1

Kelly, Shaheerah

From: Dwight Mallory <Dmallory@resoluteenergy.com>

Sent: Wednesday, October 07, 2015 1:28 PM

To: Kelly, Shaheerah

Subject: RE: MCU PSD Permit

Attachments: removed.txt; 06202015 Revised MCU O&M Plan.docx

Shaheerah,

I did confirm that the reason the Acid Gas B compressor does not have a separate maintenance table in the maintenance

plan is because it is a small machine that is only used for back up capacity and isn’t designed to be part of the primary

process train at the facility. Section III of the O&M Plan contains language to that affect and I modified the highlighted

paragraph below. I also corrected a typo that indicated that Acid Gas A was being used for backup (it should read Acid

Gas B  is a smaller unit...).

I attached a later revision of the O&M Plan. It should be the same as the copy you have except that I cleaned up a few

typos and grammar issues.

Please let me know if I can be of further assistance.

1.1 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.

1.2 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.

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. 
2

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

included in this appendices 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.

1.3 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.

The linked image cannot be displayed. The file may have been moved, renamed, or deleted. Verify that the link points to the correct file and location.

Dwight E. Mallory

Environmental/Regulatory Manager

Resolute Energy Corporation

1700 Lincoln Street, Suite 2800

Denver, CO 80203

Direct: 303-573-4886 X 1165

From: Kelly, Shaheerah [mailto:Kelly.Shaheerah@epa.gov]  

Sent: Wednesday, October 07, 2015 11:30 AM

To: Dwight Mallory <Dmallory@resoluteenergy.com>

Subject: MCU PSD Permit

  

Dwight,

  

Per our phone call, below is the revised section of the O&M plan. You mentioned that the Acid Gas B unit was a standby

unit.  It would be helpful if you would send me a statement or sentence that describes the use of the Acid Gas B unit so

we can better describe in below. Additionally, feel free to send me any corrections to the revised section below.  

  

Thanks.

  

1. PROCESS OVERVIEW & OPERATING PROCEDURES

The McElmo Creek Unit Oil Production Facility (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: inlet separation, compression and re-injection.

1.1 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.
3

1.2 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 A 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.

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. 

Isolation and operating procedures for the Acid Gas B, Ariel C-5, HOS 4, and HOS 6 compressors are included 

in the appendix to this report.

1.3 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.

************************************ 

Shaheerah Kelly

Permits Office, Air Division (AIR-3)

U.S. Environmental Protection Agency, Region 9 

San Francisco, CA 94105 

Phone: 415-947-4156 

Fax: 415-947-3579 

Email: kelly.shaheerah@epa.gov

  

  

This e-mail message and any attachments are for the sole use of the intended recipient(s) and may contain confidential, privileged, and 

proprietary information of Resolute Energy Corporation. Any unauthorized review, use, disclosure or distribution may be prohibited 

under law. If you are not the intended recipient, please contact the sender by reply E-mail of any erroneous transmission, and destroy 

the original E-mail, any attachments, and all copies of the original message. Thank you.
MCELMO CREEK UNIT 

OPERATIONS & MAINTENANCE PLAN

McElmo Creek Unit Oil Production Facility

PSD Permit Number: NU 05-01

This document shall apply to and be binding upon the owner(s) and operator(s) of 

the McElmo Creek Unit Oil Production Facility, including Resolute Natural 

Resources Company, LLC.
MCELMO CREEK UNIT OPERATIONS & MAINTENANCE PLAN

CONTENTS

I. Process Overview and Operating Procedures

II. Routine Monitoring & Surveillance

III. Maintenance Plan

IV. Training Program for Plant Operators

V. Reference Documentation

VI. Appendices

1. Life Cycle Maintenance Plan - McElmo Compressors

HOS 6, HOS 4, Ariel C-5

2. Daily Plant Reading Form

3. Isolation and Operating Procedures

HOS 6, HOS 4, Acid Gas and Ariel C-5

4. Compressor Troubleshooting Guide

5. Spare Parts List- HOS 4, HOS 6, Ariel C-5
I. Process Overview and Operating Procedures

The McElmo Creek Compression Plant serves tertiary recovery operations for the McElmo

Creek Field. The 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

Plant inlet volume can vary between 10 and 24 million standard cubic feet per day (MSCFD).

The gas is processed in three main steps: inlet separation, compression and reinjection.

Inlet Separation: The inlet separation consists of an inlet slug receiver which collects free

liquids. The gas then passes through filter vessels which collect any incoming solids.

Compression: The Plant houses four high-speed electrically-driven reciprocating compressors, 

HOS-6, HOS-4, C-5 and Acid Gas B. HOS-6, HOS-4 and C-5 are the primary facility 

compressors. The Acid Gas B compressor is a smaller unit and is only used for backup and 

excess throughput. 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 Unit. A fifth compressor, Acid Gas A, is also present at the 

plant, but 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.

Re-Injection: The four compressor units discharge into a single header, where purchased

C02 is co-mingled to achieve a daily injection rate of up to 24 MSCFD. The gas is then 

distributed to the field.

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

the Plant is automatically diverted to flare until the problem is corrected.

II. Routine Monitoring/Surveillance

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

make plant rounds each shift, during which key operating parameters of the compressors and

supporting equipment are monitored. The following are examples of the parameters that are

recorded during a shift:

• Overall Plant inlet and discharge volumes

• CO2 purchased volumes

• Flared volumes
• Discharge pressure

• Compressor run times

From the Operator's daily run time report (example attached in Appendix 2 to 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. Examples of parameters that the

Operators record includes:

• Compressor suction and discharge temperatures and pressures

• Scrubber liquid levels

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

and operating procedures included in Appendix 1 to 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.

III. 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

Appendix 1 to this O&M Plan contains specific tasks that comprise the Life Cycle Maintenance

Plan for the HOS-6, HOS-4 and C-5 compressors. The process includes Periodic Maintenance,

Predictive Maintenance, Equipment Life Cycle and Overhaul Schedules, which describe the

various levels of maintenance for the primary plant compressors. The Acid Gas B compressor is 

included in the maintenance plan, but is not addressed in Appendix 1 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. 

A. Periodic Maintenance (PM's)

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

• Oil and water levels are monitored

• Vibration levels on the motors and compressor frames are monitored

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

compressor and electric motor are noted.

Additional periodic maintenance includes:

• Compressor performance analysis (Beta)

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

and all of the auxiliary equipment.

• Foundations and equipment mounts are checked for cracks and correct make-up 

torque.

• Compressor Piping is inspected for external damage

• Corrosion coupons are pulled and monitored

Annual Inspections involve performing functional tests on the instrument and controls

systems. This includes testing safety devices, vibration probes, safety alarms and safety

shutdowns. There are PM's frequencies that extend past a year, such as coolant replacement

and lube oil replacement. The Rotating Equipment Engineer decides if this work is required.

B. 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.

C. 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 is 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 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.

D. Life Cycle Maintenance Model

The section below provides a description of the type of activities planned for each level of 
predictive maintenance. Note Levels 5 and 6 are subject to the Risk Based Work Selection 

process prior to committing to the work. The Predictive Maintenance Process is based on 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.

IV. Training Program for Plant Operators

NEW OPERATIONS PERSONNEL- NO PRIOR McELMO PLANT EXPERIENCE

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

experience consists of the following:

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

must be scheduled for only day shifts until qualified.

• Training will be conducted on the following:

• Plant operation. start up, shutdown and emergency procedures

• Surveillance requirements for plant operations personnel

• First line maintenance responsibilities
• Regulatory requirements. such as upset reporting and regulatory documentation

• Required safe work practices, permits and methods used

• Required communication procedures, including handling of community inquiries

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

approve the trainee for release from the training program

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

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:

• Emission Limits as it relates to their duties

• Monitoring as it relates to their duties

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

• Root Cause Analysis as it relates to their duties

• Right of Entry as it relates to their duties

V. Reference Documentation

The following documentation is readily available at the facility:

• Startup and isolation procedures for each unit (copies included in the appendix of this report)

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

• Piping and instrument diagrams (P&ID's) for the plant, update, to reflect DESOP review in 

May 2003

• Operating limits tables for each compressor, compiled from OEM recommendations and 

Resolute Energy practices (copies included in the operating procedures in the appendix of 

this report)

• All operator log sheets

• Compressor Troubleshooting Guide (Included in the Appendix 5 of this O&M Plan.

VI. Appendices

1. Life Cycle Maintenance Plan McElmo Compressors

HOS 6, HOS 4, Ariel C-5

2. Daily Plant Reading Form

3. Isolation and Operating Procedures
HOS 6, HOS 4, ACID GAS, Ariel C-5

4. Compressor Troubleshooting Guide

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

Life Cycle Maintenance Plan

McElmo Compressors

HOS 6, HOS 4, Ariel C-5
HOS-6 MAINTENANCE PLAN

HOS-6 LEVEL 1 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

HOS-6 LEVEL 2 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
HOS-6 LEVEL 3 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

HOS-6 LEVEL 4 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
HOS-6 LEVEL 5 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
HOS-6 LEVEL 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

HOS-6 LEVEL 7 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
HOS-4 MAINTENANCE PLAN

HOS-4 LEVEL 1 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
HOS-4 LEVEL 2 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

HOS-4 LEVEL 3 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 

HOS-4 LEVEL 4 INTERMEDIATE INTERVENTION

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L4-T1

ENGINE / COMPRESSOR CRITICAL 

SAFETY DEVICES (SEE NOTE)

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 

HOS-4 LEVEL 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 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 

HOS-4 LEVEL 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 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

HOS-4 LEVEL 7 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
ARIEL C5 MAINTENANCE PLAN

C5 LEVEL 1 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

C5 LEVEL 2 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

C5 LEVEL 3 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

C5 LEVEL 4 INTERMEDIATE INTERVENTION

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L4-T1

ENGINE / COMPRESSOR CRITICAL 

SAFETY DEVICES (SEE NOTE) 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
C5 LEVEL 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

C5 LEVEL 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 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

C5 LEVEL 7 PERFORMANCE ENHANCEMENTS

TASK TASK DESCRIPTION ACTIVITY FREQUENCY SKILL

L7-T1

PERFORMANCE BENCHMARK UPGRADES REVIEW 12000 HOURS ENGINEERING
L7

-T2

MANUFACTURES ENGINEERING 

REVISIONS REVIEW 12000 HOURS ENGINEERING

L7-T3

PRODUCTION OPERATIONS "BEST 

PRACTICE" REVIEW 12000 HOURS ENGINEERING
APPENDIX 2

Daily Plant Reading Form
RESOLUTE ENERGY CORPORATION 

Daily Plant Reading 

 

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

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: 
APPENDIX 3

Isolation and Operating Procedures

HOS 6, HOS 4, ACID GAS, C-5
Resolute Natural 

Resources 

McElmo Creek Unit

Gas Reinjection Facility

Isolation Procedure File Name HOS6ISO

Authorized

Page 1 of 3

Revised Date 3-3-15

HOS-6 COMPRESSOR 

ISOLATION PROCEDURE 

Equipment. # 

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.
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 shutdown the compressor. This procedure is for total 

compressor isolation. Dependant upon the maintenance work required, specific cylinders or utilities may be 

isolated separately, while leaving the remaining cylinders or utilities in service.

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

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

1.3 Close the 4th stage discharge isolation block valve.

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

1.5 Close the 4th stage intercooler discharge block valve.

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

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.

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 

McElmo Creek Unit

Gas Reinjection Facility

Operating Procedure File NameHOS6COMP

Authorized

Page 1 of 9

Revised Date 3/3/15

HOS-6 COMPRESSOR

OPERATING PROCEDURE 

Equipment. # 

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).
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

• 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.

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 

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
indicator will show open. 

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

• Suction and discharge pressures

• Suction and discharge temperatures

• Cylinder temperatures

• Cylinder vibration

• Motor Vibration

• Crankcase and lubricator lube oil pressure

• Crankcase and lubricator lube oil temperature

• Crankcase lube oil filter DP, and change as necessary

• Crankcase oil level

• Oil consumption

• Lubricator oil level

• Jacket water pressure

• Jacket water temperature

• Check compressor 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)

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.

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
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

• 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
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 

McElmo Creek Unit

Gas Reinjection Facility

Isolation Procedure File Name HOS4ISO

Authorized

Page 1 of 3

Revised Date 3/3/15

HOS- 4 COMPRESSOR ISOLATION

Equipment. # 

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.
WARNING All valves, switches and breakers referenced in this procedure MUST BE LOCKED AND TAGGED per the Lockout / 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.

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

McElmo Creek Unit

Gas Reinjection Facility

Operating Procedure File NameHOS4COMP

Authorized

Page 1 of 8

Date Revised 3/3/15

HOS-4 COMPRESSOR

Equipment. # 

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.
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

• 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

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

• 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 period of time.
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

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

• 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:

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 

McElmo Creek Unit

Gas Reinjection Facility

Isolation Procedure File NameARIELC5ISO

Authorized

Page 1 of 3

Date Revised 3/3/15

Ariel C5 COMPRESSOR ISOLATION

PROCEDURE

Equipment. # C5

SCOPE This procedure describes the isolation, depressurization for maintenance and returning of the C5 

Compressor back to service.

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

APPLICABLE Ariel C5 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.
WARNING All valves, switches and breakers referenced in this procedure MUST BE LOCKED AND TAGGED per the Lockout / Tag-out guidelines.

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): DE-ENERGIZE 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 DEENERGIZED AT THE SAME TIME. THE MAIN MOTOR COOLING FAN MOTORS WILL REMAIN ON FOR 300 MINUTES 

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 C5 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.

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 C5 Operating procedure for requirements on returning the compressor back into service
Resolute Natural 

Resources

McElmo Creek Unit

Gas Reinjection Facility

Operating Procedure File Name C5COMP

Authorized

Page 1 of 12

Date Revised 3/3/15

ARIEL C-5 COMPRESSOR

Equipment. # C5

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 Isolation 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.
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”)

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

• 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.

o TURN ICP POWER SWITCH TO “ON” POSITION. THIS ENABLES 24 VDC (+) POWER SUPPLY TO COMPRESSOR PANEL’S COMPONENTS.

o 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.

o 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. 

o 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

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.

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

• 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

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:

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

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

o LOCAL END DEVICE TRIP; STOP UNIT BLOWDOWN TO DEPRESSURIZE.

o 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.

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.

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.

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.

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 shutdown 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

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 

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

• 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

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

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
Resolute Natural 

Resources 

McElmo Creek Unit

Gas Reinjection Facility

Isolation Procedure File Name AGISO

Authorized

Page 1 of 3

Date: Revised 3/3/15

ACID GAS COMPRESSOR ISOLATION

Equipment. # CM-3400

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.
WARNING All valves, switches and breakers referenced in this procedure MUST BE LOCKED AND TAGGED per the Lockout / Tag-out guidelines.

1. Isolate the compressor for maintenance and lockout/tagout 

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

1.1 Ensure that the lube oil pump is not running.

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

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

1.4 Close the 4th stage discharge isolation block valve.

1.5 Close the 1st stage suction isolation block valve.

1.6 Close the isolation block valves 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.

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.

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

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

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

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

depressured.

2.5 Notify maintenance that they may begin their work.
3. 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 

McElmo Creek Unit

Gas Reinjection Facility

Operating Procedure File Name AGCOMP

Authorized

Page 1 of 8

Date Revised 3-3-15

ACID GAS COMPRESSORS "B"

Equipment # CM-1201 B

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 Compressors "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.
1.0 Initial Startup.

NOTE Initial startup is performed following an extended compressor shutdown due to maintenance or turnaround. 

Refer to the Acid Gas Compressor isolation procedure when the compressor will be returned to service.

1.1. Check that the compressor is ready for start.

• 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.

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 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.

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.

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

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

NOTE Murphy switch gauges on local panel not to exceed the PSV's setting 
3.0 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

• 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.

NOTE Use of temporary operating procedures must be approved by Supervisor

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.

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 main motor 'stop' button.

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

compressor.

6.2.2 Manually block in the 1st stage suction valve.

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

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

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

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 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

• Low Jacket Water Tank level # 2

• Vibration

• Manual shutdown

9. Problems and Solutions.

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

10. Operating Limits.

10.1. Shutdown resets:

Local Shutdown Resets and Permissives

Tag Description Position Setpoint

Reinjection Plant 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

10.2. Normal operating parameters:
NOTE The following parameters are only guidelines. Certain conditions may call for you to operate outside them.

Acid Gas Compressor Normal Operating Parameters

Description Operating Range

1st stage suction pressure 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
APPENDIX 4

Compressor Troubleshooting Guide
COMPRESSOR TROUBLESHOOTING GUIDE

I. ENGINE & FRAME SHUTDOWNS

Compressor Frame Oil Pressure

Lubrication No Flow

High Motor/Frame Vibration

II. COOLING SYSTEM SHUTDOWNS

Low Auxiliary Water Pressure

Low Coolant Level

Low Jacket Water Pressure

High Jacket Water Temperature

High Cooler Vibration

III. GAS CIRCUIT SYSTEM SHUTDOWNS

High/Low Suction Pressure

High Scrubber Level

High/Low Interstage Pressure

High/Low Discharge Pressure

High Discharge Pressure
Shutdown on Compressor Frame Oil Pressure

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.
Shutdown on Compressor Frame Oil Pressure

Troubleshooting Guide

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.
Shutdown on Lubrication No Flow

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

2. lubrication drops per minute.

3. 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.
Shutdown on High Motor/Frame Vibration

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:

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

b. 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.
Shutdown on Low Auxiliary Water Pressure

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

'

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.

I' 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.
Shutdown on Low Coolant Level

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

'

1. Check level controller float.

a. If float is not intact, replace.

2. Check micro-switch if defective.

a. Replace micro-switch if defective.

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

a. Replace wire as needed.

I' Internal Leaks 1. Repair leaks as needed.

If low coolant level continues and you have taken all corrective steps, call Mechanic.
Shutdown on Low Jacket Water Pressure

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.
Shutdown on High Jacket Water Temperature

Troubleshooting Guide

POSSIBLE CAUSE . . CORRECTIVE ACTIONS

Low Coolant 1. Check coolant level.

2. Add coolant to proper level as needed.

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

Water Pump/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.
Shutdown on High Cooler Vibration

Troubleshooting Guide

POSSIBLECAUSE· 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

6. 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.
Shutdown on High/Low Suction Pressure

Troubleshooting Guide

POSSIBLE CAUSE CORRECTIVE ACTIONS

Suction Control Valve

Malfunction

1. Start and load unit.

2. Compare suction pressure to reading on previous

Operator Report.

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

4. Adjust control valve or notify client of control valve 

problem.

Faulty 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.
Shutdown on High Scrubber Level

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.

a. 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.

a. If float is not intact, replace float.

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

a. 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.”
POSSIBLE CAUSE .· CORRECTIVEACTIONS

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.
Shutdown on High/Low Interstage Pressure

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

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.
Shutdown on High/Low Discharge Pressure

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:

Disconnect tubing.

Inject methanol into line.

Caution: Use extreme caution with methanol; high pressure 

may be trapped in tubing.

5. Warm pipes as needed.

Relief Valve 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

1. Check panel: Call I&E

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

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

2. Use volt meter to locate grounded wire.

3. 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.
Shutdown on High Discharge Temperature

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.
APPENDIX 5

Spare Parts Lists

HOS 4, HOS 6, Ariel C-5
McElmo Creek

Spare Critical Machinery Equipment

SPARE PARTS LIST

McElmo Creek Unit HOS 4 Spare Parts List

Compressor Compressor Suction/Discharge Valves

Oil Filters

Lubricator Parts

Electric Motor Driver Thermocouples

Vibration Probes

Cooler V-Belts

Pulleys

Gaskets and Seal Pins

Instruments and Controls Temperature Switches

Pressure Switches

Instrument Tubing

Position Indicators

Pressure Gauges

Thermometers

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

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

the part.
SPARE PARTS LIST

McElmo Creek Unit HOS 6 Spare Parts List

Compressor Compressor Suction/Discharge Valves

Piston Rings

Piston Rods

Gaskets

Packing Gland Assembly

Crosshead Assembly

Oil Filters

Lubricator Parts

Electric Motor Driver Thermocouples

Vibration Probes

Cooler V-Belts

Pulleys

Gaskets and Seal Pins

Instruments and Controls Temperature Switches

Pressure Switches

Instrument Tubing

Position Indicators

Pressure Gauges

Thermometers

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

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

Spare Critical Machinery Equipment

SPARE PARTS LIST

McElmo Creek Unit C5 Spare Parts List

Compressor Compressor Suction/Discharge Valves

Piston Rings

Piston Rods

Gaskets

Packing Gland Assembly

Crosshead Assembly

Oil Filters

Lubricator Parts

Electric Motor Driver Thermocouples

Vibration Probes

Cooler V-Belts

Pulleys

Gaskets and Seal Pins

Instruments and Controls Temperature 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.