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Standard Operating Procedure (SOP)
Read all of the steps in this SOP before beginning work. Follow
customer labor requirements (eg respect Union work)
DATE NEW
SOP: Borescope Inspection, Natural Gas
4/14/2011 o REVISED PAGE 1 of 3
Engines ___ Number
TYPICAL CUSTOMERS WORK TYPE WORK ACTIVITY (Description)
Oil & Gas, Landfill, Borescope Natural Gas Engine Inspection where H2S may or
Cogeneration facilities Inspection may not be present (Pre-cup, spark plug, valve
covers, borescope Inspection).
DEVELOPMENT TEAM POSITION / TITLE REVIEWED BY/DATE POSITION / TITLE
Glenn Thompson Lubrication Bill Fuller 7/26/2012 FES Advisor
Engineer
Gord Susinski Lubrication Tom Schiff 7/27/2012 FES Manager
Engineer
PLEASE UTLIZE ATTACHED GENERAL JSA AS GUIDANCE AND, IF YOU HAVE DONE A SITE SPECIFIC JSA.
PLEASE ASSESS YOUR OWN CONDITIONS OR SPECIFIC SAFETY REQUIRMENTS AND BE SAFE.
http://intratta.na.xom.com/emdn/sbps/docs/safety/jsa/JSA_Gas_Engine_Borescope_Inspection_where_H2S_may_be_present
.xls
EQUIPMENT INDEPENDENT OF JSA DESIRED DOCUMENTATION
CLIPBOARD OR TABLET PC DAY OF - DATA GATHERING FORMS
BORESCOPE INSPECTION DATA COLLECTION FORMS FINAL - BORESCOPE REPORT
FLASHLIGHT OTHER (SPECIFY)
RAGS BORESCOPE SERVICE DATA SHEET
CAMERA PRIOR INSPECTION REPORTS
BORESCOPE BORESCOPE INSPECTION JSA
BORESCOPE DUFFLE BAG - extension cords, electrical tape, 3RD PARTY SITE ASSESSMENT REPORT
Power Inverter MOBIL PEGASUS 1 SAVINGS CALCULATOR (if applicable)
LOCKS WITH KEYS AND TAGS FOR LOCK-OUT/TAG-OUT
CHEATER CORD (from customer - if available)
PNEUMATIC BARRING DEVICE (from mechanical contractor)
COLLAR LENSES FOR BORESCOPE
SIDE (90°) LENS FOR BORESCOPE
TIME ESTIMATED TO COMPLETE THIS TASK NUMBER OF PEOPLE TO PERFORM THIS TASK
5 HOURS 2
FREQUENCY TO PERFORM THIS TASK SKILLS REQUIRED TO PERFORM THIS TASK
DEPENDS ON CUSTOMER COMMITMENT - Typically at time of MECHANICAL APTITUDE
conversion to Pegasus 1, or a new to Mobil product, to get baseline NATURAL GAS ENGINE PRINCIPLES OF OPERATION
documentation of engine condition and then annually thereafter. If the (LUBRICATION FUNDAMENTALS, 2ND EDTION, PIRRO & WESSOL,
inspection is a trouble-shooting exercise then it might be a one-time FOR REFERENCE)
inspection. DISCUSS OPERATING CONDITIONS WITH OPERATORS /
MECHANICS
JOB COMPETENCIES REQUIRED TO PERFORM THIS TASK, TRAINING REQUIRED TO PERFORM THIS TASK
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PRODUCT SELECTION - NATURAL GAS ENGINES OILS LMS - TDG
OFFER EXECUTION - BASIC OFFER EXECUTION - BORESCOPE LMS - PVMG TRAINING
INSPECTIONS PETROLEUM SAFETY TRAINING (if required)
INDUSTRIES - PETRO-CHEMICAL, LANDFILL, CO-GENERATION H2S ALIVE TRAINING (FOLLOW JSA FOR SITE SPECIFIC
FACILITIES, GAS GATHERING OR TRANSMISSION - NATURAL GAS TRAINING)
ENGINES. ON THE JOB TRAINING
SITE SPECIFIC CUSTOMER ORIENTATION
PURPOSE - To describe the process of conducting a Natural Gas Engine Borescope Inspection while the
equipment is shut down, with the desired reporting that provides the value back to the customer while
supporting the standard Marketing Offer.
(External Offer Sheet:
http://intratta.na.xom.com/emdn/sbps/technical/engg_services/Americas/Nat_Gas_Engine_Inspection.pdf)
(Internal Offer Sheet: Place holder when available)
LOCATION JOB STEPS
Gas Engine site (before Notify operators / mechanics that you are on site.
borescope inspection takes Review XOM JSA with site personnel.
place) Complete a 3rd party site safety checklist with facility operators
prior to beginning work
Complete any necessary site-specific orientation required -
(determine locations of exit routes, muster points, eyewash
stations, wind socks).
Complete a hot work permit and review it with operators and
mechanics prior to starting work (if applicable)
Allow time for the operator to shut down the engine and for the
mechanics to remove valve covers (if necessary), spark plug
carriers, ignition sensors, and pre-cups. In addition, the
mechanics will install a pneumatic barring (describe this please)
device if available. By this time, the engine will have cooled
down enough to be able to start the borescope inspection.
Survey the engine area room for safety hazards
Ensure that you have the equipment required and
documentation / data collection templates prior to beginning
work
Determine location of power supply for the borescope.
If cheater cord available, plug in borescope extension cord and
tape up the connection with black electrical tape.
If the use of a power inverter connected to a vehicle battery is
required, refer to the JSA for instructions on how to connect the
inverter safely. Turn on the inverter and ensure that it outputting
the correct power level. Connect the borescope extension cord
and tape up the connections with black electrical tape. (see
photos)
Turn on the borescope
Insert memory card into drive A:
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Using menu selections set the borescope to save the
photographs to drive C: and label file as site specific (i.e.
customer name or specific location).
Obtain the engine operations log book for pertinent engine
operation information and record on the data gathering sheet
Prior to starting the inspection, ensure that you are aware of the
work that other personnel in the area are doing (i.e. mechanics,
operators etc.).
Prior to barring the engine over ensure that everyone is aware
that the engine will be turning over (simply done by yelling
"barring" and ensuring that anyone working on or around the
engine acknowledges).
If barring manually, determine the firing order. This will make it
easier to determine which cylinders have vales open at the
same time. This will save time and reduce the number of times
you will need to bar the engine over.
Gas Engine Borescope Visually inspect system (use the Collar attachment) and take
Inspection photos of and record photo numbers and ratings on the data
collection worksheet for each of the following areas:
Valve deck: Observe the valves in the seated position to look for
signs of recession/torching, cracks in head, glycol leaks,
cleanliness or signs of varnish.
Liner Top: look for signs of metal wiping at the interface
between the head and the liner (combustion chamber)
Liner Middle: look for signs of liner scoring and indicate whether
the cross hatch is present or missing. Record position of
scoring/scuffing/mirror polish (i.e. 3 O'clock position).
Liner Bottom: look for signs of liner scoring at the piston crown
and indicate whether the cross hatch is present or missing and
try to determine if the source is from the piston
Piston: circle the piston top edge and look for evidence of piston
detonation and or ash pounding on the edge of the piston.
Record the position of detonation or ash pounding damage (i.e.
at 3 O'clock position).
Visually inspect system (use the 90° attachment). Take photos of
and record photo numbers and ratings on the data collection
worksheet for each of the following areas:
Exhaust valves (in open position) for evidence of valve
recession
Intake valves (in open position) for evidence of valve recession
Amount of deposits in the tulip area of the valves
Over all look at the amount of and consistency of the ash in the
engine
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Gas Engine site (after Using menu selections set the borescope to copy the
borescope inspection takes photograph file to drive A (memory card
place) Power down all associated equipment
Remove power inverter from vehicle battery by removing the
clip from the +ve terminal and the -ve remote ground terminal.
Notify operators / mechanics that you have completed the
assessment.
Request fire eyes be turned on
Survey the engine area room for your material and clean up
Remove locks on the fuel gas valve on the engine
Sign off the hot work permit with the site operator and let them
know you are leaving the site.
Follow all road rules and speed limits when exiting the site.
Feedback about this SOP -
Send to Field Engineering
Advisor/Supervisor
DOCUMENTING YOUR WORK - The Natural Gas Engine Borescope Inspection is used to verify the
performance of Mobil premium and flagship gas engines oil. Three files are the backbone to producing
the Engineering Service Report and go as appendices.
1. The Borescope Data Summary Workbook.xls is used to record findings during the
inspection. It can be useful in preparing an Engineering Service Notice for any immediate
notification items for the customer.
2. The Borescope Finding and Photo Generator.dot.docx generates a word document that
contains all of the information inputted into the Borescope data Summary Workbook as well
as formats the photos into the word document so that you do not have to copy and paste the
photos individually. It was developed to save hours of time in writing the report. Follow the
instructions about selecting a folder to capture the photos while conducting the borescope
inspection while filling out the Borescope Data Summary Workbook.
3. TCO calculations that apply (see section below)
The Engineering Service Report using 3D Writer, is to be used to document the final Borescope
Inspection. Take the findings from the (Borescope.dot) file and document the Highlights, Discussion and
Conclusions like any ESR.
TCO calculations that may apply are Expenditures Reduction, Process Improvement, and Revenue
Enhancement and Asset Improvement as detailed below. The TCO Worksheets are the preferred format
to include in your report. Additional guidance will incorporate our messaging of TCO to include
Sustainability, Safety and Productivity relationships.
Expenditure Reduction - reduced lubricant purchase costs are the most typical expenditure savings.
These only result from the offset of extending lube application intervals from the previous lube against the
increased price of Mobil premium and flagship products. Expenditures could also be the cost of head
replacement (Waukesha Head Replacement $3K, Cat 3600 head $3.5K, Wartsila 34SG head $16K,),
reduction of overhaul frequency (large bore overhaul $100K). This may allow the customer to plan for a
replacement during a planned outage instead of an emergency shutdown. A third expenditure may come
from disposal costs of used engine oil. Find out how much the unit cost of disposal is and use the
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consumption on an annual basis. Make sure to factor in the reduced usage with Mobil premium and
flagship products as they apply or have applied in time. In addition, fuel-gas usage should be less when
using synthetic ngeo. Test data has shown that Pegasus SHC can reduce fuel-gas usage by about 1.5%
versus conventional natural gas engine oil.
Process Improvement - the hourly wages (including burden) for personnel to perform existing tasks. If
head swings or lubricant change outs are reduced, use these to determine Process improvements. If
lubricant usage is reduced, use the time to handle drums and the time to dispose of used lube to
determine Process improvements.
Revenue Enhancement - any serious abnormal engine system or lubricant condition observed may be
repaired during normal maintenance and reduce the potential for downtime. “Unscheduled Downtime”,
resulting in lost production and most often, scrapped parts or material. Waukesha and compressor down
for 1 day average $48K
Asset Improvement - use the customers "cost to carry" (usually 20%) inventories. This is used from the
Expenditures components for example, if you reduce the quantity of lube needed, take that amount cost
and multiply by the "cost to carry" to determine the Asset value.
Refer to Expenditure Reduction, Process Improvement, Revenue Enhancement, Asset Improvement and
TCO Summary Worksheet.xls.
Documentation Links:
TCO Worksheets http://intratta.na.xom.com/emdn/sbps/technical/ROAR/TCO_Worksheets.html
Borescope Data Summary Workbook
http://intratta.na.xom.com/emdn/sbps/technical/engg_services/SOP/Borescope%20Data%20Summary
%20Workbook.xls
Borescope Finding and Photo Generator
http://intratta.na.xom.com/emdn/sbps/technical/engg_services/SOP/Borescope%20Finding%20and
%20Photo%20Generator.dot
Example Engineering Service Report -
Error! Hyperlink reference not valid.
http://intratta.na.xom.com/emdn/sbps/technical/engg_services/SOP/Engineering%20Service%20Report
%20Borescope%20The%20City%20of%20Medicine%20Hat%20August%202011%20Final%201.pdf
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PPE:
- Hard Hat
- Hearing Protection
- Eye Protection
- Nomex Cover-alls with reflective stripes
- Gloves
- Steel toed boots
- 4 -head gas monitor
Safety: Wearing proper PPE
Safety: Locking out fuel gas supply Best Practice: extra locks/bags on dash
so you do not forget to remove your lock
before leaving site
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GND
Connecting power inverter red +ve cable Connecting inverter black -ve cable to
to +ve battery terminal. ground terminal on vehicle engine.
Taping extension cord connections.
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EXAMPLES OF TYPES OF PHOTOS TO TAKE
EXHAUST VALVES EXHAUST VALVE INTAKE VALVE
LINER TOP OF PISTON VALVE DECK (HEAD)
PRE-CUPS SPARK PLUGS SPARK PLUGS
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TOP OF LINER VALVE COVER
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