6931055734 - MAN - AirPack

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DRAFT - FOR

INFORMATION ONLY

AirPack C

User Manual

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This manual applies to the following parts:

• L-6931055734 - AirPack C Base Assy Zone 2

• All standard options available for this base assembly

WARNING

TXT-10004286/A DANGEROUS MACHINERY

Ignoring the instructions in this manual can result in serious injury or death.

All personnel that work with this equipment must read and understand this manual. Only qualified personnel are allowed to rig up, rig down, operate, or maintain this equipment.

Version Date Amendments

A 26 July 2013 This is the first version of this manual

REVISION HISTORY Published by: NOV Elmar Energieweg 26 2964 LE Groot-Ammers The Netherlands

Whilst every care has been taken to ensure that the information in this document is correct, no liability can be accepted by NOV Elmar for loss, damage or injury caused by any errors or omissions in this document.

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1 INTRODUCTION

TXT-10004540/A

This user manual for the AirPack C well servicing product is intended for operating, maintenance and supervisory personnel. It contains the following sections:

• Safety (important safety aspects)

• Description (of components and their function) • Unit Control description

• Setup and Removal (including installation and storage) • Operation (startup, run, shutdown)

• Maintenance (schedules and procedures) • Troubleshooting

• Appendices (reference material)

This manual (supplied in digital and printed formats) is part of the AirPack C documentation set and must be read before initial equipment installation and operation.

The validity of the manual can be compromised by post-delivery engineering modifications or regulatory changes that affect equipment use, ratings and limits. All NOV Elmar engineering changes are documented in as-built drawings, even after product delivery. This means the latest drawings always take precedence over manuals. If in doubt, contact NOV Elmar.

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2 .1 G e neral Safety

2 SAFETY

TXT-10004141/A1

2.1 General Safety

High voltages, mechanical, chemical, thermal, pressure, noise and stored energy hazards can be present in ASEP Elmar equipment. Therefore, pay special attention to safety when working with this equipment.

• Meet all applicable codes, laws and local field regulations (including environmental and additional owner/user company policy). This manual contains recommendations, but should not be assumed to satisfy all requirements of legal regulations.

• Read and understand each item in this manual and follow all procedures, precautions and advice exactly - never take short cuts. Always consider your safety and that of others. • Only use the equipment within its design scope to avoid damage or dangerous situations. This manual (in its most current revision) is a minimum requirement for all persons working with ASEP Elmar equipment. All other current and applicable documents such as certification, drawings, bill of materials, vendor documentation, etc, should be readily available at the worksite.

2.1.1 Employee responsibility

• Never leave "operation-ready" equipment unattended.

• Keep equipment clean (accumulated dirt and dust can hamper unit operations and may increase the risk of ignition).

• Correctly maintain and use equipment, apparatus, tools, and dangerous substances. • Wear personal protection equipment (PPE) where necessary; for example gloves and

protective footwear.

• Never work alone if there is a possibility of an accident.

• Keep loose clothing and long hair well away from moving mechanical parts. • Remove rings, wristwatch, etc, before working.

• Never disconnect, change or remove safety devices, and use such devices correctly. • Be aware of all emergency equipment and procedures (such as alarms, abandon ship,

etc.) and make sure they are in place and valid.

• Do not use the equipment after an emergency without verifying that the cause of the emergency has been removed or rectified.

• Immediately inform the employer and other workers of any situation that represents a serious danger to safety and health, and of any shortcomings in protection arrangements. • Plan all operations including interdependencies with other equipment operations

• If equipment is tied down using rope/line/chains, attach a "flag" to signal their location. • During installation, maintenance and/or equipment inspection:

 where possible, make sure electrical/mechanical equipment is switched off completely, and use a decal or similar to prevent unauthorized starting;

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2 .1 G e neral Safety

2.1.2 Employer responsibility

• Define the required competency of personnel working on the equipment (including supervision) and provide the required consultation, information and training.

• Ensure that only trained, qualified and competent personnel can work on the equipment. • Ensure adequate safety equipment and emergency procedures are available (fire

extinguishers, PPE, escape routes, etc.), and that personnel are trained to use them. • Ensure a suitable program for installation, operation, maintenance, periodic inspection

and testing of the equipment is defined, adhered to and recorded.

• Do not allow work to proceed until a thorough examination and risk assessment of the work site and equipment has been done. The examination should assess (as a minimum) the condition of the work site and all critical components, plus the equipment structure. Only give approval to proceed when controls to manage potential causes are in place and measures are taken to mitigate potential consequences.

2.1.3 Warnings, cautions and requirements

Equipment handling may involve residual risks which cannot be reasonably reduced by design alterations. To alert the user to potential hazards and recommend safe working practices, additional information is provided as warnings, cautions and/or requirements:

• WARNING shows a relevant icon and the text WARNING with a description of the hazard and the best practise to avoid it. Ignoring a warning can result in equipment damage, plus serious injury and/or death.

• CAUTION shows a relevant icon and the text CAUTION with a description of the hazard and the best practise to avoid it. Ignoring a caution can result in damage to equipment. • REQUIREMENT shows an icon and a description of the required PPE to minimise

possible safety risks.

Warnings, cautions and/or requirements are listed in the manual as a preceding step to a potentially dangerous action. Never proceed to following step(s) if you do not comply with or fully understand a Warning/Caution/Requirement. See the following examples:

NOTE: A warning, caution or requirement icon (occasionally with accompanying text) is often

also affixed to the equipment at a prominent location.

WARNING

TXT-10004296/A ELECTRIC SHOCK

Connecting/disconnecting an energised (live) electrical cable can cause serious injury and or equipment damage. Always ensure that an electrical cable is electrically de-energized (dead) before connecting/disconnecting it.

CAUTION

TXT-10004378/A EQUIPMENT DAMAGE

Components can be damaged during cleaning.

Take care when cleaning components; use appropriate cleaning tools.

Hearing protection

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2.2 E qui pment sp ecific s a fety

2.2 Equipment specific safety

2.2.1 Emergency Stop buttons

TXT-10004568/A

Emergency stop buttons are conveniently positioned on equipment and are easily recognized because of their bright red colour. See examples in Figure 2.1.

Press the button in an emergency situation to instantly cut primary energy supply (electric, hydraulic or pneumatic) to moving parts. This will disable further equipment movement and reduce danger to the operator. Always notify a supervisor after pressing an EMERGENCY STOP.

2.2.2 Heavy equipment

TXT-10004562/A

• Never attempt to move heavy equipment without the aid of a sufficiently dimensioned and certified mechanical device.

• Only hoist joined equipment after ensuring that the joined equipment has been certified for single lifting by checking the certification in the Documentation Package that came with your equipment.

• Make sure you cannot get trapped between a lifted load and a wall, fixed object, etc. • Never walk under a hanging load or allow heavy objects to rest in an unstable position.

2.2.3 ATEX and zoning

TXT-10004560/A

Certain equipment may optionally be certified as Rig safe, Zone 1, Zone 2, and/or ATEX. If the equipment is certified according to ATEX regulations, the following applies:

• The power supply, including driven parts, has been manufactured and assessed according to ATEX and tagged with a unique identification number.

• Only specially trained personnel may service this equipment otherwise Rig safe, Zone 1, or Zone 2 compliance will be compromised.

• Certified explosion safe equipment is suitable for use in gas hazardous classified locations, however limited to Group II Zone 2 (acc. IEC) or Class I Division 2 (acc. NEC). Check your unit data plate(s) and the specifications tables in the Appendix for the ATEX classification for your equipment.

• The design and manufacturing is based on European Directive no. 94/9/EC following conformity assessment procedure relating to internal control of production according

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2.2 E qui pment sp ecific s a fety

Annex VIII of the Directive. The construction is documented in a confidential Technical Construction File held at the offices of ASEP Elmar.

2.2.4 Doors and hatches

TXT-10004565/A

• While opening/closing hatches and doors, take account of wind conditions or sudden movement. Hatches and doors may forcibly swing open/shut causing damage or injury. • When open, the hinge side of doors and hatches can create extremely hazardous pinch

points for fingers, clothing, hoses and cables. Always check the hinge side before closing any door or hatch.

• Always use any built-in retainers to anchor the door or hatch if you need to leave it open or closed while you work.

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3.1 U nit ov erv iew

3 PHYSICAL DESCRIPTION

3.1 Unit overview

The following figure shows the naming conventions of the physical views used in the remainder of this section.

Figure 3.1 Unit overview

1 3.2 Unit rear view on page 11

2 3.3 Unit right view (spring starter) on page 12

3 3.4 Unit right view (hydraulic starter) on page 13

4 3.5 Unit right view (air starter) on page 14

5 3.6 Unit front view on page 15

6 3.7 Unit left view (spring starter) on page 16

7 3.8 Unit left view (hydraulic starter) on page 17

8 3.9 Unit left view (air starter) on page 18

8

3

5

1

7

6

4

2

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3.2

U

nit rear v

iew

3.2 Unit rear view

Figure 3.2 Unit rear view

1 Exhaust silencer/ spark arrestor 2 Exhaust gas soot collector point 3 Compressor air intake filter 4 Compressor

5 Engine shock absorber 6 Air receiver auxiliary air circuit 7 Air-oil separator element

8 Hydraulic start manifold (optional)

4

5

7

2

6

1

8

3

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3.3

U

nit right

view (spring sta

rte

r)

3.3 Unit right view (spring starter)

Figure 3.3 Unit right view

2

1

3

4

5

6

1 Engine air inlet valve 2 Exhaust gas cooler 3 Engine oil dipstick 4 Compressor oil filter 5 Compressed air filter 6 Auto drain valve

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3.4 U nit rig h t view (hydraul ic starter)

3.4 Unit right view (hydraulic starter)

2

1

3

10

7

8

13

9

11

15

4

5

6

12

14

16

17

1 Engine air inlet valve 12 hydraulic charge hand pump

2 Exhaust gas cooler 13 hydraulic tank drain valve

3 Engine oil dipstick 14 hydraulic tank suction isolation valve w/ coarse particle filter

4 Compressor oil filter (obstructed by inlet hose) 15 Air driven charge pump for hydraulic start circuit. (mounted inside air inlet channel)

5 Compressed air filter 16 Activation valve for air driven charge pump 6 Auto drain valve (obstructed by inlet hose) 17 Rig air in connector

7 Hydraulic tank filler cap 8 hydraulic hand pump handle

9 Hydraulic tank sight glass (max level) 10 Hydraulic tank

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3.5

U

nit

righ

t view (air starter)

3.5 Unit right view (air starter)

2

1

3

8

7

4

5

6

1 Engine air inlet valve 2 Exhaust gas cooler 3 Engine oil dipstick

4 Compressor oil filter (obstructed by inlet hose) 5 Compressed air filter

6 auto drain valve (obstructed by inlet hose) 7 Rig air in connector

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3.6

U

n

it front view

3.6 Unit front view

Figure 3.6 Unit front view (sound-proofed grills removed)

1 Cooler stack - consisting of: engine coolant radiator; compressed air cooler; compressor oil cooler 2 Air driven charge pump for hydraulic start circuit.

1

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3.7

U

nit le

ft view (spring sta

rte

r)

3.7 Unit left view (spring starter)

Figure 3.7 Unit left view (spring starter)

10

12

3

5

18

21

2

1

11

17

16

15

13

14

20

8

7

9

4

6

19

1 Engine air intake filter 12 Air output

2 Unit control panel 13 Fuel tank access cover

3 Fuel fine filter 14 Engine oil filter

4 Air inlet valve control handle 15 Fuel tank breather 5 Engine compressor (auxiliary pneumatics) 16 Fuel tank isolation valve/

6 Fuel pump gear drive 17 Fuel filler cap

7 Fuel pump 18 Fuel level gauge

8 Fuel prefilter/water separator 19 Auxiliary pneumatic system filter (behind panel) 9 Sentinel master valve (ENGINE SAFETY) 20 Spring starter

10 Compressor (main air system) 21 Spring starter hand crank 11 Air output

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3.8 U nit l e ft view (hydrau lic starter)

3.8 Unit left view (hydraulic starter)

Figure 3.8 Unit left view (hydraulic starter)

10

12

5

18

22

2

1

11

17

16

15

13

14

20

8

7

9

4

21

3

6

19

4 Air inlet valve control 15 Fuel tank breather

5 Engine compressor (auxiliary pneumatics) 16 Fuel tank isolation valve

8 Fuel prefilter/water separator 19 Auxiliary pneumatic system filter (behind panel) 9 Sentinel master valve (ENGINE SAFETY) 20 Hydraulic starter

10 Compressor (main air system) 21 Hydraulic accumulator

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3.9

U

nit l

e

ft view (air sta

rter)

3.9 Unit left view (air starter)

Figure 3.9 Unit left view (air starter)

10

12

5

18

2

1

11

17

16

15

13

14

20

8

7

9

4

3

6

19

4 Air inlet valve control 15 Fuel tank breather

5 Engine compressor (auxiliary pneumatics) 16 Fuel tank isolation valve

8 Fuel prefilter/water separator 19 Auxiliary pneumatic system filter (behind panel) 9 Sentinel master valve (ENGINE SAFETY) 20 Air starter

10 Compressor (main air system) 11 Air output

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4. 1 Introductio n

4 FUNCTIONAL DESCRIPTION

4.1 Introduction

The AirPack C produces compressed air for sites requiring large amounts of pneumatic energy. The main energy source is a 54 kW Caterpillar C4.4, 4-cylinder diesel engine, naturally apirated. It drives a Rotorcomp EVO9-NK-G compressor that can provide up to 5 m³/min (177 cfm) of air or a nominal pressure of 10 bar (145 psi). The engine is equipped with either spring, pneumatic or hydraulic starter. The engine and exhaust gas are water-cooled and the coolant, along with the compressor’s oil and supply air, are air-cooled over forced-air heat exchangers (radiators). The unit is CE certified for Zone 2 ATEX operation.

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4.2 O perator controls

4.2 Operator controls

1 11 9 7 6 5 4 3 2 10 12 13 8

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4.2

O

perator controls

1 ENGINE TEMPERATURE This gauge (0 ºC to +120 ºC (+32 °F to +230 °F)) shows the engine coolant temperature.

2 EXHAUST TEMPERATURE This gauge (0 °C to +250 °C (+450 °F)) shows the engine exhaust temperature. 3 ENGINE OIL PRESSURE This gauge shows the oil pressure in the engine and the engine safety system. 4 COMPRESSOR

TEMPERATURE

This gauge (0 ºC to +120 ºC (+32 °F to +230 °F)) shows the temperature of the main compressor.

5 AIR PRESSURE This gauge shows the air pressure in the main compressed air system.

6 START PRESSURE This gauge shows the current starting pressure available for the start system (on air starter and hydraulic starter equipped engines).

7 EMERGENCY STOP Press this knob to shut down the unit in an emergency. To reset it turn the knob clockwise until it springs back out.

• DO NOT restart the unit without checking that the cause for the emergency stop has been resolved.

• DO NOT use the emergency stop as a control to stop the unit during normal operations.

8 TACHOMETER This gauge shows the engine speed in RPM and the engine running hours. 9 ENGINE STOP Push this button to stop the engine; it releases automatically

10 ENGINE SAFETY The engine safety sentinel valve cuts off fuel flow when the engine oil pressure drops below a certain value.Turning lever against the spring-pressure overrides the valve for starting.

11 AIR INLET VALVE Use this handle to control the engine safety air intake control valve.

Push the handle up to bypass the engine oil pressure safety system to allow the engine to be started. Hold the handle in the upper position until the motor oil pressure has risen to approx. 2 bar.

Pull the handle down for emergency stop. This will close the air intake valve and stop the engine.

For restarting wait 2 minutes for the shutdown-derived vacuum to disappear.

12 ENGINE START Activator to start the engine. For a pneumatic start system it is a push button, for a hydraulic start system it is a twist knob. (Not present on spring starter units). Refer to

6.2 Power up on page 35 for detailed use.

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4

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4.3 Engine

The AirPack C unit’s main power source is a Caterpillar C4.4, 4-cylinder diesel engine, naturally apirated. The engine drives a compressor directly (see Figure 4.1) for supplying compressed air. The engine and the exhaust system are water cooled. The OEM documentation for the engine is included in the Documentation Package.

4.3.1 Engine safety system

The engine safety system serves as:

• An automatic shut-off system in case of an over-speed situation caused by ingress of hydrocarbon gases.

• An automatic shut-off device in case of low engine oil pressure (<0.5 bar (7.25 psi)) • An automatic shut-off device for high coolant temperature >+100 °C (>+212 °F) and high

exhaust temperature >+200 °C (>392 °F)

• A manually controlled shut-off device in case of an emergency stop

The engine safety system consists of two main sub-systems which monitor the engine oil pressure:

1. Fuel:

The sentinel master valve (fuel shut-off valve) is positioned between the fine particle filter and the fuel injection pump. See Figure 4.2.The sentinel master valve monitors the oil

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4

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ngine

pressure in the diesel engine. If the lubrication oil pressure drops under the factory setting of 0.5 bar (7.5 psi), the valve will block the supply of fuel and shut down the diesel engine. The oil pressure is also distributed to the air intake valve.

2. Air intake:

An air intake filter assembly with disposable elements cleans the input air for the diesel engine. An air inlet safety valve is positioned in the air intake system, and is used to shutdown the diesel engine manually or automatically, by cutting off the air intake supply. It is factory pre-set to trip at desired pressure values and RPM settings. See Figure 4.3 below

A lever on the control console is used to open and close this safety valve. See 4.2 Operator controls on page 20. Pushing this lever up before starting the engine will mechanically open the

WARNING

Changing factory settings can affect the safety of the system, and result in personal and/or equipment damage.

Take extreme care when adjusting factory settings. If in doubt, contact ASEP Elmar

Figure 4.2 Engine fuel system safety valve

WARNING

Changing factory settings can affect the safety of the system, and result in personal and/or equipment damage.

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4

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E

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valve, which is normally closed (spring loaded). Once the engine has started, the engine oil pressure will overcome the spring pressure and hold the valve open.

4.3.2 Engine starters

The engine has options for either a spring starter, a pneumatic starter, or a hydraulic starter. See

Figure 4.4 below for starter examples.

a) Spring starter: is activated with a lever on the starter. Activating the lever releases spring tension which turns the starter, which in turn rotates the engine.

b) Air starter: is activated from a button on the control panel. Activating the button opens a pneumatic valve, and rig air turns the starter, which in turn rotates the engine.

c) Hydraulic starter: is activated from a button on the control panel. Activating the button opens a hydraulic valve, and hydraulic accumulator pressure turns the starter, which in turn rotates the engine.

See 6.2 Power up on page 35 for more details on how to start the engine.

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4.3.3 Fuel system

The fuel is stored in a fuel tank equipped with a breather. The fuel passes from the fuel tank through to the following components:

a) Isolation valve (this valve can be closed for maintenance purposes) b) Coarse particle filter (strains large particles from the diesel)

c) Fuel/water separator filter (removes water contamination from the diesel) d) Fuel gear pump

e) Fuel primer pump (runs parallel with d above)

f) Fuel fine particle filter (removes fine particles from the diesel) g) The sentinel master valve (fuel shut-off valve)

h) Injector pump (pressurizes the fuel to the injectors)

For an overview of the fuel system see the ‘as built’ FLUID DIAGRAM- ENGINE FUEL & OIL page in the

Documentation Package.

See Figure 4.5 below. A fuel/water separator (1) separates any water contamination from the diesel fuel. The fuel fine particle filter (2) removes particles larger than 10 µm. The frequency of

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4.4 C om pre ssor (Pneum atic) sy stem

water draining or filter element replacement depends on the quality of the fuel. The primer pump (3) is used during the bleeding of the fuel system.

4.3.4 Exhaust system

The exhaust gases are led from the engine through an exhaust gas cooler, flame trap and silencer (muffler) to the exhaust pipe which exits from the side of the unit. These components remove excess heat, soot and sparks from the exhaust which could otherwise ignite an explosive atmosphere near the exhaust outlet.

The exhaust gas cooler cools the exhaust by circulating engine coolant through its heat exchanger.

4.4 Compressor (Pneumatic) system

Compressed air is provided by a directly driven compressor. Ambient air is drawn into the main compressor through an air intake filter. It is then compressed to 10 bar (145 psi) in compression chamber where cooling/ lubricating oil is injected for supply. The supply air from the compressor passes through a separating tank and an air /oil separator filter to remove excess oil. The air is finally cooled by an air-cooled heat exchanger and further dried by passing through a cyclone air dryer (see Figure 4.6).

A part of the compressed air is used to activate a pneumatic cylinder which regulates the engine speed, dependent on air consumption requirements.

Two air outputs are available for site consumption use. See belowFigure 4.7.

On air starter equipped units, rig air from the site provides air through a separate system for powering the starter system.

The auxiliary pneumatic system is used to activate the ENGINE SAFETY system and EMERGENCY STOP circuit. It is powered by a separate 225cc compressor and is equipped with its own air cleaning and regulating components.

On hydraulic starter equipped units, an air-operated oil pump can charge the hydraulic accumulator. This air-operated oil pump can be driven by rig air or by the auxiliary pneumatic system.

Figure 4.5 Fuel/water separator and primer pump

1

2

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4.4 C om pre ssor (Pneum atic) sy stem

NOTE: The ENGINE SAFETY and EMERGENCY STOP circuits must be powered by pneumatic pressure or else the engine will not remain running.

.

Figure 4.6 Air-oil separator filters and cyclone air dryer

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4.5

C

oo

ling sys

tem

The compressor’s lube oil is filtered by a disposable filter element and air-cooled through a separate oil cooler. See Appendix 1: Specifications on page 131 for the compressor specifications.

For an overview of the pneumatic system, see the ‘as built’ FLUID DIAGRAM- HYDRAULICS &

PNEUMATICS Diagram in the Documentation Package that comes with the unit. For the main

compressor details see the supplier documentation also included in the Documentation Package.

4.5 Cooling system

The AirPack C unit is equipped with a belt-driven cooling fan. The fan draws ambient air through the radiator stack, which has three separate heat exchangers for the following circuits:

• Coolant (engine and exhaust gas cooling) • Compressor oil

• Compressed air

Maintenance tasks include check/replenish the coolant level, drain/refill and bleed the (coolant) cooling system, check compressor oil level, change filters and to check the system for leaks. These are covered in 7.4 Periodic maintenance schedules on page 47.

4.6 Unit grounding

The AirPack C unit is equipped with grounding points on the right and left sides.

These shall be utilized to ground the unit to the rig or the well-head to prevent static electrical discharge. See Figure 4.8.

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5.1 M oving /position ing equip m ent

5 SETUP AND REMOVAL

5.1 Moving/positioning equipment

The unit may be moved and positioned by hoisting, or with a properly dimensioned forklift. See certification in the Documentation Package that came with this AirPack C unit.

Make sure that the lifting equipment to be used is sufficiently dimensioned, has the correct certification, and is marked accordingly. The lifting equipment may only be used by suitably qualified personnel. All equipment lifting equipment must be subject to regular scheduled inspection compliant with EN 12079 for deformation and wear. All lifting equipment repairs must have been carried out compliant with EN 12079.

Always use the lifting eyes on the four corners for hoisting. Never use the two eye bolt sockets on the top plate to lift the entire unit. These are for lifting the detached top plate only.

5.1.1 Land transportation

When loading and transporting ASEP Elmar modules on a truck, several things need to be taken into consideration (most of these are also specified in the local traffic regulations):

• Number of axles on the transport vehicle (to decide where to position one or more units) • Weight of unit(s) (total weight)

• Height of the load (bridges, aqueducts, tunnels) • Width of the load (manoeuvring)

• Travelling speed

• Cornering (dead corner)

• Securing modules and securing loose components Check all these before loading and transportation:

• Make sure lifting equipment is sufficiently dimensioned.

WARNING

TXT-10004271/A CRUSH HAZARD

Heavy objects can trap limbs and cause serious injury or death.

Never place yourself between object(s) that can suddenly move. Follow local safety regulations.

WARNING

TXT-10004327/A HOISTING HAZARD

Hoisting a unit or module using the forklift pockets is dangerous, and can result in serious injury or death.

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5.1 M oving /position ing equip m ent

• All equipment used for lifting must have the correct certification and be marked accordingly.

• Only qualified personnel are allowed to use lifting equipment.

• Before each lift, always ensure that the lifting shackles have been correctly attached to the unit.

5.1.2 Air transportation

Standard procedure for air freighting a unit depends on local travel organizations. See

Appendix 7: Air transportation on page 144

In general the following should be drained: • Fuel tank

• Engine oil • Engine coolant • Gearboxes • Air tank

• Compressor oil sump

Other liquids within components will normally remain in the unit: • Fluid/oil coolers

• Filters • Hoses

5.1.3 Draining

If the carrier requires that all fluids are drained from the reservoirs, systems and components of the machine(s), please refer to 7.4 Periodic maintenance schedules on page 47 for specific instructions on how to drain the fluid from each reservoir, system or component.

NOTE: Tag the unit or components to warn against starting before refilling.

Photocopy or print the checklist in Appendix 7: Air transportation on page 144 as an aid to ensuring that no part is overlooked when draining and refilling the machine. Use the checklist as follows:

1. Check off each item as it is drained, adding your initials. 2. Strike-out the items that are NOT present on the machine.

3. Add any items that are present on the machine, but not on this list. 4. Place this checklist in a prominent place on the machine.

5.1.4 Refilling

Replenish the fluid in each of the items listed in the checklist. ASEP Elmar recommend that new fluid/oil filters are used when refilling systems that include filters. If you have fitted new filters, please add your initials in the last column.

Refer to theAPPENDICES on page 130 for the quantity and specifications of the required fluids. Refer to 7 Maintenance on page 47 for the procedures to check and replenish fluids for each of the reservoirs, systems and components. Where applicable, remember to bleed the system of air and refill as required.

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5. 2 S ite preparati o n

5.2 Site preparation

Before positioning the unit at the site, survey the location where it will be used. There should be sufficient room on all sides for opening doors/hatches.

5.3 Rig-up

5.3.1 Positioning and grounding

1. Move the unit to the operating position.

2. Secure the unit in place according to site regulations.

3. Connect ground cables to the grounding points on the unit according to site regulations. Refer to 4.6 Unit grounding on page 28.

5.3.2 Testing

1. Start up and test the unit as described in 6 Operation on page 34. 2. Shut down the unit by performing 6.3 Normal shut down on page 42.

5.4 Rig-down

To connect/disconnect a compressed air coupling:

a) Shut off the nearest valve on the supply side of the coupling.

WARNING

TXT-10004327/A HOISTING HAZARD

Hoisting a unit or module using the forklift pockets is dangerous, and can result in serious injury or death.

Never use the forklift pockets for hoisting.

WARNING

Heavy objects can trap limbs and cause serious injury or death.

Never place yourself between object(s) that can suddenly move. Follow local safety regulations.

WARNING

TXT-10004301/A EXPLOSION HAZARD

Electrostatic discharge can cause an explosion.

Always ensure that the unit has been correctly grounded before performing any work on the unit, including connecting/disconnecting hoses or cables, refuelling, and operating the unit.

WARNING

TXT-10004358/A NOISE HAZARD

The engine noise can exceed 85 dB, causing possible hearing damage.

Always wear suitable hearing protection when working around the running engine.

WARNING

TXT-10004255/A COMPRESSED AIR

Air and/or particles under high pressure can cause severe injury, particularly to the eyes. Never connect/disconnect a compressed air coupling without first removing all pressure from the connection.

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5.5

S

tora

ge

b) Release all pressure on the consumption side of the coupling, either by operating the control or appliance, or by slowly opening a valve on the consumption side.

c) Then with eyes protected or at a safe distance from the coupling, carefully connect/ disconnect the coupling.

1. Ensure that the unit has been shut down according to 6.3 Normal shut down on page 42.

2. Disconnect the pneumatic hoses in the AirPack one by one.

3. With a clean cloth, thoroughly clean the dust caps for the connectors. 4. Fit the dust caps.

5. Check that all cables and hoses are correctly stowed.

5.4.1 Finalize

1. Make sure all access panels are correctly closed and secured. 2. Disconnect the ground cables from the grounding points.

5.5 Storage

5.5.1 Short term storage (< 1 year)

When storing the system for a short term, always take the following actions: 1. Complete the rig-down steps as described in 5.4 Rig-down on page 31. 2. If the machine is going to be stored in temperatures under -18°C (0 °F):

a) Refer to 7.4 Periodic maintenance schedules on page 47 for the procedures to remove water from:

• Fuel tank, filters & lines

• Engine cooling system & reservoir • Pneumatic anti-frost system

b) Completely fill the following fluid reservoirs (if present) with appropriate fluid for expected low temperatures:

WARNING

TXT-10004322/A HIGH PRESSURE

(Dis)connecting a pressurized line can cause serious injury and or equipment damage. Never connect or disconnect any quick connectors when the supply line is pressurized.

CAUTION

Dirty or damaged quick connectors can leak and cause equipment damage. Before connecting a quick connector, inspect and clean both ends.

WARNING

Closing a door or hatch can crush fingers and cause serious injury.

Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors and hatches are especially dangerous.

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5.5

S

tora

ge

• Fuel tank, filters & lines (fill the diesel tank completely with winter diesel if available) • Engine cooling system & reservoir

• Pneumatic anti-frost system

c) Make sure that air is removed from lines and fluid reservoirs by bleeding all apertures. Refill with fluid again to full, if necessary.

3. Close all panels and hatches on the unit and secure or lock them.

4. Cover the unit with a suitable protection cover (these can be ordered from ASEP Elmar if required).

5.5.2 Long term storage (> 1 year)

When storing the system for long periods, follow the steps in 5.5.1 Short term storage (< 1 year) on page 32, and take the following additional actions:

1. Grease exposed metal surfaces to prevent corrosion. 2. Grease all rubber seals to prevent damage and cracking. 3. Fill the diesel tank to prevent condensation.

4. Drain the coolant tank as described in 7.24 Drain/fill engine coolant on page 91.

5. See 7 Air transportation on page 144, and the checklist in the appendix, for information on other possible drain points, and how to register your actions.

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6.1 P re-s tart check list

6 OPERATION

6.1 Pre-start checklist

1. Ensure that you have read and understood section2 Safety on page 6.

2. Check environment for sufficient ventilation for dispersion of the exhaust gases. 3. Ensure that the unit has been rigged up as described in 5.3 Rig-up on page 31. 4. Perform all of the daily maintenance procedures listed in 7.4 Periodic maintenance

schedules on page 47.

5. Ensure that the engine is not running and cannot be started.

6. Visually inspect the equipment for loose or missing parts, foreign objects, hydraulic leaks from lines or components, and structural damage.

7. Check all tanks and hoses for leaks, and for other visible damage.

8. Ensure that the cooling air intake and exhaust openings are not obstructed. 9. Ensure that all components requiring lubrication are serviced as necessary. 10. Check that no unauthorized modifications have been made to the unit.

WARNING

TXT-10004360/A SHARP OBJECT

Sharp or rough objects can cause severe cuts.

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6. 2 P o w er up

6.2 Power up

The engine speed is self-regulating, dependent on the required air output. The speed will be increased when the compressor system senses no pressure build-up. In order to have the engine run at lower speeds until it reaches operating temperature, it is essential to close all air output valves.

If starting the AirPack C for the first time, read this entire section thoroughly, and be certain you understand every part before starting the unit, especially sections:

• 6.3 Normal shut down on page 42

• 6.4 Emergency stop on page 43

1. Ensure that 6.1 Pre-start checklist above has been done before proceeding.

2. Refer to the figures on the following pages. Check that the EMERGENCY STOP button (6) is not activated (i.e. it is pulled out or reset). If it is activated:

 Check that it has not been pushed in to prevent starting the unit, because someone is performing maintenance on it. (Lock out/tag out)

 Rectify the problem that caused the emergency before continuing.

WARNING

Once the unit is started, all systems are energized and components can move when the controls are operated. Do not start the AirPack C unless:

• You are authorized to operate the equipment and have read this manual. • The unit is properly positioned and anchored for operation.

• All essential maintenance has been carried out.

• There are no unauthorized persons within the danger zone.

WARNING

TXT-10004358/A NOISE HAZARD

The engine noise can exceed 85 dB, causing possible hearing damage.

Always wear suitable hearing protection when working around the running engine.

WARNING

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6. 2 P o w er up

3. If connected, remove at least one hose to the valve air output isolation valves (1) is open the valve. See Figure 6.1.

4. Alternatively, remove at least one of the blind caps (2) from the output and open the valve.

This is necessary to ensure that the compressor offers minimal

resistance when starting the engine.

5. Close the isolation valves of any remaining connected air outputs.

6. Continue below for starter type indicated.

6.2.1 For spring starter equipped engines

NOTE: Starting with a spring starter may require two persons. One to activate the starter at

the engine, and one to hold open the AIR INLET VALVE.

CAUTION

EQUIPMENT DAMAGE

Winding the spring starter with an air-hammer or any other type of power tool can seriously damage it. Only use the supplied hand crank to wind the spring starter.

Figure 6.1 Air output valves

2

1

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6. 2 P o w er up

1. Locate the spring starter on left side of the engine; see

Figure 6.3.

2. Depress and release the reset button (3).

3. Remove the hand crank from its storage location and fit it to the winding shaft (4).

4. Using the handle, wind the starter clockwise to the required power output. The maximum number of turns is 39. For most applications 33-36 turns of the handle should prove sufficient.

Figure 6.2 Start and stop controls

1

2

6

4

3

5

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6. 2 P o w er up

NOTE: Over-winding will reduce the life of the starter.

NOTE: It is possible to unwind the starter, should it become necessary, by turning the

handle counter-clockwise; additional force will be required to overcome the initial friction.

5. Remove the handle from the starter, and return it to the storage/transit location.

NOTE: The starter should never be tripped with the winding handle in place.

6. Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (1) clockwise against the spring pressure; see Figure 6.2.

NOTE: This will override the diesel safety system, until the engine oil pressure holds the

valve open.

7. Push the AIR INLET VALVE lever (2) on the control panel all the way up, and hold it in that position.

8. On the starter, pull the trip lever (5) through 90 degrees in the direction shown by the arrow in Figure 6.3, to start the engine.

9. When the ENGINE OIL PRESSURE gauge (6) shows a reading above 2 bar (29 psi), release the

AIR INLET VALVE from its upper position.

If the engine fails to start, perform steps 1-7 again or troubleshoot the system according to section 8 Troubleshooting on page 125.

10. Close the air output you opened to start the unit, and reconnect the hose, if you disconnected it in step 3 of section 6.2 Power up.

NOTE: This is necessary to keep the engine from revving too high before it is warmed up.

11. After the engine has run for about one minute check the engine oil pressure again. This should be at least 3 bar.

If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot according to section 8 Troubleshooting on page 125.

12. If required, open the isolation valves on the required air outputs.

6.2.2 For air starter equipped engines

WARNING

Air under high pressure may be ejected at great force causing bodily harm and damage to equipment. When releasing air under pressure:

• Prevent access by unauthorized persons.

• Wear appropriate personal protective equipment (PPE), especially protective glasses.

CAUTION

Leaving the pneumatic system under pressure, when the unit is not running can damage it. Always close the rig-air input isolation valve and shut off the rig-air supply point, when the unit is shut down for longer than a few minutes.

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6. 2 P o w er up

Supply air to the unit as follows:

a) Locate the rig air supply input connection on the right side of the unit, and ensure valve (6) is initially closed, as shown in

Figure 6.4.

NOTE: Rig air is used ONLY for starting the

engine. It should never be hooked up to the AirPack C for any other purpose!

b) Connect a suitable air supply (7 bar (100 psi) at 25 l/min) to the rig-air connection.

c) Open the rig-air supply at the supply point.

d) Slowly open the rig-air intake valve (6) on the unit. 1. Go to the control panel. See Figure 6.5.

2. Ensure that the START PRESSURE gauge (1) shows between 7 bar and 10 bar. Figure 6.5 AirPack C starting and stopping controls

Figure 6.4 Rig air input

rig air connection

6

2

3

5

1

4

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6. 2 P o w er up

NOTE: A minimum of 7 bar is required to start the engine.

3. Close all access panels and doors around the AirPack C, except for the control panel access hatch.

4. Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (2) clockwise against the spring pressure.

valve open.

6. Press and hold the ENGINE START button (4) until the engine starts, then release.

7. When the ENGINE OIL PRESSURE gauge (5) shows a reading above 2 bar (29 psi), release the

AIR INLET VALVE from its upper position.

If the engine fails to start, perform steps 1-7 again or troubleshoot the system according to section 8 Troubleshooting on page 125.

NOTE: Close the air output you opened to start the unit, and reconnect any hoses you may have

disconnected in step 3 of section 6.2 Power up above.

8. After the engine has run for about one minute check the engine oil pressure. This should be at least 3 bar.

If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot engine according to section 8 Troubleshooting on page 125

9. If required, open the isolation valves on the required air outputs. 10. Close the rig-air intake valve.

11. Close the shore/rig-air supply at the supply point. 12. Disconnect the shore/rig-air connection.

6.2.3 For hydraulic starter equipped engines

1. Ensure that the isolation valve for the starter accumulator is open.

2. Check the START PRESSURE gauge (1) on the power pack control panel to see if the starter accumulator has sufficient pressure to start the unit.

WARNING

Closing a door or hatch can crush fingers and cause serious injury.

Never place your hands on the edge of a door or hatch when closing it. Hinged sides of doors and hatches are especially dangerous.

WARNING

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6. 2 P o w er up

NOTE: The hydraulic starter needs 120 bar start pressure for one start attempt.

3. If there is not enough hydraulic pressure to start the unit, charge the accumulator as described in 6.5.2 Charge starter accumulator using the air-operated oil pump on page 45.

4. Reset the sentinel master valve (ENGINE SAFETY) by turning the control lever (2) clockwise against the spring pressure; see Figure 6.6.

valve open.

6. Turn and hold the ENGINE START knob (4) clockwise until the engine starts, then release. 7. When the ENGINE OIL PRESSURE gauge shows a reading above 2 bar (29 psi), release the AIR

INLET VALVE from its upper position.

If the engine fails to start, perform steps 1 to7 again or troubleshoot the system according to section 8 Troubleshooting on page 125.

Figure 6.6 AirPack C starting and stopping controls

2

3

5

1

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6.3

N

orma

l shut down

8. Close the air output you opened to start the unit, and reconnect the hose, if you disconnected it in step 3 of section 6.2 Power up above.

9. After the engine has run for about one minute check the engine oil pressure. This should be at least 3 bar.

If oil pressure has still not increased to above 2 bar then shut the engine down and troubleshoot engine according to section 8 Troubleshooting on page 125

10. Once the engine is running, the hydraulic starter circuit maybe charged again to save it for the next start. For a detailed explanation, see 6.5.2 Charge starter accumulator using the air-operated oil pump on page 45

11. If required, open the isolation valves on the required air outputs.

6.3 Normal shut down

The engine speed is self-regulating, dependent on the required air output. Allow the engine to run at near idle speed before shutdown by closing the air output valves.

1. Close all isolation valves on the air outputs.

2. Pull the ENGINE STOP lever (4) to stop the engine, See Figure 6.5

3. Check the tachometer to ensure the engine speed drops to zero RPM.

4. Disconnect one of the hoses, if all three air outputs are connected.

5. Carefully and slowly open a disconnected air output a few millimetres to bleed off the compressed air left in the unit.

6. After the gauge shows zero air pressure, close the valve.

7. Note the shut-down date and time in the running hours log (see Appendix 6: Running hours log book on page 140).

WARNING

• Wear appropriate personal protective equipment (PPE), especially protective glasses.

WARNING

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6.4

E

mergen

cy stop

8. Carry out the following daily shut-down tasks, and fix any problems as necessary:

a) Inspect all hoses, couplings, and components for signs of air leaks/ oil leaks, wear and damage.

b) Check the levels of all fluid reservoirs, replenishing as necessary: • Engine fuel level

• Engine oil level • Engine coolant level • Compressor oil level • Pneumatic line lubricator

• Hydraulic starter system reservoir

c) Check that the pneumatic system automatic water drain is working correctly.

9. If shutting down for safe maintenance, activate the EMERGENCY STOP button, and tag it with

a maintenance warning.

6.4 Emergency stop

The AirPack C has two modes of emergency stop:

• Manual, which is initiated by a person pushing the EMERGENCY STOP button • System (automatic), which is caused by a system condition

6.4.1 Manual emergency stop

The unit has an EMERGENCY STOP button. In an emergency, push this button to immediately stop the engine. This releases the air and oil pressure from the engine safety system, and chokes the diesel air inlet and sentinel fuel valves.

After resolving the emergency situation, perform a pre-start inspection (6.1 Pre-start checklist), and then restart the unit (6.2 Power up).

6.4.2 System (automatic) emergency stop

For some engine alarms, the system will automatically shut the engine down. This shutdown procedure is triggered by one or combination of the following:

• Low oil pressure: <0.5 bar (<7.25 psi)

• High engine coolant temperature (exceeds 106 °C (223 °F)) • High engine exhaust temperature (exceeds 200 °C (425 °F))

• An engine overspeed situation: >2300 rpm. Excessive rpm caused by ingress of

explosive gases into the engine intake will increase intake vacuum, causing the Sentinel valve to trip and cut off intake air.

6.5 Charge hydraulic starter accumulator

If the unit has been shut down and there is insufficient pressure to restart the unit, the starter accumulator can be pressurized by using the hand pump or by using the air-operated oil pump running on rig air.

Once the engine is running, the air-operated oil pump can also be utilized without rig air to recharge the accumulator before shutting the engine down.

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6 .5 C harge hy dra u lic sta rte r a ccumul ator

6.5.1 Charge starter accumulator using hand pump

1. Locate the hydraulic start system reservoir (3) and hand pump (5) on the inside of the left door.

2. Check the hydraulic fluid level and fill if necessary according to 7.10 Check/fill hydraulic oil on page 61.

3. Locate the hydraulic accumulator (1) on the inside of the right door.

4. Ensure that the accumulator isolation valve (2) and reservoir isolation valve (7) are open. 5. Ensure the hand pump activation knob (6) is fully closed (pointing down).

NOTE: This knob should ALWAYS be in the closed (fully clockwise) position, otherwise the

charging system will not work properly.

6. Remove the pump handle (4) from the holder and insert it into the pump’s handle socket. 7. Operate the pump and observe the START PRESSURE gauge on the power pack control panel

until the minimum start pressure is reached: 120 bar (1740 psi).

NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar (2465

psi).

8. Remove the pump handle, and store it in the holder.

9. Close the isolation valve of the starter accumulator to store the charge in case immediate starting is not required.

Figure 6.7 Hydraulic starter accumulator and reservoir w/ hand pump.

2

1

3

5

4

6

7

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6.5.2 Charge starter accumulator using the air-operated oil pump

The air-operated oil pump can be used when the engine is running or when rig air is connected. To charge the accumulator using the hand pump refer to 6.5.1 Charge starter accumulator using

hand pump.

1. Locate the hydraulic start system reservoir (3) on the inside of the left door.

2. Check the hydraulic fluid level and fill if necessary according to 7.10 Check/fill hydraulic oil on page 61.

3. When charging the starter accumulator with the engine:

a) Start up the unit according to section 6.2 Power up on page 35. b) Continue to step 5.

4. When charging the starter accumulator with rig air:

a) Connect an air supply with a pressure between 7 bar (100 psi) and 10 bar (145 psi) to the rig air in connector.

b) Open the rig air in isolation valve on the AirPack C.

5. Locate the hydraulic accumulator (1) on the inside of the right door.

6. Ensure that the accumulator isolation valve (2) and the reservoir isolation valve (4) are open.

Figure 6.8 Hydraulic starter accumulator, reservoir and air-operated oil pump.

2

1

3

4

6

5

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7. Ensure the hand pump activation knob (5) is fully closed (fully clockwise, pointing down). 8. Open the input air isolation valve (76) to activate the air-operated oil pump.

9. Operate the pump and observe the START PRESSURE gauge on the control panel until the minimum start pressure is reached: 120 bar (1740 psi).

NOTE: Maximum charging pressure of the starter accumulator is factory preset at 170 bar (2465

psi).

10. Close the input air isolation valve to deactivate the pump and keep it from starting unexpectedly.

6931055734 - MAN - AirPack

DRAFT - FOR

INFORMATION ONLY

AirPack C

User Manual

WARNING

TABLE OF CONTENTS

1

INTRODUCTION

2

SAFETY

2.1

General Safety

2.1.1

Employee responsibility

2.1.2

Employer responsibility

2.1.3

Warnings, cautions and requirements

WARNING

CAUTION

2.2

Equipment specific safety

2.2.1

Emergency Stop buttons

2.2.2

Heavy equipment

2.2.3

ATEX and zoning

2.2.4

Doors and hatches

3

PHYSICAL DESCRIPTION

3.1

Unit overview

8

3

5

1

7

6

4

2

3.2

Unit rear view

4

5

7

2

6

1

8

3

3.3

Unit right view (spring starter)

2

1

3

4

5

6

3.4

Unit right view (hydraulic starter)

2

1

3

10

7

8

13

9

11

15

4

5

6

12

14

16

17