Anadarko Petroleum Corporation

Discoverer Spirit 2-Year PSD/Title V Application

Every 500-hour 1 Change the bronze air filter.

2 Clean centrifugal (spinner) oil filter.

3 Clean and lubricate fuel rack.

4 Check fuel leak quantities from injection pumps and nozzles and make corrective repairs as needed.

5 Lubricate the mechanical over speed trip lever on the fuel rack and check to make sure it moves freely.

Every 1000-hour 1 Inspect condition of air filter, and change if needed. change turbo oil.

2 Grease electrically driven fuel supply pump with one shot of grease.

3 Grease electrically driven pre lubrication pump with one shot of grease where applicable.

4 Check for fluid leakages from the flexible coupling between engine and generator.

5 Check that the inlet and exhaust valves move freely in their guides. Check valve clearances and bridge adjustments.

6 Inspect all low pressure fuel line claps to ensure stud nuts or bolts are secure and rubber isolator between clamp and pipes is intact.

7 Check tightness of all M8 clamp screws or nuts for proper torque. All M8 fasteners should have no more than 23 Nm torque as indicated in the chart of the Wartsila Service Manual.

8 Inspect all fuel pipe shield and cladding to ensure none are loose, cracked or worn and all fasteners are secured. 

9 Charge Air Cooler. Check the tightness of the lower support screws (10) every 1000 running hours.

Every 2000-hour 1 Test and verify Engine Electrical Overspeed shutdown device.

2 Test and verify Engine Mechanical Overspeed shutdown device setting.

3 Test and verify Engine Low Lube Oil Pressure switch shutdown device setting.

4 Test and verify Engine Jacket Cooling water system (HT) High Temperature alarm device.

5 If two Charge air (Rig Saver, Barber Gate) flaps are installed on the engine, trip one and verify that the opposite one closes. Reset the flaps and repeat test on the second one. 

6 Inspect the flywheel speed pick-up sensors. Ensure that they are in good condition and that they are secure in their mountings. 

Check the air gap between the sensor faces and the flywheel teeth and ensure that they are within the range specified by the engine manufacturer.

7 Start the engine and check the stability of the signal from the pick-ups with a frequency meter at the control panel. Reading should be steady with no intermittent signal losses.

8 Test and verify High Charge Air Temperature switch alarm device.

9 Test and verify crankcase overpressure switch shutdown, if fitted.

Every 2000-hour 1 Change oil in governor.

2 Pull and test all injectors, insure opening pressure clean and repair a necessary. Refer Fuel Injection Valve Maintenance Bulletin.

3 Check water side of charge air coolers visually for leakage.

4 Open oil and fuel filters to clean wire gauge cartridge or replace filters as needed.

5 Check integrity of all fuel lines and connections, paying particular attention to flanged connections and clamp areas. Ensure all flanged connections are secure and bolted connections are torqued. 

Check integrity of clamps as well as rubbing wear to fuel line. Make corrections as necessary.

6 Remove all fuel line cladding (shields) from the low pressure fuel line outside of the hot boxes to gain access to the flange connections. Check that all M8 hex socket head screws are secure. 

If any of the N8 hex socke head screws are missing open a repair work order to remove the pipe and diagnose the cause of the missing screws.

Report findings to the Maintenance Supervisor and record all details in notes. Remount fuel pipe with OEM O-Rings and replace all M8 hex socket head screws with correct OEM socket head screws

and Nordlock washers. All hex socket head screws in fuel ile flanges are to be replaced anytime they are removed. Use a M* ball tip allen socket wrench with extensions and swivels as needed to 

access all screws with a torque wrench to properly tighten all M8 screws to 23 Nm.

7 Inspect all cladding (shields) and fasteners to ensure none are cracked or making contact with fuel lines. Secure cladding in place with all proper OEM type, fit and grade hex head fasteners.

8 Test run engine offline for 20 or 30 minutes after completion of PM then check level of governor oil.

Every 4000-hour 1 Check for cleanliness of charge air coolers by comparing inlet and outlet air temperatures of cooler remove and clean as needed.

2 Pressure test charge air coolers.

3 Inspect contact faces of camshaft lobes and tappet rollers.

4 Check that the rollers rotate by observing while rotating the engine with the turning gear.

5 Remove and replace all fuel injectors with new or reconditioned injectors. If a full set of injectors is not available, remove each injector, pressure test check spray pattern and repair as needed.

6 Check for wear in all connecting links between the governor and all injection pumps.

7 Check crankshaft alignment and record all readings on Wartsila form wv98v036. Alignment check must be done while the engine is at operating temperature.

8 Check axial clearance of crankshaft & camshaft thrust bearings.

9 Turbocharger (ABB VTR): Change lubrication oil in the turbocharger. Take care that the turbine oil is not mixed with the engine lubrication oil.

10 Use Shell Corena AS 68 or other like products listed in TOI Bulletin WF1 S VTR 184 714 for a 5000 hour renewal.

11 Check conditions of crankcase explosion relief doors and overhaul if required.

12 Change the oil and filter in the DE and NDE generator bearing. After oil is drained flush bearing and lines with clean oil then fill with filtered oil.

13 Verify cylinder exhaust temperature gauge reading corresponds to electronic reading +/ 5%. Investigate any abnormality.

14 Verify electronic bearing temperature readouts are stable. All cylinder temperatures should correspond within +/ 5%. Investigate any abnormality.

15 All of the following devices are to be set as per the engine manufacturer specifications /instrument ranges and verified against external instruments having up to date calibration records.

a. Engine speed.

b. Turbocharger speed.

c. Start air pressure.

d. Diesel fuel pressure.

e. Charge air pressure (before and after cooler).

f. Low temperature cooling water system pressure.

g. High temperature cooling water system pressure.

h. Engine oil pressure.

i. Fuel oil filter - pressure differential.

j. Lube oil filter - pressure differential.

k. Lube oil priming pressure.

l. Rocker arm lube oil pressure.

m. Charge air temperature.

n. High temperature cooling water system temperature.

o. Low temperature cooling water system temperature.

p. Turbocharger exhaust outlet temperature.

q. Engine oil temperature.

r. Alternator winding temp.

s. Alternator bearing temp.

t. Alternator bearing lube oil pressure/flow

u. Alternator cooling air temp.

v. Alternator cooling water leakage.

w. Fuel oil leakage.

x. Lube oil level switch (Sump).

y. Engine room ambient temperature.

z. Turning gear engaged start blocking.

aa. Spark arrestor flow switches.

16 Open and inspect any marshalling panels located on or near the engine. Ensure that the interior of the cabinet is clean and in good order.

17 Check the mounting of all relays, boards, PLC's, etc. in the cabinet and make sure that they are secure.

18 Check security of all wires and the torque of all terminals.

19 Check the condition of cable grounding, cabinet earth buss rail and cabinet earth strap if applicable.

Key Maintenance Schedule for Discoverer Spirit Main Engines

Main Engine Key Maintenance Schedule 1 of 1

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2/24/2014