J-1502000-09 Water Mist.pdf

GPU maintenance and testing

GPU Operating and Maintenance Manual P31030 F, May 2010

7. GPU maintenance and testing

This chapter describes the maintenance and testing routines that the GPU requires.

The table below displays the frequency of maintenance and testing routines and the chapters after the table describe the actual tasks. In addition to the information in Table 1, note the following:

• Other maintenance frequencies may be specified in local laws and regulations or in customer-specific system specifications. (items marked with * in the table)

• Refer to the respective third-party manufacturer’s instructions (as delivered with the system) for more information.

In case of maintenance or repair of the GPU, the water inlet shut off valve and the shut-off valve must be closed.

7. 1. Check all valve positions

In stand-by and operating modes the valves must be in the following positions.

Open valves

• the high pressure water outlet valve

• the water supply valve

• the air inlet to the stand-by pump

Table 1 Maintenance and testing routines for GPU

Chapter Action Weekly Monthly Every 12 months

7. 1. Check all valve positions X X X

7. 2. Check stand-by pressure and stand-by pump X X X

7. 3. Check gas cylinder pressure X X

7. 4. Check lubrication unit oil level X X

7. 5. Visually inspect unit and system fittings X X

7. 7. Check water filter X

7. 6. Check water level in water cylinders X

7. 8. Test run the unit X

7. 9. Add piston rod oil X

7. 10. Change water in water cylinders X

7. 11. Pressure test gas cylinders *)

GPU Operating and Maintenance Manual P31030 F, May 2010

Closed valves

• the test valve

• the redundancy water supply valve (optional)

• the filter drain valve

7. 2. Check stand-by pressure and stand-by pump

Check that the stand-by pressure in the system is set to the correct level (typically 25 bar).

Check that the stand-by pump is not striking too often. If it does, it indicates that there is a leak in the system or that the stand-by pump is faulty.

Report all abnormal wear, tear, leakage or damage.

7. 3. Check gas cylinder pressure

Check that the gas cylinder pressures are at the defined system operating pressure level (typically 200 bar, the minimum is 170 bar unless otherwise stated).

If the pressure is below defined system operating pressure, remove and replace the gas cylinder. Update system records.

7. 4. Check lubrication unit oil level

The maximum oil fill capacity is 45 ml. Add when necessary. If the lubrication unit uses a lot of oil, it indicates that there are problems with the stand-by pump.

Factory filling: Shell Tellus Oil DO 32.

Other suitable oils:

• Festo special oil (order code 152 811 OFSW-32 in 1 liter container)

• ARAL Vitam GF 32

• BP Energol HLP 32

• Esso Nuto H 32

• Mobil DTE 24

GPU maintenance and testing

GPU Operating and Maintenance Manual P31030 F, May 2010

7. 5. Visually inspect unit and system fittings

Check that there are no leakages. Check the hoses. Check that all fittings are tight. Check that there are no marks of damage.

Report any abnormal wear, tear, leakage or damage.

7. 6. Check water filter

To check water filter

Step 1. Close the water inlet shut-off valve.

Step 2. Open the drain valve at the bottom of the filter housing.

Step 3. Let water flow to drain for about one minute.

Step 4. Close the drain valve.

Step 5. Open the filter housing by turning it anticlockwise.

Step 6. Take out the filter cartridge.

Step 7. Clean the filter cartridge with soft brush and water.

If dirt remains, replace the filter cartridge.

Step 8. Reinstall the filter cartridge and the filter housing.

Step 9. Open the water inlet shut-off valve.

Step 10. Air the system.

a) Close the cylinder valves to avoid unintended release.

b) Bleed air from the filter through the test valve.

Step 11. Open the cylinder valves.

7. 7. Check water level in water cylinders

Check the water level every 12 months.

GPU Operating and Maintenance Manual P31030 F, May 2010

7. 8. Test run the unit

Use pressurized gas from gas cylinder rack or use gas cylinders specially reserved for GPU testing.

For instructions to test run the unit, see project-specific documentation.

7. 9. Add piston rod oil

Add oil in the piston rod lubrication tube (located behind the GPU cylinder liner) until it is full.

Factory filling: Shell Tellus Oil DO 32.

Other suitable oils:

• Festo special oil (order code 152 811 OFSW-32 in 1 liter container)

• ARAL Vitam GF 32

• BP Energol HLP 32

• Esso Nuto H 32

• Mobil DTE 24

7. 10. Change water in water cylinders

To avoid residue or bacteria build up in the water cylinders, Marioff recommends that you change the water every 1-2 years. Check project-specific documentation for details on water change because local conditions may require that the water is changed annually. Water is to be changed yearly.

7. 11. Pressure test gas cylinders

Pressure test the gas cylinders every 10 years. Check the local regulations and project-specific documentation.

If necessary, replace gas cylinders.