QSK60G - Health Check

Document ID: P06300414

Revision: B
Created: R. Philip
Approved: J. Pearson
Issue Date: 28/06/2022

APPLICABILITY

Product QSK60G Surf and Osprey Interim

Part Number N.A.

SCOPE

This document describes the steps involved to perform a “Health Check” on QSK60 Gas Surf and
Osprey Interim generators.

PLANNING

Competency

Intermediate

Advanced
Task Time Competent In Man Hrs

Entry

Core
Preparation 10 min Gas Generators 1 0.17
Isolation 10 min Gas Generators 1 0.17
Install Blow-By Kit 10 min Gas Generators 1 0.17
Check and Record Parameters 120 min Gas Generators 1 2
Remove Test Equipment and Isolations 10 min Gas Generators 1 0.17
Total Man Hrs 2.68 2.68

EQUIPMENT

Item Qty Part No.

Laptop with Cummins Insite installed 1 N/A
Inline Adapter Kit 1 4918416
Calibrated J-TEC Blow-by Meter Kit 1 VF563J-DAA0392
Calibrated Fluke Heat Gun 1 20-0015175
Flat Screwdriver 1 20-0020053
Oil Sample Tool 1 8T9208

PERSONAL PROTECTION EQUIPMENT

Item Notes
Standard PPE If in doubt refer to your local HSE representative
Personal Gas Monitor Ensure monitor is in calibration and switched on in fresh air

P06300414
Revision B, 28/06/2022
Page 1
RISK CONTROL

Risk Risk Control Measures that can minimise Legal & Other Residual Risk
Hazards Risks
Rating Scoring the risk level to ALARP Requirements Risk Scoring
S L R L M H S L R H M L
Induced hearing
loss from long-
term noise
exposure,
Appropriate hearing protection to be worn
Noise temporary noise 4 2 8 Medium ST-09 2 1 2 Low
when engine/ equipment is running.
effects such as
tinnitus, noise
pollution and lack
of concentration
Make sure the engine/ equipment is left to
cool down, if practicable before task is
Hot Surface Burns and scalds 3 2 6 Medium carried out. SOP 04 3 1 3 Low
Appropriate hand gloves to be worn during
task if engine is hot.

Make sure working area/ground is kept free

Slips, Trips Sprains, strains, GSCS
3 2 6 Medium from tools and discarded waste. 3 1 3 Low
and Falls lacerations OPO
Be aware of trailing cables.

Electrical shocks
or burns from
Safety checks of the electrical equipment
faulty electrical
and installations are carried out to ensure ST-01
Portable equipment or on
5 3 15 High that equipment continues to be safe. Where 5 1 5 Low
Appliances installation. ST-05
necessary this is done by a competent
Electrical faults
electrician.
can also lead to
fires
Gas detection system fitted to equipment.
Personal gas detection monitors used by
engineers.
Pressurised Fire, explosion, ESR
5 3 15 High Testing for leaks on the system. 5 1 5 Low
Gas Lines asphyxiation ST-01
Natural ventilation of equipment.
System isolation and depressurisation of
system
Exhaust attached to extractor system when
Fumes may
Exhaust engine is running.
cause eye
fumes, e.g.,
irritation and 3 2 6 Medium Extractor system maintained and tested to ST-09 3 1 3 Low
Carbon
breathing prevent leaks.
Monoxide
difficulties
Appropriate PPE should be worn if required.

REFERENCES

Document No. Document Title

AGG-ALL-ALL-HS-00-ST-00 HSE ST 00 – Standard Zero
AGK-ALL-ALL-HS-01-ST-01 HSE Standard 01- Working with Energy
AGK-ALL-ALL-HS-05-ST-01 HSE Standard 05- Work Equipment
HS-00-SOP-04 Personal Protective Equipment
AGK-ALL-ALL-HS-01-SOP-01 Energy Safety Rules
F01300003 QSK60 Health Check Sheet
P06000942 Containerised Gas Generators LOTO Procedure

P06300414
Revision B, 28/06/2022
Page 2
REVISION HISTORY

Prepared Reviewed Approved

Rev. Rev. Date Details of Change
By By By
A 29/08/2021 A4 Format (replaces P04300014-B) A. Giron R. Philip J. Pearson
Removed Sanction for Test and replaced
B 28/06/2022 R. Philip M. Russell J. Pearson
with LOTO

P06300414
Revision B, 28/06/2022
Page 3
DETAILED WORK INSTRUCTION

1 Preparation
1.1 Print QSK60G Health Check Form F01300003.
1.2 Open the blow-by kit box and check hose condition for cracks etc.
1.3 Check the blow-by meter calibration is within date.
1.4 Check the infrared thermometer calibration is within date.
1.5 Power on the blow-by unit with the toggle switch to check the unit has power. The unit
can be charged if there is insufficient power.

Figure 1

1.5.1 Open the generator control panel door on LHS of the container.
1.5.2 Check the service is due by checking the last SMR reading displayed on the service
sticker. If there is any discrepancies check the project maintenance schedule or MMS
to confirm.
1.5.3 Leave the door open.

2 Isolation
2.1 Isolate the genset from all energy sources in accordance with Aggreko Energy Safety
Rules and isolation document P06000942. See relevant documents links in Reference
table.
2.2 If unsure consult your line manager for more clarity.

P06300414
Revision B, 28/06/2022
Page 4
3 Install Blow-by Equipment
3.1 Remove engine crankcase breather pipe.

Figure 2

3.2 Connect standard 5ft hose to the 1½" adaptor.

Figure 3

3.3 Install 1½" adaptor to the short 3" rubber hose.

Figure 4

3.4 Install rubber hose to the engine crankcase breather.

Figure 5

P06300414
Revision B, 28/06/2022
Page 5
3.5 Install Standard 5ft hose to the flow meter ensuring the direction of flow is correct.

Figure 6

3.6 Connect the communication cable to flow meter.

Figure 7

3.7 Connect the flow meter to the display unit.

Figure 8

3.8 Blow-by setup is now complete.

Figure 9

P06300414
Revision B, 28/06/2022
Page 6
 NOTE
Ensure pipework is secure with no restrictions.

4 Load Setting and Run Generator

4.1 Switch the generator to “Fixed Load” on the GEMPAC.
4.2 Go to Menu 7051 and set the load to 50%.
4.3 Turn the key switch to “Local” position.
4.4 Press the “Semi” mode button.

Figure 10

4.5 Turn the toggle switch to “Idle” position.

Figure 11

4.6 Press the “Start” button.

Figure 12

4.7 Once engine oil temperature reaches 48°C turn toggle switch to “Rated” position.
4.8 Press the “Auto” mode button once rated rpm has is achieved.
4.9 The generator will auto synchronise and automatically close the main circuit breaker
and ramp up.
4.10 Allow generator to run for 1 hour to allow engine temperatures to stabilize.

NOTE
Fixed power only.

P06300414
Revision B, 28/06/2022
Page 7
5 Record GEMPAC Parameters
5.1 Record the following parameters from the GEMPAC using form F01300003.
5.1.1 Engine oil pressure

Figure 13

5.1.2 Kilowatt load

5.1.3 Intake Manifold Temperature

6 Record Engine Parameters and Blow-by Meter

6.1 Record the following engine parameters using Cummins Insite:
6.1.1 Engine oil temperature
6.1.2 Inlet and outlet fuel pressure
6.1.3 Throttle margin
6.1.4 Boost pressure-pre-throttle
6.1.5 Intake manifold pressure
6.1.6 Gas mass flow
6.1.7 All left and right bank cylinder temperatures
6.1.8 Switch on the blow-by meter and note the flow rate

Figure 14

P06300414
Revision B, 28/06/2022
Page 8
7 Record Temperatures using Infrared Thermometer
7.1 Check and record the following temperatures:
7.1.1 Left and right bank turbo exhaust temperatures

Figure 15

7.1.2 HT coolant outlet temperature

Figure 16

7.1.3 HT coolant inlet temperature

Figure 17

7.1.4 LT coolant outlet temperature

Figure 18

P06300414
Revision B, 28/06/2022
Page 9
7.1.5 LT coolant inlet temperature

Figure 19

7.2 Set GEMPAC to 100% load and run for 1 hour to allow engine temperatures to
stabilise.
7.3 Record the parameters on Form F01300003.

8 Remove Blow-by Equipment

8.1 Isolate the genset from all energy sources in accordance with Aggreko Energy Safety
Rules and isolation document P06000942. See relevant documents links in Reference
table.
8.2 Remove the blow-by equipment and install the crankcase breather hose.

Figure 20

8.3 Remove isolations in accordance with Aggreko Energy Safety Rules and isolation
document P06000942.

9 Job Completion
9.1 Return the generator to normal operations.
9.2 Return tools to the workshop.
9.3 Review results with your line manager.
9.4 Escalate any abnormalities.
9.5 Update Service Records.
9.6 Upload results to SharePoint.

- - - END OF DOCUMENT - - -

P06300414
Revision B, 28/06/2022
Page 10