FSR NAME CSA NUMBER

Solar Turbines
A Caterpillar Company

8000 hours maintenance, compressor set.

PD Number Report Dates

Customer Name Package S/N Unit Name

Model Engine S/N Starts

Site Engine Hours Package Hours

General Inspection:............................................................................................................................................................................................................................2
Electrical system and Control systems.............................................................................................................................................................................................2
Air systems..........................................................................................................................................................................................................................................3
Calibrations sheet...............................................................................................................................................................................................................................4
Data summary....................................................................................................................................................................................................................................5
Data summary (continued)................................................................................................................................................................................................................6
Lube Oil & Servo Oil Systems..........................................................................................................................................................................................................7
Wet Seal System.................................................................................................................................................................................................................................7
Dry Gas Seal System..........................................................................................................................................................................................................................7
Gas fuel system...................................................................................................................................................................................................................................8
Start Systems & Auxiliary motors....................................................................................................................................................................................................9
Fire and gas system............................................................................................................................................................................................................................9
Performance......................................................................................................................................................................................................................................10
Solonox set-up...................................................................................................................................................................................................................................11
Exchanged pieces..............................................................................................................................................................................................................................11
Alignment check...............................................................................................................................................................................................................................11
Boroscope inspection........................................................................................................................................................................................................................12
Vibration survey...............................................................................................................................................................................................................................14
Conclusions and recommendations................................................................................................................................................................................................16

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General Inspection:

Before engine shutdown

1. Fill performance section, and data summary parameters before water-wash ______
2. Check magnetic pick-up voltage ______
3. Take lube oil sample ______
4. Observe and record all panels & package instrument readings. Note any malfunction indications
and that all oil filled gages are full ______
5. Visually inspect unit for fuel, oil and air leak. Especially check for air leaks at case flanges,
boroscope plugs, T5 probes and fuel nozzles) ______
6. Inspect engine and package components for proper operating conditions. Note unusual noises,
vibrations, discolorations, cracks &chaffing lines ______
7. Check lube oil tank vent fan & mist precipitator for proper operation ______
After engine shutdown
1. Visually inspect the control console electrical connections for cleanliness and security ______

Electrical system and Control systems.

1. Check batteries and charger for proper operation ______

2. Check floating and high rate voltage ______
3. Check batteries connection and electrolyte level ______
4. For Nicad batteries, have a full discharge by running the DC oil pump,
plot voltage versus time to access batteries condition. ______

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 5. Check all indicator lights ______
6. Test and calibrate as necessary all safety warnings and shutdowns devices (see calibration sheet)
- switches ______
- back-up overspeed ______
- T5 box ______
- Speed monitor ______
- MFAC ______
7. Visually inspect all gages and indicators for proper operation ______
8. Remove and check magnetic pickup for mechanical integrity ______
9. Check condition of thermocouple harnesses. Check integrity of support grommets ______
10. Inspect compensator and mesure resistance as applicable, check isothermal plate for rust, cracks… ______
11. Remove and inspect ignitor cable. Inspect ignitor plug for erosion, proper gap. Replace plug if necessary ______
12. Change lithium battery in Plc. ______

Air systems.

1. Check air inlet filters for water carry over , pre-filter condition ______
2. Check inlet duct for rust, salt contamination, obstruction ______
3. Perform detergent wash ______
4. Inspect & replace air inlet filters as needed ______
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 5. If air dryer installed check its operation ______
6. If self-cleaning filters system installed, check supply pressure, manually cycle through cleaning operation ______
7. Check inlet guide vanes for position, check torque paint on full-open stops and actuator cylinder linkage. ______
8. Inspect engine compressor variable vane mechanism for wear. Check for bent arms, loose linkages,
loose bushings. Ensure stop settings are correct. Check for damaged signal wires to actuator if applicable ______
9. Inspect bleed valve actuator mechanism for proper operation ______
10. Inspect intake and exhaust systems for damage, leaks, debris ______

Calibrations sheet.
Alarm or shutdown switch Customer tag Solar tag Plc address Settings Calibration Remark
Low lube oil pressure
Lube oil filter differential pressure
high
High lube oil pressure
Low oil tank level alarm
Low oil tank level shutdown
High oil tank pressure,AL
High oil tank pressure,SD
Low servo hyd oil pressure, AL
Low servo hyd oil pressure, SD
Low gas fuel pressure
High gas fuel pressure.
Low liquid fuel press (transfer)
High inlet air differential pressure
High start fuel flow
Flameout switch
Servo oil filter ΔP
Lube oil filter ΔP

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 Alarm or shutdown transmitter Customer tag Solar tag Plc address Settings Calibration Remark
Lube oil pressure
Servo hyd oil pressure
PCD pressure
Gas fuel pressure
Gas-PCD ΔP pressure
Sparking air pressure
Compressor suction pressure
Compressor discharge pressure
Seal oil filter Δ
Lube oil filter ΔP
Seal oil ΔP, main manifold
Seal oil ΔP
Buffer air ΔP
Compressor flow ΔP

Data summary.

System Units Description Cust. tag Solar tag Min Max Alarm Shutdown Before visit After visit
% GP speed
% PT speed
Bar PCD
kW Power
mbard Delta P air filter
ºC T1
ºC T5 average
ºC T5-1
ºC T5-2
ºC T5-3
ºC T5-4
ºC T5-5
ºC T5-6
ºC T5-7
ºC T5-8
Turbine
ºC T5-9

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 ºC T5-10
ºC T5-11
ºC T5-12
ºC T5-13
ºC T5-14
ºC T5-15
ºC T5-16
ºC T5-17
ºC T5 minimum
ºC T5 avg- T5 min
ºC T5 maximum
ºC T5 max- T5 avg
ºC Cold junction
ma Butterfly valve
ma Pilot gas valve
Actuators ma Secondary valve
ma Guide vanes
ma Bleed valve

Data summary (continued).

System Units Description Cust. tag Solar tag Min Max Alarm Shutdown Before visit After visit
mm/s Accessory drive
μm Bearing 1X
μm Bearing 1Y
μm Bearing 2X
μm Bearing 2Y
Vibration μm Bearing 3X
Turbine μm Bearing 3Y
μm Bearing 4X
μm Bearing 4Y
μm Bearing 5X
μm Bearing 5Y
μm DE bearing X
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 Vibration μm DE bearing Y
Compressor μm DE bearing X
μm DE bearing Y
ºC Oil tank
Bar Header pressure
ºC Header temperature
ºC GP thrust bearing
ºC GP thrust brg- header
ºC PT thrust bearing
Lube oil ºC PT thrust brg- header
ºC Bearing 1 drain
ºC Brg 1 drain – header
ºC Bearing 2&3 drain
ºC Brg 2&3 drain - header
ºC Bearing 4&5 drain
ºC Brg 4&5 drain –header

Lube Oil & Servo Oil Systems.

1. Check oil tank level, record consumption ______

2. Check oil cooler louver operation as applicable ______
3. Check and record lube oil filter ΔP. Change filters if ΔP limit exceeded ______
4. Check servo oil filter “pop-out” indicator; change filter if popped ______
5. Exchange demister filter if needed ______
6. Check oil cooler belt tension ______

Wet Seal System.

1. Check degassing tank oil level and temperature ______

2. Check seal oil sight gages for proper flow of oil and gas ______
3. Check seal oil filter, record ΔP. Change filter if ΔP exceeds limits ______
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 4. Check buffer air and buffer gas filters; replace if necessary ______
5. Check overhead seal oil tank sight gage, if required ______
6. Check seal oil coalescer elements; replace if necessary ______
7. Inspect and clean seal oil trap inlet strainers ______

Dry Gas Seal System.

1. Check seal gas and buffer air flows ______

2. Check and record dry gas leakage on each end of each compressor ______
3. Check and record seal gas and buffer air coalescing filter ΔP, replace if ΔP exceeds 20 PSI ______
4. Drain buffer air coalescer (and seal gas coalescer if applicable) ______

Gas fuel system.

1. Inspect fuel control system for security, leaks and proper operation. Include gas fuel control valve, fuel control
actuator, throttle valve and all linkage connection ______
2. Inspect fuel control poppet valve, replace as necessary. ______
3. Remove and inspect fuel injectors for cracks, excessive oxidation or damage ______
4. Check and record T5 spread.

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Start Systems & Auxiliary motors.

1. Inspect and test pre/post lube oil pump, seal oil pump, back-up lube oil pump and back-up seal oil pump ______
2. Inspect starter clutch if applicable to ensure lock-up in one direction and free rotation in the other ______
3. Check pneumatic starter assembly (if applicable) for unusual wear, oil consumption. Verify proper operation
of starter when unit is restarted including starter lubricator. ______
4. Check the starter seals for gas leaking into the accessory drive ______
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 5. Check electro-hydraulic start system (if applicable). Include the pump/motor assembly
and the accessory drive or engine mounted hydraulic start motor. ______
6. Check DAC start system for grounds, insulation, VFD, terminals cleanliness ______
7. Record coast down and start-up timer ______
8. Add grease to electrical motor roller bearings ______

Fire and gas system.

1. Check fire detectors for cleanliness and sensitivity with UV torch ______
2. Check proper working of percussion head, strobes and horn ______
3. Check fire bottle for proper charge ______
4. Check sealing of enclosure in case CO2 is released: doors, dampers… ______
5. Check calibration of gas detectors and record value displayed for 50 % LEL sample gas. ______

TX 399-1 TX 399-2 TX 399-3 TX 399-4

Performance.

Record parameters before detergent wash ______

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 Input parameters. Output parameters.

T1 % of minimum speed
Atmospheric pressure % of minimum power
T5 % of minimum PCD
Inlet losses % of minimum T5
Exhaust losses
PCD
Power

Record parameters after detergent wash ______

Input parameters. Output parameters.

T1 % of minimum speed
Atmospheric pressure % of minimum power
T5 % of minimum PCD
Inlet losses % of minimum T5
Exhaust losses
PCD
Power

Solonox set-up.

Check emissions values to be below maximum guarantee ______

Power NGP T5 Exhaust temp O2 CO Nox Nox Pems

kW % ˚C ˚C % ppm ppm mg mg
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Exchanged pieces.

Description Solar part number Quantity

Alignment check.

Check alignment ______

Bore. Face.

0 0

Boroscope inspection.

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Legend: Legend:

Legend: Legend:

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Legend: Legend:

Legend: Legend:

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Vibration survey.

Legend: Legend:

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Legend: Legend:

Legend: Legend:

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Legend: Legend:

Conclusions and recommendations.

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