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This cleaning and maintenance webpage is the second of four procedural web pages dedicated to the decommissioning and recommissioning of the CP-JHC burner. The cleaning and maintenance procedures aim to guide the user in preparing the components for the new laboratory and reassembly. These procedures are designed to be completed before transportation as the Thebarton laboratory has greater space for the completion of these procedures.
The order of subsystem cleaning and maintenance is not crucial to the completion of these processes. However, it is suggested that the subsystem processes are completed in the order of subsystem reassembly for the smoothest transition to the transportation procedure and reassembly procedure. The procedure order is as follows:
Burner subsystem
Gas subsystem
Water subsystem
Electrical Subsystem
Burner Subsystem
Burner Subsystem
For the burner subsystem, there is more than just cleaning and maintenance required before transporting the components to the new laboratory space. These are the processes are labelling and small-scale reassembly. Cleaning and maintenance should occur before labelling and small-scale reassembly where possible.
Please note: For repeated procedures, a general procedure is given. Alongside this general procedure is a checklist of components in each of the burner blocks. Not all components in a block will undergo the same level of cleaning and maintenance.
Cleaning
Cleaning
Procedure:
Transport the component to be cleared into a workspace.
a. For components directly exposed to the combustion process, transport to a space outside of the Thebarton laboratory into open away from buildings. Where necessary use a forklift and transport the pallet on which the component is being stored on.
b. For components not directly exposed to the combustion process, choose a safe space which suits the component being cleaned.
Note any labels or stickers on the component and their location down onto a piece of paper.
Where possible, remove loose debris and dirt with a brush.
For components directly exposed to the combustion process continue to step 4. For components not directly exposed to the combustion process, skip to step 8a.
Using a degreasing product, apply the product evenly onto the areas that were exposed to the combustion process. Leave this product for 10-15 minutes or the recommended length of time on the product label.
a. For areas of large build-up, agitate the degreaser with a scrubbing brush before leaving the product for 10-15 minutes.
Wash the degreasing product off using water from a hose or a pressure washer.
Wipe down and dry off the component.
If the component is not yet clean, repeat steps 3 to 6.
Wipe down any surfaces of the component which have not been previously cleaned using soap and water. Then, dry the component off. Repeat if necessary.
Only for PC400:
a. Remove a thermocouple gasket.
b. Clean the hole and inspect for damage.
c. Spray the hole and gasket with anti-fuse spray.
d. Screw gasket back into PC400.
e. Wipe away all excess spray remnants.
e. Repeat steps a to e for all thermocouple gaskets.
Once the component is dry and clean check the component over for any damage. Damage can include dents, rust, discolouration or cracks.
a. For repairable damage, take photos of the damage and complete the repairs form. Add component to repair checklist.
b. For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
c. For the non-repairable and consequential damage, take photos of the damage and submit a replacement form. Add component to repair checklist with note of replacement.
Replace any components with missing forward damaged labels and stickers ensuring a similar location and orientation.
Return component to its storage location.
Component Checklist:
Block 1:
PC100
PC200
PC300
Block 2:
PC400
PC1100
Block 3:
OTSI Quartz Glass viewing panes
Block 4:
PC500
Block 5:
2x PC600
1x PC700 (horizontal)
Block 6:
3x PC700
Block 7:
PC800
PC900
PC1200
Block 8:
unistrut frame (if considerably unclean)
Maintenance
Maintenance
For maintenance of the burner subsystem, there are four forms to be used.
A general documentation form to submit documentation about progress of procedure completion.
A repairs form is provided to identify repairable damage and highlight what sort of procedure would need to be taken to achieve the repair.
A non-consequential damage form is provided and is suitable for non-repairable but not consequential damage. This damage needs to be documented to note any changes to the burner system.
A replacement form is provided for any components which need to be replaced. This form is necessary documentation for component replacement, even if the component is immediately replaced.
Once the maintenance check procedure has been performed for all blocks, the repairs from the checklist can be initiated. A procedure for each repair is not provided and expertise expertise of the user is relied upon. It is suggested to group similar tasks together for efficiency, such as ordering replacement parts.
Maintenance Check Procedure:
Complete this procedure for components which were not cleaned.
Check components for any damage. Damage can include dents, rust, discolouration or cracks. Report any newly identified damage that was not previously reported.
a. For repairable damage, take photos of the damage and complete a repair form. Add component to repair list.
b. For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
c. For the non-repairable and consequential damage, take photos of the damage and complete a replacement form. Add the component to the repair checklist with a note of replacement.
Return the component to its storage location.
Component Checklist:
Block 1:
all nuts and bolts connecting listed components together including at the PC300-PC400 connection
Block 3:
PC 1001 Bottom Quartz Tube
PC 1002 Top Quartz Tube
PC 1003 Central Fuel Jet Assembly
PC 1010 Alumina Brick
PC 1011 Middle Shelf Assembly
PC 1014, PC1015, PC1016 Ring Burners
PC 1018 Top Shelf
PC 1021 Pilot Injector
PC 1022 Flow Straightener
PC 1023 Rakes
Ceramic alumina tubing.
Stetight ceramic balls
Block 4:
nut and bolt connections connecting PC500 to PC400
Block 5:
all nuts and bolts connecting listed components together including at the PC500-PC600 connection
Block 6:
all nuts and bolts connecting listed components together including at the PC700-PC800 connection
Block 7:
all nuts and bolts connecting listed components together including at the PC700-PC800 connection
Block 8:
Unistrut extension frame
all fasteners used to connect the frame together
Labelling
Labelling
This additional labelling procedure is a recommendation or supporting documentation of the burner and its components. Most components holding pressure are already labelled. These final additions just provide extra traceability. These editions are the window panels and the fastening components of the body of the pressure vessel and exhaust system. The procedures are listed below can be completed separately. It is suggested that these labelling procedures occur after cleaning of the relevant components.
Labelling Procedure 1: Labelling of the window panels
Retrieve both different types of window panels from storage. There should be eight 20mm-thick quartz glass window panels and eight 6mm-thick sapphire plate windows. Note: It is more important to label the quartz glass windows than the sapphire ones as the quartz windows hold greater pressure under testing.
Using a lead pencil label the edge of the window. Suggested labels are is following:
a. For quartz glass window panels label: QG01. Change the last two numbers for each window with no repetition, such as increasing the last digit from 01 through to 08.
b. For sapphire crystal window panels label: SC01. Change the last two numbers for each window with no repetition, such as increasing the last digit from 01 through to 08.
Write down all labels used and specify for what panel type. Also, record the date. Then submit this information for documentation, either through the form or automatically into Google Drive.
Take photos of all labels on each of the windows. Submit these photos to the photo form or automatically into Google Drive.
Carefully pack up the window panels so they are stored carefully for transportation. Play spike into the desired organisation location with other window components.
Labelling Procedure 2: Labelling of fasteners which hold pressure
Retrieve the fasteners storage box. From the box, collect the fasteners, i.e. the nuts and bolts, which connect any of the following connection types:
PC100-PC200
PC200-PC300
PC300-PC400
PC400-PC500
PC500-PC600
PC600#1-PC700#2
PC700#2-PC600#3
PC600#3-PC700#4
PC700#4-PC700#5
PC700#5-PC700#6
PC700-PC800
PC800-PC900
For the bag of the first listed connection, take out all components.
Select a component to label. Using a permanent marker or an engraver, label the component. If using an engraver be careful to not damage the component.
a) The first letter should reference the connection point. Reference this list:
A = PC100-PC200
B = PC200-PC300
C = PC300-PC400
D = PC400-PC500
E = PC500-PC600
F = PC600#1-PC700#2
G = PC700#2-PC600#3
H = PC600#3-PC700#4
I = PC700#4-PC700#5
J = PC700#5-PC700#6
K = PC700-PC800
L = PC800-PC900
b) The next letter should specify the component type. For a nut stop the label with an N, for a bolt start the label with a B.
c) Then use two numbers to specify the component such as 01. It would be recommended that for each component type increase the number by one digit, e.g. BA01 then BA02.
Once labelled, write down the component label onto a piece of paper which will record all components for the specific connection point.
Then move on to the next component and repeat the process of steps 3 and 4.
Once all the components are labelled for one connection point, place all the components back into the bag and then back into the storage box. Submit the written piece of paper containing all labels to the documentation form or directly to Google Drive.
Then repeat steps 3 to 6 for another connection point. Repeat until all bags are completed.
Return the box containing all the bags of fasteners to its storage location ready for transportation.
Small Scale Assembly
Small Scale Assembly
This small reassembly procedure is included before transportation as it will be easier to reassemble these components in the Thebarton laboratory rather than the new laboratory.
Materials and components needed:
Previous firebrick
Cutting utensils including a Stanley knife, ¼” copper pipe, 95mm hole saw attachment
Masking tape
New fire bricks
New superwool board
Alumina bricks
Procedure:
Using the previous firebrick as a reference, cut the new firebrick to have the same or slightly smaller outer diameter. By using the previous firebrick as a reference this firebrick should be able to fit through the base of PC400.
Cut out the centre hole of the firebrick. This centre hole should have a diameter of hole 95mm.
Next, cut out the superwool board too much in the inner 95mm hole. It is recommended to cut the hole by hand using a 95 mm hole saw attachment.
Bank at the smaller holes using using ¼” copper pipe. These small holes are for the M10 threaded rod to go through.
Finally cut back the outer diameter of the superwool to match the fire brick using the firebrick as a top guide. Easiest done with the Stanley knife.
Next assemble firebrick, superwool board and alumina bricks using masking tape to hold these components together. An example of the desired product is shown in the photo to the left. Note previously the optimal arrangement for the alumina brick was found to be with the order increasing from thinnest to thickest brick from bottom to top. Except for the thinnest brick with the shelf cut out which was placed at the top.
Once the assembly is completed take a photo and submit the photo to the photo form or straight to Google Drive.
Place the assembly safely into a box for storage and transportation. Label the box and place blocks in the desired storage location.
Gas Subsystem
Gas Subsystem
The gas system cleaning and maintenance contains two primary procedures, the cleaning and maintenance procedure, and the bubble testing procedure. Both of the procedures are general procedures for all of the components, and are to be repeated for each component of the system using the gas system cleaning checklist.
Tools Required
Tools Required
Label maker
Wire brush
Water
Soap
Bucket
A cloth
Bucket/tub/plastic storage container
Compressed air from laboratory (Thebarton)
Cleaning and Maintenance Procedures
Cleaning and Maintenance Procedures
Prepare a soapy water mixture by mixing soap and water in a bucket
Using the order of cleaning is indicated in the gas system cleaning checklist (Block 1 (GS01) → Block 2 (GS02) → Block 3 (GS03) → Block 4 (GS04) → Block 5 (GS05)). Note that If the labelling of components is removed at any point of the procedure, replace immediately with the label maker
a. Disconnect downstream fasteners
b. Scrub thread tape off around the inlet and outlet connections using a wire brush
c. Wrap new thread tape around the outlet of the component and reattach the downstream fasteners
d. Wipe down the outside of each gas component with the soapy water mixture
e. Test each gas component using bubble testing outlined in the bubble testing procedure
Test each gas component using bubble testing outlined in the bubble testing procedure below in the order indicated in the gas system cleaning checklist
Bubble Testing Procedure
Bubble Testing Procedure
This procedure will be repeated with each component in the order indicate in the gas system cleaning checklist. This procedure occurs at step 3c of the cleaning and maintenance procedure for the gas system
Retrieve the storage boxes labelled GS01, GS02, GS03, GS04, and GS05
Fill a large bucket with water
Attach the compressed air supply to the gas component to the inlet of the gas component
Attach a hose to the outlet of the component
Submerge the entire component under water inside the large bucket
a. Ensure that the outlet hose is being exhausted into the air
Turn on the compressed air supply
Observe the component carefully for the appearance of bubbles (any bubble formation from the component indicate the presence of escaping air and the location of leaks)
a. If no bubbles form:
i. Turn off the compressed air supply
ii. Detach the component from the compressed air and the exhaust hose
iii. Dry the component, and store it in the assigned storage box based on the block the component belongs to
iv. Record in the bubble testing form that the component did not show sign of leaks
b. If bubbles form:
i. Turn off the compressed air supply
ii. Detach the component from the compressed air and the exhaust hose
iii. Dry the component and mark where the bubble formation originated from
iv. Record in the bubble testing form that the component did show signs of leaks
v. Inspect the marked areas, and determine the level of damage
For repairable damage, take photos of the damage and complete a repair form. Add component to repair checklist.
For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
For non-repairable and consequential damage, take photos of the damage and complete a replacement form. Add the component to the repair checklist with a note of replacement.
vi. For any damage noted, either commence repairs if all resources are available and knowledge accessible. If not book a time for repairs to other completed or to be completed by another professional.
vii. Store component in the assigned storage box based on the block the component belongs to
Water Subsystem
Water Subsystem
The cleaning and maintenance procedures for the water system have been combined as the inspection for maintenance can generally occur when the individual component is being cleaned to ensure an efficient and more stream-lined process.
Tools Required
Tools Required
Replacement Zip Ties
Water
Soap
Bucket
A cloth
Cleaning and Maintenance Procedures
Cleaning and Maintenance Procedures
Retrieve the water system pallet.
Prepare soapy water mixture by mixing soap and water.
Use a cloth to wipe down the outside of each of the hoses and the connector attached with the soapy water mixture in a systematic order as follows and as indicated on the water system cleaning and maintenance checklist:
a. Red loop:
i. R1
ii. R2
iii. R3
b. Blue loop:
i. B1
ii. B2
iii. B3
c. Yellow loop:
i. Y1
ii. Y2
iii. Y3
d. Green loop:
i. G1
ii. G2
iii. G3
iv. G4
When wiping down the hoses check for any obvious damage or holes in the hoses and connectors.
a. For repairable damage, take photos of the damage and complete a repair form. Add the component to the repair checklist.
b. For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
c. For non-repairable and consequential damage, take photos of the damage and complete a replacement form. Add the component to the repair checklist with a note of replacement.
d. If time, resources and skill permits, repair any damage or problems that need to be fixed. If not book a time to solve the damage later. Document any plans for reference if not included in the previous documentation step.
If any of the zip tie(s) used to label the water hoses are removed during the cleaning and maintenance process, replace the zip tie(s) with the same colour(s) immediately.
Log in the C&M documentation form.
Electrical Subsystem
Electrical Subsystem
For the electrical system, cleaning and maintenance procedures are combined. Cleaning overall has a minimal impact on the system, or is generally incorporated into maintenance. Where possible cleaning has been highlighted, but emphasis is on maintaining components and preparing for reassembly. Combining cleaning and maintenance procedures will also save time and prevent unnecessary repetition.
Cleaning and Maintenance Procedures
Cleaning and Maintenance Procedures
Procedure 1: Electrical Loops (Block 1: ES01, Block 2: ES02, Block 3: ES03)
Repeat this procedure for each of the electrical loop blocks.
Collect the electrical loop box.
At a workstation, remove all wires and component bags from the box.
For wires:
a. Wipe away any dirt off the outside of the wire. Ensure labels are not moved.
b. Use a multimeter to check functionality. If the wire works continue to step c. If a component is not functional, complete step 5 and then return to this step .
c. Place wire back into box.
d. Repeat steps a to c for all wires.
For thermocouples bags:
a. Check each bag has the following components: washer, resistor, and thermocouple.
Note: some bags may have an additional LED light
b. Use a multimeter to check functionality of components required to carry the electrical current. If a component is not functional, complete step 5 and then return to this step .
c. Place components back into the labelled bag, and place the bag into the box.
d. Repeat for all thermocouples.
For damaged components, need to report through one of the following steps:
a. For repairable damage, take photos of the damage and complete a repair form. Add component to repair checklist.
b. For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
c. For the non-repairable and consequential damage, take photos of the damage and complete a replacement form. Add the component to the repair checklist with a note of replacement.
Pleace electrical loop box back into storage.
Procedure 2: Ignition Controllers (ES04)
Collect the 'flame supervision unit and handset' box.
If the flame supervision unit is noticeably dusty, give the unit a quick wipe-down to remove any extra dust.
Look over the flame supervision unit for any damage or deterioration of the components. For any damage or deterioration complete one of the following forms for documentation purposes:
i. For repairable damage, take photos of the damage and complete a repair form. Add the component to the repair checklist.
ii. For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
iii. For non-repairable and consequential damage, take photos of the damage and complete a replacement form. Add the component to the repair checklist with a note of replacement.
If time, resources and skill permits, repair any damage or problems that need to be fixed. If not book a time to solve the damage later. Document any plans for reference if not included in the previous documentation step.
Repeat steps 2 to 4 for the handset component.
Procedure 3: Main electrical board (Block 5: ES05)
Collect the cable boxes and main electrical board.
Give the board a quick wipe-down to remove any extra dust.
Look over the main board for any damage or deterioration of the components. For any damage or deterioration complete one of the following forms for documentation purposes:
i. For repairable damage, take photos of the damage and complete a repair form. Add component to repair checklist.
ii. For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
iii. For non-repairable and consequential damage, take photos of the damage and complete a replacement form. Add the component to the repair checklist with a note of replacement.
If time, resources and skill permits, repair any damage or problems that need to be fixed. If not book a time to solve the damage later. Document any plans for reference if not included in the previous documentation step.
Repeat steps 2 to 4 for the other components of this block, i.e. the cables.
Procedure 4: CCTV system (Block 6: ES06)
Retrieve 'CCTV cameras and equipment' box.
For each camera in the box complete the following:
a. Clean off the camera housing using a cloth to wipe it down and brush away debris.
b. Clean up the camera lens by blowing away debris with compressed air and then remove the remaining debris by using a microfiber wipe.
c. Check all over the camera and camera houses for any damage or corrosion.
i. For repairable damage, take photos of the damage and complete a repair form. Add component to repair checklist.
ii. For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
iii. For non-repairable and consequential damage, take photos of the damage and complete a replacement form. Add the component to the repair checklist with a note of replacement.
d. Check the power supply of the camera. If it is a battery recharge. If it is a cable ensure the port is clean and clear of debris.
For each camera accessory complete the following:
a. Clean off the accessory with a wipe and brush away any debris.
b. Check all over for any damage.
i. For repairable damage, take photos of the damage and complete a repair form. Add component to repair checklist.
ii. For the non-repairable and non-consequential damage, take photos of the damage and submit a documentation form.
iii. For non-repairable and consequential damage, take photos of the damage and complete a replacement form. Add the component to the repair checklist with a note of replacement.
For any damage noted in steps 2 or 3, either commence repairs if all resources are available and knowledge accessible. If not book a time for repairs to other completed or to be completed by another professional.
For items to be replaced, order replacement straight away or book a time for replacement ordering.
Place all components back into 'CCTV cameras and equipment' box and return to storage.
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