ENERFLEX

PHASE 4-RC-06_x000D_
Daily Activity Report

SI NO Date Location Unit Tag

1 18-Jun-15

2 19-Jun-15

3 20-Jun-15

4 21-Jun-15

5 22-Jun-15

6 23-Jun-15

7 24-Jun-15
8 25-Jun-15

9 26-Jun-15
10 27-Jun-15

11 28-Jun-15

12 29-Jun-15

13 30-Jun-15

14 1-Jul-15

15 2-Jul-15

16 3rd, July 2015

17 4th, July 2015

18 5-Jul-15

19 6-Jul-15
20 7-Jul-15

21 9-Jul-15

22 10-Jul-15

23 11-Jul-15

24 12-Jul-15

25 13-Jul-15

26 14-Jul-15

27 15-Jul-15

28 16-Jul-15

29 19-Jul-15

30 23-Jul-15
31 25-Jul-15

32 26-Jul-15

33 28-Jul-15

34 29-Jul-15

35 30-Jul-15

36 31-Jul-15

37 2-Aug-15

38 3-Aug-15

39 4-Aug-15

40 5-Aug-15

41 6-Aug-15

42 7-Aug-15
43 8-Aug-15

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 PHASE 4-RC-06_x000D_
Daily Activity Report

Issues & Discription

fixed the issue that for I/P converter for recycle valve on unit 1.

unit 6 trip @8:17 am due to 3rd stage scrubber high level. And adjusted the dumping
controller for it and started again @8:26am.// unit 1 engine and compressor oil
changed// engine and compressor oil filter changed// microspin cleaned and
changed the filter// engine oil sump cleaned// both air filter cleaned// dumping
controller adjusted for the same unit (1)//valve tempreture cup//log sheet reading.

unit 1,2,and 3 suction strainer cleaned.// unit 2 and 3 engine and compressor oil
changed, engine and compressor oil filter changed, air filters cleaned, micro spin
cleaned and filter changed, kinco engine oil level kill switch controller adjusted, and
aux pump belt checked and adjusted.//compressor oil cooler hose broken need to
replace it (we need two for unit 3 and 8)// unit 6 2nd stage scrubber opend flange
and cleaned it by air pressure, then it became working proparly.

unit 4 and 5: suction strainer cleaned// Aux pump belt checked// oil changed for
both engine and compressor// oil filters changed for both engine and compressor//
air filtrs cleaned and added prefilter// engine kinco oil level kill switch controller
adjusted// micro spin cleaned and changed the filter.

unit 6 and 7: suction strainer cleaned// Aux pump belt checked// oil changed for
both engine and compressor// oil filters changed for both engine and compressor//
air filtrs cleaned and added prefilter// engine kinco oil level kill switch controller
adjusted// micro spin cleaned and changed the filter.//unit 6 changed water pump
belt and changed the AUX pump belt (run hour 576).// unit 2 fownded 5th cylender
high voltage and in engine HMI high ignation power alar, 5th cylender spark plug
changed.// Added SAE-50 in main tank (force feed)

unit 2 compressor cooler hose fixed.// SAE-50 added.//unit 6 tripped due to 2nd
stage scrubber high level. After inspection founded it's not dumping. So opened the
flangenand apply air pressure inside it, then it start draining and by pushing more air
the liquid come out quickly and it's like creamy very thick, also founded a piece of
metal come out of scrubber after this work it look working proparly. ( this work done
twise time). and to be in safe side we opened discharge valve cranck end and head
for both first and second stage and founded clear nothing inside it.

SAE-50 finished adding all bareels.// unit 8 engine oil cooler fixed and cam magnatic
pick up fixed.// shipped all parts from the four wooden boxes to the spare conix and
move the big polly that for unit 8 to the shaded area.
unit 1 tripped due to expansion jackit water tank low low level. Coolant added and
restart the unit.// inlet seperator pumps strainers cleaned.// closed drain strainer
cleaned.// compressor valve temperature reading.// daily log sheet reading.// MCSC
put tag on all PRV.// unit 1 again tripped due to pre cat over range and high ignation
power.// unit 2 & 4 changed the pre filters.

unit 6 HC sensor over ride it.// unit 5 2 cylenders no spark and 2 cylenders high
voltage, so we change 4 spark plug.// unit 7 on cylender show low tempreture and
high voltage and we changed it, also unit 7 its swaping between right bank exsust
with left bank.

Adding coolant to jacket side in unit 1.// MCSC did a part of installing check valve for
first stage cylinders.// lube flow rate adjusted for all units and these are the results:
right side 1:12.75, 2:12.14, 3:12.21, 4:12.5, 5:11.97, 6:12.42, 7:12.36 abd left side
1:14.7, 2:14.02, 3:14.24, 4:14.15, 5:14.50, 6:14.67, 7:14.73

check valve for first stage for all units done.// HC sensor for unit 6 calibrated and
over riding removed.// chefron ship to us 12 SAE-50 barrels.// @ 9:30 am plant
tripped due to fault fire alarm, ovrided the faulty sensor and restart the plant.//
Tatweer working on discharge flow meter to correct the flow yesterday reading, but
still there is problem it increase with every hour by 1.5 minutes, and they will update
us later what they will do.

prepare new air filters for all units to change it after sand storm.// checked HSE ( fire
extenguser & SCABA).// still working with unit 1 on jackit issue.

All air filters changed.// Tourableshooting on unit 1 (jacket water level issue).//
closed drain icrease in leve because of instrument air diaphragm chocked, we
opened it and release it and strainer cleaned, now its working proparly.

Inlet separator both suction strainers and NRVs cleaned.SAE50 oil 09 barrels filled in
the tank. Pre air filters washed. Logs for all units. engine no 01 j water filled.

Pre air filter changed. Compressor valve temp. measured. Closed drain pump stuck
and closed drain tank level high. Rectify and cleared the problem.

Unit 1PM: valves receicion. // valves adjustment. // compression test. //

greasing. // changed pre filters. // oil cooler pipe changed. // waste gate new
tubing. // coolant added.// checked for any leack. //Oil sample done for all
engines.
Unit 2PM: valves recession. // valves adjustment. // compression test. // greasing. //
changed pre filters. // coolant added.// checked for any leackage.
All pre filters changed.// unit 3,4,5 3rd stage dumping controller secrew adjusted.//
breather fixed for force feed tank by MCSC.// cleaned closed drain strainer and
diaphragm of instrument air line checked. // inlet seperator NRV checked and
founded in good condition. // compressor valve cup temperature done.

unit 4 change ferrol of the waste gate with new one( it was brocken).// unit 3 PM:
valve recission, compression test, valve adjusment, new spark plug, regab spark
plug, belt tension checked, greesing bolts tightening.

Close drain pump stuck dueto malfunctioning of regulator, Rectified and cleared the
problem. Inlet separator strainer and NRV cleaned.Measured compressor valves
temperatures. Log for all units done.

Unit 4 PM: valve recission, compression test, valve adjusment, new spark plug
replacement, regap spark plug, belt tension checked and adjusted, greasing the
bearing,bolts tightening. All pre filters changed. Coolant filling in both auxilliary and
jacket water circuit..... Unit #3 Auxilliary water pump belts replacement.

replace coupling of pump B with pump A and remove the cup of strainer B to replace
it because the thrid is dameged.// unit 3 tripped due to 3rd stage scrubber high
level, drained and restart it again.// unit 6 instrument air founded faulty.// oil
sample taken.

Unit 6 PM: compression test, spark plug changed, belt tenssion checked, fuel rasio
adjusted, waste gate tube replaced.// unit 7: one spark plug changed because of no
spark alarm.

Unit 5 PM: valve recission, compression test, valve adjusment, new spark plug
replacement, regap spark plug, belt tension checked and adjusted, greasing the
bearing,bolts tightening. All pre filters changed. Coolant filling in both auxilliary and
jacket water circuit

unit 8 removed one card from PLC and return it back just to take S/N to make spare
list.// unit 3 tripped two time due to secrubber high level, adjusted secrw for level
controller and restart back.

Unit 7 PM: valve recission, compression test, valve adjusment, new spark plug
replacement, regap spark plug, belt tension checked and adjusted, greasing the
bearing,bolts tightening. Coolant filling in jacket water circuit

All units pre air filters replaced and cleaned the dusty filters with pressure washer.
Inlet separator pump NRV was stuck and inlet separator tank level was getting
higher, solved the problem and now its normal. Measured compressor valve
temps.Performed several jobs at RC02.

remove all empty barrels.// remove empty wooden boxes.// fill 4 barrels for SAE-50
tank.// inlet seperator strainer cleaned.
 RC1 unit4 Actuator butterfly was stuck,rectified and put on load.RC2 unit1-
troubleshooting 2nd stage scrubber level high.RC7 unit# 3&4 troubleshooting,RC8
unit3 scrubber level high. RC #FILLED JACKET WATER in unit 1. Cleaned instrument
air compressor filters.Inspected all the units and other auxiliaries.

pre filter changed for all units.// air filters changed for all units.// SAE-50 filled.//
tools graving.// oil sample taken for all engines.

Check NRV for inlet seperator. // strainers cleaned for both inlet seperator
and closed drain l.// unit 3 and 5 engine oil cooler tube changed.// diphragm
adjusted for closed drain pump.// trying to fix corrosion inhabiter tank cap
but its locked with puti mixing. 

Unit 6 engine oil cooler tube replaced. // all pre filters changed with new
ones. // NRV checked for both inlet seperator and closed drain.// tools
graving.

working at RC-1 LP3 second stage with headen discharge valve and restart the unit
back to normal tempreture.// rc-06 closed drain pump was not working fine opened
the diphragm and fixed it and restart it again tonormal situation. And adjusted the
air regulator for the same pump.// tatweer came to see the comunication
problem.//strainer cleaned for both closed drain and inlet seperator.// NRV
checked.

RC1# UNIT1 Tripped, restored it. RC#6 unit#3 stage 4 scrubber level high, restored.
RC#7 Unit#6 stage3 scrubber level high twice.found scrubber drain blocked.Opened
it with compressed air, now OK RC#6 HD220 FFL oil filled in storage tank.

All pre filters changed and cleaned the old ones. // unit 2 tripped and after
truoble shooting founded right air filter is damged so replased with new one
and restart it again and the load is normal.// oil sample done. //  unit 7 L1
cylender exhaust temperature varying, replaced spark plug and it back to
normal condition. // shell was lying by the contractor.

working at RC-02 in unit 4 changed the water pump.// and RC-06 normal working
( NRV checked, strainers cleaned for both inlet seperator and closed drain, log sheet
reading, valve temp. reading)

Inlet separator suction strainers and NRVs cleaned.// closed drain strainer
cleaned.// adjusted dumping controller for all stages for all units(1 to 7).// greesing

Unit 1 greasing done.// half of our team went to rc2, working on LP2 and the
second half went to rc8 because tatweer are working on the suction line and
reducing the suction flow.// unit 7 engine oil changed, engine oil filters
changed, and microspin cleaned and filter changed.

Unit 5,6 engine oil changed, engine oil filters changed, and microspin cleaned
and filter changed.// unit 5 instrument air gage replaced. // inlet seperator
pump coupling brocken at last time and we fixed it with new one.
RC2-UNIT#2: L1 & L3 leaky cylinder heads replacement with rebuild ones. RC6
routine operational checks.
 RC#6 Units# 1, 2, 3, 4 lube oil changes and lube oil filters and microspin filters
replacement. IA Compressor#2 swapped to lead with IA Compressor#1 to
compensate running hours.RC#7 Unit#4 ER3 Shutdown but HMI was cleared.online
now
REMARKS
Mahdi, Fayez,ayoub, Shahzad
Unit Tag PM Location
Activity
CP-01 ### RC-08 PM
CP-02 ### Other places CM
CP-03 ### BM
CP-04 ### Operational
CP-05 ### Rebuild
CP-06 ### Trouble shooting
CP-07 Documentation
CP-08 Other work
PLANT
AREA Support
Preparation
House keeping
Preventive maintenance Sub Equipment
corrective maintenance Engine
Breakdown maintenance Compressor Activity This section is to classify
Cooler Fan PM-Preventive maintenanace-The scheduled m
actively attending
recommended the jobinorder
activities beforetoit leads
ensuretoequ
aS
Operational investigation which might lead to revisiting
BM- Breakdown maintenance is the type of m the
Other Frequent BM points to lack of pro-active CM o
Mechanical OTHER- Downtime due to operational/known
Electrical Operational- operational support

Instrumentation
Pumps

Issues - The causes for the downtime. The com

might vary for different sites & operating cond
Lube oil no flow
Engine Instr Casused by instrumentati
Compr Instr Caused by instrumentatio
Leaks Any kind of leakages on t
Cooler core Oil cooler core failures w
Faulty instrument Both engine & compresso
Other Any other causes which d
Compressor valves valve repalcement jobs.

The intent of this document is for detai

optimization. This can also be used to determ
operations for existi
The data logging needs to be done only o
 LEGEND

This section is to classify the activity to the maintenance category.

enanace-The scheduled maintenance over a period of duration to carry out regular OEM
jobinorder
ties beforeto
it leads
ensuretoequipment
a SD or break down.&Frequenty
integrity corrective maintenance indicates further
availability.
might lead to revisiting the PM program, design issues,
ntenance is the type of maintenance carried out after the material revision
equipment etc.
fails which leads to a SD.
o lack of pro-active CM or design issues.
ue to operational/known design issues or caused by factors outside the package
onal support

r the downtime. The common casues seen in our site are only listed in this document which
nt sites & operating conditions.

Casused by instrumentation on the engine side. Spark plugs were also routed to this category.
Caused by instrumentation on the compressor side.
Any kind of leakages on the package
Oil cooler core failures which is one of the main causes for Bahrain site.
Both engine & compressor casues which was identified as faulty indications
Any other causes which doesn’t fall under the listed causes.
valve repalcement jobs.

Introduction

his document is for detailed analysis for the unti downtime & can be used as a tool for operations & maintenance
an also be used to determine the spare stocking strategy by analyzing the casues for downtime over a certain period of
operations for existing projects & for packages with similar operating conditions._x000D_
needs to be done only on the "main log" sheet by the operator & the whoever does the analysis can customize the
charts/graphs.