Items of Importance

Machined and knurled new knobs for 3600 Cat’s barring devices at Howard and Ponder

compressor stations.

Machined special keys for torque convertors that are being installed on TC fin fans.

Tri-Cities units 4 and 5 need PCC chambers ordered. The nozzle holes are starting to erode and the engines cannot be tuned properly anymore. We do not keep spares here.

6/4/12 Ordered full port ½” sst ball valves for oil centrifuges on the Tri-Cities Cats Unit #1 Tri-Cities needs 6 high pressure kiene valves added to low stage compressor

cylinders, the current ones on it are the old power cylinder type that leak. $127.50 each. Engine room for TC Units 1,2, and 3 need more powerful fans with vents in bottom of

engine room. The engine room is way to hot when closed up and has no air circulation. Don Duncan is supposed to contact Danny Athar. (Done)

North Zulch needs friction drive for unit #3 (encoder driver for Windrock) partially completed. (Done)

Ordered 2 Cat Adam III ignition coils made in Germany $387 each to try out here at Tri-Cities from Cypress Engines Accessories

They also have a new spark plug (Denso) for 3600 series Cats that are getting upwards of 6000 hrs before needing to be pulled and regapped.

Machined 64 aluminum standoffs for new fan motor enclosures with addition of the new

torque convertors.

New oil filler caps for Tri-Cities Cats. Oil centrifuge project.

Tri-Cities emissions are now due when engines are running, starting June 1st

Dyna-probe is being blamed for inaccurate readings on piston pin clearances. I still think its inaccurate readings from measuring devices

Picked up spare starter for units 4 & 5 from Masco at Ferris Tx 6/08/12 Most of the parts are now in to finish oil centrifuge project. Brian Beck has requested me to be at Groesbeck Compressor Station on Monday and

Tuesday (June 11th -12th) to help him and Mike Davidson with one of the units there. 6/12/12 Bumped bearings and obtained rod run outs from Groesbeck compressor

station Unit #2. Throws #1 & #2 had .015 and .016.

Homemade engine barring device used at Groesbeck. 6/13-14/12 Went to Howard to help with catalytic convertor removal. Brought 2 fin

fan pillar block bearings back to elongate the bolt holes so the 9.562” bolt spacing’s would fit the 8.125” on fan mounting holes and re-install bearings and shaft.

Ordered PCC combustion chamber for Tri-Cities. 1st price was $2700.00 and 2nd price was $2300.00

Dotson and Shad want to discuss making a bearing a bearing puller for the removal of the Howard fin-fan pillar block bearings.

Worked on a drawing this weekend for a fin fan jack press and a valve cap remover so one person can lower and reinstall a discharge valve cap by themselves at Howard and Ponder stations.

6/18/12 started piping up centrifuges on Tri-Cities units. Ordered 16 combustion probes, 6 engine oil filters and 5 hydrax oil filters. Started installing sst tubing to centrifuges. Cut grating on units 1 & 2 for 2” drain line

to oil filler cap. TC unit #1 hot start oil pump motor has bad bearings and they need to be replaced. All vent fans in engine room for units 1, 2 and 3 need belts replaced. Ran emissions test on units 3, 4 and 5 Thursday and Friday. All within limits. Picked up remaining fittings and clamps for Tri-Cities centrifuge project once they

are installed 2” drain hoses can be installed and the project will be completed. June 25th 2012 ordered new fan belts for vent fans (engine room)

Made a spanner wrench for air compressors on west side.

6/26/12 put in new charcoal filters (middle dehy) Replaced all fan belts on vent fans (engine room) Redressed chipping tools for T-Rex

Ran emissions test Bethel Unit #1 6/28/12

Took trolley apart on withdrawal filter separator and cleaned and regreased bearings and reassembled.

7/2/12Helped with Bethel Unit 2 air box, job went safely & completed within estimated time.

Ordering repair parts for TC Unit #1 turbo coolant outlet is seeping coolant when unit is running. They should be here july 9th are 10th.

7/9/12 , finished installing centrifuge on TC Unit #1 and #2 and started the centrifuge on Unit #2. I mentioned to Greg that it and the hrs needed to be recorded so a maintenance schedule could be followed and kept up with.

Ran emissions test on TC unit #2, made some changes on report configuration after it printed. I need to get with Dave Link and make sure all my reports and configurations are correct. I am missing some data that should be on the reports.

7/10/12 Software changes on emissions testing (e-com) Machined chipper bits for T-Rex Oil samples prepared for shipment Did 5 hr check on TC unit #2 oil centrifuge Ordered drill rod, rack gear and pinion gears for valve cap remover tool

7/16/12 Performance review with Marlan 7/17/12 pulled some wire with John and Duncan on TC unit #2 interstage cooler

vibration switch reset. Schaeffer’s oil demo most of morning until 1:00pm 7/18/12 Pulled wire with John for TC unit #3 interstage cooler vibration, getting

milling machine ready to cut slots for rack gears on valve cap tools. John, James and me have tubing now run to all centrifuges, all that is needed is

grating cut and large drain hoses installed and project will be complete. 7-19-12 cut rest of gratings for oil drain lines off centrifuges 7-20-12 Picked up CAT adapter cable and drain line for last centrifuge in Longview

Tx. August:Started deep slots in drill rod for Valve cap remover that will hold the rack

gears. (see below) Started removing dust from engine room #1

Started machining plates for Howard Fin Fan bearing puller. Some parts should be finished today. Still need to get dimensions for upper and lower pull rods so they can be threaded.

Added evaporative cooler to blow air on ice machine to keep it from going down. Ordered some tooling for lathe and milling machine.

Unit #1 TC ran early sat morning (Aug 11th) for 3 hrs. I need to find out if it needs to be restarted for emission test are the test ran in June is in the correct time frame for this quarter.

Bethel overhaul to start this wed. 8/14/12 CECO here to run emissions on Rodessa unit. As of 4:00pm engine was

passing fine. Later after crunching the numbers the unit was failing. Started modifications to mounting base for oil pump motor on unit # 1 TC on hot

start. Ordered new shim stock, made extra heavy 3/8” nuts to be welded on back side of plate. Will also add a footing for motor to rest on to keep alignment when motor is removed for repairs.

Ran emission test on 3616 Wednesday morning. Engine went down during test. Cates finished puller for Howard Thursday. CAT was supposed to be here Friday for 3616. Matt says its loosing oil pressure.

Tim Malone thinks the oil regulators may not be holding good anymore.

8/21/12 took puller to Howard Comp Station, picked up 2 pillar block bearing to

elongate holes. Unit #3 North Zulch needs windrock encoder finished and some pressure packing

changed. Unit #1 TC needs hot start oil pump motor finished. Hot start TC unit #1, found loose coupling on oil pump. Woodruff key was wrong

size and broke. Encoder friction driver is completed for North Zulch unit #3

TC unit #1 oil hot start repaired and put back on engine. CAT found a weak spring on priority oil valve and will bring Monday 8/27/12 to

replace. This spring may have been the culprit causing a reduction in oil pressure.

Dave Link coming to check fuel on Rodessa unit 8/27/12 Seth needs help this week to replace pressure packing on unit #3 North Zulch. (I

will try to go help Seth on Tuesday). I also have the RMA number for Windrock to be shipped to TN for checks and

repairs. The number is good for 30 days once issued.

Week ending: 8/30/13Picked up new cutting torch for shopFinished up drawing for Bethel well valve #1Helped Robert disassemble 6” withdrawal block valve at Bethel. Gears are in need of replacement.

Metro Gear & Sprocket will replace all three gears for $580.00 I have a dividing head for making spur gears. The problem is vertical mills cannot

make very many gears due to the gear running into the spindle because of small cutter diameters and the cutter being close to the spindle. Gears are normally made on horizontal mills on a small scale. They make gear machines that once set up are left unattended to finish the product.

Started machining clamps for Opelika out of 2’ X 2” bar stock

Bar and clamps need to be finished and installed inside fin fans for TC units #2 and #3 for lifting motors.

Week ending:9/6/13 Pulled JW motor out of TC Unit #2 on Tuesday.Wed thru Friday worked at Bethel on unit #3. Found one bad HE suction valve on cylinder #3. Plugs on unloaders look to be bad. All have pits and cylinder 5 CE has a good suction valve and it still runs hot. I believe the plugs and unloaders in general on all cylinders are past due for reconditioning. Some of the low stage cylinders are showing same symptoms.

Week ending 9/13/13:Worked on TC units #2 and #3 JW fin fan motors and fan shafts. The motors needed new bearings installed and both fan shafts had bad bearings. The welder that cut the bearing races off has gouged both shafts. I will take up the road with a new bearing and see if they can be dressed up enough to be used again.I will be attending Dave Link’s Windrock training the rest of the week.

Week ending Sept 20, 2013:Took pulleys and shafts to Toms Machine shop to have gouges removed from shaft and new bearings fitted.Left Monday for Waxahachie: Windrock training at Howard admin from Tuesday thru Thursday.Friday: Took pro-flow to Groesbeck compressor station.Next week: Try to get windrock portable to update. It’s not able to communicate with pc until then. Brian went to pick up crosshead for North Zulch Unit #2 Friday, so Tuesday I will try to head to North Zulch to help install new crosshead.When do I need to have the drill mechanism made for Bethel well #1 valve repair?

Week ending Sept 27, 2013Tightened front drive belts on TC unit #1 and greased all bearings with manual grease gun on the fan unit.Made new .125 thick shims for coolant pump for units 4 & 5, motor was low and it prematurely wore coupling out.Bethel well valve #1 meetingNeed to replace idler tightening rod on Opelika #1 (material in stock)Picked up gear reducer from Metro Sprocket and Gear for Bethel.

Week ending Oct 4, 2013Changed spark plugs in TC unit #2 and installed Beru spark plugs at 4160 hrs, unit still would not start. I believe it was due to oil level being to high.Loaded up material and drawings for Cates to machine hand drill mechanism for Bethel well valve #1 to take Tuesday morning.

Week ending Oct 18, 2013Worked on Groesbeck dividing block stands.Helped Owen get dimensions for SW Research to make part for Bethel Well valve #1Machined keys for Atmos meter run project at the ETC facility at BethelUnited Way fundraiserTalked to Cates and nothing had been done on drill mechanism, due to lack of understanding of how it worked. They said maybe 2 more weeks for completion.

Week ending 10/25/13Finished dividing block stands for Groesbeck Compressor Station

Put fan belt back on unit #4Took a working drawing to Cates on Monday so they could finish the drill mechanism.Started machining electric motor lifting devices.

Dehy meeting on Wednesday Had Toms Machine shop drill and tap holes on stands. My lathe doesn’t have the

capacity.

Week ending 11-8-13 Took new drawing and steel material to Cates Machine shop for drill to be made

for valve at SWR. Dave Link here Tuesday and Wednesday for emissions testing. Torque converter fell off unit #5 (marred shaft on cooler motor. Marlan here Friday for personal development plans.

Week ending 11-15-13: Helped with Veterans memorial at Athens Arboretum Dave Link came. We discussed unit #4 engine oil sample. Had come down from 14 ppm

(lead) to 12 ppm and caution had went away. Will continue to monitor samples for changes.

Ordered some miscellaneous tooling for SWR drill for San Antonio test P-card receipts Machined battery clips off battery holders for John Machined two nuts into bushing removers for centrifuges on dehy’s Thursday Atmos broadcast

Next week: Monday after safety meeting see where Cates is on drill for test at SWR. Testing at SWR rest of week pending I am relieved from jury duty. I am going to find

this evening if I can get it post poned.

Week ending 11/22/13 Valve testing at SWR from Tuesday – Thursday Cut aluminum for adapter plate Started cleaning shop Helped change filters on dehy Next week will depend on weather. Change mechanical drill base to a pivot base using jack bolts.

Week ending 12/06/13Finished adjustable base Monday and fitted to a valve Tuesday that it wasn’t designed for..

Wed went to North Zulch to assist Robert with running on unit #2. Had some difficulty getting the unit running so we could only get a compressor horsepower run.Thursday helped reinstall unloaders on Bethel unit #3Friday cleaned in machine shop.Next week: hope to get another run on Unit 2 at North ZulchIf Bethel run unit 3 need to check with Windrock to see rebuilt unloaders have solved the hot valve problem with cylinder #5 HEMay install new part on Bethel Master Valve for well #1

Week ending 12-13-2013 Made brace for contactor #3 to help stabilize sight glass Cleaned centrifuges on all units at Tri-Cities. Most had accumulated ¼” to ½” of carbon

with the upper sections having the most. One centrifuge (unit #4) looked as if it had stalled out since carbon was washed out on one side.

Unit #5 centrifuge had upper bronze bushing wore out and egged but showed signs of still rotating.

Both units #4 and #5 have centrifuges mounted on loose hand rails. I hope by clamping the hand rails at 90 degrees will stabilize them.

Machined slotted sockets for centrifuge bushings. Next week: Bushings should arrive for Unit #5 centrifuge Monday start preparing Bethel well valve surface to accommodate the o-ring Tuesday, Wednesday: SWRI will be there to oversee cavity air bleed encapsulation.

Week ending 12-20-13: Sat picked up mouse for David Farnham and delivered to Tri-Cities Cleaned paint off large area of valve at Bethel #1 and polished in preparation of cap

installation over cavity air bleed Tuesday, met SWR at Bethel for installation of cap over cavity air bleed. Wed, p-card receipts for Whitney, sent off Windrock for yearly maintenance inspection. Went to check valve cap temperatures on Bethel unit #3 / Cylinder 5 after unloader

repairs. Had checked suction valve for breakage due to high heat and we never found any problems in the valve. Plugs on unloaders looked worn. They had unloaders rebuilt and everything seems fine now with no heating of suction valve. Helped Don get oil samples at TC, checked centrifuges for any unusual vibrations.

Bushings for unit #5 TC centrifuge still held up in Dallas due UPS overload of packages. Oil samples sent in. P-card receipts sent in. Lubrication gear box on TC unit #5 has a lot of wear on worm gear assembly for

compressor lubrication. TC unit #4 is probably in same shape.

Week ending 01-10-13 Maintenance mill #2, partially disassembled cross slide to clean and remove debris from

ways and lead screw cover. Replaced fin fan motor on Unit #2 West side Monday found rod nut loose on Unit #1 compressor cylinder #5. Compressor cylinder

vibration switch was not tripped. Helped with tear down of unit #1 compressor cylinder Dave Link here Wednesday for site visit at TC and Bethel Ordered some material for motor lifting devices Next week: Will find out if Robert Millward is through helping with turbine at Waha. If

he is maybe we can use his analyzer to get caught up with Howard Compressor Station. Emission will be due starting this 1st quarter of the year.

Week ending 01-17-14

Assisted John on TC unit #4 exhaust stack replacement for catalytic differential measurement.

Assisted with tear down of TC unit #1 compressor. Ordered necessary tooling and supplies for the maintenance on this compressor during the week.

Week ending 01-24-14 Left Monday for Windrock and Emissions training at Howard admin office Tuesday

through Thursday. Friday helped with loading of parts from TC unit #1 compressor that were being taken to

Cates Machine Shop for repairs.Next week: Will help some with reassemble of TC unit #1, Howard needs 2 more bearings bored out for fin fans. Windrock has not been shipped back from factory for its yearly maintenance.

Week ending: 01-31-13 Assisted in removal of compressor cylinders, suction and discharge bottles from TC unit

#1 The continuous of having to bar the flywheel on TC unit #5 was due to a partially

clogged starter screen. Need to check all starter screens on all units. Assisted John with relief valve TC unit #3. Water found in pilot, seat was in good shape.

Adjusting screw had been compressed that caused relief valve to lose its set point. Discharge cooler guard almost completed.

This week: Cut new door studs for TC unit #1 compressor. Will try and find out why the Windrock has not arrived here at Tri-Cities. Assist with TC unit #1 overhaul. Howard compressor station needs hole elongated in two bearings.I still need to get with Dave Link are Joe Lavy about making new compressor horsepower routes for quick checks of compressor performance with vibration and ultrasonics.