McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01

APPENDIX A

MCELMO CREEK UNIT

OPERATIONS & MAINTENANCE PLAN

September 2016

This document shall apply to the owner(s) and operator(s) of the McElmo Creek

Unit Oil Production Facility, including Resolute Natural Resources Company, 

LLC.
Operations & Maintenance Plan 

McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

Page 1 of 9

MCELMO CREEK UNIT OPERATIONS & MAINTENANCE PLAN

PSD Permit No. NU 05-01, Appendix A

Table of Contents

1. PURPOSE.................................................................................................2

2. PROCESS OVERVIEW ............................................................................2

2.1 Inlet Separation...................................................................................................2

2.2 Compression.......................................................................................................2

2.3 Re-Injection.........................................................................................................3

3. ROUTINE MONITORING & SURVEILLANCE ........................................3

4. MAINTENANCE PLAN.............................................................................4

4.1 Periodic Maintenance .........................................................................................4

4.2 Predictive Maintenance......................................................................................5

4.3 Equipment Life Cycle and Overhaul Schedule ....................................................5

4.4 Life Cycle Maintenance Model ............................................................................6

5. TRAINING PROGRAM FOR PLANT OPERATORS ................................6

5.1 New Operations Personnel – No Prior MCU Facility Gas Compression Plant

Experience..........................................................................................................6

5.2 Operations Personnel with Prior Plant Experience (Out of the MCU Facility Gas 

Compression Plant more than 1 year).................................................................7

5.3 Operator Training on PSD Permit .......................................................................8

6. REFERENCE DOCUMENTATION ...........................................................8

ATTACHMENTS

A-1 Life Cycle Maintenance Plan HOS 6, HOS 4, and Ariel C-5

A-2 Daily Plant Reading Form

A-3 Isolation and Operating Procedures HOS 6, HOS 4, Acid Gas B, and Ariel C-5

A-4 Compressor Troubleshooting Guide

A-5 Spare Parts List for HOS 6, HOS 4, and Ariel C-5
Operations & Maintenance Plan 

McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

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1. PURPOSE 

This operation and maintenance plan (O&M Plan) contains the operating procedures, 

routine monitoring and surveillance, maintenance plan, and training program for plant 

operators for the McElmo Creek Unit Oil Production Facility (MCU Facility) gas 

compression plant.

2. PROCESS OVERVIEW

The MCU Facility gas compression plant serves tertiary recovery operations for the 

McElmo Creek Field. The gas compression plant receives produced gas through a 

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

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 gas compression plant inlet volume 

can vary between 10 and 24 million standard cubic feet per day (MMSCFD).

The gas is processed in three main steps: (1) inlet separation, (2) compression, and 

(3) re-injection.

2.1 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.

2.2 Compression

The gas compression plant houses the following five (5) compressors:

Compressor Operating Status

Acid Gas A Nonoperational

Acid Gas B Operational

Aerial C-5 Operational

HOS-4 Operational

HOS-6 Operational

Acid Gas B, Aerial C-5, HOS-4, and HOS-6 are high-speed electrically-driven 

reciprocating compressors. Aerial C-5, HOS-4, and HOS-6 are the primary facility 

compressors. 

Acid Gas B is a smaller unit and is only used for backup and excess throughput. Acid 

Gas A is non-functioning and uneconomical to return to service. It remains at the plant 

as a source of spare parts for the Acid Gas B compressor.
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McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

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The compressors provide approximately 8,000 combined brake horsepower (BHP) and 

each compressor consists of four or five compression stages which raise the pressure 

of the incoming gas from 40 psig to 2,900 psig. Each stage has a dedicated aerial 

cooler and liquid scrubber vessel. Inter stage dehydration takes place to remove water 

for corrosion mitigation on the HOS-6 compressor. 

Operations, maintenance and isolation procedures for Ariel C-5, HOS 4, and HOS 6 

compressors are included as attachments to this O&M Plan (see the Life Cycle 

Maintenance Plan in Attachment A-1, and the Isolation and Operation Procedures in

Attachment A-3 of this O&M Plan). Operating and isolation procedures are included for 

the Acid Gas B compressor. However, a separate maintenance table has not been 

developed for the Acid Gas B compressor because it is only capable of handling 1.6 

MMCF/day and was never intended to be part of the primary process train at the facility.

2.3 Re-Injection

The compressor units discharge into a single header, where purchased carbon dioxide 

(CO2) is co-mingled to achieve a daily injection rate of up to 24 MMSCFD. The gas is 

then distributed to the field. 

During gas compression plant upsets or compressor downtime events, a portion or all of 

the inlet volume to the gas compression plant is automatically diverted to flare until the 

problem is corrected.

3. ROUTINE MONITORING & SURVEILLANCE

The gas compression 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:

• Overall gas compression plant inlet and discharge volumes

• CO2 purchased volumes

• Flared volumes

• Discharge pressure

• Compressor run times

From the operator’s daily run time report (see Daily Plant Reading Form in Attachment 

A-2 of this O&M Plan), 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 Resolute Natural 

Resources Company, LLC and original equipment manufacturer (OEM) standards

(e.g., compressor suction and discharge temperatures and pressures, or scrubber liquid 
Operations & Maintenance Plan 

McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

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levels).

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

maintenance plan and operating procedures (see the Life Cycle Maintenance Plan in 

Attachment A-1 of this O&M Plan, and the Isolation and Operation Procedures in 

Attachment A-3 of this O&M Plan). The operators are very familiar with prescribed

operating limits, as this is part of their training. If the operator observes a parameter

that is out of specification, appropriate corrective action is performed. 

4. MAINTENANCE PLAN

Resolute Natural Resources Company, LLC utilizes a Rotating Equipment Engineer to 

assess ongoing reliability improvements, including oversight of the following items:

• Periodic maintenance that will be performed on the equipment.

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

• Equipment life cycle

• Overhaul schedule

• Spare parts inventory

Attachment A-1 of this O&M Plan contains specific tasks that comprise the Life Cycle 

Maintenance Plan for the primary facility compressors Aerial C-5, HOS-4, and HOS-6. 

The Life Cycle Maintenance Plan includes periodic maintenance, predictive 

maintenance, equipment life cycle and overhaul schedules which describes the various 

levels of maintenance for the primary plant compressors. 

The Acid Gas A compressor is mentioned in the maintenance plan, but is not addressed 

in Life Cycle Maintenance Plan in Attachment A-1 of this O&M Plan because it is nonfunctioning, and remains at the plant as a source of spare parts for the Acid Gas B 

compressor.

The Acid Gas B compressor is also included in the maintenance plan, but is also not 

addressed in Life Cycle Maintenance Plan in Attachment A-1 of this O&M Plan because 

it is only capable of handling 1.6 million cubic feet per day (MMCF/day) and was never 

intended to be part of the primary process train at the facility.

4.1 Periodic Maintenance

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

performed by the Plant Operator and in addition to monitoring process parameters 

and plant mechanics the following daily equipment checks are made:

• The compressor piping, inter stage coolers and block valves and 

compression valves are inspected for fluid leaks;
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McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

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• Oil and water levels are monitored;

• Vibration levels on the motors and compressor frames are monitored; and

• 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; and

• 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 periodic maintenance frequencies that extend past a year, such 

as coolant replacement and lube oil replacement. The Rotating Equipment Engineer 

decides if this work is required.

4.2 Predictive Maintenance

The Rotating Equipment Engineer assesses predictive maintenance which involves 

performing detailed inspections for internal wear. The inspections reveal the remaining 

life of a compressor component. Some examples of the 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.

4.3 Equipment Life Cycle and Overhaul Schedule

The Rotating Equipment Engineer determines the life cycle for the compressors. This 

life cycle information and the data taken during the predictive maintenance are used to 

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 
Operations & Maintenance Plan 

McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

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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. 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.

4.4 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 crankcase lubricant for effects of degradation.

LEVEL 3 - CONDITION MONITORING PREDICTIVE MAINTENANCE 

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

energy utilization.

LEVEL4 - INTERMEDIATE INTERVENTION PREVENTIVE MAINTENANCE 

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

invasive, downtime required.

LEVEL 5 - PREEMINENT INTERVENTION PREVENTIVE MAINTENANCE 

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

and driven equipment. This includes a suite of maintenance task considerations and 

milestone targets that are subject to the Predictive Maintenance Process review prior to 

execution.

LEVEL 6 - ZERO HOUR TURNAROUND PREVENTIVE MAINTENANCE 

Scheduled overhaul of driver and replacement of major wear components. This includes 

a suite of maintenance task considerations and milestone targets that are subject to the 

Predictive Maintenance Process review prior to execution.

5. TRAINING PROGRAM FOR PLANT OPERATORS

5.1 New Operations Personnel – No Prior MCU Facility Gas Compression Plant

Experience

The plant training for new operations persons with no prior MCU Facility Gas 
Operations & Maintenance Plan 

McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

Page 7 of 9

Compression 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:

o Plant operation, start up, shutdown and emergency procedures;

o Surveillance requirements for plant operations personnel;

o First line maintenance responsibilities;

o Regulatory requirements. such as upset reporting and regulatory 

documentation;

o Required safe work practices, permits and methods used; and

o 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.

5.2 Operations Personnel with Prior Plant Experience (Out of the MCU Facility 

Gas Compression Plant more than 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; and

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

required to approve the trainee for release from the training program.
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McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

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5.3 Operator Training on PSD Permit

Operators will be trained on the following sections of the Permit. New operators will be 

trained on these sections as part of their overall plant training while Permit is in effect:

6. REFERENCE DOCUMENTATION

The following documentation is readily available at the facility:

• Original Equipment Manufacturer (OEM) maintenance manuals for each unit.

• Piping and instrument diagrams (P&IDs) for the MCU Facility gas 

compression plant.

• Operating limits tables for each compressor, compiled from OEM 

recommendations and Resolute Energy practices.

• All operator log sheets. (See Daily Plant Reading Form in Attachment A-2 of 

this O&M Plan)

PSD Permit Section Section Name Duties

IX.C. Emission Limitations

Emission limits as it relates 

to their duties

IX.D. Main Flare Operational 

Requirements

IX.E Monitoring, Testing, and 

Emissions Calculations

Monitoring as it relates to 

their duties

IX.F Operation and Maintenance of 

Main Flare and Compressors

Operation and 

maintenance of the Main 

Flare and compressors as 

it relates to their duties Appendix A O&M Plan

IX.G Root Cause Analysis

Root cause analysis as it 

relates to their duties IX.H Corrective Action

Appendix B Root Cause Failure Analysis 

Program

V Right to Entry Right of Entry as it relates 

to their duties
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McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01, Appendix A

September 2016

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• Startup, Isolation and Operating Procedures for Compressors HOS-6, HOS-4, 

Aerial C-5, and Acid Gas B. (See Isolation and Operating Procedures in 

Attachment A-3 of this O&M Plan)

• Compressor Troubleshooting Guide (See Compressor Troubleshooting Guide

in Attachment A-4 of this O&M Plan)
McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01

MCELMO CREEK UNIT OPERATIONS &

MAINTENANCE PLAN

ATTACHMENT A-1:

LIFE CYCLE MAINTENANCE PLAN

Routine Monitoring & Preventative Maintenance Plan for 

Compressors HOS-6, HOS-4, & Aerial C-5

September 2016
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 1 of 16

LIFE CYCLE MAINTENANCE PLAN

Routine Monitoring & Preventative Maintenance Plan

for Compressors HOS-6, HOS-4, & Aerial C-5

Table of Contents

1. HOS-6 MAINTENANCE PLAN................................................................................. 2

1.1 LEVEL 1 - HOS-6 OPERATION SURVEILLANCE....................................................... 2

1.2 LEVEL 2 - HOS-6 SERVICE TIME BASED TESTING ................................................. 2

1.3 LEVEL 3 - HOS-6 CONDITION MONITORING............................................................ 3

1.4 LEVEL 4 - HOS-6 INTERMEDIATE INTERVENTION.................................................. 4

1.5 LEVEL 5 - HOS-6 PREEMINENT INTERVENTION ..................................................... 5

1.6 LEVEL 6 - HOS-6 ZERO HOUR OVERHAUL.............................................................. 6

1.7 LEVEL 7 - HOS-6 PERFORMANCE ENHANCEMENTS.............................................. 6

2. HOS-4 MAINTENANCE PLAN................................................................................. 7

2.1 LEVEL 1 - HOS 4 OPERATION SURVEILLANCE....................................................... 7

2.2 LEVEL 2 - HOS 4 SERVICE TIME BASED TESTING.................................................. 7

2.3 LEVEL 3 - HOS 4 CONDITION MONITORING............................................................ 8

2.4 LEVEL 4 - HOS 4 INTERMEDIATE INTERVENTION .................................................. 9

2.5 LEVEL 5 - HOS 4 PREEMINENT INTERVENTION ....................................................10

2.6 LEVEL 6 - HOS 4 ZERO HOUR OVERHAUL .............................................................11

2.7 LEVEL 7 - HOS 4 PERFORMANCE ENHANCEMENTS.............................................11

3. ARIEL C-5 MAINTENANCE PLAN ........................................................................ 12

3.1 LEVEL 1 - ARIEL C-5 OPERATION SURVEILLANCE................................................12

3.2 LEVEL 2 - ARIEL C-5 SERVICE TIME BASED TESTING ..........................................12

3.3 LEVEL 3 - ARIEL C-5 CONDITION MONITORING.....................................................13

3.4 LEVEL 4 - ARIEL C-5 INTERMEDIATE INTERVENTION...........................................14

3.5 LEVEL 5 - ARIEL C-5 PREEMINENT INTERVENTION ..............................................15

3.6 LEVEL 6 - ARIEL C-5 ZERO HOUR OVERHAUL.......................................................16

3.7 LEVEL 7 - ARIEL C-5 PERFORMANCE ENHANCEMENTS ......................................16
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 2 of 16

1. HOS-6 MAINTENANCE PLAN

LEVEL 1 - HOS-6 OPERATION SURVEILLANCE

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L1-T1 JACKET WATER PUMP SEAL (LEAKAGE) CHECK 12 HOURS OPERATIONS

L1-T2 LUBE OIL PUMP SEAL (LEAKAGE) CHECK 12 HOURS OPERATIONS

L1-T3

GAS COMPRESSOR PRESSURE CASE 

VENT TEMPERATURE CHECK 12 HOURS OPERATIONS

L1-T4 MOTOR BEARING OIL LEVEL CHECK 12 HOURS OPERATIONS

L1-T5 COMPRESSOR OIL LEVEL CHECK 12 HOURS OPERATIONS

L1-T6 COOLING WATER SUMP LEVEL CHECK 12 HOURS OPERATIONS

L1-T7

SHUTDOWN PANEL MASTER 

ANNUNCIATION CHECK 12 HOURS OPERATIONS

L1-T8 MOTOR BEARING TEMPERATURE CHECK 12 HOURS OPERATIONS

L1-T9 COMPRESSOR OIL HEADER PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T10 MOTOR BEARING TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T11 OIL FILTER DIFFERENTIAL PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T12 OIL HEADER INLET TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T13 OIL HEADER OUTLET TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T14 JACKET WATER PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T15 PACKING WATER PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T16 INLET COOLING WATER TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T17

OUTLET COOLING WATER 

TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T18

GAS COMPRESSOR CYLINDER SUCTION 

PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T19

GAS COMPRESSOR CYLINDER 

DISCHARGE PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T20

GAS COMPRESSOR CYLINDER SUCTION 

TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T21

GAS COMPRESSOR CYLINDER 

DISCHARGE TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T22

COMPRESSOR CYLINDER UNLOADER 

POSITIONS RECORD SEMI-WEEKLY OPERATIONS

L1-T23 MOTOR AMPERAGE & VOLTAGE RECORD SEMI-WEEKLY OPERATIONS

L1-T24 LUBE OIL MAKE-UP METER RECORD SEMI-WEEKLY OPERATIONS

L1-T25

CONTROL PANEL INDICATOR AND 

ANNUNCIATOR LAMPS

TEST & 

REPLACE MONTHLY OPERATIONS

L1-T26 RUNHOUR METER RECORD MONTHLY OPERATIONS

LEVEL 2 - HOS-6 SERVICE TIME BASED TESTING

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L2-T1 LUBE OIL ANALYSIS TEST 740 HOURS MECHANICAL

L2-T2 START COUNTER RECORD 2000 HOURS MECHANICAL

L2-T3 JACKET WATER ANALYSIS TEST 2000 HOURS MECHANICAL
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

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LEVEL 3 - HOS-6 CONDITION MONITORING

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L3-T1

MOTOR-COMPRESSOR PERFORMANCE 

ANALYSIS ANALYZE 2000 HOURS

VENDOR

SERVICE

L3-T2 ENERGY UTILIZATION RATIO ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T3 VIBRATION JACKET WATER PUMPS ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T4

VIBRATION COMPRESSOR DRIVE MOTOR 

BEARINGS ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T5 VIBRATION LUBE OIL PUMP ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T6 VIBRATION PROCESS PIPING SYSTEM ANALYZE 4000 HOURS

VENDOR 

SERVICE

L3-T7

LOOSE FOUNDATION FASTENERS / 

CHOCKS

VISUAL 

INSPECTION 2000 HOURS MECHANICAL

L3-T8 PRESSURE CASE VENT PIPING

VISUAL 

INSPECTION 2000 HOURS MECHANICAL

L3-T9 COMPRESSOR JACKETWATER PIPING

VISUAL 

INSPECTION 2000 HOURS MECHANICAL

L3-T10 EXTERNAL OIL LEAKAGE

VISUAL 

INSPECTION 2000 HOURS MECHANICAL
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

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LEVEL 4 - HOS-6 INTERMEDIATE INTERVENTION

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L4-T1

MOTOR / COMPRESSOR CRITICAL SAFETY 

DEVICE

FUNCTION 

TEST 8000 HOURS INSTRUMENT

L4-T2 DRIVE MOTOR BEARING LUBE OIL REPLACE 8000 HOURS MECHANICAL

L4-T3 CRANKCASE AND DRIVETRAIN

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T4 LUBE OIL FILTERS REPLACE 12000 HOURS MECHANICAL

L4-T5

CRANCASE LUBE OIL AND CLEAN 

CRANKCASE REPLACE 12000 HOURS MECHANICAL

L4-T6 CRANKCASE LUBE OIL SUMP CLEAN 12000 HOURS MECHANICAL

L4-T7 CRANKCASE LUBE OIL FEED LINES

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T8 CRANKCASE OIL SUCTION SCREEN

INSPECT / 

CLEAN 12000 HOURS MECHANICAL

L4-T9 GAS COMPRESSOR ROD (SCORING)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T10

GAS COMPRESSOR PACKING CASE (ROD 

CENTERING)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T11 GAS COMPRESSOR WIPER PACKING

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T12

GAS COMPRESSOR PACKING CASE (LUBE 

CONNECTIONS)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T13 CROSSHEAD SHOE CLEARANCE

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T14

TORQUE COMPRESSOR CRANK FRAME 

FOUNDATION FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T15

TORQUE COMPRESSOR CYLINDER 

DISTANCE PIECE FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T16

TORQUE CRITICAL CRANKCASE 

FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T17 LUBE OIL PUMP COUPLING INSPECT 12000 HOURS MECHANICAL
McElmo Creek Unit Oil Production Facility

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PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

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LEVEL 5 - HOS-6 PREEMINENT INTERVENTION

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L5-T1 MOTOR WINDING POLARIZATION INDEX

TEST & 

RECORD 25000 HOURS

VENDOR 

SERVICE

L5-T2 MOTOR LEAD CONNECTIONS

INSPECT & 

TORQUE 25000 HOURS

VENDOR 

SERVICE

L5-T3 MOTOR CONTACTOR

TEST & 

INSPECT 25000 HOURS

VENDOR 

SERVICE

L5-T4 MOTOR CONTACTOR BUS STAB

INSPECT & 

LUBRICATE 25000 HOURS

VENDOR 

SERVICE

L5-T5 SUPERVISORY RELAYS

CALIBRATE & 

INSPECT 25000 HOURS

VENDOR 

SERVICE

L5-T6 MOTOR GROUND WIRE / CONNECTIONS

INSPECT & 

TORQUE 25000 HOURS MECHANICAL

L5-T7 MAIN BEARING CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T8 CONNECTING ROD BEARING CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T9 CROSSHEAD PIN CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T10

GAS COMPRESSOR ROD PRESSURE 

PACKING CASE

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL

L5-T11 GAS COMPRESSOR WIPER PACKING

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL

L5-T12

GAS COMPRESSOR PISTON RINGS AND 

RIDERS REPLACE 36000 HOURS MECHANICAL

L5-T13 GAS COMPRESSOR ROD PROFILE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T14 PROFILE COMPRESSOR CYLINDER LINER

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T15 COMPRESSOR VALVES AND CAGES

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL

L5-T16 FORCE FEED LUBRICATOR SYSTEM

INSPECT & 

SERVICE 36000 HOURS MECHANICAL

L5-T17 COMPRESSOR ROD RUNOUT

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T18 CRANKSHAFT WEB DEFLECTION

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T19 DRIVE MOTOR BASE BOLT TORQUE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T20 CRANKSHAFT THRUST BEARING

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T21 COMPRESSOR CYLINDER UNLOADERS RECONDITION 36000 HOURS MECHANICAL

L5-T22 CRANKCASE PRESSURE RELIEF DOOR RECONDITION 36000 HOURS MECHANICAL
McElmo Creek Unit Oil Production Facility

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PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

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LEVEL 6 - HOS-6 ZERO HOUR OVERHAUL

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L6-T1 MAIN BEARINGS REPLACE 72000 HOURS MECHANICAL

L6-T2 CONNECTING ROD BEARINGS REPLACE 72000 HOURS MECHANICAL

L6-T3 CONNECTING ROD BUSHINGS REPLACE 72000 HOURS VENDOR SERVICE

L6-T4 CROSSHEAD PIN INSPECT 72000 HOURS MECHANICAL

L6-T5 CROSSHEAD SHOES INSPECT 72000 HOURS MECHANICAL

L6-T6 CRANKSHAFT OIL SEAL REPLACE 72000 HOURS MECHANICAL

L6-T7 MAIN LUBE OIL PUMP COUPLING INSPECT 72000 HOURS MECHANICAL

L6-T8 CRANKSHAFT THRUST BEARING REPLACE 72000 HOURS MECHANICAL

L6-T9 OIL THERMOSTAT ELEMENTS REPLACE 72000 HOURS MECHANICAL

L6-T10 JACKET WATER THERMOSTAT ELEMENTS REPLACE 72000 HOURS MECHANICAL

L6-T11 GAS COMPRESSOR VALVE COVER STUDS INSPECT 72000 HOURS MECHANICAL

L6-T12 GAS COMPRESSOR HEAD STUDS INSPECT 72000 HOURS MECHANICAL

L6-T7 ELECTRIC MOTOR DRIVER RECONDITION 72000 HOURS VENDOR SERVICE

LEVEL 7 - HOS-6 PERFORMANCE ENHANCEMENTS

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L7-T1 PERFORMANCE BENCHMARK UP-GRADES REVIEW 12000 HOURS ENGINEERING

L7-T2

MANUFACTURES ENGINEERING 

REVISIONS REVIEW 12000 HOURS ENGINEERING

L7-T3

PRODUCTION OPERATIONS "BEST 

PRACTICE" REVIEW 12000 HOURS ENGINEERING
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 7 of 16

2. HOS-4 MAINTENANCE PLAN

LEVEL 1 - HOS 4 OPERATION SURVEILLANCE

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L1-T1 JACKET WATER PUMP SEAL (LEAKAGE) CHECK 12 HOURS OPERATIONS

L1-T2

PRE/POST LUBE OIL PUMP SEAL 

(LEAKAGE) CHECK 12 HOURS OPERATIONS

L1-T3

GAS COMPRESSOR PRESSURE CASE 

VENT TEMPERATURE CHECK 12 HOURS OPERATIONS

L1-T4

JACKET WATER-LUBE OIL COOLER BANK 

FAN BELT CHECK 12 HOURS OPERATIONS

L1-T5

MOTOR BEARING OIL LEVEL (IF 

APPLICABLE) CHECK 12 HOURS OPERATIONS

L1-T6 COMPRESSOR OIL LEVEL CHECK 12 HOURS OPERATIONS

L1-T7 JACKET WATER SURGE TANK LEVEL CHECK 12 HOURS OPERATIONS

L1-T8

SHUTDOWN PANEL MASTER 

ANNUNCIATION CHECK 12 HOURS OPERATIONS

L1-T9 MOTOR BEARING TEMPERATURE CHECK 12 HOURS OPERATIONS

L1-T13 PULSATION BOTTLES DRAIN 12 HOURS OPERATOR

L1-T10 COMPRESSOR OIL HEADER PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T11 MOTOR BEARING TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T12 OIL FILTER DIFFERENTIAL PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T13 OIL HEADER INLET TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T14 OIL HEADER OUTLET TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T15 JACKET WATER PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T16 INLET JACKET WATER TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T17 OUTLET JACKET WATER TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T18

GAS COMPRESSOR CYLINDER SUCTION 

PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T19

GAS COMPRESSOR CYLINDER DISCHARGE 

PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T20

GAS COMPRESSOR CYLINDER SUCTION 

TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T21

GAS COMPRESSOR CYLINDER DISCHARGE 

TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T22 MOTOR WINDING TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T23 MOTOR AMPERAGE & VOLTAGE RECORD SEMI-WEEKLY OPERATIONS

L1-T24 LUBE OIL MAKE-UP METER RECORD SEMI-WEEKLY OPERATIONS

L1-T25 RUNHOUR METER RECORD MONTHLY OPERATIONS

LEVEL 2 - HOS 4 SERVICE TIME BASED TESTING

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L2-T1 LUBE OIL ANALYSIS TEST 740 HOURS MECHANICAL

L2-T2 START COUNTER RECORD 2000 HOURS MECHANICAL

L2-T3 JACKET WATER ANALYSIS TEST 4000 HOURS MECHANICAL
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 8 of 16

LEVEL 3 - HOS 4 CONDITION MONITORING

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L3-T1

MOTOR-COMPRESSOR PERFORMANCE 

ANALYSIS ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T2 ENERGY UTILIZATION RATIO ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T3 VIBRATION JACKET WATER PUMPS ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T5

VIBRATION COMPRESSOR DRIVE MOTOR 

BEARINGS ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T6 VIBRATION PRE / POST LUBE OIL PUMP ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T7

VIBRATION JACKET WATER / LUBE OIL 

COOLER FAN MOTOR ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T8 VIBRATION PROCESS PIPING SYSTEM ANALYZE 4000 HOURS

VENDOR 

SERVICE

L3-T9

LOOSE FOUNDATION FASTENERS / 

CHOCKS

VISUAL 

INSPECTION 2000 HOURS MECHANICAL 

L3-T10 PRESSURE CASE VENT PIPING

VISUAL 

INSPECTION 2000 HOURS MECHANICAL 

L3-T11 COMPRESSOR JACKET WATER PIPING

VISUAL 

INSPECTION 2000 HOURS MECHANICAL 

L3-T12 EXTERNAL OIL LEAKAGE

VISUAL 

INSPECTION 2000 HOURS MECHANICAL 
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 9 of 16

LEVEL 4 - HOS 4 INTERMEDIATE INTERVENTION

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L4-T1

ENGINE / COMPRESSOR CRITICAL SAFETY 

DEVICES

FUNCTION 

TEST MONTHLY INSTRUMENT

L4-T2 ENGINE / COMPRESSOR SAFETY DEVICE

FUNCTION 

TEST 8000 HOURS INSTRUMENT

L4-T4

BLOWER MOTOR BEARING GREASE (IF 

APPLICABLE) LUBRICATE 2900 HOURS MECHANCIAL

L4-T3 MOTOR BEARING GREASE LUBRICATE 2900 HOURS MECHANCIAL

L4-T4 CRANKCASE AND DRIVE TRAIN

VISUAL 

INSPECTION 12000 HOURS MECHANICAL 

L4-T5

JACKET WATER-LUBE OIL COOLER BANK 

FAN BELT REPLACE 12000 HOURS MECHANICAL 

L4-T6 LUBE OIL FILTERS REPLACE 12000 HOURS MECHANICAL 

L4-T7 CRANKCASE LUBE OIL REPLACE 12000 HOURS MECHANICAL 

L4-T8 CRANKCASE LUBE OIL SUMP CLEAN 12000 HOURS MECHANICAL 

L4-T9 CRANKCASE LUBE OIL FEED LINES

VISUAL 

INSPECTION 12000 HOURS MECHANICAL 

L4-T10

JACKET WATER-LUBE OIL COOLER BANK 

(EXTERNAL) CLEAN 12000 HOURS MECHANICAL 

L4-T11 CRANKCASE OIL SUCTION SCREEN

INSPECT / 

CLEAN 12000 HOURS MECHANICAL 

L4-T12 GAS COMPRESSOR ROD (SCORING)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL 

L4-T13

GAS COMPRESSOR PACKING CASE (ROD 

CENTERING)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL 

L4-T14

GAS COMPRESSOR WIPER PACKING 

(LEAKAGE)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL 

L4-T15

GAS COMPRESSOR PACKING CASE (LUBE 

CONNECTIONS)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL 

L4-T16 CROSSHEAD SHOE CLEARANCE

CHECK & 

RECORD 12000 HOURS MECHANICAL 

L4-T17

TORQUE COMPRESSOR CRANK FRAME 

FOUNDATION FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL 

L4-T18

TORQUE COMPRESSOR CYLINDER 

DISTANCE PIECE FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL 

L4-T19

TORQUE CRITICAL CRANKCASE 

FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL 

L4-T20 PRE/POST LUBE OIL PUMP COUPLING INSPECT 12000 HOURS MECHANICAL 

L4-T21 GAS COMPRESSOR ROD RUNOUT

CHECK & 

RECORD 12000 HOURS MECHANICAL 

L4-T22 MOTOR WINDING POLARIZATION INDEX

TEST & 

RECORD 25000 HOURS

VENDOR 

SERVICE

L4-T23 MOTOR LEAD CONNECTIONS

INSPECT & 

TORQUE 25000 HOURS

VENDOR 

SERVICE

L4-T24 MOTOR CONTACTOR

TEST & 

INSPECT 25000 HOURS

VENDOR 

SERVICE

L4-T25 MOTOR CONTACTOR BUS STAB

INSPECT & 

LUBRICATE 25000 HOURS

VENDOR 

SERVICE

L4-T26 SUPERVISORY RELAYS

CALIBRATE & 

INSPECT 25000 HOURS

VENDOR 

SERVICE

L4-T27 MOTOR GROUND WIRE / CONNECTIONS

INSPECT & 

TORQUE 25000 HOURS MECHANICAL 
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 10 of 16

LEVEL 5 - HOS 4 PREEMINENT INTERVENTION

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L5-T1 MAIN BEARING CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T2 CONNECTING ROD BEARING CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T3 CROSSHEAD PIN CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T4

GAS COMPRESSOR ROD PRESSURE 

PACKING CASE

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL 

L5-T5 GAS COMPRESSOR WIPER PACKING

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL 

L5-T6 GAS COMPRESSOR ROD PROFILE

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T7 PROFILE COMPRESSOR CYLINDER LINER

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T8 COMPRESSOR VALVES AND CAGES

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL 

L5-T9 FORCE FEED LUBRICATOR SYSTEM

INSPECT & 

SERVICE 36000 HOURS MECHANICAL 

L5-T10 CRANKCASE RELIEF DOORS RECONDITION 36000 HOURS MECHANCIAL

L5-T11 COMPRESSOR ROD RUNOUT

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T12 CRANKSHAFT WEB DEFLECTION

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T13 DRIVE MOTOR BASE BOLT TORQUE

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T14 CRANKSHAFT THRUST BEARING

CHECK & 

RECORD 36000 HOURS MECHANICAL 

L5-T15

COMPRESSOR CYLINDER VALVE 

UNLOADER (C&D ONLY) RECONDITION 36000 HOURS MECHANICAL 

L5-T16

GAS COMPRESSOR PISTON, ROD, NUT 

(BALANCE)

WEIGHT & 

RECORD 36000 HOURS MECHANICAL 

L5-T17

MOTOR DRIVE COUPLING GROMMETS (IF 

APPLICABLE) REPLACE 36000 HOURS MECHANICAL 
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 11 of 16

LEVEL 6 - HOS 4 ZERO HOUR OVERHAUL

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L6-T1 MAIN BEARINGS REPLACE 72000 HOURS MECHANICAL

L6-T2 CONNECTING ROD BEARINGS REPLACE 72000 HOURS MECHANICAL

L6-T3 CONNECTING ROD BUSHINGS REPLACE 72000 HOURS

VENDOR 

SERVICE

L6-T4 CROSSHEAD PIN INSPECT 72000 HOURS MECHANICAL

L6-T5 CROSSHEAD SHOES INSPECT 72000 HOURS MECHANICAL

L6-T6 JACKET WATER PUMP RECONDITION 72000 HOURS MECHANICAL

L6-T7 MAIN OIL PUMP RECONDITION 72000 HOURS

VENDOR 

SERVICE

L6-T8 CRANKSHAFT OIL SEAL REPLACE 72000 HOURS MECHANICAL

L6-T9 MAIN LUBE OIL PUMP COUPLING INSPECT 72000 HOURS MECHANICAL

L6-T10 CRANKSHAFT THRUST BEARING REPLACE 72000 HOURS MECHANICAL

L6-T11 OIL THERMOSTAT ELEMENTS REPLACE 72000 HOURS MECHANICAL

L6-T12 JACKET WATER THERMOSTAT ELEMENTS REPLACE 72000 HOURS MECHANICAL

L6-T13 GAS COMPRESSOR VALVE COVER STUDS INSPECT 72000 HOURS MECHANICAL

L6-T14 GAS COMPRESSOR HEAD STUDS INSPECT 72000 HOURS MECHANICAL

LEVEL 7 - HOS 4 PERFORMANCE ENHANCEMENTS

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L7-T1 PERFORMANCE BENCHMARK UP-GRADES REVIEW 18000 HOURS ENGINEERING

L7-T2 MANUFACTURES ENGINEERING REVISIONS REVIEW 18000 HOURS ENGINEERING

L7-T3 PRODUCTION OPERATIONS "BEST PRACTICE" REVIEW 18000 HOURS ENGINEERING
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 12 of 16

3. ARIEL C-5 MAINTENANCE PLAN

LEVEL 1 - ARIEL C-5 OPERATION SURVEILLANCE

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L1-T1

PRE/POST LUBE OIL PUMP SEAL 

(LEAKAGE) CHECK 12 HOURS OPERATIONS

L1-T2

GAS COMPRESSOR PRESSURE CASE 

VENT TEMPERATURE CHECK 12 HOURS OPERATIONS

L1-T3

MOTOR BEARING OIL LEVEL (IF 

APPLICABLE) CHECK 12 HOURS OPERATIONS

L1-T4 COMPRESSOR OIL LEVEL CHECK 12 HOURS OPERATIONS

L1-T5

SHUTDOWN PANEL MASTER 

ANNUNCIATION CHECK 12 HOURS OPERATIONS

L1-T6 MOTOR BEARING TEMPERATURE CHECK 12 HOURS OPERATIONS

L1-T13 PULSATION BOTTLES DRAIN 12 HOURS OPERATOR

L1-T7 COMPRESSOR OIL HEADER PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T8 MOTOR BEARING TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T9 OIL FILTER DIFFERENTIAL PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T10 OIL HEADER INLET TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T11 OIL HEADER OUTLET TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T12

GAS COMPRESSOR CYLINDER SUCTION 

PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T13

GAS COMPRESSOR CYLINDER DISCHARGE 

PRESSURE RECORD SEMI-WEEKLY OPERATIONS

L1-T14

GAS COMPRESSOR CYLINDER SUCTION 

TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T15

GAS COMPRESSOR CYLINDER DISCHARGE 

TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T16 MOTOR WINDING TEMPERATURE RECORD SEMI-WEEKLY OPERATIONS

L1-T17 MOTOR AMPERAGE & VOLTAGE RECORD SEMI-WEEKLY OPERATIONS

L1-T18 LUBE OIL MAKE-UP METER RECORD SEMI-WEEKLY OPERATIONS

L1-T19 RUNHOUR METER RECORD MONTHLY OPERATIONS

LEVEL 2 - ARIEL C-5 SERVICE TIME BASED TESTING

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L2-T1 LUBE OIL ANALYSIS TEST 740 HOURS MECHANICAL

L2-T2 START COUNTER RECORD 2000 HOURS MECHANICAL
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 13 of 16

LEVEL 3 - ARIEL C-5 CONDITION MONITORING

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L3-T1

MOTOR-COMPRESSOR PERFORMANCE 

ANALYSIS ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T2 ENERGY UTILIZATION RATIO ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T3

VIBRATION COMPRESSOR DRIVE MOTOR 

BEARINGS ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T4 VIBRATION PRE / POST LUBE OIL PUMP ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T5 VIBRATION LUBE OIL COOLER FAN MOTOR ANALYZE 2000 HOURS

VENDOR 

SERVICE

L3-T6 VIBRATION PROCESS PIPING SYSTEM ANALYZE 4000 HOURS

VENDOR 

SERVICE

L3-T7

LOOSE FOUNDATION FASTENERS / 

CHOCKS

VISUAL 

INSPECTION 2000 HOURS MECHANICAL

L3-T8 PRESSURE CASE VENT PIPING

VISUAL 

INSPECTION 2000 HOURS MECHANICAL

L3-T9 EXTERNAL OIL LEAKAGE

VISUAL 

INSPECTION 2000 HOURS MECHANICAL

L3-T10

MOTOR COOLING AIR FILTER (IF 

APPLICABLE) CLEAN 2000 HOURS MECHANICAL
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 14 of 16

LEVEL 4 - ARIEL C-5 INTERMEDIATE INTERVENTION

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L4-T1

ENGINE / COMPRESSOR CRITICAL SAFETY 

DEVICES

FUNCTION 

TEST MONTHLY INSTRUMENT

L4-T2 ENGINE / COMPRESSOR SAFETY DEVICE

FUNCTION 

TEST 8000 HOURS INSTRUMENT

L4-T3 DRIVE MOTOR BEARING LUBE OIL REPLACE 8000 HOURS MECHANICAL

L4-T4 CRANKCASE AND DRIVE TRAIN

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T5 LUBE OIL COOLER BANK FAN BELT REPLACE 12000 HOURS MECHANICAL

L4-T6 LUBE OIL FILTERS REPLACE 12000 HOURS MECHANICAL

L4-T7 CRANKCASE LUBE OIL REPLACE 12000 HOURS MECHANICAL

L4-T8 CRANKCASE LUBE OIL SUMP CLEAN 12000 HOURS MECHANICAL

L4-T9 CRANKCASE LUBE OIL FEED LINES

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T10 LUBE OIL COOLER BANK (EXTERNAL) CLEAN 12000 HOURS MECHANICAL

L4-T11 CRANKCASE OIL SUCTION SCREEN

INSPECT / 

CLEAN 12000 HOURS MECHANICAL

L4-T12 GAS COMPRESSOR ROD (SCORING)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T13

GAS COMPRESSOR PACKING CASE (ROD 

CENTERING)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T14

GAS COMPRESSOR WIPER PACKING 

(LEAKAGE)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T15

GAS COMPRESSOR PACKING CASE (LUBE 

CONNECTIONS)

VISUAL 

INSPECTION 12000 HOURS MECHANICAL

L4-T16 CROSSHEAD SHOE CLEARANCE

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T17

TORQUE COMPRESSOR CRANK FRAME 

FOUNDATION FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T18

TORQUE COMPRESSOR CYLINDER 

DISTANCE PIECE FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T19

TORQUE CRITICAL CRANKCASE 

FASTENERS

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T20 PRE/POST LUBE OIL PUMP COUPLING INSPECT 12000 HOURS MECHANICAL

L4-T21 GAS COMPRESSOR ROD RUNOUT

CHECK & 

RECORD 12000 HOURS MECHANICAL

L4-T22 MOTOR WINDING POLARIZATION INDEX

TEST & 

RECORD 25000 HOURS

VENDOR 

SERVICE

L4-T23 MOTOR LEAD CONNECTIONS

INSPECT & 

TORQUE 25000 HOURS

VENDOR 

SERVICE

L4-T24 MOTOR CONTACTOR

TEST & 

INSPECT 25000 HOURS

VENDOR 

SERVICE

L4-T25 MOTOR CONTACTOR BUS STAB

INSPECT & 

LUBRICATE 25000 HOURS

VENDOR 

SERVICE

L4-T26 SUPERVISORY RELAYS

CALIBRATE & 

INSPECT 25000 HOURS

VENDOR 

SERVICE

L4-T27 MOTOR GROUND WIRE / CONNECTIONS

INSPECT & 

TORQUE 25000 HOURS

VENDOR 

SERVICE
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 15 of 16

LEVEL 5 - ARIEL C-5 PREEMINENT INTERVENTION

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L5-T1 MAIN BEARING CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T2 CONNECTING ROD BEARING CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T3 CROSSHEAD PIN CLEARANCE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T4

GAS COMPRESSOR ROD PRESSURE 

PACKING CASE

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL

L5-T5 GAS COMPRESSOR WIPER PACKING

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL

L5-T6 GAS COMPRESSOR ROD PROFILE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T7 PROFILE COMPRESSOR CYLINDER LINER

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T8 COMPRESSOR VALVES AND CAGES

INSPECT & 

RECONDITION 36000 HOURS MECHANICAL

L5-T9 CRANKCASE RELIEF DOORS RECONDITION 36000 HOURS MECHANCIAL

L5-T10 FORCE FEED LUBRICATOR SYSTEM

INSPECT & 

SERVICE 36000 HOURS MECHANICAL

L5-T11 COMPRESSOR ROD RUNOUT

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T12 CRANKSHAFT WEB DEFLECTION

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T13 DRIVE MOTOR BASE BOLT TORQUE

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T14 CRANKSHAFT THRUST BEARING

CHECK & 

RECORD 36000 HOURS MECHANICAL

L5-T15

COMPRESSOR CYLINDER VALVE 

UNLOADER RECONDITION 36000 HOURS MECHANICAL

L5-T16

GAS COMPRESSOR PISTON, ROD, NUT 

(BALANCE)

WEIGHT & 

RECORD 36000 HOURS MECHANICAL

L5-T17

MOTOR DRIVE COUPLING GROMMETS (IF 

APPLICABLE) REPLACE 36000 HOURS MECHANICAL
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Lifecycle Maintenance Plan

PSD Permit No. NU 05-01, Appendix A, Attachment A-1

September 2016

Page 16 of 16

LEVEL 6 - ARIEL C-5 ZERO HOUR OVERHAUL

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L6-T1 MAIN BEARINGS REPLACE 72000 HOURS MECHANICAL

L6-T2 CONNECTING ROD BEARINGS REPLACE 72000 HOURS MECHANICAL

L6-T3 CONNECTING ROD BUSHINGS REPLACE 72000 HOURS

VENDOR 

SERVICE

L6-T4 JACKET WATER PUMP RECONDITION 72000 HOURS MECHANICAL

L6-T5 MAIN OIL PUMP RECONDITION 72000 HOURS

VENDOR 

SERVICE

L6-T6 CROSSHEAD PIN INSPECT 72000 HOURS MECHANICAL

L6-T7 CROSSHEAD SHOES INSPECT 72000 HOURS MECHANICAL

L6-T8 CRANKSHAFT OIL SEAL REPLACE 72000 HOURS MECHANICAL

L6-T9 MAIN LUBE OIL PUMP COUPLING INSPECT 72000 HOURS MECHANICAL

L6-T10 CRANKSHAFT THRUST BEARING REPLACE 72000 HOURS MECHANICAL

L6-T11 OIL THERMOSTAT ELEMENTS REPLACE 72000 HOURS MECHANICAL

L6-T12 GAS COMPRESSOR VALVE COVER STUDS INSPECT 72000 HOURS MECHANICAL

L6-T13 GAS COMPRESSOR HEAD STUDS INSPECT 72000 HOURS MECHANICAL

LEVEL 7 - ARIEL C-5 PERFORMANCE ENHANCEMENTS

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L7-T1 PERFORMANCE BENCHMARK UP-GRADES REVIEW 12000 HOURS ENGINEERING

L7-T2 MANUFACTURES ENGINEERING REVISIONS REVIEW 12000 HOURS ENGINEERING

L7-T3 PRODUCTION OPERATIONS "BEST PRACTICE" REVIEW 12000 HOURS ENGINEERING
McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01

MCELMO CREEK UNIT OPERATIONS &

MAINTENANCE PLAN

ATTACHMENT A-2:

DAILY PLANT READING FORM

September 2016
RESOLUTE ENERGY CORPORATION 

Daily Plant Reading 

Revised September 2016 

NAME:

DATE: Date Reporting for: 

UNIT

Unsch Schd

Stdby

R / T 

Reason for Downtime

D / T D / T Hrs. 

4245 (HOSS-6) 0 0 0 0.00

4249 (HOSS-4) 0 0 0 0.00

4246 (A.G.C.-A) 0 0 0 0.00

4247 (A.G.C.-B) 0 0 0 0.00

Ariel C-5 0 0 0 0.00

CO2 Booster Pmp A 0 0 0 0.00

CO2 Booster Pmp B 0 0 0 0.00

TOTAL FLOW MCU TOTAL INJECTION

Plant Inlet (FI 1999 "P") Recycle Gas Frm MCU to Field (FI-2001)

Inlet Bypass (FI 9999 "P") KM CO2 to MCU (FI-2003)

TOTAL TOTAL

Plant Flare (FI 2083 "P") Compressor Discharge Pressure 

Total Inlet Gas Volume Inlet Header Pressure 

OXYGEN ANALYZER READING PANAMETRIC DEW POINT READING (LBS.)

O2 Reading in PPM Dew Point Reading (0030 hrs)

CO2 PURCHASE MTR RDG (Daniel Sr. Meter) RECYCLE GAS Frm MCU COMPR TO AU (FI-2000)

Yesterday's Total mcf Yesterday's Total Volume

CO2 Inlet Pressure psig

CO2 Inlet Temp deg F CO2 TRUNKLINE PRESSURES

Main Disch Header psi

MCU CO2 PURCHASE MTR RDG (FI-2003) Trunk line 100 psi

Yesterday's Total mcf Trunk line 200 psi

Trunk line 300 T/A psi

AU CO2 PURCHASE MTR RDG (FI-2002) Trunk line 400 psi

Yesterday's Total mcf Trunk line 600 psi

COMMENTS: 
Resolute Energy Corporation ~ Four Corners Operations

Revised September 2016

McELMO CREEK UNIT DAILY REINJECTION FAC. READINGS DATE:

CO2 INLET HEADER / DISCHARGE HEADER

KM TO MCU PLANT ( FI2003 Rate )

KM TO ANETH UNIT ( FI2002 Rate )

RECYCLE GAS TO MCU ( FI2001 Rate )

MCU TO ANETH UNIT ( FI2000 Rate )

INLET DENSITY

INLET PSI FROM KM (PIT 301 )

INLET TEMP FROM KM ( TT-201 )

CO2 BOOSTER PUMP ( P 300-A )

CO2 INLET VOL. MSCFD (FIT 201)

CO2 OULET VOL. GPM (PCV 301)

INLET PRESSURE (PIT301)

PUMP Hz (P 300A) --- ( oil level ) oil % oil % 

PUMP THRUST CHAMBER TEMPERATURE

DISCHARGE PRESSURE (PIT 302)

PERCENT OPEN (PCV 301) % %

FINAL DISCHARGE PRESSURE (PIT 304)

TODAY'S (MSCF)

PREVIOUS DAY (MSCF)

MCC-AIR CONDITIONER (ROOM TEMP-OK) / / / /

CO2 BOOSTER PUMP ( P 300-B )

CO2 INLET VOL. MSCFD (FIT 201)

CO2 OULET VOL. GPM (PCV 301)

INLET PRESSURE (PIT301)

PUMP Hz (P 300A) --- ( oil level ) oil % oil % 

PUMP THRUST CHAMBER TEMPERATURE

DISCHARGE PRESSURE (PIT 302)

PERCENT OPEN (PCV ) % %

FINAL DISCHARGE PRESSURE (PIT 304)

TODAY'S (MSCF)

PREVIOUS DAY (MSCF)

MCC-AIR CONDITIONER (ROOM TEMP-OK) / / / /

MAIN DISCHARGE HEADER PRESSURE 

MAIN DISCHARGE HEADER From Facility

TRUNKLINE 100 DISCH PRESS

TRUNKLINE 200 DISCH PRESS

TRUNKLINE 300 DISCH PRESS T/A T/A T/A T/A

TRUNKLINE 400 DISCH PRESS

TRUNKLINE 600 DISCH PRESS

INLET HEADER 

INLET SLUG RECEIVER PRESSURE

INLET SLUG RECEIVER LEVEL % % % %

OXYGEN ANALYZER READING (PPM)

INLET FILTER VESSELS 

REVERSE COALESCER D.P. / / / /

REVERSE COALESCER PRESSURE / / / /

REVERSE COALESCER TEMPERATURE / / / /

COMMENTS: 
McElmo Creek Unit Oil Production Facility 

PSD Permit No. NU 05-01

MCELMO CREEK UNIT OPERATIONS &

MAINTENANCE PLAN

ATTACHMENT A-3:

ISOLATION & OPERATING

PROCEDURES

Isolation and Operating Procedures 

for Compressors HOS-6, HOS-4, Aerial C-5, and Acid Gas B

September 2016
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

ISOLATION PROCEDURE 

Page 1 of 4

Revised September 2016

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

HOS-6 Compressor back to service.

REQUIREMENTS Operators are required to shut down compressor and isolate

APPLICABLE HOS-6 Compressor Operating Procedure

DOCUMENTS

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact Supervisor and or Environmental Health & 

Safety Supervisor

SAFETY Locks must be used by Operations and Maintenance Personal 

For applicable safety requirements, refer to the Resolute Natural Resources Safety 

Manual and Safety Data Sheets (SDS).

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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

ISOLATION PROCEDURE 

Page 2 of 4

Revised September 2016

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

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

1. Isolate the compressor for maintenance.

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

This procedure is for total compressor isolation. Dependent 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-1700)

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

etc)

1.8 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 H2S 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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

ISOLATION PROCEDURE 

Page 3 of 4

Revised September 2016

2. Depressurize the compressor for maintenance.

WARNING Atmospheric vents will release process gas that contains LEL, Benzene and H2S.

Caution: Any opening of kiene valves or any other valves will vent process gas to atmospherics 

to depressurize compressor

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 four cylinder to verify depressurization.

2.4 Open the cylinder head and crank end kiene vent valves or any other valves to verify that 

the cylinders to be worked on are depressurize and remain clear of the vented area. 

2.5 Notify maintenance that they may begin work.

3. Completed Maintenance and Pressure check compressor.

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

service and remove all isolation locks and tags.

3.1. Pressure check compressor with process gas.

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

3.1.2 Open all isolation block valves on the PSV's for the (1st, 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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

ISOLATION PROCEDURE 

Page 4 of 4

Revised September 2016

WARNING Make sure atmospheric vents valves or any other valves that were opened during blow 

down 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-1700, SDV-1700).

3.1.9 Verify pressures across cylinders 

3.1.10 Verify that no leaks are detected on all repaired components.

4. Return compressor to service.

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

service.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 1 of 11

Revised September 2016

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 Personnel are required to restart or shut down compressors

APPLICABLE HOS-6 Compressor Isolation Procedure

DOCUMENTS

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact Supervisor and or Environmental Health & Safety 

Supervisor.

SAFETY For applicable safety requirements, refer to the Resolute Natural Resources Safety Manual and 

Safety Data Sheets (SDS).
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 2 of 11

Revised September 2016

1.0 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.

 Maintenance work complete

 Temporary blinds removed and equipment restored

 Oxygen purged from compressor and piping

 Compressor and piping pressure checked using process gas

 Compressor isolation valves returned to service

 Safety devices, vents, and PRVs returned to service with isolation lock open.

 Instruments, controls, and electrical power returned to service

 Lock-out/Tag-out removed

1.2. Start compressor using normal startup procedure.

2.0 Normal Startup.

NOTE Normal startup is performed following a brief compressor shutdown 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.

 Plant ESD and local panel shutdowns are reset

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

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

 Control panel power on HMI

 Crankcase oil level with Mobil 505 oil
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 3 of 11

Revised September 2016

 Lubricator oil level with NGL-888

 Check Oil Day tank level Mobil 505

 Check Oil Day tank level with NGL-888

 Visually verify that all Suction scrubbers are empty

 Ensure that the compressor is depressurized

 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 

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

10.4% 

2.2 Start and load compressor.

CAUTION The compressor should not have more than 5 psig on the 1st stage suction. Depressure as 

needed to prevent overloading the compressor motor.

2.2.0 Verify HMI permissive (Shutdown) is reset.

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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 4 of 11

Revised September 2016

Compressor Starting Sequence 

Warning: Ensure that all personnel are clear and motor starter, near free of the electrical power supply 

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

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.

2.2.3 Verify that the compressor oil pressure is above 35 psig.

2.2.3 When the compressor starts ups, the suction shutdown valve should open 

automatically and the indicator will show open. 

Step 

Number

Status Step Description

0 AVAILABL WAITING FOR START

1 PRE-LUBE START PRELUBE PUMP AND HEATER & GLYCOL PUMPS

PRE-LUBE CHECK COMPRESSOR OIL TEMP

3 PURGING CHECK IF PURGE REQUIRED

4 PURGING CLOSE 1ST & 2ND STAGE BD VALVES, OPEN 3RD & 4TH STAGE BD VALVES

5 PURGING OPEN SUCTION BLOCK VALVE & SET SUCTION PRESSURE CONTROL 

VALVE TO MAINTAIN 15 PSI DIFF 1ST TO 4TH

6 PURGING TIMED PURGE

7 STARTING CLOSE SUCTION BLOCK VALVE & SET SUCTION PRESS TO 15 PSI AT 1ST 

STAGE SUCT

8 STARTING OPEN 2ND, 3RD, & 4TH STAGE BD VALVES

9 STARTING OPEN DISCHARGE BLOCK VALVE

10 STARTING ENABLE PROCESS COOLER FANS & LOUVERS

11 STARTING START JACKET WATER FAN & PUMP

12 STARTING VERIFY SUCTION PRESS, OIL PRESS, ETC.

13 STARTING START MAIN MOTOR

14 WARM-UP WARM-UP

15 WARM-UP CLOSE 2ND, 3RD, & 4TH STAGE BD VALVES

16 WARM-UP SET SUCTION PRESS TO 12 PSI AT 1ST STAGE SUCTION

17 WARM-UP ACTIVATE GLYCOL CIRCULATION

18 WARM-UP WAIT FOR 4TH STAGE DISCHARGE PRESSURE TO BUILD

19 ONLINE ENABLE ONLINE ROD LOAD & 1ST STG DISCHG PRESS PIDS

20 SHUTDOWN GLYCOL TO RECIRC, SET 4TH STG DISCH TEMP TO 150 DEGF

21 SHUTDOWN SET SUCTION PRESS TO 9 PSI AT 1ST STAGE SUCTION
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 5 of 11

Revised September 2016

2.2.4 Close the 2nd stage discharge to flare valve (PCV-1746).

2.2.5 Close the 3rd stage discharge to flare valve (PCV-1747).

2.2.6 The 1st Stage Suction Pressure Controller (PIC-1700) in the "auto" mode with a 

setpoint 12 psig on the SCADA

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

3.0 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

o Suction and discharge pressures

o Suction and discharge temperatures

o Cylinder temperatures

o Cylinder vibration

o Motor Vibration

o Crankcase and lubricator lube oil pressure

o Crankcase and lubricator lube oil temperature

o Crankcase lube oil filter DP, and change as necessary

 Crankcase oil level

 Oil consumption

o Lubricator oil level
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 6 of 11

Revised September 2016

 Jacket water pressure

 Jacket water temperature

 Check compressor lube oil level and fill as needed with NGL-888

 Check Jacket water tank level and fill as needed with Ambitrol 

 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 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

 Verify the chemical injection pumps is in “Auto position”.(verify oil level and chemical 

level)
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 7 of 11

Revised September 2016

4.0 Temporary Operation.

NOTE Use of temporary operating procedures must be approved by the Supervisor

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.

5.0 Emergency Operation.

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

M:\Departments\Environmental\Resolute EA Plans\H2S Contingency Plan

6.0 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 stop button on HMI Panel. Once the STOP button is press. The compressor 

will idle down and shut down.

6.2.2 Ensure suction/discharge shutdown valve is closed since this valve closes 

automatically. 

6.2.3 The flare blowdown will opened to flare automatically

6.2.4 Open the 2nd stage discharge to flare valve at (PCV-1746).

6.2.5 Open the 3rd stage discharge to flare valve (PCV-1747).

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

period.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 8 of 11

Revised September 2016

7.0 Emergency Shutdown (ESD)

NOTE ESD of the Gas Reinjection Facility can be initiated from any of the 6 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 shut down all the 

reinjection compressors, isolate the inlet area and depressurize 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 (PB1) One push button station is located inside the Control Room above 

the Fire, H2S and LEL Detection System's readout panel is located on the South wall of 

the Rosemount panel inside the MCC Control Room. 

7.1.2. ESD Station (PB2) Located on a pipe rack support beam on the southeast corner of the 

Acid Gas compressor building.

7.1.3. ESD Station (PB3) Located outside between the Control Room and the MCC building.

7.1.4. ESD Station (PB5) located on the north wall outside of the Inlet building.

7.1.6. E-STOP Station: Location on HOS-6 HMI Panel

7.1.7 E-STOP Station Located on a building support beam on the northeast corner of the 

HOS-6 Compressor building. The HOS-6 Compressor building.

7.1.8. ESD Station (PB6) : Located on a building support beam on the northwest corner of the 

HOS-4 Compressor building.

7.1.9. ESD Station (PB7: Located on cooler fan support beam on the southeast corner of the 

HOS-4 Compressor's Cooler Fan bay.

7.1.10 ESD PB’s Station: Located in MCC building on the southeast corner of the HOS 6 soft 

start MCC building.

7.1.1 ESD Station (PB8): Located on Flare/Dehydration walkway
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 9 of 11

Revised September 2016

7.2 Fire, H2S and LEL Detection Systems ESD:

7.2.1. Fire: There are 14 Fire Detection sensors located throughout the facility. Any detection 

by either of these sensors will initiate an audible alarm, ESD’s reinjection facility, 

automatically isolating the inlet area and depressurize the facility.

7.2.2. H2S: There are 18 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. Any detection by either of these sensors at 50 PPM 

H2S will initiate an audible alarm, illuminate a beacon light and shutdown all 

reinjection compressors, automatically isolating the inlet area and depressurize the 

facility 

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

by either of these sensors at 20 % 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, automatically isolating the inlet area and depressurize the 

facility 

7.3 HOS-6 Compressor ESD.

7.3.1 Local ESD. Trip compressor ESD by pressing 'Stop' button on local control panel to shut 

down that compressor only.

8.0 Safety Shutdown.

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

 Plant ESD

 Fire, H2S, and LEL Detection systems

 Low instrument air pressure

 Electrical power failure

 Low discharge pressure

 Low pressure suction
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 10 of 11

Revised September 2016

 High discharge pressure on all stages of the cylinders.

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

 Low pressure suction on either of the 1st, 2nd, 3rd or 4th stage

 Low compressor oil pressure

 Low compressor oil level

 No flow compressor cylinder oil

 Low pressure Jacket Water

 Cooler failure

 Vibration Compressor

 Compressor manual shutdown

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

9.0 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 Permissive

Tag Description Position Setpoint

Reinjection Plant ESD Total Reinjection Plant ESD Reset N/A

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
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-6 COMPRESSOR 

OPERATING PROCEDURE 

Page 11 of 11

Revised September 2016

10.2. Normal operating parameters:

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

outside them.

HOS-6 Compressor Normal Operating Parameters

Description Operating Range

Crankcase Oil Pressure 45 to 75 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

1st Stage Suction Temperature 45 to 100 degrees F

1st Stage Discharge Temperature 250 to 280 degrees F

2nd Stage Suction Temperature 80 to 110 degrees F

2nd Stage Discharge Temperature 250 to 280 degrees F

3rd Stage Suction Temperature 100 to 120 degrees F

3rd Stage Discharge Temperature 250 to 280 degrees F

4th Stage Suction Temperature 100 to 120 degrees F

4th Stage Discharge Temperature 240 to 280 degrees F

1st Stage Suction Pressure 8 to 12 psig

1st Stage Discharge Pressure 95 to 105 psig

2nd Stage Suction Pressure 90 to 105 psig

2nd Stage Discharge Pressure 370 to 380 psig

3rd Stage Suction Pressure 350 to 380 psig

3rd Stage Discharge Pressure 1000 to 1050 psig

4th Stage Suction Pressure 1000 to 1040 psig

4th Stage Discharge Pressure 2750 to 2950 psig

1st Stage Vibration (Cyl #1) 0.30 to 0.40 in/s

1st Stage Vibration (Cyl #3) 0.30 to 0.40 in/s

2nd Stage Vibration (Cyl #2) 0.30 to 0.44 in/s

2nd Stage Vibration (Cyl #4) 0.30 to 0.44 in/s

3rd Stage Vibration (Cyl #5) 0.30 to 0.38 in/s

4th Stage Vibration (Cyl #6) 0.30 to 0.40 in/s

Motor Vibration (All Bearings) 2.0 to 3.0 in/s
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

ISOLATION PROCEDURE 

Page 1 of 3

Revised September 2016

SCOPE This procedure describes the isolation, depressurization and returning of the HOS-4 

Compressor back to service.

REQUIREMENTS Personnel’s are required to shut down compressor and isolate

APPLICABLE HOS-4 Compressor Operating Procedure

DOCUMENTS Pre-Start Safety Review Checklist

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Supervisor and or Environmental Health & 

Safety Supervisor

SAFETY Locks must be used by Operations and Maintenance Personal 

For applicable safety requirements, refer to the Resolute Natural Resources Safety Manual and 

Safety Data Sheets (SDS).

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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

ISOLATION PROCEDURE 

Page 2 of 3

Revised September 2016

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

TAGGED per the Lock-out / 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 Close the 4th stage discharge isolation block valve

1.4 Close the 1st stage suction isolation block valve.

1.5 Close the isolation block valves for the closed drain

1.6 Close the isolation block valve for the midpoint drain.

1.7 Place the H2S and LEL Detection system in the "calibration" 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.

WARNING Atmospheric vents will release process gas that contain LEL, Benzene and H2S.

Caution: Any opening of kiene valves or any other valves will vent process gas to atmospherics to 

depressurize compressor

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

2.2 Open the cylinder head and crank end kiene vent valves or any other valves to verify that the 

cylinders to be worked on are depressurize and remain clear of the vented area

2.3 Notify maintenance that they may begin work.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

ISOLATION PROCEDURE 

Page 3 of 3

Revised September 2016

3. Completed Maintenance Pressure check compressor.

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

and remove all isolation locks and tags.

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 kiene valves on all four stages.

3.1.3 Open the isolation block valve for the close drain.

3.1.4 Open the isolation block valve for the mid point drain.

WARNING WARNING: Make sure atmospheric vents valves or any other valves that were opened during 

blow down are closed before pressurizing compressor with process gas.

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 repaired components.

3.1.9 Return LEL, H2S, monitors back to service at Control Room and log in the Safety Device 

Bypass log book.

4. Return compressor to service.

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

into service
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 1 of 9

Revised September 2016

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 one shutdown, problems and solutions, and operating limits.

REQUIREMENTS Operators are required to restart or shut down compressor

APPLICABLE HOS-4 Compressor Isolation Procedure

DOCUMENTS Operation Table Limits

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Supervisor and or Environmental Health & 

Safety Supervisor

SAFETY For applicable safety requirements, refer to the Resolute Natural Resources Safety Manual and 

Safety Data Sheets (SDS).

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

mixture of gas.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 2 of 9

Revised September 2016

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.

 Maintenance work complete

 Temporary blinds removed and equipment restored

 Oxygen purged from compressor and piping

 Compressor and piping pressure checked using process gas

 Compressor piping rechecked for leaks

 Compressor isolation valves returned to service and locked

 Safety devices, vents, and PRVs returned to service with isolation lock open

 Instruments, controls, and electrical power returned to service

 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.

 Plant ESD and local panel shutdowns are reset

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

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

 Crankcase oil level with Mobil 505 oil
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 3 of 9

Revised September 2016

 Lubricator oil level with NGL-888

 Check Oil Day tank level Mobil 505

 Verify that all Suction scrubbers are empty 

 Ensure that the compressor is depressurized

 Ensure that the manual block valves are opened to 1st stage suction and 4th

stage discharge lines open position

 Ensure that all kiene valves and bleeder valves are closed 

 Verify the chemical injection pumps is in “Auto position”. (verify oil level 

and chemical level)

Startup Sequence steps: Local panel HMI

Step Number Status Step Description

0 AVAILABLE WAITING FOR START

1 PRE-LUBE START PRELUBE PUMP & HEATER AND GLYCOL 

PUMPS

2 PRE-LUBE CHECK COMP OIL TEMP

3 PURGING CHECK IF PURGE REQUIRED

4 PURGING OPEN STG#2 BD & STG#4 BD, BP VLVS CLOSE STG#2 

BP VLV

5 PURGING SET SUCT PRESS TO 15 PSI OPEN SUCT BLK VLV

6 PURGING TIMED PURGE

7 STARTING OPEN 2ND STAGE BYPASS VALVE

8 STARTING TIMED PURGE

9 STARTING SPARE STEP

10 STARTING OPEN DISCHARGE BLOCK VALVE

11 STARTING START PROCESS COOLERS AND JW PUMP

12 STARTING VERIFY PERMISSIVES (PRESSURES AND TEMPS)

13 STARTING START MAIN MOTOR

14 WARM-UP TIMED STEP

15 WARM-UP WARM-UP / STOP PRE-LUBE PUMP / ENABLE SUCT. 

PRESS CONTROL

16 WARM-UP CLOSE STG#2 BD & STG#4 BD, BP VALVES

17 WARM-UP CLOSE STAGE #2 BYPASS VALVES

18 WARM-UP SPARE

19 ONLINE ENABLE ONLINE CONTROLS(Calculations)

20 SHUTDOWN OPEN BYPASS VALVES SPARE

21 SHUTDOWN COMPRESSOR COOLDOWN
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 4 of 9

Revised September 2016

Note: The 1st Stage Suction Pressure Controller (PIC-3411) is in manual by SCADA with an output of 

75 % closed on the HMI

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.

CAUTION After 2 unsuccessful starts; the compressor motor starter will trip for 58 min a time delay in 

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

duration in the MCC building.

3. Normal Operation.

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

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
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 5 of 9

Revised September 2016

 Jacket water temperature

 Check compressor lube oil level and fill as needed with NGL-888

 Check Jacket water tank level and fill as needed with Ambitrol 

 Check Jacket water pump and cooler fans for proper operation

 Check suction scrubber levels and drain manually if needed

 General housekeeping duties

 Check compressor after cooler fans operation

4. Temporary Operation.

NOTE Use of temporary operating procedures must be approved by the Supervisor

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. 

M:\Departments\Engineering\MCU Plant Operation\Emergency Planning and Response

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 or shut down 

compressor.

6.1. Shut down compressor.

6.2.1. Press main 'stop' button.

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

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 6 of 9

Revised September 2016

period of time.

7.0 Emergency Shutdown (ESD)

NOTE ESD of the Gas Reinjection Facility can be initiated from any of the 6 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 shut down all the 

reinjection compressors, isolate the inlet area and depressurize 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 (PB1): One push button station is located inside the Control Room above 

the Fire, H2S and LEL Detection System's readout panel is located on the South wall of 

the Rosemount panel inside the MCC Control Room. 

7.1.2. ESD Station (PB2): Located on a pipe rack support beam on the southeast corner of the 

Acid Gas compressor building.

7.1.3. ESD Station (PB3): Located outside between the Control Room and the MCC building.

7.1.4. ESD Station (PB5): Located on the north wall outside of the Inlet building.

7.1.6. E-STOP Station: Location on HOS-6 HMI Panel

7.1.7 E-STOP Station: Located on a building support beam on the northeast corner of the 

HOS-6 Compressor building. The HOS-6 Compressor building.

7.1.8. ESD Station (PB6): Located on a building support beam on the northwest corner of the 

HOS-4 Compressor building.

7.1.9. ESD Station (PB7): Located on cooler fan support beam on the southeast corner of the 

HOS-4 Compressor's Cooler Fan bay.

7.1.10 ESD PB’s Station: Located in MCC building on the southeast corner of the HOS 6 soft 

start MCC building.

7.1.1 ESD Station (PB8): Located on Flare/Dehydration walkway
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 7 of 9

Revised September 2016

7.2 Fire, H2S and LEL Detection Systems ESD:

7.2.1. Fire: There are 14 Fire Detection sensors located throughout the facility. Any detection 

by either of these sensors will initiate an audible alarm, ESD’s reinjection facility, 

automatically isolating the inlet area and depressurize the facility.

7.2.2. H2S: There are 18 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. Any detection by either of these sensors at 50 PPM H2S will 

initiate an audible alarm, illuminate a beacon light and shutdown all reinjection 

compressors, automatically isolating the inlet area and depressurize the facility 

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

by either of these sensors at 20 % 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, automatically isolating the inlet area and depressurize the 

facility 

7.3. HOS-4 Compressor Shut down

7.3.1. E-STOP. Trips individual compressor stop. By pressing the local “ESD button” on 

control panel to shut down the compressor.

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
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 8 of 9

Revised September 2016

 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

 Low cylinder lube oil level

 Low water level surge tank

 Vibration Compressor motor

 Manual shutdown

8.2. See critical operating limits tables procedure for safety shutdown trip points. 

M:\Departments\Engineering\MCU Plant Operation\Operating Procedures\Operating Limits 

Table Compressor

9. Problems and Solutions.

NOTE Refer to the Compressor Troubleshooting guide in control room

10. Operating Limits.

10.1. Shutdown resets:
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

HOS-4 COMPRESSOR 

OPERATING PROCEDURE 

Page 9 of 9

Revised September 2016

Local Shutdown Resets and Permissive

Tag Description Position Set point

Reinjection Plant ESD Total Reinjection Plant ESD Reset N/A

Bentley-Nevada 

Vibration Monitor

Compressor motor and frame excessive vibration Reset N/A

Fire Detection Fire Detection Reset N/A

H2S Detection H2S Detection Reset 10 PPM

LEL Detection LEL Detection Reset 50 PPM

Remote Shutdown Resets

Tag Description Position Set point

Manual Shutdown Local panel shutdown Reset N/A

E-STOP HOS-4 Run/Stop 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.

HOS-4 Compressor Normal Operating Parameters

Description Operating Range

1st stage suction pressure 15 to 24 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 1150 to 1260 psig

4th stage suction pressure 1145 to 1260 psig

4th stage discharge pressure 2750 to 2950 psig

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
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

ISOLATION PROCEDURE 

Page 1 of 3

Revised September 2016

SCOPE This procedure describes the isolation, depressurization for maintenance and returning 

of the C-5 Compressor back to service.

REQUIREMENTS Personnel’s are required to shut down compressor and isolate

APPLICABLE Ariel C-5 Compressor Operating Procedure

DOCUMENTS Pre-Start Safety Review Checklist

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Supervisor and the Operations Compliance 

Technician.

SAFETY Locks must be used by Operations and Maintenance Personals

For applicable safety requirements, refer to the Resolute Natural Resources Safety Manual and 

Safety Data Sheets (SDS).

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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

ISOLATION PROCEDURE 

Page 2 of 3

Revised September 2016

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

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

1. Isolate the compressor for maintenance. Lockout/Tagout 

1.1 Ensure that the lube oil pump is not running. Put in “off” position 

1.2 De-energize the electrical breaker for the motor by C-5 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 closed drain isolation block valve

1.7 Close the isolation block valve for the mid point drains.

2. Depressurize the compressor for maintenance.

WARNING: Atmospheric vents will release process gases that contain H2S, LEL, and Benzene. 

Caution: Any opening of kiene valves or any other valves will vent process gas to 

atmospherics to depressurize compressor

2.1 Close the main isolation block valve to the Flare header and lockout/tagout 

2.2 Open the cylinder head and crank end kiene vent valves or any other valves to verify that the 

cylinders to be worked on are depressurize and remain clear of the vented area

2.3 Notify maintenance that they may begin their work.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

ISOLATION PROCEDURE 

Page 3 of 3

Revised September 2016

3. Maintenance Completed and Pressure check compressor.

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

and remove all isolation locks and tags.

3.1. Pressure check compressor with process gas.

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

3.2 Close the atmospheric kiene vent valves on all 5 stages.

3.3 Open the isolation block valve for the close drain.

3.4 Open the isolation block valve for the mid point drain.

WARNING: Make sure atmospheric vents valves or any other valves that were opened during blow down 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 cylinders

3.1.8 Verify that no leaks are detected on all repaired components.

4. Return compressor to service.

4.1. Refer to the Ariel C-5 Operating procedure for requirements on returning the compressor back 

into service
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 1 of 15

Revised September 2016

SCOPE This procedure describes the startup and shutdown of the Ariel C-5 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 Personnel’s are required to shut down compressor and isolate 

APPLICABLE Ariel C-5 Compressor Operating Procedure

DOCUMENTS

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact the Supervisor and or Environmental Health & 

Safety Supervisor 

SAFETY For applicable safety requirements, refer to the Resolute Natural Resources Safety Manual and 

Safety Data Sheets (SDS).

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

mixture of gas.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 2 of 15

Revised September 2016

1.0 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.

 Maintenance work complete

 Temporary blinds removed and equipment restored

 Oxygen purged from compressor and piping

 Compressor and piping pressure checked using process gas

 Compressor piping rechecked for leaks

 Compressor isolation valves returned to service

 Safety devices, vents, and PRVs returned to service

 Instruments, controls, and electrical power returned to service

 Lock-out/Tag-out removed

2.0 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.

 Plant ESD and local panel shutdowns are reset

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

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

 Verify the Main Breaker Power is “On” on Power Flex 7000

• It VSD is Trips (Warn or Fault Light will be “On”)
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 3 of 15

Revised September 2016

o Press Alarm (F6)

o Read what is trip it

• Press Ack (F6)

o This will Acknowledge fault or warning

• Press Rest (F7)

o This will rest Fault or Warn

• Press Exit (F10)

o Take you back to Main Display

• Control panel power on Panel View

• Crankcase oil level okay

• Lubricator oil reservoir level okay

• Jacket water level okay

• Verify that all Suction scrubbers are empty, both visually

• Ensure that the compressor is depressurized

• Ensure that the manual flare block valve is “Open” and car seal

• Ensure that the manual closed drain block is”Open”

• Ensure that the manual open drain block is “Open”

• Ensure that the manual Instrument air block valve is “Open”

• Ensure that all kiene valves and bleeder valves are closed

• Ensure that the all PSV’s manual block valve is “Open” and car seal

• Verify the Vent Fan “A” is in “Auto” position

• Verify the Vent Fan “B” is in “Auto” position

• Verify the Pre-lube pump is in “Auto” position

• Verify the Oil cooler fan is in “Auto” position
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 4 of 15

Revised September 2016

• Verify the Oil heater is in “Auto” position

• Verify the Packing Water Pump is in “Auto” position

• Verify the Fin Fan VFD in “On” position

• Verify the HVAC in “On” position

• Verify the chemical injection pumps is in “Auto position”. (verify oil level 

and chemical level)

2.1.2 Start compressor using normal startup procedure.

PRIOR TO START-UP, OPERATOR MUST MAKE CERTAIN EQUIPMENT IS IN ACCEPTABLE CONDITION AS 

DESCRIBED IN INSTRUCTION, OPERATION MANUAL, AND PER LOCAL MAINTENANCE AND SAFETY 

PROCEDURES.

NOTE: THE LUBE OIL HEATER HE-731-C5 AND PRELUBE PUMP P-733-C5 ARE CONTROLLED FROM THE PANEL. 

WHEN THE COMPRESSOR IS DOWN THE HEATER AND PRELUBE PUMP SHOULD BETURNED ON TO MAINTAIN 

THE COMPRESSOR OIL AT A WARM TEMPERATURE, READY FOR A COMPRESSOR START.

 THE HEATER AND PRELUBE PUMP SHOULD TURN OFF IF A COMPRESSOR LOW LEVEL

SHUTDOWN IS ANNUNCIATED (LSLL-731-C5).

 THE HEATER WILL BE CONTINOUSLY CONTROLLED BY TE-731-C5 CYCLING ON AT 80 

DEG F ANDOFF AT 100 DEG. F. THE HEATER SHOULD ALSO BE TURNED OFF BY THE 

PANEL ANYTIME THE PRELUBE PUMP IS NOT RUNNING AND/OR THE OIL PRESSURE 

HAS DROPPED BELOW 9 PSIG (OIT ADJUSTABLE) AND HAS BEEN HELD FOR 10 

SECONDS.

 WHEN THE COMPRESSOR IS RUNNING THE PANEL AUTOMATICALLY SHUTS OFF THE

PRELUBE/HEATER SYSTEM AFTER A SUCCESSFUL COMPRESSOR START AND OIL 

PRESSURE HAS ATTAINED AND HELD A MINIMUM OF 35 PSIG FOR 10 SECONDS. THE 

HEATER AND PRELUBE WILL TURN OFF IF THERE IS AN ESD CONDITION DISPLAYED ON 

THE OIT. OPERATOR TO ENERGIZE HEATER/PRELUBE CIRCUIT APPROXIMATELY 6-10 

HOURS.

 PRIOR TO A START ATTEMPT TO ENSURE OIL HAS BEEN WARMED.

 TURN ICP POWER SWITCH TO “ON” POSITION. THIS ENABLES 24 VDC (+) POWER 

SUPPLY TO COMPRESSOR PANEL’S COMPONENTS.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 5 of 15

Revised September 2016

 PUSH “LIGHT TEST/RESET” BUTTON TO RESET ICP ANNUNCIATOR.

 CHECK ALL CLASS “A” SHUTDOWNS ARE CLEAR. IF NOT CLEAR SEQUENCING WILL NOT 

BE ALLOWED TO CONTINUE AND OPERATOR MUST INVESTIGATE CAUSES AND 

CORRECT THEM, THEN BEGIN AGAIN. CONFIRM THE FOLLOWING LUBE OIL 

PERIMETERS ARE MET.

 CHECK COMPRESSOR LUBE OIL TEMPERATURE START PERMISSIVE FOR >65° DEGREES. 

ICP WILL VERIFY OIL TEMPERATURE OF 65°F USING THE AVERAGE OF 5 OUT OF 6 

BEARING RTD’S. 

 CHECK COMPRESSOR LUBE OIL PRESSURE START PERMISSIVE FOR >10 PSIG. RISING 

AND HELD FOR 60 SECONDS. THE “READY TO START” MESSAGE WILL APPEAR ON THE 

PANEL. THE PLC WILL ENERGIZE THE STOP SIGNALS TO BOTH VFDs. THESE SIGNALS 

WILL REMAIN ENERGIZED UNLESS THERE IS A SHUTDOWN.

PUSH THE “START” BUTTON ON

Startup Sequence Steps:

Step Number Status Step Description

0 AVAILABLE WAITING FOR START

1 PRE-LUBE START PRELUBE

2 PRE-LUBE START LUBE HEATER

3 PURGING TIMED STEP

4 PURGING OPEN DISCHARGE BLOWDOWN BLOCK VALVE

5 PURGING OPEN SUCTION VALVE WITH 20 PSIG SETPOINT

6 PURGING TIMED STEP

7 PURGING CLOSE BYPASS VALVE PT-121 AND PT-242 > 5 PSI

8 PURGING TIMED STEP

9 PURGING OPEN DISCHARGE BLOWDOWN VALVE AND PT-242 < 25 PSIG

10 PURGING CLOSE DISCHARGE BLOWDOWN VALVE

11 STARTING OPEN DISCHARGE SHUTDOWN BLOCK VALVE

12 STARTING VERIFY SUCTION PRESSURE

13 STARTING START COMPRESSOR OIL COOLER

14 STARTING START PROCESS COOLER

15 STARTING START MAIN MOTOR

16 WARM-UP TIMED WARM-UP

17 WARM-UP RAMP TO RUN SPEED

18 -- ENABLE SUCTION AND RECYCLE

19 ONLINE ENABLE ONLINE CONTROLS
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 6 of 15

Revised September 2016

3.0 Normal Operation Daily Task.

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

NOTE 1: THE ICP WILL CHECK BOTH “OPEN” AND “CLOSED” VALVE LIMIT SWITCHES TO VERIFY CORRECT 

POSITION FOR STARTUP AND ALL SEQUENCING OPERATIONS. IF, AT ANY TIME, THE ICP RECEIVES EITHER 

TWO ENERGIZED OR TWO DE-ENERGIZED LIMIT SWITCH SIGNALS FROM THE SAME VALVE, THE ICP WILL 

ABORT THE START SEQUENCE OR SHUT THE UNIT DOWN IF RUNNING AND LIGHT THE “VALVE SEQUENCE 

MALFUNCTION” LAMP ON THE DISPLAY SCREEN AND DISPLAY THE VALVE NUMBER AT FAULT.

NOTE 2: THE ICP WILL CONTINUOUSLY MONITOR THE POSITIONS OF THE “OPEN” AND “CLOSED” VALVE 

LIMIT SWITCHES WHILE THE UNIT IS STARTING UP OR IN OPERATION. IF, AT ANY TIME, THE ICP RECEIVES 

A CHANGE IN STATUS FROM ANY LIMIT SWITCH (“OPEN” POSITION CHANGES TO “CLOSED” OR “CLOSED 

POSITION CHANGES TO “OPEN”) THAT IS OUT-OFSEQUENCE, THE ICP WILL ABORT THE START SEQUENCE 

OR SHUT THE UNIT DOWN IF RUNNING AND LIGHT THE “VALVE SEQUENCE MALFUNCTION” LAMP ON THE 

DISPLAY SCREEN AND DISPLAY THE VALVE NUMBER AT FAULT.

NOTE 3: NOTES 1 & 2 APPLY TO RECYCLE VALVE LIMIT SWITCHES ONLY DURING THE PURGE CYCLE.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 7 of 15

Revised September 2016

 Crankcase oil level with Mobil 505 oil

 Check Oil Day tank level Mobil 505

 Check Oil Day tank level NGL-888

 Jacket water pressure

 Jacket water temperature

 Check compressor lube oil level and fill as needed with NGL-888

 Check Jacket water tank level and fill as needed with Ambitrol 

 Check Jacket water pump and cooler fans for proper operation

 Check suction scrubber levels and drain manually if needed

 General housekeeping duties

 Check compressor after cooler fans operation

4.0 Temporary Operation.

NOTE Use of temporary operating procedures must be approved by the Supervisor

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.

5.0 Emergency Operation.

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

M:\Departments\Environmental\Resolute EA Plans\H2S Contingency Plan
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 8 of 15

Revised September 2016

6.0 Normal Shutdown.

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

decrease or alarm. Control Room operator will coordinate any normal shutdown.

6.1. Shut down compressor.

6.2.1. Press main motor 'stop' button.

SHUTDOWN SEQUENCE

THE UNIT WILL BE SHUT DOWN BY ONE OF TWO METHODS:

 LOCAL ESD (EMERGENCY SHUTDOWN) BUTTON IS PRESSED; STOP UNIT AND BLOW FLAT.

 REMOTE ESD; STOP UNIT. LOCAL STOP BUTTON IS PRESSED; STOP UNIT AND BLOWDOWN TO 

PRESSURIZE.

 LOCAL END DEVICE TRIP; STOP UNIT BLOWDOWN TO DEPRESSURIZE.

 LOSS OF REMOTE RUN PERMISSIVE SIGNAL; STOP UNIT AND BLOWDOWN TO PRESSURIZED

ICP WILL ENGAGE THE FOLLOWING SHUTDOWN VALVE SEQUENCE:

NORMAL SHUTDOWN (PSD; LOCAL STOP; LOCAL END DEVICE TRIP; LOSS OF REMOTE RUN 

PERMISSIVE): DE-ENERGIZE THE STOP SIGNAL TO THE MAIN MOTOR; DE-ENERGIZE THE STOP SIGNAL 

TO THE PROCESS COOLER MOTOR, ALSO THE PACKING WATER PUMP OIL COOLER FAN MOTOR. ALL 

DE-ENERGIZED AT THE SAME TIME. THE MAIN MOTOR COOLING FAN MOTORS WILL REMAIN ON FOR 

300 MINUTES (IN TEST MODE ONLY)

ESD: ALL OF THOSE IN A NORMAL SHUTDOWN PLUS SHUTDOWN THE OIL HEATER AND PRELUBE 

PUMP. ESD BUTTON ON PANEL SHOULD BE INSTALLED AND WIRED BY PANEL BUILDER. THE BUTTON 

SHALL BE PUSH TO SHUTDOWN AND PULL TO RUN (NO SPRING RETURN). THE BUTTON SHOULD BE 

MOUNTED THROUGH THE RIGHT SIDE OF THE PANEL AND APPROXIMATELY 6-12” DOWN FROM THE 

TOP OF THE PANEL.

CLOSE SUCTION BLOCK/CONTROL VALVE.

UPON ANY SHUTDOWN, THE PLC SHALL IMMEDIATELY DRIVE THE RECYCLE VALVE AND STARTUP BYPASS 

VALVES TO THEIR FULLY CLOSED POSITION TO PREVENT THE VESSELS AND PIPING ON THE SUCTION SIDE IF 

THE COMPRESSOR FROM BEING OVER PRESSURIZED.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 9 of 15

Revised September 2016

o OPEN BLOWDOWN VALVE AFTER UNIT HAS BLOWNDOWN TO A DISCHARGE PRESSURE OF 20 PSIG, 

OPEN RECYCLE AND BYPASS VALVES.

o ICP WILL DETERMINE TYPE OF SHUTDOWN PARA AND WILL EITHER CLOSE BLOWDOWN VALVE.

o WHEN SUCTION PRESSURE REACHES 5 PSIG, OR LEAVE IT OPEN FOR A FLAT BLOWDOWN.INDICATE 

CAUSE OF SHUTDOWN ON OIT DISPLAY.

SHUTDOWNS ANNUNCIATOR:

CLASS "A"

SHUTDOWN OR ALARM – ACTIVE AT ALL TIMES.

CLASS "B"

SHUTDOWN OR ALARM – BYPASSED DURING START-UP FOR 60 SECONDS (LOW OIL

PRESSURES, LOW SUCTION TEMPERATURE AND NO-FLOWS). (EACH TEMP ON INDIVIDUAL ADJUSTABLE 

TIMER)

CLASS “C”

SHUTDOWN OR ALARM – BYPASSED UNTIL FIRST TIME CLEAR. LOCAL INDICATION.

WARNING! THE COMPRESSOR PACKAGE WILL BE OFF-LINE FOR AN EXTENDED PERIOD; OPERATOR MUST 

MANUALLY PURGE THE SYSTEM OF H2S USING SWEET NATURAL GAS TO PREVENT CORROSION. VIA VALVE 

MAINTENANCE SCREEN THROUGHOUT.

WARNING! THE COMPRESSOR PACKAGE MUST BE FULLY BLOWN DOWN PRIOR AND PURGED WITH SWEET 

GAS AND BLOWN DOWN (TO PREVENT EXPOSURE TO H2S) TO SERVICE OR

SEVERE PERSONAL INJURY MAY OCCUR.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 10 of 15

Revised September 2016

Emergency Shutdown (ESD)

7.0 SHUTDOWN SEQUENCE

Local Stop button is pressed; Stop unit and blown down to depressurized and blow down to the Flare header to 

depressurize the compressor.

THE UNIT WILL BE SHUT DOWN BY ONE OF TWO METHODS:

1-LOCAL ESD (EMERGENCY SHUTDOWN) BUTTON IS PRESSED; STOP UNIT AND BLOW DOWN REMOTE 

ESD; STOP UNIT.

2-LOCAL STOP BUTTON IS PRESSED; STOP UNIT AND BLOWDOWN TO DEPRESSURIZE

LOCAL END DEVICE TRIP; STOP UNIT BLOWDOWN TO PRESSURIZE.

LOSS OF REMOTE RUN PERMISSIVE SIGNAL; STOP UNIT AND BLOWDOWN TO DEPRESSURIZE ICP WILL 

ENGAGE THE FOLLOWING SHUTDOWN VALVE SEQUENCE:

NORMAL SHUTDOWN (PSD; LOCAL STOP; LOCAL END DEVICE TRIP; LOSS OF REMOTE RUN PERMISSIVE): DEENERGIZE THE STOP SIGNAL TO THE MAIN MOTOR; DE-ENERGIZE THE STOP SIGNAL TO THE PROCESS COOLER 

MOTOR, ALSO THE PACKING WATER PUMP AND OIL COOLER FAN MOTOR. ALL DE-ENERGIZED AT THE SAME 

TIME. THE MAIN MOTOR COOLING FAN MOTORS WILL REMAIN ON FOR 300 MINUTES 

7.1. Reinjection Facility ESD:

7.1.1. ESD Station (PB1) One push button station is located inside the Control Room above 

the Fire, H2S and LEL Detection System's readout panel is located on the South wall of 

the Rosemount panel inside the MCC Control Room. 

7.1.2. ESD Station (PB2) Located on a pipe rack support beam on the southeast corner of the 

NOTE ESD of the Gas Reinjection Facility can be initiated from any of the 6 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 shut down all the reinjection 

compressors, isolate the inlet area and depressurize 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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 11 of 15

Revised September 2016

Acid Gas compressor building.

7.1.3. ESD Station (PB3): Located outside between the Control Room and the MCC building.

7.1.4. ESD Station (PB5): located on the north wall outside of the Inlet building.

7.1.6. E-STOP Station: Location on HOS-6 HMI Panel

7.1.7 E-STOP Station: Located on a building support beam on the northeast corner of the 

HOS-6 Compressor building. The HOS-6 Compressor building.

7.1.8. ESD Station (PB6): Located on a building support beam on the northwest corner of the 

HOS-4 Compressor building.

7.1.9. ESD Station (PB7): Located on cooler fan support beam on the southeast corner of the 

HOS-4 Compressor's Cooler Fan bay.

7.1.10 ESD PB’s Station: Located in MCC building on the southeast corner of the HOS 6 soft 

start MCC building.

7.1.11 ESD Station (PB8): Located on Flare/Dehydration walkway

7.2 Fire, H2S and LEL Detection Systems ESD:

7.2.1. Fire: There are 14 Fire Detection sensors located throughout the facility. Any detection 

by either of these sensors will initiate an audible alarm, ESD’s reinjection facility, 

automatically isolating the inlet area and depressize the facility.

7.2.2. H2S: There are 18 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. Any detection by either of these sensors at 50 PPM 

H2S will initiate an audible alarm, illuminate a beacon light and shutdown all 

reinjection compressors, automatically isolating the inlet area and depressize the 

facility 

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

by either of these sensors at 20 % 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, automatically isolating the inlet area and depressize the 

facility 
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 12 of 15

Revised September 2016

7.3. Ariel C5 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.

8.0 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 pressure

 Electrical power failure

 High discharge pressure on either the 1st, 2nd, 3rd, 4th, and 5th stage cylinders

 High discharge temperature on either of the 1st, 2nd, 3rd,4th and 5th stage cylinders

 High level in either of the 1st, 2nd, 3rd, 4th and 5th 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 (primary/secondary)

 Low water level surge tank

 Cooler fan vibration

 Cooler oil/heater fan vibration

 Vibration Compressor motor
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 13 of 15

Revised September 2016

 Manual shutdown

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

9.0 Problems and Solutions.

10. Operating Limits.

10.1. Shutdown resets:

Local Shutdown Resets and Permissive

Tag Description Position Setpoint

Reinjection Plant ESD Total Reinjection Plant ESD Reset N/A

Vibration Monitor Compressor motor and frame excessive vibration Reset N/A

Fire Detection Fire Detection Reset N/A

Remote Shutdown Resets

Tag Description Position Setpoint

Manual Shutdown Local panel shutdown Reset N/A

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

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 14 of 15

Revised September 2016

10.2. Normal operating parameters:

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

them.

Ariel C5 Compressor Normal Shut down Parameters

Description Shut down 

1st stage suction pressure 14 psig

1st stage discharge pressure 65 psig

1st stage suction temperature degrees F

1st stage discharge temperature 305 degrees F

2nd stage suction temperature degrees F

2nd stage discharge temperature 305 degrees F

3rd stage suction temperature degrees F

3rd stage discharge temperature 305 degrees F

4th stage suction temperature degrees F

4th stage discharge temperature 305 degrees F

5th stage suction temperature degrees F

5th stage discharge temperature 320 degrees F

Lube oil pressure 35 psig

3rd stage suction temperature degrees F

3rd stage discharge temperature 305 degrees F

4th stage suction temperature degrees F

4th stage discharge temperature 305 degrees F

5th stage suction temperature 110 degrees F

5th stage discharge temperature 320 degrees F

Lube oil pressure 35 psig
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

AERIAL C-5 COMPRESSOR 

OPERATING PROCEDURE 

Page 15 of 15

Revised September 2016

Ariel C5 Compressor Normal Operating Parameters

Description Operating Range

1st stage suction pressure 20 to 30 psig

1st stage discharge pressure 65 to 100 psig

2nd stage suction pressure 60 to 120 psig

2nd stage discharge pressure 180 to 300 psig

3rd stage suction pressure 150 to 330 psig

3rd stage discharge pressure 450 to 600 psig

4th stage suction pressure 400 to 600 psig

4th stage discharge pressure 1000 to 1300 psig

5th stage suction pressure 1000 to 1300 psig

5th stage discharge pressure 2500 to 2970 psig

1st stage suction temperature 45 to 105 degrees F

1st stage discharge temperature 150 to 305 degrees F

2nd stage suction temperature 50 to 120 degrees F

2nd stage discharge temperature 150 to 305 degrees F

3rd stage suction temperature 80 to 120 degrees F

3rd stage discharge temperature 150 to 305 degrees F

4th stage suction temperature 90 to130 degrees F

4th stage discharge temperature 150 to 305 degrees F

5th stage suction temperature 100 to 140 degrees F

5th stage discharge temperature 150 to 305 degrees F

Lube oil pressure 45 to 100 psig

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

them.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

ISOLATION PROCEDURE 

Page 1 of 3

Revised September 2016

SCOPE This procedure describes the isolation, depressurization for maintenance 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 Supervisor and the Operations Compliance 

Technician.

SAFETY Locks must be used by Operations and Maintenance Personals 

For applicable safety requirements, refer to the Resolute Natural Resources Manual and Safety 

Data Sheets (SDS).

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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

ISOLATION PROCEDURE 

Page 2 of 3

Revised September 2016

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

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

1. Isolate the compressor for maintenance and lockout/tagout 

NOTE Refer to the Acid Gas Compressor Operating procedure for requirements to shut down 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 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 "calibration" mode in the Control Room, and 

place log into Critical Safety Device (CSD) log book in the Control Room.

2. Depressurize the compressor for maintenance.

WARNING Atmospheric vents will release process gas that contain LEL, Benzene and H2S.

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.

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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

ISOLATION PROCEDURE 

Page 3 of 3

Revised September 2016

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. Maintenance Completed and 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's for 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.

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

3.1.6 Open the 1st stage suction pressure controller 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 Acid Gas Compressor Operating procedure for requirements on returning the 

compressor back into service
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 1 of 10

Revised September 2016

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

(CM-1201B). 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 Compressor "B" (CM-1201B) Isolation Procedure

DOCUMENTS

SPECIAL None

EQUIPMENT

ENVIRONMENTAL For environmental concerns, contact Supervisor and or Environmental Health & Safety 

Supervisor 

SAFETY For applicable safety requirements, refer to the Resolute Natural Resources Safety Manual and 

Safety Data Sheets (SDS).

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

mixture of gas.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 2 of 10

Revised September 2016

1.0 Initial Startup.

1.1. Check that the compressor is ready for start.

 Maintenance work complete

 Temporary blinds removed and equipment restored

 Oxygen purged from compressor and piping

 Compressor and piping pressure checked using process gas

 Compressor piping rechecked for leaks

 Compressor isolation valves returned to service

 Safety devices, vents, and PRVs returned to service

 Instruments, controls, and electrical power returned to service

 Lock-out/Tag-out removed

1.2. Start compressor using normal startup procedure.

2.0 Normal Startup.

2.1. Prepare the compressor for start.

2.1.1. Check compressor is ready for start.

 Plant ESD and local panel shutdowns are reset

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

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.

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

shutdown after performing the initial startup checks.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 3 of 10

Revised September 2016

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

Control Room.

 Control panel power on

 Manual switch is in the "run" position for the Murphy Mark III annunciator

 Electrical motor oil level

 Crankcase oil level okay

 Lubricator oil reservoir level okay

 Jacket water level okay

 Visually verify that all Suction scrubbers are empty

 Ensure that the compressor is depressurized

 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. If 

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-1605, and HT-1606).

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

2.2.4 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 III 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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 4 of 10

Revised September 2016

2.2.7 Press the main motor 'start' button.

2.2.8 Pre-Lube for one minutes

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.

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

3.0 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

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

NOTE Murphy switch gauges on local panel not to exceed the PSV's setting 
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 5 of 10

Revised September 2016

 Lubricator oil level

 Jacket Water Pressures

 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 for proper operation

 Check suction scrubber levels and drain level as needed

 General housekeeping duties

 Check aftercooler fans operation

 Check all 4-sides electrical motor oil level

4.0 Temporary Operation.

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 returned to normal operation or when 

a temporary procedure becomes permanent. Complete all documentation required.

5.0 Emergency Operation.

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

M:\Departments\Environmental\Resolute EA Plans\H2S Contingency Plan

5.2. See end of procedure for emergency shutdown (ESD) instructions.

NOTE Use of temporary operating procedures must be approved by Supervisor.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 6 of 10

Revised September 2016

6.0 Normal Shutdown.

6.1. Shut down compressor.

6.2.1. Press main motor 'stop' button.

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 10 to 15 minutes, then turn off the motor cooling fan.

7.0. Emergency Shutdown (ESD):

7.1. Reinjection Facility ESD:

7.1.1. ESD Station (PB1): One push button station is located inside the Control Room above 

the Fire, H2S and LEL Detection System's readout panel is located on the South wall of 

the Rosemount panel inside the MCC Control Room. 

7.1.2. ESD Station (PB2): Located on a pipe rack support beam on the southeast corner of the 

Acid Gas compressor building.

7.1.3. ESD Station (PB3): Located outside between the Control Room and the MCC building.

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

Control Room operator will coordinate any normal shutdown. 

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

the compressor. 

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 ESD. Both systems will shut down 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.
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 7 of 10

Revised September 2016

7.1.4. ESD Station (PB5): located on the north wall outside of the Inlet building.

7.1.6. E-STOP Station: Location on HOS-6 HMI Panel

7.1.7 E-STOP Station: Located on a building support beam on the northeast corner of the 

HOS-6 Compressor building. The HOS-6 Compressor building.

7.1.8. ESD Station (PB6): Located on a building support beam on the northwest corner of the 

HOS-4 Compressor building.

7.1.9. ESD Station (PB7): Located on cooler fan support beam on the southeast corner of the 

HOS-4 Compressor's Cooler Fan bay.

7.1.10 ESD PB’s Station: Located in MCC building on the southeast corner of the HOS 6 soft 

start MCC building.

7.1.11 ESD Station (PB8): Located on Flare/Dehydration walkway.

7.2 Fire, H2S and LEL Detection Systems ESD:

7.2.1. Fire: There are 14 Fire Detection sensors located throughout the facility. Any detection 

by either of these sensors will initiate an audible alarm, ESD’s reinjection facility, 

automatically isolating the inlet area and depressurize the facility.

7.2.2. H2S: There are 18 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. Any detection by either of these sensors at 50 PPM 

H2S will initiate an audible alarm, illuminate a beacon light and shutdown all 

reinjection compressors, automatically isolating the inlet area and depressurize the 

facility.

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

by either of these sensors at 20 % 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, automatically isolating the inlet area and depressurize the 

facility.

7.3. Acid Gas Compressor ESD.

7.3.1. Local E-STOP. Trip individual compressor ESD by pressing 'Stop' button on local control 
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 8 of 10

Revised September 2016

panel to shut down that compressor only.

8.0 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, 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 cylinders

 No flow cylinder lubricator on the 4th stage cylinder

 Low cylinder lube oil level

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

 Jacket Water pressure

 Low Jacket Water Tank level # 1
Resolute Natural 

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 9 of 10

Revised September 2016

 Low Jacket Water Tank level # 2

 Vibration

 Manual shutdown

9. Problems and Solutions.

10. Operating Limits.

10.1. Shutdown resets:

Local Shutdown Resets and Permissives

Tag Description Position Setpoint

Reinjection Plant ESD Total Reinjection Plant ESD Reset N/A

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

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

Resources Company

McElmo Creek Unit 

Gas Compression Plant

ACID GAS “B” COMPRESSOR

OPERATING PROCEDURE 

Page 10 of 10

Revised September 2016

10.2. Normal operating parameters:

Acid Gas Compressor Normal Operating Parameters

Description Operating Range

1st stage suction pressure 10 to 18 psig

1st stage discharge pressure 90 to 100 psig

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

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

outside them.
McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01

MCELMO CREEK UNIT OPERATIONS &

MAINTENANCE PLAN

ATTACHMENT A-4:

COMPRESSOR TROUBLESHOOTING GUIDE 

September 2016
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 1 of 17

COMPRESSOR TROUBLESHOOTING GUIDE

Table of Contents

1. ENGINE & FRAME SHUTDOWNS..................................................................2

1.1 Compressor Frame Oil Pressure Shutdown Troubleshooting Guide .........3

1.2 Lubrication No Flow Shutdown Troubleshooting Guide .............................4

1.3 High Motor/Frame Vibration Shutdown Troubleshooting Guide.................5

2. COOLING SYSTEM SHUTDOWNS.................................................................6

2.1 Low Auxiliary Water Pressure Shutdown Troubleshooting Guide..............7

2.2 Low Coolant Level Shutdown Troubleshooting Guide ...............................8

2.3 Low Jacket Water Pressure Shutdown Troubleshooting Guide .................9

2.4 High Jacket Water Temperature Shutdown Troubleshooting Guide ........10

2.5 High Cooler Vibration Shutdown Troubleshooting Guide.........................11

3. GAS CIRCUIT SYSTEM SHUTDOWNS........................................................12

3.1 High/Low Suction Pressure Shutdown Troubleshooting Guide................13

3.2 High Scrubber Level Shutdown Troubleshooting Guide ..........................14

3.3 High/Low Interstage Pressure Shutdown Troubleshooting Guide............15

3.4 High/Low Discharge Pressure Shutdown Troubleshooting Guide............16

3.5 High Discharge Temperature Shutdown Troubleshooting Guide.............17
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 2 of 17

1.ENGINE & FRAME SHUTDOWNS
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 3 of 17

1.1 Compressor Frame Oil Pressure Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Low Oil Level

(High level can cause 

foaming, resulting in low 

pressure)

1. Check oil level.

2. Add oil as needed.

3. Check frame oil level controller

4. Restart unit.

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. Start unit.

2. Check for normal oil pressure at discharge.

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 troubleshooting.

6. Check pump suction screen for obstruction.

7. If clogged, clean or replace screen.

Relief Valve Stuck Open or 

Set Too Low

1. Check relief valve setting and position.

2. Correct as needed.

High Oil Level Caused by 

Water/Liquid Dilution

1. Check day tank water levels to see if there is a leak in head, gasket or liner.

2. Call Mechanic.

Low Oil Viscosity 1. Change oil.

2. Check recent oil sample analysis results.

POSSIBLE CAUSE CORRECTIVE ACTIONS

High Oil Level 1. Check oil level.

2. Add oil as needed.

Binding or Tightness in 

Compressor Crankshaft

1. Roll motor and compressor by hand.

2. Check for binding or tightness

3. If binding or tightness exists, notify Mechanic immediately. Do NOT start unit.

4. If no binding or tightness is found, start motor.

Dirty Oil Filters 1. Check differential pressure across filters.

2. Check filter, if pressure drop exceeds compressor manufacturer parameters.

Clogged or Blocked Oil 1. Clean oil cooler fins.

2. Check cooling fan operation.

3. Replace oil cooler as needed.

Faulty Gauge 1. 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 Resolute Energy parameters.

Broken Thermostat 1. Scan piping for temperature variances.

2. Replace thermostat and control valve if needed.

Stuck Oil Thermostat 1. Check for bypass around oil cooler.

2. Replace thermostat.

If high compressor frame oil temperature continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 4 of 17

1.2 Lubrication No Flow Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Insufficient Oil in Lubricator 

Box

1. Check oil in lube box.

2. Check oil regulator supply to lube box.

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

Broken Lubricator Drive 1. Ensure gear drive and all couplings are not broken or stripped.

2. Replace drive coupling or chain as needed.

Faulty Lubricators 1. Ensure all lubricators are pumping the proper amount of 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.

3. If rupture disc continues to blow, replace distribution block and cylinder 

check valves.

Faulty No-Flow Switch 1. 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 Component 

Troubleshooting Guide."

If no lube flow continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 5 of 17

1.3 High Motor/Frame Vibration Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Loose Mounting Bolts 1. Check bolts.

2. Tighten as needed.

3. If motor or frame mounts are loose, call Mechanic for 

alignment/deflection checks.

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

2. Check for binding or noise.

3. Listen for unusual knocking or noise.

4. Reset vibration switch.

5. Clear panel.

6. Start up unit.

Short in Wire to Panel 1. 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 cannot be found, refer to “Panel Component 

Troubleshooting Guide.”

Broken Valve, Piston or Piston 

Rod

1. Pull valve caps and inspect or replace valves as necessary.

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

piston.

3. Repair or replace parts as needed.

High Scrubber Level 1. Check scrubber for high liquid level.

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

If high motor/frame vibration continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 6 of 17

2. COOLING SYSTEM SHUTDOWNS
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 7 of 17

2.1 Low Auxiliary Water Pressure Shutdown Troubleshooting Guide

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.

Water Coupling Failure 1. Visually inspect auxiliary water pump and coupling for wear and leaks.

2. Replace pump and/or coupling as needed.

Blockage in Intercooler I 1. Start motor.

2. Check differential temperature and pressure across intercooler.

3. 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 view 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.

If low auxiliary water pressure continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 8 of 17

2.2 Low Coolant Level Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Gauge Cocks on Sight Glass 

are Closed

1. Ensure gauge cocks on sight glass are open and you have true coolant 

tank reading.

Coolant Leaks 1. 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 pump seal; change water pump is seal is 

leaking.

Malfunctioning Level 

Controller on Surge Tank I

1. Check level controller float.

• If float is not intact, replace.

2. Check micro-switch if defective.

• Replace micro-switch if defective.

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

• Replace wire as needed.

Internal Leaks 1. Repair leaks as needed.

If low coolant level continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 9 of 17

2.3 Low Jacket Water Pressure Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Low Coolant Level 1. Check coolant level.

2. Add coolant to proper level as needed.

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

4. Check hoses; repair or replace as needed.

Water Pump/Coupling Failure 1. Visually inspect water pump and couplings for wear or leaks.

2. Replace pump/couplings as needed.

3. Repair any leaks found.

4. Start motor

5. Check jacket water pressure.

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

7. If pressure is low, replace water pump or couplings as needed.

8. Check hoses/couplings on pump inlets.

9. Repair/Replace parts as needed.

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

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

Faulty Valve Position 1. Ensure proper inlet/outlet valve position.

Cracked Cylinder or Liner 1. Check crankcase oil level.

2. Check for water in crank case.

3. Drain oil and check for leaking liner.

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

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

2. Repair as needed.

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

If low jacket water pressure continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 10 of 17

2.4 High Jacket Water Temperature Shutdown 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/Coupling Failure 1. Visually inspect water pump and couplings and cooler fan belts for 

wear or leaks.

2. Replace pump or couplings as needed.

Faulty Gauge 1. Start motor.

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

temperature gauges.

3. Calibrate or replace gauge as needed.

Low Temperature Differential 

on Cooler

1. Ensure proper louver position.

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.

Sticking Thermostats 1. 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 Adjustment 1. Check pitch on fan blades; torque to specs.

If high jacket water temperature continues and you have all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 11 of 17

2.5 High Cooler Vibration Shutdown Troubleshooting Guide

POSSIBLE CAUSE· CORRECTIVE ACTIONS

Loose Mounting Bolts 1. Check bolts.

2. Tighten as needed.

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

2. Check for binding or noise.

3. Ensure start switch is off.

4. Listen for unusual knocking or noise.

5. Reset vibration switch.

6. Clear panel.

7. Start up unit.

Vibration Switch is Set Too

Sensitive

1. Check sensitivity setting.

2. Adjust as needed.

Mechanical

Malfunction

1. Visually inspect belts and cooler blades to see if they are loose or 

damaged.

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

must enter cooler.

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

Wiring or Vibration Switch 

Malfunction

1. Start unit.

2. Check panel.

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

4. Replace wire as needed.

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

Troubleshooting Guide."

Loose Fan Blades 1. Replace fan blades as needed.

2. Check torque; re-torque bolts and check blades for proper angle.

If high cooler vibration continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 12 of 17

3. GAS CIRCUIT SYSTEM SHUTDOWNS
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 13 of 17

3.1 High/Low Suction Pressure Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Suction Control Valve 

Malfunction

1. Start and load unit.

2. Compare suction pressure to reading on previous

3. Operator Report.

4. Check custody charts for high or low suction condition.

5. Adjust control valve or notify client of control valve problem.

Faulty Instruments 1. Use test gauges to check panel instruments for accuracy.

2. Calibrate or replace instruments as needed.

Frozen, Plugged or Broken 

Lines

1. Thaw sensing lines with methanol.

Use extreme caution when using methanol. Wear appropriate 

PPE.

2. Replace broken tubing.

Dump Valve Hung Open 1. Check scrubber dumps.

2. Reset dump controller.

Recycle Malfunction 1. Check recycle valve operation.

2. Adjust as needed for proper setting.

Intake Screen or Filter 

Plugged

1. Check differential pressure across filter/screen.

2. Change/Clean filter/screen as needed.

If high/low suction pressure continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 14 of 17

3.2 High Scrubber Level Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Closed Sight Glass Gauge 

Cocks

1. Ensure sight glass gauge cocks are open.

2. Check for level in sight glass.

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

Level Controller Malfunction 1. Ensure level controller has adequate air supply 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 parts; tighten or replace as needed.

Blockage in Dump Valve 1. Check output to dump 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 1. 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 

Malfunction

1. Ensure float on high level shutdown is intact. 

• If float is not intact, replace float.

2. Inspect micro-level switch in high level shit-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 grounde3d wire cannot be found, refer to “Panel Component 

Troubleshooting Guide.”

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. Check for trapped pressure; relieve trapped pressure SLOWLY if 

possible.

Liquid Carryover in Scrubber 1. Drain air supply.

High Pressure in Tank or 

Scrubber

1. Ensure pressure of vessel being dumped into is lower than pressure of 

fluid being dumped.

If high scrubber level continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 15 of 17

3.3 High/Low Interstage Pressure Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS·

Faulty Valve or Rings 1. Trend interstage pressure

2. Check for hot valve/operators log.

3. Repair or replace as needed.

Gas Leak 1. Check for relief valve venting.

2. Inspect relief valves for possible malfunction.

3. Reset or replace relief valves as needed.

Faulty Gauges 1. Use test gauge on interstage scrubber to test accuracy against panel 

instruments.

2. Calibrate or replace gauges and reset instruments.

Dump Valves Hung in Open 

Position

1. Ensure dump valves ae in closed position.

2. Set dump controller for proper level control.

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

2. Check meters for flow changes; set parameters to proper setting.

If high/low interstage pressure continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 16 of 17

3.4 High/Low Discharge Pressure Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

High Discharge Pressure 1. Check trend – SCADA for system pressure.

2. If high pressure, contact production supervisor to determine cause.

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

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

3. Check pressure on panel view to ensure pressure is released.

4. Check for frozen tubing lines:

5. Disconnect tubing.

6. Inject methanol into line.

7. Caution: Use extreme caution with methanol; high pressure may be 

trapped in tubing.

8. Warm pipes as needed.

Relief Valve Malfunction 1. Check relief valve setting.

2. Repair or replace relief valve as needed.

Gauge Malfunction 1. Use manometer (test gauge) to check panel instruments for malfunction.

2. Calibrate or replace instruments as needed.

Short in Wire – Panel I 1. Check panel: Call I&E

2. If panel clears, load unit and monitor closely.

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

4. Use volt meter to locate grounded wire.

5. Replace wire.

Bad Valves or Compressor 

Ring

1. Ensure temperatures and pressures are within normal 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 

Malfunction

1. Check recycle/dump valves; adjust as needed.

If high/low discharge pressure continues and you have taken all corrective steps, call Mechanic.
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan - Compressor Troubleshoot Guide

PSD Permit No. NU 05-01, Appendix A, Attachment A-4

September 2016

Page 17 of 17

3.5 High Discharge Temperature Shutdown Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Hot Valves 1. Trend unit – SCADA

2. Pyro scan valve caps.

3. Repair or replace valves as needed.

4. Review operator log.

High Interstage Temperature 1. Check louver position on cooler.

2. Open louvers as needed to cool gas.

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

Faulty Gauges 1. Use test gauges on suction/discharge pressure.

2. Compare with normal run condition.

3. Calibrate or replace gauges as needed.

Inadequate Lubrication 1. Check lubricator for proper cylinder lubrication.

2. Increase output or replace lubricator as needed.

Cylinder Piston Ring Damage 1. Inspect cylinder piston rings.

2. Replace piston rings as needed.

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

2. Check suction pressure; calibrate discharge temperature.

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.
McElmo Creek Unit Oil Production Facility

PSD Permit No. NU 05-01

MCELMO CREEK UNIT OPERATIONS &

MAINTENANCE PLAN

ATTACHMENT A-5:

SPARE PARTS LIST 

Spare Parts List for Compressors HOS-6, HOS-4, and Aerial C-5

September 2016
McElmo Creek Unit Oil Production Facility

McElmo Creek Unit O&M Plan – Spare Parts List

PSD Permit No. NU 05-01, Appendix A, Attachment A-5

September 2016

McElmo Creek Unit Oil Production Facility - Gas Compression Plant 

Spare Critical Machinery Equipment

Spare Parts List

Equipment HOS 6 Compressor HOS-4 Compressor ARIEL C-5 Compressor

Compressor • Compressor Suction/Discharge

Valves

• Piston Rings

• Piston Rods

• Gaskets

• Packing Gland Assembly

• Crosshead Assembly

• Oil Filters

• Lubricator Parts

• Compressor

Suction/Discharge Valves

• Oil Filters

• Lubricator Parts

• Compressor Suction/Discharge 

Valves

• Piston Rings

• Piston Rods

• Gaskets

• Packing Gland Assembly

• Crosshead Assembly

• Oil Filters

• Lubricator Parts

Electric Motor Driver • Thermocouples

• Vibration Probes

• Thermocouples

• Vibration Probes

• Thermocouples

• Vibration Probes

Cooler • V-Belts

• Pulleys

• Gaskets and Seal Pins

• V-Belts

• Pulleys

• Gaskets and Seal Pins

• V-Belts

• Pulleys

• Gaskets and Seal Pins

Instruments and

Controls

• Temperature Switches

• Pressure Switches

• Instrument Tubing

• Position Indicators

• Pressure Gauges

• Thermometers

• Temperature Switches

• Pressure Switches

• Instrument Tubing

• Position Indicators

• Pressure Gauges

• Thermometers

• Temperature transmitter

• Pressure transmitter

• 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.