HomeMy WebLinkAboutRESPONSE - RFP - 8646 CNG SITE MAINTENANCE CONTRACTOR 20181 1301 Academy Ct.
Fort Collins, CO 80524
www.cgrs.com
800.288.2657
March 29, 2018
City of Fort Collins
Mr. Doug Clapp
Purchasing Division
215 N. Mason Street
2nd Floor
POB 580
Fort Collins, CO 80522
RE: Request for Proposal
8646 CNG Site Maintenance Contractor 2018
Dear Mr. Clapp:
CGRS, Inc. is pleased to provide the City of Fort Collins our Proposal for 8646 CNG Site Maintenance Contractor
2018.
If you have any questions or concerns regarding this proposal, please do not hesitate to contact me at any time,
via the phone numbers or email listed below. Thanking you in advance for your time and consideration.
Regards,
Cory Kahler
CNG Services Project Manager
ckahler@cgrs.com
720.537.9387 (c)
970.493.7780 (o)
1 1301 Academy Ct.
Fort Collins, CO 80524
www.cgrs.com
800.288.2657
CNG SERVICES
RE: Bid Documents for
City of Fort Collins
Purchasing Department
Request for Proposal
8646 CNG Site Maintenance Contractor 2018
CGRS follows manufacturer recommendations for equipment service. Preventative service provides value to the
customer by allowing CGRS to trend and identify issues with equipment before a breakdown occurs. This minimizes
equipment downtime and keeps the equipment operating at peak performance. All site visits will be recorded on
CGRS cloud-based system allowing for real-time access for customers.
Weekly preventative/scheduled maintenance includes:
• Check and drain and record oil in all site filters including dispenser filters.
• Check and drain oil recovery tank, (blowdown) record and compare with compressor oil
consumption.
• Check and record operating pressures and temperatures
• Check oil level in compressors and day tank and fill as needed
• Inspect and repair oil and gas leaks
• Inspect safety relief valves
• Verify PLC/HMI functions
• Inspect/clean dispensers and card readers
• Inspect fueling hoses
• Verify call-out system and ESD functions
• Test, clean and calibrate various components as needed
• Check and record dryer dew point and regen as needed
• Replace oil and filters as recommended by manufacturer
• Keep site clean and free of free standing oil/fluids and other debris.
• Annual site pressure washing with contact water capturing and disposal
• 400-hour and 2000-hour service as required during weekly preventative maintenance visits
• Electronic station data, analytics and reporting
In addition to weekly preventative maintenance, we follow manufacturer recommended scheduled maintenance
intervals for compressor component inspection, adjustment and replacement. This work includes but is not limited
to the following and is defined in the manufacturer documents and completed with prior approval and coordination
with city staff during normal business hours and billed at standard hourly rates.
• PRV recertification (3 years as required by code)
• 4000-hour major service
• 8000-hour major service
• 16000-hour major service
Non-Emergency repairs as required during normal business hours
• 24/7/365 Emergency services with on-site response within a maximum 30-minute phone response, and a
maximum of 2-hour on-site response
2 1301 Academy Ct.
Fort Collins, CO 80524
www.cgrs.com
800.288.2657
Safety is a priority for CGRS and our customers. Natural gas leaks would not only cost the City money in utility fees
due to gas emissions, but also create a hazardous working atmosphere for personnel in the area. We go above
and beyond to provide a safe working environment at our maintained sites. CGRS is making steps to be the industry
leader in Colorado by identifying leaks and correcting them in a timely manner. We utilize FLIR industrial infrared
cameras quarterly to monitor for methane emissions. This is the same technology used in oil field applications when
monitoring, not only methane; but, H2S and other hazardous gasses that pose a safety risk for personnel.
This is a service provided at no additional cost to our contracted customers.
1 1301 Academy Ct.
Fort Collins, CO 80524
www.cgrs.com
800.288.2657
REFERENCES
RE: Bid Documents for
City of Fort Collins
Purchasing Department
Request for Proposal
8646 CNG Site Maintenance Contractor 2018
American Natural Gas, LLC (ANG)
Joe Matzner
518.631.4798
jmatzner@americannaturalgas.com
Laramie County Public Works
Rob Geringer
307.633.4302
rgeringer@laramiecounty.com
Sparq Natural Gas
Sufyan Qarni
405.365.1654
Sufyan.qarni@sparqng.com
1 1301 Academy Ct.
Fort Collins, CO 80524
www.cgrs.com
800.288.2657
CNG TEAM
RE: Bid Documents for
City of Fort Collins
Purchasing Department
Request for Proposal
8646 CNG Site Maintenance Contractor 2018
Our technicians regularly attend industry specific training and certification courses in order to obtain the most recent
and up-to-date expertise regarding CNG codes, best industry practices, site safety and equipment maintenance. At
CGRS, we understand our customers can never miss a rollout of CNG powered vehicles. We will work directly with
the City to insure our work does not affect daily operations of fueling stations without prior notice and scheduling.
CGRS technicians have attended one or more of the following courses and re-certify as required:
• Ariel CNG Compressor Mechanics Training
• NGVi CNG Station Operations and Maintenance Training
• NGVi CNG Codes and Standards Training
• Swagelok Tubing Certification
• OSHA 40-hour Hazwoper Training
• Syn-Tech Systems (FuelMaster POS) ASR training
Page 2
City of Fort Collins
215 N. Mason Street
Fort Collins, CO 80522
Prepared for:
1301 Academy Ct.
Fort Collins, CO 80524
www.cgrs.com
800.288.2657
Statement
of
Qualifications
2
Statement of Qualifications
www.cgrs.com
800.288.2657
1301 Academy Ct.
Fort Collins, CO 80524
Table of Contents
A. Executive Summary………………………………………………………………………………………………………..3
B. Corporate Overview ................................................................................................................................................... 3
General Company Information ............................................................................................................................. 3
History & Areas of Expertise/Services Offered .................................................................................................... 4
Our People & Commitment .................................................................................................................................. 5
C. Operations and Maintenance ................................................................................................................................... 6
Trained Field Technicians .................................................................................................................................... 6
Fully Stocked Service Trucks………………………………………………………………………………………….…6
Remote Monitoring and Analytics………………………………………………………………………………………..6
D. Safety ............................................................................................................................................................................
7
Summary of Health and Safety Program………………………………………………………………………………..7
E. Current Maintenance Contracts………………………………………………………………………………………….8
3
Statement of Qualifications
www.cgrs.com
800.288.2657
1301 Academy Ct.
Fort Collins, CO 80524
A. Executive Summary
With over 30 years of experience putting customers first, conducting business with integrity, and streamlining our
processes through innovation, CGRS has become a recognized local industry leader in refined fuels. We are
uniquely qualified and home to a staff of over 80 of the highest skilled, diversely disciplined, predominately locally
educated and trained, professional engineers, geologists, hydrologists, scientists, CAD designers, and construction,
compressed natural gas (CNG) and remediation experts.
We are stakeholders in our customers’ success and are committed to providing quality services with integrity. Based
on our expertise and resources, we are confident in our ability to deliver results and successfully meet the needs of
The City of Fort Collins.
We hope in the pages below, exemplifying our experience, expertise, and proven track record of success, that you
will agree we are the right firm for the job; we look forward to partnering with City of Fort Collins.
B. Corporate Overview
General Company Information
History:
Established in 1987 by President and CEO Eric Hick
Description of Company Business and Background:
Size: 80+ employees
Location(s): Headquarters in Fort Collins, Colorado. Field offices include Colorado Springs,
Colorado; Grand Junction, Colorado; and Sacramento, California.
CGRS Services Offered:
CNG Operations and Maintenance Contracts
Compliance Services
Construction Services
Energy Services
Engineering Services
Environmental Services
CGRS Construction Services, offering:
Design-Build
Refined Fuels
Compressed Natural Gas
Water and Waste Water Treatment
4
Statement of Qualifications
www.cgrs.com
800.288.2657
1301 Academy Ct.
Fort Collins, CO 80524
History & Areas of Expertise
CGRS at its core is about Integrity, Innovation, and Excellent Customer Service. We were founded on these values
30 years ago and are committed to staying true to our roots as we set our sights on the future.
CGRS, Inc. began as an environmental consulting, compliance and construction company providing industry and
regulatory compliance expertise and services to owners and operators in the upstream and downstream petroleum
industry.
Over time, we have diversified to meet our ever-evolving customer needs by becoming experts in the markets of
Natural Resources/Environmental, Liquid and CNG Fueling, Oil & Gas, and Water and Waste Water. Our service
offerings are multifaceted and include:
Air Emissions Management
CNG Maintenance
Compliance Inspection and Testing
Construction
Engineering/Design
Design/Build
Leak Detection
Permitting
Reclamation and Material Management
SPCC, Mapping and Aerial Services
Stormwater Management
Water Quality Sampling and Assessment
Since opening our doors in 1987, we have experienced exponential growth, attracting industry experts while
continuously expanding our service offerings. Though we have evolved, our goals have remained the same – to
provide customized, practical solutions to our customers.
CGRS has a proven track-record of success providing compliance, assessment, construction, and remediation
services addressing the wide array of environmental health and safety regulations that affect the oil and gas
industry, commercial, industrial businesses, and government entities. Our scope of work is vast – having focused
proficiency in the Rocky Mountain region, in addition to an extensive variety of environmental and construction
projects in 40 of the 50 states with both private business and government sectors. Specifically, CGRS has
completed numerous projects over the course of 20 years for the Colorado Department of Labor & Employment,
Division of Oil and Public Safety, Colorado Department of Public Health & Environment (CDPHE), and Colorado Oil
& Gas Conservation Commission (COGCC). CGRS is also an approved Contractor for the State of Nebraska, the
State of Montana, and for the State of Wyoming Department of Environmental Quality.
5
Statement of Qualifications
www.cgrs.com
800.288.2657
1301 Academy Ct.
Fort Collins, CO 80524
By cross-pollinating expertise and resources from our Energy, Environmental, Engineering, Compliance, and
Construction departments, our staff, which includes engineers, geologists, hydrogeologists, field technicians, and
support staff, are uniquely qualified to offer a comprehensive range of services tailored to meet the specific needs
of our customers. Collaboration combined with extensive experience have placed us in a position to continuously
raise the level of proficiency and excellence for our customers, and ensure problems are identified upfront,
efficiencies are realized, and costs are minimized.
Our People & Our Commitment
In all that we do, we strive to deliver quality solutions, with integrity and expertise every-time. This is our
mission statement and foundation for our behavior. Our core values of integrity, innovation, and customer service
are the cornerstones of this foundation. They represent how we interact with each other, the service attitude we
embody, the experiences we create for our customers, and the benefits we give back to the environment and
community. We believe so strongly in our core values, our logo was developed to embody these qualities,
representing our commitment to staying true to them.
Our people are our greatest asset, and we believe our team is what sets us apart from others. CGRS takes pride
in hiring talented individuals who convey our core values, have a can-do attitude, operate openly and honestly, and
strive to be the best. Whether in the field or in the office—the talent, enthusiasm, and commitment of our team is
the driving force behind every completed project and happy client we serve. Because of this, CGRS invests in
employees through training and development, encourages out of the box creativity and collaboration, and promotes
giving back to the community. Senior leadership and management are actively involved in projects, offering decades
of refined knowledge, wisdom and support.
For 30 years, we’ve been making things better, safer, more efficient and more sustainable all thanks to those who
make up the CGRS team.
6
Statement of Qualifications
www.cgrs.com
800.288.2657
1301 Academy Ct.
Fort Collins, CO 80524
C. Operation and Maintenance Contracts
CGRS has a comprehensive Operation & Maintenance (O&M) procedure structured to meet individual customer
needs. We work to maintain current O&M standards through close collaboration with equipment manufacturers.
The result is that our team is highly trained and skilled to keep equipment operating at peak performance while
minimizing downtime.
Trained Field Technicians
Our technicians have extensive CNG, mechanical and electrical training and experience. We regularly attend
training courses with leading industry and manufacturer training programs. Our continuing education keeps our
team up to date on the latest equipment advances, as well as codes and standards for vehicle fueling stations. In
addition, we regularly work with manufacturers to make sure our maintenance practices follow manufacturers’
recommendations.
Fully Stocked Service Trucks
All CGRS service trucks are stocked with standard high-pressure fittings and components, compressor oil, and
other vital parts. Our service technicians are tooled up with appropriate tools to ensure that each site visit is as
efficient as possible. We maintain great working relationships with many part suppliers, allowing for expedited parts
in the event we do not have a required part in-hand to complete a repair.
Remote Monitoring and Analytics
Where applicable, CGRS remotely monitors CNG equipment to see “real time” run details. This also allows us to
receive alarms and faults when they happen. In many cases, this allows us to have equipment back up and running
with little or no impact on fueling operations. Our service technicians gather and record station operation data at
each site visit and record it into a database that can then be accessed by the customer, at their convenience. This
data can also be transferred electronically, as can data trending charts and monthly reports.
7
Statement of Qualifications
www.cgrs.com
800.288.2657
1301 Academy Ct.
Fort Collins, CO 80524
With an O&M contract, CGRS will provide a turnkey maintenance agreement that will require little or no assistance
from City staff. We understand that when we are hired as a service provider, we handle all aspects of O&M for the
entire system, including preventative and scheduled maintenance functions.
CGRS has the knowledge and training to ensure our customers NEVER miss a rollout. We understand the
importance of making sure the vehicles that rely on CNG are fueled and ready for service at the start of each shift.
That’s why our CNG services division operates on a 24/7/365 schedule. Rain, snow, day or night, we are ready to
respond to any equipment failures or concerns.
D. Safety
Summary of Health and Safety Program
CGRS maintains an active Health and Safety program, in addressing human health and risk assessment projects.
As a standard operations procedure, CGRS prepares site specific health and safety plans for each project based
on recognized and potential safety hazards. Based on years of experience working in diverse environmental project
settings including oil & gas exploration, industrial, commercial, transportation, construction, retail fueling, bulk
storage, production and processing, mining, federal, state, and municipal facilities, CGRS is fully capable of
providing design, review, and preparation of work plans for ecological and human health risk assessments.
An effective health and safety program is not only based on OSHA requirements but also on sound industry practice
which include management leadership, employee participation, worksite analysis to identify safety and health
hazards, effective elimination or control of identified hazards, and safety and health training. To be effective, a
health and safety program must protect and promote worker health and safety in a manner that is compatible with
the company culture and objectives. Proper development and implementation will produce a successful health and
safety program that will eliminate or control hazards, thus reducing loss from injuries and illnesses and contributing
to productivity and employee morale.
Our health and safety program provides policies and procedures to assist in anticipating, recognizing, and
controlling health and safety hazards in the work environment. Written programs are required by several OSHA
regulations including, Hazard Communication (29 CFR 1910.1200), Emergency Action Plan (29 CFR 1910.38),
Respiratory Protection (29 CFR 1910.134) and many other specific standards. CGRS has significant experience
developing and accessing health and safety programs and procedures for our clients and our own internal health
and safety program. CGRS has developed and implemented health and safety programs for industry, construction,
and hazardous waste operations.
Prior to initiating field activities, a comprehensive health and safety plan (HASP) will be developed by the Program
Manager and approved by the Health and Safety Manager. As a daily practice, job safety analyses (JSAs) are also
required before starting work on any site. The Site Safety Officer (SSO) or Site Supervisor will review the Site
Health and Safety Plan (SHSP) with all members of the field crew, and each member will sign and date a copy of
the SHSP, indicating that they have reviewed, understand, and will comply with all aspects of the SHSP. SHSPs
will be revised or rewritten for different phases of a project if site activities are distinctly different, or if areas of
differing hazard are involved, or as-information about contaminants and hazards change.
8
Statement of Qualifications
www.cgrs.com
800.288.2657
1301 Academy Ct.
Fort Collins, CO 80524
E. Current Maintenance Contracts
American Natural Gas, LLC (ANG)
10405 East 40th Avenue
Denver, CO 80239
Contact: Drew West; awest@americannaturalgas.com
City of Fort Collins
Streets Facility CNG
625 9th Street
Fort Collins, CO 80521
Contact: Tracy Ochsner; TOCHSNER@fcgov.com
Laramie County Public Works
13797 Prairie Center Circle
Cheyenne, WY 82009
Contact: Rob Geringer; rgeringer@laramiecounty.com
Additional Maintenance Sites
Gain Clean Fuels
19401 E. 32nd Parkway
Aurora, CO 80011
Contact:
Sparq Natural Gas
350 E. Collins Street
Eaton, CO 80615
620 W. 4th Street
Pueblo, CO 81003
806 E. Goddard Avenue
Trinidad, CO 81082
Contact: Sufyan Qarni; sufyan@qarni@sparqng.com
Official Purchasing Document
Last updated 10/2017
RFP 8646 CNG Site Maintenance Contractor 2018 Page 8 of 32
4.0 Pricing:
Monthly rate for preventative maintenance of the CNG fuel site:
Year One:
Transfort $
Wood Street $
Year Two - Five: (based on an Annual renewal option)
Transfort
Wood Street
Streets Site
Hourly rates charged for repair work performed under this agreement:
A. Normal Hours (From AM To PM)
Service Technician, Normal Rate: $ per hour
Service Technician, Overtime Rate: $ per hour
B: Material Costs:
Please indicate below your company mark-up on materials used in performing normal
maintenance and repairs to existing equipment:
percent markup for materials.
Please indicate below your company mark-up on parts and/or equipment installed as
part of an update or modification to the existing system:
percent markup for parts and equipment.
Copies of material invoices are to be included with billing statements.
C. Trip Charges
The City does not pay trip charges or travel time for non-emergency service work.
Emergency call-out trip charge, if any: $
D. Emergency Call-out
When the Contractor responds to an emergency call-out, the City will pay a minimum of
two (2) hours of the assigned technician's applicable rate. If emergency repairs require
more than eight (8) hours, the Contractor will be expected to assign personnel in a
manner which will minimize overtime charges.
2100.00
600.00
$ 2205.00
$ 630.00
$ 1050.00
7:00 5:00
90.00
135.00
25
20
100
1 1301 Academy Ct.
Fort Collins, CO 80524
www.cgrs.com
800.288.2657
APPENDIX
RE: Bid Documents for
City of Fort Collins
Purchasing Department
Request for Proposal
8646 CNG Site Maintenance Contractor 2018
Ariel Recommended Maintenance Intervals
RECOMMENDED MAINTENANCE INTERVALS FOR
INTERMITTENT DUTY- RECIPROCATING COMPRESSORS
PAGE 1 OF 4 ER-8.2.2
5 Page 2, #9: Changed shutdown pressure to 45 psig (3.1 barg).
4 015308 10-10-08
3 014795 11-19-07
2 014487 8-17-07
1 EC5947 ---
REV DESCRIPTION 0 --- 5-10-94 5 015364 9-13-10
REV EC DATE REV EC DATE
Like all equipment, Ariel compressors do require maintenance. The frequency of
maintenance is dictated by the environment in which the compressor is placed, the loads the
user imposes on the compressor and the cleanliness of the gas.
First and foremost on the preventative maintenance list is the completion and compliance
with the Ariel Corporation Packagers Standard and Compressor Start Up Check List. All items
must be adhered to, both before and after start up.
The following is a guide only and, as stated above, may vary due to operating conditions. The
time intervals start from the start up date of the unit. If your oil supplier's recommended oil
service changes are more frequent than the Ariel recommendations, the supplier’s intervals
should be followed. Regular oil analysis is recommended. If problems develop the oil should
be changed immediately and the cause of the problem determined and corrected.
A log book should be kept with each unit. Every maintenance item can be entered with
exacting detail in order that records will be available for tracking maintenance costs per unit
and for trouble-shooting.
Operator logs should be reviewed by qualified personnel to determine trends in compressor
performance and/or maintenance.
CAUTION! BE SURE THAT THE COMPRESSOR IS COMPLETELY VENTED TO
RELIEVE ALL GAS PRESSURE, AND THE DRIVER WILL NOT EXERT
TORQUE ON THE COMPRESSOR CRANKSHAFT THAT COULD RESULT IN
INJURY, PRIOR TO TAKING COUPLING READINGS, RE-CHECKING
BOLTING TORQUES ON PRESSURE CONTAINING COMPONENTS OR
REMOVING ACCESS COVERS FOR PERFORMING INTERNAL
INSPECTION OR MAINTENANCE ON THE COMPRESSOR. IN THE CASE
OF A DIRECT DRIVE MOTOR, THE BREAKER IS LOCKED OUT. FAILURE
TO FOLLOW THESE STEPS CAN RESULT IN SERIOUS PERSONAL
INJURY OR DEATH.
Daily
After running a new compressor (or after a re-location, re-configuring or major overhaul) for
the first 24 hours, shutdown, vent gas system and perform a hot alignment check at coupling
within 30 minutes, while barring driver shaft to packager’s recommendations. Realign if
necessary to hold coupling hub face and rim hot alignment within 0.005 inch (0.13 mm) TIR,
except for hub O.D. >17 in. (>43 cm) angular hub-face limit is increased to 0° 1’ (0.0167°).
Also check fastener torque on gas nozzle flange, valve cap, cylinder head, compressor rod
packing flange and, if applicable, crosshead guide to frame bolting. Reference Ariel Technical
Manual, Fastener Torque Tightening Values or Toolbox Torque Chart, ER-63. After 150 hours,
repeat this fastener torque check.
RECOMMENDED MAINTENANCE INTERVALS FOR
INTERMITTENT DUTY- RECIPROCATING COMPRESSORS
PAGE 2 OF 4 REV 5 ER-8.2.2
If bearing temperatures increase or a visual inspection of the crankcase indicates bearing
wear, check main, connecting rod and crankshaft-thrust bearing clearances. Replace
affected bearings if clearances are out of tolerances. See the Ariel Technical Manual for
instructions and clearance tolerances.
1. Check frame oil pressure. It should be 50 to 60 psig (3.5 to 4.2 barg) when at
operating temperature. Compressor inlet oil temperature is 190°F
(88°C) maximum.
2. Check frame oil level. It should be visible in the sight glass and approximately
mid-level when running, if not, determine and correct cause. Do not overfill. Check
oil makeup tank for sufficient oil supply.
3. Check lubricator block cycle time. Refer to information plate on top of lubricator
box for correct cycle time. Very dirty or wet gas may require a more frequent cycle
time than normal.
4. Check primary and secondary packing vents for blowing. If blowing, determine
cause and, if necessary, replace packing internal parts.
5. Check and correct any gas leaks.
6. Check and correct any oil leaks.
7. Check operating pressure and temperatures. If not normal, determine cause of
abnormality and correct. It is recommended that a daily log of operating
temperatures and pressure be kept for reference.
8. Check shutdown set points.
9. Low oil pressure shutdown 45 psig (3.1 barg) minimum.
10. High discharge gas temperature shutdowns are to be set within 10% or as close
as practical above the normal operating discharge temperatures, but not to
exceed the “Maximum Discharge Temperature Shutdown Setting” for the service
in which the compressor is operating.
11. High and low pressure shutdowns are to be set as close as practical.
Consideration should be given to the rod load capacity of the machine.
12. Check lubricator box oil level.
13. Check for unusual noises or vibrations.
Every 400 Hours (in addition to Daily Requirements)
After running a new compressor (or after a re-location, re-configuring or major overhaul) for
400 hours, shutdown, vent gas system and check fastener torque on gas nozzle flanges,
valve caps, cylinder heads and compressor rod packing flanges. Reference Ariel Technical
Manual, Fastener Torque Tightening Values or Toolbox Torque Chart, ER-63. Fasteners that
turn at the first month check, should be re-checked after 800 hours. If loosening persists,
consult your packager or Ariel to help determine the cause and recommend the correction.
1. Check and confirm safety shutdown functions.
Every 2000 Hours (plus Daily & 400 Hours)
1. Drain and replace lubricator box oil.
RECOMMENDED MAINTENANCE INTERVALS FOR
INTERMITTENT DUTY- RECIPROCATING COMPRESSORS
PAGE 3 OF 4 REV 5 ER-8.2.2
2. Change oil filter or when oil filter differential pressure exceeds the filter change
value, see filter information plate on the top cover or Ariel Technical Manual, Lube
Section for value.
3. Change oil. A more frequent oil change interval may be required if operating in an
extremely dirty environment or if the oil supplier recommends it or if an oil analysis
dictates it.
4. Clean sintered element in the small oil filter supplied on the force feed lubrication
system or every time main oil filter is changed.
5. Clean strainer when oil is changed.
6. Open frame when oil is changed and visually inspect for foreign material.
Disassembly is not recommended unless a reason for it is found.
7. Check cylinders for the proper lubrication rates. Reference Ariel Technical
Manual, Lube Section for a practical indication using the paper test method.
4000 Hours (plus Daily/400 & 2000 Hours)
1. Check crosshead guide clearance with feelers and if outside the limits listed in the
Ariel Technical Manual, Clearances Table, replace the affected parts.
2. Inspect valves for broken plates and loose center bolts, replace broken parts and
tighten center bolts. Reference Ariel Technical Manual, Fastener Torque
Tightening Values or Toolbox Torque Chart, ER-63.
3. Inspect cylinder bores for damage or wear. If the cylinder bore surface is
blemished or gouged, efficiency can be affected and/or rapid ring wear can result,
or is more than 0.001 inch per inch of cylinder bore diameter (0.001 mm/mm) out
of round or tapered, the cylinder body should be replaced or the bore restored.
Contact Ariel for re-boring and bore restoration guidelines.
4. Inspect piston ring end gap. Replace rings that are outside the maximum limit
listed in the Ariel Technical Manual, Clearance Tables.
5. Re-tighten hold down stud-nuts to proper torque values. Inspect for frame twist or
bending to be sure the main bearing bores are in alignment. Check frame top
cover mounting surface flatness tolerance and/or soft foot (reference Ariel
document ER-82 or Technical Manual Section 2). For soft foot check, more than
0.002 inch (0.05 mm) pull down requires re-shimming.
6. Realign if necessary to hold coupling hub face and rim hot alignment within 0.005
inch (0.13 mm) TIR, except for hub O.D. >17 in. (>43 cm) angular face limit is
increased to 0° 1’ (0.0167°).
7. Inspect piston rods for damage and excessive wear. If gouged or scratched,
replace the rod. If the rod is more than 0.005 inch (0.13 mm) under size, out of
round more than 0.001 inch (0.03 mm), or tapered more than 0.002 inch (0.05
mm) replace the rod.
8. Rebuild cylinder packing cases.
9. Rebuild oil wiper cases.
10. Check and re-calibrate all temperature and pressure gauges.
11. Check and record compressor rod run out.
12. Grease VVCP stem threads at grease fitting, with 2 to 3 pumps of multi-purpose
RECOMMENDED MAINTENANCE INTERVALS FOR
INTERMITTENT DUTY- RECIPROCATING COMPRESSORS
PAGE 4 OF 4 REV 5 ER-8.2.2
grease using a standard hand pump grease gun.
13. Clean crankcase breather filter.
14. Adjust drive chains.
15. Pressure test distribution blocks.
16. Check gas nozzle flange, valve cap, cylinder heads, compressor rod packing,
crosshead pin through bolt, crosshead guide to frame, crosshead guide to
cylinder, cylinder mounting flange to forged steel cylinder, distance piece to
cylinder, distance piece to crosshead guide and tandem cylinder to cylinder
fastener torque.
17. If the compressor is equipped with crankcase over-pressure relief valves, inspect
and exercise valves to the manufacturer’s recommendations.
8,000 Hours (plus Daily/400/2000 & 4000 Hours)
1. Check main, connecting rod, and crankshaft-thrust bearing clearances with a pry
bar and dial indicator. See the Ariel Technical Manual for instructions and
clearance tolerances. Any time bearing clearances are outside the limits, replace
the affected bearings. Disassembly to check clearances is not recommended.
Disassembly should be performed if the pry bar check indicates excessive
clearance.
2. Check auxiliary end chain drive for sprocket teeth undercutting and chain for
excessive stretching.
16,000 Hours (plus Daily/400/2000/4000 & 8000 Hours)
1. Check crosshead pin to crosshead pin bore and connecting rod bushing bore by
removing crosshead pins.
2. Check for excessive wear in the auxiliary end drive chain tightener.
3. Check for excessive ring groove wear in pistons.
32,000 hours (plus Daily/400/2000/4000/8000 & 16,000 Hours)
1. Replace lubricator distribution blocks.
2. Replace crosshead bushings.