankcase.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain steps to troubleshoot an engine that has excessive
pressure in the crankcase.
PROCEDURE
1. Inspect the crankcase breather system, ensuring the filter and associated lines are not clogged. A
clogged breather system will not allow normal pressure in the crankcase to be vented to atmosphere.
2. Perform a compression test. If one or more cylinders are found to have low compression, a wet
compression test (applying oil to the cylinder through the spark plug hole) should be performed. If
compression increases during the wet compression test, the piston(s) and piston rings should be
removed and inspected for damage.
NOTE: If compression did not increase during the wet compression test, leaking valves in the head
or improper valve adjustment may be the probable causes of the low compression.
3. On selected model engines equipped with turbochargers, the ventura should be disassembled and
inspected. If the ventura is defective, engine exhaust gases can leak into the crankcase, causing
excessive pressure.
NOTE: The ventura is a component mounted to the exhaust outlet of the turbocharger. The ventura
creates a low pressure area in the exhaust that allows crankcase pressure to vent into the exhaust.
60 MECHANIC 17-18
OSA 303
COMPETENCY
Explain steps to troubleshoot an engine that shuts down on high oil temperature.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain steps to troubleshoot an engine that shuts down on
high oil temperature. The Qualifier will select 6 of the 8 common symptoms that could cause an engine to
shut down on high oil temperature and have the employee state the causes and solutions.
PROCEDURE
1. Symptom: Low oil pressure
CAUSE SOLUTION
Insufficient oil, inaccurate gauge. Add oil as needed.
Oil gauge line plugged, lube oil filters Check with a test gauge.
plugged.
Lube oil regulator stuck open. Clean or replace line. Change filters or
clean filters.
Clogged oil inlet screen. Clean or free valve. Remove and clean
screen
2. Symptom: Low Oil Level
CAUSE SOLUTION
Faulty level indicator. Replace level indicator.
External oil leaks Replace gasket, hoses or "O" Rings on

covers, flanges and piping.
Consumption through combustion Check or replace piston rings.
MECHANIC 17-18 61
3. Symptom: Low temperature differential across the oil cooler.
CAUSE SOLUTION
Inadequate cooler capacity. Check manufacturer specifications for

proper size cooler.
Air/water restriction in the cooler. Clean cooler coil, check for proper water
volume.
4. Symptom: Thermal bypass valve stuck in the closed position.
CAUSE SOLUTION
Damaged or broken bypass valve Replace bypass valve
5. Symptom: Shut-down switch improperly set or defective.
CAUSE SOLUTION
Clogged sensing line. Clean or replace sensing line.
Broken internal parts of the switch. Replace switch.
6. Symptom: Low coolant pressure.
CAUSE SOLUTION
Gauge inaccurate. Replace gauge.
Faulty thermostats Replace thermostats
7. Symptom: High coolant temperature.
CAUSE SOLUTION
Gauge inaccurate. Low coolant level. Replace gauge. Fill coolant system.
Faulty thermostats. Air in cooling system. Replace thermostats. Purge air from
system.
8. Symptom: Engine overloaded.
CAUSE SOLUTION
Heavy or excess load on engine. Remove some of the load from the engine.
62 MECHANIC 17-18
OSA 304 (AQ)
COMPETENCY
Explain steps to troubleshoot an engine that shuts down on low oil pressure.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain steps to troubleshoot an engine that shuts down on
low oil pressure. The Qualifier will select 7 of the 10 common symptoms that could cause an engine to
shut down on low oil pressure and have the employee state the causes and solutions.
PROCEDURE
1. Symptom: Low oil level
CAUSE SOLUTION
Low oil level in crankcase Fill crankcase to specified level
2. Symptom: Shutdown switch improperly set or defective.
CAUSE SOLUTION
Switch not calibrated correctly. Recalibrate switch.
Wrong switch for application. Replace switch with recommended part.
3. Symptom: Dirty Oil Filter.
CAUSE SOLUTION
Extended filter change. Replace filters with new ones.
Contaminated oil. Replace oil and filters
MECHANIC 17-18 63
4. Symptom: Oil pressure regulator / relief valve improperly set or defective.
CAUSE SOLUTION
Not enough spring tension on valve. Adjust tension on valve.
5. Symptom: Defective oil pump
CAUSE SOLUTION
Damaged or worn internal parts Replace pump.
6. Dirty oil pump inlet screen
CAUSE SOLUTION
Contaminated oil. Change oil, clean screen.
Wrong type of oil. Use manufacturer's recommended oil.
7. Symptom: Excessive bearing clearance.
CAUSE SOLUTION
Worn bearings. Replace bearings.
Oil cavitation. Check for air leaks in suction line of

pump.
Overdue oil change
Replace oil within the guidelines of the
manufacturer.
8. Symptom: Loose, broken or disconnected piping.
CAUSE SOLUTION
Broken suction line to oil pump. Replace line.
Broken pipe flange bolts. Replace bolts and gaskets or "O"Ring as

needed.
64 MECHANIC 17-18
9. Symptom: High oil temperature
CAUSE SOLUTION
Oil cooler not working. Check cooler for blockage.
Stuck oil bypass thermostat. Replace thermostat. Reduce engine load.
Heavy load on engine.
10. Symptom: Improper viscosity oil in engine.
CAUSE SOLUTION
Wrong oil. Check manufacturer's oil recommendation
and replace oil with the recommended oil
or equivalent.
MECHANIC 17-18 65
OSA 305
COMPETENCY
Explain the principle of operation of a carburetor.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the principle of operation of a carburetor. The
employee will be allowed to use (Figure 1) only.
PROCEDURE
1. With the engine stopped, spring tension holds the diaphragm assembly closed, preventing air and fuel
from entering the engine.
2. As the engine is started, the vacuum in the cylinders, created by the intake stroke of the pistons, causes
a low pressure situation in the inner chamber to develop.
3. The low pressure in the inner chamber is sensed in the outer chamber through holes in the diaphragm
assembly.
4. This allows the pressures in the inner and outer chambers to equalize.
5. The higher inlet pressure acting on the lower side of the diaphragm assembly overcomes spring tension,
causing the diaphragm assembly to move upward.
6. The upward movement of the diaphragm assembly allows air to enter the inner chamber. Simultaneously,
the upward movement of the diaphragm assembly unseats the fuel valve, allowing fuel to enter the inner
chamber.
7. The fuel / air mixture is drawn into the power cylinder(s) through the open intake valve(s).
8. A carburetor is equipped with two adjustments:
66 MECHANIC 17-18
a) Idle adjustment - The idle adjustment screw can be adjusted to allow an additional amount of air
to enter the inner chamber. The additional air in the inner chamber decreases the differential
between the air in the inner chamber and the inlet air, causing the diaphragm assembly to close
slightly. This causes a leaner fuel/air mixture to enter the power cylinders.
b) Mixture adjustment - The mixture adjustment screw can be adjusted to regulate the amount of fuel
;;;;;;
entering the inner chamber. Less fuel entering the inner chamber will cause a leaner fuel/air mixture
entering the power cylinders.
;;;;;;;
Outer
Fuel Chamber
;;;;;;;
Valve
;; ;;;
Diaphragm
Assembly
;;; ;;;
;
Inner Air In
;;; ;;;
; ;
Chamber
;;;;;;;
;;;;;;
;
Gas
Idle
;;;
Fuel In
Adjustment
Exhaust Screw
(Closed)
;;;;;;
Intake Mixture
(Open) Adjustment
Screw
Piston
Intake (Down) Stroke
Figure 1: Typical Carburetor Assembly
MECHANIC 17-18 67
OSA 306
COMPETENCY
Balance the load on a naturally aspirated “V” block engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee balance the load on a naturally aspirated “V” block
engine. The employee will be allowed to use the procedure section and/or the manufacturer’s manual to
obtain the fuel gas pressure specifications.
PROCEDURE
1. Perform a JSA and follow Company guidelines and procedures.
NOTE: The steps listed below outline a generic procedure for an engine equipped with Impco 600
carburetors.
2. Adjust the governor and carburetor linkages, ensuring the carburetor butterflies are synchronized in the
full open and closed positions.
3. Adjust the manual throttle linkages, ensuring the manual butterflies are synchronized in the full open
and closed positions.
4. Place the manual throttle lever in the full open position.
5. Turn the idle adjusting screw in on one carburetor until the carburetor butterflies are slightly open.
6. Start the engine.
7. Turn the idle adjusting screw that was adjusted in or out until the desired idle RPM is obtained.
8. Turn the idle adjusting screw in on the opposite bank carburetor until the screw contacts the carburetor
lever, without changing the idle speed.
9. Ensure the primary and secondary fuel gas regulators for each bank are properly adjusted with the engine
operating at no load. Refer to the manufacturer’s manual to obtain the fuel gas pressure specifications.
10. Turn the carburetor mixture adjustment screw on one carburetor clockwise until it stops, then turn the
adjusting screw counterclockwise six full turns.
68 MECHANIC 17-18
11. Repeat (Step 9.) for the carburetor on the opposite bank.
12. Apply the maximum available load to the engine.
NOTE: A load that produces 3" to 6" intake manifold vacuum is preferred.
13. Ensure the primary and secondary fuel gas pressures remain within the manufacturer’s specifications.
14. Turn the carburetor mixture adjustment screw on either carburetor clockwise until the intake manifold
vacuum for the bank being adjusted begins to decrease. Back off the adjustment screw slightly until
maximum vacuum is obtained. Record the reading.
16. Turn the carburetor mixture adjustment screw on either carburetor clockwise until the intake manifold
vacuum for the bank being adjusted drops 3/4" on the vacuum test gauge. Record the reading.
18. The intake manifold pressure recorded in (Steps 15. and 16.) should be 1.5" less than the pressures
recorded in (Steps 13. and 14.) If the pressures did not drop 1.5" on each bank, adjust the carburetor
mixture adjustment screw on each bank 1/2 of the additional pressure drop needed for each bank.
Example:
Left bank Right bank
Pressures recorded in (Steps 13. and 14.) 5.0" 5.0"
Pressures recorded in (Steps 15. and 16.) 4.1" 4.1"
Amount of actual pressure drop .9" .9"
Amount of required pressure drop 1.5" 1.5"
Amount of additional pressure drop needed .6" .6"
Amount of adjustment required on each bank .3" .3"
NOTE: Because the left bank and right bank governor butterfly valves are connected together, any
adjustment on one bank that causes governor response will produce the same vacuum
change on both banks.
19. If the final intake manifold vacuum readings for each bank differ by more than .5", repeat (Steps 1.
through 17.)
NOTE: Do not attempt to equalize bank to bank intake manifold vacuum readings by adjusting the
carburetor butterfly valves out of synchronization.
If the intake manifold vacuum readings for each bank still differ by more than .5" after repeating (Steps
1. through 17.), problems other than carburetor adjustment may be the cause. Other areas that should
be checked include: valve adjustment, low compression, cylinder(s) not firing, or a defective carburetor(s).
MECHANIC 17-18 69
OSA 307
COMPETENCY
Remove and install a power cylinder head on a natural gas engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove and install a power cylinder head on a natural
gas engine. The employee will be allowed to use the procedure section and/or the manufacturer’s manual
to obtain the cylinder head bolt torque and valve clearances.
PROCEDURE
1. Conduct a JSA and follow Company guidelines and procedures.
2. Removal procedure:
a. Drain the coolant below the level of the head.
b. Disconnect the secondary ignition lead from the spark plug.
c. Remove the rocker arm cover.
d. Disconnect the oil lines on the rocker arm assembly.
e. Remove the rocker arm assembly.
f. Remove the push rods.
g. Disconnect the governor and manual throttle linkages from the carburetor.
h. Disconnect the gas piping at the carburetor.
i. Disconnect the air intake piping at the carburetor.
j. Remove the intake manifold assembly.
k. Disconnect the exhaust pipe at the exhaust manifold, and secure as necessary.
70 MECHANIC 17-18
l. Remove the exhaust manifold.
m. Disconnect the coolant piping from the head to be removed.
n. Remove the head bolts.
o. Remove the cylinder head.
p. Clean all gasket sealing surfaces and parts for assembly.
q. Visually inspect the power cylinder head for cracks.
3. Installation procedure:
a. Install a new head gasket.
b. Install the cylinder head and head bolts. Torque the cylinder head bolts to the manufacturer’s
specifications.
NOTE: On some applications, it is easier to align the intake and exhaust manifolds before
torquing the head bolts.
c. Install the intake manifold assembly with new gaskets.
d. Install the exhaust manifold with new gaskets.
e. Connect the exhaust pipe to the exhaust manifold.
f. Connect the air intake piping to the carburetor.
g. Connect the gas piping to the carburetor.
h. Connect the governor and manual throttle linkages to the carburetor.
i. Connect the coolant piping to the head.
j. Install the push rods and rocker arm assembly.
k. Connect the oil lines to the rocker arm assembly.
l. Adjust the valve clearances to the manufacturer’s specifications.
m. Install the rocker arm cover gasket and rocker arm cover.
n. Connect the secondary ignition lead to the spark plug.
o. Change the engine oil and filters.
p. Fill the cooling system with coolant.
q. Bleed the air from the cooling system.
4. Start engine and check for proper operation.
MECHANIC 17-18 71
OSA 308
COMPETENCY
Remove, inspect, and install a piston and rod assembly on a natural gas engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove, inspect, and install a piston and rod
assembly on a natural gas engine. The employee will be allowed to use the procedure section and/or the
manufacturer’s manual for specifications. The employee will not be required to hone the liner when performing
this Skill Assessment.
PROCEDURE
a. Drain the coolant below the level of the head.
b. Drain the engine oil.
c. Remove the cylinder head.
d. Remove the engine oil pan.
e. Ensure the rod cap and rod are match marked to aid in proper installation.
f. Remove the rod cap and its bearing half.
g. Remove the piston, rod, and its bearing half.
NOTE: It may be necessary to remove the carbon ridge from the inside top edge of the liner
before removing the piston and rod. Some pistons are designed with threaded holes in the top
surface, so that a lifting device can be attached to aid in the piston and rod removal.
h. Clean all gasket sealing surfaces and parts for assembly.
72 MECHANIC 17-18
Figure 2: Cylinder Liner Hold-Down Clamp
RING LAND
SKIRT AREA
Figure 3: Typical Piston
MECHANIC 17-18 73
3. Inspection procedure for piston and rings:
a. Remove the piston rings from the piston.
b. Clean the piston and liner.
c. Check the piston ring end gap. Refer to the manufacturer’s manual for clearances.
d. Check the piston pin to piston pin bore clearance.
1) Remove a piston pin retainer (snap ring).
2) Remove the piston pin.
3) Clean the piston pin and piston pin bore.
4) Measure the diameter of the piston pin.
5) Measure the inside diameter of the piston pin bore.
6) Subtract the diameter of the piston pin from the inside diameter of the piston pin bore.
7) Refer to the manufacturer’s manual to ensure that the reading obtained in (Step 6) is within
limits.
4. Inspection procedure for connecting rod:
a. Visually inspect the connecting rod, to see if it is bent.
NOTE: If it is suspected that the connecting rod is bent, it should be sent to a proper facility so that
it may be thoroughly inspected.
b. Check the diameter of the piston pin bushing bore in two places, 90° apart. Refer to the
manufacturer’s manual for limits.
c. Remove the bearing halves from the bearing bore.
d. Install the bearing cap onto the connecting rod, ensuring the match marks are aligned.
e. Torque the connecting rod bolts. Refer to the manufacturer’s manual for torque specifications.
f. Measure the inside diameter of the bearing bore in two places, 90° apart. Refer to the manufacturer’s
manual for limits.
g. Remove the rod cap bolts and rod cap.
h. Ensure the lubrication port between the bearing bore and the bushing bore is not plugged.
74 MECHANIC 17-18
5. Check the connecting rod running clearance:
a. Install the bearing halves into the bearing bore.
b. Install the bearing cap onto the connecting rod, ensuring the match marks are aligned.
c. Torque the connecting rod bolts. Refer to the manufacturer’s manual for torque specifications.
d. Measure the inside diameter of the bearing bore in two places, 90° apart. Record the reading.
e. Remove the rod cap bolts and rod cap.
f. Remove the bearing halves.
g. Using an outside micrometer, measure the diameter of the connecting rod bearing journal in two
places, 90° apart where the connecting rod checked in (Step e). will be installed. Record the reading.
Refer to the manufacturer’s manual for limits.
h. Subtract the reading obtained in (Step 7) from the reading obtained in (Step 4) to obtain the
connecting rod running clearance. Refer to the manufacturer’s manual for limits.
6. Assemble the piston and rod:
a. Refer to the manufacturer’s manual to determine the direction the reference marks (if any) on the
piston and rod should face.
b. Place the rod inside the piston.
c. Install the piston pin.
d. Secure the piston pin with a piston pin retainer (snap ring).
MECHANIC 17-18 75
7. Check the cylinder liner: (Figure 2)
a. Inspect the liner for scoring, pitting, and cracks.
b. Using an inside micrometer, check the internal bore of the liner for wear in two places, 90° apart,
in the upper area of the liner. Repeat this step in the middle and lower areas of the liner. Refer to
the manufacturer’s manual for limits.
c. Place a cylinder liner hold-down clamp over the liner being inspected.
d. Torque the clamp hold-down bolts to the torque specifications for the head bolts. Refer to the
manufacturer’s manual for torque specifications.
e. Check the liner bore for out-of-roundness, using a dial bore gage (Starrett P/N 84 or equivalent). Refer
to the manufacturer’s manual for limits.
f. Remove the cylinder liner hold-down clamp.
NOTE: If new piston rings will be placed in a used liner, the liner should be honed to prepare
the liner for the new rings.
8. Install the piston rings on the piston. Refer to the manufacturer’s manual for the correct placement of
the piston rings.
9. Check the piston ring side clearance: (Figure 3)
a. Refer to the manufacturer’s manual for the side clearance for the top piston ring.
b. Select a feeler gauge .0005" larger than the maximum side clearance allowed.
c. Holding the ring in the bottom of the ring groove, insert the feeler gauge, if possible, between the ring
land and the ring. This clearance should be checked around the entire circumference of the piston.
If the feeler gauge slides in at any point, the clearance is above the maximum allowable.
d. Select a feeler gauge the same size as the minimum side clearance allowed.
e. Holding the ring in the bottom of the ring groove, insert the feeler gauge between the ring land and
the ring. This clearance should be checked around the entire circumference of the piston. The feeler
gauge should slide freely all around the groove.
f. Repeat (Steps 1 through 5) for each additional piston ring.
76 MECHANIC 17-18
a. Stagger the piston rings around the piston. Lubricate the rings and piston liberally.
b. Compress the rings into the piston, using a ring squeezer.
c. Install the upper bearing half into the rod and lubricate it liberally.
d. Refer to the manufacturer’s manual to determine the direction the reference marks (if any) on the
piston and rod should face.
e. Position the piston and rod assembly into the liner until the ring squeezer is resting squarely upon
the top of the cylinder liner.
f. Using a wood block or equivalent, slowly tap the piston and rod assembly into the liner while holding
the ring squeezer squarely upon the liner.
NOTE: In the installation process, care must be taken to ensure that the rod is properly guided
onto position in order to protect the rod bearing and crankshaft journal from damage.
g. Continue to tap the piston and rod assembly into the liner until the rod insert is seated onto the
crankshaft journal.
h. Install the lower rod bearing half into the rod bearing cap. Lubricate it liberally.
i. Install the rod bearing cap onto the rod, ensuring the match marks are aligned.
j. Torque the connecting rod bolts. Refer to the manufacturer’s manual for torque specifications.
k. Check the connecting rod side clearance.
1) Force the connecting rod to one side of the crankshaft web.
2) Using a feeler gauge, measure the clearance between the connecting rod and the crank-
shaft web on the opposite side. Refer to the manufacturer’s manual for clearances.
l. Install the cylinder head.
m. Install the oil pan.
n. Change the engine oil filters.
o. Fill the engine with the manufacturer's recommended oil or equivalent to the proper level.
p. Fill the cooling system with the manufacturer's recommended coolant or equivalent to the proper
level.
q. Bleed the air from the cooling system.
MECHANIC 17-18 77
OSA 309
COMPETENCY
Remove, inspect, and install a power cylinder liner on a natural gas engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove, inspect, and install a power cylinder liner
on a natural gas engine. The employee will be allowed to use the procedure section and/or the
manufacturer’s manual for specifications.
PROCEDURE
2. Removal procedure: (Figure 2)
a. Drain the coolant and engine oil.
b. Remove the cylinder head.
c. Remove the oil pan.
d. Remove the piston and rod assembly.
NOTE: Wrapping the crankshaft journal area with a lint free rag or equivalent will prevent it from
becoming contaminated while the liner is being pulled, and during the cleaning process.
e. Using a liner cylinder puller, remove the liner.
f. Once the liner is pulled loose from its sealing surface, the puller can be removed and the liner lifted
out of the block by hand.
g. Clean all parts and gasket surfaces for assembly.
78 MECHANIC 17-18
3. Inspection procedure
a. Thoroughly clean the upper liner seat area and lower liner seal area in the block.
NOTE: Rust buildup or foreign matter remaining in the upper liner seat area will prevent the liner
from bottoming and interfere with proper head gasket sealing. Rust buildup or foreign matter
remaining in the lower liner seal area will damage the o-rings when the liner is installed and cause
coolant to leak into the crankcase. Rust buildup or foreign matter remaining in the lower liner seal
area can also cause the liner to distort.
b. Check the outside area of the liner for pitting, nicks, cracks, and burrs.
c. Using a depth micrometer, check the depth of the liner counterbore in the block. Refer to the
manufacturer’s manual for limits.
d. Using an outside micrometer, check the flange height of the liner. Refer to the manufacturer’s
manual for limits.
e. Subtract the depth of the liner counterbore obtained in (Step c.) from the flange height of the liner
obtained in (Step d). The difference will be the projection of the liner above the block when the liner
is installed. Refer to the manufacturer’s manual for limits.
f. Remove the o-rings from the liner.
g. Thoroughly clean the upper liner seat area, o-ring groove area, and internal bore of the liner.
h. Check the outside area of the liner for pitting, nicks, cracks, and burrs.
i. Check the internal bore of the liner for scoring and cracks.
j. Using an inside micrometer, check the internal bore of the liner for wear in two places, 90° apart,
in the upper area of the liner. Repeat this step in the middle and lower areas of the liner. Refer to
the manufacturer’s manual for limits.
MECHANIC 17-18 79
a. Install the o-rings onto the liner. Refer to the manufacturer’s manual for the correct placement of
the o-rings.
NOTE: After slipping the o-rings over the liner and into the grooves, running a pencil or like
instrument under the o-rings will distribute the rubber material around the liner evenly. Additionally,
this will untwist any o-rings which may have been rolled during installation. Care should be taken
to ensure that the o-rings are installed in the proper groove. An o-ring which is comprised of a different
material that is compatible with oil should be installed in the bottom groove. This special o-ring is
normally a different color. If lubricating oil is placed on o-rings that are not compatible with oil, the
o-rings will deteriorate. Additionally, the lubricating oil causes the o-rings to swell, which could
cause the liner to pop out of the block after the liner is installed.
b. Lubricate the o-rings on the liner and the lower liner seal area in the block with liquid soap.
c. Align the liner in the block and force it down with a smart, firm thrust of the hands.
d. Ensure that the liner is firmly seated into its bore.
e. Install a cylinder liner hold-down clamp over the liner being installed. (Figure 2)
f. Torque the clamp hold-down bolts to the torque specifications for the head bolts. Refer to the
manufacturer’s manual for torque specifications.
g. Check the liner bore for out-of-roundness, using a dial bore gage (Starrett P/N 84 or equivalent).
h. Install the piston and rod assembly.
i. Install the cylinder head.
j. Install the oil pan.
k. Change the engine oil filters.
l. Fill the engine with the manufacturer's recommended oil or equivalent to the proper level.
m. Fill the cooling system with the manufacturer's recommended coolant or equivalent to the proper
level.
n. Bleed the air from the cooling system.
80 MECHANIC 17-18
OSA 310
COMPETENCY
Explain main bearing torquing procedures for a Waukesha VHP Series engine.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain main bearing torquing procedures for a Waukesha
VHP Series engine. The employee will be allowed to use (Figure 4).
PROCEDURE
2. Main bearing cap torquing procedures on 6, 12 and 16 cylinder engines includes:
a. Torque nuts (1) through (4) (in that order) to 75 ft. lb. (102 N-m). If installing replacement caps that
will be align bored, torque to only 30 ft. lb. (40 N-m). When installing more than one cap, torque nuts
(1) through (4) to 75 ft. lb. (102 N-m) on all caps before torquing side bolts.
b. Torque all left side bolts (5) to 250 ft. lb. (339 N-m), starting from the front of the engine.
c. Torque all right side bolts (6) to 250 ft. lb. (339 N-m), starting from the front of the engine.
d. Torque nuts (1) through (4) to 275 ft. lb. (373 N-m) to two steps: first 175 t. lb. (237 N-m), and then
275 ft. lb. (373 N-m).
NOTE: The values specified on (Figure 4) are to be used only in the absence of specified torquing
instructions and are not to be construed as authority to change existing torque values. A tolerance of
+ or - 3% is permissible on these values, which are for oiled threads.
MECHANIC 17-18 81
BOLTS
BOLT
Figure 4: Torque Recommendations
82 MECHANIC 17-18
DIESEL ENGINE
DIESEL ENGINE
OSA 401
COMPETENCY
Remove and install a fuel injection pump on a 4 cycle diesel engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove and install a fuel injection pump on a 4 cycle
diesel engine. The employee will be allowed to use the procedure section and/or the manufacturer's manual.
PROCEDURE
1. Conduct a JSA and follow company guidelines and procedures.
a. Disconnect the fuel supply line.
b. Disconnect the fuel injection lines.
c. Disconnect the throttle control linkage.
d. Disconnect the fuel injection pump lubricating oil line.
e. Remove the fuel injection pump.
a. Remove the valve rocker cover.
b. Rotate the engine in the direction of rotation while observing the intake and exhaust valve opening
and closing on the number one cylinder.
c. When the intake valve is fully closed, continue to rotate the engine until the Top Dead Center
(TDC) mark on the flywheel for the number one cylinder aligns with the pointer on the flywheel
housing.
MECHANIC 17-18 83
DIESEL ENGINE
d. Remove the timing gear cover and gasket from the accessory drive.
e. Remove the timing gear from the accessory drive.
f. Remove the timing plug from the fuel injector pump housing.
g. Insert the injection pump timing tool into the timing hole.
h. While holding a slight pressure on the timing tool, rotate the fuel injection pump until the timing
tool drops into the timing notch in the injection pump.
i. Install the fuel injection pump.
j. Connect the governor lubrication oil line.
k. Connect the throttle control linkage.
l. Connect the fuel supply line.
m. Connect the fuel injection lines.
n. Install the timing gear onto the accessory drive.
o. Install the timing gear cover and gasket.
p. Remove the injection pump timing tool.
q. Install the timing plug onto the fuel injection pump.
r. Install the valve rocker cover.
s. Purge the fuel system.
84 MECHANIC 17-18
DIESEL ENGINE
OSA 402
COMPETENCY
Remove and install a blower on a Detroit Diesel inline engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove and install a blower on a Detroit Diesel inline
engine. The employee will remove and install the blower with the governor drive, water pump, fuel transfer
pump, and the drive shaft cover attached to the blower. The employee will be allowed to use the procedure
section and/or the manufacturer's manual.
PROCEDURE
a. Drain the cooling system.
b. Remove the governor control housing.
1) Disconnect the throttle linkage attached to the governor lever.
2) Remove the breather tube.
3) Remove the governor cover.
4) Remove the valve rocker cover from the engine.
5) Disconnect the fuel rod from the injector control tube lever.
6) Remove the clip that secures the fuel rod to the governor control housing.
7) Remove the fuel rod.
8) Remove the governor control housing mounting bolts.
9) Remove the governor control housing.
MECHANIC 17-18 85
DIESEL ENGINE
Figure 1: Typical Detroit Diesel Inline Blower Assembly
86 MECHANIC 17-18
DIESEL ENGINE
c. Disconnect the oil inlet tube from the governor drive housing.
d. Disconnect the fuel lines from the fuel transfer pump.
e. Remove the water pump outlet flange bolts.
f. Loosen the water pump inlet hose clamps and slide the hose off the water pump inlet flange.
g. Remove the air cleaner.
h. Remove the air inlet housing.
i. Remove the blower drive cover plate.
j. Remove the blower drive shaft snap ring.
k. Remove the blower drive shaft.
NOTE: Some blower drive shafts have a tapped hole in the end, which can be used to aid in
removing the shaft from the engine.
l. Loosen the outboard seal clamp.
m. Slide the outboard seal clamp seal toward the blower until it is free of the blower drive assembly.
n. Remove the blower mounting bolts.
o. Remove the blower from the cylinder block.
p. Clean all parts for installation.
a. Install the blower mounting gasket and the blower onto the cylinder block.
NOTE: Ensure the water pump outlet flange and water pump outlet flange seal ring are installed
on the water pump outlet.
b. Install the blower mounting bolts.
c. Slide the outboard seal clamp seal toward the blower drive assembly until it covers the drive shaft
cover and the blower drive assembly.
d. Tighten the outboard seal clamp.
e. Install the blower drive shaft.
NOTE: It may be necessary to rotate the blower rotors to align the blower drive shaft splines with
the blower assembly.
MECHANIC 17-18 87
DIESEL ENGINE
f. Install the blower drive shaft snap ring.
g. Install the blower drive cover plate and gasket.
h. Install the air inlet housing and gasket.
i. Install the air cleaner.
j. Slide the water pump inlet hose onto the water pump inlet flange.
k. Tighten the water pump inlet hose clamps.
l. Install the water pump outlet flange bolts.
m. Connect the fuel lines to the fuel transfer pump.
n. Purge the fuel system.
o. Install the governor control housing.
1) Ensure the three segments of the thrust bearing are positioned toward the blower.
2) Install the governor control housing and gaskets, ensuring the mounting dowels are
aligned.
NOTE: Care must be taken to prevent any segment of the thrust bearing from sliding
forward when the governor control housing is installed.
3) Install the fuel rod into the governor control housing.
4) Install the clip that secures the fuel rod to the governor control housing.
5) Connect the fuel rod to the injector control tube lever.
6) Install the governor cover and gasket.
7) Install the breather tube.
8) Install the valve rocker cover.
p. Connect the throttle linkage to the governor lever.
q. Connect the oil inlet tube onto the governor drive housing.
r. Fill the cooling system with coolant, and check for leaks.
s. Bleed the air from the cooling system.
88 MECHANIC 17-18
DIESEL ENGINE
OSA 403
COMPETENCY
Adjust the valves on a four-valve head on a diesel engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee adjust the valves on four-valve head on a diesel engine.
The employee will be allowed to use the procedure section and/or the manufacturer’s manual to obtain the
valve clearances.
PROCEDURE
1. Conduct a JSA and follow Company guidelines and procedures
2. Remove the valve rocker cover.
3. Rotate the engine in the direction of rotation until the opposing cylinder intake rocker arm is fully
depressed on the cylinder to be adjusted.
4. Loosen the valve rocker adjustment locknut.
5. Place the proper thickness feeler gauge between the valve stem and the rocker arm. Turn the push rod
adjustment screw, until a slight drag is felt on the feeler gauge as it is pulled from between the stem and
the rocker arm. Refer to the manufacturer’s manual for the valve clearance.
6. Hold the push rod adjusting screw and tighten the locknut.
7. Recheck the clearance and, if necessary, readjust the push rod.
8. Repeat (Steps 3. through 6.) for further adjustment of valves on this cylinder.
9. Install the valve rocker cover.
MECHANIC 17-18 89
DIESEL ENGINE
Figure 2: Typical Valve Adjustment Four-Valve Head
90 MECHANIC 17-18
DIESEL ENGINE
OSA 404
COMPETENCY
Remove, install and adjust a fuel injector control tube assembly (rack) on a Detroit Diesel engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove, install and adjust a fuel injector control tube
assembly (rack) on a Detroit Diesel engine. The employee will be allowed to use the procedure section and/
or the manufacturer's manual.
PROCEDURE
The employee will demonstrate as follows: (Figures 3,4 and 5)
a. Remove the valve rocker cover.
b. Remove the cotter pin and clevis pin connecting the fuel rod to the injector control tube lever.
c. Loosen the adjusting screws on each injector rack control lever and slide the levers away from the
injectors.
d. Remove the bolts and lockwashers on each support bracket.
e. Remove the fuel injector control tube assembly.
MECHANIC 17-18 91
DIESEL ENGINE
a. Install the fuel injector control tube assembly.
b. Install the bolts and lockwashers on each support bracket.
c. Check the control tube to ensure it is not binding in the brackets. Tap the control tube lightly to align
the control tube in the bracket, if necessary.
d. Slide each injector rack control lever towards its fuel injector until each aligns with its fuel injector
control rack.
e. Ensure the return spring is installed on the number one injector rack control lever.
NOTE: If the return spring is not installed, attach the curled end of the spring to the fuel injector
side of the injector rack control lever and the extended end of the spring to the support bracket on
the side opposite the fuel injector.
f. Position the fuel rod in the injector control tube lever.
g. Install the clevis pin and secure it with a cotter pin.
4. Adjustment procedure:
a. Disconnect any linkages attached to the stop lever on the governor.
b. Loosen the locknut and back out the buffer screw on the governor approximately three turns.
c. Secure the speed control lever to the maximum speed position.
d. Move the stop lever to the run position. Hold it in that position with light finger pressure.
e. Turn the inner adjusting screw on the number one injector rack control lever in until the injector rack
has moved into the full fuel position.
NOTE: The full fuel position on the fuel injector is when the fuel injector control rack clevis is
positioned against the injector body.
f. Turn the outer adjusting screw in until it touches the injector control tube.
g. Alternately tighten both the inner and outer adjusting screws until tight.
NOTE: Overtightening the injector rack control lever adjusting screws during installation or
adjustment can result in damage to the injector control tube.
92 MECHANIC 17-18
DIESEL ENGINE
Figure 3: Typical Fuel Injection and Rack Assembly
MECHANIC 17-18 93
DIESEL ENGINE
Figure 4: Typical Fuel Injector Control Tube Assembly
94 MECHANIC 17-18
DIESEL ENGINE
5. Ensure the injector rack control lever is properly adjusted. (Figure 5)
a. Hold the speed control lever in the maximum speed position.
b. Using a screwdriver, press downward on the number one injector rack control lever. The rack should
rotate downward.
c. Release the screwdriver tension. The rack should rotate back upward.
NOTE: If the injector rack control lever does not return to its original position, it is too loose. To
correct this condition, back off the outer adjusting screw slightly and tighten the inner adjusting
screw slightly.
d. The setting is too tight if, when moving the stop lever from the stop to the run position, the injector
rack becomes tight before the stop lever reaches the end of its travel. To correct this condition, back
off the inner adjusting screw slightly and tighten the outer adjusting screw slightly.
6. Adjust the remaining injector rack control levers.
a. Remove the cotter pin and clevis pin connecting the fuel rod to the injector control tube lever.
b. Hold the injector rack control tube lever in the full fuel position.
c. Turn the inner adjusting screw on the number two injector rack control lever in until the injector rack
has moved into the full fuel position.
d. Turn the outer adjusting screw in until it touches the injector control tube.
e. Alternately tighten both the inner and outer adjusting screws until tight.
f. Recheck the number one injector rack control lever.
1) Using a screwdriver, press down on the number one injector rack control lever. It should be
snug.
2) Using a screwdriver, press downward on the number two injector rack control lever. It
should be snug.
NOTE: If the number one injector rack control lever has become loose, slightly back off the
inner adjusting screw on the number two injector rack control lever and tighten the outer
adjusting screw slightly.
3) If the number two injector rack control lever is loose, slightly back off the outer adjusting
screw on the number two injector rack control lever and tighten the inner adjusting screw
slightly.
MECHANIC 17-18 95
DIESEL ENGINE
Typical Variable Speed Mechanical Governor
Figure 5: Typical Fuel Injector Rack Check
96 MECHANIC 17-18
DIESEL ENGINE
7. Repeat (Step 6.) for each remaining injector rack control lever. After an injector rack control lever is
adjusted, recheck the adjustment for that lever and any levers previously set.
8. Position the fuel rod in the injector control tube lever.
9. Install the clevis pin and secure it with a cotter pin.
10. Reconnect any linkages that were disconnected from the stop lever on the governor.
11. Start the engine and run it until normal operating temperature is reached.
12. Adjust the governor buffer screw.
a. Ensure the engine is idling approximately 15 RPM below the recommended idle speed.
b. Turn the buffer screw in until the engine is operating at the recommended idle speed.
MECHANIC 17-18 97
DIESEL ENGINE
OSA 405 (AQ)
COMPETENCY
Inspect a turbo charger on a diesel engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee inspect a turbo charger on a diesel engine.
PROCEDURE
Note: Make sure all Lock Out/Tag Out, and Bypass procedures are followed.
1. Remove the air inlet filter to view the air compressor impeller for cracks, missing blades or metal,
excessive amounts of carbon, and make certain the impeller nut is tight and the impeller wheel is secure
on the shaft with no play, assembly must turn free.
2. Lift up and push in on the impeller shaft to check for excessive movement. If excessive movement is
evident, place a dial indicator on the shaft and check the movement using the manufacturer guidelines
and tolerances.
3. Remove the exhaust connection from the turbine wheel outlet (exhaust outlet) and check for similarities
as described in (Step 1).
4. Inspect the turbine wheel housing for cracks, and check the clamping lip for abnormal shape and cracks.
5. If any of the above are present, replace the turbo charger.
6. Reinstall all components.
98 MECHANIC 17-18
DIESEL ENGINE
OSA 406
COMPETENCY
Explain the procedure to perform an annual Preventive Maintenance (PM) task on a diesel engine.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the procedure to perform an annual Preventive
Maintenance (PM) task on a diesel engine.
PROCEDURE
1. Visually check for oil, fuel and coolant leaks.
2. Crank the engine and loosen each fuel connection one at a time to the fuel injector and listen for a change
in engine sound or performance. If no sound or performance change is noticed, this would indicate some
sort of performance malfunction with that particular cylinder. (fuel or compression problems) This
procedure is similar on Detroit Diesels except there are no external fuel lines. Remove the valve cover
and push down on each injector plunger and hold it for a few seconds to determine if a change in that
cylinders performance is noticed. If a change in performance is noticed, replace the injectors or repair
the abnormal condition of the cylinder.
3. Remove the valve cover or covers and inspect the pushrods making sure they are not bent or have
broken rocker arm cups.
4. Inspect the rocker arms for excessive play.
5. Adjust the valves according to the manufacturer's specifications.
6. Replace the oil, fuel, and air filters.
7. Install a dial indicator on the crankshaft pulley; push the crank shaft in and out to create the thrust motion
and record the movement against the manufacturer's specifications.
8. Clean or replace the crank case vent element or filter.
9. Test or replace the coolant thermostats.
10. Replace the oil, fuel, and air filters.
11. Check or replace and tighten all belts.
MECHANIC 17-18 99
DIESEL ENGINE
100 MECHANIC 17-18

G T E
GAS
AS
TURBINE
URBINE
ENGINE
NGINE
OSA 501
COMPETENCY
Disassemble, inspect, and reassemble the combustor assembly on a Solar Saturn gas producer.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee disassemble, inspect, and reassemble the
combustor assembly on a Solar Saturn gas producer. The employee will be allowed to use (Figures 1
and 2),the procedure section and/or the manufacturer's manual.
PROCEDURE
2. Disassembly procedure:
a. Remove the fuel manifold lines.
b. Remove the igniter plug fuel gas line.
c. Remove the fuel distribution manifold.
1) Disconnect the supply line to the manifold.
2) Remove the mounting bolts securing the manifold to the compressor diffuser case.
d. Remove the igniter plug.
e. Remove the diffuser tube oil supply line.
f. Disconnect the engine oil drain tube.
g. Remove the engine oil drain fitting.
h. Disconnect the Pressure Compressor Discharge (Pcd) and combustor drain lines connected to
the engine.
MECHANIC 17-18 101

GAS TURBINE ENGINE
i. Remove the sixth stage bleed valve.
j. Remove the combustion case insulation blankets.
k. Remove the nuts and bolts securing the rear of the combustion case.
l. Remove the bolts securing the front of the combustion case.
m. Install three jacking bolts into the forward flange of the combustion case.
n. Tighten the jacking bolts evenly until the combustion case disengages from the compressor
diffuser case.
o. Remove the jacking bolts.
p. Slide the combustion case toward the air inlet housing until it clears the combustor dome.
q. Remove the combustor outer liner.
1) Bend the corners back on the lockstrips, located at the 3 and 9 o’clock positions.
2) Remove the clampstrips.
3) Remove the combustor outer liner halves.
3. Inspection procedure:
a. Inspect the combustor assembly. (Figure 1)
1) Check outer liners at small holes for cracks. Cracks at maximum of six holes in a row, or
four holes connected in pairs are allowed.
2) Check large holes in liners and slots in dome for cracks; cracks shall not exceed 1/2 inch
in length. (Refer to Step 8.)
3) Check louvers on inner and outer liners for warping and erosion. Louvers may not be
closed at any point to less than 0.050-inch gap. Maximum allowable erosion is two spots
1/4-inch deep and two holes wide.
4) Check nuts on outer liners for security and for condition of threads.
5) Check outer lip of dome for erosion. Maximum allowable erosion in three spots 1-inch
wide to depth of outer spacer.
6) Check inner lip of dome for erosion. Maximum allowable erosion is three spots 1-inch
wide, feathered to 3/8-inch depth.
102 MECHANIC 17-18

GAS TURBINE ENGINE
7) Check all corners of slots in dome for cracks. Cracks connecting three slots to holes are
allowed providing no adjacent slots are cracked through. No cracks are allowed that
could propagate and release a piece of metal.
8) Check for any cracks that could form and release a piece of metal from any part of
combustor.
9) Check combustion case for cracks at bosses.
b. Inspect the fuel nozzles for looseness, wear, and foreign material.
c. Inspect the combustor assembly for evidence of lubricating oil.
d. Inspect the turbine nozzle. (Figure 2)
4. Assembly procedure:
a. Install the combustor outer liner.
1) Ensure the aft end of each liner half slides into the groove on the shroud.
2) Ensure the forward end of each liner half fits into the groove on the combustor dome.
3) Ensure the igniter plug boss in the lower half of the outer liner aligns with the recessed
area in the combustor dome.
4) Pull the liner halves together at the 3 and 9 o’clock positions, and install the clampstrip,
lockstrip, and bolts.
5) Bend the corners on each lockstrip to secure the bolts.
b. Slide the combustion case toward the exhaust collector until it contacts the diffuser case. Ensure
the igniter plug boss on the combustion case aligns with the igniter plug boss on the combustor
outer liner.
NOTE: This can be accomplished by placing the 1/4 inch PCD outlet on the combustion case
at the 12 o’clock position.
c. Install the front and rear combustion case bolts finger tight, ensuring the bolts are coated with high
temperature thread lubricant.
NOTE: If the front combustion case bolts cannot be installed, it may be necessary to tighten four
rear combustion case bolts in a staggered sequence until the front bolts can be installed.
d. Tighten the front combustion case bolts in a staggered sequence until the combustor case is
seated against the diffuser housing.
e. Tighten the rear combustion case bolts.
MECHANIC 17-18 103

GAS TURBINE ENGINE
f. Check the front combustion case bolts, ensuring they are tight.
g. Install the combustion case insulation blankets.
h. Install the sixth stage bleed valve.
i. Connect the PCD and combustor drain lines to the engine.
j. Install the engine oil drain fitting and gasket.
k. Connect the engine oil drain tube.
l. Install the diffuser tube oil supply line.
m. Install the fuel distribution manifold.
1) Install the mounting bolts securing the manifold to the compressor diffuser case.
2) Connect the supply line to the manifold.
n. Install the fuel manifold lines.
o. Install the igniter plug.
p. Install the igniter plug fuel gas line.
5
7
8
4
2
2
3
Figure 1: Typical Combustor Assembly Inspection
104 MECHANIC 17-18

GAS TURBINE ENGINE
NOTE: Root Cracks - Vane cracking at the intersection of the trailing edge of the vane and inner and outer
shroud ring is normal. Cracks of this type, at both inner and outer shroud ring and on any number of vanes,
do not require replacement of the nozzle. Root cracks, which require replacement of the nozzle, are
cracks that are over 1/4 inch long and branch toward an intersection with a trailing edge crack with
eventual termination that would allow a sizable piece of vane to be dislodged.
NOTE: Trailing - Edge Cracks - The cracks at the trailing edge of the vanes will vary from the short (1/
8-inch long) hairline-type that results from repeated stress cycling, to the notched and multiple branching
type of crack that usually occurs when the engine has been operated with clogged or excessively
carboned fuel nozzles. Cracks caused by this condition usually occur in a localized nozzle segment
including five to seven adjacent vanes, while the remaining vanes show cracks to a much lesser degree
or none at all.
NOTE: three trailing-edge hairline cracks spaced 1/2 inch or more apart do not require nozzle
replacement, provided the cracks are not more than 1/2-inch long and are parallel. Cracks in this category
require nozzle replacement if the spreading of the crack would eventually intersect another crack, or if
spreading was such that the end of the crack forms a hook indicating that continued spreading would
result in a piece becoming loose. Notching, wide cracks, and multiple branch cracks require nozzle
replacement. However, the nozzle need not be replaced if this type of crack does not exceed 1/2 inch
in length, with adjacent cracks no closer than 1/2 inch, and branching would not permit pieces of the vane
to separate.
Figure 2: Typical Turbine Nozzle Inspection
MECHANIC 17-18 105

GAS TURBINE ENGINE
OSA 502 (AQ)
COMPETENCY
Explain the possible causes of high exhaust gas temperature (EGT).
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the possible causes of high exhaust gas
temperature (EGT). The Qualifier will select seven(7) of the ten(10) possible symptoms of high (EGT) and
have the employee state the causes and solutions.
PROCEDURE
1. Symptom: Dirty air inlet filters
CAUSE SOLUTION
Extended air filter use. Replace filter when differential indicates

change out.
Environment (sandblasting, pressure Shield filters from elements.

washing, paint chipping.
2. Symptom: Wet air inlet filters
CAUSE SOLUTION
Heavy rain. Check seal on filter doors and check
mist extractors.
Platform cleaning. Reduce or direct water source away

from filters.
106 MECHANIC 17-18

GAS TURBINE ENGINE
3. Symptom: Restriction in the air intake system.
CAUSE SOLUTION
Collapsed air filters. Replace filters.
Air inlet connection boot damaged. Replace boot.
Equipment stored in front of air in let. Remove and place equipment away from
air inlet.
4. Symptom: Restriction in the exhaust system.
CAUSE SOLUTION
High wind blowing directly in the exhaust. Direct the exhaust upward if possibe.
Collpased exhaust expansion joint. Replace expansion joint.
Dirty blade nozzle. Detergent wash engine (may need to

repeat if necessary).
5. Symptom: Dirty compressor blades in the gas turbine engine.
CAUSE SOLUTION
Lack of detergent wash. Detergent wash engine.
Extended run time on air filters. Change air filters.
Leaking internal oil seal. Depending on what seal is leaking, the

engine will probably have to be changed
out.
6. Symptom: Damaged blades in the gas turbine engine.
CAUSE SOLUTION
Blade failure. Replace gas producer engine.
Foreign object being introduced in the Check filtration inlet.

engine.
Overheating engine. Check temperature topping control.

Clean / Detergent wash engine.
MECHANIC 17-18 107

GAS TURBINE ENGINE
7. Symptom: Engine overloaded.
CAUSE SOLUTION
Too much load on engine. Reduce the load on engine.
Dirty or damaged turbine blades. Clean and inpect blading for damage.
8. Symptom: Defective temperature indicating system.
CAUSE SOLUTION
Bad temperature control box. Replace and calibrate control box.
Defective T7 thermocouples. Replace T7 harness.
Loose or broken wires. Check wiring and replace broken wires.
9. Symptom: Excessive engine RPM.
CAUSE SOLUTION
Defective speed switch. Change speed switch.
Faulty speed indicator. Replace or calibrate speed meter.
108 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 503
COMPETENCY
Explain the purpose and principle operation of a variable guide vane system on a gas turbine engine.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the purpose and principle operation of a variable
guide vane system on a gas turbine engine.
PROCEDURE
1. Purpose:
a. A variable guide vane system, installed on selected models of engines, allows the guide vanes
in the inlet of the compressor section to be positioned at their minimum opening during start-up.
This restricts the amount of air entering the engine.
b. The restriction in the compressor section causes the velocity of the air to increase. The increased
air velocity causes the compressor rotor to spin when the air contacts the compressor blades.
2. Principle of operations:
a. When the engine is not running, the variable guide vanes are placed in the minimum open position
by the variable vane control actuator.
b. When engine speed reaches approximately 25% during start-up, the variable guide vanes begin
to open, allowing a larger volume of air to enter the engine.
NOTE: The opening of the variable guide vanes are controlled by the variable vane control
actuator. The actuator is controlled by PCD. As PCD increases, the actuator output shaft
extends, causing the variable guide vanes to open.
c. When engine speed reaches approximately 75%, the variable guide vanes are fully open,
allowing all the air available to enter the engine.
MECHANIC 17-18 109

GAS TURBINE ENGINE
Figure 3: Typical Turbine Variable Guide Vane System
110 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 504 (AQ)
COMPETENCY
Explain the principle of operation of the secondary gas fuel valve on a gas turbine engine.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the principle of operation of the secondary gas
fuel valve on a gas turbine engine. The employee will be allowed to use (Figures 4) when explaining this
Assessment.
PROCEDURE
1. When the fuel system is given an electrical signal to open, fuel gas from the primary gas fuel valve
enters the lower body of the secondary gas fuel valve, exerting pressure on the lower diaphragm.
2. Simultaneously, the same electrical signal is given to the pilot vent valve solenoid.
3. The solenoid opens, allowing pilot gas to enter the upper body of the secondary gas fuel valve. The
pilot pressure exerts pressure on the upper diaphragm.
4. As long as the pilot and fuel gas pressures are equal, fuel gas is allowed to flow to the gas fuel control
valve.
5. When the electrical signal is removed from the fuel system, the primary gas fuel valve and the pilot
vent valve solenoid close. The closed primary gas fuel valve blocks the flow of fuel gas to the engine.
6. If during shutdown the primary gas fuel valve remains open due to contaminants or other factors, the
closed secondary gas fuel valve blocks the flow of fuel gas to the gas fuel control valve.
7. The secondary gas fuel valve blocks the flow of fuel gas to the gas fuel control valve because there
is no pilot pressure on top of the valve to hold it open.
MECHANIC 17-18 111

GAS TURBINE ENGINE
Pcd Pressure
Spring
Upper
Diaphragm
Lower
Diaphragm
Fuel Gas Out Fuel Gas In
Fuel Gas
Seal Seat
Pilot Pressure
Figure 4: Typical Secondary Gas Fuel Valve
112 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 505
COMPETENCY
Explain the principle of operation of the gas fuel control valve on a gas turbine engine.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the principle of operation of the gas fuel control
valve on a gas turbine engine. The employee will be allowed to use (Figure 5) when explaining this
Assessment.
PROCEDURE
1. When the fuel system is energized, the primary and secondary gas fuel valves open, allowing fuel
gas to flow to the inlet of the gas fuel control valve.
2. Fuel gas, entering the valve, flows to the bottom of the main poppet valve.
3. Additionally, a small amount of fuel gas flows through a filter and restrictor orifice to the number one
and two loader valves and the upper side of the main poppet valve diaphragm.
NOTE: This gas is referred to as control gas.
4. The control gas flows through the number one and two loader valves, allowing the control gas to
pressurize the lower side of the main poppet valve diaphragm.
5. The main poppet valve diaphragm at this time is pressurized equally on both sides. However, control
gas on the upper side of the main poppet valve diaphragm pressurizes quicker than the control gas
on the lower side. This action forces the main poppet valve to slightly open, allowing fuel gas to flow
through the throttle valve to the fuel manifold.
6. As the engine speed accelerates, PCD increases, causing the number one loader valve to begin
closing. This reduces the amount of control gas flowing to the lower side of the main poppet valve
diaphragm.
7. This results in more pressure on the upper side of the main poppet valve diaphragm and causes the
main poppet valve to open wider.
MECHANIC 17-18 113

GAS TURBINE ENGINE
NOTE: This action is progressive - as PCD increases, the main poppet valve will open wider.
8. When engine speed reaches approximately 45%, the number one loader is fully closed and the
number two loader begins to close.
9. As PCD increases, the process continues. The number two loader closes, allowing less control gas
to the bottom side of the main poppet valve diaphragm, which results in the main poppet valve opening
wider.
10. When the engine reaches rated speed, the main poppet valve is fully open. Engine speed is controlled
by the governor, which is connected to the throttle valve.
Spring
Adjustor Pcd
No. 1 Loader No. 2 Loader Spring
Valve Valve Adjustor
Spring
Spring
Restrictor
Orifice
Filter
Spring Outlet
Inlet
Spring
Throttle Control
Main Main Poppet Valve Valve
Control Gas Diaphragm
Poppet Valve
PCD
Fuel Gas
Figure 5: Typical Gas Fuel Control Valve
114 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 506
COMPETENCY
Explain the adjustment procedure for the number one loader on the gas fuel control valve.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the adjustment procedure for the number one
loader on the gas fuel control valve. The employee will be allowed to use (Figure 6) when explaining this
Assessment.
PROCEDURE
1. Adjustment of the number one loader should be attempted only after all other attempts to correct
possible malfunctions, such as no lightoff, flameout, or poor acceleration, have been investigated.
2. Adjustment procedure:
a. Disconnect the electrical input lead to the ignition exciter.
b. Install a pressure gauge into the side of the gas fuel control valve at the plug near the throttle valve.
c. Ensure the gas fuel control valve filter is clean.
d. Energize the fuel system.
e. Observe the pressure gauge. The pressure should be 1 psi ± .5 psi.
f. If the pressure is not within limits, remove the number one loader cap, and screw the adjusting
screw in or out until the desired pressure is obtained.
NOTE: The number one loader can be identified by a stamp on the gas fuel control valve body.
g. Install the loader cap, and recheck the pressure.
h. Deenergize the fuel system.
i. Remove the pressure gauge from the side of the gas fuel control valve.
j. Connect the electrical input lead to the ignition exciter.
MECHANIC 17-18 115

GAS TURBINE ENGINE
Figure 6: Typical Gas Fuel Control Valve
116 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 507
COMPETENCY
Remove, inspect and install the filter element and poppet valve in a gas fuel control valve on a Solar gas
turbine engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove, inspect, and install the filter element and
poppet valve in a gas fuel control valve on a Solar gas turbine engine. The employee will be allowed to
use the procedure section and/or the manufacturer's manual.
PROCEDURE
2. Filter element:
a. Remove the filter element cap.
b. Remove the filter element.
c. Remove the o-ring from the filter element and discard the o-ring.
d. Clean the filter element with diesel fuel, then blow it dry with compressed air.
e. Clean the filter element cap and the recessed area in the gas fuel control valve where the filter
element will be installed.
f. Ensure the filter element cap o-ring is serviceable.
g. Lubricate a new o-ring and install it onto the filter element.
h. Install the filter element into the gas fuel control valve, ensuring it is fully seated in the recessed
area.
i. Install the filter element cap.
MECHANIC 17-18 117

GAS TURBINE ENGINE
3. Poppet valve
a. Remove the poppet valve cap.
b. Remove the poppet valve spring.
c. Remove the poppet valve.
d. Clean the poppet valve.
e. Clean the poppet valve cap and the recessed area in the gas fuel control valve where the poppet
valve will be installed.
f. Ensure the poppet valve cap o-ring is serviceable.
g. Install the poppet valve into the recessed area of the gas fuel control valve, ensuring the stem
on the poppet valve enters the poppet valve guide.
h. Slide the poppet valve in and out of the poppet valve guide several times, ensuring the poppet
valve does not bind.
i. Install the poppet valve spring.
j. Install the poppet valve cap.
118 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 508 (AQ)
COMPETENCY
Check the backup post-lube pump of a gas turbine engine for proper operation.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee check the backup post-lube pump of a gas turbine
engine for proper operation.
PROCEDURE
2. Press the start button and immediately press the stop button.
3. Ensure that the auxiliary lube oil pump comes on and pressurizes the lube oil system to approximately
12 psi.
4. Remove the power from the auxiliary lube oil pump motor.
NOTE: This can be accomplished by closing the block valve if the pump is driven pneumatically
or turning OFF the AC breaker if the pump is driven electrically.
5. Observe the lube oil system pressure dropping.
6. Approximately 15 seconds after the lube oil system pressure drops below 4 psi, the backup post-lube
pump will come on.
7. Ensure the backup post-lube pump comes on and pressurizes the lube oil system to approximately
12 psi.
8. Restore the power to the auxiliary lube oil pump motor.
MECHANIC 17-18 119

GAS TURBINE ENGINE
OSA 509
COMPETENCY
Explain the start-up procedure from the control panel / console of a Solar turbine compressor.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the start-up procedures from the control
panel / console of a Solar turbine compressor.
PROCEDURE
NOTE: The steps listed below outline a generic procedure. Always follow specific unit start-up and
shutdown procedure.
1. Control "master selector" switch is moved to local position.
2. "Reset" switch is depressed / toggled.
a) Summary start circuits are armed.
b) Malfunction and alarm lights illuminated.
c) Engine ready to run light illuminates.
3. "Reset" switch is released.
a) All malfunction and alarm lights extinguished.
b) Ready to run light remains illuminated.
4. "Start" switch is pressed and released.
a) Start circuits are energized and start sequence begins.
b) Run light illuminates, starting cycle.
c) Auxiliary oil pump begins lubrication cycle.
120 MECHANIC 17-18

GAS TURBINE ENGINE
d) Auxiliary seal oil pump starts.
e) Auxiliary seal oil pump on light illuminates
5. Gas compressor "yard valve" sequence begins.
a) Bypass "yard valve" closes.
b) "Loading valve" opens to purge compress.
c) After 30 seconds of purge, "vent valve" closes and compressor begins to pressurize.
d) When compressor is pressurized to a preset differential, "suction", "discharge" and "bypass

valves" opens and "loading valve" closes.
6. Thirty seconds after "suction", "discharge" and "bypass valves" open, starter begins to crank engines.
7. Ten seconds after 15% engine speed.
a). Light off occurs within a few seconds and combustion begins.
b). Engine temperature starts to increase.
8. Ten to twenty five seconds after light off, ignition is shut-off.
9. Engine driven oil pump pressure reaches 35 psig, aux. lube oil pump is shut-off.
10. Engine speed reaches 60%.
a) Starter system is de-activated.
b) Hourmeter starts to log engine operating hours.
11. Engine speed reaches idle speed. Approximately 70%.
12. Engine speed is increased to selected loading speed (depending on unit) by turning pneumatic speed
control knob clockwise or toggling speed increase knob.
13. "Bypass valve" closes.
14. Auxiliary seal oil pump is shut-off.
15. Compressor is now on-line.
MECHANIC 17-18 121

GAS TURBINE ENGINE
OSA 510
COMPETENCY
Change the lube oil filters on a Solar gas turbine engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee change the lube oil filters on a Solar gas turbine
engine. The employee will change the lube oil filters in one filter canister on a Solar gas turbine engine.
The employee will be allowed to use the procedure section and/or the manufacturer's manual.
PROCEDURE
NOTE: The steps listed below outline a generic procedure for a Solar Saturn Mark II gas turbine
engine.
a. Open the filter canister drain valve.
b. Open the needle valve on the filter canister cover.
c. Remove the filter canister cover.
d. Remove the filter canister o-ring.
e. Remove the filter element retainer.
f. Remove the filter element end guide gasket.
g. Remove the filter element end guide.
h. Remove the filter element gaskets and filter elements.
122 MECHANIC 17-18

GAS TURBINE ENGINE
NEEDLE VALVE
FILTER ELEMENT RETAINER FILTER CANISTER COVER
FILTER ELEMENT END GUIDE FILTER ELEMENT END GUIDE GASKET
FILTER CANISTER O-RING
FILTER ELEMENTS
FILTER ELEMENT GASKET
FILTER CANISTER DRAIN VALVE
Figure 7: Typical Lube Oil Filter Canister
MECHANIC 17-18 123

GAS TURBINE ENGINE
a. Inspect the filter canister, filter elements, and the top of the filter element end guide for signs of
metal, contamination, and foreign objects.
b. Clean the filter canister, filter element retainer, and filter element end guide.
a. Place a filter element gasket in the bottom of the filter canister, ensuring it is flush and centered
on the bottom flange.
b. Place a filter element on top of the gasket.
c. Place a filter element gasket on top of the filter element.
d. Place another filter element on top of the gasket.
e. Place a filter element gasket on top of the second filter element.
f. Install the filter element end guide.
g. Place the filter element end guide gasket on top of the end guide.
h. Install the filter element retainer.
i. Install the filter canister o-ring.
j. Install the filter canister cover.
k. Close the filter canister drain valve.
l. Start the auxiliary lube oil pump by placing the auxiliary seal oil pump switch, located on the
control panel, in the manual position.
m. When the filter canister is filled with oil, close the needle valve on top of the filter canister cover.
n. Place the auxiliary seal oil pump switch in the auto position.
124 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 511
COMPETENCY
Remove and install the diffuser O-Ring tube on a Solar gas turbine engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove and install the diffuser O-Ring tube on
a Solar gas turbine engine. Employee will be allowed to use the procedure section and/or the
manufacturer's manual.
PROCEDURE
NOTE: The steps listed below outline a generic procedure. The O-Ring located on the end of the
diffuser tube requires periodic replacement due to the high operating temperature within the gas
turbine engine.
a. Disconnect the oil supply line to the diffuser tube.
b. Remove the retaining bolts and the clamp.
c. Remove the diffuser tube from the compressor diffuser.
NOTE: It may be necessary to twist the diffuser tube slightly to break the o-ring seal on the
compressor diffuser.
d. Remove the gasket from the compressor diffuser.
e. Remove the o-ring from the diffuser tube.
MECHANIC 17-18 125

GAS TURBINE ENGINE
a. Lubricate the o-ring and install it on the diffuser tube.
b. Place the gasket in the recessed area of the compressor diffuser.
c. Install the diffuser tube in the compressor diffuser.
d. Coat the retaining bolts with a high temperature thread lubricant, and install the clamp and bolts.
e. Connect the oil supply line to the diffuser tube.

.
Figure 8: Typical Diffuser Assembly
126 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 512 (AQ)
COMPETENCY
Disassemble, inspect and reassemble a spare or removed bleed valve on a Solar gas turbine engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee disassemble, inspect, and reassemble a spare
or removed bleed valve on a Solar gas turbine engine. Employee will be allowed to use the procedure
section and/or the manufacturer's manual.
PROCEDURE
NOTE: The steps listed below outline a generic procedure for a Solar Saturn gas turbine engine.
2. Disassembly procedure:
a. Place the bleed valve in a vice with the cover facing up.
b. While pressing down on the cover, remove the snap ring.
c. Slowly release the pressure on the cover, allowing the cover to be pushed from the housing by
the spring.
d. Remove the cover.
e. Carefully remove the seal from the piston.
NOTE: The seal is very fragile and will break if it is spread apart too far when it is removed.
f. Remove the piston.
g. Remove the spring.
MECHANIC 17-18 127

GAS TURBINE ENGINE
a. Clean the valve body center bore and the outside diameter of the piston.
b. Inspect the valve body center bore for scratches and nicks.
c. Inspect the outside diameter of the piston for scratches and nicks.
d. Inspect the spring for wear.
e. Install the piston into the valve body and slide it in and out several times, ensuring the piston does
not bind.
f. Remove the piston.
a. Place the valve body in a vice with the cover opening facing up.
b. Install the spring into the valve body.
c. Install the piston into the valve body with the seal side of the piston facing up.
d. Install the seal onto the piston.
e. Compress the seal around the piston, and install the cover over the compressed seal.
f. Press down on the cover, and install the snap ring.
128 MECHANIC 17-18

GAS TURBINE ENGINE
Figure 9: Typical Bleed Valve
MECHANIC 17-18 129

GAS TURBINE ENGINE
OSA 513
COMPETENCY
Detergent wash a gas turbine engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee detergent wash a gas turbine engine.The
employee will be allowed to use the procedure section and/or the manufacturer's manual.
PROCEDURE
NOTE: The steps listed below outline a generic procedure for a gas turbine engine.
2. Prewash procedure:
a. Disconnect the engine rear seal air line. Place a cap on the male fitting.
b. Disconnect the sixth stage bleed valve air line. Place a cap on the male fitting.
c. Disconnect the fuel control air line. Place a cap on the male fitting.
d. Disconnect the engine combustor drain line.
e. Disconnect the exhaust collector drain line.
f. Disconnect the sixth stage bleed valve from the engine. Place a cover over the opening on the
engine.
g. Remove the detergent wash access doors located on the air inlet duct assembly.
h. Mix one pint of domestic detergent with two gallons of potable water in a garden sprayer.
Pressurize the sprayer.
i. Ensure the engine has been shut down a minimum of two hours or until temperature reaches a
safe level to allow the internal engine parts to cool.
130 MECHANIC 17-18

GAS TURBINE ENGINE
3. Wash procedure:
a. Crank the engine by placing the detergent wash switch, located on the control panel, in the “on”
position.
b. Spray the washing solution into the air inlet at a rate of one gallon per minute. Keep the spray
moving around the inlet so that all areas of the compressor are washed.
c. Just before all of the washing solution is used, stop cranking the engine by turning the detergent
wash switch to the “off” position.
d. Continue spraying the washing solution into the air inlet until the engine has coasted down to
approximately 10% engine speed.
e. Rinse the garden sprayer and fill it with potable water. Pressurize the sprayer.
f. Crank the engine by placing the detergent wash switch in the “on” position.
g. Spray the water into the air inlet at a rate of one gallon per minute. Keep the spray moving around
the inlet so that all areas of the compressor are rinsed.
h. Continue spraying the water until the water draining out of the combustor and exhaust collector
drain lines is clean and free of soap.
NOTE: It may be necessary to refill the garden sprayer with potable water.
i. Remove the bleed valve cover on the engine.
j. Allow the engine to continue cranking for approximately 30 seconds to allow all the water in the
engine to drain.
k. Turn the detergent wash switch to the “off” position.
4. Postwash procedure:
a. Install the detergent wash access doors onto the air inlet duct assembly.
b. Connect the sixth stage bleed valve onto the engine, ensuring its o-ring is in place.
c. Connect the exhaust collector drain line.
d. Connect the engine combustor drain line.
e. Remove the cap from the fuel control air line fitting and connect the air line.
f. Remove the cap from the sixth stage bleed valve air line fitting and connect the air line.
g. Remove the cap from the engine rear seal air line fitting and connect the air line.
h. Start the engine and allow it to run for approximately five minutes to dry all the internal engine
components.
MECHANIC 17-18 131

GAS TURBINE ENGINE
Figure 10: Typical Gas Turbine Engine Detergent Wash Disconnect Points
132 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 514
COMPETENCY
Explain the flow of the seal oil system of a gas turbine compressor engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee explain the flow of the seal oil system of a gas
turbine compressor engine. The employee will be allowed to use (Figure 11) only.
PROCEDURE
The employee will explain as follows (Figure 11):
1. The function of the seal oil system is to provide a flow of oil to the compressor seals at a higher
pressure than the suction gas pressure to counteract any escape of gas through the bearings and
seals.
2. The oil is pumped through a 10-micron filter to the seal oil flow regulator, which maintains constant
flow.
3. Oil flows to the differential pressure regulator where it is maintained at 20 psi above suction gas
pressure.
4. Oil is directed to the front and back of the oil seals in the gas compressor to prevent gas leakage.
5. Oil is routed to an oil-gas separator where the oil is directed back to the tank.
MECHANIC 17-18 133

GAS TURBINE ENGINE
TYPICAL COMPRESSOR
TURBINE ENGINE
SEAL OIL
PUMP ORIFICE
BUFFER GAS ∆P
FROM LUBE OIL REGULATOR
DISTRIBUTION SUCTION DISCHARGE
MANIFOLD
SEAL OIL / GAS SEPARATOR
PNUEMATIC OR
ELECTRIC MOTOR
AUXILIARY
SEAL OIL
PUMP
SEAL OIL ∆P
REGULATOR
SEAL OIL
FLOW REGULATOR
FILTER
OIL TANK
LEGEND
SEAL OIL BUFFER GAS
AUX. SEAL OIL OIL RETURN
SEAL OIL GAS SUCTION GAS
CHECK VALVE SIGHT GLASS
RELIEF VALVE FLOW INDICATOR
Figure 11: Seal oil and buffer gas system
134 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 515 (AQ)
COMPETENCY
Explain the function of a dry gas seal in a turbine compressor.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the function of a dry gas seal in a turbine
compressor.
PROCEDURE
1. Seals are a critical subsystem in a centrifugal compressor and represent a significant advance in shaft
sealing. Gas seals help eliminate the need for complex seal oil systems and maintenance associated
with them.
2. A turbine gas compressor utilizes an impeller mounted on a shaft located between two bearings with
the gas space surrounding the impeller. They are separated from the bearings by dry gas seals,
including at least primary dry gas seals. The primary dry gas seal located near the discharge end of
the compressor has a larger diameter than the corresponding seal at the suction end of the
compressor so that the pressurized gas acts on the respective rotary parts of the dry gas seals thus
pushing the shaft towards the discharge end of the compressor. This counteracts the dynamic forces
on the impeller.
3. The main component of the gas seal is a pair of seal rings. A stationary ring is held against a rotating
ring by spring pressure. The contact face of the rotating ring utilizes groves or tapered lands on the
outer portion. Compressor discharge gas is maintained at a pressure slightly above that of the
process gas to be contained and introduced into the sealing area.
4. As gas pressure and shaft rotation interact during normal operation, the rotating ring creates a gas
pumping or lifting effect which pushes the spring-loaded stationary ring away from the rotating ring.
The pressurized effect created by the rings function as the primary seal and breaks down gas
pressure to just above atmospheric pressure.
MECHANIC 17-18 135

GAS TURBINE ENGINE
Figure 13: Dry Gas Seal
136 MECHANIC 17-18

GAS TURBINE ENGINE
OSA 516
COMPETENCY
Start, synchronize and load a turbine generator.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee start, synchronize and load a turbine generator.
The employee will be allowed to use the procedure section and/or the manufacturer's manual.
PROCEDURE
Note: The steps listed below outline a generic procedure. Consult the manufacturer's manual for startup
and shutdown procedures.
2. Make sure the generator which is running is operating at the desired voltage and Hertz range.
3. Start the standby or secondary unit. Adjust speed and voltage if necessary.
4. Locate the synchro-meter and adjust the engine speed so the synchro meter seems to settle on 0
(zero) which is usually located at the top (12 o'clock position).
5. When the meter indicates the desired position, close the main breaker and open the main breaker
on the unit that will be shut down.
6. After the breakers have been activated and de-activated, adjust the speed and hertz on the recently
started unit if necessary.
MECHANIC 17-18 137

GAS TURBINE ENGINE
OSA 517
COMPETENCY
Trace the gas flow through and explain the functions of the major components of a turbine driven
centrifugal compressor including surge control.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee trace the gas flow through and explain the
functions of the major components of a turbine driven centrifugal compressor including surge control. The
employee will be allowed to use (Figures 13) when explaining this Assessment
PROCEDURE
Trace the flow:
1. Compressor Case: houses all the components of the centrifugal compressor.
2. Suction End Housing: The suction flange which is on the drive end and houses the “capsule”
also contains the bearing and seal assembly along with the balance piston.
3. Discharge End Housing: The discharge flange which is on the aft side of the compressor case
contains the discharge “capsule” and also contains the bearing and seal assembly.
4. Impeller Shaft: depending on the staging arrangements, is fitted with the appropriate amount and
size impellers.
5. Guide Vane: directs gas into the impeller inlet or eye as sometimes referred to.
6. Diaphragm: is the component that the guide vane bolts to forming the diffuser area. When the
guide vane and the diaphragm are bolted together, this assembly is referred to as a stator.
7. Impeller: accelerates gas to a higher level of energy. It is the only moving component that adds
velocity to the gas.
138 MECHANIC 17-18

GAS TURBINE ENGINE
Figure 13: Turbine Compressor Cutout
MECHANIC 17-18 139

GAS TURBINE ENGINE
Surge Control:
1. The capacity control system for a Solar Turbine compressor is the use of a calculated program
to protect the unit from damage during a surge event. The capacity unit (surge control) is designed
to slow the unit down to a safe speed which is based on suction and discharge pressure, flow
through the compressor, gravity of the gas, inlet and outlet temperatures, speed of the
compressor and differential between the suction and discharge pressures.
Figure 14: Internal Centrifugal Compressor Components
140 MECHANIC 17-18

I S
IGNITION
GNITION
SYSTEMS
YSTEMS
NOTE: Competencies in this section may require documented OJT with a Company Electrician prior
to the demonstration of the competency. The Electrician should also be in attendance during the
demonstration to ensure that all safe practices are followed. The employee shall explain each step
of the electrical procedure to the Qualifier and Electrician prior to being performed. The Electrician
should initial the record of the training in the Supervisor’s Documentation Copy of the OSAs if OJT was
conducted prior to Competency administration.
OSA 601
COMPETENCY
Check the output voltage on a spare or removed Altronic III ignition unit.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee check the output voltage on a spare or removed
Altronic III ignition unit. The employee will be allowed to use (Figure 2) and the procedure section.
PROCEDURE
NOTE: The steps listed below outline a generic procedure. Ensure the ignition unit is not in a
hazardous location when performing this Competency because a spark may occur.
2. Remove the back cover from the ignition unit.
3. Determine the number of pickup coils mounted on the back plate.
NOTE: The number obtained is the number of cylinders the ignition unit is wired for.
4. Using (Figure 2), determine which pins are used to supply voltage to the ignition coils.
MECHANIC 17-18 141

IGNITION SYSTEMS
Pick-up
Coils Back
Cover
Stator
Windings
Ignition
Unit Alternator Pointer
Input Section Window
Shaft
Bearing
Bearing
Rotor Electrical Plug
Cannon Plug
Figure 1: Typical Altronic III Ignition Unit
142 MECHANIC 17-18

IGNITION SYSTEMS
Number of Pins Used to

Pickup Coils Supply Voltage
2 A-C
3 A-B-C
4 A-B-C-D
5 A-B-C-D-E
6 A-B-C-D-E-F
8 A-B-C-D-E-F-H-I
10 A-B-C-D-E-F-H-I-J-K
12 A-B-C-D-E-F-H-I-J-K-L-M
16 A-B-C-D-E-F-H-J-
K-L-M-N-P-R-S-T
Figure 2: Typical Altronic III Harness Connections
5. Check the stator windings output voltage.
a. Place an analog volt meter on the AC volt scale.
b. Connect one lead of the volt meter to one pin of the electrical plug in the alternator section.
c. Connect the other lead of the volt meter to the other pin of the electrical plug in the alternator section.
d. Spin the ignition unit input shaft by hand.
e. The meter should read approximately 75 VAC.
NOTE: If no voltage is indicated, switch the positions of the volt-ohm meter leads on the electrical
plug. The speed at which the ignition unit input shaft is turned will bear a direct relationship to the
voltage indicated.
MECHANIC 17-18 143

IGNITION SYSTEMS
6. Install the back cover onto the ignition unit.
7. Check the ignition unit output voltage.
a. Place an analog volt meter on the DC volt scale.
b. Connect the positive lead of the volt meter to a pin used to supply voltage to an ignition coil.
c. Connect the negative lead of the volt meter to the backcover case.
d. Spin the ignition unit input shaft by hand while observing the volt meter. If voltage is being supplied
to the ignition coil, the meter will deflect slightly.
e. Repeat (Steps 6.b. through 6.d.) for the remaining pins used to supply voltage to the ignition coils.
NOTE: If no voltage was indicated in (Step 4.), the alternator section is defective. If voltage was
indicated in (Step 4.) and no meter movement is noted in (Step 6.), the ignition unit back cover is
defective.
144 MECHANIC 17-18

IGNITION SYSTEMS
OSA 602 (AQ)
COMPETENCY
Explain the term and probable causes of an engine backfiring.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the term and probable causes of an engine
backfiring.
PROCEDURE
1. A backfire is an improperly timed explosion of the fuel/air mixture in the intake manifold or cylinder of
an internal combustion engine. An afterfire is an improperly timed explosion of the fuel/air mixture in
the cylinder, exhaust manifold, or muffler of an internal combustion engine. Although the explosion
takes place in different parts of the engine and associated equipment, both are commonly referred to
as backfire.
2. Improper ignition timing :
a) Worn or broken ignition unit (magneto) coupling
b) Incorrect timing of an ignition unit
c) Incorrect camshaft to crankshaft timing
d) Bad ignition unit (magneto)
MECHANIC 17-18 145

IGNITION SYSTEMS
3. Improper fuel mixture:
a) High fuel pressure
b) Incorrect fuel injection valve timing
c) Damaged diaphragm in carburetor
d) Vacuum leak
e) Unseated fuel injection valve
4. Incorrect intake or exhaust valve adjustment:
a) An intake or exhaust valve that is adjusted too tight will allow the valve to stay partially open,
causing fuel to enter the intake or exhaust manifold.
5. Malfunctioning safety switch:
a) A safety switch can cause a backfire when the switch temporarily makes and breaks due to
corrosion or vibration. When the switch makes, ignition ceases temporarily. When the switch
breaks, ignition starts again, igniting the rich fuel mixture in the power cylinder.
146 MECHANIC 17-18

IGNITION SYSTEMS
OSA 603 (AQ)
COMPETENCY
Explain the probable causes of a misfiring ignition system.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the probable causes of a misfiring ignition system.
PROCEDURE
1. Spark plug not operating properly. Causes of a spark plug not operating properly may include:
a. Incorrect gap
b. Fouled due to wet gas or cylinder burning oil
c. Carbon on the plug
d. Wrong plug for application
e. Improper grounding of the plug
2. Faulty ignition unit (magneto)
3. Primary or secondary wiring, loose or defective (including spark plug extension)
4. Moisture or corrosion in the system
5. Faulty individual cylinder kill switch
6. Faulty coil
MECHANIC 17-18 147

IGNITION SYSTEMS
OSA 604
COMPETENCY
Identify and explain the function of an Altronic CPU 95 ignition system.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee identify and explain the function of an Altronic CPU
95 ignition system.
PROCEDURE
1. Identify the Altronic CPU-95 Ignition system.
2. Explain the function.
a. The Altronic CPU-95, DC-powered ignition system is a microprocessor-based capacitor discharge

system designed for application on natural gas fueled engines. The system features crankshaft
triggered timing accuracy and the capability to vary timing electronically by several means,
including an external 4-20 mA control signal connected to the optional Display Module. The system
is field programmable and offers a variety of advanced control methods, emissions reduction,
primary and secondary spark diagnostics, self diagnostics, serial communications and engine
protection features.
b. The CPU-95 ignition system consists of two main parts: an optional user interface Display Module
and an engine mounted Ignition Module. The optional Display Module has an alphanumeric 16-
character x 2-line back-lit LCD display that shows the operating status, engine RPM, energy level,
single or double-striking mode, current loop input value, ignition timing, set-up, and diagnostic
information. The Display Module is a means of monitoring or changing monitored parameters, all
of the ignition system functions are performed in the Ignition Module. Change increment is
dependent on the number of holes or teeth being sensed.
148 MECHANIC 17-18

IGNITION SYSTEMS
Figure 3: Altronic CPU-95 Ignition System

MECHANIC 17-18 149
IGNITION SYSTEMS
150 MECHANIC 17-18

C S
COOLING
OOLING
SYSTEMS
YSTEMS
OSA 701 (AQ)
COMPETENCY
Explain what effect fan pitch has on horsepower or amps.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain what effect fan pitch has on horsepower or amps.
PROCEDURE
1. The degree of pitch of the fan blades will have a direct effect on the amount of horsepower required for
an internal combustion engine to drive the fan.
2. Increasing the pitch of the fan blades on an electric motor enables the fan to move more air, but at the
same time causes the fan to require more horsepower or amps to drive it.
MECHANIC 17-18 151

COOLING SYSTEMS
OSA 702
COMPETENCY
Explain steps to troubleshoot a unit that is shutting down on high water temperature.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain steps to troubleshoot a unit that is shutting down
on high water temperature. The Qualifier will name seven (7) of the ten (10) symptoms for a unit which is
shutting down on high water temperature and have the employee state the causes and solutions
PROCEDURE
1. Symptom: Coolant level low.
CAUSE SOLUTION
External leaks. Repair leaks as needed.
Falulty level indicator. Repair or replace coolant level indicator.
2. Symptom: Water pump pressure low.
CAUSE SOLUTION
Weak or faulty water pump. Check pump for proper pressure / volume
rating or replace if needed.
Faulty pressure gauge. Replace gauge.
Belts slipping Tighten belts (if applicable).
152 MECHANIC 17-18

COOLING SYSTEMS
3. Symptom: Fan belt tension.
CAUSE SOLUTION
Bad or worn belts. Replace belts.
Idler pulley bearing broken. Replace idler bearing.
Grease on surface of belts. Clean belts.
4. Symptom: Check cooling coils for external dirt or scale buildup and bent fins.
CAUSE SOLUTION
Cooling coils clogged with dirt and debris. Clean coils with recommended solution.
Bent cooling coil fins. Try to straighten fins.
5. Symptom: Low temperature differential across the cooler.
CAUSE SOLUTION
Dirty cooler. Faulty thermostat. Clean cooler. Replace thermostat.
6. Symptom: Cooling louvers closed.
CAUSE SOLUTION
Broken linkage. Repair linkage if needed.
7. Symptom: Thermostats stuck in the closed position.
CAUSE SOLUTION
Old or damaged thermostat. Replace with new ones
Corrosion on thermostats Replace thermostats.
8. Symptom: Incorrect engine ignition timing.
CAUSE SOLUTION
Broken drive disc. Replace disc with a new one.
Loose magneto mounting bolts. Tighten bolts after retiming.
MECHANIC 17-18 153

COOLING SYSTEMS
9. Symptom: Angle of fan blades.
CAUSE SOLUTION
Loose or broken fan hub clam bolts. Tighten or replace bolts.
Wrong pitch angle. Bent blades. Recheck angle with a protractor. Replace
bent blades.
10. Symptom: Restricted engine exhaust.
CAUSE SOLUTION
Collapsed muffler. Replace muffler.
Equipment stored in front of exhaust. Move equipment to allow for free air
movement.
Wrong size exhaust pipe or muffler. Replace with manufacturer recommended

equipment.
154 MECHANIC 17-18

COOLING SYSTEMS
OSA 703
COMPETENCY
Remove and install a water pump on an engine.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove and install a water pump on an engine. The
Qualifier will not select a water pump that drives a magneto.
PROCEDURE
a. Drain the coolant.
b. Loosen the water pump inlet hose clamps and slide the hose away from the pump.
c. Remove the bolts securing the water pump outlet flange to the cylinder block.
d. Remove the water pump mounting bolts.
e. Remove the water pump.
f. Clean all parts and gasket surfaces for assembly.
MECHANIC 17-18 155

COOLING SYSTEMS
a. Install the water pump gasket onto the water pump.
b. Install the water pump.
NOTE: On gear-driven pumps, ensure the drive gears mesh together.
c. Install the water pump outlet flange gasket.
d. Install the bolts securing the water pump outlet flange to the cylinder block.
e. Slide the water pump inlet hose in place and secure it with the hose clamps.
f. Fill the engine with coolant.
g. Check for coolant leaks.
h. Bleed the air from the cooling system.
156 MECHANIC 17-18

S S
STARTER
TARTER
SYSTEMS
YSTEMS
OSA 901
COMPETENCY
Explain the principle operation of a typical turbine type starter.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the operation of a typical turbine type starter.
PROCEDURE
The employee will explain as follows: (Figure 1 and 2)
1. Regulated pneumatic pressure enters the starter through the inlet port and flows through a turbine
nozzle, which directs the pneumatic pressure to a turbine wheel. The pneumatic pressure flows across
the turbine wheel, causing the starter to spin.
2. The pneumatic pressure is piped away from the unit through an exhaust port. Automatic Trip Valves
(ATV) shuts off the flow of pneumatic pressure when the starter cranking speed begins to exceed safe
limits.
MECHANIC 17-18 157

STARTER SYSTEMS
INSTALLATION
(Dwg. TP1909)
5 Vehicular Installation
Figue 1: Typical
Figue 3: Typical Pneumatic Starter System (Pre-Engaged Starter Drive)
158 MECHANIC 17-18

STARTER SYSTEMS
INSTALLATION
(Dwg. TP1910)
Figue 2: Typical 6Stationary Installation
MECHANIC 17-18 159

STARTER SYSTEMS
OSA 902
COMPETENCY
Explain the principle of operation of a direct AC type starter system.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the principle of operation of a direct AC type starter
system.
PROCEDURE
1. The AC volt starter does not use a solenoid mounted on the starter like the typical DC volt starter. Instead
it uses a direct inertia drive to move the starter drive bendix into the flywheel teeth.
2. The AC volt starter is a starter type in which you may order the horsepower and AC voltage input to match
the equipment requirements. These starters are typically used for back-up to pneumatic starters but
in some cases are the primary source.
160 MECHANIC 17-18

STARTER SYSTEMS
OSA 903
COMPETENCY
Explain the principle of operation of a vane-type pneumatic starter system.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the principle operation of a vane-type pneumatic
starter system. The employee will be allowed to use (Figure 3) to explain this Assessment.
PROCEDURE
1. When the starter relay valve is activated, pilot pressure flows from the relay valve to the inlet port on the
starter drive housing.
NOTE: The inlet port is the port located nearest to the starter gear case.
2. The pilot pressure applies force against the drive housing piston, pushing the starter drive into the
flywheel ring gear. Simultaneously, the movement of the piston uncovers the outlet port on the drive
housing, directing pilot pressure to the starter control valve, causing it to open.
NOTE: The outlet port is the port located nearest to the starter drive.
3. Pneumatic pressure enters the inlet of the starter motor.
4. Internal passages direct the pneumatic pressure to the end plates.
5. The end plates direct the pneumatic pressure into the cylinder. The pressure comes in contact with the
vanes, causing the rotor to turn. The pressure is then allowed to exit the starter through the exhaust port.
6. The turning rotor transfers the power being developed by the motor to the starter drive.
7. The starter drive, which is now engaged with the flywheel, causes the engine to rotate.
NOTE: The automatic trip valve prevents overspeed of the turbine by shutting off the flow of pneumatic
pressure when the starter cranking speed begins to exceed its safe limits.
MECHANIC 17-18 161

STARTER SYSTEMS
Figue 3: Typical Pneumatic Starter System (Pre-Engaged Starter Drive)
162 MECHANIC 17-18

G
GOVERNORS
OVERNORS
OSA 1001
COMPETENCY
Remove, inspect and reinstall a magnetic pickup.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove, inspect and reinstall a magnetic pickup.
The employee will be allowed to use the procedure section and/or the manufacturer’s manual for the
magnetic pickup ohm resistance and to obtain the distance the magnetic pickup should be positioned
from the tooth or blade.
PROCEDURE
a. Remove the cannon plug from the magnetic pickup.
b. Loosen the magnetic pickup locknut.
c. Unscrew the magnetic pickup from its mounting point.
a. Clean the tip of the magnetic pickup.
b. Check the tip of the magnetic pickup for nicks and burrs.
c. Check the magnetic pickup ohm resistance.
1) Connect a volt-ohm meter to the connecting pins on the magnetic pickup.
2) Place the volt-ohm meter on the ohms scale and note the reading.
3) Refer to the manufacturer’s manual for the allowable magnetic pickup ohm resistance.
MECHANIC 17-18 163

GOVERNORS
a. Slowly roll the engine over until a tooth or blade is centered over the magnetic pickup mounting point.
b. Screw the magnetic pickup locknut to the top of the magnetic pickup.
c. Screw the magnetic pickup into its mounting point until it touches the tooth or blade.
d. Unscrew the magnetic pickup the distance specified by the manufacturer. (Refer to the
manufacturer’s manual for specification)
e. While holding the magnetic pickup to prevent it from turning, tighten the magnetic pickup locknut.
f. Install the cannon plug onto the magnetic pickup.
164 MECHANIC 17-18

GOVERNORS
OSA 1002
COMPETENCY
Adjust the compensating needle valve in a Woodward EP2 hydraulic governor.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee adjust the compensating needle valve in a
Woodward EP2 hydraulic governor. The employee will be allowed to use the procedure section and/or the
manufacturer's manual.
PROCEDURE
1. The needle valve is factory set at two (2) turns out from the closed position. If instability is experienced
during operation with cold multi viscosity oils, the needle valve can be turned in until stability is obtained.
2. The actuator/governor should not be run at a needle valve opening of less than one (1) turn out from
the closed position, as response would not be acceptable
3. A wider needle valve opening provides quicker response but less stability. The adjustment must be
made at startup before the engine oil warms up.
Note: The temperature compensated speeder spring minimizes speed drift caused by temperature change
MECHANIC 17-18 165

GOVERNORS
OSA 1003 (AQ)
COMPETENCY
Adjust the governor linkage on a hydro mechanical governor.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee adjust the governor linkage on a hydro mechanical
governor. The employee will be allowed to use the procedure section and/or the manufacturer's manual.
PROCEDURE
2. With the engine shut down, disconnect the governor linkage at the carburetor lever and the governor lever.
3. Back off the idle screw until the butterfly can be placed in the no fuel position.
NOTE: Most throttle shafts have slots cut in the end of the shaft to indicate the position of the butterfly.
4. Ensure the butterfly is in the no fuel position.
5. Ensure the governor lever is in the no fuel position.
NOTE: Use only hand pressure to ensure the governor lever is in the no fuel position.
6. Adjust the length of the governor linkage until it can be installed on the carburetor lever and the governor
lever without moving the butterfly or the governor lever off the no fuel position.
7. Install the governor linkage.
8. Rotate the governor lever to the full fuel position.
9. Ensure the butterfly is near the full open position but has not rotated past full open.
10. Start the engine.
11. Adjust the idle screw until the desired engine RPM is obtained.
166 MECHANIC 17-18

GOVERNORS
Figure 1: Typical Hydro Mechanical Governor Linkage
MECHANIC 17-18 167

GOVERNORS
OSA 1004
COMPETENCY
Explain the principle of operation of a Woodward 2301 governor.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the principle of operation of a Woodward 2301
governor.
PROCEDURE
1. The Woodward 2301 load sensing and speed control is an electronic control type governor. The system
comprises the 2301 Electronic Control, a magnetic pick-up, current and potential transformers, and a
hydraulic actuator. The system provides isochronous (constant speed) or droop (speed regulation)
operation of such prime movers as diesel, gas engines, steam and gas turbines.
2. As many as four engines driving a common load can be operated from one 2301 Electronic Control by
connecting the actuators in series. Since each actuator receives the same input signal, each engine
receives the same amount of fuel.
3. The output of the 2301 Electronic Control provides a unidirectional continuous voltage level to the
actuator to provide the desired speed and load relationship called for by the input signals to the control.
168 MECHANIC 17-18

P D P
POSITIVE
OSITIVE
DISPLACEMENT
ISPLACEMENT
PUMPSUMPS
OSA 1101 (AQ)
COMPETENCY
Explain the possible causes of knocking in the fluid end of a positive displacement pump.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the possible causes of knocking in the fluid end of
a positive displacement pump. The Qualifier will name the five (5) symptoms for knocking in the fluid end
of a positive displacement pump and have the employee state the causes and solutions.
PROCEDURE
1. Sympton: Pump cavitating
Cause Solution
Loose retaining nut on piston. Check the threads on the pump shaft and secure the
piston retaining nut and retorque
Plunger may have unscrewed from pony Check the threads in the pony rod or crosshead for
rod or crosshead. damage and also check the threads on the plunger
for thread damage.
2. Sympton: Air in the system
Cause Solution
Lack of suction pressure of volume Check upstream of pump to ensure proper inlet volume
and flow. (i.e. plugged suction strainer, closed or partially
closed suction valve)
Pump could be running faster than rated Check manufacturer's recommendations for speed
speed rating of pump.
Air leak on inlet or suction sude. Check all gaskets and O rings associated with the
suction end of the pump
MECHANIC 17-18 169

POSITIVE DISPLACEMENT PUMPS
3. Sympton: The suction stabilizer not charged to the required pressure
Cause Solution
The internal bladder sould be faulty. Inspect the bladder for damage
Pressure leadk from the charge fitting. Check the charge connection for damage or looseness.
Changes in the pipeline operating pressure Check the operating conditions and adjust accordingly.
4. Sympton: A broken or weak valve spring
Cause Solution
Wrong pressure rating on the material for Check the manufacturer's guidelines to ensure the
the spring. material for the spring is correct.
Improperly installed spring. Make sure the springs are not crooked or bent when
installing them to the pump.
Debris or trashed in contact withspring Clean all the debris and trash from the valvel pockets.
during operation.
Wrong material for the application. Check the manufacturer's pump data to ensure the
pump material integrity is correct for the application.
5. Sympton: A loose liner
Cause Solution
Broken flange lip on the liner. Remove and inspect the liner for damage.
Excessive wear in the liner outside Inspect the liner to pump housing bore for excessive
diameter bore. wear.
Wrong spacer gaskets. Inspect the gaskets with the manufacturer's part list for
the particular model to ensure the correct spacer gaskets.
Wrong liner. Check to make sure the correct liner is used.
170 MECHANIC 17-18

OSA 1102
COMPETENCY
Replace a valve and seat in a positive displacement pump.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee replace a valve and seat in a positive displacement
pump. The Qualifier will have the employee remove, inspect, and install a new valve and seat in a positive
displacement pump. The employee will not be required to lap the valve to the valve seat. Employee will be
allowed to use the procedure section and/or the manufacturer's manual.
PROCEDURE
a. Remove the valve cover.
b. Remove the valve spring and the valve.
c. Remove the valve seat from the fluid end, using a pulling tool.
1) Position the valve seat adapter under the valve seat.
2) Screw the stem into the valve seat adapter.
3) Place the bridge on top of the valve cap seating area.
4) Screw the wing nut onto the stem until it is snug against the bridge.
5) Strike the wing nut with a nonferrous hammer until the valve seat is removed from the
fluid end.
MECHANIC 17-18 171

a. Inspect the valve seat deck for nicks and cracks.
b. Inspect the valve seat for wear, nicks, and washout.
NOTE: Washout is a condition that occurs when solids or liquids cut into the valve seat.
c. Inspect the valve for nicks, cracks, and wear.
d. Inspect the spring for cracks and proper tension.
NOTE: Proper spring tension can be checked by comparing the removed spring to a new one.
e. Ensure the valve cover sealing area is clean.
a. Ensure the valve seat deck is clean and dry.
b. Install the valve seat in the fluid end, using an installation tool.
1) Position the valve seat squarely in the bore of the fluid end.
2) Place a valve seat installation tool on top of the valve seat.
3) Strike the installation tool squarely with a nonferrous hammer until the valve seat is firmly
seated in the fluid end.
4) Remove the installation tool.
c. Install the valve and the valve spring.
d. Install the valve cover and gasket.
5. Start pump and check for peoper operation.
172 MECHANIC 17-18

Figure 1: Valve Removal and Installation Tools
MECHANIC 17-18 173

OSA 1103
COMPETENCY
Replace a plunger and seal in a positive displacement pump.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee replace a plunger and seal in a positive
displacement pump. The employee will be allowed to use the procedure section and/or the manufacturer's
manual.
PROCEDURE
2. Begin with draining the fluid from the fluid end of the pump housing.
3. Remove the packing well cover.
4. Remove the suction valve cover from the front of the pump housing.
5. Locate the area where the plunger is threaded into the pony rod on the power end.
6. Using a strap wrench or pipe wrench, loosen the plunger from the pony rod by
unscrewing it from the threads.
7. After removing the plunger from the plunger bore, remove the packing seal.
8. When installing new packing always install the same amount of packing rings.
9. Install the new packing into the packing housing.
10. Install the new plunger by pushing it in the plunger bore until contact is made with the
pony rod, screw the plunger into the pony rod and tighten.
11. Install new gaskets or O rings on the valve cover and install it to the pump housing.
12. Replace the packing well cover.
13. Fill the pump with fluid, and check for leaks.
174 MECHANIC 17-18

Seal
Figure 2: Typical Plunger-Type Positive Displacement Pump
MECHANIC 17-18 175

OSA 1104
COMPETENCY
Disassemble and reassemble a double diaphragm pump.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee disassemble and reassemble a double diaphragm
pump.The employee will be allowed to use the the procedure section and/or the manufacturer's manual.
PROCEDURE
The employee will demonstrate as follows: (Figure 3,4 and 5)
1. Double Diaphragm Pump
a. The double diaphragm pump (Figure 3) is a reciprocating pump which moves liquid by the back
and forth movement of two diaphragms. As with all equipment used in the production process, the
operation of these types of pumps should be inspected on a regular basis to ensure that they are
working properly.
b. To start the diaphragm pump, first make sure there is a level of liquid to be
pumped. Remove the oil plug from the oil pot (if applicable) and check the oil level in the pot. If
the oil level is low, add clean, 10W oil to the pot. Check for obvious leaks at all pump connections,
if leaks are found, tighten or repair the leaks.
c. Open the suction and discharge lines. Open the supply valve found on or near the pump. Listen
for the operation of the pump. You should be able to hear the pump stroking. If the pump is not
stroking, check to make sure the supply valve and the suction block valves are open. If these
valves are open, and the pump is still not stroking, the pump should be repaired.
d. Listen to the operation of the pump. It is possible that the pump is stroking, but not transferring
liquids. In most cases, the pump strokes are faster when the pump is not transferring liquid than
when liquid is being transferred. Watch the level on the vessel the pump is servicing. If the level
in the vessel does not decrease, the pump should be repaired.
176 MECHANIC 17-18

1/2" NPT Female

Air Valve
Connection
1" NPT Female

Air Exhaust
Figure 3: Double Diaphragm Pump
MECHANIC 17-18 177

Note: Disassembly and Reassembly Procedures (This procedure is for a Wilden M8 Pump)
1. Main pump body repairs (Figure 5)
a. Isolate and bleed off the pressure from the pump.
b. Loosen and remove the small clamp band screws that connect the fluid chambers to the discharge
and suction manifolds.
c. Remove the discharge manifold, and inspect the valve balls and the valve seats.
d. Remove the main body of the pump from the suction manifold. Inspect the valve balls and the valve
seats.
e. Before starting the disassembly, mark a line from each liquid chamber to its corresponding air
chamber. This line will assist in proper alignment during the assembly. Remove the large clamp
from only one liquid chamber of the center section to expose the diaphragm and its piston plate.
f. The diaphragm and the piston plate can be removed by unscrewing them from the connecting air
shaft. The opposite diaphragm will be held tight by the opposite liquid chamber.
g. Remove the remaining large clamp and remaining liquid chamber. The second diaphragm and
piston plate is now available for inspection.
NOTE: Use a vise with wood blocks as a method of securing the air shaft while unscrewing the
second diaphragm and piston plate. It is important not to scar the chrome plated air shaft.
h. Upon removing the second diaphragm and piston plate, the air shaft can now be removed for
inspection.
i. Remove the o-rings from the center block bushing and flush out the center block, removing grit and
contaminants. Install new o-rings in the center block.
j. Lubricate the o-rings with a light oil and install the air shaft into the center block bushing.
k. Install the outside piston plate and diaphragm to the air shaft. Turn the pump over and install the
second piston plate and diaphragm. Tighten both piston plates to the air shaft simultaneously to
ensure a tight, secure fit.
l. Align the marks and install the liquid chamber with a large clamp band to the side of the pump where
the diaphragm is in the full stroke position.
m. Turn the pump over. While using pry bars, force the second side of the pump to the full stroke
position. Align the marks and install the second liquid chamber and large clamp band.
178 MECHANIC 17-18

n. Replace the valve seats in the suction manifold with the molded seat o-ring facing the suction
manifold. Replace the suction valve balls and attach the pump liquid chambers to the suction
manifold with small clamp bands.
o. Replace the valve seats in the liquid chamber with the molded seat o-ring facing the water chamber.
Replace the discharge valve balls and attach the pump discharge manifold with small clamp bands.
2. Air valve repairs (Figure 4)
a. Unscrew and remove the oil pot from the air valve. Empty any oil in the pot and flush the pot with
solvent.
b. Unscrew and remove the capillary rod from the

air valve and inspect the pores of the rod. Clean SNAP RING
the capillary tube if necessary with solvent. AIR VALVE CAP

O-RING
AIR VALVE
c. Unscrew and remove the air valve screen from END CAP
the air supply inlet and inspect the screen for
accumulated dirt and scale. Clean the screen as
AIR VALVE BUSHING
needed and replace in the air valve.
d. Remove the four screws from the air valve

cylinder and remove the air valve cylinder from AIR VALVE
SCREEN
the center block of the pump.
e. Remove the snap rings from the ends of the air

valve, and remove the valve caps. Remove and
inspect the air valve piston. The piston should
be a dark, dull gray color. If the piston appears
to be a shiny aluminum color, replace it. AIR VALVE
GASKET
AIR VALVE
f. Install the air valve piston and check for free ASSEMBLY
movement. Replace the o-rings on the valve

caps. Install the upper valve cap (with the guide
rod) in the air valve cylinder so that the guide rod
fits into the piston. Replace the upper valve cap
snap ring. Replace the lower valve cap and lower
cap snap ring. CAPILLARY ROD
g. Install the air valve cylinder to the center block PLUG

OIL BOTTLE
of the pump with a new gasket.
h. Replace the capillary rod. Fill the oil pot with a

light weight oil, and install the oil pot to the air Figure 4: Wilden M-8 Air Valve
valve. Newer model pumps do not require this.
MECHANIC 17-18 179

LARG ECLAMP BAN DS DISCHAR GE MANIFOLD
SMALL CLAMP BAND S
VALVE BALL
VALVE SEAT
PISTON
PLATE (OU TER)
LIQUID
CH AMBER
CH ECKBO DY
CEN TER BLO CK

DIAPHRAGM
PISTON PLATE BLOC K GASKET

( INN ER)
AIR CH AMBER AIR SHAFT
VALVE
BALL
VALVE SEAT
SUC TION
MAN IFOLD
Figure 5:5:4SDFSD5:5554: Double Diaphragm Pump
Figure 5: Main Body Pump
180 MECHANIC 17-18

OSA 1105
COMPETENCY
Explain the function of the major components of a progressive cavity type pump.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the function of the major components of a
progressive cavity type pump.
PROCEDURE
Main components:
1. Rotor : The rotor of the pump is a steel helix which has been coated with a smooth hard surface
material normally chromium. The rotor fits inside a pump body or stator which is normally a rubber
lined steel tube.
2. Stator : The core of the stator has a helical cavity, the wavelength of each helix in the rotor is exactly
half that of the rotor.
3. Rotor shaft seals : The rubber Rotation of the rotor inside the stator causes the cavity to progress
along the pump thus inducing fluid flow.
MECHANIC 17-18 181

Figure 6: Progressive Cavity Pump
182 MECHANIC 17-18

OSA 1106
COMPETENCY
Explain the principle of operation of a gear type pump.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the principle of operation of a gear type pump.
PROCEDURE
Gear Pumps.
1. A gear pump is a rotary pump that consists of two gears that rotate in opposite directions within a close-
fitting housing. This type of pump traps a volume of incoming liquid in the spaces between the gear
teeth, moves this liquid around the pump housing, and discharges it by the meshing of the gears. Gear
pumps may be powered by hand cranks, electric motors or gas engines.
2. The gear pump is often used as a recycle (or circulating) pump to circulate the liquid from the bottom
of a tank back through a process vessel (e.g., Heater-Treater). These types of pumps are also used
on hydraulic cranes.
MECHANIC 17-18 183

SUCTION DISCHARGE
PORT PORT
GEARS
CASING
Figure 7: Gear Type Pump
184 MECHANIC 17-18

S -S C P
CENTRIFUGAL
INGLE
PUMPS
TAGE ENTRIFUGAL UMPS
OSA 1201
COMPETENCY
Disassemble, inspect, set the impeller clearance and reassemble a single-stage horizontal pump.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee disassemble, inspect, set the impeller clearance
and reassemble a single-stage horizontal pump. The Qualifier will select a spare or removed pump that
contains a noncartridge-type mechanical seal. The employee will be allowed to use the procedure section
and/or the manufacturer’s manual.
PROCEDURE
NOTE: The steps listed below outline a generic procedure. Due to the numerous types of pumps and
mechanical seals available, it is recommended that the employee review the manufacturer’s manual
for the pump selected prior to beginning this Competency.
2. Disassembly procedure: (Figure 1)
a. Remove the casing attaching bolts (2) from the stuffing box cover (1).
b. Remove the casing (3).
NOTE: Some pump assemblies are designed with jacking bolts (4) to aid in removing the casing.
c. Remove the casing gasket (5).
d. Remove the impeller (6) from the shaft (7).
1) Attach a chain wrench or equivalent to the bearing housing end of the shaft to prevent it
from turning.
2) Tap the impeller with a soft-faced hammer to loosen the impeller.
MECHANIC 17-18 185

SINGLE-STAGE CENTRIFUGAL PUMPS
Figure 1: Typical Horizontal Centrifugal Pump
186 MECHANIC 17-18

NOTE: Some impellers are designed with a nut cast on the impeller eye, which allows a
wrench to be used to loosen the impeller. Most impellers that screw onto the shaft have left
handed threads. Use caution when removing the impeller. Some impellers slide onto a keyed
shaft and are held in place by a locknut threaded onto the end of the shaft.
e. Remove the gland nuts (8) and carefully slide the gland (28) toward the bearing frame (10).
(Figure 2)
f. Remove the frame attaching nuts (11) connecting the frame adapter (12) to the stuffing box cover
(1), and remove the stuffing box cover.
g. Remove the shaft sleeve (13), with the rotating part of the mechanical seal (26) attached, from
the shaft (7).
h. Slide the gland (28) and stationary part of the mechanical seal (9) off the shaft (7).
i. Slide the deflector (14) off the shaft (7).
j. Drain the oil from the bearing frame (10).
k. Remove the bearing housing bolts (15).
l. Using the impeller adjusting bolts (16), remove the shaft (7), bearings (17, 19), and the bearing
housing (20) from the bearing frame (10).
m. Using a bearing puller or similar device, remove the inboard bearing (17) from the shaft (7).
NOTE: Never use a hammer to drive the bearing off the shaft.
n. Remove the bearing housing retaining ring (18), which secures the outboard bearing (19) in the
bearing housing (20).
o. Remove the bearing housing (20) from the outboard bearing (19).
p. Straighten the tab on the bearing lockwasher (27).
q. Remove the locknut (21), which secures the outboard bearing (19) to the shaft (7).
r. Remove the bearing lockwasher (27).
s. Using a bearing puller or similar device, remove the outboard bearing (19) from the shaft (7).
MECHANIC 17-18 187

Figure 2: Typical Noncartridge-Type Mechanical Seal
188 MECHANIC 17-18

a. Inspect the shaft for wear.
1) Inspect the oil seal seating areas for burrs, pitting, and wear.
2) Inspect the shaft sleeve area for burrs or grooves that would interfere with the running fit of
the shaft sleeve.
3) Inspect the threaded areas of the shaft.
b. Impeller:
1) Inspect the impeller vanes for wear and cracks.
2) Inspect the threaded area of the impeller for wear.
NOTE: Some impellers have a machined groove around the threaded bore in which an o-ring
(24) is used to seal the impeller to the shaft. This seal prevents the threaded area from
becoming contaminated and seizing to the shaft. Wear in the vane and surface areas of the
impeller will reduce the overall performance of the pump.
c. Shaft sleeve:
1) Loosen the rotating part of the mechanical seal (26) set screws, and slide the seal off the
shaft sleeve.
2) Inspect the shaft sleeve for wear, burrs, or grooves that would interfere with the sealing of
the mechanical seal to the shaft sleeve.
3) Inspect the inside bore of the shaft sleeve for burrs or foreign material that would interfere
with the running fit of the sleeve on the shaft.
d. Mechanical seal (rotating part):
1) Inspect the machined face of the seal for scratches, chipping, or heat cracks.
2) Inspect the o-ring in the inside diameter of the seal for cuts, contamination, and pliability.
3) Ensure the spring section of the seal retracts freely.
MECHANIC 17-18 189

e. Mechanical seal (stationary part):
2) Ensure the seal is fully seated into the gland and that it fits snugly.
f. Frame bearings:
1) Clean and inspect the two frame bearings for roughness and noise when rotated.
2) Inspect each bearing for looseness and wear.
g. Oil seals:
1) Inspect the bearing frame and bearing housing oil seals for wear, cracking, or cuts.
2) Check for pliability of the rubber sealing material.
h. Casing:
1) Inspect the entire fluid area within the casing (including the wear plate) for scoring,
washout, and pitting.
2) Inspect the casing gasket sealing area for pitting, corrosion, and erosion.
3) Inspect the outer surfaces of the casing for cracks, corrosion, and erosion.
i. Stuffing box cover:
1) Inspect the fluid area for scoring, washout, and pitting.
2) Inspect the gasket sealing areas for pitting, corrosion, and erosion.
j. General:
1) Inspect the frame adapter, bearing frame, and bearing housing for cracks, corrosion,
erosion, and wear.
2) Clean all parts for assembly.
190 MECHANIC 17-18

a. Using a press, install the inboard bearing (17) and outboard bearing (19) onto the shaft (7).
b. Install the bearing lockwasher (27) and locknut (21) onto the shaft (7).
c. Tighten the locknut (21) and bend the tab on the bearing lockwasher (27).
d. Install the bearing housing (20) over the outboard bearing (19).
NOTE: Care should be taken when installing the bearing housing to prevent damaging the bearing
housing oil seal (22).
e. Install the bearing housing retaining ring (18).
f. Unscrew the impeller adjusting bolts (16) until they are flush with the back side of the bearing
housing (20).
g. Install the assembled shaft into the bearing frame (10).
NOTE: Care should be taken when installing the shaft to prevent damaging the bearing frame oil
seal (23).
h. Install the bearing housing bolts (15) and draw the bearing housing (20) into the bearing frame
(10).
i. Install the deflector (14) onto the shaft (7).
j. Install the shaft sleeve (13) onto the shaft (7).
k. Perform a preliminary impeller adjustment.
1) Install the stuffing box cover (1) onto the frame adapter (12).
2) Install the frame attaching nuts (11).
3) Install the impeller (6) onto the shaft (7), ensuring the impeller o-ring (24) (if applicable) is
installed.
4) Loosen the bearing housing bolts (15).
5) Using the impeller adjusting bolts (16), position the impeller until the desired clearance is
obtained between the face of the stuffing box cover (1) and the back of the impeller (6)
with a feeler gauge. Refer to the manufacturer’s manual for the clearance.
6) Scribe a line on the shaft sleeve (13) with a soft pencil at the face of the stuffing box cover
(1).
MECHANIC 17-18 191

NOTE: This line will be used as a reference point when the mechanical seal is installed.
7) Remove the impeller (6) from the shaft (7).
8) Remove the frame attaching nut (11) connecting the frame adapter (12) to the stuffing box
cover (1), and remove the stuffing box cover.
l. Perform a preliminary mechanical seal preinstallation check.
1) Ensure the outboard gasket is installed in the gland (28).
2) Ensure the stationary part of the mechanical seal is installed in the gland with the lapped
seal face up.
3) Ensure the inboard gasket is installed in the gland.
4) Place the gland on a workbench with the lapped seal facing up.
5) Place the rotating part of the mechanical seal against the stationary part of the mechani-
cal seal with the lapped faces together.
6) Measure the distance from the inboard gasket to the top of the mechanical seal.
7) Determine the amount of compression of the mechanical seal.
a) Multiple spring mechanical seals used on shafts less than 2" in diameter require 1/8"
compression.
b) Multiple spring mechanical seals used on shafts 2" in diameter and over require 3/16"
compression.
c) Single spring seals require 1/2 the free height of the spring.
8) Subtract the required compression of the seal determined in (Step l.7) from the length of the
seal determined in (Step l.6).
NOTE: This will be the working height of the seal from the face of the stuffing box cover.
m. Measure the distance obtained in (Step l.8) from the scribed line marked in (Step k.6) toward the
impeller end of the shaft. Scribe a second line with a soft pencil at this point.
192 MECHANIC 17-18

n. Install the mechanical seal.
1) Install the assembled gland onto the pumpshaft, ensuring the lapped seal face of the
mechanical seal faces the impeller.
2) Install the rotating part of the mechanical seal onto the pump shaft, ensuring the lapped
seal face of the mechanical seal faces the gland. Align the end of the setscrew side of
the seal with the scribed line determined in Step m. Tighten the setscrews.
o. Install the stuffing box cover (1) onto the frame adapter (12).
p. Install the frame attaching nuts (11).
q. Install the impeller (6) onto the shaft (7), ensuring the impeller o-ring (24) (if applicable) is installed.
r. Install the casing gasket (5) and the casing (3).
s. Install the casing attaching bolts (2), and rotate the pump shaft while tightening the bolts evenly.
t. Adjust the impeller clearance.
1) Loosen the impeller adjusting bolts and locknuts.
2) While turning the pump shaft, tighten the bearing housing bolts until the impeller starts to
rub against the casing.
3) Loosen the bearing housing bolts until a feeler gauge, corresponding to the desired
clearance, can be placed between each bearing housing bolt head and the bearing
housing. Refer to the manufacturer’s manual to obtain the impeller clearance.
4) Tighten the impeller adjusting bolts until the bearing housing is seated against the
bearing housing bolts. Tighten the locknuts.
5) Tighten the bearing housing bolts.
u. Slide the gland (28) toward the stuffing box cover (1) and secure it with the gland nuts(8).
v. Fill the bearing frame (10) with oil.
MECHANIC 17-18 193

OSA 1202
COMPETENCY
Disassemble, inspect, set the impeller clearance and reassemble a single-stage vertical pump.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee disassemble, inspect, set impeller clearance and
reassemble a single-stage vertical pump. The Qualifier will select a spare or removed pump that contains
a cartridge-type mechanical seal. The employee will be allowed to use the procedure section and/or the
manufacturer’s manual for impeller clearances.
PROCEDURE
The employee will demonstrate as follows: (Figures 3 through 6)
NOTE: The steps listed below outline a generic procedure. Due to the numerous types of pumps and
mechanical seals available, it is recommended that the employee review the manufacturer’s manual
for the pump selected prior to beginning this Assessment.
2. Disassembly procedure: (Figure 3)
a. Remove the coupling. (Figure 4)
b. Remove the motor from the motor support. (Figure 5)
NOTE: In some applications there is sufficient clearance to remove the impeller from the casing
without removing the motor.
c. Remove the stuffing box cover nuts and washers.
d. Remove the impeller and stuffing box assembly from the casing.
e. Remove the stuffing box cover gasket.
194 MECHANIC 17-18

Figure 3: Typical Flanged Adjustable Coupling
MECHANIC 17-18 195

Figure 4: Typical Vertical Centrifugal Pump
f. Remove the impeller from the shaft.
1) Attach a chain wrench or equivalent to the coupling side of the shaft to prevent it from
turning.
2) Tap the impeller with a soft-faced hammer to loosen the impeller.
NOTE: Some impellers are designed with a nut cast on the impeller eye, which allows a
wrench to be used to loosen the impeller. Most impellers that screw onto the shaft have
left handed threads. Use caution when removing the impeller. Some impellers slide onto a
keyed shaft and are held in place by a locknut threaded onto the end of the shaft.
g. Remove the gland nuts.
h. Carefully remove the gland from the shaft.
196 MECHANIC 17-18

Figure 5: Typical Rigid Adjustable Spacer Coupling
MECHANIC 17-18 197

i. Remove the shaft from the stuffing box cover.
j. Loosen the rotating part of the mechanical seal set screws, and slide the seal off the shaft.
a. Inspect the shaft for wear:
1) Inspect the shaft for wear, burrs, or grooves that would interfere with the sealing of the
mechanical seal to the shaft.
2) Inspect the threaded areas of the shaft.
b. Impeller:
1) Inspect the impeller vanes for wear and cracks.
2) Inspect the threaded area of the impeller for wear.
NOTE: Some impellers have a machined groove around the threaded bore in which
an o-ring is used to seal the impeller to the shaft. This seal prevents the threaded area
from becoming contaminated and seizing to the shaft. Wear in the vane and surface
areas of the impeller will reduce the overall performance of the pump.
c. Mechanical seal: (rotating part) (Figure 6)
2) Inspect the o-ring in the inside diameter of the seal for cuts, contamination, and pliability.
3) Ensure the spring section of the seal retracts freely.
d. Mechanical seal: (stationary part)
2) Ensure the seal is fully seated into the gland and that it fits snugly.
e. Casing:
1) Inspect the entire fluid area within the casing (including the wear plate) for scoring, wash-
out, and pitting.
2) Inspect the casing gasket sealing area for pitting, corrosion, and erosion.
3) Inspect the outer surfaces of the casing for cracks, corrosion, and erosion.
198 MECHANIC 17-18

Figure 6: Typical Cartridge-Type Mechanical Seal
MECHANIC 17-18 199

f. Stuffing box cover:
1) Inspect the fluid area for scoring, washout, and pitting.
2) Inspect the gasket sealing areas for pitting, corrosion, and erosion.
a. Ensure all of the parts are clean.
b. Install the impeller onto the shaft, ensuring the o-ring (if applicable) is installed.
c. Place the stuffing box cover over the shaft.
d. Install the stuffing box cover gasket in the casing.
e. Place the impeller, shaft, and stuffing box cover in the casing.
f. Install the stuffing box cover washers and nuts.
g. Perform a preliminary impeller adjustment.
1) Adjust the impeller clearance.
2) Scribe a line on the shaft with a soft pencil at the face of the stuffing box cover.
NOTE: This line will be used as a reference point when the mechanical seal is installed.
3) Remove the stuffing box cover nuts and washers.
4) Remove the impeller, shaft, and stuffing box cover from the casing.
5) Remove the stuffing box cover from the shaft.
6) Remove the impeller from the shaft.
h. Perform a preliminary mechanical seal preinstallation check.
1) Ensure the outboard gasket is installed in the gland.
2) Ensure the stationary part of the mechanical seal is installed in the gland with the lapped
seal face up.
3) Ensure the inboard gasket is installed in the gland.
4) Place the gland on a workbench with the lapped seal facing up.
5) Place the rotating part of the mechanical seal against the stationary part of the mechanical
seal with the lapped faces together.
200 MECHANIC 17-18

6) Measure the distance from the inboard gasket to the top of the mechanical seal.
7) Determine the amount of compression of the mechanical seal.
a) Multiple spring mechanical seals used on shafts less than 2" in diameter require 1/8"
compression.
b) Multiple spring mechanical seals used on shafts 2" in diameter and over require 3/16"
compression.
c) Single spring seals require 1/2 the free height of the spring.
8) Subtract the required compression of the seal determined in (Step h.7) from the length of
the seal determined in (Step h.6).
NOTE: This will be the working height of the seal from the face of the stuffing box cover.
i. Measure the distance obtained in (Step h.8.) from the scribed line marked in (Step g.2) toward the
impeller end of the shaft. Scribe a second line with a soft pencil at this point.
j. Install the mechanical seal.
1) Install the assembled gland onto the pump shaft, ensuring the lapped seal face of the
mechanical seal faces the impeller.
2) Install the rotating part of the mechanical seal onto the pump shaft, ensuring the lapped
seal face of the mechanical seal faces the gland. Align the end of the setscrew side of the
seal with the scribed line determined in (Step i.). Tighten the setscrews.
k. Place the shaft, gland, and mechanical seal in the stuffing box cover.
l. Install the impeller, ensuring the o-ring (if applicable) is installed.
m. Install the impeller and stuffing box assembly in the casing.
n. Install the stuffing box cover washer and nuts.
o. Position the gland away from the stuffing box cover.
p. Adjust the impeller clearance until the line scribed in (Step 3.g.) is even with the face of the stuffing
box cover.
q. Compress the gland against the stuffing box cover and secure it with the gland nuts.
r. Inspect the shaft for wear, burrs, or grooves that would interfere with the sealing of the mechanical
seal to the shaft.
MECHANIC 17-18 201

202 MECHANIC 17-18

A C
AIR
IR
COMPRESSORS
OMPRESSORS
OSA 1301 (AQ)
COMPETENCY
Explain the steps to troubleshoot an air compressor that runs but does not compress air.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the steps to troubleshoot an air compressor that runs
but does not compress air.
PROCEDURE
1. When troubleshooting an air compressor that does not compress air, the following should be checked:
a. Proper oil pressure on units equipped with an oil pump
NOTE: Some units are equipped with a hydraulic loadless starting system, which requires the unit
to attain a predetermined oil pressure setting before the compressor starts compressing air.
b. Proper direction of rotation
c. Proper operation of the unloading mechanism
d. Leaking or broken suction or discharge valves
e. Blown head gasket
f. Broken piston rings
g. A cracked piston
MECHANIC 17-18 203

AIR COMPRESSORS
OSA 1302
COMPETENCY
Trace the flow of air through a rotary (screw) air compressor system.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee trace the flow of air through a rotary (screw) air
compressor system. The Qualifier will have the employee trace the flow through a rotary (screw) air
compressor by indicating arrows and labeling the components on (Appendix 3).
PROCEDURE
NOTE: The steps listed below outline a generic system.
1. Air enters the compressor inlet port after flowing through the air filter and inlet control valve.
2. The compressor reduces the volume and increases the pressure of the air.
3. The air discharged from the compressor enters the sump, where the majority of the oil is separated
from the air.
4. The air then flows through the oil separator, which removes the remainder of the oil.
5. The air leaving the separator flows through the aftercooler, where the air is cooled before it arrives
at an air storage tank or point of use.
204 MECHANIC 17-18

AIR COMPRESSORS
Figure 1: Typical Rotary Air Compressor System
MECHANIC 17-18 205

AIR COMPRESSORS
OSA 1303
COMPETENCY
Explain the function of an inlet control valve on a rotary (screw) air compressor.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the function of an inlet control valve on a rotary
(screw) air compressor.
PROCEDURE
The employer will explain as follow:
1. The inlet control valve on rotary (screw) air compressor loads and unloads the air compressor. The load/
unload condition is determined by a pre-determined system pressure setting which is sensed by the inlet
control valve. The rotary (screw) air compressor is a constant run application for which the inlet control
valve makes load/unload conditions much smoother.
206 MECHANIC 17-18

AIR COMPRESSORS
OSA 1304 (AQ)
COMPETENCY
Explain the function of the lubricating system on a rotary (screw) air compressor system.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the function of the lubricating system on a rotary
(screw) air compressor system.
PROCEDURE
The employer will explain as follow:
1. Air and oil are mixed in the compressor, as it exits the discharge port it enters the oil sump. The Air Oil
Separator is also attached to one end of the oil sump which has a larger opening. Natural forces of gravity
make most of the oil settle toward the bottom of the oil sump and the air under pressure is forced through
the larger opening leading to the Air Oil Separator which is still mixed with some oil in a mist form.
2. The oil from the bottom of the oil sump is directed to the Thermal Bypass Valve where it may return
to the compressor or depending on the oil temperature, it may be directed through the oil cooler and then
back to the compressor.
3. The air/oil mixture which passes through the Separator is separated where the air exits to the air system,
and the oil is forced through the middle of the separator and exits through tubing and returns into the
compressor to complete its cycle.
MECHANIC 17-18 207

AIR COMPRESSORS
208 MECHANIC 17-18

C
CLUTCHES
LUTCHES
OSA 1901 (AQ)
COMPETENCY
Explain the purpose of a clutch.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the purpose of a clutch.
PROCEDURE
1. The purpose of a clutch is to allow an engine to be started with no load. Once the engine is at the desired
speed, the clutch can be manually or automatically engaged to allow the power from the driver to be
transferred to the driven equipment.
MECHANIC 17-18 209

CLUTCHES
OSA 1902
COMPETENCY
Explain the principle operation of a Sprague type clutch.
ADMINISTRATION
Explain: The Qualifier will have the employee explain the principle operation of a Sprague type clutch.
PROCEDURE
The employee will explain as follows : (Figure 1)
1. A Sprague type clutch resembles a roller bearing assembly. A starter shaft is fitted through the center
of the spragues. The outer portion of the Sprague clutch is fitted inside an engine pinion shaft. As the
starter begins to rotate, the small spragues which are shaped like an hour glass make contact with the
starter shaft causing them to lock against the starter shaft and the out housing which forces the engine
pinion shaft to rotate. After enough engine speed is accomplished, it will out spin the starter speed and
relax the Spragues and disengage the Sprague clutch.
Figure 1: Typical Sprague Assembly
210 MECHANIC 17-18

A
ALIGNMENT
LIGNMENT
OSA 2201
COMPETENCY
Define soft foot and explain the method used to check and correct it.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee define soft foot and explain the method used to check and
correct it.
PROCEDURE
1. Soft foot is the condition when all of a unit’s feet are not resting on the same plane as the foundation.
NOTE: Soft foot results in distortion/deflection when a unit’s hold-down bolts are tightened and can
affect vibration levels as well as alignment.
2. Procedure to check and correct soft foot:
a. Check the unit’s feet, ensuring they are not worn, broken, cracked, or bent.
b. Check the feet for soft foot, using a dial indicator.
1) Mount a dial indicator on a fixed surface in close proximity to the foot being checked.
2) Place the dial indicator pointer on the top surface of the foot.
3) Zero the dial indicator.
4) Loosen the hold-down bolt.
5) Any soft foot will be recorded on the indicator as a positive reading.
MECHANIC 17-18 211

ALIGNMENT
6) Correct the soft foot by adding the appropriate amount of shims under the foot.
7) Torque the hold-down bolt and recheck for a soft foot.
8) Repeat (Steps 1 through 7) until no indicator movement is noted when the hold-down bolt is
loosened.
NOTE: If it is impossible to attain no indicator movement after a serious attempt to

correct the soft foot, .002" indicator movement is allowable.
9) Repeat (Steps 1 through 8) for the other feet on the unit.
NOTE: If for some reason the dial indicator reads a negative number, check to ensure
that it was not bumped or moved while loosening the bolt. If this has not occurred,check
to see if the base or sole plate is warped and causing deflection of the dial indicator stem
away from the foot of the machine.
212 MECHANIC 17-18

ALIGNMENT
OSA 2202
COMPETENCY
Define indicator arm sag and explain the method used to check and compensate for it.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee define indicator arm sag and explain the method used to
check and compensate for it. The employee will be allowed to use the procedure section and/or the
manufacturer's manual. The employee will be allowed to use (Figure 1) when explaining this Assessment.
PROCEDURE
The employee will explain as follows: (Figures 1)
1. Indicator arm sag is a condition caused by the weight of the dial indicator on the indicator arm. This
weight causes a slight droop in the indicator arm and must be taken into consideration when dial
indicator readings are interpreted.
2. Procedure to check and compensate for indicator arm sag: (Figure 1)
a. Assemble the clamp and the dial indicator onto the shaft that is to be aligned.
b. Place the dial indicator pointer in the position on the rim where the readings will be obtained.
c. Measure and record the distance from the back of the clamp to the dial indicator.
d. Remove the clamp and dial indicator from the shaft.
e. Assemble the clamp and the dial indicator onto a test shaft, ensuring the dial indicator is in the
same position as in (Step c.)
f. Rotate the dial indicator to the 12 o’clock position.
MECHANIC 17-18 213

ALIGNMENT
g. Zero the dial indicator.
h. Rotate the dial indicator to the 6 o’clock position.
i. Record the dial indicator reading. This reading is the indicator arm sag.
j. Remove the clamp and dial indicator from the test shaft.
k. Repeat Steps a. and b.
l. Rotate the dial indicator to the 12 o’clock position.
m. Zero the dial indicator.
n. Place the indicator dial on the positive number that equals the indicator arm sag record in
(Step i.). This will compensate for the indicator arm sag.
NOTE: Keeping the distance between the back of the clamp and the position where the indicator
is mounted (Step c.) as short as possible will reduce indicator arm sag. Horizontal alignment
readings are not affected by indicator arm sag. Face (angular) alignment is not affected by indicator
arm sag.
214 MECHANIC 17-18

ALIGNMENT
Figures 1: Typical Dial Indicator Arm Sag Check
MECHANIC 17-18 215

ALIGNMENT
OSA 2203
COMPETENCY
Explain the items that should be checked prior to aligning a unit.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the items that should be checked prior to aligning
a unit.
PROCEDURE
1. Coupling:
a) When inspecting the coupling, check for worn teeth, loose set screws, and loose connecting bolts.
2. Foundation:
a) When inspecting the foundation, check for worn areas, cracks, warpage, foreign matter, and loose
hold-down bolts.
3. Shims:
a) When inspecting the shims, check for cleanliness and correct length and width. Use the right
thickness of shims to reduce the total number of shims (e.g., do not use 20-.001" shims when you
can use 1-.020" shim).
4. Coupling gap:
a) Coupling manufacturers provide a dimension between the coupling halves (gap) that must be
maintained during alignment.
5. Ensure all connected piping and braces are disconnected from the unit being aligned.
216 MECHANIC 17-18

ALIGNMENT
OSA 2204
COMPETENCY
Perform a face (angular) and rim (parallel) alignment.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee perform a face (angular) and rim (parallel) alignment.
The Qualifier will select two components and ensure the components are misaligned before the employee
begins. The final alignment total indicator reading shall not exceed .005". The employee will be allowed to
use the procedure section and/or the manufacturer's manual.
PROCEDURE
The employee will demonstrate as follows: (Figures 2, 3 and 4)
2. Check and correct for soft foot.
3. Check for indicator arm sag.
4. Perform a prealignment check.
5. Ensure the surface where the coupling face readings are to be taken is true.
a. Ensure the face surface is clean and free of nicks and burrs.
b. Mount a dial indicator on a fixed surface in close proximity to the face. (Figure 2)
c. Place the dial indicator pointer on the surface of the face.
d. Remove all thrust from both shafts.
MECHANIC 17-18 217

ALIGNMENT
e. Zero the dial indicator.
f. Rotate the shaft 360° while watching the dial indicator needle.
g. Any reading other than zero indicates that the face is not true.
NOTE: If the face is not true, the coupling should be replaced. If the coupling is not replaced,
inaccurate indicator readings could result.
6. Ensure the surface where the coupling rim readings are to be taken is true.
a. Ensure the outer surface of the coupling rim is clean and free of nicks and burrs.
b. Mount a dial indicator on a fixed surface in close proximity to the rim.
c. Place the dial indicator pointer on the surface of the rim.
d. Remove all thrust from both shafts.
e. Zero the dial indicator.
f. Rotate the rim 360° while watching the dial indicator needle.
g. Any reading other than zero indicates that the rim is not true.
NOTE: If the rim is out of round, the coupling should be replaced. If the coupling is not replaced,
inaccurate indicator readings could result.
7. Perform a preliminary alignment of the coupling halves.
a. Place a straight edge across the coupling halves in the vertical position.
b. Add or remove shims until a preliminary vertical alignment is achieved.
1) Add or remove an equal amount of shims under the inboard feet of the movable compo-
nent until the straight edge is level and is touching both coupling halves.
2) Add or remove an equal amount of shims under the outboard feet of the movable compo-
nent until the straight edge is level and is touching both coupling halves.
c. Place a straight edge across the coupling halves in the horizontal position.
d. Position the moveable component until the straight edge is level and is touching both coupling
halves.
218 MECHANIC 17-18

ALIGNMENT
Rim (Parallel)
Face (Angular) Alignment
Alignment
Stationary Moveable
Component Component
Figure 2: Typical Face and Rim Alignment
MECHANIC 17-18 219

ALIGNMENT
8. Perform a vertical face alignment.
a. Assemble the clamp and dial indicator onto the coupling of the stationary component.
b. Place the dial indicator pointer onto the face of the opposite coupling being aligned. Ensure the
pointer is contacting the inside coupling face. (Figure 2) If component configuration dictates placing
the pointer on the outside coupling face, care must be taken to ensure that the reading obtained in
(Step g.) is inverted. (If Step g. indicates to add shims, they must be removed.)
c. Rotate the dial indicator to the 12 o’clock position.
d. Zero the dial indicator.
NOTE: The thrust must be removed from both shafts before the dial indicator is adjusted, and at
each point where a vertical or horizontal face reading is taken.
e. Rotate the dial indicator to the 6 o’clock position and record the reading. (This is the total indicator
reading).
f. Rotate the dial indicator back to the 12 o’clock position and verify that the indicator returns to zero.
g. Using (Figure 3), determine the amount of shims that need to be added or removed from under the
feet of the moveable component. Add or remove the shims.
h. Repeat (Step 7.) until the reading obtained at the 6 o’clock position is as close to zero as possible.
9. Perform a horizontal face alignment.
a. Rotate the dial indicator to the 3 o’clock position.
b. Zero the dial indicator.
c. Rotate the dial indicator to the 9 o’clock position and record the reading. (This is the total indicator
reading.)
d. Rotate the dial indicator back to the 3 o’clock position and verify that the dial indicator returns to
zero.
e. Using (Figure 3), determine the amount of adjustment needed at the outboard and inboard feet. If
component configuration dictated placing the pointer on the outside coupling face, these readings
must be inverted. (If Figure 3 indicates to move the inboard feet +.020", they must be moved -.020".)
220 MECHANIC 17-18

ALIGNMENT
f. Position the moveable component. (Figure 4)
1) Place a dial indicator on a fixed surface to monitor horizontal movement of the inboard feet
of the movable component. The dial indicator must be placed on the same side that the 3
o’clock reading is taken.
3) Place a dial indicator on a fixed surface to monitor horizontal movement of the outboard
feet of the movable component. The dial indicator must be placed on the same side that
the 3 o’clock reading is taken.
5) Position the movable component until the positive or negative readings obtained in Step
e. are obtained on the dial indicators monitoring the inboard and outboard feet horizontal
movement.
g. Repeat (Step 8.) until the reading obtained at the 9 o’clock position is as close to zero as possible.
10. Perform a final face alignment.
c. Rotate the dial indicator to the 6 o’clock position and record the reading. (This is the vertical plane
indicator reading.)
d. Rotate the dial indicator back to the 12 o’clock position and verify that the dial indicator returns
to zero.
e. Rotate the dial indicator to the 3 o’clock position.
f. Zero the dial indicator.
g. Rotate the dial indicator to the 9 o’clock position and record the reading. (This is the horizontal
plane indicator reading.)
h. Rotate the dial indicator back to the 3 o’clock position and verify that the indicator returns to zero.
MECHANIC 17-18 221

ALIGNMENT
Si
So
Li
Lo
So = 1/2 (TIR) X Lo
R
Si = 1/2 (TIR) X Li
R
So
= The amount of adjustment needed at the outboard feet
Si
= The amount of adjustment needed at the inboard feet
Lo
= The distance from the center of the coupling to the center of the outboard feet
Li
= The distance from the center of the coupling to the center of the inboard feet
TIR = The difference between the two readings on opposite sides of the shaft
(If a negative reading is obtained, ensure the negative number is used in the formula.)
R = 1/2 the diameter of the coupling
Example:
Lo = 60" So = .0025 X 60 So = .038

Li = 10" 4
R = 4"
TIR = .005" Si = .0025 X 10 Si = .006
4
Figure 3: Figuring Face Adjustment
222 MECHANIC 17-18

ALIGNMENT
Dial Indicators
DRIVEN
T
ENGINE EQUIPMEN
Figure 4: Typical Horizontal Face Alignment Adjustment
MECHANIC 17-18 223

ALIGNMENT
i. Figure the total indicator reading.
1) Compare the vertical plane indicator reading obtained in Step c. to the horizontal plane
indicator reading obtained in (Step g.).
2) The larger of the two numbers is the total indicator reading.
j. If the total indicator reading is not within the manufacturer’s limits for allowable misalignment,
repeat (Steps 7. through 9.) until an acceptable reading is obtained.
11. Perform a vertical rim alignment.
a. Assemble the clamp and dial indicator onto the coupling of the stationary component.
b. Place the dial indicator pointer onto the rim of the opposite coupling being aligned.
c. Rotate the dial indicator to the 12 o’clock position.
d. Place the indicator dial on the number obtained during the indicator arm sag check in (Step 2.).
NOTE: The thrust must be removed from both shafts before the dial indicator is adjusted and at
each point where a vertical or horizontal rim reading is taken.
e. Rotate the dial indicator to the 6 o’clock position and record the reading. (This is the total indicator
reading.)
f. Rotate the dial indicator back to the 12 o’clock position and verify that the indicator returns to its
original reading.
g. Calculate the amount of shim adjustment required.
1) If a positive total indicator reading was obtained in (Step e.), add shims under each foot of
the movable component equal to one-half of the total indicator reading (e.g., if a +.010
reading was obtained in (Step e.), add .005" shim under each foot of the movable compo-
nent).
2) If a negative total indicator reading was obtained in (Step e.), remove shims under each foot
of the movable component equal to one-half of the total indicator reading.
h. Repeat (Step 10.) until the reading obtained at the 6 o’clock position is as close to zero as possible.
224 MECHANIC 17-18

ALIGNMENT
12. Perform a horizontal rim alignment.
c. Rotate the dial indicator to the 9 o’clock position and record the reading. (This is the total indicator
reading).
d. Rotate the dial indicator back to the 3 o’clock position and verify that the indicator returns to zero.
e. Position the movable component.
1) If a positive total indicator reading is obtained in (Step c.), move the movable component
one-half of the total indicator reading toward the 3 o’clock position.
2) If a negative total indicator reading is obtained in (Step c.), move the movable component
one-half of the total indicator reading toward the 9 o’clock position.
NOTE: When positioning the movable component, it will be necessary to move theinboard
and outboard feet equally.
f. Repeat (Step 11.) until the reading obtained at the 9 o’clock position is as close to zero as possible.
13. Perform a final rim alignment.
b. Place the indicator dial on the number obtained during the indicator arm sag check in (Step 2.).
c. Rotate the dial indicator to the 6 o’clock position and record the reading. (This is the vertical plane
indicator reading.)
d. Rotate the dial indicator back to the 12 o’clock position and verify that the indicator returns to its
original reading.
e. Rotate the dial indicator to the 3 o’clock position.
f. Zero the dial indicator.
g. Rotate the dial indicator to the 9 o’clock position and record the reading. (This is the horizontal plane
indicator reading).
MECHANIC 17-18 225

ALIGNMENT
h. Rotate the dial indicator back to the 3 o’clock position and verify that the indicator returns to zero.
i. Figure the total indicator reading.
1) Compare the vertical plane indicator reading obtained in (Step c.) to the horizontal plane
indicator reading obtained in (Step g.).
2) The larger of the two numbers is the total indicator reading.
j. If the total indicator reading is not within the manufacturer’s limits for allowable misalignment,
repeat (Steps 10. through 12.) until an acceptable reading is obtained.
14. Perform a final alignment.
a. Repeat (Steps 9. and 12.) until both readings are within the manufacturer’s limits for misalignment.
b. The larger of the two readings is the final alignment total indicator reading.
226 MECHANIC 17-18

ALIGNMENT
OSA 2205
COMPETENCY
Demonstrate the procedure to perform a reverse alignment on a pump.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee demonstrate the procedure to perform a reverse
alignment on a pump.The employee will be allowed to use the procedure section and/or the manufacturer's
manual.
PROCEDURE
1. Learn about the machine you are aligning.
a. Visually check coupling, pipe hangers, base bolts, coupling spacing etc.
b. Check for coupling & shaft run out
2. Prepare the machine.
a. Remove all existing shims from under the feet
1) if old shims are to be used, clean themthoroughly.
2) always use minimum amount of shims.
b. Clean the base thoroughly.
1) scrape and file away all rust, nicks, and burrs
c. Examine the base bolts and holes.
1) retap if necessary
2) replace bolts if necessary
MECHANIC 17-18 227

ALIGNMENT
3. Installation of alignment brackets
a. Clean mounting surface, file off nicks and burrs.
b. Check indicators for sticking and loose needle.
c. Aim indicator stem directly toward center line of shaft.
4. Measurement
a, measure distance between the two indicators.
b. measure distance between indicator and front feet.
c. measure distance between front and back feet.
5. Layout graph paper
a. mark indicator position
b. mark feet position.
c. remember to mark + and - signs (this eliminates confusion)
Figure 5: Example Graph Layout
6. Check for Soft Foot
a. The horizontal move is the part of the alignment process that aligns the shaft's centerlines from
side to side. View the machine from the pump end, zero the indicators on the left, and then rotate
and read on the right. Make sure that you always view the pump from the same direction in order
for you to keep the left and right directions correct. There is no sag compensation on the
horizontal move.
b. For example:
The indicator on the pump reads -8
The indicator on the motor reads +10
228 MECHANIC 17-18

ALIGNMENT
c. The shafts are collinear at 1/2 the Total Indicator Reading.

Using graph paper to illustrate the position. Under the indicator position mark the point that is
1/2 the indicator reading. (-4 for the pump and +5 for the motor) Connect these points and
extend the line past the motors feet. This will show you how much you need to move the motor
for horizontal alignment.
d. These indicator readings mean that you need to move the motor:
1) front foot .006" left

2) back foot .007" left
7. Vertical Move:
a. The vertical move is the part of the alignment process that aligns the two shaft's centerlines
into their proper up and down position. Usually you will have to add or remove shims in this
step. The indicators are zeroed on the top and read at the bottom. (start with a plus + reading
if you need to compensate for sag)
b. Example:
1) the indicator on the pump reads -12

2) the indicator on the motor reads +8
c. This means that the shafts are one half the total indicator reading from being collinear at these
points. Using a square grid graph paper to illustrate the position. Under the indicator position
mark the point that is half the indicator reading. ( -6 for pump side indicator and +4 for the motor
side indicator) Connect these two points with a line and then continue the line past the lines
representing the feet on the motor. The graph now shows that the front foot needs to have a
.003" shim added and the back foot needs to have a .001" shim added.
8. Tighten all bolts and recheck indicator readings.
9. Remove alignment brackets.
MECHANIC 17-18 229

ALIGNMENT
OSA 2206
COMPETENCY
Demonstrate the procedure to perform a laser alignment on a pump.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee demonstrate the procedure to perform a laser
alignment on a pump.The employee will be allowed to use the procedure section and/or the manufacturer's
manual.
PROCEDURE
Note: Using a laser alignment tool is very similar to the reverse alignment method, this is a
generic procedure since different types of equipment require special conditions
and needs associated with the particular device.
1. Learn about the machine you are aligning.
a. Visually check coupling, pipe hangers, base bolts, coupling spacing etc.
b. Check for coupling & shaft run out
2. Prepare the machine.
a. Remove all existing shims from under the feet
1) if old shims are to be used, clean themthoroughly.
2) always use minimum amount of shims.
b. Clean the base thoroughly.
1) scrape and file away all rust, nicks, and burrs
230 MECHANIC 17-18

ALIGNMENT
c. Examine the base bolts and holes.
1) retap if necessary
2) replace bolts if necessary
3. Installation of alignment laser heads and mounting brackets.
a. Clean mounting surface, file off nicks and burrs.
b. Check the laser heads for proper battery voltage.
c. Mount the laser head brackets to the selected area and secure them in place.
d. Aim laser heads so the each laser beam projects from one head to the other head in the targeted
area.
4. Basic step by step procedures for laser alignment using a Rotaline Laser Alignment Kit
a. This procedure is for a basic motor to pump set-up. We use the pump as the fixed point,
already checked for zero soft foot, and take it that on this application there is zero thermal
growth.
b. The Rotalign can be a complicated and a confusing machine, and will accept ( by showing a smiley
face) readings if the wrong information is fed into the computer, even if the shaft is visually
misaligned. RPM play a critical role when setting up the machine, and the students needs to
understand that acceptance by the Rotalign is not always good enough to meet OEM specifications.
There is a huge amount of Menu’s and functions on this machine, and care needs to be taken do
choose the correct functions for what you want to achieve.
1) Switch on computer and select Shaft Alignment.
2) Set up the machine. Insert all dimensions needed, almost like in reverse alignment. Pay
attention to which part will be stationary. This might save you some frustration later in the
alignment stages.
a) Select machine type.

b) Name the machine.
c) Machine mounting type – choose “fixation” and press Edit.
d) Thermal growth – add values for risings, sinks or moving.
e) Select coupling type.
f) Enter dimensions.
MECHANIC 17-18 231

ALIGNMENT
5. Laser beam adjustment – The laser and receiver have been installed prior to setting up the machine.
You should have the laser striking the red cap on the receiver. If you do have that, remove the plastic
red cap.
6. Make sure the receiver is correctly connected to the computer, then press the “M” key.
7. The position of the laser beam is marked with a dot in a circle and on a X & Y Axis. If the
dot is outside the circle, use the adjustment wheels on the laser to align the laser.
8. Check receiver status green & red LED’s.
9. Once the beam is centered, the display automatically switches over into the measurement mode. This
Display prompts you to “Turn the shafts”.
a. Standard method is the continuous “sweep” method, which automatically begins measurement
when the shafts are rotated.
b. If the laser is not centered (with the “Sensor O.K” on the status line), you may press “Start sweep”
to begin measurement manually.
c. The shafts must be rotated in normal operating direction at least 70 degrees.
d. The slower, the more accurate. If the shaft rotation is restricted, you can select a different method
of measurement.
10. Press the STOP soft key to quit measuring and to display results.
11. Press the result key to display and evaluate the results.
a. This display shows the measured alignment condition along with numerical values for actual
machine condition.
b. Sign convention – Positive = machine to high(vertical), or on the horizontal axis to far away from
the viewer.
12. Press the “Coupling” soft key to display alignment condition at the coupling.
a. Coupling results are shown in the form of gap and offset values.
b. Sign convention – Offset: negative = right (movable) machine to be moved toward 6’o clock
(vertically) or toward 9’o clock (horizontally)Gap: negative = coupling opens towards the bottom
(vertically) or toward the viewer (horizontally).
232 MECHANIC 17-18

ALIGNMENT
13. Check Alignment quality.
a. Smiley face – Excellent.
b. O.K – Acceptable.
c. Sad Face – Out of tolerance.
14. Correcting alignment.
a. The advance design of the receiver allows you to follow alignments correction in a real-time
interactive display.
b. Press “V” key to switch to Vertical.
c. Turn shafts to 9 or 12 o’clock position, this is important.
d. Press the “move” key.
e. You can now remove or add shims to desired reading.
15. Remeasure – Take another reading with all bolted down before starting Lateral (Horizontal) positioning.
16. Save measurement results.
MECHANIC 17-18 233

ALIGNMENT
OSA 2207
COMPETENCY
Explain thermal growth and it's effect on alignment.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain thermal growth and it's effect on alignment.
PROCEDURE
1. Thermal growth affects all material from expansion. Thermal growth is a condition which normally occurs
as the material absorbs heat from developing energy in rotating equipment. As the heat increases so
do the molecules in the material which cause them to increase in size, causing the material to change
its structural dimensions.
2. When aligning a machine or equipment, consideration for thermal growth or expansion should be
factored in. This information should be available from the material manufacturer. An initial cold
alignment should be performed and checked against a "hot alignment".
234 MECHANIC 17-18

G
GEARBOXES
EARBOXES
OSA 2301
COMPETENCY
Explain how to adjust the thrust on a gearbox shaft equipped with tapered roller bearings.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain how to adjust the thrust on a gearbox shaft equipped
with tapered roller bearings. The employee will be allowed to use (Figure 1) when explaining this
Assessment.
PROCEDURE
1. Separate the driver and the driven equipment couplings.
2. Using a dial indicator, check the thrust on the shaft being adjusted.
3. Refer to the manufacturer’s manual for the correct shaft thrust.
4. Remove the bearing seal cap and shims.
5. Add or remove shims to obtain the correct shaft thrust.
6. Install the bearing seal cap and shims.
7. Using a dial indicator, recheck the thrust on the shaft to ensure correct shaft thrust has been attained.
8. Connect the couplings separated in (Step 1).
MECHANIC 17-18 235

GEARBOXES
Shim Here
Tapered
Roller
Bearing
Seal Cap
Ffigure 1: Typical Thrust Adjustment
236 MECHANIC 17-18

GEARBOXES
OSA 2302 (AQ)
COMPETENCY
Explain the items that could cause unusual vibration and noise in a gearbox.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the items that could cause unusual vibration and noise
in a gearbox.
PROCEDURE
1. Coupling alignment
2. Unstable foundation
3. Loose hold-down bolts
4. Unbalanced rotating parts
5. Coupling wear
6. Worn or broken teeth
7. Excessive bearing clearance
8. Inadequate lubrication
MECHANIC 17-18 237

GEARBOXES
238 MECHANIC 17-18

C
COUPLINGS
OUPLINGS
OSA 2401 (AQ)
COMPETENCY
Explain the purpose of a flexible coupling.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the purpose of a flexible coupling.
PROCEDURE
1. The purpose of a flexible coupling is to:
a. Transmit torque from the driver to the driven equipment.
b. Allow for a limited amount of shaft misalignment.
c. Dampen vibration.
MECHANIC 17-18 239

COUPLINGS
0000000000000000
0000 000
000 00
00 0
00
00
00
00
00
0000 000000000000
00 000 00000
00
00
FLANGES
0 0 0000000000000
00 0 0
00
0 0 00
00 0 0
0
RUBBER
ELEMENT
Figure 1: Typical Para-Flex Coupling
240 MECHANIC 17-18

COUPLINGS
OSA 2402
COMPETENCY
Explain the types of couplings used in offshore applications.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the types of couplings used in offshore applications.
The employee will be allowed to use (Figures 1 through 5) only when explaining this Assessment.
PROCEDURE
The employee will explain as follows: (Figures 1 through 5).
1. Para-flex coupling - A para-flex coupling consists of two flanges that are connected by a rubber element.
The rubber element can be replaced without moving the driver or the driven equipment. A para-flex
coupling does not require any type of lubrication. (Figure 1)
2. Grid coupling - A grid coupling consists of two hubs that are connected by a grid. A two piece cover
surrounds the hubs and the grid. When the cover is removed, the grid can be replaced without moving
the driver or the driven equipment. After the cover is installed, the grid coupling should be filled with
grease. (Figure 2)
3. Gear coupling - A gear coupling consists of two hubs and two flanges. Each hub and flange has gear
teeth that are used to transfer torque. The gear teeth should be periodically inspected for wear. A gear
coupling should be filled with grease after the coupling halves are bolted together. (Figure 3)
4. Lovejoy coupling - A lovejoy coupling consists of two hubs that have a cushion (spider) between them.
When one hub is slid back on its shaft, the spider can be replaced without moving the driver or the driven
equipment. A lovejoy coupling does not require any type of lubrication. (Figure 4)
5. Disc coupling - A disc coupling consists of two hubs, two shim packs, and a spacer. The spacer and
shim packs can be replaced without moving the driver or the driven equipment. A disc coupling does
not require any type of lubrication. (Figure 5)
MECHANIC 17-18 241

COUPLINGS
Plug
Cover
Grid
Seal Seal
Hubs
Figure 2: Typical Grid Coupling
242 MECHANIC 17-18

COUPLINGS
Figure 3: Typical Gear Coupling
MECHANIC 17-18 243

COUPLINGS
Figure 4: Typical Lovejoy Coupling
244 MECHANIC 17-18

COUPLINGS
SPACER
HUB HUB
DISC
Figure 5: Typical Disc Coupling
MECHANIC 17-18 245

COUPLINGS
OSA 2403
COMPETENCY
Remove, inspect, and reinstall grid coupling.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee remove, inspect, and reinstall grid coupling.The
employee will be allowed to use the pocedure section and/or the manufacturer's manual.
PROCEDURE
a. Remove the cover.
b. Locate the split on the grid.
c. Lift one end of the grid at the split and carefully remove the grid from the hubs.
a. Clean the cover, grid, and hubs.
b. Inspect the hubs for missing, chipped, and worn teeth.
c. Ensure the hubs are securely attached to the shafts.
d. Inspect the grid to ensure it is not broken, worn, cracked, or chipped.
NOTE: If the grid is damaged, it should be replaced and alignment and spacing checked.
246 MECHANIC 17-18

COUPLINGS
e. Inspect the cover to ensure it is not cracked and its mating flanges are free of burrs.
f. Inspect the seals for nicks, cuts, and pliability.
a. Install the grid onto the hubs.
1) Align the hub teeth.
2) Place the grid over the hub teeth, ensuring it is equally spaced on each side of the
hub.
3) Start the end of the grid in the hub teeth.
NOTE: A soft mallet may be used to help press the grid into the teeth.
4) Continue installing the grid until it is in place all the way around the hub.
b. Hand pack the grid with coupling grease. Wipe off any grease above the grid.
c. Install the cover and ensure the following:
1) The match marks on the covers align.
2) The seals fit into the grooves in the cover.
3) The gaskets between the cover halves are installed.
d. Grease the coupling:
1) Remove the plug from each half of the cover.
2) Install a grease fitting in place of one of the plugs.
3) Pump coupling grease into the coupling until a steady flow of grease comes out of the plug
hole on the opposite side of the grease fitting.
MECHANIC 17-18 247

COUPLINGS
Plug
Cover
Grid
Seal Seal
Hubs
Figure 6: Typical Grid Coupling
248 MECHANIC 17-18

COUPLINGS
OSA 2404
COMPETENCY
Explain the importance of determining the magnetic center of a sleeve bearing type motor.
ADMINISTRATION
EXPLAIN: The Qualifier will have the employee explain the importance of determining the magnetic center
of a sleeve bearing type motor.
PROCEDURE
1. When an electric motor is energized, the energy will force the rotor to move to a neutral position as the
power on each side of the rotor will balance the movement of the rotor shaft. This is the position the
rotor shaft will run, and therefore called magnetic center.
2. After a repair of a motor has been provided the repair facility usually makes a scribed line on the rotor
shaft to indicate the magnetic center. This magnetic center is important when connecting the coupling
assembly. When the coupling is tightened it should not pull or separate the opposing shafts or the
magnetic center of the motor and thrust of the driven equipment will be out of tolerance which could
possible cause a failure for either component.
MECHANIC 17-18 249

COUPLINGS
250 MECHANIC 17-18

COMPUTER BASED TEST
OSA 6001 (CLDC ONLY)
COMPETENCY
Complete a randomly selected Production Maintenance Computer Base Test (CBT) for the Mechanic Pay
Salary Grade 18 level.
ADMINISTRATION
DEMONSTRATE: The Qualifier will have the employee complete a randomly selected Production
Maintenance Computer Base Test (CBT) for the Mechanic Pay Salary Grade 18 level.. Employee must
be able to demonstrate his or her proficiency on randomly selected Mechanical Operations computer based
tests questions. Employee will be required to make a 75% or higher overall score to be given credit for this
Skill Assessment. This Skill Assessment may be taken once all other Skill Assessments have been
completed.
PROCEDURE
Employee is required to register in Knowledge Planet for the available testing dates. All CBT testing will be
administrated at "CLDC ONLY".
NOTE: The Computer Based Test will include questions from all section of this Production Maintenance
Mechanical Skill Assessment Manual.
MECHANIC 17-18 251

COMPUTER BASED TEST
252 MECHANIC 17-18

HES
Health, Environment and Safety
Standard Operating Procedure 10

Lockout and Tagout Procedures
Issued 1 February 1994

Revised 15 November 2003
Contents Page
1.0 INTRODUCTION.....................................................................................................................2
2.0 DEFINITIONS..........................................................................................................................2
3.0 PERSONNEL ROLES AND RESPONSIBILITIES.............................................................4
4.0 DISCIPLINARY ACTION........................................................................................................5
5.0 LOCKOUT AND TAGOUT DEVICES .................................................................................5
6.0 DOCUMENTATION ...............................................................................................................6
7.0 PRE-JOB PLANNING............................................................................................................7
8.0 MECHANICAL ISOLATION ..................................................................................................7
9.0 ELECTRICAL ISOLATION....................................................................................................8
10.0 INITIAL LOCKOUT AND TAGOUT.......................................................................................9
11.0 MULTIPLE LOCKOUT AND TAGOUT PROCEDURES...................................................9
12.0 REMOVAL OF LOCKS AND TAGS..................................................................................10
13.0 VARIANCE PROCEDURE .................................................................................................10
ATTACHMENT A - APPROVED LOCKOUT AND TAGOUT TAG............................................12
ATTACHMENT B - STANDARD DRAWING FOR SKILLETS/SPECTACLE BLINDS...........13
ATTACHMENT C - LOCKOUT/TAGOUT VARIANCE APPROVAL FORM .............................14
ATTACHMENT D - FEEDER BREAKERS ADDENDUM..........................................................15
ATTACHMENT E - MAN ON LINE TAG ADDENDUM................................................................16
Appendix 1 Lockout/Tagout Procedures

SOP-10 Lockout and Tagout Procedures
1.0 INTRODUCTION
These Lockout and Tagout procedures must be followed during maintenance and repair
work on equipment connected to or containing mechanical, electrical or other energy sources.
The purpose of this procedure is to protect against accidental injury to personnel and damage
to company property that could occur if the equipment accidentally becomes energized during
such work.
1.1 Lockout and Tagout is generally accomplished by isolating the equipment to be

worked on from external energy sources, neutralizing internal energy sources, and
placing locks and warning tags on isolation devices to prevent accidental energy
release, or to prevent people from using it.
1.2 This SOP does not apply to normal operating activities such as running or retrieving
pigs, changing chokes, changing orifice plates, replacing pressure gauges, collecting
samples or conducting simple and routine operational equipment checks and
adjustments that do not endanger personnel or facilities.
1.3 When equipment is replaced, repaired, renovated or modified, or when new

equipment is installed, energy isolating devices for the equipment shall be designed to
accept lockout devices and/or spectacle blinds.
2.0 DEFINITIONS
2.1 Affected Personnel
People who may be affected by the isolation of a piece of equipment. This would
include, but may not be limited to, operators and maintenance personnel working in the
area or adjacent areas.
2.2 Authorized Group Representative
A person who represents a specific group (such as mechanics, electricians, operators,

etc.) and who has the authority to place a group lock.
2.3 Blinding
The installation of a blind flange or insertion of a solid steel plate between mating
flanges to prevent liquid, gas or vapors from passing through a pipeline or nozzle.
Block valves are not considered to be blinds.
2.4 Double Block and Bleed
The closing, locking and tagging of valves on either side of a bleeder that is locked
open and tagged. This may also be accomplished utilizing a double block and bleed
valve especially designed for this purpose.
Appendix 1 Lockout/Tagout Procedures continues

Page 2 of 16 November 15, 2003
2.5 Energy Isolation Devices
Devices that physically prevent the transmission or release of energy. Examples

include: circuit breakers, disconnect switches, valves, blinds or similar devices.
2.6 Critical Equipment
Any equipment (such as gas compressor, turbine, etc) that requires energy isolation
devices, removing tubings or bypassing before maintenance or repair can be
conducted. An Lockout / Tagout checklist shall be filled for any critical equipment.
2.7 Lockout
Before starting maintenance or repair work on a piece of equipment, the power

source(s) must be de-energized or physically disconnected, locked, and properly
tagged in a safe position. The only exception is when simple equipment checks and
adjustments are made that will not endanger personnel.
2.8 Operator
The representative of the department or unit that has responsibility for operating and/or
supervising the facility or equipment.
2.9 Other Groups
Includes Mechanics, Electricians, Instrument Technicians, Facilities Engineering

personnel, and Contractors who may be involved with the maintenance or repair work.
2.10 Person-in-Charge (PIC)
For daily routine work the PIC is the person responsible for on-site completion of the
work assignment. For non-routine or major jobs, the PIC is designated in writing by the
Section Supervisor responsible for the facility (e.g., Area Supervisor, Terminal
Supervisor, Municipal Services and Aviation (MS&A) Superintendent,
Telecommunications Supervisor, etc.).
A PIC may be anyone (i.e., Production Operations, Maintenance, Facilities, or a third

party contractor). However, the PIC is clearly identified for each task or project, and
must be knowledgeable and capable of the responsibilities of the PIC. The PIC is
responsible for pre-job planning, communication with all persons and departments
involved with the task or project, job-site inspection and coordination with the facility
Operator or Supervisor. The PIC insures that all applicable SOP's are followed and
has full authority to suspend work should problems develop that may present a risk to
personnel or the facility.
2.11 Tagout
A securely attached "Do Not Operate" tag is used to warn others that the control
position on a piece of equipment is not to be changed. These tags can also be used

to warn of an hazardous condition or defective piece of equipment. Tags attached to

any equipment shall be “Readable.’’ A tag that is not readable should be replaced.
2.11 Bar Clip
A device that is used to receive multiple locks.
3.0 PERSONNEL ROLES AND RESPONSIBILITIES
3.1 Supervisors
a. Supervisors are responsible for implementing these Lockout and Tagout

procedures in their respective operations.
b. Supervisors shall ensure that employees performing Lockout and Tagout are
trained and authorized to do the work.
c. Supervisors shall ensure that lockout and tagout devices (i.e. chains, locks,
tags, multi-clamps) are available and well maintained in their facilities. This is
critical for the implementation and success of lockout and tagout process.
d. Supervisors shall ensure that all tags attached to the equipment are readable.
Replace any tags that are not readable.
e. The Supervisor should ensure that all tags state the reasons for the tagout;
name of the person placed it, and date.
f. Supervisors shall carry out facility audits in a regular monthly basis.
g. Supervisors should address positive reinforcement on tasks well done and

encourage that pre-job safety meetings are held before starting lockout and
tagout on equipment.
3.2 Operators
a. Operators are responsible for following these procedures when performing

maintenance or repairs on equipment. They are also responsible for controlling
the Lockout and Tagout boxes in their platforms.
b. Operators shall maintain their key locks all the time while they are performing
maintenance or repairs on equipment involving lockout and tagout.
c. Lead Operators shall collect all the keys of locks installed on the equipment if
maintenance/repair works do not finish at the end of the day. The keys should
be placed inside the lockout and tagout boxes in their facilities.
d. Note: All keys should be identified according to their respective locks.
e. Operators shall maintain their lockout/tagout boxes with all necessary lockout
and tagout equipment (i.e. locks, tags, chains, etc.) as defined in section 4.0.
f. Operators shall carry out a weekly inventory of lockout and tagout equipment.
Defective equipment shall be taken out of service.
g. Operators shall ensure that lockout and tagout log books are signed and
updated.
h. Lead Operators shall maintain a lockout and tagout preventive maintenance

checklist while critical equipment is being locked. Also P&ID are required to be
attached to the checklist.
3.3 Other Groups
a. Other groups are responsible for following these procedures when performing
maintenance or repairs on equipment.
b. Other groups shall carry their lockout and tagout devices during maintenance or
repair of equipment at unmanned facilities.
c. Other groups shall use lockout and tagout devices available in lockout and
tagout boxes on manned facilities where they are performing the tasks.
d. Other groups shall hand over their lock keys to the Lead Operator after
completion of the job or at the end of the day.
e. Other groups will need to have P&ID for marking up the location(s) where
lockout and tagout devices were applied for the work being carried on critical
equipment.
3.4 Support Departments
a. The HES Department is responsible for revising these procedures based on

recommendations from Operations Supervisors or any other concerned party.
b. The CABGOC Learning and Development Center (CLDC) shall act as a

resource for training in lockout and tagout procedures.
4.0 DISCIPLINARY ACTION
Removing any lock or tag, or tampering with locked or tagged equipment is subject to
disciplinary action up to and including dismissal.
5.0 LOCKOUT AND TAGOUT DEVICES
5.1 All locks used for lockout will be keyed padlocks. The Lead Operator shall retain
spare keys of each lock assigned to the groups in the control room (Master Lock Box).
Locks and their keys should be individually numbered for identification purposes.

5.2 Locks should be coded:
Group Color Code Warehouse Symbol No.

Operators Yellow 555355790
Mechanics Blue 555355792
Electricians Red 555355794
Instrument Technicians Green 555355796
Facilities Engineering White 555355798
General none 555355800
(Key Blanks) 555355800
5.3 Depending on the facility (size and number of personnel), locks will be placed in a
lockout/tagout box so access can be controlled.
5.4 Every lock must be accompanied by a completed tag to identify the person who
applied the lock. Tags approved for Lockout and Tagout (Attachment A) are
available from the main Warehouse (Symbol no. 555100760). The tag reads
"Danger Do Not Operate". These tags are weather resistant and contain an eyelet
so they can be fastened to the equipment with a tie-wrap or wire.
5.5 Where multiple locks are required, bar clips shall be used (Warehouse Symbol no.
558101310).
5.6 If chain is needed to lockout valves or other equipment, yellow-coated safety chain
should be used (Warehouse Symbol no. 555350810).
6.0 DOCUMENTATION
6.1 Each major facility or area should maintain a lockout/tagout log book to document
lockout/tagout activities. All personnel authorized to lock and tag equipment should
enter the date and time that the lock and tag were installed, the name or initials of the
person who installed the lock and tag, the equipment description, the reason for the
lockout.
The person removing the lockout and tagout should sign his/her name, date, and time
that the lock/tag out were removed.
6.2 The log book should also contain a "blind list" to document instances where
mechanical equipment is isolated by other means, such as disconnecting lines and
using skillets, blind flanges or using double block and bleed. In these instances, the
same information required in paragraph 6.1 should be entered into the log book.
6.3 Log books should be color coded by section:
Yellow (top section of log book) Operations

Green Instrumentation
Red Electrical
Blue Maintenance
White Other or Construction
Orange (bottom section) Blind List
6.4 Log books should be Acco-bounded so that the pages stay in place. Binders are
not recommended because it is easy to tear out or lose pages.
6.5 Grease boards may also be used to record lockout/tagout and blind list information,
but only in addition to a written log. If a grease board is used, entries should be color
coded to match the log book color codes.
7.0 PRE-JOB PLANNING
7.1 Prior to starting a Lockout and Tagout operation, a planning team shall review the work
to be performed and develop a Pre-Job Plan. As a minimum, the team should consist
of PIC and the Operator, with the participation of other involved groups as necessary.
The Pre-Job Plan may be an informal discussion with other groups involved for minor
jobs, or a formal written plan for major, non-routine jobs. Pre-Job Plans should
address:
7.1.1 Identification of all energy sources associated with the equipment to be

isolated.
7.1.2 Identification of energy isolation devices that will be used.
7.1.3 Identification of other Lockout and Tagout equipment that will be needed, such
as chains, blind flanges, skillets, spectacle blinds, etc.
7.1.4 Special hazards or considerations involved.
7.1.5 The possibility that energy may need to be released during the work, to test or
position equipment.
7.1.6 Notifications of all affected employees.
7.2 The planning team should walk the job, flag isolation points with red plastic tape, and
enter the isolation point in the lockout/tagout log or blind list, as well as marking up the
P&ID if critical equipment is locked and tagged.
8.0 MECHANICAL ISOLATION
8.1 The preferred method for mechanically isolating equipment from process lines is
disconnecting lines and installing blind flanges, skillets or spectacle blinds. Blind
flanges, skillets and spectacle blinds must be rated (working pressure and size) for the
lines where they will be used (see Attachment B - Standard Drawing for Skillets /
Spectacle Blinds).
8.2 Double block and bleed may also be used to isolate equipment from process lines.
Bleed lines should be carefully checked to ensure they are not plugged.
8.3 Isolation using a single block valve is not an acceptable alternative except in certain
specific situations where all the following conditions are met:
8.3.1 The isolation block valve closes tight, does not leak, and is locked closed;
8.3.2 The specific job activity is continuous and uninterrupted through to completion,
and is conducted during daylight hours;
8.3.3 No confined space entry or hot work is involved; and
8.3.4 Approval from Area Superintendent is granted through the Lockout/Tagout

Variance Approval form procedure (Attachment C).
8.4 All valves used for mechanical isolation must be locked out, either on the valve body or
by use of a chain through the handle.
8.5 Mechanical isolation in preparation for confined space entry must be achieved by
installing blind flanges, skillets, or disconnecting and removing all associated lines.
(Note: Other requirements contained in SOP-5 “Confined Space Entry” Procedures
must also be met.)
8.6 Internal mechanical energy sources associated with equipment being worked on
(pressurized fluid, springs, elevated components, rotating equipment and gears) must
be neutralized or physically blocked out to prevent accidental release. Examples:
• Bleeding down steam, air, or hydraulic lines and cylinders.

• Blocking out gears and other mechanisms.
• Placing blocks under raised dies, lifts, or any equipment that might descend,
slide, fall or roll.
• Releasing coiled springs and any spring-loaded devices.
• Chaining rotating equipment.
• Discharging large capacitors.
8.7 If mechanical isolation cannot be achieved as described in this section, an approved

variance must be obtained prior to commencing repairs and maintenance on the
equipment. The variance procedure is described in section 13.
9.0 ELECTRICAL ISOLATION
9.1 Equipment should be carefully reviewed to ensure that all electrical energy sources
have been identified.
9.2 Equipment must be isolated from electrical energy sources by opening and locking all
main power supplies. If the main power supply cannot be locked out, the equipment
must be physically disconnected from the power source by a qualified electrician.
9.3 After the equipment has been isolated from the main power supply, local electrical
switches and start/stop stations should be activated to confirm that the isolation is
completed.
9.4 Lockout of electrical equipment is to be made at the main power supply. Lockout of
local switches may leave other portions of the equipment energized. Special attention
must be given to equipment connected to alternate power sources. In all cases an
attempt shall be made to start the equipment locally to ensure it is properly isolated.
9.5 If electrical isolation cannot be achieved as described in this section, an approved

variance must be obtained prior to commencing repairs and maintenance on the
equipment. The variance procedure is described in Section 13.
10.0 INITIAL LOCKOUT AND TAGOUT
The Person-in-Charge (PIC) and the Operator are responsible for the initial lockout and
tagout. Prior to commencing maintenance or repair work on equipment connected to or
containing energy sources, the PIC and the Operator shall:
10.1 Notify all affected personnel on the nature of the work to be performed.
10.2 Shut down the equipment by normal procedures.
10.3 Mechanically isolate and lockout the equipment as described in Section 8.
10.4 Electrically isolate and lockout the equipment as described in Section 9.
10.5 Apply a tag at each location where equipment has been altered for lockout and tagout,
including valves, flanges, skillets, spectacle blinds, switches, and blocking devices.
The tag should identify the person who applied it, the reason the tag has been applied,
and the date the tag was applied.
10.6 Notify affected employees that the initial lockout and tagout is completed.
10.7 If only the Operator will be performing the maintenance or repair, when the above
lockout and tagout is complete, the work may proceed. If Other Groups will be
performing work on the equipment, the Operator should advise and assist them with
the multiple lockout and tagout procedures described in Section 10.
11.0 MULTIPLE LOCKOUT AND TAGOUT PROCEDURES
If more than one group (Operators, Mechanics, Electricians, etc.) are involved in the
maintenance or repair work:
11.1 The Operator (or the Operator's designee) must first lockout and tagout the equipment
before using the bar clip on it as described in section 10.0.
11.2 One Authorized Representative from each Other Groups involved on the task must
place a lockout / tagout on the bar clip.
11.3 Each Group representative is responsible for all employees while work is being
performed.
11.4 Even in a group lockout situation, any employee working on the equipment may elect to
place his or her assigned lock and tag on the bar clip, if he or she feels it is necessary.
The individual employee's lock and tag must be removed when the employee has
completed his or her work or at the end of the workday.

12.0 REMOVAL OF LOCKS AND TAGS
Locks and tags used for lockout and tagout may only be removed as follows:
12.1 Following the completion of maintenance and repairs,
12.1.1 The Operator shall perform a final check of the equipment to ensure it is ready
to be reactivated.
12.1.2 Authorized representatives shall remove any locks and tags installed by their
group.
12.1.3 The Operator shall be the last to remove his or her lock(s) and tag(s), and then
proceed to reactivate the equipment.
12.2 If lockout and tagout is in progress during crew or shift change, employees who have
installed locks and tags are responsible for turning over their keys to their relief’s and
explaining the nature of the work underway, including special hazards or
considerations involved.
The Operator is responsible for advising all, and including any in-coming personnel
involved on the work underway, and any significant aspects of the Pre-Job Plan,
including special hazards and considerations involved.
12.3 If the work being performed requires that energy be released to test or position
equipment, the following procedures shall be followed:
• Notify all affected personnel.

• Remove the lockout device(s).
• Only when safe to do so, energize and proceed with testing or positioning.
• Once testing or positioning is completed, de-energize and reinstall lockout
device(s), if applicable.
12.4 In an emergency, locks and tags may be removed by the Operator.
13.0 VARIANCE PROCEDURE
13.1 If it becomes necessary to vary from this SOP in unique situations, the Operator and
Other Group Representatives that will be directly involved in conducting the work shall
produce and obtain approval of a safe alternative procedure, using the Lockout/Tagout
Variance Approval form (Attachment C), prior to beginning the work. This applies to
any variance from these guidelines, even if the varied Lockout and Tagout procedures
are considered more stringent.
13.2 The proposed alternative procedure(s) shall be reviewed and signed by the Operator
and Other Group Representatives that will be directly involved in conducting the work
prior to submission for approval.
13.3 Each Variance Approval request shall be reviewed and approved, prior to starting
work, by a level of management equivalent to the Area Superintendent in the
department or unit that owns the equipment or facility involved.
13.4 A copy of the approved Variance Approval shall be maintained at the job. The
approved variance shall be distributed as follows:
Original Person approving the variance

Copy Supervisor responsible for facility
Copy Job site
Copy Maintenance Supervisor (if applicable)

ATTACHMENT A - APPROVED LOCKOUT AND TAGOUT TAG

ATTACHMENT B - STANDARD DRAWING FOR SKILLETS/SPECTACLE BLINDS
The drawing is not available in the electronic version of the SOP. The drawing is available in
the gray Chevron Piping Manual, Volume 2, Specifications and Drawings. See the tab
Standard Drawings, drawing# GC-L31452-22. Gray manuals are housed in the Facilities
Engineering library.
http://techstds.ric100.chevrontexaco.net/document.asp?id=2320
http://techstds.ric100.chevrontexaco.net/tech_standards/gray/PIM/dwgs/gc-l31452-22.pdf
http://techstds.ric100.chevrontexaco.net/document.asp?id=2320

ATTACHMENT C - LOCKOUT/TAGOUT VARIANCE APPROVAL FORM
LOCKOUT / TAGOUT
VARIANCE APPROVAL
(Please Print)
Location: Date:
Equipment No. and/or equipment involved:
Section number(s) of this SOP that will not be followed:
Description of safe alternative procedure:
(Continue on the back if necessary)
The above variance from the preferred method of controlling energy as outlined in the Standard Operating
Procedure will not endanger Company employees, contractors, the general public, the environment, or
company property.
This variance is valid from (date): until (date):
(Print and sign names)

Person-in-Charge: Date:
Operator: Date:
Other Group Date:

Representatives:
Date:
Approved By* Date:
* Must be approved by a level of management equivalent to the Area Superintendent in the department or
unit that owns the equipment or facility involved prior to beginning the work. The approved variance
shall be distributed as follows:
Original Person approving the variance

Copy Job Site
Copy Supervisor responsible for facility
Copy Maintenance Supervisor (if applicable)
CABGOC - 02/94 Report Control No.:

ATTACHMENT D - FEEDER BREAKERS ADDENDUM
Lock-Out Tag-Out for 5KV Feeder Breakers at Malongo Power Station
WARNING
THIS PROCEDURE MUST BE FOLLOWED TO PREVENT RECLOSING OF HIGH VOLTAGE AERIAL

LINES WHILE IN CONTACT WITH PEOPLE OR EQUIPMENT. BREAKERS MUST BE RACKED OUT
AND LOCKED.
MANPOWER REQUIREMENTS
1 POWER STATION OPERATOR, DESIGNATED “OPERATOR-IN-CHARGE”

1 QUALIFIED LINEMAN DESIGNATED “LINEMAN IN CHARGE”
1 POWER DISTRIBUTION FOREMAN OR DESIGNATED PIC
REQUIRED PREPLANNING
1. Outage is approved in advance and all materials and equipment are requisitioned and staged.
2. Line Crew / Power Station Operators “tailgate” meeting performed by “Lineman in Charge”. Work is
described in detail, visually identifying line.
3. Lineman in Charge to strictly coordinate commencement of and stoppage of line work.
PROCEDURE
1. Prior to line work proceeding, Lineman in Charge and Power Distribution Foreman fill in Section 1 of the
Man on Line tag, describing the work, naming the line to be de-energized and signs and dates.
2. Operator in Charge and Lineman in Charge identify line feeder breaker to be de-energized.
3. Operator in Charge and Lineman in Charge open line breaker and rack breaker from bus into the
disconnect position.
4. Operator in Charge and Lineman in Charge install locks and tags onto breaker.
5. Operator in Charge and Lineman in Charge attempt to re-close the breaker and verify that the breaker
can not be closed.
6. Operator in Charge fills in Section 2 of Man on Line tag verifying affected line is de-energized and
cannot be closed. Operator in Charge and Lineman in Charge sign and date Section 2.
7. Do Not Operate tag is placed on breaker control switch.
8. Man on Line tag is placed on breaker cubicle.
9. Line work may proceed as directed by the Lineman
10. At the completion of the line work, the Lineman in Charge fills in Section 3 stating that the line is clear
of all tools, shunts and people. Lineman in Charge signs and dates.
11. Operator in Charge, Lineman in Charge, and Power Distribution Foreman reconfirm that the line is clear
and ready to reenergize. Both Operator and Lineman in Charge, and Power Distribution Foreman sign
and date tag.
12. Operator and Lineman in Charge remove locks and tags from the breaker.
13. The breaker is racked into the bus and energized.
Note: The same Foreman in charge and the same Lineman in charge must both sign the MOL Tag in area
number 1 and number 3. If there is a change in personnel from the start of a job to its completion a new
MOL Tag shall be required.

ATTACHMENT E - MAN ON LINE TAG ADDENDUM

SASBU Incident Report CAB-42B Casefile:
IT IS THE SUPERVISOR’S RESPONSIBILITY TO INVESTIGATE ALL ACCIDENTS AND COMPLETE THIS FORM.
(Report ChevronTexaco U.S. Expat Injuries on CABGOC - 42A, Fires on CABGOC - 106, MVCs on CABGOC - 407, Spills on CABGOC - 140)
A. INCIDENT CATEGORY
1. Employee Type 2. On-the-Job (Industrial) 3. Off-the-Job (Non-Industrial)
Injury/Illness Class Injury Class
a) CABGOC Angolan National a) Lost Workday (LWD) a) Lost Time Injury
b) ChevronTexaco Expatriate (Non U.S.) b) LW Restricted Duty b) Fatal Injury
c) CABGOC Personal Service Contractor c) Medical c) Compensible Illness-
d) Countable Contractor d) First Aid Non-US Expats (e.g.,
e) Service Company Contractor e) Fatality Malaria, Food
f) CABGOC 180-Day Contractor Poison)
B. GENERAL INFORMATION (COMPLETED BY SUPERVISOR)
Informacão Geral (Preenchido pelo Supervisor)
1. NAME OF EMPLOYER 2. NATURE OF BUSINESS

Nome da Entidade Patronal Natureza da Actividade
3. NAME OF INJURED 4. SEX a) MALE / Masculino 5. SERVICE DATE (d/mmm/y)

Nome do Sinistrado Sexo b) FEMALE / Feminino Data de Admissão
6. OCCUPATION 7. EMPLOYEE # 8. BIRTHDATE (d/mmm/y)

Profissão No. de Identif. do Empregado Data de Nascimento
9. NATIONALITY 10. DATE OF INCIDENT(d/mmm/y) 11. TIME 12. WORK DAYS LOST
Nacionalidade Data do Incidente Hora Dias de Baixa
13. PERFORMING USUAL TASK a) YES b) NO IF “NO” EXPLAIN WHY IN ITEM “E” BELOW
A Desempenhar a Tarefa Habitual Sim Não Explique o Porquê No Item “E” Abaixo
14. LOCATION OF INCIDENT (FIELD, FACILITY, RIG, ETC.).

Local do Incidente (Campo Petrolifero, Instalacão, Sonda, etc.).
15. GEOGRAPHICAL JURISDICTION a) MUNICIPALITY b) PROVINCE

Jurisdicão Geográfica Município Provincia
C. INDUSTRIAL INJURY / ILLNESS OR OFF-THE-JOB INJURY / Ferimento / Doença de Trabalho ou Ferimento Ocorrido Fora das Horas de
Trabalho
1. DESCRIBE INJURY / ILLNESS, BODY PARTS INVOLVED, COST OF TREATMENT, ETC.

Descreva o Ferimento / Doença, Partes do Corpo Envolvidas, Custo do Tratamento, etc
2. DESCRIBE THE MEDICAL TREATMENT EMPLOYEE RECEIVED

Descricão do Tratamento Médico Recebido Pelo Empregado
3. WAS THE INJURED TREATED BY A DOCTOR OR NURSE? a) YES b) NO

O Ferido Recebeu Tratamento de um Médico ou Enfermeiro? Sim Não
4. WAS THE INJURED HOSPITALIZED? a) YES b) NO c) IF YES, WHERE?

O Ferido Foi Hospitalizado? Sim Não Em Caso Afirmativo, Onde?
D. IF PROPERTY DAMAGE OCCURRED, DESCRIBE DAMAGE, ESTIMATE COST, ETC.
Se Ocorreram Danos Patrimoniais, Descreva-os, Estime os Custos, etc.
E. GIVE FULL DETAILS OF HOW INCIDENT OCCURRED

Faculte Todos os Pormentores Sobre Como Ocorreu o Incidente
Appendix 2 Root Cause Analysis

THIS FORM TO BE COMPLETED BY THE DIRECT SUPERVISOR / INCIDENT INVESTIGATOR. THE INFORMATION SUMMARIZED BELOW
SHOULD BE OBTAINED BY CONDUCTING A ROOT CAUSE ORIENTED INCIDENT INVESTIGATION.
F. IMMEDIATE / DIRECT OR BASIC CAUSE(S): WHAT ACTIONS, BEHAVIORS AND/OR CONDITIONS CAUSED OR COULD CAUSE THE
EVENT? Causa(s) Imediata(s) / (Directa(s) ou Básica(s): Que Acções, Procedimentos e/ou Condições Causaram ou Poderão Ter Causado a
Ocorrência?
Information error / omission Failure to follow rules or procedures Inadequate warning / safety devices
Failure to act on warning devices Improper manual handling Personal Protective Equipment (PPE)
Personal factors Tool & equipment issues Work environment issues
Poor housekeeping External factors RSI -- workstation layout
Other -- describe:
G. ROOT CAUSE(S): WHAT SPECIFIC PHYSICAL OR HUMAN ELEMENTS AND/OR MANAGEMENT SYSTEMS CAUSED OR COULD
CAUSE THIS EVENT? Causa(s) Primordial / Indirecta: Que Características Físicas ou Causas Humanas e/ou Sistemas de Gestão Causaram
ou Poderiam Ter Causado Esta Ocorrência?
Design issues Hardware / material issues Maintenance issues
Procedural issues Planning issues Organizational issues
Incompatible goals Induction / training issues Psychological & physical factors
Repetitive stress injury (RSI) factors Inadequate MOC Other:
H. TENETS OF OPERATIONAL EXCELLENCE: WHAT SPECIFIC TENETS WERE VIOLATED, THAT ALLOWED INCIDENT TO OCCUR?
Remember: There is always time to due the job right. Always do jobs safely, or don't do them at all.
Respect design /environmental limits Operate and move to safe & controlled conditions
Keep safety devices armed Follow safe work practices/procedures; stop unsafe conditions
Exceed customer requirements Address abnormal conditions; clarify procedures
Don't compromise dedicated systems Report compliance information on time
Follow written procedures Involve the right people in job
I. REMEDIAL ACTION(S): WHAT HAS AND/OR WILL BE DONE TO CONTROL THE OWNERSHIP EST. COMPLETED
CAUSES LISTED IN SECTION F AND G? Acção(ões) Correctiva(s): O Que Foi e/ou ASSIGNED TO COMP. (INITIAL /
Será Feito Para Controlar as Causas Apresentadas nas Alíneas F e G? Responsabilidad DATE DATE)
e Atribuída a Estim. Da Concluído
REMEDIAL ACTIONS (LIST 1, 2, 3, etc.) / Acções Correctivas: Data Concl. (Rubrica e Data)
Step 1: 1: /
Step 2: 2: /
Step 3: 3: /
* Submit a “Final” or “Closed” copy to HSE when all remedial actions have been completed. *Submeta uma copia “final” ou “encerrada” quando
todas as acções correctivas tiverem sido concluídas.
J. WITNESS(ES) 1. 2.
Testemunhas
K. INVESTIGATOR(S): NAME / Nome SIGNATURE / Assinatura
O(s) Investigador(es):
____________________________________
____________________________________
____________________________________
____________________________________
SUPERVISOR: ____________________________________
L. MANAGEMENT REVIEW SIGNATURE / Assinatura DATE / Data

Revisão da Direcção
a. SUPERINTENDENT / MGR. _________________________________ ____________________________
b. GEN. MGR., OPERATIONS _________________________________ ____________________________
c. MANAGER, HES _________________________________ ____________________________
M. INCIDENT CLOSED / Incidente Encerrado
1. DATE: 2. TOTAL DAYS FOR CLOSURE:

Total de dias até ao encerramento:
3. SUPERVISOR SIGNATURE: _____________________________________
Assinatura do Supervisor:
Appendix 2 Root Cause Analysis continued

Appendix 3
GLOSSARY
ACRONYMS & ABBREVIATIONS
AC - Alternating Current FLP - Flowline Pressure

ADMIN GUIDE - Administration Guide FOG - Field Ordering Guide
API - American Petroleum Institute FSV - Flow Safety Valve
APIMPMS - API Manual of Petroleum Meas Standard FTP - Flowing Tubing Pressure
AQ - Alternate Qualifier GIH - Going in Hole
Bbl - Barrel G/L - Gas Lift
Bbls - Barrels GLR - Gas Liquid Ratio
BCPD - Barrels of Condensate Per Day GO - General Office
BPD - Barrels Per Day GOR - Gas Oil Ratio
BHP - Bottom Hole Pressure GP - Gravel Pack
BLPD - Barrels of Liquid Per Day Hgr - Hanger
BML - Below Mud Line HMI - Human/Machine Interfaces
BOPD - Barrels of Oil Per Day HP - High Pressure
BPV - Back Pressure Valve HPG - Hydraulically Set Gravel Pack Packer
BS&W - Basic Sediment and Water ICC - Interstate Commerce Commission
BTM - Bottom ID - Inside Diameter
BTU - British Thermal Unit IFR - Instrument Flight Rules
BWPD - Barrels of Water Per Day Imp Blk - Impression Block
CaCl - Calcium Chloride IP - Intermediate Pressure
CB - Type of Ring Joint ISO - International Standards Organization
CF/B - Cubic Foot Per Barrel I/O - input/output
CFM - Cubic Feet Per Minute JP-5 - Jet Petroleum 5
CFR - Code of Federal Regulations JSA - Job Safety Analysis
CIRC - Circulate K - Kilobyte
CMT - Cement KB - Kelly Bushing
CO2 - Carbon Dioxide KBE - Kelly Bushing Elevation
CP - Casing Pressure KCl - Potassium Chloride
CPR - Cardiopulmonary Resuscitation KTS - Knots
CPU - Central Processing Unit LACT - Lease Automatic Custody Transfer
CREST - Coordinated Recruiting, Employee LEL - Lower Explosion Limit
Selection, and Training LN - Landing Nipple
CS - Hydril Type Threads LP - Low Pressure
CSCB - Hydril Type of Threads with CB Ring Joints L/S - Long String (Tubing)
CSG - Casing MAWP - Manufacturers Allowable Working Pressure
CTN - ChevronTexaco Telecommunication Network MCF - Thousand Cubic Feet
DC - Direct Current MD - Measured Depth
DISP - Displacement In Vibration Terminology MMCF - Million Cubic Feet
EOT - End of Tubing MMI - Man/Machine Interfaces
EQUIP - Equipment MMS - Minerals Management Service
ERTC - Employee Resource & Training Center MOD - Modified
ELS - Electrical Specialist MPR - Maximum Production Rate
E&S - Environmental Safety Fire & Health MSDS - Material Safety Data Sheet
ESD - Emergency Shut Down MSL - Mean (average) Sea Level
Est - Estimated N2 - Nitrogen
FC - Flow Coupling NOW - Nonhazardous Oilfield Waste
FCC - Federal Communication Commission O&M - Operating and Mechanical
MECHANIC 17-18 1
GLOSSARY
ACRONYMS & ABBREVIATIONS (CONT.)
OD - Outside Diameter SPF - Shots per Foot

OJT - On-The-Job Training S/S - Short String; String Shot (Tubing)
OM - Operation Manager SSCSV - Subsurface Controlled Safety Valve
OS - Operations Supervisor SSSV - Subsurface Safety Valve
OSA - Operations Skill Assessment SSV - Surface Safety Valve
O/S - Overshot S/T - Side Track
OSHA - Occupational Safety and Health Administration Stab - Stabilizer
OTP - Operator Training Program Susp - Suspend
P&A - Plug and Abandon SW - Saltwater or Seawater
PBTD - Plug Back Total Depth SX - Sacks
PB - Proportional Band T - Trainee
PC - Profit Center TBG - Tubing
PCB - Printed Circuit Board TD - Total Measured Depth
PENET - Penetration Temp - Temperature
PERF - Perforate THF - Tubing Hanger Flange
PFD - Personal Flotation Device TIH - Trip in Hole
PLC - Programmable Logic Controller TOC - Top of Cement
POOH - Pull Out of Hole TUB - Tubing
PPG - Pounds Per Gallon TVD - True Vertical Depth
Prep - Prepare USCG - United States Coast Guard
PROD - Production VFR - Visual Flight Rules
PSI - Pounds Per Square Inch VOM - Volt Ohm Meter
PSIA - Pounds Per Square Inch - Absolute W/ - With
PSIG - Pounds Per Square Inch - Gauge WD - Water Depth
PSO - Pressure Surface Open WIH - Went in Hole
P/U - Pick Up WL - Wireline
R/D - Rig Down W/O - Work Order
Rd - Round WOW - Waiting on Weather
R&D - Research and Development W/X Pin - With Cross Pin
Ret - Retrieved or Retainer ZES - Zero Electrical State
Rev - Reverse
RIH - Run in Hole
ROB - Remaining on Board
RR - Rig Released
Rtns - Returns
RTU - Remote Terminal Unit
R/U - Rig Up
Schl - Schlumberger (Logging Company)
SCADA - Supervisory Control and Data Acquisition
SCBA - Self Contained Breathing Apparatus
SCSSV - Surface Controlled Subsurface Safety Valve
SDFN - Shut Down For Night
SICP - Shut In Casing Pressure
SIDP - Shut In Drill Pipe Pressure
SITP - Shut In Tubing Pressure
Sk or Sks - Sacks
2 MECHANIC 17-18
GLOSSARY
OIL FIELD DEFINITIONS

Abandon: To withdraw or depart from an area in the face of danger.
Abort: To stop in the early stages.
Accumulator: A small tank or vessel to hold air or liquid under pressure for use in a hydraulic or air-actuated
system. Accumulators, in effect, store a source of pressure for use at a regulated rate in mechanisms
or equipment in a plant or in drilling or production operations.
Acidizing: The treatment of formations with hydrochloric or other type acids in order to increase production
or injection.
Affirmative: Yes
Allowable: The amount of oil or gas a well or leasehold is permitted to produce under proration orders of
a state regulatory body. Under a lease allowable, the lease is considered a producing unit. In some
instances, if a lease has eight wells, for example, and one of the eight is unable to make its production
for some reason, the other seven wells can increase their flow to make up the loss of the ailing well.
Annulus: The area between two strings of pipe in a well bore.
Anodes: Metallic plates which, when attached to the hull of a vessel, decompose because of electrolysis,
thereby reducing deterioration of the hull plate.
API: American Petroleum Institute; the oil industry’s trade association. The API, through its research
and engineering work, establishes operating and safety standards for all segments of the petroleum
industry; issues specifications for the manufacture of pipe, pressure vessels, and other equipment;
and furnishes statistical and other information to government agencies having to do with the
industry.
API Gravity: Gravity (weight per unit of volume) of crude oil or other liquid hydrocarbons as measured by
a system recommended by the API. API gravity bears a relationship to true specific gravity but is more
convenient to work with than the decimal fractions that would result if petroleum were expressed in
specific gravity.
Back Load: Any material or equipment ready to be shipped to the shorebase from an offshore location.
Back Off: To unscrew one threaded piece (such as a section of pipe) from another.
Back Pressure: The pressure resulting from restrictions of full natural flow of oil or gas.
Baffles: Plates or obstructions built into a tank or other vessel to change the direction of fluid flow.
Ballast: Water taken on board into specific tanks to permit the proper angle of repose of the vessel in
the water, and to ensure structural stability.
Ball Valve: A type of quick-opening valve with a spherical core, a ball with a full-bore port, that fits and turns
in a mating cavity in the valve body. Like plug valves, ball valves open or close by a quarter turn, 90
degrees, or the valve handle attached to the spherical core.
MECHANIC 17-18 3
GLOSSARY
OIL FIELD DEFINITIONS (Cont.)
Bbl: Barrel, 42 US gallons.
Bean: A choke used to regulate the flow of fluid from a well.
Below Minimums: Weather conditions below the minimum prescribed by regulation for the particular action
involved.
Bill of Lading: A receipt listing material shipped, which is signed by the shipper or issued by a common carrier
generally used by Chevron, for hazardous material shipments.
Blank Off: To close off by sealing or plugging.
Bleed: To drain off liquid or gas, generally slowly, through a valve called a bleeder. To bleed down, means
to slowly release the pressure of a well or of pressurized equipment.
Blind Flange (Blank Flange): A solid disc used to dead end a companion flange.
Block and Tackle: Pulley blocks with associated rope or cable for hoisting or hauling.
Blowout: An uncontrolled flow of gas, oil, or other fluids from a well.
Bottom Hole Pressure (BHP): The reservoir pressure at the bottom of the well bore.
Bourdon Tube: A small, crescent-shaped tube closed at one end, connected to a source of gas pressure
at the other, used in pressure recording devices or in pilot-operated control mechanisms to actuate
recording instruments.
Bow: The forward part of a marine vessel.
Brine: Water that has a large quantity of salt (sodium chloride) dissolved in it; salt water.
BTU (British Thermal Unit): A standard measure of heat content in a substance that can be burned to
provide energy, such as oil, gas, or coal. One BTU equals the amount of energy required to raise the
temperature of one pound of water one degree Fahrenheit at or near 39.2 degrees Fahrenheit.
Bulk Tank: A tank that holds large amounts of material for transport.
Bull Plug: A short, tapered pipe fitting used to plug the open end of a pipe or throat of a valve.
Buoy: A stationary floating object used as an aid for navigation.
Butterfly Valve: A type of quick-opening valve whose orifice is opened and closed by a disk that pivots on
a shaft in the throat of the valve.
Bypass Valve: A valve by which the flow of liquid or gas in a system may be shunted past a part of the system
through which it normally flows; a valve that controls an alternate route for liquid or gas.
4 MECHANIC 17-18
GLOSSARY
Caisson: A single, unmanned well structure that generally does not have any production processing
equipment on location. Also, the casing in which vertical seawater lift pumps and fire water pumps are
placed which extends from the platform decking into the water.
Capsule: A boat-like escape device for abandoning a platform.
Casing: Round hollow steel tubes varying in length and diameter. They are connected together (welded or
screwed) and placed inside a drilled well bore to prevent cave-in from external pressure.
Casinghead: The top of the casing set in a well; the part of the casing that protrudes above the surface and
to which the control valves and flow pipes are attached.
Casing Pressure: Pressure between the casing and the well’s tubing.
Casing String: The entire length of all the joints of the same size casing.
Catalyst: A substance that hastens or retards a chemical reaction without undergoing a chemical change
itself during the process.
Cathodic Protection: An anti-corrosion technique for metal installations, such as pipelines, tanks, and
buildings, in which weak electric currents are set up to offset the current associated with metal corrosion.
Carbon or non-ferrous anodes buried near the pipeline are connected to the pipe. Current flowing from
the corroding anode to the metal installation control the corrosion of the installation.
Catwalk: An elevated walkway between two or more structures.
Ceiling: The height above the earth’s surface of the lowest layer of clouds (or obscuring phenomena) that
is reported as “broken”, “overcast”, or “obscuration.”
Centrifugal Pump: A pump made with blades or impellers in a close-fitting case. The liquid is pushed forward
by the impellers as they rotate at high speed. Centrifugal pumps, because of their high speed, are able
to handle large volumes of liquid.
Centrifuge: A motor-driven machine in which samples of oil or other liquids are rotated at high speed, causing
suspended material to be forced to the bottom of a graduated sample tube so that the percent of impurities
or foreign matter may be observed. Some centrifuges are hand-operated. See Shake Out.
Certification: The act of attesting that a vessel has met specific legal requirements by the issuance of various
certificates, or the validation of documents by certain governments or private agencies.
Cheater: A length of pipe used to increase the leverage of a wrench.
Check Valve: A valve (FSV) that allows flow in one direction only.
Chlorination: To treat or cause to combine with chlorine or a chlorine compound.
Choke: A type of orifice installed for the purpose of restricting and controlling flow.
MECHANIC 17-18 5
GLOSSARY
Christmas Tree: The assembly of valves, pipes, and fittings used to control flow or oil and gas from the well.
Clevis: A U-shaped metal link or shackle with the ends of the U drilled to hold a pin or bolt; used as a
connecting link for a chain or cable.
Combustible Liquid: Any liquid having a flash point at or above 100°F and below 200°F.
Come-along: A lever and short lengths of chain with hooks attached to the ends of the chains, used for
tightening or pulling a chain. The hooks are alternately moved forward on the chain being tightened.
Companion Flange: A two-part connector or coupling; one part is convex, the other concave. The two halves
are held together by bolts and nuts. This type flange or “union” is used on small-diameter piping.
Completed Well: A well that is made ready to produce oil or natural gas. Completion involves cleaning out
the well, running steel casing and tubing into the hole, adding permanent surface control equipment, and
perforating the casing so oil or gas can flow into the well and be brought to the surface.
Condensate: Liquid hydrocarbons produced with natural gas, which are separated from the gas by cooling
and various other means. Condensate generally has an API gravity of 50° to 120° and is water-white,
straw, or bluish in color.
Condensation: The transformation of a vapor or gas to a liquid, by cooling or an increase in pressure, or

both simultaneously.
Conductor Casing: A well’s surface pipe used to seal off near-surface water, to prevent the caving in or
sloughing of the walls of the hole, and to conduct the drilling mud through loose, unconsolidated, shallow
layers of sand, clays, and shales. See Casing.
Coordinates: The intersection of lines of reference, usually expressed in degrees/minutes/seconds of

latitude and longitude, used to determine position or location.
Core: Samples of subsurface formations taken as a well is being drilled.
Crack A Valve: To open a valve so slightly as to permit a small amount of fluid or gas to escape.
Crane: A device used to lift, lower, or shift loads by means of a projecting swinging arm.
Crewboat: A marine vessel used to transport passengers and cargo. Generally the most expeditious means
of transportation on water.
Crude, Crude Oil: Unprocessed oil, just as it comes from the formation. Liquid petroleum as it comes out
of the ground. No two crude oils are exactly alike. They range from very light (high in gasoline) to very
heavy (high in residual oil). Sour crude is high in sulfur content. Sweet crude is low in sulfur and therefore
often more valuable.
6 MECHANIC 17-18
GLOSSARY
Day Tank: A fuel tank aboard a vessel where metered fuel is used by vessel. Also for engine lube.
Dead Well: A well that has ceased to produce oil or gas, either temporarily or permanently.
Decibel: A unit of measure for the relative intensity of noise/sound level.
Dehydrator: A tank or tower through which gas is run to remove entrained water. A common method of gas
dehydration is through the use of various glycols - diethylene, triethylene, and tetraethylene. Dehydration
is accomplished by contact of the wet gas with a pure or “lean” glycol solution. Gas is fed into the bottom
of a trayed or packed tower through the glycol solution. As the gas percolates upward through the solution,
the lean glycol absorbs the entrained water, and dry gas is taken off at the top of the tower. Gas must
be extremely dry to meet pipeline specifications; it may not contain more than 7 pounds of water per million
standard cubic feet.
Deluge System: An automatically activated fire suppression system, which discharges large volumes of
water continually in a small area.
Demulsifier: A chemical used to “break down” crude oil/water emulsions so the water may be removed from
the oil.
Density: The weight of a substance per unit of volume. For instance, the density of a drilling mud may be
described as “10 lbs per gallon” or “75 lbs per cubic foot”.
Desiccant Drying: The use of a drying agent to remove moisture from a stream of air or gas. In certain
product pipelines, great effort is made to remove all water vapor before putting the line in service. To
accomplish this, desiccant-dried air or an inert gas is pumped through the line to absorb the moisture that
may be present even in the ambient air in the line.
Dew Point: The temperature at which water vapor condenses out of a gas at 14.7 psia (pounds per square
inch absolute), or at sea level.
Discovery Well: An exploratory well that encounters a new and previously untapped petroleum deposit. A
successful wildcat well.
Distillate: A generic term for several petroleum fuels that are heavier than gasoline and lighter than residual
fuels. Home heating oil, diesel, and jet fuels are the most common types of distillate fuels.
Double-acting Pump: A reciprocating pump (plunger pump) with two sets of suction and discharge valves
permitting it to pump fluid during the forward and backward movement of each plunger. (Single-action
pumps discharge on the forward stroke and draw in fluid on the return stroke.)
Down-comer: A pipe in which the flow of liquid or gas is downward.
Downhole: A term to describe tools, equipment, and instruments used in the wellbore. For example, a
downhole tool is used in the wellbore. Also, conditions or techniques applying to the wellbore.
MECHANIC 17-18 7
GLOSSARY
Downstream: All operations that take place after crude oil is produced, including transportation, refining, and
marketing. Also indicates position or direction of flow.
Downtime: Time during which wells are off production.
Drill String: Lengths of steel tubing screwed together to form a pipe connecting the drill bit to the drilling rig.
The string is rotated to drill the hole and also serves as a conduit for drilling mud. Also called the drill pipe
or drill stem.
Drilling Mud: An emulsion of water, clays, chemical additives, and weighing materials that flushes rock
cuttings from a well, lubricates and cools the drill bit, and maintains the required pressure at the bottom
of the well. Examination of cuttings returned to the surface helps geologists evaluate underground rock
formations.
Drilling Rig: The surface equipment used to drill for oil or gas consisting chiefly of a derrick, a winch for lifting
and lowering drill pipe, a rotary table to turn the drill pipe, and engines to drive the winch and rotary table.
Drip Pan: An open container, located on deck underneath production equipment to contain hydrocarbon
drippage.
Drive Pipe: A metal casing driven into the bore hole of a well to prevent caving in of the walls and to shut
off surface water. The drive pipe, first used in an oil well by Colonel Drake, was the forerunner of the
modern conductor or surface pipe. See Casing.
Dry Chemical Fire Extinguisher: Any of the hand held, wheeled, or stationary extinguishers that use a dry
chemical agent to extinguish fires.
Dry Gas: Natural gas that is produced without liquid hydrocarbons. Also gas that has been dehydrated to
remove water (pipeline gas).
Dry Hole: A well that either finds no oil or gas, or finds too little to make it financially worthwhile to produce.
Dual Completion: The completion of a well in two separate producing formations, each at different depths.
Wells sometimes are completed in three or even four separate formations with four strings of tubing
inserted in the casing. This is accomplished with packers that seal off all formations except the one to
be produced by a particular string of tubing.
Dual Packer: A packer used in dual completion wells, which isolates the tubing strings from the casing to
prevent well pressure from entering the casing.
Elastomer: Any of various elastic materials or substances resembling rubber.
Emergency Alarm: A signal (as a loud noise, flashing light) that warns or alerts during an emergency.
Emergency Shutdown Valve (ESD): A valve that will “shut-in” all systems on a platform.
8 MECHANIC 17-18
GLOSSARY
Emulsion: A mixture of crude oil and formation water. Generally requires time, heat, and chemicals called
demulsifiers or emulsion breakers, or electricity, to separate the water from the oil.
Emulsion Treater: A tall cylindrical vessel, a type of oil heater for “breaking down” oil-water emulsions
with heat and the addition of certain chemicals. Emulsion treaters have a gas-fired furnace at the
bottom of the vessel to heat the stream of oil piped through from the well to the stock tanks; a heater-
treater.
Enhanced Oil Recovery: Injection of water, steam, gases, or chemicals into underground reservoirs to
cause oil to flow toward producing wells, thus permitting more recovery than would have been
possible from natural pressure or pumping alone.
Entrained Oil: Oil occurring as part of the gas stream, but as a relatively small percentage of total flow.
Special separators are used to remove the liquid from the gas stream.
Evacuation: To remove personnel from an area in an organized fashion, and to ensure the safety of those
people.
Exploratory Well: A well drilled to an unexplored depth or in unproven territory, either in search of a new
reservoir or to extend the known limits of a field that is already partly developed.
Explosion-proof Motors: A totally enclosed electric motor with no outside air in contact with the motor
windings; an enclosed brushless motor. Cooling is by conduction through the frame and housing.
Extinguishing Material: The agent (water, dry chemical, or Halon) that puts out a fire.
Fail-safe: Said of equipment or systems so constructed that, in the event of failure or malfunction of any part
of the system, devices are automatically activated to stabilize or secure the safety of the operation.
Fastline (Whipline): A secondary rope system of a crane, usually of lighter load capacity than provided by
the main rope system.
Female Connection: A pipe, rod, or tubing coupling with the threads on the inside.
Field: An area consisting of a single reservoir or multiple reservoirs all grouped on, or related to, the same
individual geological structural feature and/or stratigraphic condition. The field name refers to the surface
area, although at times it may refer to both the surface and the underground productive formations.
Final: Commonly used to mean that an aircraft is on the final approach course or is aligned with a landing
area.
Fire Monitor: A jointed device holding a rotating nozzle of a high pressure water system generally located
on the deck of a vessel or platform, or dockside. It can be manually controlled to direct and adjust water
spray in extinguishing fires.
Fire Station Bill: A posted diagram of platforms, buildings, and office areas that indicates the location of fire
stations, safety equipment, and exits. General instructions for fire emergencies along with personnel
stations and duties are listed on the station bill. It also lists the phone numbers for local authorities and
medical treatment facilities.
MECHANIC 17-18 9
GLOSSARY
Fire Wall: A wall built around oil tanks, oil pumps, and other oil handling equipment to contain any oil which
may be accidentally discharged from the equipment. It also serves to block the spread of a fire or give
protection for a period of time while emergency action is taken.
First Responder: A person trained in advanced first aid who can administer emergency treatment to injured
or sick persons before professional medical care is available.
Fishing: The effort to recover tools, cable, pipe, or other objects from the wellbore, which have become
accidentally lost in the well. Many special and ingeniously designed fishing tools are used to recover
objects lost downhole. The object being sought downhole by the fishing tools is referred to as the fish.
Fishing Tool: A tool designed to recover equipment lost in a well.
Flame Arrestor: A safety device installed on a vent line of a storage or stock tank that, in the event of lightning
or other ignition of the venting vapor, will prevent the flame from flashing to the vapor inside the tank.
Flame arrestors have a “membrane” of fine-mesh screen across the vent opening. The vapor venting
from the tank may be ignited but the flame will not flash through the fine screen into the tank. The fine
screen “breaks up” and cools the flame at the surface of the screen, preventing the ignition of the vapor
behind the screen.
Flammable Liquid: Any liquid having a flash point below 100°F.
Flange: The fittings (end connections) used to connect with nuts and bolts, vessels, valves, and piping.
Flange Up: To finish a job; to bring to completion.
Flash Point: The minimum temperature at which the flammable vapors of a substance (in contact with a
spark or flame) will ignite.
Flight Plan: Specified information relating to the intended flight of an aircraft.
Flite-Trak: A computer software system that is a real time interactive system whose main function is to
maintain a display of the latest position and status for aircraft in communication with the dispatcher
terminal.
Flow Couplings: A short section of thick-walled pipe placed above and below the subsurface safety valve.
It is constructed to resist the abrasive action of the flow stream as it enters and exits the SSSV.
Flowing Pressure: The pressure at the wellhead of a flowing well.
Flowing Well: A well that produces without any means of artificial lift.
Flowline: The pipe through which oil travels from the well to the field processing facility.
Flowstring: The string of casing or tubing through which fluids from a well flow to the surface.
10 MECHANIC 17-18
GLOSSARY
Fluid: A substance (as a gas or liquid) tending to flow or conform to the outline of its container.
Fluid Level: The distance from the surface to the top of the liquid in the tubing or casing in a well. The static
fluid level is taken when the well is not producing, and after it has stabilized.
Full Bore: Designation for a valve, ram, or other fitting whose opening is as large in cross section as the pipe,
casing, or tubing it is mounted on.
Fusible Plug: A fail-safe device; a plug in a service line equipped with a seal that will melt at a predetermined
temperature, releasing pressure which actuates shut-down devices; a meltable plug.
Gas: Any fluid, combustible or non-combustible, which is produced in a natural state from the earth and which
maintains a gaseous or rarified state at ordinary temperature and pressure conditions.” Code of Federal
Regulations (CFR), Title 30, Mineral Resources, Chapter II, Geological Survey, 221.2.
Gas Free: The process of removing all hazardous gases and residues from the vessels.
Gasket: An elastic packing material used to prevent joints from leaking.
Gas Lift: The raising, or lifting, of liquid from a well by means of injecting gas into the liquid.
Gas Lift Mandrel: A section of the tubing string machined or profiled to accept and retain gas lift valves.
Gas-Oil Ratio: The number of cubic feet of natural gas produced with a barrel of oil. The ratio is expressed
500:1 or 1000:1, whatever the volume of gas measured at the well that is produced per barrel of oil. A
high gas-to-oil ratio is extremely undesirable because the pressure in the reservoir, the explosive force
to move the oil in the formation to the bore holes, is being depleted. And with the reservoir pressure gone,
a great percent of the oil may not be recoverable, except by a costly secondary recovery program.
Gas Regulator: A device for controlling the pressure of gas.
Gas Sniffer: A colloquial term for a sensitive electronic device that detects the presence of gas or other
hydrocarbons in the stream of drilling mud returning from down hole.
Gate Valve: A pipeline valve made with a wedge-shaped disk or “tongue”, which is moved from open to closed
(up to down) by a threaded valve stem. Some valves have stems that remain in the valve bonnet (do not
rise), and when they are rotated by the valve wheel screw into the disk, raise the disk and open the valve.
Other valves have a rising stem that is firmly attached to the wedge. The valve stem is threaded, and when
the threaded valve wheel is turned, the stem rises through the wheel, raising the disk to open position.
Gauge: An instrument for or a means of measuring or testing.
Gauge Tape: A metal tape used to measure the depth of liquid in a tank.
Generator Package: A self-contained mechanical system that converts mechanical energy into electrical
energy.
MECHANIC 17-18 11
GLOSSARY
Glycol Dehydrator: A facility for removing minute particles of water from natural gas not removed by the
separator.
Gone To Water: A well in which the production of oil has decreased and the production of water has increased
to the point where the well is no longer profitable to operate.
Gravel Pack Liner: A slotted or perforated pipe arranged with a wire wrapping and surrounded by small sized
gravel used to prevent or minimize the entry of sand from the formation of the production tubing.
Gravel Packing: Using gravel to fill the cavity created around a well bore as it passes through the producing
zone, to prevent caving in or the incursion of sand, and to facilitate the flow of oil into the well bore.
Gross Weight: The empty weight plus the useful load.
Halon: A colorless, odorless, electrically nonconductive gas that extinguishes fires by inhibiting the reaction
of fuel and oxygen.
Hand Held Fire Extinguisher: A small, portable fire extinguisher operated by hand, usually by one person.
Handrail: A railing or piping along a passageway or stairway that serves as a support or a guard.
Handy: Hand-tight; a pipe connection or nut that can be unscrewed by hand.
Hard Hat: Molded plastic hat worn in the field for protection.
Hatch: 1) An opening in the roof of a tank through which a gauging tape may be lowered to measure its
contents. 2) The opening from the deck into the cargo space of marine vessels.
Hazardous Material: A substance or material that has been determined by the Secretary of Transportation
to be capable of posing an unreasonable risk to health, safety, and property when transported in
commerce, and which has been so designated.
Hazardous Substances: Generally defined as materials which, when spilled, are likely to do significant
damage to our environment, including water, land, or air.
Hazardous Wastes: Hazardous material or substances to be discarded. These materials are highly
regulated in transportation, disposal, or treatment.
Hazardous Waste Site: A secured and isolated staging area where properly packaged and labeled
hazardous waste is accumulated and stored for periodic shipment to a State/Federal approved
hazardous waste disposal site.
Headache: A warning cry given by a fellow worker when anything is accidentally dropped or falls from overhead
toward another worker.
Header: An accessory system of valves and piping to a main piping system (or other conductor) that serves
to divide flow into several parts, to combine several flows into one, or to reroute a flow to any one of several
possible destinations.
12 MECHANIC 17-18
GLOSSARY
Heading: An intermittent or unsteady flow of oil from a well. This type of flow is often caused by a lack of gas
to produce a steady flow, thus allowing the well’s tubing to load up with oil until enough gas accumulates
to force the oil out.
Helideck: An area on a structure used for the landing and takeoff of helicopters and which includes some
or all of the various facilities useful to helicopter operation, such as parking, tiedown, fueling,
maintenance, safety shelf or net, etc.
Helmsman: The operator of the capsule and man-in-charge when abandoning the platform.
Hoisting: The process of lifting.
Holidays: Flaws in the protective coating on pipes and vessels.
Hook Block: Block with hook attached used in lifting service. It may have a single sheave for double or triple
line, or multiple sheaves for four or more parts of line.
Horsepower: A standard unit of power that is often classified in connection with engines as brake,
continuous, input intermittent, output, or shaft horsepower.
Hot Tapping: Making repairs or modifications on a tank, pipeline, or other installation without shutting down
operations.
Hurricane: Low pressure weather system with closed circulation of tropical origin in which the maximum
sustained surface wind is greater than or equal to 64 knots. (MPH = KTS x 1.15)
Hydrocarbons: Petroleum - A mixture of compounds in which hydrogen and carbon are the principle
elements.
Hydrogen Sulfide (H2S): An odorous and noxious compound of sulfur found in “sour” gas. See Sour Gas.
Hydrostatic Head: The height of a column of liquid; the difference in height between two points in a body
of liquid. The hydrostatic head in an oil well is the height of the column of oil in the bore hole or casing.
The hole full of drilling mud also represents a hydrostatic head. The pressure exerted by several thousand
feet of “head” often causes the drilling mud to penetrate cracks and fissures, and even very porous
formations.
Hydrostatic Testing: Filling a pipeline or tank with water under pressure to test for tensile strength (its ability
to hold a certain pressure without rupturing). Water is used for testing because it is non-compressible;
if the pipe or tank does rupture, there is no potentially dangerous expansion of the water as would be the
case if a gas under very high pressure were used.
Ignition Magneto: An electric current generator used on stationary engines in the field. A magneto is geared
to the engine and once the engine is started, the magneto supplies electric current for the ignition system.
Current is produced by an armature rotating in a magnetic field created by permanent magnets.
Impact Wrench: An air-operated wrench for use on nuts and bolts of large engines, valves, and pumps. Impact
wrenches have taken the place of heavy end-wrenches and sledge hammers in tightening and loosening
large nuts.
MECHANIC 17-18 13
GLOSSARY
Injection Pump: A pump that 1) injects chemicals into a flowline system for the purpose of treating emulsions
or corrosion, and 2) injects liquids underground for disposal or to enhance recovery.
Inland Waters: Considered to be the canals, lakes, rivers, and their tributaries, and the bays and sounds of
the land mass of a country.
In-Line Equipment: Pumps, separators, and heat exchangers integral to a process or processing chain; in
the line, not auxiliary or only supporting.
Inspection Plate: A flat metal plate fitted with a gasket and bolted over an opening in the gearbox of a pump
or the crankcase of an engine. By removing the plate, an inspection of the gears or crank and connecting-
rod bearings can be made.
Instrument Flight Rules (IFR) Conditions: Weather conditions below the minimum for flight under visual
flight rules.
Interface: The point where two dissimilar fluids come together.
Intermediate Casing String: The casing set in a well after the surface casing. Also called protection casing.
Jack-up Barge: Self-propelled barges designed with three or four moveable legs that, when lowered to the
sea floor, elevates the barge out of the water.
Jack-up Drilling Rig: Drilling rigs constructed on a Jack-up barge. These rigs are jacked-up out of the water
to perform their work once on location.
Jam Nut: A nut used to jam and lock another nut securely in place; the second and locking nut on a stud bolt.
After the first nut is threaded and tightened on a stud, a second nut is tightened down on the first nut to
prevent it from working loose.
Joint: A length of pipe, casing or tubing, usually from 20 to 30 feet long.
Joint Venture: A business or enterprise entered into by two or more partners. Joint venture leasing is a
common practice. Usually the partner with the largest interest in the venture will be the operator.
JP-5: Mid-distillate jet petroleum fuel used in helicopters.
Kill a Well: To stop a well from producing so that surface connections may be removed from well service
or workover equipment. It is usually accomplished by circulating water or mud to load the hole and render
it incapable of flowing.
Knot: One nautical mile per hour; used as a unit of measurement in expressing the rate of speed of seagoing
vessels and the relative speed of water currents.
Kolor-Kut: Chemical paste that is applied to strapping tape when obtaining tank soundings. This chemical
paste will turn colors to indicate if water is present in the tank.
Landing Nipple: A short section of pipe placed in the tubing string. It is machined to the profile of the
downhole tool which it will accept and lock in place, such as safety valves and tubing plugs.
14 MECHANIC 17-18
GLOSSARY
Life Preserver: A flotation device designed to help save a person from drowning.
Liquefied Petroleum Gas: Butane, propane, and other light ends separated from natural gasoline or crude
oil by fractionation or other processes. At atmospheric pressure, liquefied petroleum gases revert to the
gaseous state.
Liquid Hydrocarbons: Petroleum components that are liquid at normal temperatures and atmospheric
pressure.
Liquid Mud: A water or oilbase drilling fluid whose properties have been altered by dissolved or suspended
solids. It is used for circulating out cuttings and many other functions while drilling a well.
Load Binder: A chain latching device used to secure loads.
Load Capacity: The maximum load in tons that equipment is designed to lift when properly used.
Logbook (Logs): The records of daily operations.
Long String (Tubing): In a dual completed well, the tubing string to the deepest zone.
Lubricant: A substance, usually petroleum-based, that is used to reduce friction between the moving parts.
Lubricator: A specially fabricated length of pipe that is usually temporarily placed above a valve on top of
the Christmas tree. Lubricators are used to run special tools, usually on a wireline, into a producing well
without having to kill the well.
Mae West: An inflatable, USCG approved PFD usually worn when flying in a helicopter. Once inflated, the
Mae West is designed to keep the head above water.
Male Connection: A pipe, rod, or coupling with threads on the outside circumference.
Manifold: An accessory system of valves and piping to a main piping system (or other conductors) that serve
to divide flow into several parts, to combine several flows into one, or to reroute a flow to any one of several
possible destinations.
Master Valve: A large valve located on the Christmas tree used to shut in a well.
Material Safety Data Sheet: A written or printed document that lists physical and chemical characteristics,
physical or health hazards, exposure limits, application precautions on use and safe handling, personal
protection equipment, and emergency and first aid procedures.
Mayday: The international radio telephone distress signal. When repeated three times, it indicates imminent
and grave danger and that immediate assistance is requested.
MCF: The abbreviation for 1,000 cubic feet (usually applied to natural gas).
MECHANIC 17-18 15
GLOSSARY
Measuring Tank: A calibrated tank that automatically measures the volume of liquid run in and then released.
Measuring tanks are used in Lease Automatic Custody Transfer (LACT) systems and may also be
referred to as metering tanks or dump tanks.
Methanol: Methylalcohol; a colorless, flammable liquid derived from methane (natural gas).
MMCF: The abbreviation for 1,000,000 cubic feet (usually applied to natural gas).
Mud Samples: The well cuttings obtained at designated footage intervals during drilling. From an
examination of these cuttings, a geologist determines the type rock and formations being drilled and
estimates oil and gas content.
Natural Gas: A mixture of hydrocarbon compounds and small amounts of various non-hydrocarbons (such
as carbon dioxide, helium, hydrogen sulfide, and nitrogen) existing in the gaseous phase or in solution
with crude oil in natural underground reservoirs.
Nautical Mile: A unit of length used in sea navigation equal to 1852 meters or approximately 6076 feet.
Nav-Aid: A device (light, horn, etc.) or system used to provide a navigator with navigational data; an aid to
navigation.
Needle Valve: A valve used on small, high-pressure piping where accurate control of small amounts of liquid
or gas is desired. The “tongue” of the valve is a rod that tapers to a point and fits into a seat which permits
fine adjustments as when used with pressure gauges.
Nipple: A pipe fitting that is usually threaded on both ends and is less than 12 inches in length.
Non-Hazardous Oilfield Waste (NOW): Is defined in State Order 29-B as waste generated by the drilling
and production of oil and gas wells.
Non-sparking Tools: Hand tools made of bronze or other non-ferrous alloys for use in areas where
flammable oil or gas vapors may be present.
Off Limits: An area that is restricted for particular things, such as “smoking”.
Off Production: Said of a well when it is shut in or temporarily not able to produce.
Offshore Platform: A fixed structure from which wells are drilled offshore for the production of oil and natural
gas.
Offshore Waters: A common term for those waters which are beyond inland water limits and have the
technical classification of “oceans”.
Oil and Gas Separator: An item of production equipment used to separate the liquid components of the well
stream from the gaseous components.
16 MECHANIC 17-18
GLOSSARY
Oil-base Mud: An oil-base mud that contains from less than 2 percent up to 40 percent water. The water
is spread out, or dispersed, in the oil as small droplets.
Oil Emulsion Mud: A water base mud in which water is the continuous phase and oil is the dispersed phase.
The oil is spread out, or dispersed, in the water in small droplets, which are tightly emulsified so that they
do not settle out. Because of its lubricating abilities, an oil-emulsion mud increases the drilling rate and
ensures better hole conditions than other muds.
Oil Slick: A film of oil floating on water, which is considered a pollutant.
Oil Spill: A mishap that permits oil to escape from a tank, an offshore well, an oil tanker, or a pipeline. Oil
spill has come to mean oil on a body of water where even small amounts of oil spread and become highly
visible.
Oil Well: A well completed for the production of crude oil from at least one oil zone or reservoir.
Orifice Meter: A measuring instrument that records the flow rate of a fluid by measuring the “pressure drop”
through a “designed orifice” in a line.
OSHA: Occupational Safety and Health Administration; a government agency that sets and enforces working
condition standards relative to on-the-job safety and health.
Outage: A failure or interruption of a service or operation..
Packer: A device that seals or closes off the annulus between the tubing string and the casing string.
Packing: Any tough, pliable material (rubber or fiber) used to fill a chamber or “gland” around a moving rod
or valve stem to prevent the escape of gas or liquid; any yielding material used to effect a pressure-tight
joint. Packing is held in place and compressed against a moving part by a “follower”, an adjustable
element of the packing gland.
Packing Gland: A stuffing box; a chamber that holds packing material firmly around or against a moving rod
or valve stem to prevent the escape of gas or liquid. An adjustable piece that fits into the gland to compress
the packing against the moving part is called the “follower” and can be screwed into the gland or forced
into the gland by nuts on stud bolts.
Pad Eye: A half circle of steel rod, or plate, the ends of which are welded to a pad or doubleplate. The doubler,
in turn, is welded in a convenient location so that the pad eye may then be used as a means of securing
blocks, shackles, lines, and so forth. A pad eye is as strong as the material in its component parts and
the quality of workmanship of the weld attachment.
Paraffin: Heavier paraffin-base hydrocarbons often form a waxlike substance called paraffin. Paraffin may
accumulate on the walls of tubing, flowlines, and other production equipment, thus restricting the flow of
well fluids to the extent that it must be removed.
Passenger Manifest: A list of passengers for a marine vessel or aircraft.
MECHANIC 17-18 17
GLOSSARY
Perforating: To make holes through the casing opposite the producing formation to allow the oil or gas to flow
into the well. Shooting steel bullets through the casing walls with a special downhole “gun” is one method
of perforating.
Perforations: Holes that have been pierced in the casing and cement, through which formation fluids enter
the well bore.
Permeability: A measure of the ability of fluids to flow through a porous rock.
Personnel Net: A net attached to a floatable ring, on which personnel ride when being transferred from boat
to rig on offshore locations. It is usually rigged to a crane.
Personnel Ramp: An adjustable stairway with handrails used by personnel for boarding or departing the deck
of a vessel.
Petrochemicals: Chemicals derived from crude oil or natural gas, including ammonia, carbon black, and
thousands of organic chemicals.
Petroleum: Strictly speaking, crude oil. In a broader sense it refers to all hydrocarbons, including oil, natural
gas, natural gas liquids, and related products.
PFD (Personal Flotation Devices): A device (as a life jacket or life buoy) designed to save a person from
drowning by buoying up the body while in the water.
PH (pH): A symbol used in expressing both acidity and alkalinity on a scale whose values run from 0 to 14,
with 7 representing neutrality; numbers less than 7, increasing acidity; and numbers greater than 7,
increasing alkalinity.
Pig: A device inserted in a pipeline for the purpose of sweeping the line clean of water, rust, or other foreign
matter.
Pig Trap (Scraper Trap): A facility on a pipeline for inserting and retrieving a scraper or “pig”. The trap is
essentially a “breech-loading” tube isolated from the pipeline by valves. The scraper is loaded onto the
tube like a shell into a shotgun; a hinged plug is closed behind it, and line pressure is then admitted to
the tube behind the scraper. A valve is opened ahead of the scraper and it is literally pushed into the line
and moved along by the oil pressure.
Pinching A Valve: Closing a valve part way to reduce the flow of liquid or gas through a pipeline.
Pitot Tube: A measuring device for determining the gas-flow rates during tests. The device consists of a
tube with a 1/8th-inch inside diameter inserted in a gas line horizontal to the line’s long axis. The impact
pressure of the gas flow at the end of the tube compared to the static pressure in the stream are used
in determining the flow rate.
Plug and Abandon (P&A): The act of placing plugs in a depleted well or dry hole, then abandoning it.
Plug Back: To fill up the lower section of the well bore to produce from a formation higher up. If the well has
been cased, the casing is plugged back with cement to a likely formation and then perforated.
18 MECHANIC 17-18
GLOSSARY
Plunger: The piston in the fluid end of a reciprocating pump.
Plunger Pump: A reciprocating pump in which plungers or pistons moving forward and backward or up and
down in cylinders drawing in a volume of liquid and, as a valve closes, pushes the fluid out into a discharge
line.
Porosity: A measure of the openings in reservoir rock or sands. It determines the amount of fluid a reservoir
can store.
Port: The left side of a ship or aircraft looking forward.
Ports: The connectors on the back of a computer, that are a part of the main system board or an adapter
card that is plugged into the main system board.
Positive-displacement Pump: A pump that displaces or moves a measured volume of liquid on each stroke
or revolution; a pump with no significant slippage; a plunger or rotary pump.
Potable Water: Drinking water.
PPM: Parts per million; a measure of the concentration of foreign matter in air or a liquid.
Pressure Relief Valve: A valve that opens at a preset pressure to relieve excessive pressures within a vessel
or line; also called a relief valve, safety valve, or pop valve.
Prime Mover: The term describes any source of motion; in the oil field, it refers to engines and electric motors;
the power source.
Producing Zone: The zone or reservoir from which oil and/or gas are produced.
Production: The yield of an oil or gas well. Also that branch of the petroleum industry that has to do with bringing
the well fluids to the surface and separating them, and with storing, gauging, and otherwise preparing the
product for the pipeline.
Production Casing (Production String): The last string of casing set in a well; the casing string set to the
top or through the producing formation and inside of which is usually suspended the tubing string. Also
called the oil string or long string.
Production Packer: An expandable plug-like device for sealing off the annular space between the well’s
tubing and the casing. The production packer is run as part of the tubing string, inside the casing; when
lowered to the proper depth, the packer is mechanically or hydraulically expanded and “set” firmly against
the casing wall, isolating the production formation from the upper casing while permitting the oil or gas to
flow up the tubing.
Production Platform (Processing Platform): An offshore structure providing a central processing and
disposition point for fluids produced from wells on adjacent producing and well platforms. The treated oil
and gas is moved to shore through submarine pipelines. Produced water is generally disposed of within
the field.
MECHANIC 17-18 19
GLOSSARY
Production Skid: A prefabricated oil and gas production unit assembled on a base or skid on the shore and
transported to an offshore platform by one or more derrick barges. After the skid has been lifted into
position and secured to the platform, it is connected to the flowlines of the offshore wells it is to serve and
begins its function of receiving, separating, treating, storing, and pumping the oil and gas to shore
stations. See Production Platform.
Production String: The tubing set just above or through the producing zone of a well. It reaches from the
pay zone to the surface.
Proved Reserves: An estimate of the amount of oil or natural gas believed to be recoverable from known
reservoirs under existing economic and operating conditions.
PSIA: Pounds per square inch absolute; pressure measurement which excludes atmospheric pressure.
PSIG: Pounds per square inch gauge which includes atmospheric pressure. (as observed on a gauge).
PSIG = PSIA + 14.7
Pulsation Dampener: Various devices for absorbing the transient, rhythmic surges in pressure that occur
when fluid is pumped by reciprocating pumps. Air chambers, which act as air cushions, are installed on
the discharge lines of reciprocating pumps. To protect pressure gauges and other instruments from the
constant pounding, fine-mesh, sieve-like disks are placed in the small tubing or piping to which the gauge
is attached; this arrangement “filters out” much of the surging that can damage delicate gauges.
Pump: A device used to increase the pressure of or move liquids. Types of pumps include sucker rod,
reciprocating, centrifugal, rotary, gear, and jet.
Pup Joint: A joint of pipe or tubing shorter than standard length.
PVC: Polyvinylchloride; a tough, durable, petroleum-derived plastic that can be extruded or molded, and is
used for pipe, fittings, and light structural members. PVC is highly resistant to salt water and chemicals.
Refining: Manufacture of petroleum products by a series of processes that separate crude oil into its major
components, and blend or convert these components into a wide range of finished products, such as
gasoline or kerosene.
Remote Control Station: A centrally located station containing equipment to control and regulate operations
in one or more fields.
Reserve: A porous and permeable underground formation of producible oil and/or natural gas, confined by
impermeable rock or water barriers and characterized by a single natural pressure system.
Reservoir: Area or strata where oil or gas is trapped. Usually a layer of sand, shale, or rock that contains
the gas and/or oil. The thickness of the reservoir can vary from a few feet to several hundred feet.
20 MECHANIC 17-18
GLOSSARY
Reservoir Pressure: The pressure at the face of the producing formation when the well is shut in. It is equal
to the shut-in pressure (at the wellhead) plus the weight in pounds of the column of oil in the hole. The
hydrostatic pressure exerted by a column of oil 5,000 feet high, for example, would be several thousand
pounds. In a flowing well, the reservoir pressure would be sufficient to overcome the pressure of the
hydrostatic head.
Riser: A pipe through which liquid or gas flows upward.
Rock A Well: To agitate a “dead” well by alternately bleeding and shutting in the pressure on the casing or
tubing so that the well will start to flow.
Roger: I have received all of your last radio transmission.
Running Tool: Specialized tools used to run equipment in a well, such as a wireline running tool for installing
retrievable gas lift valves. Various tubing-type running tools are also used.
Run Time: Hours that the machinery runs.
Rupture Disk: A thin, metal plug or membrane in a fitting on a pressure line made so as to blow out or rupture
when the pressure exceeds a predetermined level; a safety plug.
SAE Number: A classification of lubricating oils in terms of viscosity only. A standard established by the
Society of Automotive Engineers (SAE 20; SAE 10W-30, multi-viscosity lubricating oil).
Safety Lockers: An enclosure containing safety equipment and supplies.
Safety Shackle: Weldless, drop forged steel fitted with a threaded bolt drilled through the end to receive a
pin and cotter key.
Saltwater Disposal: The method and system for the disposal of salt water produced with crude oil. A typical
system is composed of collection centers and disposal wells in which treated salt water is injected into
a suitable formation.
Sand: A loose material most commonly composed of small quartz grains formed from the disintegration of
preexisting rocks.
Sand Control: Any method by which large amounts of sand are prevented from entering the wellbore. Methods
include: gravel pack, screen liner, and sand consolidation.
Sanded Up: A well plugged by sand that has drifted and washed into the wellbore from the producing formation
by the action of the oil.
Scraper, Pipeline: A pig; a cylindrical, plug-like device equipped with scraper blades, wire brushes, and
toothed rollers used to clean accumulations of wax, rust, and other foreign matter from pipelines. The
scraper is inserted in the line at a “trap” and is pushed along by the pressure of the moving column of oil.
MECHANIC 17-18 21
GLOSSARY
Scrubbing: Purifying a gas by putting it through a water or chemical wash; also the removal of entrained water.
Natural gas when it is produced or when it flows from the well under pressure usually contains impurities,
traces of other gases and microscopic droplets of water, as well as liquid hydrocarbons. Before it can be
accepted by a gas transmission line, or a trunk line, the gas must be stripped of the liquid hydrocarbons,
scrubbed, and dried out.
Seamless Pipe: Pipe made without an axial seam; pipe made from a billet or solid cylinder of hot steel and
“hot-worked” on a mandrel into a tubular piece without a seam.
Seas/Wave: Highest of 1/3 of all waves measured in 10-15 minute’s time. Swells: waves that originate and
move out of this area. (Northeast and east swells are most noted in the Gulf and are not associated with
tropical systems). Southerly swells are quite common along the Texas coast also. A wind of 15KTS or
higher, sustained for more than 12 hours, will generally form swells, especially in deep water.
Secondary Recovery: The extraction of oil from a field beyond what can be recovered by normal methods
of flowing or pumping; the use of water flooding, gas injection, and other methods to recover additional
amounts of oil.
Seismic Exploration: A method of prospecting for oil or gas by sending shock waves into the earth.
Reflections of the shock waves.
Self-propelled: Containing within itself the means for its own propulsion.
Semisubmersible Drilling Rig: Floating offshore drilling structure that has hulls submerged in the water but
not resting on the sea floor. Semisubmersible rigs are either self-propelled or towed to a drilling site, and
are either anchored or dynamically positioned over the site, or both.
Separator: A pressure vessel (either horizontal or vertical) used for the purpose of separating well fluids into
gaseous and liquid components. Separators segregate oil, gas, and water with the aid, at times, of
chemical treatment and the application of heat.
Shackle: A U-shaped metal fitting used as a connection for line, cable, or chain and which has a pin secured
through its end by a nut, cotter pin, or screw threads.
Shake Out: To force the sediment in a sample of oil to the bottom of a test tube by whirling the sample at
high speed in a centrifuge machine. After the sample has been whirled for three to five minutes, the
percent BS&W (sediment and water) is read on the graduated test tube.
Shock: A condition of the body resulting from a depressed state of many vital body functions; a depression
that could threaten life, even though the victim’s injuries would not otherwise be fatal.
Shorebase: The onshore center of organization, supply, or activity. Headquarters and staging area to move
materials, equipment, and personnel by vessel/aircraft to and from work locations.
Short String: In a dual well, the tubing string for the shallower zone.
Shut-in: To close valves on a well so that it stops producing; said of a well on which the valves are closed.
22 MECHANIC 17-18
GLOSSARY
Shut-in Pressure: Pressure as recorded at the wellhead when the valves are closed and the well is shut in.
To allow the pressure to build up to its peak, the well is shut in for 24 hours or even longer. This permits
the gas to move out of the formation toward the bore hole and build its head of pressure. See Reservoir
Pressure.
Side Loading: A load applied at an angle to the vertical plane of the crane boom.
Sight Glass: A glass tube in which the height of a liquid in a tank or pressure vessel may be observed. The
glass tube is supported by fittings that extend through the vessel wall, thus allowing the fluid in the tank
to assume a corresponding level in the glass.
Skid the Rig: To move a rig with a standard derrick from the location of a last or completed hole preparatory
to starting a new hole. Skidding the rig allows the move to be accomplished with little or no dismantling
of equipment.
Skimmer Tank: A produced water processing tank designed to skim oil from the surface of the water.
Snatch Block: A block whose frame can be unlatched to insert a rope or wire line; a single-sheave block
used more often for horizontal pulling than for hoisting with an A-frame or mast. Snatch block is so named
because it opens to grasp or snatch the bight of a rope or cable. For those who may have forgotten their
rope lore, a bight is the middle of a slack rope or a loop in a rope being held with its two ends together.
Snubbing: A procedure for servicing wells that are under pressure. Tubing, packers, and other downhole
tools are withdrawn from the well through a stack of rams (valve-like devices that close around the pipe
or tubing being withdrawn and seal off the well pressure). As each joint of tubing is withdrawn, it is
unscrewed.
Solenoid: An electrical unit consisting of a coil of wire in the shape of a hollow cylinder and a moveable core.
When energized by an electric current, the coil acts as a bar magnet, instantly drawing in the moveable
core. Solenoids are used for opening and closing quick-acting, plunger-type valves.
Solution Gas: Natural gas dissolved and held under pressure in crude oil in a reservoir.
Solvent: A liquid capable of absorbing another liquid, gas, or solid to form a homogenous mixture; a liquid
used to dilute or thin a solution.
Sounding: To ascertain the depth of fluid in a tank with a strapping tape.
Sour Crude Oil: Crude oil that contains significant amounts of hydrogen sulfide; often less valuable than
sweet crude oil.
Sour Gas: Natural gas containing hydrogen sulfide.
Splash Zone: The area where ocean waves strike the support members of offshore platforms and production
installations; the water line. The splash zone is particularly subject to corrosion because of the action of
both salt water and air.
MECHANIC 17-18 23
GLOSSARY
Splice: To unite (rope, wire) by lapping two ends together or by applying a piece that laps upon two ends, and
making fast.
Standby: Means the pilot must pause for a few seconds, usually to attend to other duties of a higher priority.
If the delay is lengthy, the caller should reestablish contact.
Starboard: The right side of a ship or aircraft looking forward.
Stern: The rear end of a boat.
Stopcock: A type of plug valve usually installed on a small-diameter piping; pet cock.
Storm Choke: A safety valve installed in the well’s tubing below the surface to shut the well in when the flow
of oil reaches a predetermined rate. Primarily used on offshore, bay, or townsite locations, the tubing
valve acts as an automatic shut-off in the event there is damage to the control valve or the Christmas tree.
Normally the flow valves are damaged or torn away by a storm or other cause, and the well is wide open,
flowing full stream. It is at this moment that the high pressure stream activates the storm choke, shutting
the well in completely.
Straight Bill of Lading: A shipping document for handling hazardous material transportation.
Strap: To measure and record the dimensions of marine vessel’s diesel fuel tanks or oil tanks to prepare
tank tables (gauging tables) for determining accurately the volume of oil in a tank at any measured depth.
Strapping Table: A chart used to convert readings of liquid levels in the tanks of a barge to volume
measurements of that liquid.
Stuffing Box: A packing gland; a chamber or “box” to hold packing material around a moving pump rod, valve
stem, or wireline to prevent the escape of gas or liquid.
Subsurface Safety Valve (Storm Choke): A safety device installed in the well’s tubing below the surface
to automatically shut the well in when predetermined flow rate, pressure, or other conditions are reached.
Subsurface Safety Valve (SSV): A subsurface valve that will shut off well flow when actuated. The valve may
be surface controlled or subsurface controlled.
Sunset: The mean solar times of sunset and sunrise as published in the Nautical Almanac, converted to local
standard time for the locality concerned.
Surface Casing: The first string of casing to be set in a well. Its principal purpose is to protect fresh water
sands.
Surge Tank: A vessel on a flow line whose function is to receive and cushion sudden rises or surges in the
stream of liquid.
Survey: A critical examination or inspection for the purpose of ascertaining desired facts and conclusions when
necessary.
24 MECHANIC 17-18
GLOSSARY
Survey, Damage: A survey that determines the exact extent of damages incurred and specifies repair
requirements.
Survey Report: The written evidence of the survey.
Swage Nipple: An adapter; a short pipe fitting that is a different size on each end (for example, 2-inch to
3-inch or 2-inch to 4-inch).
Sweet Crude Oil: Crude oil that is low in sulfur. Often more valuable than sour crude oil.
Swing: Rotation of the upper structure of a crane for movement of loads in a horizontal direction about the
axis of rotation.
System Prompt: A letter indicating a drive followed by the ">" symbol.
Tank: An enclosed space used for holding liquids.
Tank Table: A table giving the barrels of fluid contained in a storage tank corresponding to the linear
measurement on a gage line. See Strapping Table.
Temperature Bomb: A device used down hole to measure bottom-hole and circulating temperatures on a
drilling well. One technique involves attaching a temperature-sensitive probe in a protective sleeve
attached to a carrier mounted on the drill pipe.
Temperature Conversion: (F° to C°) C° = 5/9 (F° - 32°); (C° to F°) F° = 9/5 (C° + 32°)
Thermohydrometer: A hydrometer that has a thermometer as an integral part of the instrument to show the
temperature of the liquid. This is of first importance as the density or API gravity varies with the
temperature. Hydrometers used by pipeline gaugers are thermohydrometers.
Thief: A metal cylinder with a spring actuated closing device that is lowered into a tank to obtain samples
of oil at any given depth.
Thief Hatch: An opening in the top of a tank large enough to admit a thief and other oil-sampling equipment.
Thieving A Tank: Taking samples of oil from different levels in a tank of crude oil and from the bottom to
determine the presence of sediment and water with the use of a thief.
Thread Protector: A device screwed onto pipe threads to protect the threads from damage when not in use.
Torque: A turning or twisting force; a force that produces a rotation or torsion, or tends to.
Torque Wrench: A tool for applying a turning or twisting motion to nuts, bolts, pipe, or anything to be turned
and which is equipped with a gauge to indicate the force or torque being applied. Torque wrenches are useful
in tightening a series of bolts or nuts with equal tension, as on a flange or engine head.
Total Measured Depth (TD): The maximum depth reached in a well.
MECHANIC 17-18 25
GLOSSARY
Tour: A work period; a shift of work, usually eight hours, performed by drilling crews, pump station operators,
and other oil field personnel.
Tow: To push or pull vessels on a waterway. Also refers to the unit comprised of the towing vessel and the
vessels being towed, or only the vessels being towed.
Triplex Pump: A reciprocating pump with three plungers or pistons working in three cylinders. The triplex
pump discharges fluid more evenly than the duplex or two-plunger pump, as it has a power stroke every
one-third of a crankshaft revolution compared to every half revolution for the duplex pump.
Trunk Line: Main line.
Tube Turn: A welded or flanged fitting in the shape of a U, used in the construction of manifolds, exchanger
bundles, and other close pipe work.
Tubing: Smaller diameter pipe run inside the final casing string that serves as a pathway for reservoir fluids
to reach the surface.
Tubing Head: The top of the string of tubing with control and flow valves attached.
Turbocharger: A centrifugal blower driven by an engine’s exhaust-gas turbine to supercharge the engine.
To supercharge is to supply air to the intake of an engine at a pressure higher than the surrounding
atmosphere.
Turbulent Flow: The movement of liquid through a pipeline in eddies and swirls, which tends to keep the
column of liquid “together” rather than running like a river with the center of the stream moving faster than
the edges.
Turnkey Contract: A contract in which a drilling contractor agrees to furnish all materials and labor and do
all that is required to drill and complete a well in a workman-like manner. When on production, he “delivers”
it to the owner ready to “turn the key” and start the oil running into the lease tank, all for an amount specified
in the contract.
TVD: Total vertical depth. TVD is always less than a well’s total depth (TD) because of the inevitable deviation
from the vertical of the well bore.
Two-cycle Engine: An internal combustion engine that produces one power stroke for each revolution of
the crankshaft; intake, compression, power, and exhaust stroke are accomplished in one revolution.
Two-stage Compressor: Two-stage identifies a type of compressor that intakes gas, and compresses or
raises the pressure in the first chamber of the compressor, and then passes the gas into the second-stage
chamber where it is further compressed, raising the pressure to the required level.
U-bolt: A bolt in the shape of a U, both ends of which are threaded. A follower or saddle-piece fits over the
threaded ends and is held in place by nuts. U-bolts or U-clamps are used to hold two ends of wire together
or to make a loop in a length of wire cable by turning back the running part (the loose end) on the standing
part of the cable and clamping them together.
26 MECHANIC 17-18
GLOSSARY
Unscheduled Run: Special run that requires special scheduling of equipment and vessel/aircraft. Usually
referred to as a hot shot run.
Vapor Lock: A condition that exists when a volatile fuel vaporizes in an engine’s fuel line or carburetor,
preventing the normal flow of liquid fuel to the engine. To handle gas lock or vapor lock the gas must be
bled off the system by removing a line or loosening a connection, or the lines and carburetor cooled
sufficiently to condense the gas back to a liquid.
Vapor Recovery Unit: A facility for collecting and condensing vapors of volatile products being loaded into
open tanks at refineries, terminals, and service stations. The vapors are drawn into a collecting tank and
through the use of pressure and cooling are condensed to a liquid. VR units significantly reduce air
pollution by petroleum vapors.
V-belt: A type of “endless” V-shaped belt used in transmitting power from an engine’s grooved drive-pulley to
the grooved sheave of a pump, compressor, or other equipment.
Vent: A connection in a vessel, line, or pump to permit the escape of air or gas.
VFR Conditions: Weather conditions equal to or better than the minimum for flight under visual flight rules.
Viscosity: A measure of how easily a liquid will pour or flow.
Visibilities: Flight: the visibility forward from the cockpit of an aircraft in flight. Ground: the visibility
determined by identifying a prominent object (structure, rig, etc.).
Void Space: Empty or vacant space between two objects.
Waterflooding: The most common enhanced recovery method (usually referred to as secondary recovery).
Water is pumped into an oil reservoir to push the oil toward producing wells. This method of recovery is
often used after a field’s own internal pressure is no longer sufficient to provide adequate oil production.
Watertight: Of such construction or fit as to prevent the passage of water, except when structural discontinuity,
hysical rupture, or purposeful opening may occur.
Waterwell: A well drilled to: 1) obtain a fresh water supply to support drilling and production operations, or
2) obtain a water supply to be used in connection with an enhanced recovery program.
Well: A hole drilled in the earth for the purpose of finding or producing crude oil or natural gas.
Wellhead: The equipment used to maintain surface control of a well.
Wet Gas: Natural gas containing significant amounts of liquefiable hydrocarbons.
Wildcat Well: A well drilled in previously unexplored areas; also rank wildcat.
Winch: A machine used for pulling or hoisting by winding rope or cable around a power-driven drum or spool.
MECHANIC 17-18 27
GLOSSARY
Windchill Factor: The combined effect of low temperature and wind on the human body.
Wireline Tools: Special tools or equipment made to be lowered into and retrieved from the well on a wireline
(small-diameter steel cable), for example, packers, swabs, gas lift valves, measuring devices, etc.
Work Boat: A boat or self-propelled barge used to carry supplies, tools, and equipment to a job site offshore.
Workover: Operations on a producing well to restore or increase production. A workover may be done to
wash out sand, acidize, hydraulically fracture, mechanically repair, or for other reasons.
28 MECHANIC 17-18
LIST OF REFERENCE MATERIAL
(SUGGESTED LIST - OTHERS MAY APPLY)
SUBJECT 100 - SAFETY, POLICY, EQUIPMENT, AND PROCEDURES
Safe Practices Manual

Loss Prevention Guide No. 7
Loss Prevention Guide No. 3 "Lockout and Tagout Procedures.
Fire Protection Manual
Policy 530
SASBU Standard Operating Procedures
SUBJECT 200 - TOOLS AND MEASUREMENT DEVICES
Snap-On Industrial Catalog 500

Starset Catalog 29
SUBJECT 300 - NATURAL GAS ENGINES (FOUR CYCLE)
Waukesha Sercie Manual 7042 Series

Caterpillar Service Manual G-399 Series
SUBJECT 400 - RECIPROCATING COMPRESSORS
ERTC OTP Level 8000 Course
SUBJECT 500 - DIESEL ENGINES
Detroit Diesel Inline Service Manual
SUBJECT 900 - GAS TURBINES ENGINES
ERTC OTP Centrifugal Compressor Course
SUBJECT 1100 - IGNITION SYSTEM
Altronic Form AII-II-7-85

Altronic Form AII-PL-9-85
SUBJECT 1200 - COOLING SYSTEM
Waukesha Operations and service manual VHP. Series
MECHANIC 17-18 1
LIST OF REFERENCE MATERIAL
SUBJECT 1300 - SHEAVE AND BELT DRIVES
Falk Power Products - 5PC-88

Standard Catalog - 78
SUBJECT 1400 - STARTER SYSTEM
Ingersoll Rand 6.0 Edition

Delco Remy DR5133C - Edition
United Technologies Series - 463-A
SUBJECT 1500 - GOVERNORS
Woodward - Bulletin - 82560E

Woodward - Bulletin - 04022K
Barber Coleman - Dyna 1 Manual
SUBJECT 1700 - SINGLE STAGE CENTRIFUGAL PUMPS
API - Centrifugal Pumps

OTP Level 2000
SUBJECT 1800 - AIR COMPRESSORS
Bauer Compressor RA20-30 Manual
NOTE: This is a partial listing of reference materials. Please consult ERTC for additional information
about a topic or visit our website at http://laf-ctnau.chevrontexaco.com/ertc
2 MECHANIC 17-18
TRAINING EQUIPMENT AND
EQUIVALENTS LIST
The following is a list of specific manufacturer’s equipment referenced in the OSA's. The equivalents shown
may be considered as a substitute if the primary equipment is unavailable or impracticable to obtain.
Substituted equipment and procedures must be approved by the POMT PDC as an acceptable substitute
before a Qualifier is allowed to qualify an employee on that Skill Assessment.
Manufacturer, Model Equivalent(s)
Note: Since manufacturers continuously update their products, please consult with the
manufacturer if a component is no longer made for an equivalent item or for information
about a new product.
MECHANIC 17-18 1
Manufacturer, Model Equivalent(s)
2 MECHANIC 17-18

Mechanical 17 18

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Mechanical 17 18

Uploaded by

Copyright:

Available Formats

PRODUCTION MAINTENANCE

MECHANICAL GRADES 17-18

A program produced Operations Training Program

1.0 Operations Training Program (OTP) .......................................................................... iii

2.0 Employee Feedback ................................................................................................... v

3.0 OSA Administration Guidelines ................................................................................... v

4.0 Documentation and Filing ............................................................................................ x

1.0 OPERATIONS TRAINING PROGRAM MANUAL (OTP)

MECHANIC 17-18 iii

Section II - Job Description

Section III - List of Skill Assessments

Section IV - Qualification In Operations Skill Assessments (OSAs)

1) The exact Skill Assessment is stated.

2) Ensures that the (O&M) employee knows what to expect--no surprises

3) Specifies which of the two modes of Skill Assessment administration is acceptable:

a) DEMONSTRATE: The procedure shall be demonstrated (perform hands-on skills to complete

1) Lists step-by-step procedures

2) References support material if applicable

1.11 Section V contains additional material to complete various Skill Assessments.

Section VII - List of Reference Material

Section VIII - Training Equipment

2.0 EMPLOYEE FEEDBACK

3.0 ADMINISTRATION GUIDELINES

Skill Assessment Qualifiers

3.11 These selected Skill Assessments shall be administered as follows:

3.14 An Operations Manager (OM) shall not administer Skill Assessments.

Skill Assessment Administration

MECHANIC 17-18 vii

viii MECHANIC 17-18

Repeating Skill Assessments

Unsatisfactory Attempt of a Skill Assessment - After Qualifying Period

4.0 DOCUMENTATION AND FILING

4.1.3 When an employee attempts to qualify on Skill Assessments at CLDC, documentation

1. Inspects equipment, diagnoses mechanical problems, establishes baseline performance and

A. IMMEDIATE SUPERVISOR: Mechanical or offshore Foreman depending on assigned area. May

C. FUNCTIONAL ASSISTANCE: Company and equipment manufacturer manuals, division

C. OPERATIONS OR FUNCTIONS: May be temporally assigned to jobs of equal or lower

NOTE: Excerpted from: Job Description (GO-400)

MECHANIC 17- 18 xiii

1. Inspects equipment, diagnoses mechanical problems, establishes baseline performance and

A. IMMEDIATE SUPERVISOR: Mechanical or offshore Foreman depending on assigned area. May

A. PERSONNEL: Provides assistance to Operations when it comes to making decisions about

C. OPERATIONS OR FUNCTIONS: May be temporally assigned to jobs of equal or lower

E. CONTACTS: Company or other regulatory agencies.

F. SKILL ENHANCEMENT: It is recommended that the Maintenance Technician Grade 18 receive

NOTE: Excerpted from: Job Description (GO-400)

MECHANIC 17- 18 xvii

100. SAFETY, POLICY, EQUIPMENT, AND PROCEDURES

_____/_____ 17 (AQ) OSA 103 Explain Zero Mechanical State (ZMS)

_____/_____ 17 OSA 105 Lockout and tagout a turbine package.

_____/_____ 17 OSA 106 Lockout and tagout an electric motor.

_____/_____ 18 OSA 116 Demonstrate the procedure to purchase material against an

MECHANIC 17-18 xvii

200. TOOLS AND MEASUREMENT DEVICES

_____/_____ 17 (AQ) OSA 201 Explain using a cylinder liner puller.

_____/_____ 17 OSA 202 Explain the use of a thermographic camera in performing a

_____/_____ 17 OSA 203 Demonstrate the proper use of a Digital multi-meter.

_____/_____ 17 OSA 204 Demonstrate the use of a photo tachometer.

_____/_____ 18 (AQ) OSA 206 Explain the use of a Bore Scope.

_____/_____ 18 OSA 207 Demonstrate the proper use of a torque multiplier

300. NATURAL GAS ENGINE (FOUR-CYCLE)

_____/_____ 17 OSA 305 Explain the principle of operation of a carburetor.

xviii MECHANIC 17-18

400. DIESEL ENGINE

_/_ 17 (AQ) OSA 103 Explain Zero Mechanical State (ZMS)

_/_ 17 OSA 105 Lockout and tagout a turbine package.

_/_ 17 OSA 106 Lockout and tagout an electric motor.

_/_ 18 OSA 116 Demonstrate the procedure to purchase material against an

_/_ 17 (AQ) OSA 201 Explain using a cylinder liner puller.

_/_ 17 OSA 202 Explain the use of a thermographic camera in performing a

_/_ 17 OSA 203 Demonstrate the proper use of a Digital multi-meter.

_/_ 17 OSA 204 Demonstrate the use of a photo tachometer.

_/_ 18 (AQ) OSA 206 Explain the use of a Bore Scope.

_/_ 18 OSA 207 Demonstrate the proper use of a torque multiplier

_/_ 17 OSA 305 Explain the principle of operation of a carburetor.

_/_ 18 (AQ) OSA 405 Inspect a turbo charger on a diesel engine.

_/_ 17 OSA 406 Explain the procedure to perform an annual Preventive

_/_ 17 OSA 513 Detergent wash a gas turbine engine.

_/_ 18 OSA 516 Start, synchronize and load a turbine generator.

_/_ 18 OSA 703 Remove and install a water pump on an engine.

_/_ 17 OSA 903 Explain the principle of operation of a vane-type pneumatic

_/_ 17 OSA 1001 Remove, inspect and reinstall a magnetic pickup.

_/_ 17 OSA 1104 Disassemble and reassemble a double diaphragm pump.

_/_ 17 (AQ) OSA 1901 Explain the purpose of a clutch.

_/_ 18 OSA 2205 Demonstrate the procedure to perform a reverse alignment on a

_/_ 18 OSA 2206 Demonstrate the procedure to perform a laser alignment on a

_/_ 17 (AQ) OSA 2401 Explain the purpose of a flexible coupling

_/_ 18 OSA 2403 Remove, inspect, and reinstall a grid coupling.

_/_ 18 OSA 6001 Complete a randomly selected Production Maintenance computer