Date:9-12Dec.

2023

Site Service Report

Attendance:

1- Eng. Mohamed Fawzy EMC

2- Eng. Gasser Gad SG
3- Eng. Ahmed Taha SG

The following work has been done:-

- Compressors each has Ip address

o PLC IP 192.168.1.37
o HMI IP 192.168.1.38
o RedLion 192.168.1.39
o HMI User = ics , Password = EMC6811
- Quality problem has been viewed for RPM, Engine Oil Press. On
Trend of Comp.A repeatedly each hour. Virtually happened pressure
dropped to zero, speed dropped 100rpm; without any physical sign
on engine sound.
- Hence, ESM has been requested to be swapped between engines A
and B.
- Comp.A has been shut down, then ESM has been removed from A, all
sockets have been cleaned by dry clean spray.
- Then Comp.B has been shut down, then ESM has been removed from
B, all sockets have been cleaned by dry clean spray.
- The two ESM have been swapped, then two comp. have started,
loaded for more than 20 hours without any S/D and /or Quality
alarm. Running normally successfully.

- Upload HMI [3xfiles] & PLC applications from Comp.A and B.

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 - Comp.A has been requested to S/D then DO card#3 wiring has been
checked / amended in both inside logix and inside cabinet as per
existing as-built, two relays have been found defected so they
replaced by new stock ones [availability took around 2hours], then
DO has been tested by force, Valves have been tested manually
successfully.
- Open / close travel times for valves have been checked. All are ok as
per original logic.
- Existing Logix has been compared with original logic.
- Remote Start/stop have been isolated by introducing [AFI] into logix
rung7,8. Remote stop has been found forced to 1 to be healthy; it is
unused so force has been removed.
- Engine ESD has been found deactivated by force to 0, force has been
removed, TOFR timer has been introduced to isolate between ESD to
ESM and ESD from Engine [as per original logic].
- Warm up timer has been amended to be 180sec. instead of 250sec.
as per client’s request [as per original logic].
- Local:2:I.Data.12 has been removed from routine Alarm2 rung0
because it has no function[added then left].
- Fire_ESD point has been written inside logix as its description;
Description[30], and First_Out_List_En[5]text has been written inside
logix [Fire ESD Trip], to appear instead of spare.
- AI Card#6 has been checked [signals; RPM, engine oil press, Load,
Comp oil Press, Fuel Gas Press] by mA injection [0, 25, 50, 75,100%
and quality]. All are ok.
- Quality trips for the RPM, Engine Oil Pressure, load have been
connected / activated as trips.
- Hw configuration has been checked inside each. Card properties; the
two DO’s have been found with mismatch Fw 2.0 instead of 3.0, so
have been amended. All cards have been unchecked to impact cpu

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 major fault in case of connection loss. Filter inside cards have been
selected to be on 50hz not 60hz.

- System of Comp. A has been rest / ready to start, then application

has been burnt on CF, CF loading to CPU has been amended into CPU
memory corrupt instead of User initiated.
- Then Comp. A has been tested running and loaded successfully more
than 15hours. [loaded 82%, 1080 rpm, disch. Press. 700psi].

- Earth has been adapted and measured by petrosannan = 1.68 ohm,

which is ok.
- Hmi editable backup [*.apa] has been requested, because available
backup [*.mer] is runtime file not convertible due to its ver.6.0.
- Suction SOV is recommended to have new SOV instead of the
defected one.

The following work has been done:-

- After S/D for two Comp.’s, 3xRLYs have been swapped between two
Comp. [RLY’s of Comp.B have been taken then installed into Comp.A]
then Valves have been tested manually successfully, Comp.A has
been running successfully. [RLY’s of Comp.A have been taken then
installed into Comp.B].
- Logix and HMI Application files of Comp.A have been downloaded
into Comp.B.
- System of Comp. B has been rest / ready to start, then application
has been burnt on CF, CF loading to CPU has been amended into CPU
memory corrupt instead of User initiated. IO force has been removed
from CPU of B as unit A.
- then Comp.B DO card#3 wiring has been checked / amended in both
inside logix and inside cabinet as per existing as-built, [existing DO

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 card of B has DO9 defected, used card of A has DO8,9 defected] so it
is replaced by new stock one [availability took around more than
1hour], then DO has been tested by force, Valves have been tested
manually successfully.
- AI Card#6 has been checked [signals; RPM, engine oil press, Load,
Comp oil Press, Fuel Gas Press] by mA injection [0, 25, 50, 75,100%
and quality]. All are ok.
- Comp.B has been running successfully.

- Now the two Units A,B have same logix, HMI, as-built on CPU and on
CF [Compact Flash] memory.
- Now Both units A,B are running, loaded around 92% @ 1070rpm,
705psi disch. Press.

Recommendations
- Hunger structure needs to be installed to cover the two compressors’
skids.[essentially needed]
- Then Sunshade has to be added on the top of each cabinet.
- Then Coolers for cabinets’ with air filter regulator will be needed to
be installed on the top of each cabinet + flex hose. To avoid excess
heat and over temp. inside cabinet specially in summer.
- Spares have to be available for both compressors for inside cabinet
components and field devices @ Operation area. To reduce
compressors down time.
- Fused T.B is preferred to be installed for each signal.
- Add Gravel limestone around compressor area to facilitate
movement.

SG Site Team Leader

Gasser Gad

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