APPENDIX B

MCELMO CREEK UNIT OPERATIONS & MAINTENANCE PLAN

OCTOBER 2004
MCELMO CREEK UNIT OPERATIONS & MAINTENANCE PLAN

CONTENTS

I. Process Overview and Operating Procedures

II. Routine Monitoring / SurveiUance

III. Maintenance Plan

IV. Training Program for Plant Operators

V. Reference Documentation

VI. Appendices

I. Life Cycle Maintenance Plan McElmo Compressors

HOS 6. HOS 4. ACID GAS A&B

2. Daily Plant Reading Form

3. Isolation and Operating Procedures

HOS 6,11054, ACID GAS A&B

4. Compressor Troubleshooting Guide

5. Spare Parts List -HOS 4 and HOS 6
Process Overview and Operating Procedures

The McElmo Creek Compression Plant serves tertiary recovery operations for the

MeElmo Creek Field. The goal of the Plant is to receive produced gas through a

gathering system, pressure the gas up to a suitable working pressure then re-inject

the gas to maintain reservoir pressure. The natural gas is injected with produced

water in a dual injection system. Due to varying water injection demands in the

field, and to the number of wells being serviced at any time, the Plant inlet

volume can vary between 10 and 18 million standard cubic feet per day

(MSCFD).

To describe the plant process in more detail, the gas is processed in three main

steps: inlet separation, compression and re-injection.

Inlet Separation. The inlet separation consists of an inlet slug receiver which

collects free liquids. The gas then passes through filter vessels which collect any

incoming solids.

Compression. The Plant consists of four high-speed electrically-driven

reciprocating compressors which utilize 6300 Brake Horsepower (BHP). Each

compressor consists of four stages which raise the pressure of the incoming gas

from 40 psig to 2900 psig. Each stage has a dedicated aerial cooler and liquid

scrubber vessel. On the largest compressor, inter stage dehydration takes place to

remove water for corrosion mitigation.

Isolation and operating procedures for the Acid Gas A&B and HOS 4 and HOS 6

compressors are included in the appendix to this report.

Re-Injection. The four units discharge into a single header, where purchased CO2

is co-mingled to achieve a daily injection goal of 24 MSCFD. The gas is then

distributed to the field. During Plant upsets, additional CO2 is purchased to meet

the daily injection goal.

During Plant upsets or compressor downtime events, a portion or all of the inlet

volume to the Plant is automatically diverted to flare until the problem is

corrected.

II. Routine Monitoring / Surveillance

The plant is manned 24 hours a day by operators who work 12-hour shifts. The

operators make plant rounds each shift, during which key operating parameters of

the compressors and supporting equipment are monitored. The following are

examples of the parameters that are recorded during a shift:
r Overall Plant inlet and discharge volumes

> CO2 purchased volumes

> Flared volumes

r Discharge pressure

> Compressor run times

From the Operator’s daily run time report (example attached in appendix to this

report), a compressor reliability spreadsheet and flare volume report are updated.

The Operators monitor key operating parameters for the compressors to ensure

the units are operating within prescribed operating limits based on ExxomMobil

andoriginal equipment manufacturer (OEM) standards. Examples of parameters

that the Operators record include:

> Compressor suction and discharge temperatures and pressures

> Scrubber liquid levels

The detailed parameters that are checked during the shift are included in the

maintenance plan and operating procedures included in the appendix to this

report.

The operators are very familiar with prescribed operating limits, as this is part of

their training. Should the operator observe a parameter that is out of specification,

appropriate corrective action is taken. For example, if compressor suction

temperature is too low, the operator will open cooler louvers to adjust. If the

Operator cannot resolve the issue through organized troubleshooting, he then

contacts Plant Engineering, Maintenance and Reliability (M&R) Supervisor

andlor the contract mechanic to resolve the problem.

III. Maintenance Plan

ExxonMobil utilizes an Equipment Strategies Program (ESP) approach to

ongoing reliability improvements. The ESP includes the following items:

1. Periodic maintenance that will be performed on the equipment.

2. Predictive maintenance that is to be done on the equipment.

3. Equipment life cycle

4. Overhaul schedule

5. Spare parts inventory

The appendix to this report contains the specific steps in the Life Cycle Maintenance Plan

for the McElmo equipment strategy developed for these types of compressor units. The

ESP is applied to the compression equipment and the reliability efficiency ofthe

compressors is measured. The process consists of Periodic Maintenance, Predictive
Maintenance. Equipment Life Cycle and Overhaul Schedule and the Life Cycle

Maintenance Model which describes the various levels within the program and how they

are applied.

A. Periodic Maintenance (PM’S)

Periodic maintenance begins with daily inspections of the compressors, which are

performed by the Plant Operator. In addition to monitoring process parameters,

the following daily equipment checks are made:

> The compressor piping, inter stage coolers and block valves and compression

valves are inspected for fluid leaks

> Oil and water levels are monitored

> Vibration levels on the motors and compressor frames are monitored

> General observations of physical conditions (i.e., unusual sounds) of the

compressor and electric motor are noted.

Additional periodic maintenance includes:

> Compressor performance analysis (Beta)

> Lube oil analysis data to determine the condition of the electric motor,

compressor and all of the auxiliary equipment.

> Foundations and equipment mounts are checked for cracks and correct make

up torque.

> Compressor Piping is inspected for external damage

> Corrosion coupons are pulled and monitored

Annual Inspections involve performing functional tests on the instrument and

controls systems. This includes testing safety devices, vibration probes, safety

alarms and safety shutdowns. There are PM’s frequencies that extend past a year,

such as coolant replacement and lube oil replacement. The predictive

maintenance is the tool that is used to decide ifthis work is required.

B. Predictive Maintenance

Predictive maintenance involves performing detailed inspections for internal

wear. The inspections reveal the remaining life of a compressor component.

Some examples ofthe predictive maintenance include inspecting the compressor

main bearings, compressor cylinder and piston inspections, electric motor

winding/insulation inspection, crankshaft web deflections and electric motor

bearing inspection.

The results of predictive maintenance inspections are recorded, trended and used

to determine when the next major maintenance is due.
C. Equipment Life Cycle and Overhaul Schedule

The Equipment Strategy Program assists in determining the life cycle for the

compressors. This life cycle information and the data taken during the predictive

maintenance helps us determine when the electric motor and compressor should

be overhauled. An overhaul involves opening up the machine and replacing all

worn parts with new or refurbished parts. Overhauls can take up to one month or

more to complete. The compressor is restored as much as possible and another life

cycle begins. The common practice is to hire additional contract mechanics to

perform this work. A normal life cycle for a McElmo compressor is 40,000

hours. This equates to the compressor and electric motor being overhauled about

every 5 to 6 years. Overhauls are recorded and all of the data and measurements

kept on file. These files are kept on site and with the contractor that performed

the work.

D. Life Cycle Maintenance Model

The section below provides a description of the type of activities planned for each Level.

Note Levels 5 and 6 are subject to the Risk Based Work Selection process prior to

committing to the work. The Risk Based Work Selection process is based on earlier and

ongoing data obtained and analyzed during the maintenance cycles.

LEVEL 1 OPERATIONS SURVEILLANCE AUTONOMOUS MAINTENANCE

Collection and review of process parameters along with routine observation of machinery

operations.

LEVEL 2 RUNTIME BASED TESTING PREDICTIVE MAINTENANCE

Scheduled collection and monitoring of both crankcase lubricant for effects of

degradation.

LEVEL 3 CONDITION MONITORING PREDICTIVE MAINTENANCE

Scheduled analysis of the engine and compressor performance, vibration profile, and

energy utilization.

LEVEL 4 INTERMEDIATE INTERVENTION PREVENTIVE MAINTENANCE

Scheduled driver tune-up and testing !reconditioning of safety devices. Minimally

invasive, downtime required.

LEVELS PREEMINENT INTERVENTION PREVENTIVE MAINTENANCE

Scheduled inspection / reconditioning of minor wear components in both the driver and

driven equipment. A suite of maintenance task considerations and milestone targets that

are subject to Risk Based Work Selection review prior to execution.

LEVEL 6 ZERO HOUR TURNAROUND PREVENTIVE MAINTENANCE

Scheduled overhaul of driver and replacement of major wear components. A suite of

maintenance task considerations and milestone targets that are subject to Risk Based

Work Selection review prior to execution.
IV. Training Program for Plant Operators

NEW OPERATIONS PERSONNEL - NO PRIOR MCELMO PLANT

EXPERIENCE

The plant training for new operations persons with no prior McElmo Relnjection Plant

experience consists of the following:

Training for one month with another Plant Operator in the Reinjection Plant. Trainee

must be scheduled for only day shifts until qualified.

Training will be conducted on the following:

• Plant operation, start up, shutdown and emergency procedures

• Surveillance requirements for plant operations personnel

• First line maintenance responsibilities

• Regulatory requirements, such as upset reporting and regulatory

documentation

• Required safe work practices, permits and methods used

• Required communication procedures, including handling of community

inquiries

• The Plant Supervisor will evaluate the individual’s performance and is required to

approve the trainee for release from the training program

• Following the training program the first shifts must be scheduled during day shift

OPERATOR WITH PRIOR PLANT EXPERIENCE (Out of the Plant >1 year)

• Ensure all ongoing required training has been completed and reviewed

• Review all procedures, including plant operation, start up, shutdown and emergency

procedures

• Work with another Operator for one week during day shift

• The Plant Supervisor will evaluate the individual’s performance and is required to

approve the trainee for release from the training program

OPERATOR TRAINING ON CONSENT DECREE

Following the effective date of the Consent Decree existing operators will be trained on the

following sections of the Consent Decree. New operators will be trained on these sections as part

of their overall plant training while the consent decree is in effect:

• Paragraph 9a - Emission Limits as it relates to their duties

• Paragraph 10 -Monitoring as it relates to their duties

• Paragraph 11 -Contents of the O&M plan as it relates to their duties

• Paragraph 12- Root Cause Analysis as it relates to their duties

• Paragraph 31 -Right of Entry as it relates to their duties
V. Reference Documentation

The following documentation is readily available at the facility:

> Startup and isolation procedures for each unit (copies included in the appendix

of this report)

> Original Equipment Manufacturer (OEM) maintenance manuals for each unit

> Piping and instrument diagrams (P&ID’s) for the plant, updated to reflect

DESOP review in May 2003

> Operating limits tables for each compressor, compiled from OEM

recommendations and ExxonMobil practices (copies included in the operating

procedures in the appendix of this report)

> All operator log sheets

> Compressor Troubleshooting Guide (copies included in the appendix of this

report)
VI. Appendices

1. Life Cycle Maintenance Plan McElmo Compressors

HOS 6, HOS 4, ACID GAS A&B

2. Daily Plant Reading Form

3. Isolation and Operating Procedures

HOS 6. HOS 4, ACID GAS A&B

4. Compressor Troubleshooting Guide

5. Spare Parts List -HOS 4 and HOS 6
APPENDIX 1

Life Cycle Maintenance Plan

McElmo Compressors

HOS 6, HOS 4, ACID GAS A&B
The following pages describe the Level I tasks performed by the plant operators during

each shift.

Critical monitoring devices for pressure. temperature, level, and vibration are equipped

with High and High High alarms. High alarms warn operators of a process malfunction

allowing operators to troubleshoot the process for operational or mechanical

malfunctions. Operational problems are corrected by an operator allowing equipment to

continue operating. Mechanical problems that can be easily repaired by the operator are

repaired. Mechanical problems that cannot be repaired by the operator are communicated

to the supervisor on duty and a decision is made to either shut down that piece of

equipment or to continue running, depending on the criticality of the equipment andlor

the severity of the malfunction, until repairs can be made. Monitoring frequency of the

equipment will be increased, again depending on the criticality of the equipment or the

severity of the malfunction until repairs can be made.

High High alarms will automatically shutdown equipment ensuring the safety of

personnel, preventing damage to equipment, and minimizing impact on the environment.

The supervisor on duty is notified of a shutdown and a decision is made whether to repair

immediately, depending on day (weekend, weekday), time of day(night tour or day tour)

availability of parts and personnel necessary to perform repairs, in order to minimize

impact on the environment.
Routine Monitoring I Preventative Maintenance Plan

EMAINTENANCE PLAN I I

HOS6

LEVEL I OPERATION SURVEILLANCE —

TASK rAsKDEscR1pT1oN- - t4k ACTIVITYL’ FREQUENCYjSKILV

COMPRESSOR - Z

Li-Ti 1ST SUCTION CHECK 12 HOURS 1OPERATIONS

TEMP &

PRESSURE

L1-T2 1STDISCHARGE CHECK 12HOURS OPERATIONS

TEMP &

PRESSURE

L1-T3 2ND SUCTION CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

L1-T4 2ND DISCHARGE CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

Li-T5 3RDSUCTION CHECK 12HOURS OPERATIONS

TEMP &

PRESSURE

L1-T6 3RD DISCHARGE CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

L1-T7 4TH SUCTION CHECK 12 HOURS OPERATIONS

TEMP&

PRESSURE

L1-T8 14TH DISCHARGE CHECK 12 HOURS OPERATIONS

TEMP&

PRESSURE

L1-T9 JACKET WATER LEVEL CHECK 12 HOURS OPERATIONS ; LEVEL I

Li-Tb JACKET WATER PRESSURE CHECK 12 HOURS OPERATIONS

PRESSURE

L1-T11 JACKET WATER TEMP IN lOUT CHECK TEMP 12 HOURS OPERATIONS

L1-T12 FRAME OIL LEVEL CHECK 12 HOURS OPERATIONS

LEVEL

L1-T13 COMP OIL PRESSURE CHECK 12 HOURS OPERATIONS

PRESSURE

L1-T14 LUBE OIL LEVEL UCON - 1 CHECK 12 HOURS OPERATIONS

LEVEL

L1-T15 HI/LOLUBEOILPRESSURE(FOR CHECK 12HOURS OPERATIONS

CYLINDERS) PRESSURE

L1-T16 VIBRATION ON ISTSTAGEWEST/EAST CHECK 12 HOURS OPERATIONS

VIBRATION

L1-T17 VIBRATION ON 2ND STAGE WEST/EAST CHECK :12 HOURS OPERATIONS

! VIBRATION

L1-T18 VIBRATION ON 3RD STAGE CHECK 12 HOURS OPERATIONS

! VIBRATION

L1-T19 VIBRATION ON 4TH STAGE CHECK 12 HOURS OPERATIONS : VIBRATION

L1-T20 VIBRATION ON MOTOR WEST! EAST CHECK 12 HOURS OPERATIONS

(GEARBOX) VIBRATION
L1-T21 VIBRATION ON MOTOR (GEAIBOX) CHECK 12 HOURS OPERATIONS

VIBRATION k SCRUBBERS# 4 t’ k

L1-T22 1ST/2NDSTAGESCRUBBERS CHECK 12HOURS OPERATIONS

LEVEL

L1-T23 3RD/4THSTAGESCRUBBERS CHECK 12HOURS OPERATIONS

LEVEL
MAINTENANCE PLAN

HOS4

LEVEL I OPERATION SURVEILLANCE - ti-At

TASK TASKEDESCRjPTION ACTIVITY FREQUENC’( SKILL!.

COMPRESSOR .-sa

Li-TI 1ST SUCTION CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

L1-T2 1ST DISCHARGE CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

L1-T3 2ND SUCTION CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

L1-T4 .2ND DISCHARGE CHECK 12 HOURS OPERATIONS

: . 1EMP&

PRESSURE

L1-T5 3RDSUCTION CHECK 12HOURS OPERATIONS

•TEMP &

PRESSURE

L1-T6 3RD DISCHARGE CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

L1-T7 4TH SUCTION CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

L1-T8 4TH DISCHARGE CHECK 12 HOURS OPERATIONS

TEMP &

PRESSURE

L1-T9 JACKET WATER LEVEL CHECK 12 HOURS OPERATIONS

LEVEL

LI-Tb JACKET WATER PRESSURE CHECK 12 HOURS OPERATIONS

PRESSURE

Li-Ti 1 JACKET WATER TEMP IN / OUT CHECK TEMP 12 HOURS OPERATIONS

L1-T12 FRAME OIL LEVEL CHECK 12 HOURS OPERATIONS

LEVEL

L1-T13 COMP OIL PRESSURE (OFF CONTROL CHECK 12 HOURS OPERATIONS

PANEL) PRESSURE

Li-T14 LUBE OIL LEVEL UCON - 1 CHECK 12 HOURS OPERATIONS

LEVEL

L1-T15 HI/LO LUBE OIL PRESSURE (FOR CHECK 12 HOURS OPERATIONS

CYLINDERS)

L1-T16 AFTERCOOLER FAN ON HI / LO CHECK TEMP 12 HOURS OPERATIONS

Li-T17 VIBRATION ON MOTOR NW & SW CHECK 12 HOURS OPERATIONS

VIB RATION

Li-Tb 8 VIBRATION ON MOTOR NE & SE CHECK 12 HOURS OPERATIONS

VIBRATION

L1-T19 VIBRATION ON 1ST/2ND STAGE CHECK 12 HOURS OPERATIONS

VI B RATION

L1-T20 [VIBRATION ON 3RD / 4TH STAGE CHECK 12 HOURS OPERATIONS

VIBRATION
L1-T21 VIBRATION ON COMPRESSOR WEST CHECK 12 HOURS OPERATIONS

VIBRATION

SCRUBBERS

L1-T22 1ST/2NDSTAGESCRUBBERS CHECK 12HOURS OPERATIONS

LEVEL

L1-T23 3RD/4THSTAGESCRUBBERS CHECK 12HOURS OPERATIONS

LEVEL
z

U)

0

aUI

H0

2

U)

0ci

LU

H02

U)

0

a

UI

4

H0

2

U)

0a

UI

H02U)

0

t

0aw

H0

2

U)

0a

UI

H02U)

0

a

UI

H0

2U)

IL

Ui

0a

UI

H0z

U)

0aLii

4

H0

z

U)

r@4

I0D

U)

0

aw4

H

02(I)

(N

3D

0

D

U)

0

aUI

H

02U)

0

aUI

H

0zCl)

@4

3:0

DCd)

zU)

2U)

@4

3:

0

D

U)

2U)

(N

3:0

D

U)

2

U)

@4

I0D

C’)

p

@4r

0

Dct

U)

@43:

0

D

U)

a

ftCUI U) U)

D

UI

OH

eq

:3:0

DU)

a

UI U)

C,,

D

w

eq

I0

DU)

OH1w

UI

oa

OH

1w

On

@4I

0

U)

aUI

C’)

U)

D

UI

@4

I0

D

U)

OH

1wUJOn

@4

I

0

D

U)

w

ww

OaU)

OHa

rwr

@4

I

0

D

U)

UI

OHa

IUI

UIUI oaU)

sco8

(‘4I

0

D

U)

a

ccUI U)

Cd)D

UI

(N

I

0D

U)

OH

1w

UJoa

It

UI

OHaIwIt

W2Woacn

st:Qo

eq

I

0DIt

U)

aItUI

U) U)D

DCUI

0

I

UI

0

a

UI UI UiIt It XLiiD

D Dr

U)U)JU)

S11

UIOCOOUIOCOOWOCOO Owow >www>www>UIww UI>W> wIItIwIItIwIItI IwIw oaooaoion-o O..JO.J

I

0z

I

a

0

Ui-I

-J

C-)

Ui

C-)

0

2

Co0

U)

HU)

D0

F

0z

U)

H

U)C—)

I

4It(9

UI

-,U)40

UIH>2

UIIt

-JUI>

Lii-J

2

0It

II

UIz

C

(N2C

U)D0

H

0

2

4U)

44

2C4

0

C(9

4U)

4

0

C(9

@42

CC

U)

0

I

4It(9

UI

aIt

wU) U)

0a::UI

0ULi

C-)

0

2

Hcc0

-J

0

0

a0

-J

C,,ItC

(-I)0

0

H

0

2

C,,cc

C

CU)0

I

4It(9

UI

4

2I

UIz

42

0UI

a

2

40

wH

4

H

UIIt

a

ItUI U)

U)0cc

UI

H3D

U)0

C)H

0

2

-J

UI—0

-J

aIt

wU)U)

0

ItUI

LI0

It

H

ICU)

0

I

4It(9

UI

2

-J

Ui-J

4

LLHUI

ccC-)

00

-J

UIItU

42

02

3:

-J

0

-J0

mUI0

-J

-JUI>

UI

-J0

0

02

:4.

U)H

(N2C

U)

H4(3

UIU)0

It

0

UIIt

U)

UI

0

-J-J

UI>UI-J

C,,

It

C

HI

U)

H

4(3

UIU)0

It

0

UIcc

U)

-J

F;

eq

FC,,

a

4

2UI-J

-J

F

-J

I-:

to

-j

F

Ci,

-J

FF—

-JF;

-J

F;C)

-J

F0

-J

F;

-J

F;

(N

-JF;

C,,

-J

F;

U,

-J

F;

CD

-J

F;

F—
NOTE LEVELS 2 THROUGH 6 ARE THE SAME FORALL COMPRESSORS

TASK

LEVEL 2tIrsaVicIMEBASED

$TASKDESCRIPTION

TESTING (**R-

.ACTIVITY

1n

FREQIJENCV1SKIP

L2-T1 LUBE OIL ANALYSIS TEST 740 HOURS MECHANICAL

L2-T2 JACKET WATER ANALYSIS TEST 4000 HOURS MECHANICAL

LEVEL 3 CONDITIONMONITORING

TASK TASK DESCRIPTION ACTIVITY FREQUENCY

L3-T1 MOTOR-COMPRESSOR PERFORMANCE ANALYZE QUARTERLY MECHANICAL

ANALYSIS

L3-T2 HORSE POWER UTILIZATION RATIO ANALYZE QUARTERLY MECHANICAL

L3-T3 VIBRATION COMPRESSOR DRIVE ANALYZE QUARTERLY MECHANICAL

MOTOR BEARINGS

L3-T4 VIBRATION PRE I POST LUBE OIL PUMP ANALYZE QUARTERLY MECHANICAL

L3-T5 LOOSE FOUNDATION FASTENERS / VISUAL QUARTERLY MECHANICAL

CHOCKS INSPECTION

L3-T6 PRESSURE CASE VENT PIPING VISUAL QUARTERLY MECHANICAL

INSPECTION

L3-T7 COMPRESSOR JACKET WATER PIPING VISUAL QUARTERLY MECHANICAL

INSPECTION
LEVEL 4 INTERMEDIATE INTERVENTION

TASKSS.g TASIDESGRJPTION • %t4t ACTiVITY FREQUENC.* SKILI*L

L4-T1 COMPRESSOR CRITICAL SAFETY TEST QUARTERLY INSTRUMENT

DEVICES

L4-T2 MOTOR BEARING GREASE LUBRICATE QUARTERLY MECHANCIAL

L4-T3 CRANKCASE AND DRIVE TRAIN VISUAL QUARTERLY MECHANICAL

INSPECTION

L4-T4 JACKET WATER-LUBE OIL COOLER REPLACE QUARTERLY MECI-iANLCAL

BANK_FAN_BELT

L4-T5 LUBE OIL FILTERS REPLACE REPLACE AS MECHANICAL

NEEDED

I PER

ANALYSIS

L4-T6 CRANKCASE LUBE OIL REPLACE REPLACE AS MECHANICAL

NEEDED

PER

ANALYSIS

L4-T7 CRANKCASE LUBE OIL SUMP CLEAN AS NEEDED MECHANICAL

P ER

ANALYSIS

L4-T8 CRANKCASE LUBE OIL FEED LINES VISUAL AS NEEDED MECHANICAL

INSPECTION

L4-T9 JACKET WATER-LUBE OIL COOLER CLEAN AS NEEDED MECHANICAL

BANK (EXTERNAL)

L4-T1O GAS COMPRESSOR ROD (SCORING) VISUAL ANNUAL MECHANICAL

INSPECTION

L4-T1 1 ‘GAS COMPRESSOR PACKING CASE VISUAL ANNUAL [MECHANICAL

(ROD CENTERING) ‘INSPECTION

L4-T12 GAS COMPRESSOR WIPER PACKING VISUAL ANNUAL MECHANICAL

(LEAKAGE) INSPECTION

L4-T13 GAS COMPRESSOR PACKING CASE VISUAL ANNUAL MECHANICAL

(LUBE CONNECTIONS) INSPECTION

L4-T14 CROSSHEAD SHOE CLEARANCE CHECK & ANNUAL MECHANICAL

RECORD

L4-T15 TORQUE COMPRESSOR CRANK FRAME CHECK & ANNUAL MECHANICAL

FOUNDATION FASTENERS RECORD

L4-T16 TORQUE COMPRESSOR CYLINDER CHECK & ANNUAL MECHANICAL

DISTANCE PIECE FASTENERS RECORD

L4-T17 TORQUE CRITICAL CRANKCASE CHECK & ANNUAL MECHANICAL

FASTENERS RECORD

L4-T18 GAS COMPRESSOR ROD RUNOUT CHECK & ANNUAL MECHANICAL

RECORD

L4-T19 MOTOR WINDING POLARIZATION INDEX TEST& 250O0 VENDOR

RECORD HOURS SERVICE

L4-T20 MOTOR LEAD CONNECTIONS INSPECT & 25000 VENDOR

TORQUE HOURS SERVICE

L4-T21 MOTOR CONTACTOR TEST & 25000 VENDOR

INSPECT HOURS SERVICE
LEVEL 4 INTERMEDIATE INTERVENTION : ,te4J::

TASK: TASKOESCRIPTION: 7 ACTJVITYa% REQUENC S$JrflfiJCZJ

L4-T22 MOTOR CONTACTOR BUS STAB INSPECT & 25000 VENDOR

LUBRICATE HOURS SERVICE

L4-T23 SUPERVISORY RELAYS CALIBRATE & 25000 VENDOR

INSPECT HOURS SERVICE

L4-T24 MOTOR GROUND WIRE! CONNECTIONS INSPECT & 25000 MECHANICAL

TORQUE HOURS

LEVEL 5 PREEMINENTINTERVENTION.

TASK TASIQDESCRIPTION ‘ 1ACTIVIrnt4! IFREQUENG4jSKIPIr

L5T1 MAIN BEARING CLEARANCE CHECK & 36000 MECHANICAL

RECORD HOURS

L5-T2 CONNECTING ROD BEARING CHECK & 36000 MECHANICAL

CLEARANCE RECORD HOURS

L5-T3 CROSSHEAD PIN CLEARANCE CHECK & 36000 MECHANICAL

RECORD HOURS

L5-T4 GAS COMPRESSOR ROD PRESSURE INSPECT & 36000 MECHANICAL

PACKING CASE RECONDITION HOURS

L5-T5 GAS COMPRESSOR WIPER PACKING INSPECT & 36000 MECHANICAL

RECONDITION HOURS

L5-T6 GAS COMPRESSOR ROD PROFILE CHECK & 36000 MECHANICAL

RECORD HOURS

L5-T7 PROFILE COMPRESSOR CYLINDER CHECK & ‘36000 MECHANICAL

LINER RECORD HOURS

L5-T8 COMPRESSOR VALVES AND CAGES INSPECT & 36000 MECHANICAL

RECONDITION HOURS

L5-T9 FORCE FEED LUBRICATOR SYSTEM INSPECT & 36000 MECHANICAL

SERVICE HOURS

L5-T10 CRANKCASE RELIEF DOORS RECONDITION 36000 MECHANCIAL

HOURS

L5-T1 I COMPRESSOR ROD RUNOUT CHECK & 36000 MECHANICAL

RECORD HOURS

L5-T12 CRANKSHAFT WEB DEFLECTION CHECK & 36000 MECHANICAL

RECORD HOURS

L5-T13 DRIVE MOTOR BASE BOLT TORQUE CHECK & 36000 ‘MECHANICAL __________ RECORD HOURS

L5-T14 CRANKSHAFT THRUST BEARING CHECK & 36000 MECHANICAL ‘ RECORD HOURS

L5-T15 GAS COMPRESSOR PISTON, ROD, WEIGHT & 36000 MECHANICAL

NUT (BALANCE) RECORD HOURS

L5-T16 MOTOR DRIVE COUPLING CHECK & 36000 MECHANICAL

RECORD HOURS
I LEVEL 6;* ZERHOURIOVERHAUL

LTASK .1TASKZDESCRIPTION AaIvnv,.> FREQUENCY’ SKILL

IL6T1 MAIN BEARINGS REPLACE 72000 MECHANICAL

HOURS

L6-T2 CONNECTING ROD BEARINGS REPLACE 72000 MECHANICAL

HOURS

L6-T3 CONNECTING ROD BUSHINGS REPLACE 72000 VENDOR

HOURS SERVICE

L6-T4 CROSSHEAD PIN INSPECT 72000 MECHANICAL

HOURS

L6-T5 CROSSHEAD SHOES INSPECT 72000 MECHANICAL

HOURS

L6-T6 JACKET WATER PUMP RECONDITION 72000 MECHANICAL

HOURS

L6-T7 MAIN OIL PUMP RECONDITION 72000 VENDOR

HOURS SERVICE

L6-T8 CRANKSHAFT OIL SEAL REPLACE 72000 MECHANICAL

HOURS

L6-T9 MAIN LUBE OIL PUMP COUPLING INSPECT 72000 MECHANICAL

HOURS

LB-Tb CRANKSHAFT THRUST BEARING CHECK 72000 MECHANICAL

HOURS

LB-Tb I OIL THERMOSTAT ELEMENTS CHECK 72000 MECHANICAL

. HOURS

L6-T12 JACKET WATER THERMOSTAT REPLACE 72000 MECHANICAL

ELEMENTS HOURS I

L6-T1 3 GAS COMPRESSOR VALVE COVER INSPECT 72000 MECHANICAL

STUDS HOURS

L6-T14 GAS COMPRESSOR HEAD STUDS INSPECT 72000 MECHANICAL

HOURS
APPENDIX 2

Daily Plant Reading Form
EzinWEl-ftráncr

&

H. NAME:

DATE: I DATEREPORTING FOR:

yB PD72 Dji

4245 (HOSS-6)

4246 (AG.C-A)

4247(AGC.-B)

4249 (HOSS-4}

McuCO2’ruRcAsssMkT,Mothy2zi4l,ii*

TODAY’S Readings

YES TERDA I’S Readings

TOTAL

TOTAL COMPRESSOR VOL —

TOTAL INJECTION 4

DISCHARGE PRESSURE

YES TERDA Y’S Readings

(Øfl#J&arkrowq..,,.

TODA Y’S Readings

P3201 YESTERDA I’S P-9202 YESTERDA Y’S

CUMUL4 TIVE FLOW CUMULATIVE FLOW

YESTERDArSI’Boosw,stafion) TODAY’S t’BooSTaSWUOn) TOTAL MAKE UP TOTAL PRODUCED

MAKE UP READING MAKE UP READING

F&’tr

-J’a,

YESTERDA I’S TODAY’S TOTAL RUNTJME

RUNTIME P-9201 RUNTIME P-9201 P-9201

YESTERDAY’S TODAY’S TOTAL RUNTIME DISCHARGE

RUNTIME P-9202 RUNTIME P-9202 P-9202 PRESSURE

HEADER PRESSURE

APPENDIX 3

Isolation and Operating Procedures for:

HOS 6, HOS 4, ACID GAS A&B
ExxonMobil Production Isolation Procedure -

Aneth Operations File Name I-IOS6ISO

McElmo HOS$ COMPRESSOR Authorized Creek Unit ISOLATION PROCEDURE Gas Reinjecuon Facility Page 1 of 4

Equipment. # CM-12W

SCOPE This procedure describes the isolation, depressurization and returning of the

HOS-6 Compressor back to service.

REQUIREMENTS None

APPLICABLE HOS-6 Compressor Opearting Procedure

DOCUMENTS Pre-Start Safety Review Checklist (See Attachment)

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Field Foreman and the Operations

Compliance Technician.

SAFETY Locks must be used by Operations and Maintenance Personal

For applicable safety requirements, refer to the ExxonMoibl Production Safety Manual

and Material Safety Data Sheets (MSDS).

Care must be taken to completely depressure the compressor which may contain

explosive or sour gas.

Safety devices taken out of service or being returned to service MUST be logged in the Critical

Safety Device (CSD) log book in the Control Room.
Isolate the compressor for maintenance.

NOTE Refer to the HOS-6 Operating procedure for requirements to shutdown the compressor.

This procedure is for total compressor isolation. Dependant upon the maintenance work

required, specific cylinders or utilities may be isolated separately, while leaving the

remaining cylinders or utilities in service.

1.1 Ensure that the pre-lube oil pump is not running.

1 .2 De-energize the electrical breaker for the motor in the MCC building.

1.3 Close the 4th stage discharge isolation block valve.

1 .4 Close the 3rd stage suction valve downstream of the Glycol Contactor.

1.5 Close the 4th stage intercooler discharge block valve.

1.6 Close the 1st stage suction isolation block valves ( SDC-1 700)

• Change setpoint to zero on DCS PCV-1 700,

1.7 Close all isolation block valves on the PSV’s rack for the (1st, 2nd, 3rd and 4th

stages,etc)

1.6 Close the isolation block valve on the 1st Stage Suction Scrubber.

1.9 Close all isolation block valves for the closed drain

1.10 Close all isolation block valve for the open drain.

1.11 Place the H2S and LEL Detection system in the “calibration” mode in the Control Room.

NOTE While the 1125 and LEL Detection system is in the “calibration” mode, the sensors are still

active and MUST be monitored from the Control Room. Tag it with Pink BYPASS tag and

Log in the LOG BOOK.

ExxonMobii Production Isolation Procedure

Aneth Operations I File Name HDS6ISO

MeElmo Creek HOS-6 COMPRESSOR Authorized Umt

Gas Reinjecuon Facilit 3’ ISOLATION PROCEDURE Pane 2 of 4

Equipment. CM-1210

j All valves, switches and breakers referenced in this procedure MUST BE LOCKED

AND TAGGED per the Lock-out I Tag-out guidelines. I

I
n

ExxonMobil Production Isolation Procedure

I File Name HOS6ISO Aneth Operations HOS-6 COMPRESSOR Authorized MeElmo Creek Unit ISOLATION PROCEDURE Page 3 of 4 Gas Reinjection Facility

Equipment. # CM-1210

2. Depressurize the compressor for maintenance.

Ii WARNING Atmospheric vents will release process gas that contains LEL and H2S. ii

2.1 Open the blowdown valves on all stages to the Flare header to depressure the

compressor.

2.2 Close the blowdown valves on all stages to the Flare header.

2.3 Open the atmospheric vent valves on all 4 cylinder stages to verify depressurization.

2.4 Open the cylinder head and crank end vent valves to verify that the cylinders to be worked

on are depressured.

2.5 Notify maintenance that they may begin their work.

3. Pressure check compressor.

WARNING Make sure all maintenance work is completed before returning the compressor to

service.

3.1. Pressure check compressor with process gas.

3.1.1 Close the atmospheric vent valves on all 4 cylinder stages.

3.1.2 Open all isolation block valves on the PSV’s for the (1 st, 2nd, 3rd and 4th

stages,etc.)

3.1.3 Open all isolation block valve for the closed drain.

3.1.4 Open all isolation block valve for the open drain.

WARNING Make sure atmospheric vents are closed before pressurizing compressor with

process gas.

3.1.5 Open the 4th stage discharge isolation block valve.

3.1.6 Open the 3rd stage suction valve downstream of the Glycol Contactor.

3.1.7 Open the 4th stage intercooler discharge block valve.

3.1.8 Open the 1st stage suction isolation block valves (PCV-1 700, SDV-1 700).
ExxonMobil Production Isolation Procedure

File Name HOS6ISO Aneth Operations

McElmo HOS-6 COMPRESSOR Authorized Creek Unit ISOLATION PROCEDURE Page 4 of 4 Gas Reinjection Facility

______________________________

Egwpment. CM-l210

3.1.9 Verify pressures across compressor.

3.1.10 Verify that no teaks are detected on all items worked.

4. Return compressor to service.

4.1. Refer to the HOS-6 Operating procedure for requirements on returning the compressor

back into service
ExxomMobi( Production [ Operating Procedure

i File Name HOSCCOMP Aneth Operations

McEImo

HOS-6 COMPRESSOR Authorized -

Creek Unit I OPERATING PROCEDURE Page 1 of 10 Gas Reinjection Facility I

Equipment. CM-1210 I

SCOPE This procedure describes the startup and shutdown of the HOS-6 compressor.

Applicable steps are initial startup, normal startup, normal operation, temporary

operation, emergency operation, normal shutdown, Emergency Shutdown (ESD),

safety shutdown, problems and solutions, and operating limits.

REQUIREMENTS None

APPLICABLE HOS-6 Compressor Isolation Procedure

DOCUMENTS

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Field Foreman and the Operations

Compliance Technician.

SAFETY For applicable safety requirements, refer to the ExxonMobil Production Safety Manual

and Material Safety Data Sheets (MSDS).
ExxonMobil Production Operating Procedure

File Name HOS6COMP Aneth Operations HOS-6 COMPRESSOR Authorized McElmo Creek Unit OPERATING PROCEDURE Page 2 of 10 Gas Reinjecton Facility

Equipment. CM- 1210

Initial Startup.

j NOTE Initial startup is performed following an extended compressor shutdown cue to

‘ maintenance or turnaround.

1.1. Check that the compressor is ready for start.

Li Maintenance work complete

Temporary blinds removed and equipment restored

J Oxygen purged frorn compressor and piping

Li Compressor and piping pressure checked using process gas

U Compress& piping rechecked for leaks

Li Compressor isolation valves returned to service

Li Safety devices, vents, and PRVs returned to service

J Instruments, controls, and electrical power returned to service

Li Lock-out/Tag-out rernoved

1.2. Start compressor using normal startup procedure.

2. Normal Startup.

NOTE Normal startup is performed following a brief compressor shutdown due or following an

extended shutdown after performing the initial startup checks.

2.1. Prepare the compressor for start.

2.1.1. Check compressor is ready for start.

Li Plant ESD and local panel shutdowns are reset

J Verify that the LEL, H2S and Fire systerns are in normal operation

Li Motor electrical breaker is reset and in service in the MCC building

Li Control panel power on

Li Control panel lights working

Li Crankcase oil level okay

Li Lubricator oil reservoir level okay
Ensure that the manual block valves on the 1st stage suction and 4th

stage discharge lines are in the open position

J Ensure that all kiene valves and bleeder valves are closed

Li The 1st Stage Suction Pressure Controller (PIC-1700) resets

automatically to 10.4%

Start and load compressor,

CAUTION The compressor should not have more than 10 psi 9on the 1st stage suction.

Depressure as needed to prevent overloading the compressor motor.

2.2.1 Start the pre-lube oil pump.

( NOTE The pre-lube oil pump switch is located at the southwest corner of the compressor skid.

2.2.2 Start the 1st, 2nd, 3rd and 4th stage cooler fans.

2.2.3 Start the lube oil cooler fans.

2.2.4 Start the jacket water cooler fans.

2.2.5 Stan the jacket water pump.

2.2.6 Press the Nredn electrical reset button by Control Panel

2.2.7 Turn the bypass timer clockwise to 5 minutes.

NOTE Allow the indicators to sequence to “green.” The indicators that are bypassed by the timer

will not sequence until after startup and the first indicator in the series clears.

2.2.8 Verify discharge valve is open on the 4th stage discharge

WARNING If the panel indicator does not rotate from “clear” to “red” indicating that the

I discharge valve is open, visually inspect the valve position to ensure it is opened,

ExxonMobil Production Operatmg Procedure

McEhno Creek Umt

File Name HOS6cO 1

OPEIt4TING PROCEDURE Page 3 of 10

Aneth Operanons HOS-6 COMPRESSOR Authorized

Gas Reinjection Facility

Equipment. # CM-12 10

J Jacket water level okay

Visually verify that all Suction scrubbers are empty

J Ensure that the compressor is depressurized

Li

2.2
ExxonMobil Production Operatmg Proceduie

Aneth File Name HOS6COMP Operations

McElmo HOS-6 COMPRESSOR Authorized Creek Umt OPERATING PROCEDURE Gas Reinjection Page 4 of 10 Facilit

Equipment. 4 CM-1210

Warning: Ensure that all personnel are clear and free of the electrical power supply

system components immediately prior to starting motor. In particular do not stand

in front of motor starter, near motor transformer or under aerial fuses. A

minimum distance of 25 feet should be maintained for unqualified personnel.

Rationale: Across the line motor starting creates approximately 6X full load current.

Consequently the electrical system is stressed during starting and the probability

of failure is greater.

2.2.9 Press and hold the ‘green” start button and the “Lube” pump will run for 1 minute

before the compressor starts.

CAUTION After 2 unsuccessful starts; the compressor motor starter will trip a time delay in

the MCC building and prevent you from restarting the compressor. Verify the time

delay duration in the MCC building.

2.2.10 Verify that the compressor oil pressure is above 45 psig.

2.2.11 When the compressor starts ups, the suction valve should open automatically

and the indicator will show open.

2.2.12 Close the 2nd stage discharge to flare valve (PCV-1 746).

CAUTION Ensure that the Contactor back pressure control valve (PCV-1 637) is open before

you begin to close the 3rd stage discharge to flare pressure controller (PlC-I 747).

2.2.13 Close the 3rd stage discharge to flare valve (PCV-1 747).

2.2.14 The 1st Stage Suction Pressure Controller (PIC-1700) in the “auto” mode with a

setpoint 15 psig on the Rosemont OCS.

2.2.15 Reset the bypass timer back to zero.

2.2.16 Start the glycol pumps and place the Dehydration system in service.

3. Normal Operation.

3.1. See tables at end of procedure for normal operating parameters. (Page 9 of 10)

3.2. Perform daily rounds, including but not limited to the items below:

• Troubleshoot, acknowledge, reset, and clear compressor alarms

• Check compressor normal operating parameters

• Suction and discharge pressures

• Suction and discharge temperatures

• Cylinder temperatures
ExxonMobil Production Operating Procedure

Aneth Operanons File Name FIOS6CDMP

McElmo l-Ios-6 COMPRESSOR Authorized Creek Umt OPERATING PROCEDURE Gas Renijection Page 5 of 10 Facility

Equipment. 4 CM-1210

• Cylinder vibration

• Motor Vibration

• Crankcase and lubricator lube oil pressure

• Crankcase and lubricator lube oil temperature

• Crankcase lube oil filter dp, and change as necessary

• Crankcase oil level

• Oil consumption

• Lubricator oil level

• Jacket water pressure

• Jacket water temperature

• Check compressor crankcase and lubricator lube oil level and fill as needed

• Check pulsating bottle supports

• Check vibration and temperature monitors

• Clean oil off skid and foundation

• Check packing vent temperatures

• Check crankcase pressure

• Check all gauges

• Check for lose bolting

• Check Jacket water tank level and fill as needed

• Check Jacket water pump and cooler fans for proper operation

• Check suction scrubber levels and drain manually if needed

• Drain suction and discharge pulsating bottles

• Check distance piece purge or vent system

• Check interstage cooler delta pressure and temperature

• Check motor bearing oil sump level and sight level condition

• General housekeeping duties
ExxonMobil Procjucnon Operatmg Procedure

File Name HOS6COMP Aneth Operations I-iOs-6 COMPRESSOR Authothed McElmo Creek Unit OPERATING PROCEDURE Page 6 0110 Gas Reinjecuon Facility

Equipment. # CM-1210

• Check compressor aftercooler fans operation

4. Temporary Operation.

NOTE Use of temporary operating procedures must be approved by the Field foreman.

4.1. Document any temporary procedure changes with a Management of Change (MOC) work

order, and a procedure revision request form.

4.2 Follow up on temporary procedures when the system is returned to normal operation or

when a temporary procedure becomes permanent. Complete all documentation required.

5. Emergency Operation.

5.1. Refer to Emergency Response Plan for emergency response instructions.

6. Normal Shutdown.

NOTE Normal shutdown is usually done for compressor maintenance or when inlet gas rates

decrease. Control Room operator will coordinate any normal shutdown.

6.1. Shut down compressor.

6.2.1. Press the Motor stop button.

6.2.2 Ensure suction valve is closed since this valve closes automatically.

6.2.3 Open the 3rd stage discharge to flare valve (PCV-1 747).

6.2.4 Open the 2nd stage discharge to flare valve at (PCV-1 746).

NOTE Turn off the associated pumps and cooler fans if the compressor will be down for an

extended period.

7. Emergency Shutdown (ESD)

NOTE ESD of the Gas Reinjection Facility can be initiated from any of the 7 pull stations located

throughout the facility or from 1 push button station located in the Control Room. The

Fire, H2S and LEE. detection systems will also initiate an ESD. Both systems will

shutdown all the reinjection compressors, isolate the inlet area and depressure the facility.

NOTE The ESD pull stations located throughout the facility are easily identified by the red and

white stripes painted on the building or pipe rack support beams.

7.1. Reinjection Facility ESD:

7.1.1. ESD Station One push button station is located inside the Control Room above

the Fire, H2S and LEE. Detection System’s readout panel and a pull station is

located on the southeast wall inside the MCC building (beside the Control Room).
ExxonMobjj Production Operatmg Procedure

File Name HOS6COMP Aneth Operations [[OS-a COMPRESSOR Authorized McElmo Creek Unit OPERATING PROCEDURE Page 7 of 10 Gas Remjecuon Facility

Equipment. # CM-1210

7.1.2. ESD Station Located on a pipe rack support beam on the southeast corner of the

Acid Gas compressor building.

7.1.3. ESD Station Located outside between the Control Room and the MCC building.

7.14. ESD Station Located on the north wail outside of the Inlet Area’s Air Compressor

building.

7.1.5. ESD Station Located on a building support beam on the northwest corner of the

HOS-6 Compressor building.

7.1.6. ESD Station: Located on a building support beam on the northwest corner of the

HOS-4 Compressor building.

7.1.7. ESD Station: Located on cooler fan support beam on the southeast corner of the

HOS-4 Compressor’s Cooler Fan bay.

7.2 Fire, H2S and LEL Detection Systems ESD:

7.2.1. Fire: There are 10 Fire Detection sensors located throughout the facility. Any

detection by either of these sensors will initiate an audible alarm and a shutdown

of all reinjection compressors, isolate the inlet area and depressure the facility.

7.2.2. H25: There are 23 H2S Detection sensors located throughout the facility. Any

detection by either of these sensors at 10 PPM H23 will initiate an audible alarm

and illuminate a “blue” beacon light. Any detection by either of these sensors at

50 PPM H2S will initiate an audible alarm, illuminate a “blue” beacon light and

shutdown all reinjection compressors, isolate the inlet area and depressure the

facility

7.2.3. LEL: There are 8 LEL Detection sensors located throughout the facility. Any

detection by either of these sensors at 30 % LEL will initiate an audible alarm.

Any detection by either of these sensors at 50 % LEL will initiate an audible alarm

and shutdown all reinjection compressors, isolate the inlet area and depressure

the facility

7.3 HOS-6 Compressor ESD.

7.3.1 Local ESD. Trip individual compressor ESD by pressing ‘Stop’ button on local

control panel to shut down that compressor only.

8. Safety Shutdown.

8.1 Any condition below causes a safety shutdown of the compressor:
ExxonMobil Production Operating Procedure

File Name HQS6COMP Aneth Operations HOS-6 COMPRESSOR Authorized McElmo Creek Unit OPERATING PROCEDURE Page 8 of 10 Gas Reinjection Facility

Equipment. 4 CM-1210

• Plant ESD

• Fire! H2S, and LEL Detection systems

• Low instrument air pressure

• Electrical power failure

• Low discharge pressure

• Low pressure suction

• High discharge pressure on either of the 2nd or 4th stage cylinders

• High level in either of the 1st, 2nd, 3rd or 4th stage suction scrubbers

• Low pressure suction on either of the 2nd, 3rd or 4th stage

• Low compressor oil pressure

• Low compressor oH level

• No flow compressor cylinder oil

• Low pressure Jacket Water

• Cooler failure

• Vibration Compressor

• Compressor manual shutdown

8.3. See critical operating limits tab’es at end of procedure for safety shutdown trip points.

9. Problems and Solutions.

I NOTE Refer to the Compressor Troubleshooting guide located in the Control Room. I
ExxonMobil Production Operating Procedure

File Name HOS6COMP Aneth Operanons HOS-6 COMPRESSOR Authorized McElmo Creek Umt OPERATING PROCEDURE I Page 9 of 10 Gas Reinjection Facility

Equipment. 4 CM-1210

10. Operating Limits.

10.1. Shutdown resets:

Local Shutdown Resets and Permissive

Tag Description Position Setpoint

Reinjection Plant Total Reinjection Plant ESD Reset N/A

ESD

Fire Detection Fire Detection Reset N/A

H2S Detection H2S Detection Reset 50 PPM

LEL Detection LEL Detection Reset 50 %

Remote Shutdown Resets

Tag Description Position Setpoint

__Manual_Shutdown Local panel shutdown Reset N/A

10.2. Normal operating parameters:

NOTE The following parameters are only guidelines. Certain conditions may call for you to

operate outside them.
ExxonMobii Production Operating Procedure

File Name HOS6COMP Aneth Operations

McElmo

BOS-6 COMPRESSOR Authorized Creek Unit OPERATING PROCEDURE Page 10 of 10 Gas Reinjection Facility I________________________________________________

Equipment. CM-I 210

HOS-6 Compressor Normal Operating Parameters

Description Operating Range

Crankcase Oil Pressure 50 to 65 psig

Crankcase Oil Temperature 150 to 170°F

Oil Filter Differential Pressure 0 to 5 psig

Jacket Water Temperature 100 to 110°F

Jacket Water Temperature Change 10 °F

i Stage Suction Temperature 45 to 100 degrees F

1st Stage Discharge Temperature 250 to 280 degrees F

2 Stage Suction Temperature 80 to 110 degrees F

2’ Stage Discharge Temperature 250 to 250 degrees F

3’° Stage Suction Temperature 100 to 120 degrees F

3rd Stage Discharge Temperature 250 to 280 degrees F

4 Stage Suction Temperature 100 to 120 degrees F

4tfl Stage Discharge Temperature 240 to 280 degrees F

i’ Stage Suction Pressure 14 to 16 psig

i’ Stage Discharge Pressure 95 to 105 psig

2 Stage Suction Pressure I 90 to 105 psig 20d Stage Discharge Pressure 370 to 380 psig

3(0 Stage Suction Pressure 350 to 380 psig 31d Stage Discharge Pressure 1000 to 1050 psig

4fl Stage Suction Pressure 1000 to 1040 psig 4tfl Stage Discharge Pressure 2750 to 2950 psig

151 Stage Vibration (Cyl #1) 0.38 to 0.40 in/s

1 Stage Vibration (Cyl #3) 0.36 to 0.40 in/s

2° Stage Vibration (Cyl #2) 0.38 to 0.44 in/s

2 Stage Vibration (Cyl #4) 0.38 to 0.44 in/s

3(0 Stage Vibration (Cyl #5) 0.34 to 0.38 in/s

4U1 Stage Vibration (C #6) 0.35 to 0.40 in/s

Motor Vibration (Al Bearings) 2.0 to 3.0 in/s
ExxonMobif Production Isolation Procedure

FLIC Name HOS4ISO Aneth Operations

McElmo Creek Unit HOS- 4 COMPRESSOR ISOLATION Authorized

Page lofJ Gas Remjection Facility

Equipment. # CM-3400

SCOPE This procedure describes the isolation, depressurization and returning of the

HOS-4 Compressor back to service.

REQUIREMENTS None

APPLICABLE HOS-4 Compressor Operating Procedure

DOCUMENTS Pre-Start Safety Review Checklist

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Field Foreman and the Operations

Compliance Technician.

SAFETY Locks must be used by Operations and Maintenance Personal (Two Sets)

For applicable safety requirements, refer to the ExxonMobil Production Safety Manual

and Material Safety Data Sheets (MSDS).

Care must be taken to completely depressure the compressor which may contain

explosive or sour gas.

Safety devices taken out of service or being returned to service MUST be logged in

the Critical Safety Device (CSD) log book in the Control Room.
WARNING All valves, switches and breakers referenced in this procedure MUST BE LOCKED

AND TAGGED per the Lock-out I Tag-out guidelines.

1. Isolate the compressor for maintenance.

NOTE Refer to the HOS-4 Operating procedure for requirements to shutdown the compressor.

1.1 Ensure that the lube oil pump is not running.

1 .2 De-energize the electrical breaker for the motor in the MCC building.

1.3 Place the local control panel power switch in the “off’ position.

1.4 Close the 4th stage discharge isolation block valve.

1.5 Close the 1st stage suction isolation block valve.

1.6 Close the isolation block valves for the closed drain

1.7 Close the isolation block valve for the open drain.

1.8 Place the H2S and LEL Detection system in the ucalibrationK mode in the Control Room.

[iiãThE While the H25 and LEL Detection system is in the calibration Mmode, the sensors are still

active and MUST be monitored from the Control Room.

2. Depressurize the compressor for maintenance.

j jWARNING Atmospheric vents will release process gas that contain LEL and H2S. ii

2.1 Open the 1/2 blowdown valve to the Flare header to depressure the compressor.

2.2 Open the 3)4 blowdown valve to the Flare header to depressure the compressor.

2.3 Close the 1/2 blowdown valve to the Flare header after depressurizing the compressor.

2.4 Close the 3/4 blowdown valve to the Flare header after depressuring the compressor.

2.5 Close the main isolation block valve to the Flare header.

2.6 Open the atmospheric vent valves on all 4 cylinder stages to verify depressurization.

2.7 Open the cylinder head and crank end vent valves to verify that the cylinders to be worked

on are depressured.

ExxonMobil Production Isolation Procedure I

Aneth Operations File Name HOS4ISO

McElmo Creek Unit HOS- 4 COMPRESSOR ISOLATION i Authorized

GasReinjectionFacility

_________

Page 2 of 3

I Equipment. 4 CM-3400
ExxonMobil Production I Isolation Procedure

Aneth operations File Name HOS4JSO

McElmo Creek Unit HOS- 4 COMPRESSOR ISOLATION i Authorized

Gas Reinjection Facility Page 3 of 3

Equipment. # CM-3400

2.8 Notify maintenance that they may begin their work.

3. Pressure check compressor.

WARNING Make sure all maintenance work is completed before returning the compressor to

service.

3.1. Pressure check compressor with process gas.

3.1.1 Open the main isolation block valve to the Flare header.

3.1.2 Close the atmospheric vent valves on all 4 cylinder stages.

3.1.3 Open the isolation block valve for the close drain.

3.1.4 Open the isolation block valve for the open drain.

WARNING Make sure atmospheric vents are closed before pressurizing compressor with

process gas.

3.1.5 Open the isolation block valve for the 1st stage suction.

3.1.6 Open the 1st stage suction valve from the local control panel to pressurize the

compressor.

3.1.7 Verify pressures across compressor.

3.1.8 Verify that no leaks are detected on all items worked.

4. Return compressor to service.

4.1. Refer to the HOS-4 Operating procedure for requirements on returning the compressor

back into service
ExxonMobil Production Operatmn Procedure -

File Name HOS4COMP Aneth Operations -

McElmo Creek Unit HOS-4 COMPRESSOR Authonzed

Page lofIl Gas Rerniecnori Facility

I I Equipment. U CM-3400

SCOPE This procedure describes the startup and shutdown of the HOS-4 compressor.

Applicable steps are initial startup, normal startup, normal operation, temporary

operation, emergency operation, normal shutdown, Emergency Shutdown (ESD),

safety shutdown, problems and solutions, and operating limits.

REQUIREMENTS None

APPLICABLE HOS-4 Compressor Isolation Procedure

DOCUMENTS

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Field Foreman and the Operations

Compliance Technician.

SAFETY For applicable safety requirements, refer to the ExxonMobil Production Safety Manual

and Material Safety Data Sheets (MSDS).

Care must be taken to completely purge out a compressor which may contain an

explosive mixture of gas.
ExxonMol,jl Production I Operating Procedure

Aneth Operations File Name HOS4COMP

McElmo Creek Unit 1-LOS-I COMPRESSOR Authorized

Gas Reinjection Facility Page 2 of 11

. Equipment. CM-3400

1. Initial Startup.

NOTE Initial startup is performed following an extended compressor shutdown due to

maintenance or turnaround.

1.1. Check that the compressor is ready for start.

Li Maintenance work complete

Li Temporary blinds removed and equipment restored

Li Oxygen purged from compressor and piping

J Compressor and piping pressure checked using process gas

Li Compressor piping rechecked for leaks

Li Compressor isolation valves returned to service

Li Safety devices, vents, and PRVs returned to service

J Instruments, controls, and electrical power returned to service

Li Lock-out/Tag-out removed

1.2. Start compressor using normal startup procedure.

2. Normal Startup.

NOTE Normal startup is performed following a brief compressor shutdown due or following an

extended shutdown after performing the initial startup checks.

2.1. Prepare the compressor for start.

2.1.1. Check compressor is ready for start.

Li Plant ESO and local panel shutdowns are reset

Li Verify that the LEL, H2S and Fire systems are in normal operation

Motor electrical breaker is reset and in service in the MCC building

Li Control panel power on

Li Manual switch is in the “on” position for the Murphy Mark Ill annunciator
2.2 Start

2.2.1

2.2.3

2.2.4

ExxonMobil Production Operanng Procedure

File Name I-IOS4COMP Aneth Operanons

McElmo Creek Unit HOS4 COMPRESSOR Auth0t

Page 3ofIl Gas Reiniection Facihtv

______________________________

I Equipment. if CM-3400 I

J Reset the Bentley-Nevada vibration monitors

J Control panel lights working

U Enclosure pressure indicator for the Control panel is in the safe zone

Crankcase oil level okay

Lubricator oil reservoir level okay

IJ Jacket water level okay

J Verify that all Suction scrubbers are empty, both visually and on the

Rosemont DCS

J Ensure that the compressor is depressurized

J Ensure that the manual block valves on the 1st stage suction and 4th

stage discharge lines are in the open position

Ensure that all kiene valves and bleeder valves are closed

LI Permissive to startup HOS-4 on the Rosemont DCS

J The 1st Stage Suction Pressure Controller (PIC-341 1)is placed in

manual with an output of 9.4% open on the Rosemont DCS

and load compressor.

Open the 1 / 2 bypass valve by turning the VO-3412 controller counter-clockwise

for a zero psig output.

2.2.2 Open the 3 / 4 bypass valve by turning the VO-3414 controller counter-clockwise

for a zero psig output.

NOTE The 1 I 2 blowdown valve (VO-3462) automatically opens when the compressor is

shutdown.

Press the reset button on the Murphy Mark Ill (timer is for 5 minutes).

Open the 3 I 4 blowdown valve by turning the VO-3424 controller counter

clockwise for a zero psig output.

2.2.5 Press the “lube oil pump on” button.
ExxonMobil Production Operatmg Procedure 1

Aneth Operations File Name HOS4COMP

F McElmo Creek Unit HOS-4 COMPRESSOR Authonzcd

Gas Reinjecrion Facility I

____________________________

Page 4 of 11

Equipment. I 4 CM-3400

2.2.6 Press the “Jacket water pump on” button.

2.2.7 Press the “Fan 4 1 on” button

2.2.8 Press the “Fan #2 on” button

NOTE Fan #2 can be started on either low or high speed based on ambient temperature. Use

low speed if the ambient temperature is below 75 degrees F. Use high speed if the

ambient temperature is above 75 degrees F.

2.2.9 Press the “open discharge valve” button.

WARNING If the panel light does not come on indicating that the discharge valve is open,

visually inspect the valve position to ensure it is opened.

2.2.10 Press and hold the “open suction valve” button until the “open” indication light

comes on.

2.2.11 Allow the compressor to purge for a minimum of 30 seconds.

2.2.12 Press the “close suction valve” button.

2.2.13 Press the “close 1 / 2 blowdown valve” (VO-3462) button.

2.2.14 Close the 3/4 blowdown valve by turning the VO.3424 controller clockwise for at

least a 40 psig output.

2.2.15 Press and hold the “Yellow PPS-3416” button.

NOTE This will complete the start permissive sequence and illuminate the “Ready to Start” light.

2.2.16 Press the “motor start” button while still pressing the “Yellow PPS-3416” button.

I NOTE You have 5 minutes to place the 1st Stage Suction Pressure Controller (PIC-341 1) in

auto” on the Rosemont DCS or the compressor will shutdown.

CAUTION After 2 unsuccessful starts; the compressor motor starter will trip a time delay in

the MCC building and prevent you from restarting the compressor. Verify the time

delay duration in the MCC building.

2.2.17 Verify that the compressor oil pressure is above 45 p51g.

2.2.18 Press and hold the “open suction valve” button until the “open” indication light

comes on.

2.2.19 Close the I / 2 bypass valve by turning the VO-3412 controller clockwise for at

least a 40 psig output.
ExxonMobil Production Operatmg Procedure

Aneth Operations File Name HOS4COMP 1

Gas Reinjection Facility Page 5 of I I

McElmo Creek Unit 110S4 COMPRESSOR Authorized

j

Equipment. ft CM-3400

2.2.20 Close the 3 / 4 bypass valve by turning the VO-3414 controller clockwise for at

least a 40 psig output.

2.2.21 Press the ‘Timer 0 button on the Murphy Mark Ill annunciator.

2.2.22 Set the 1st Stage Suction Pressure Controller (PIC-341 1) in the “auto’ mode with

a setpoint between 22 to 27 psig on the Rosemont DCS.

3. Normal Operation.

3.1. See tables at end of procedure for normal operating parameters.

3.2. Perform daily rounds, including but not limited to the items below:

• Troubleshoot, acknowledge, reset, and clear compressor alarms

• Check compressor normal operating parameters

• Suction and discharge pressures

• Suction and discharge temperatures

• Cylinder temperatures

• Lube oil pressure

• Lube oil filter dp

• Lube oil temperature

• Crankcase oil level

• Lubricator oil level

• Jacket water pressure

• Jacket water temperature

• Check compressor lube oil level and fill as needed

• Check Jacket water tank level and fill as needed

• Check Jacket water pump and cooler fans for proper operation

• Check suction scrubber levels and drain manually if needed

• General housekeeping duties

• Check compressor aftercooler fans operation
ExxomMobil Production Operaimg Procedure

Aneth Operations File Name HOS4COMP

McElmo Creek Unit HOS-.4 COMPRESSOR Authorized

Gas Reinjecton Facility

______________________________

Page 6 of II

Equipment. # CM-3400

4. Temporary Operation.

NOTE Use of temporary operating procedures must be approved by the Field foreman.

4.1. Document any temporary procedure changes with a Management of Change (MOC) work

order, and a procedure revision request form.

4.2 Follow up on temporary procedures when the system is returned to normal operation or

when a temporary procedure becomes permanent. Complete all documentation required.

5. Emergency Operation.

5.1. Refer to Emergency Contingency Plan for emergency response instructions.

6. Normal Shutdown.

NOTE Normal shutdown is usually done for compressor maintenance or when inlet gas rates

decrease. Control Room operator will coordinate any normal shutdown.

6.1. Shut down compressor.

6.2.1. Press main motor ‘stop’ button.

6.2.2 Press the “close suction valve” button.

6.2.3 Press the “close discharge valve” button.

6.2.4 Open the 1 / 2 bypass valve by turning the VO-3412 controller counter-clockwise

for a zero psig output.

6.2.5 Open the 3/4 bypass valve by turning the vO-3414 controller counter-clockwise

for a zero psig output.

6.2.6 Open the 3 / 4 blowdown valve by turning the VO-3424 controller counter

clockwise for a zero psig output.

NOTE Turn off the associated pumps and cooler fans if the compressor will be down for an

extended period.
ExxonMobil Production Operating Procedure

Aneth Operations I File Name HOS4COMP

McElmo Creek Unit l-IOS-4 COMPRESSOR Authorized

Gas Reinjection Facility Page 7 of 11

Equipment. # CM-3400

7. Emergency Shutdown (ESD)

NOTE ESD of the Gas Reinjection Facility can be initiated from any of the 7 pull stations located

throughout the facility or from 1 push button station located in the Control Room. The

Fire, H2S and LEL detection systems will also initiate an ESO. Both systems will

shutdown all the reinjection comQressors, isolate the inlet area and depressure the facility.

NOTE The ESD pull stations located throughout the facility are easily identified by the red and

white stripes painted on the building or pipe rack support beams.

7.1. Reinjection Facility ESD:

7.1.1. ESD Station One push button station is located inside the Control Room above

the Fire, H2S and LEL Detection System’s readout panel and another pull station

is located on the southeast wall inside the MCC building (beside the Control

Room).

7.1.2. ESD Station Located on a pipe rack support beam on the southeast corner of the

Acid Gas compressor building.

7.1.3. ESD Station Located outside between the Control Room and the MCC building.

7.1.4. ESD Station Located on the north wall outside of the Inlet Building Air

Compressor building.

7.1.5. ESD Station Located on a building support beam on the northwest corner of the

HOS-6 Compressor building.

7.1.6. ESO Station Located on a building support beam on the northwest corner of the

HOS-4 Compressor building.

7.1.7. ESD Station Located on cooler fan support beam on the southeast corner of the

HOS-4 Compressor’s Cooler Fan bay.

7.2 Fire, H2S and LEL Detection Systems ESD:

7.2.1, Fire: There are 10 Fire Detection sensors located throughout the facility. Any

detection by either of these sensors will initiate an audible alarm and a shutdown

of all reinjection compressors, isolate the inlet area and depressure the facility.

7.2.2. H2S: There are 23 H2S Detection sensors located throughout the facility. Any

detection by either of these sensors at 10 PPM H2S will initiate an audible alarm
ExxonMobil Production Operating Procedure - I

Aneth Operanons File ?same HOS4COMP t

McElmo Creek Unit HOS-4 COMPRESSOR Authorized

Page Sofll Gas Remjection Facility i I

Equipment. # CM-3400

and illuminate a “blue’ beacon light. Any detection by either of these sensors at

50 PPM H2S will initiate an audible alarm, illuminate a “blue” beacon light and

shutdown all reinjection compressors, isolate the inlet area and depressure the

facility

7.2,3. LEL: There are S LEL Detection sensors located throughout the facility. Any

detection by either of these sensors at 30 % LEL will initiate an audible alarm.

Any detection by either of these sensors at 50 % LEL wdl initiate an audible alarm

and shutdown all reinjection compressors, isolate the inlet area and depressure

the facility

7.3. HQS-4 Compressor ESD.

7.3.1. Local ESD. Trip individual compressor ESD by pressing ‘Stop’ button on local

control panel to shut down that compressor only.

7.3.2. Remote ESD. Trip compressor ESD on the Rosemont DCS in the Control Room.

8. Safety Shutdown.

8.1. Any condition below causes a safety shutdown of the compressor:

• ESD pull stations

• Fire, H2S, and LEL Detection systems

• Low instrument air header pressure

• Electrical power failure

• Low discharge pressure on either the 1st, 2nd, or 3rd stage cylinders

• High discharge pressure on either the 1st, 2nd, 3rd, or 4th stage cylinders

• High discharge temperature on either of the 1st, 2nd, 3rd or 4th stage cylinders

• High level in either of the 1st, 2nd, 3rd or 4th stage suction scrubbers

• Low 1st stage suction pressure

• High 1st stage suction pressure

• Low compressor oil pressure

• Low compressor oil level

• No flow cylinder lubricator
Aneth erations File Ne HOS4COMP

romMobil

Production i Operating Procedure I

McElmo Creek Unit HOS4 COMPRESSOR Authorized

Gas Renijecuon Faci1i

Equipment. # CM-3400

Page 9 of II

J • Low cylinder tube oil Level

• Low water level surge tank

• Cooler fan ‘A” vibration

• Cooler fan “B’ vibration

• Vibration Compressor motor

• Manual shutdown

8.3. See critical operating limits tables at end of procedure for safety shutdown trip points.

9. Problems and Solutions.

NOTE Refer to the Compressor Troubleshooting guide located in the Control Room.
ExxonMobil Production Operating Procedure I

Aneth Operations File Name HOS4CDMP

McEImo Creek Unit 1-105-4 COMPRESSOR Authorized

Gas Reinjection Facility Page 10 of 11

Equipment. # CM-3400 I

10. Operating Limits.

10.1. Shutdown resets:

Local Shutdown Resets and Permissives

Tag Description Position Setpoint

Reinjection Plant Total Reinjection Plant ESD Reset N/A

ESD

Bentley-Nevada Compressor motor and frame excessive Reset N/A

Vibration Monitor vibration

Fire Detection Fire Detection Reset N/A

H2S Detection H2S Detection Reset 50 PPM

LEL Detection LEL Detection Reset 50 %

Remote Shutdown Resets

Tag Description Position Setpoint

Manual Shutdown Local panel shutdown Reset N/A

Rosemont DCS HOS-4 Run/Stop Run N/A

10.2. Normal operating parameters:

NOTE The following parameters are only guidelines. Certain conditions may call for you to

operate outside them.

HOS-4 Compressor Normal Operating Parameters

Description Operating Range

1st stage suction pressure 20 to 27 psig

1st stage discharge pressure 65 to 78 psig

2nd stage suction pressure 60 to 78 psig

2nd stage discharge pressure 300 to 330 psig

3rd stage suction pressure 295 to 330 psig

3rd stage discharge pressure 1 150 to 1260 psi 9

4th stage suction pressure 1145 to 1260 psig

4th stage discharge pressure 2750 to 2950 psi 9

1st stage suction temperature 45 to 105 degrees F

1st stage discharge temperature 250 to 290 degrees F

2nd stage suction temperature 90 to 120 degrees F

2nd stage discharge temperature 275 to 315 degrees F

3rd stage suction temperature 100 to 120 degrees F

3rd stage discharge temperature 275 to 315 degrees F

4th stage suction temperature 105 to 110 degrees F

4th stage discharge temperature 225 to 260 degrees F

Lube oil pressure 45 to 55 psig
ExxomMobil Production

Aneth Operations

McElmo Creek Unit

Gas Reinjecrion Facility

Operatin2 Procedure

HOS-4 COMPRESSOR

Equipment.

m CM-3400

Aui

Page 11 of 11
ExxonMobil Production Isolation Procedvse

File Name AGISO Aneth Operations

McElnio Creek Unit ACID GAS COMPRESSOR ISOLATION Authorized

Gas Reinjection Facility Page 1 of 3

Equipment # CM-l201 A/B

SCOPE This procedure describes the isolation, depressurization and returning of the Acid

Gas compressor back to service.

REQUIREMENTS None

APPLICABLE Acid Gas Compressor Operating Procedure

DOCUMENTS Pre-Start Safety Review Checklist

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Field Foreman and the Operations

Compliance Technician.

SAFETY Locks must be used bV Operations and Maintenance Personal (Two Sets)

For applicable safety requirements, refer to the ExxonMobil Production Safety Manual

and Material Safety Data Sheets (MSDS).

Care must be taken to completely depressure the compressor which may contain

explosive or sour gas.

Safety devices taken out of service or being returned to service MUST be logged in

the Critical Safety Device (CSD) log book in the Control Room.
Exxon.MobiI Production isolation Procedure

Aneth Operations File Name AGISO

McElmo Creek Unit ACID GAS COMPRESSOR ISOLATION Authonzed

Gas Remjeccion facility Page 2 of 3

I Equipment # CM-1201 A/B

WARNING All valves, switches and breakers referenced in this procedure MUST BE LOCKED

AND TAGGED per the Lock-out / Tag-out guidelines.

Isolate the compressor for maintenance.

NOTE Refer to the Acid Gas Compressor Operating procedure for requirements to shutdown the

compressor. J

1.1 Ensure that the lube oil pump is not running.

1.2 De-energize the electrical breaker for the motor in the MCC building.

1.3 Place the local control panel power switch in the “off’ position.

1.4 Close the 4th stage discharge isolation block valve.

1.5 Close the 1st stage suction isolation block valve.

1.6 Close the isolation block valves on the PSV’s for the 1st, 2nd, 3rd and 4th stages.

1.7 Close the isolation block valves for the closed drain

1.8 Close the isolation block valve for the open drain.

1.9 Place the H2S and LEL Detection system in the “caIibration mode in the Control Room.

‘NOTE While the H2S and LEL Detection system is in the “calibration” mode, the sensors are still

active and MUST be monitored from the Control Room.

2. Depressurize the compressor for maintenance.

Ii WARNING Atmospheric vents will release process gas that contain LEL and H2S. ii

2.1 Open the blowdown valves on all stages to the Flare header to depressure the

compressor.

2.2 Close the blowdown valves on all stages to the Flare header.

2.3 Open the atmospheric vent valves on all 4 cylinder stages to verify depressurization.

2.4 Open the cylinder head and crank end vent valves to verify that the cylinders to be worked

on are depressured.

2.5 Notify maintenance that they may begin their work.
ExxonMobil Production Isolation Procedure

Aneth Operations File Name AGISO

McElmo Creek Unit ACID GAS COMPRESSOR ISOLATION Authorized

Gas ReinjectionFacilitv Page 3 of3

Equipment 4 CM-1201 A/B

3. Pressure check compressor.

WARNING Make sure all maintenance work is completed before returning the compressor to

service.

3.1. Pressure check compressor with process gas.

3.1.1 Close the atmospheric vent valves on all 4 cylinder stages.

3.1.2 Open the isolation block valves on the PSV 1sfor the 1st, 2nd, 3rd and 4th stages.

3.1.3 Open the isolation block valve for the closed drain.

3.1.4 Open the isolation block valve for the open drain.

WARNING Make sure atmospheric vents are closed before pressurizing compressor with

process gas.

Open the isolation block valve for the 1st stage suction.

Open the 1st stage suction pressure controller to pressurize the compressor.

Verify pressures across compressor.

Verify that no leaks are detected on all items worked.

3.1.5

3.1.6

3.1.7

3,1.8

compressor to service.

Refer to the Acid Gas Compressor Operating procedure for requirements on returning the

compressor back into service

4. Return

4.1.
ExxonMobil Production Operating Procedure

Aneth Oceranons File Name AGCOMP

McElmo Creek Unit ACID GAS COMPRESSORS “A” and ,,‘, Authonzed

Gas Remjecnon Page 1 of9 Facility

Eguipment#CM-l201 A/B

SCOPE This procedure describes the startup and shutdown of the Acid Gas Compressors

“A” and B” (CM-12Q1NB). Applicable steps are initial startup, normal startup,

normal operation, temporary operation, emergency operation, normal shutdown,

emergency shutdown, safety shutdown, problems and solutions, and operating

limits.

REQUIREMENTS None

APPLICABLE Acid Gas Compressors “A” and “B” (CM-12O1NB) Isolation Procedure

DOCUMENTS

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Field Foreman and the Operations

Compliance Technician.

SAFETY For applicable safety requirements, refer to the ExxonMobil Production Safety Manual

and Material Safety Data Sheets (MSDS).

Care must be taken to completely purge out a compressor which may contain an

explosive mixture of gas.
ExxonMobil Production Qerating Procedure

Aneth Operations I File Name AGCOMP

McEhno Creek Unit ACID GAS COMPRESSORS “A” and “B” Authorized

Gas Reinjection Facility Page 2 of 9

Equipment # CM-1201 AfB

Initial Startup.

‘NOTE Initial startup is performed following an extended compressor shutdown due to

maintenance or turnaround. Refer to the Acid Gas Compressor isolation procedure when

the compressor will be returned to service.

1 .1 Check that the compressor is ready for start.

Li Maintenance work complete

Li Temporary blinds removed and equipment restored

Li Oxygen purged from compressor and piping

Li Compressor and piping pressure checked using process gas

U Compressor piping rechecked for leaks

Li Compressor isolation valves returned to service

J Safety devices, vents, and PRVs returned to service

Li Instruments, controls, and electrical power retume to service

Li Lock-out/Tag-out removed

1.2. Start compressor using normal startup procedure.

2. Normal Startup.

NOTE Normal startup is performed following a brief compressor shutdown due or following an

extended shutdown after performing the initial startup checks.

_____ ______

2.1. Prepare the compressor for start.

2.1.1. Check compressor is ready for start.

Li Plant ESD and local panel shutdowns are reset

Li Verify that the LEL, H25 and Fire systems are in normal operation

Li Motor electrical breaker is reset and in service in the MCC building under

the Control Room.

Li Control panel power on
ExxonMobil Production Operating Procedure

Meth Operations File Name AGCOMP

McEhno Creek Unit ACID GAS COMPRESSORS “A” and “B” I Authonzed

Gas Reinjecüon Facility Page 3 of 9

Equipment CM-1201 AIR

J Manual switch is in the “run’ position for the Murphy Mark III annunciator

‘j Electrical motor oil level

LI Crankcase oil level okay

J Lubricator oil reservoir level okay

J Jacket water level okay

Visually verify that all Suction scrubbers are empty

U Ensure that the compressor is depressurized

J Ensure that all kiene valves and bleeder valves are closed

2.2 Start and load compressor.

NOTE The compressor should not have more than 10 psig of suction pressure on the 1st stage.

It there is more than 10 psig, the pressure should be bled off. This is to prevent

overloading the compressor driver.

__________

2.2.1 Start the motor cooling fan (CM-1203).

2.2.2 Start the aftercooler fans (HT-1 603, HT-1 604, HT-1 605, and HT-1 606).

2.2.3 Ensure the 1st stage suction valve is manually closed.

2.14 Reset the Murphy switch gauges high/low shut down. Turn the Murphy switch

qauge (low) to zero setting.

2.2.5 Zero out the timer on the Murphy Mark Ill on the annunciator panel.

2.2.6 Verify and manually opens the 4th stage discharge valves.

NOTE Ensure that the 4th Stage discharge isolation block valve located on the south side of the

compressor building is open.

2.2.7 Press the main motor ‘start button,

2.2.8 1 minute Pre-Lube

CAUTION After 2 unsuccessful starts; the compressor motor starter will trip a time delay in

the MCC building and prevent you from restarting the compressor.

2.2.9 Manually open the 1st stage suction valve.
ExxonMobil Production Operatmg Procedure

Aneth Operations File Name AGCOMP

McElmo Creek Urüt ACID GAS COMPRESSORS “A” and “B” Authorized

Gas Reinjection Facility Page 4 of 9

I Eguipment#CM-1201 AID

NOTE At 200 psig, the 4th stage blowdown valve to flare will close automatically.

Reset all murphy switches shut down setpoint to normal shut down setting on

panel.

NOTE Murphy switch gauges on local panel not to exceed the PSV’s setting

3. Normal Operation.

3.1. See tables at end of procedure for normal operating parameters.

3.2. Perform daily rounds, including but not limited to the items below:

• Troubleshoot, acknowledge, reset, and clear compressor alarms

• Check compressor normal operating parameters

• Suction and discharge pressures

• Suction and discharge temperatures

• Cylinder temperatures

• Lube oil pressure

• Lube oil filter dp

• Lube oil temperature

• Crankcase oil level

• Lubricator oil level

• Jacket Water Pressure (3)

• Jacket Water temperature

• Check compressor lube oil level and fill as needed

• Check Jacket Water tank level and fill as needed

• Check Jacket Water pump and coaler for proper operation

• Check suction scrubber levels and drain level as needed

• General housekeeping duties

• Check aftercooler fans operation
ExxonMobil Production Opemtmg Procedure

Aneth Operations File Name AGCOMP

McEhno Creek Unit ACID GAS COMPRESSORS “A” and “B” Authorized

Gas Reinjection Facility

_____________________

Page 5 of 9

Equipment # CM-1201 A/B

• Check all 4-skies electrical motor oil level

4. Temporary Operation.

NOTE Use of temporary operating procedures must be approved by the Field foreman.

4.1. Document a temporary procedures with a management of change (MOC) work order,

procedure revision request, and/or safety devices jumpering log book.

4.2 Follow up on temporary procedures when the system is retumed to normal operation or

when a temporary procedure becomes permanent. Complete all documentation required.

5. Emergency Operation.

5.1. Refer to Emergency Contingency Plan for emergency response instructions.

5.2. See this procedure for emergency shutdown (ESD) instructions.

6. Normal Shutdown.

NOTE Normal shutdown is usually done for compressor maintenance or when inlet gas rates

decrease. Control Room operator will coordinate any normal shutdown.

6.1. Shut down compressor.

6.2.1. Press main motor ‘stop’ button.

NOTE On any Acid Gas compressor shutdown, the blowdown valves to flare will open and

depressure the compressor.

6.2.2 Manually block in the 1st stage suction valve.

6.2.3 Manually block in the 4th stage discharge valve. (Maintenances)

6.2.4 Wait 1010 15 minutes, then tum off the motor cooling fan.
ExxonMobjl Production Operatmg Procedure

Aneth Operations File Name AGCOMP

McEhno Creek Unit ACID GAS COMPRESSORS “A” and “B” Authorized

Gas Reinjecnon Facility Page 6 of 9

EguipmentCM-l2Ol A8

7. Emergency Shutdown (ESD)

NOTE ESD of the Gas Reinjection Facility can be initiated from any of the 7 ESD pull stations

located throughout the facility or from 1 push button station located in the Control Room.

The Fire, H2S and LEL detection systems will also initiate an ESD. Both systems will

shutdown all the reinjection compressors, isolate the inlet area and depressure the facility.

NOTE The ESD pull stations located throughout the facility are easily identified by the red and

white stripes painted on the building or pipe rack support beams.

7.1. Reinjection Facility ESD:

7.1.1. ESO Station One push button station is located inside the Control Room above

the Fire, H2S and LEL Detection System’s readout panel and a pull station is

located on the southeast wall inside the MCC building (beside the Control Room).

7.1.2. ESD Station Located on a pipe rack support beam on the southeast corner of the

Acid Gas compressor building.

7.1.3. ESD Station Located outside between the Control Room and the MCC building.

7.1.4. ESD Station Located on the north wall outside of the Inlet Building of Air

compressor.

7.1.5. ESD Station Located on a building support beam on the northwest corner of the

HOS-6 Compressor building.

7.1.6. ESD Station: Located on a building support beam on the northwest corner of the

HOS-4 Compressor building.

7.1.7. ESD Station: Located on cooler fan support beam on the southeast corner of the

HOS-4 Compressor’s Cooler Fan bay.

7.2 Fire, H2S and LEL Detection Systems ESD:

7.2.1. Fire: There are 10 Fire Detection sensors located throughout the facility Any

detection by either of these sensors will initiate an audible alarm and a shutdown

of all reinjection compressors, isolate the inlet area and depressure the facility.

7.2.2. H2S: There are 23 H2S Detection sensors located throughout the facility. Any

detection by either of these sensors at 10 PPM H2S will initiate an audible alarm

and illuminate a “blue” beacon light. My detection by either of these sensors at
ExxonMobil Production Operating Procedure

Aneth Operations File Name AGCOMP

McElmo Creek Unit ACID GAS COMPRESSORS “A” and “B” Authorized

Gas Reinjection Facility Page 7 of 9

Eguipment# CM-1201 AJB

50 PPM H2S will initiate an audible alarm, illuminate a “blue” beacon light and

shutdown all reinjection compressors, isolate the inlet area and depressure the

facility

7.2.3. LEL: There are 8 LEL Detection sensors located throughout the facility. Any

detection by either of these sensors at 30 % LEL will initiate an audible alarm.

Any detection by either of these sensors at 50 % LEL will initiate an audible alarm

and shutdown all reinjection compressors, isolate the inlet area and depressure

the facility

7.3. Acid Gas Compressor ESD.

7.3.1. Local ESD. Trip individual compressor ESD by pressing ‘Stop’ button on local

control panel to shut down that compressor only.

8. Safety Shutdown.

8.1. Any condition below causes a safety shutdown of the compressor:

• ESD pull stations

• Fire, H25, and LEL Detection systems

• Low instrument air header pressure

• Electrical power failure

• Low discharge pressure on either the 1st, 2nd, 3rd or 4th stage cylinders

• High discharge pressure on either the 1st, 2nd, 3rd, or 4th stage cylinders

• High discharge temperature on either of the 1st, 2nd, 3rd or 4th stage cylinders

• High level in either of the 1st, 2nd, 3rd or 4th stage suction scrubbers

• Low 1st stage suction pressure

• High 1st stage suction pressure

• Crank case oil pressure

• Oil level low

• No flow cylinder lubricator on either of the 1st, 2nd, or 3rd stage cyiinders

• No flow cylinder lubricator on the 4th stage cylinder

• Low cylinder lube oil level
!

ExxonMobil Production Operating Procedure

Aneth Operations I File Name AGCOMP

McElmo Creek Unit ACID GAS COMPRESSORS “A” and “B” Authorized

Gas Reinjection Facility Page 8 of 9

, Eguipment#CM-1201 AJB 1

• Jacket Water 1st, 2nd, 3rd low pressure

• Jacket Water pressure

• Low Jacket Water Tank level 4 1

• Low Jacket Water Tank level 4 2

• Vibration

• Manual shutdown

9. Problems and Solutions.

NOTE Refer to the Compressor Troubleshooting guide located in the Control Room.

10. Operating Limits.

10.1. Shutdown resets:

Local Shutdown Resets and Permissives

Tag Description Position Setpoint

Reinjection Plant Total Reinjection Plant ESD Reset N/A

ES D

Fire Detection Fire Detection Reset N/A

H2S Detection H2S Detection Reset 50 PPM

LEL Detection LEL Detection Reset 50 %

Remote Shutdown Resets

Tag Description Position Setpoint

Manual Shutdown Local panel shutdown Reset T N/A

10.2. Normal operating parameters:

NOTE The following parameters are only guidelines. Certain conditions may call for you to

operate outside them.

Acid Gas Compressor Normal Operating Parameters

Description Operating Range

1st stage suction pressure 18 to 20 psi 9

1st stage discharge pressure 90 to 100 psig
ExxonMobjl Production Operatmg Procedure

Aneth Operations File Name AGCOMP

McElmo Creek Unit ACID GAS COMPRESSORS “A” and “B” Authorized

Gas Reinjection Facility Page 9 of 9

Equipment # CM-1201 A/B

2nd stage suction pressure 85 to 100 psig

2nd stage discharge pressure 400 to 410 psig

3rd stage suction pressure 395 to 410 psig

3rd stage discharge pressure 1150 to 1250 psig

4th stage suction pressure 1145 to 1250 psig

4th stage discharge pressure 2750 to 2950 psig

1st stage suction temperature 45 to 100 degrees F

1st stage discharge temperature 230 to 250 degrees F

2nd stage suction temperature 90 to 100 degrees F

2nd stage discharge temperature 270 to 280 degrees F

3rd stage suction temperature 110 to 125 degrees F

3rd stage discharge temperature 270 to 280 degrees F

4th stage suction temperature 110 to 125 degrees F

4th stage discharge temperature 270 to 280 degrees F

Lube oil pressure 45 to 55 psig

Jacket water pressure 20 to 25 psig

Crankcase lube oil pressure 60 to 90 psig
APPENDIX 4

Compressor Troubleshooting Guide
COMPRESSOR TROUBLESHOOTING GUIDE

ENGINE & FRAME SHUTDOWNS

Low Engine/Frame Oil Pressure

High Engine/Frame Oil Temperature 3

High/Low Intake Manifold Pressure 4

High Manifold Temperature 6

Lubricator No Flow 7

High Main Bearing Pressure/Temperature 8

Engine Overspeed 9

High Engine/Frame Vibration 10

II. COOLING SYSTEM SHUTDOWNS

Low Auxiliary Water Pressure 11

Low Coolant Level 12

Low Jacket Water Pressure 3

High Jacket Water Temperature 14

High Cooler Vibration 15

III. GAS CIRCUIT SYSTEM SHUTDOWS

High/Low Suction Pressure 16

High Scrubber Level 17

High/Low Interstage Pressure 19

HighlLow Discharge Pressure 20

High Discharge Pressure 21

IV. IGNITION & PANEL BOARD

Altronic Ignition 22

CEC Ignition 23

Ignition System 24

Panel Board Components 25
Shutdown on Low Engine/Frame Oil Pressure

Troubleshooting Guide

POSSLE CAUSE CORRECJVE ACTIONS

Low Oil Level (High I. Check oil level.

level can cause foaming, 2. Add oil as needed.

resulting in low 3. Restart unit.

pressure.)

Dirty Filters 1. Check differential pressure across filters, strainer and

cooler.

2. If differential pressure is high, replace filters and strainer;

clean cooler.

Oil Pump Malfunction 1. Stan unit.

2. Check for normal oil pressure at pumpout.

3. If oil pressure at pump out is low, oil pump is faulty;

• repair or replace as needed.

4. If air is present, change pump.

5. If oil pressure at header is normal, continue

F troubleshooting.

6. Check pump suction screen for obstruction.

• 7. If clogged. clean or replace screen.

Gauge Malfunction I. Use manometer (test gauge) to check panel gauges for

malfunction.

2. Check wiring and tattle tale; repair or replace as needed.

3. Calibrate or replace gauges as needed.

4. Check oil sensing line for pluggage.

Engine is Misfiring 1. Load unit.

• 2. Use digital or hand-held pyrometer (test gauge) to check

for misfires causing unit to bog down. (Statiscope or

timing light can be used, if pyrometer is not available.)

3. Check ignition: replace plugs or wire if necessar.

4. Check fuel system; adjust to specs.

Relief Valve Stuck I. Check relief valve setting and position.

Open or Set Too Low 2. Correct as needed,

High Oil Level Caused I. Check day tank water levels to see if there is a leak in

by Water/Liquid head, gasket or liner.

Dilution 2. Call Mechanic.
POSSIBLECAUSE•IZ

Low Oil Viscosity I. Change oil.

2. Check recent oil sample analysis results.

Unit Bogging Down I. Check chart or meters to verify that suction and discharge

are normal.

2. Check for proper oil level in governor.

3. Check for broken or loose linkage; repair or replace as

needed.

If low engine/frame oil pressure continues and you have taken all corrective steps,

call Mechanic.

2
Shutdown on High Engine/Frame Oil Temperature

Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

High Oil Level I. Check oil level.

2. Adjust oil level as needed.

Binding or Tightness in f 1. Roll engine and compressor by hand.

Compressor Engine 2. Check for binding or tightness.

3. If binding or tightness exist, notify Mechanic

immediately. Do NOT start unit.

4. If no binding or tightness is found, sian engine.

Dirty Oil Filters 1. Check differential pressure across filters.

;

2. Change filter if pressure drop exceeds ExxonMobil

parameters.

Clogged or Blocked Oil I. Check auxiliary water level.

Cooler 2. Add coolant as needed.

3. Check pressure and temperature differentials across

cooler.

4. Clean or replace oil cooler as needed.

Faulty Gauge I. Use test gauge or pyrometer to compare pressure and

temperature panel gauges.

2. Calibrate or replace gauge as needed.

3. Ensure kill setpoint is set to ExxonMobil parameters.

Amot Valve Not Letting 1. Replace amot valve.

Oil Into Cooler

t Broken Thermostat I. Scan piping for temperature variances.

2. Replace thermostat.

Engine Overload 1. Check engine load.

2. Check for misfires.

3. Check timing; adjust to engine specs.

Stuck Oil Thermostat I. Check for bypass around oil cooler.

2. Replace thermostat.

If high engine/frame oil temperature continues and you have taken all corrective

steps, call Mechanic.

3
Shutdown on High /Low Intake Manifold Pressure

Troubleshooting Guide

--POSSmLECAUSE CORRECTIVE ACTIONS

Faulty Timing 1. Start unit.

2. Use timing light to check timing.

3. Adjust magneto as needed to adjust timing.

4. Check drive for wear.

• Damaged Drive ii. Inspect drive coupling or figure 8 for damage.

: Coupling or Figure 8 2. Repair or replace drive coupling or figure 8 as needed.

Engine is Misfiring 1. Load unit.

2. Use digital pyrometer to check for cyLinder temperature

variances.

3. Check rpm and engine fuel pressure.

4. Use timing light to check plug firing.

. If plug is not firing, refer to “Panel Component

Troubleshooting Guide.”

• If plug is firing, continue to next step.

5. Tap on emission valve to see if it is stuck.

6. Use volt meter to check magneto voltage.

7. Check cannon plug and wiring harness.

8. Repair or replace parts as needed.

9. Check for liquid in fuel.

Ignition Problem I. Use volt ohm meter to check magneto voltage.

Note: Voltage should be 150-190 DC (Altronic III) or

120-125 DC (cm.

2. If you have an Aitronic III ignition, refer to “Altronic III

Ignition Troubleshooting Guide.”

3. If you have a CEC ignition, refer to “CEC Ignition

Troubleshooting Guide.”

Insufficient Fuel Supply I. Check fuel pressure at Fisher 99 and prechamber pressure

on Fisher 95.

2. Set pressure to ExxonMobil parameters or factory specs

as needed.

• 3. Check for liquid in fuel; drain fuel scrubbers or fuel

supply lines.

4. Check carburetors; repair or clean diaphragms.

5. Check complete fuel system; set to specs.

Faulty Wires or Coils I. Check plug wires, coils and all wiring.

2. Replace as needed.

4
POSSIBLE CAUSE CORRECTIVE ACTIONS

Engine Overload 1. Check chart or meter for engine overload (caused by

excess suction).

2. Start and load unit.

3. Check suction control valve for malfunction, causing

sudden increase in suction gas flow.

4. Contact client as needed.

‘ Gauge Malfunction 1. Use manometer to check panei gauges for malfunction.

2. Calibrate or replace gauges as needed.

!

Load Changes 1. Check meters or chart for flow changes.

(SuctionlDischarge 2. Check recycle and control valves; adjust if possible or

Pressure) notify client of possible problems.

Governor I. Check oil in governor; replace or add oil as needed.

MalfunctionlFaultv p 2. Check governor linkage and rod ends: repair or replace as

Linkage needed.

Panel Malfunction I Check panel gauges and tubing to panel for accuracy.

2. Check tubing for obstruction or leak.

3. Replace gauges/tubing as needed.

! Turbo Malfunction I. Check thrust by hand: measure turbo output and balance

banks.

I 2. Replace turbo if thrust is out.

Compressor Packing 1. Check packing.

Leaks 2. Replace packing if leaks are present.

If high/low intake manifold pressure continues and you have taken all corrective

steps, call Mechanic.

5
Shutdown on High Manifold Temperature

Troubleshooting Guide

POSSIBLE CAUSE COU1ECT1VE ACTIONS

Low Auxiliary Water L Check auxiliary water level.

Level 2. Add coolant as needed.

3. Check for water on skid, indicating cracked pipe/hose or

loose connection.

4. Check louvers; adjust as needed.

Belt/Pump Malfunction I. Check auxiliary water pump and belts.

2. Repair or replace as needed.

Auxiliary Water High I. Start and load unit.

F Temperature or Low 2. Check gauge for auxiliary water pressure.

Pressure 3. If there is low pressure, replace water pump.

4. Use pyro scarmer to check differential temperature across

intercooler.

• If differential temperature is high, inspect and clean

intercooler.

5. Check for air lock in system; bleed air from system.

6. Check main cooler system; check for proper valve

position; clean cooler as needed.

Gauge Malfunction I. Use manometer (test gauge) to check panel gauges for

malfunction.

2. Calibrate or replace gauges as needed.

Fuel is Too Rich I. Adjust fuel system using oxygen meter.

2. Check for liquid.

Engine is Overloaded I. Check manifold pressure with engine running.

2. Check for gas flow changes.

Wrong Timing Setting I I. Check timing and adjust if needed.

Intake Valve Leak I. Check individual inlet temperatures to check for leaks.

2. Repair leaks as needed.

Mechanic.

If high manifold temperature continues and you have taken all corrective steps, call

6
Shutdown on Lubrication No Flow

Troubleshooting Guide

. POSSIBLE CAUSE CORRECTIVE ACTIONS

Insufficient Oil in 1. Check oil in lube box.

Lubricator Box 2. Check oil regulator supply to lube box.

3. Repair or replace oil regulator supply in lube box as

needed.

Broken Lubricator I. Ensure gear drive and all couplings are not broken or

Drive stripped.

2. Replace drive coupling or chain as needed.

Faulty Lubricators l. Ensure all lubricators are pumping the proper amount of

I I lubrication drops per minute.

2. Prime or replace lubricator as needed.

Blown Rupture Disc 1. Disconnect lubricator lines at cylinders.

2. Prime Lubricator System with Trebon Gun.

I 3. If rupture disc continues to blow, replace distribution

block and cylinder check valves.

Faulty No-Flow Switch I Check lubricator no-flow switch for sensitivity.

, 2. Adjust sensitivity setting to manufacturer’s

specifications.

3. Use volt ohm meter to inspect no-flow switch for wiring

short.

4. Replace wiring as needed.

5. If grounded wire cannot be found, refer to “Panel

j Component Troubleshooting Guide.”

If no lube flow continues and you have taken all corrective steps, call Mechanic.

7
Shutdown on High Main Bearing Pressure/Temperature

Troubleshooting Guide

POSSIBLE CAUSE COIU{EC’TDTE ACTIONS I Main Bearing Switch 1 Use Trebon gun to pressure probe header at switch to 25Z

Malfunction 45 psi. Hold 30 seconds.

• If pressure does not hold, do NOT start unit; skip to

the main bearing probe rupture (below).

i • If pressure holds, inspect switch for wiring short or

proper contact.

2. Adjust setpoint of main bearing switch.

3. Start unit panel should clear immediateiy.

Main Bearing Probe I. Do NOT stan unit.

Rupture 2. Notify Mechanic immediately for probe replacement and

bearing inspection.

Engine Bogging Down 1. Check setpoint on switch; set to specs or ensure setpoint

is lower than engine oil pressure kill setpoint.

2. Check’ignition and fuel settings; set to specs.

3. Check timing and set to specs.

If high main bearing temperature continues and you have taken all corrective steps, call Mechanic.

8
Shutdown on Engine Overspeed

Troubleshooting Guide

POSSIBLE CAUSE CORRECTWE ACTIONS

Tachometer 1 Start engine and idle.

Malfunction 2. Cheek magneto voltage with volt ohm meter.

3. If voltage is high or low, inspect magneto for possible

malfunction.

4. If magneto is malfunctioning, repair or replace as needed.

5. If voltage is normal, load unit.

6. Use timing light with digital display to determine

tachometer accuracy.

7. Replace tachometer if accuracy is still in doubt.

8. Check cannon plug in mag back.

Speed Controller I. Inspect speed controller gauges for proper supply and

Malfunction output.

2. If low supply or output, inspect, repair and/or replace

gauges or regulator.

Governor Malfunction 1. Check oil level in governor.

2. Add oil as necessary.

3. Check governor linkage. !

4. Replace governor rod ends as needed.

5. Bleed governor or adjust compensating needle to

eliminate engine surge.

Old Style Overspeed 1. Inspect wiring with volt ohm meter.

Switch Malfunction 2. Replace wiring as needed.

3. Inspect overspeed switch for malfunction or short.

4. Replace switch.

Load Reduction 1. Ensure suction/discharge pressures are within normal

ranges. -

2. If reduced load is present and unit is running too fast,

slow unit to proper rpm; determine cause of load change;

inspect pressure kills for proper setting.

If engine ovenpeed continues and you have taken all corrective steps, call Mechanic.

9
Shutdown on High Engine/Frame Vibration

Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVEACTIONS

Loose Mounting Bolts I. Check bolts.

2. Tighten as needed.

3. If engine or frame mounts are Loose, call Mechanic for

alignmentldeflection checks.

Vibration Switch I. Roll unit over by hand 4-5 revolutions.

Tripped 2. Check for binding or noise.

3. Ensure start switch and fuel are off.

4. Roll engine over with starter.

; 5. Listen for unusual knocking or noise.

6. Reset vibration switch. : 7 Ensure no liquid is present in fuel to cause detonation: .

drain fuel scrubber and check carburetor as needed.

8. Clear panel.

9. Start up unit.

Vibration Switch to Set 1. Check-sensitivity setting.

Too Sensitive 2. Adjust as needed.

Short in Wire to Panel I. Check panel:

. If panel clears, load unit and monitor closely.

! • If panel does not clear, continue to next step.

2. Use volt meter to located grounded wire.

3. Replace wire.

4. If grounded wire carmot be found, refer to “Panel

Component Troubleshooting Guide.”

Broken Valve, Piston or I. Pull valve caps and inspect or replace valves as

Piston Rod necessary.

2. Pull head and inspection doors; inspect crosshead, rod,

rod nut and piston.

3. Repair or replace parts as needed.

‘ High Scrubber Level I. Check scrubber for high liquid level.

2. If liquid is found, replace level controller and repair

dump valves.

If high engine/frame vibration continues and you have taken all corrective steps, call

Mechanic.
Shutdown on Low Auxiliary Water Pressure

Troubleshooting Guide

If low auxiliary water pressure continues and you have taken all corrective steps,

call Mechanic.

. POSSIBLE CAUSE CORRECTIVE ACTIONS

[ Low Coolant Level 1. Check coolant level; add coolant as needed.

2. Check for leak on skid; repair leak as needed.

EWater Pump/Belt 1. Visually inspect auxiliary water pump and belt for wear

Failure and leaks.

2. Replace pump and/or belt as needed.

Blockage in Intercooler I. Start engine. !

2. Check differential temperature and pressure across

intercooler.

• If temperature differential is high or pressure

differential is low, inspect intercooler for possible

blockage.

Faulty Gauge 1. Use test gauge to test auxiliary water pressure.

2. Verify pressure on panel board gauge.

3. Calibrate or replace gauge as needed.

Air in System 1. Bleed out on highest point of system and at the top of

pump.

2. Check seal in water pump; replace pump as needed.

II
Shutdown on Low Coolant Level

Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS..

Gauge Cocks on Sight 1. Ensure gauge cocks on sight glass are open and you have

Glass are Closed true coolant tank reading.

Coolant Leaks I. Check for loose hoses, fittings or piping causing coolant

leaks; repair or replace as needed.

2. Check for leak on skid; repair leak as needed.

3. Check for leaking water ump seal; change water pump if

seal is leaking.

Malfunctioning Level 1. Check level controller float.

Controller on Surge • If floatis not intact, replace.

• Tank 2. Check micro-switch on level controller.

• Replace micro-switch if defective.

3. Use volt ohm meter to check for shorts in wire.

• Replace wire as needed.

Internal Leaks I. Check crankcase for coolant.

2. Check for head gasket or liner leaking into base.

3. Repair leaks as needed.

If low coolant level continues and you have taken all corrective steps, call Mechanic.

12
Shutdown on Low Jacket Water Pressure

Troubleshooting Guide

POSSIBLE CAUSE CO1U{ECTWE ACTIONS

Low Coolant Level 1. Check coolant level. El

2. Add coolant to proper level as needed.

3. Check for leak on skid; repair leak as needed.

r

4. Check hoses; repair or replace as needed.

Water Pump/Belt fl I. Visually inspect water pump and belts for wear or leaks.

Failure 2. Replace pump/belts as needed.

3. Check for coolant leak; check engine base for coolant

leak.

4. Repair any leaks found.

5. Start unit.

6. Check jacket water pressure.

. If pressure is low, use test gauge to verify panel gauge

accuracy.

• If pressure is low, replace water pump or belts as

needed.

7. Check hoses/couplings on pump inlets.

. Repair/Replace parts as needed.

Faulty Gauge I. Use test gauges to check panel gauges for accuracy.

2. If panel gauge is inaccurate, calibrate or replace gauge.

Faulty Valve Position I. Ensure proper inlet/outlet valve position.

Cracked Head, Head I. Check crankcase oil level.

Gasket or Liner 2. Check for water in crank case.

3. Drain oil and check for leaking liner.

• If leak is found, repair/replace parts as needed.

Air Trapped in System 1. Bleed air at highest point on system.

2. Replace radiator cap with new one.

Plugged/Dirty Cooler 1. Clean cooler coils as needed.

If low jacket water pressure continues and you have taken all corrective steps, call

Mechanic.

13
Shutdown on High Jacket Water Temperature

Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Low Coolant 1. Check coolant level.

2. Add coolant to proper level as needed.

3. Check for leak on skid; repair leak as needed.

Water Pump or Belt 1. Visually inspect water pump, water belts and cooler fan

Failure, belts for wear or leaks.

2. Replace pump or belts as needed.

Faulty Gauge 1. Start engine.

2. Use test gauges or pyro scanner to check water pressure

and temperature gauges.

3. Calibrate or replace gauge as needed.

Low Temperature I. Ensure proper louver position.

Differential on Cooler 2. Check cooler fins for possible blockage.

Caution: Use proper lock/tag procedures if you must

enter cooler.

3. Remove blockage or wash cooler fins.

4. Check tubes for scale obstructions; clean as needed.

Incorrect Ignition I. Check ignition timing.

Timing 2. Advance or retard timing to ExxonMobil parameters as

necessary.

Overload Detonation I. Check manifold pressure.

2. Check oxygen setting.

3. Check suctionidischarge pressures for changes in load or

‘ gas flow.

Sticking Thermostats I. Use pyro scanner on each side of thermostat if possible.

2. Remove thermostats and test in hot water.

: 3. Repair/replace thermostats as needed.

Fan Blades Need I. Check pitch on fan blades: torque to specs.

Adjustment

Incorrect Antifreeze I. Determine if antifreeze is mixed correctly.

Mixure 2. Check freeze point and pH levels; drain/replace

antifreeze as needed.

If high jacket water temperature continues and you have all corrective steps, call

Mechanic.

14
Shutdown on High Cooler Vibration

Troubleshooting Guide

POSSIBLECAUSE [ CORRECTIVE ACTIONS

Loose Mounting Bolts fl. Check bolts.

• 2. Tighten as needed.

Vibration Switch 1. Roll unit over by hand 4— 5 revolutions.

Tripped 2. Cheek for binding or noise.

3. Ensure start switch and fuel are off.

j 4. Roll engine over with starter.

5. Listen for unusual knocking or noise.

6. Reset vibration switch.

7. Clear panel.

8. Start up unit.

Vibration Switch is Set fl. Check sensitivity setting.

Too Sensitive 2. Adjust as needed.

Mechanical 1. Visually inspect belts and cooler blades to see ifthey are

Malfunction loose or damaged.

Caution: To prevent injury, use lock-out/tag-out

procedure ifyou must enter cooler.

2. Tighten. repair or replace belts, bearings or blades.

Wiring or Vibration 1. Start unit.

Switch Malfunction 2. Check panel.

3. If panel does not clear, use volt meter to locate grounded

wr

4. Replace wire as needed.

5. If grounded wire cannot be found, refer to “Panel

Component Troubleshooting Guide.”

Loose Fan Blades I. Replace fan blades as needed.

2. Check torque; retorque bolts and check blades for proper

angle.

If high cooler vibration continues and you have taken all corrective steps, call

Mechanic.

15
Shutdown on High/Low Suction Pressure

Troubleshooting Guide

POSSIBLE. CAUSE CORRECHVE ACTIONS.

Suction Control Valve 1. Start and load unit.

Malfunction 2. Compare suction pressure to reading on previous

Operator Report.

3 Check custody charts for high or low suction condition.

4. Adjust control valve or notify client of control valve

problem.

Faulty Gauges 1. Use test gauges to check panel gauges for accuracy.

2. Calibrate or replace gauges as needed.

Frozen, Plugged or I. Thaw sensing lines with methanol.

Broken Lines Use extreme caution when using methanoL Wear

appropriate ppe.

2. Replace broken tubing.

Dump Valve Hung 1. Check scrubber dumps.

Open 2. Reset dump controller.

Recycle Malfunction 1. Check recycle valve operation.

2. Adjust as needed for proper setting.

Client Production 1. Check separator pressure.

Equipment Problems 2. Look for possible equipment problems; notify Field

Reliability Specialist as needed.

Intake Screen or Filter 1. Check differential pressure across filter/screen.

Plugged 2. Change/Clean filter/screen as needed.

If highilow suction pressure continues and you have taken all corrective steps, call

Mechanic.

16
Shutdown on High Scrubber Level

Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Closed Sight Glass I. Ensure sight glass gauge cDcks are open.

Gauge Cocks 2. Check for level in sight glass.

3. If there is no level, adjust controller as needed to

maintain level.

Level Controller I. Ensure level controller has adequate air supply and

Malfunction gas/air output pressure to dump valve.

2. Check supply regulator for malfunction.

. Repair or replace regulator if necessary.

3. Ensure level controller is working properly.

4. Check controller pans; tighten or replace as needed.

Blockage in Dump I. Check output to dump valve.

Valve 2. Ensure dump valve is operational.

3. Remove any blockage in valve.

4. Check for trapped pressure; relieve trapped pressure

SLOWLY if possible.

Frozen Dump Lines I. Check dump line for freezing.

2. Warm lines as needed.

: Caution: Use extreme caution when warming lines as

high pressure is trapped in lines.

3. Check for trapped pressure; relieve trapped pressure

SLOWLY if possible.

High Level Shutdown 1. Ensure float on high level shutdown is intact.

Malfunction • If flowat is not thtacL replace float.

2. Inspect micro-level switch in high level shut-down

switch.

• Replace shut-down switch as needed.

Short in Wiring 1. Reset panel.

2. If panel will not clear, check for short in wire; replace

wire from high level shut-down switch.

3. If grounded wire cannot be found, refer to “Panel

Component Troubleshooting Guide.”

‘7
POSSIBLE CAUSE CORRECTIVE ACTIONS

Valve Off Skid is Closed 1. Trace piping off skid to find possible closed valve.

2. Open valve if closed.

3. Check for trapped pressure; relieve trapped pressure

SLOWLY if possible.

Plugged Dump Line 1. Unscrew piping and remove obstruction if possible.

2. Run coiled cleaner in line.

3. Check for trapped pressure; relieve trapped pressure

! SLOWLY if possible.

Liquid Carryover in I. Drain customer’s air or supply gas.

Scrubber

High Pressure in IL. Ensure pressure of vessel being dumped into is lower

Customer Tank or than pressure of fluid being dumped.

Scrubber

If high scrubber level

Mechanic.

continues and you have taken all corrective steps, call

18
Shutdown on High/Low Interstage Pressure

Troubleshooting Guide

I POSSIBLE CAUSE CORRECTIVE ACTIONS

Faulty Valve or Rings I. Start and load unit.

2. Use pyro scanner to check for hot valves or rings.

3. Repair or replace as needed.

Gas Leak 1. Check for relief valve venting.

2. Ensure relief valve socks are in place.

3. Inspect relief valves for possible malfunction.

j

4. Reset or replace relief valves as needed.

: Frozen Cooler or 1. Adjust louvers to waun gas.

Tubing to Panel Gauges 2. Inject methanol into tubing lines.

Caution: Use extreme caution with methanol; high

pressure may be trapped in tubing; wear appropriate

ppe.

Faulty Gauges I. Use test gauge on interstage scrubber to test accuracy

:• against panel board gauge.

2. Calibrate or replace gauges and set kill.

Dump Valves Hung in I. Ensure dump valves ae in closed position.

Open Position 2. Set dump controller for proper.

Load Change 1. Check reycle valve for proper operation; reset as needed.

2. Check meters for flow changes; set kill switch to proper

setting.

If high/low interstage pressure continues and you have taken all corrective steps,

call Mechanic.

19
Shutdown on High/Low Discharge Pressure

Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

High Dehy or Rack 1. Check chart or meter run for discharge pressure.

Pressure 2. If high pressure, contact client to determine cause.

Frozen Pipes or 1. Open blowdown to release discharge pressure to

Equipment atmosphere.

2. If nothing exits blowdown, close louvers as needed to

warm the cooler.

3. Check pressure on panel gauge to ensure pressure is

released.

4. Check for frozen tubing lines:

• Disconnect tubing.

• Inject methanol into line.

Caution: Use extreme caution with methanol; high

pressure may be trapped in tubing.

5. Warm pipes as needed.

Relief Valve I. Check relief valve setting.

Malfunction 2. Ensure relief valve socks are in place.

3. Repair or replace relief valve or socks as needed.

Gauge Malfunction I. Use manometer (test gauge) to check panel gauges for

malfunction.

2. Calibrate or replace gauges as needed

Short in Wire in Panel I. Check panel:

• If panel clears, load unit and monitor closely.

. If panel does not clear, continue to next step.

2. Use volt meter to locate grounded wire.

3. Replace wire.

Bad Valves or 1. Ensure temperatures and pressures are within normal

Compressor Ring ranges.

2. If temperatures and pressures are abnormal, inspect for

bad valves, piston rings or piston.

3. Repair/replace parts as needed.

Broken Piping 1. Inspect piping for leaks; repair/replace piping as needed.

Recycle/Dump Valve I. Check recycle/dump valves; adjust as needed.

Malfunction

If high/low discharge pressure continues and you have taken all corrective steps, call

Mechanic.

20
Shutdown on High Discharge Temperature

Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Hot Valves 1. Load unit.

2. Pyro scan valve caps.

3. Repair or replace valves as needed.

High Interstage 1. Check louver position on cooler.

Temperature 2. Open louvers as needed to cool gas.

3. Check cooler fins for dirt, dust or other obstructions.

Faulty Gauges I. Use test gauges on suction/discharge pressure.

2. Calculate suction/discharge temperatures.

3. Calibrate or replace gauges as needed.

Inadequate Lubrication I. Check lubricator for proper cyliner lubrication.

2. Increase output or replace lubricator as needed.

Cylinder Piston Ring I. Inspect cylinder piston rings.

Damage 2. Replace piston rings as needed.

Low Suction Pressure 1. Check recycle load changes; reset recycle valve.

2. Check suction pressure; calibrate discharge temperature

and set kill to proper setting.

High Recycle Rate 1. Check recycle valve and flow.

2. Make adjustments as needed.

If high discharge temperature continues and you have taken all corrective steps, call

Mechanic.

21
Altronic III Ignition Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Faulty Harness Wire 1. Set volt ohm meter to ohms.

2. Disconnect power harness from ignition module.

3. Thoroughly check each harness wire for continuity.

• If wires are good, skip to “Faulty Mag Back.”

• If bad wire is found, change cannon Plug and harness.

4. Start Unit. If unit will not start, continue.

5. Check all terminals for proper grounding.

6. Replace bad electrical connections.

Faulty Mag Back (Back I. Set volt ohm meter to DC and check voltage.

Plates) Nose: Vollage should be 150-190 DC

a If voltage does not meet requirements, change mag

back (back plates).

2. Start Unit. If unit will not start, call Mechanic.

Bad Mag Back Drive 1. Check condition of drive gear teeth.

Gear 2. If teeth are missing, change figure 8.

3. Change coupling disc.

Broken Roll Pin in 1. Replace roll pin and damaged parts.

Figure 8 or Flange 2. Change mad drive adapter.

Mount

Oil in Magneto 1. Change seal or magneto (bad mag drive seal on flange

mount).

Faulty Wires, Plug or I. Visually inspect all wires, plugs and coils.

Coils 2. Replace any that are damaged.

Faulty Mag 1. Check for proper mag and backs.

2. Check mag drive.

3. Repair or replace as needed.

22
CEC Ignition Troubleshooting Guide

POSSIBLE CAUSE- COREECTIVEACTIONS

Faulty Generator or I. Disconnect generator wires to regulator.

Magneto Discs 2. Set volt ohm meter to volts AC and check voltage.

• If voltage meets requirements, skip to “Faulty

Regulator.”

3. Check condition of drive discs.

• Replace discs as needed.

• If discs are okay, replace generator.

4. Start unit. If engine will not start, continue to

troubleshoot.

Faulty Regulator 1. Reconnect wires from generator to regulator.

2. Disconnect -f/_ wires from regulator to ignition module.

3. Roll engine over.

4. Set volt ohm meter to volts DC and check voltage out of

regulator.

Note: Voltage should be 10-32 DC

. If voltage does not meet requirements ,change

regulator.

5. Start unit. If engine will not start, continue to

troubleshoot.

Faulty Harness Wire I. Set meter to ohms.

2. Disconnect power harness from ignition module.

3. Thoroughly check each harness wire for continuity.

• If wires are good. skip to “Faulty Harness or Ignition

Module.”

• If bad wire is found, change cannon Plug and harness.

4. Start unit.

• If engine will not start, continue to troubleshoot.

Faulty Harness or I. Set meter to volts DC and check voltage.

Ignition Module Note: Voltage should be at least 120 volts DC

2. If voltage doen not meet requirements, change ignition

module.

3. Start unit. If engine will not start, notify Mechanic.

Connection Box Wire I. Inspect for loose wires or connections.

are Loose 2. Tighten or replace wires as needed.

23
APPENDIX 5

Spare Parts List - HOS 4

Spare Parts List - HOS 6
SPARE PARTS LIST

MeElmo Creek

Spare Critical Machinery Equipment

MeElmo Creek Unit HOS 4 Spare Parts List

Compressor f Compressor Suction/Discharge Valves

Ldi Filters

Lubricator Parts

Electric Motor Driver Thermocouples

Vibration Probes

Cooler V-Belts

Pulleys

: Gaskets and Seal Pins

Instruments and Controls Temperature Switches

Pressure Switches

Instrument Tubing

Position Indicators

Pressure Gauges

Thermometers

* These parts are housed in a multipurpose building on site. The inventory of spares is

maintained by logging any part removed arid initiating a purchase requisition to replace

the part.
SPARE PARTS LIST

MeElmo Creek Unit HOS 6 Spare Parts List

Compressor Compressor Suction/Discharge Valves

Piston Rings

Piston Rods

Gaskets

Packing Gland Assembly

Crosshead Assembly

Oil Filters

Lubricator Parts

Electric Motor Driver Thermocouples

Vibration Probes

Cooler V-Belts

Pulleys

Gaskets and Seal Pins

; Instruments and Controls Temperature Switches

Pressure Switches

Instrument Tubing

Position Indicators

Pressure Gauges

Thermometers

* These parts are housed in a multipurpose building on site. The inventory of spares is maintained

by logging any part removed and initiating a purchase requisition to replace the part.