Embedded Files
This disassembly webpage is the first of four procedural web pages dedicated to the decommissioning and recommissioning of the CP-JHC burner. The disassembly procedure aims to guide the user through the process of dissembling and organising the subsystem components. The final result of this procedure is to have all components disassembled into transportable sizes, and organised in a way that it is easy to identify and collect components for future procedures.
The CP-JHC burner subsystems should be disassembled in the following order:
Electrical subsystem
Water subsystem
Gas subsystem
Burner subsystem
Before any disassembly, the burner PC600s and PC700s will be labelled to allow for a greater understanding of component locations.
Labelling of PC600 & PC700
Labelling of PC600 & PC700
The PC600s and PC700s are components of the burner system. There are two PC600s and four PC700s. There is small variations in each components shape which affects the connections and shape of the burner subsystem. Hence, these components are required to be labelled in order to be reassembled. The labelling of the components is also beneficial to the disassembly processes of other subsystems, as it allows for direct reference to individual components without confusion.
Labelling Procedure:
Labelling Procedure:
On a 3 pieces of A4 paper, have either printed or written numbers 1 through to 6 in larger sizes.
Cut numbers out, does not have to be neat. Place cut out numbers in A4 sheet of laminating paper in such a way that they are not overlapping and will be individually sealed during lamination.
Laminate the numbers. Cut out the laminated numbers with a border of plastic. Using clear packaging tape to stick a number to each PC600 and PC 700 piece. Let #1 start at the PC600 connected to PC 500, and #6 be the PC700 connected to PC800. Ensure the number is in the direction readable to a person standing on the ground. To the left is a diagram showing the numbering of the PC600s and PC700s.
Take photos of each label for reference. Attach photos into photo submission form.
Electrical Subsystem
Electrical Subsystem
Disassembly Procedure:
Disassembly Procedure:
For the disassembly of this subsystem, labelling and organisation processes have been included where necessary. Each stage is a different electrical block, thus it is not necessary to complete the whole disassembly procedure in one attempt. However, it is recommended to complete the whole block in one session. It is necessary to remove the electrical system before continuing to the other subsytem procedures.
Stage 1: Remove CCTV system (Block 6: ES06)
Disconnect and collect all eight CCTV cameras either from setup or from storage.
Ensure all CCTV cameras have protective equipment for storage, this is equipment such as lens covers.
Collect all CCTV camera accessories. This may include stands, any power or transmission wires, or batteries.
Write down all components collected on a sheet of paper. Submit this to the disassembly documentation form or directly to Google Drive.
Place all cameras and accessories into a box ensuring that they are protected and will not be damaged. Label the box and note down any accessories that either do not box or have separate storage.
Place the box and any other containers for equipment into the designated storage space for the electrical subsystem.
Stage 2: Remove Main electrical board (Block 5: ES05)
Disconnect all cables running from the electrical mains to the electrical board.
a. If the cables can be unconnected from the board do so. Then carefully wind the cables up and place them into a box. Label the box 'Mains to board'.
b. If the cable cannot be unconnected or runs the risk of incorrect connection during reassembly, keep the cable connected. Carefully wind up the cable. Place the cable tie around the cable wire so they do not round. Place into the box 'Mains to board' which can remain located at the base of the main electrical board.
Once all mains to board cables are sorted, either secure the 'mains to board' box to the base panel of the main electrical board or move it to the storage location. Disconnect all cables running from the electrical board to the burner.
a. If the cables can be unconnected from the board do so. Then carefully wind the cables up and place them into a box. Label the box 'Board to burner'.
b. If the cable cannot be unconnected or runs the risk of incorrect connection during reassembly, keep the cable connected. Carefully wind up the cable. Place the cable tie around the cable wire so they do not round. Place into the box 'Board to burner' which can remain located at the base of the main electrical board.
Once all board-to-burner cables are sorted, either secure the 'mains to board' box to the base panel of the main electrical board or move to the storage location.
Once all cables have been sorted ensure everything on the main electrical board is secure and closed.
Wheel the board into a safe storage location.
Stage 3: Remove Ignition Controllers (Block 4: ES04)
Disconnect cables running to and from the Flame supervision unit. Carefully wind up all cables and secure them.
Place cables and unit into a box or container and label 'flame supervision unit and handset'.
Disconnect handset cables. Wind up cables and secure them with a tie.
Place the handset into the storage box. Then move the box to a storage location.
Stage 4: Remove High Pressure Loop (Block 3: ES03)
This procedure uses the electrical loop labelling table and labelling diagram.
At the top of the table write the loop name.
Label and disconnect the first wire using the following process:
a. Find a start of the high pressure loop, wired in green single core cable.
b. Using paper, a pen and clear tape create a label using the following convention:
(Connection number): (wire letters) e.g. start with 00:aa
c. Write label on document and show the start position of the wire on the wiring diagram. Also note down if there is a zip tie securing the wire, and if so note location on diagram.
d. Take the label, label the first end of the wire by looping the tape around and sealing the paper label inside the clear tape.
e. Follow the wire to the other end, use same labelling procedure as previously but with a new label code (e.g. 01:aa).
f. Write code into table.
g. Disconnect wire and place in storage box.
Repeat steps 2 for following wires, until a wire is connected to a sensor or thermocouple.
For a sensor (any switches):
a. Write the sensor number in the table. Note down connection point and wire connection.
b. Label location on combustion diagram, and take a photo of labeled wires connected to the sensor.
c. Leave sensor for removal during gas system procedure.
d. Once completed, continue on with repeated wire removal steps.
Stage 5: Remove Low Pressure Loop (Block 2: ES02)
This procedure uses the electrical loop labelling table and labelling diagram.
At the top of the table write the loop name.
Label and disconnect the first wire using the following process:
a. Find a start of the high pressure loop, wired in yellow single core cable.
b. Using paper, a pen and clear tape create a label using the following convention:
(Connection number): (wire letters) e.g. start with 00:aa
c. Write label on document and show the start position of the wire on the wiring diagram. Also note down if there is a zip tie securing the wire, and if so note location on diagram.
d. Take the label, label the first end of the wire by looping the tape around and sealing the paper label inside the clear tape.
e. Follow the wire to the other end, use same labelling procedure as previously but with a new label code (e.g. 01:aa).
f. Write code into table.
g. Disconnect wire and place in storage box.
Repeat steps 2 for following wires, until a wire is connected to a sensor.
For a sensor (any switches):
a. Write the sensor number in the table. Note down connection point and wire connection.
b. Label location on combustion diagram, and take a photo of labeled wires connected to the sensor.
c. Leave sensor for removal during gas system procedure.
d. Once completed, continue on with repeated wire removal steps.
Stage 6: Remove Thermal Loop (Block 1: ES01)
This procedure uses the electrical loop labelling table and labelling diagram.
At the top of the table write the loop name.
Label and disconnect the first wire using the following process:
a. Find a start of the high pressure loop, wired in red single core cable.
b. Using paper, a pen and clear tape create a label using the following convention:
(Connection number): (wire letters) e.g. start with 00:aa
c. Write label on document and show the start position of the wire on the wiring diagram. Also note down if there is a zip tie securing the wire, and if so note location on diagram.
d. Take the label, label the first end of the wire by looping the tape around and sealing the paper label inside the clear tape.
e. Follow the wire to the other end, use same labelling procedure as previously but with a new label code (e.g. 01:aa).
f. Write code into table.
g. Disconnect wire and place in storage box.
Repeat steps 2 for following wires, until a wire is connected to a sensor or thermocouple.
For a sensor (any switches):
a. Write the sensor number in the table. Note down connection point and wire connection.
b. Label location on combustion diagram, and take a photo of labeled wires connected to the sensor.
c. Leave sensor for removal during gas system procedure.
d. Once completed, continue on with repeated wire removal step 2.
For a thermocouple fuse:
a. Write the thermocouple number in the table. Note down connection point and wire connection.
b. Label location on combustion diagram, and take a photo of labeled wires connected to the sensor.
c. Label a small ziplock bag with thermocouple number.
d. Remove screw and place into ziplock bag.
e. Place the loose thermocouple components (washer, resistor, LED light and thermocouple) into the ziplock bag.
Note the gasket will be removed during maintenance.
f. Place ziplock bag into loop box.
g. Once completed, continue on with repeated wire removal process of step 2.
Water Subsystem
Water Subsystem
For the purpose of these procedures, the pipes in the water system loops are referred to as the first letter of the colour loop and the pipe number in order from inlet to outlet. For example, pipe R1 is the first pipe in the red loop from the inlet pipe, and R2 is the next pipe going downstream. The labelling of the PC 600 and PC 700 pieces will occur prior to the disassembly of the water system Phase 1: Labelling. The water system is already adequately labelled with zip ties, however, replacement zip ties should be available to replace existing zip tie labelling at any point in the process if damage occurs.
Tools Required:
Tools Required:
Spanner
Ladder
1 Pallet
masking tape
marker
replacement zip ties
Disassembly Procedures:
Disassembly Procedures:
Stage 1: Remove Water Manifold Board (Block 1: WS01)
Ensure that the laboratory hose is turned off
Disconnect the laboratory hose from the inlet and the outlet of the water system
Using maker and masking tape, label the diverge and converge components with the system loop colour
Take a photo of the water manifold board and upload it to the photo submission form, ensure that the zip tie labelling of the inlet and outlet can be seen in the photo
a. upload the photo in the photo submission form
At the inlet side of the board use a spanner to remove the hoses for each loop at the inlet from left to right G1, Y1, B1, R1 (Green → Yellow → Blue → Red). Keep all components of the Swagelok connectors connected to the board.
a. note that the hoses at this inlet point are labelled with one zip tie, with the colour indicating the loop
At the outlet side of the board, use a spanner to remove the hoses for each loop at the outlet from left to right R3, B3, Y3, G4 (Red → Blue → Yellow → Green). Keep all components of the Swagelok connectors connected to the board.
a. note that the hoses at this point are labelled with two zip ties, one with the colour indicating the loop, and one white, indicating that they are the outlet
With the water manifold board isolated from the rest of the water system, place it onto a pallet dedicated for the water system
Log stage in the disassembly documentation form
Stage 2: Remove the Red loop (Block 2: WS02)
Starting at the inlet of the red loop just detached from the water manifold board, follow the hose and use a spanner to detach R1, the first hose of the red loop, from PC 700 #6 (the base of the PC700 piece attached to PC800). Keep all components of the Swagelok connector attached to R1
a. note that this connection should be indicated with one red zip tip and one white zip tie
Loop Pipe R1 around itself and store on the water system pallet
At the top of the same PC700 #7 piece, use a spanner to detach the inlet of pipe 2 of the red loop (R2). Keep all components of the Swagelok connector attached to R2
a. note that this connection should be indicated with two red zip ties
At the bottom of PC1003 use a spanner to detach the outlet of R2. Keep all components of the Swagelok connector attached to R2
a. note that this connection should be indicated with two zip ties and one white zip tie
Loop pipe R2 around itself and store on the water system pallet
At the top of PC1003 use a spanner to detach the inlet of R3. Keep all components of the Swagelok connector attached to R3
a. note that this connection should be indicated with three red zip ties
Loop pipe R3 around itself and store on the water system pallet
Log stage in the disassembly documentation form
Stage 3: Remove the Blue loop (Block 3: WS03)
Starting at the inlet of the blue loop detached from the water manifold board in stage 1, follow the hose and use a spanner to detach B1 from the base of the middle PC700 #5. Keep all components of the Swagelok connectors attached to B1.
a. note that this connection should be indicated with one blue zip tip and one white zip tie
Loop Pipe B1 around itself and store on the water system pallet
At the top of the same PC700 #5 piece use a spanner to detach the inlet of B2. Keep all components of the Swagelok connectors attached to B2
a. note that this connection should be indicated with two blue zip ties
At the bottom of PC500 use a spanner to detach the outlet of B2. Keep all components of the Swagelok connectors attached to B2.
a. note that this connection should be indicated with two blue zip ties and one white zip tie
Loop pipe B2 around itself and store on the water system pallet
At the top of PC500 use a spanner to detach the inlet of B3. Keep all components of the Swagelok connectors attached to B3.
a. note that this connection should be indicated with three blue zip ties
Loop pipe B3 around itself and store on the water system pallet
Log stage in disassembly documentation form
Stage 4: Remove the Yellow loop (Block 4: WS04)
Starting at the inlet of the yellow loop detached from the water manifold board in stage 1, follow the hose and use a spanner to detach Y1 from the base of the middle PC700. Keep all components of the Swagelok connectors attached to Y1.
a. note that this connection should be indicated with one yellow zip tip and one white zip tie
Loop Pipe Y1 around itself and store on the water system pallet
At the top of the same PC700 piece use a spanner to detach the inlet of Y2. Keep all components of the Swagelok connectors attached to Y2
a. note that this connection should be indicated with two yellow zip ties
At the inner mid-point of PC500 use a spanner to detach the outlet of Y2. Keep all components of the Swagelok connectors attached to Y2.
a. note that this connection should be indicated with two yellow zip ties and one white zip tie
Loop pipe Y2 around itself and store on the water system pallet
At the top of PC500 use a spanner to detach the inlet of Y3. Keep all components of the Swagelok connectors attached to Y3.
a. note that this connection should be indicated with three yellow zip ties
Loop pipe Y3 around itself and store on the water system pallet
Log stage in the disassembly documentation from
Stage 5: Remove the Green loop (Block 5: WS05)
Starting at the inlet of the green loop detached from the water manifold board in stage 1, follow the hose and use a spanner to detach G1 from the side of PC600 #3. Keep all components of the Swagelok connectors attached to G1
a. note that this connection should be indicated with one green zip tip and one white zip tie
Loop Pipe G1 around itself and store on the water system pallet
At the top of the same PC600 #3 piece use a spanner to detach the inlet of G2. Keep all components of the Swagelok connectors attached to G2.
a. note that this connection should be indicated with two green zip ties
On PC700 #2, use a spanner to detach the outlet of G2. Keep all components of the Swagelok connectors attached to G2
a. note that this connection should be indicated with two green zip ties and one white zip tie
Loop pipe G2 around itself and store on the water system pallet
On the same PC700 #2 piece, use a spanner to detach the inlet of G3. Keep all components of the Swagelok connectors attached to G3.
a. note that this connection should be indicated with three green zip ties
On PC600 #1, use a spanner to detach the outlet of G3. Keep all components of the Swagelok connectors attached to G3.
a. note that this connection should be indicated with three green zip ties and one white zip tie
Loop pipe G3 around itself and store on the water system pallet
On PC600 #1, use a spanner to detach the inlet of G4. Keep all components of the Swagelok connectors attached to G4.
a. note that this connection should be indicated with four green zip ties
Loop G4 around itself and store on the water system pallet
Log stage in the disassembly documentation form
Gas Subsystem
Gas Subsystem
The disassembly of the gas system has been divided into five stages, one for each of the established blocks. To ensure that the procedures are manageable, a number of the larger blocks have been divided further into substages.
The gas booster board (GS02) and the flowmeter board (GS03) can both be detached from the rest of the system. However, as each of the individual gas components must be cleaned and maintained to ensure continued functionality, the complete disassembly of the blocks will take place.
Tools Required:
Tools Required:
Spanner
Ladder
5 storage boxes labelled GS01, GS02, GS03, GS04, and GS05
masking tape
marker
Disassembly Procedures:
Disassembly Procedures:
Stage 1: Remove the natural gas isolation valve train (Block 1: GS01)
Ensure that the gas supply is turned off and is not flowing through pipes for each of the three gas inputs (air from the compressor, natural gas from mains, and bottled gases)
Disconnect hose assembly HA01 from the natural gas from the mains using a spanner.
a. Keep the fasteners upstream of HA01 attached
b. Using masking tape and a marker, label the inlet of the hose as “inlet” by wrapping the masking tape around and leaving a tag that can be written on
Disconnect hose assembly HA01 from manual ball valve BV08 using a spanner
a. Keep the fasteners downstream of HA01 attached
b. Using masking tape and a marker, label the outlet of the hose as “outlet” by wrapping the masking tape around and leaving a tag that can be written on
Store HA01 in the storage box labelled GS01
Disconnect ball valve BV08 from filter FIL03 using a spanner
a. Keep the fasteners downstream of BV08 attached
Store BV08 in the storage box labelled GS01
Disconnect FIL03 from PG13 using a spanner
a. Keep the fasteners downstream FIL03 attached
Store PG13 in the storage box labelled GS01
Disconnect FIL03 from SV04 using a spanner
a. Keep the fasteners downstream of FIL03 attached
Store FIL03 in the storage box labelled GS01
Disconnect SV04 from SV05 using a spanner
a. Record any fasteners used in additional components form
b. Keep the fasteners downstream of SV04 attached
Store SV04 in the storage box labelled GS01
Disconnect SV05 from CV46 using a spanner
a. Record any fasteners used in additional components form
b. Keep the fasteners downstream of SV05 attached
Store SV05 in the storage box labelled GS01
Disconnect CV46 from CV47 using a spanner
a. Record any fasteners used in additional components form
b. Keep the fasteners downstream of CV46 attached
Store CV46 in the storage box labelled GS01
Disconnect CV47 from HA02 using a spanner
a. Record any fasteners used in additional components form
b. Keep the fasteners downstream of CV47 attached
c. Using masking tape and a marker, label the inlet of the hose as “inlet” by wrapping the masking tape around and leaving a tag that can be written on
Store CV47 in the storage box labelled GS01
Disconnect HA02 from BV34 using a spanner
a. Record any fasteners used in additional components form
b. Keep the fasteners downstream of HA02 attached to the hose
c. Using masking tape and a marker, label the outlet of the hose as “outlet” by wrapping the masking tape around and leaving a tag that can be written on
Store HA02 in the storage box labelled GS01
Log stage in the disassembly documentation form
Stage 2: Remove the gas booster (Block 2: GS02)
Stage 2.1: From NG Isolation valve train to vent
Take a photo of the gas booster board and upload it to the photo submission form
Disconnect BV34 from SN01 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of BV34 attached
Store BV34 in the storage box labelled GS02
Disconnect SN01 from PS19+20 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of SN01 attached
Store SN01 in the storage box labelled GS02
Disconnect PS19+20 from BV04 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PS19+20 attached
Store PS19+20 in the storage box labelled GS02
Disconnect BV04 from the vent using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of BV04 attached
Store BV04 in the storage box labelled GS02
Stage 2.2: From reticulated NG supply to gas booster
Disconnect the Reticulated NG supply from FIL04 using a spanner
Disconnect FIL04 from CV04 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL04 attached
Store FIL04 in the storage box labelled GS02
Disconnect CV04 from EBV01 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV04 attached
Store CV04 in the storage box labelled GS02
Disconnect EBV01 from its connection
a. Record any fasteners used in the additional components form
b. Store EBV01 in the storage box labelled GS02
Stage 2.3: From compressed air to gas booster
Disconnect Compressed air from EBV03 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of Compressed air attached
Store Compressed air in the storage box labelled GS02
Disconnect EBV03 from BV06 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of EBV03 attached
Store EBV03 in the storage box labelled GS02
Disconnect BV06 from FIL02 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of BV06 attached
Store BV06 in the storage box labelled GS02
Disconnect FIL02 from REG01 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL02 attached
Store FIL02 in the storage box labelled GS02
Disconnect REG01 from PG10 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of REG01 attached
Store REG01 in the storage box labelled GS02
Disconnect PG10 from CV02 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG10 attached
Store PG10 in the storage box labelled GS02
Disconnect CV02 from CV03 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV02 attached
Store CV02 in the storage box labelled GS02
Disconnect CV03 from PG07 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV03 attached
Store CV03 in the storage box labelled GS02
Disconnect PG07 from the gas booster using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG07 attached
Store PG07 in the storage box labelled GS02
Disconnect the air vent from the gas booster using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG07 attached
Store the air vent in a box labelled GS02
Stage 2.4: From gas booster to vent
Disconnect the Gas booster from PG08 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the Gas booster attached
Store the Gas booster in the storage box labelled GS02
Disconnect PG08 from PS09+10 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG08 attached
Store PG08 in the storage box labelled GS02
Disconnect PS09+10 from the Receiver tank using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PS09+10 attached
Store PS09+10 in the storage box labelled GS02
Disconnect the Receiver tank from CV01 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the Receiver tank attached
Store the Receiver tank in the storage box labelled GS02
Disconnect CV01 from EBV02 (also disconnect from HP natural gas outlet here) using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV01 attached
Store CV01 in the storage box labelled GS02
Disconnect EBV02 from the HP natural gas outlet
a. Record any fasteners used in the additional components form
b. keep any fasteners attached to the EBV02 component
Disconnect EBV02 from BV05
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of EBV02 attached
Store EBV02 in the storage box labelled GS02
Disconnect BV05 and SNB02 (permanently joined) from the vent
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of SNB02 attached
Store BV05 & SNB02 in the storage box labelled GS02
Disconnect the vent component from its connection
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the vent attached
Store the vent component in the storage box labelled GS02
Keep the physical board with the storage box (GS02)
Log stage in the disassembly documentation form
Stage 3: Remove the flow meter board (Block 3: GS03)
Stage 3.1: Natural gas from booster lines
Disconnect RED02 from natural gas from the booster
a. Keep any fasteners downstream of REG02 attached
Disconnect REG02 from SV01 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of REG02 attached
Store REG02 in the storage box labelled GS03
Disconnect SV01 from FIL06 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of SV01 attached
Store SV01 in the storage box labelled GS03
Disconnect FIL06 from MFC05 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL06 attached
Store FIL06 in the storage box labelled GS03
Disconnect MFC05 from SNB03 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of MFC05 attached
Store MFC05 in the storage box labelled GS03
Disconnect SNB03 from CV09 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of SNB03 attached
Store SNB03 in the storage box labelled GS03
Disconnect CV09 from the pilot/igniter
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV09 attached
Store CV09 in the storage box labelled GS03
Disconnect SV02 from FIL07 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of SV02 attached
Store SV02 in the storage box labelled GS03
Disconnect FIL07 from MFC06 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL07 attached
Store FIL07 in the storage box labelled GS03
Disconnect MFC06 from CV10 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of MFC06 attached
Store MFC06 in the storage box labelled GS03
Disconnect CV10 from the Rings using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV10 attached
Store CV10 in the storage box labelled GS03
Disconnect FIL11 from MFC09 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL11 attached
Store FIL11 in the storage box labelled GS03
Disconnect MFC09 from CV08 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of MFC09 attached
Store MFC09 in the storage box labelled GS03
Disconnect CV08 from the Jet using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV08 attached
Store CV08 in the storage box labelled GS03
Stage 3.2: Air from compressor lines
Disconnect EBV04 from Air from the compressor using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners attached to EBV04
Disconnect EBV04 from FIL04 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of EBV04 attached
Store EBV04 in the storage box labelled GS03
Disconnect FIL04 from the Equilibar using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL04 attached
Store FIL04 in the storage box labelled GS03
Disconnect FIL08 from MFC10 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL08 attached
Store FIL08 in the storage box labelled GS03
Disconnect MFC10 from CV06 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of MFC10 attached
Store MFC10 in the storage box labelled GS03
Disconnect CV06 from the Rake using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV06 attached
Store CV06 in the storage box labelled GS03
Disconnect FIL09 from MFC11 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL09 attached
Store FIL09 in the storage box labelled GS03
Disconnect MFC11 from CV12 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of MFC11 attached
Store MFC11 in the storage box labelled GS03
Disconnect CV12 from the Coflow air using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV12 attached
Store CV12 in the storage box labelled GS03
Stage 3.3: Hydrogen Cylinder lines
Disconnect SV07 from the Hydrogen Cylinder’s BOC 135G using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners attached to SV07
Disconnect SV07 from FIL10 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of SV07 attached
Store SV07 in the storage box labelled GS03
Disconnect FIL10 from MFC04 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL10 attached
Store FIL10 in the storage box labelled GS03
Disconnect MFC04 from CV07 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of MFC04 attached
Store MFC04 in the storage box labelled GS03
Disconnect CV07 from the Ring using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV07 attached
Store CV07 in the storage box labelled GS03
Disconnect FIL05 from MFC07 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL05 attached
Store FIL05 in the storage box labelled GS03
Disconnect MFC07 from CV11 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of MFC07 attached
Store MFC07 in the storage box labelled GS03
Disconnect CV11 from the Jet using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV11 attached
Store CV11 in the storage box labelled GS03
Keep the physical board with the storage box (GS03)
Log stage in the disassembly documentation form
Stage 4: Remove the main pressure vessel peripherals (Block 4: GS04)
Stage 4.1: Remove inlets to pressure vessel
Disconnect the Main Jet Fuel from Flowmeter(s) from FBA03 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the Main Jet Fuel from Flowmeter(s) attached
Store Main Jet Fuel from Flowmeter(s) in the storage box labelled GS04
Disconnect FBA03 from BV08 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FBA03 attached
Store FBA03 in the storage box labelled GS04
Disconnect BV08 from the Main Jet using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of BV08 attached
Store BV08 in the storage box labelled GS04
Disconnect Rake Air from Flowmeter from FS07 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of Rake Air from Flowmeter attached
Store Rake Air from Flowmeter in the storage box labelled GS04
Disconnect FS07 from Rake using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FS07 attached
Store FS07 in the storage box labelled GS04
Disconnect Ring Burner Fuel from Flowmeter(s) from FBA08 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the Ring Burner Fuel from Flowmeter(s) attached
Store Ring Burner Fuel from Flowmeter(s) in the storage box labelled GS04
Disconnect FBA08 from BV02 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FBA08 attached
Store FBA08 in the storage box labelled GS04
Disconnect BV02 from the Ring Burner using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of BV02 attached
Store BV02 in the storage box labelled GS04
Disconnect Ignition Fuel from Flowmeter from FBA09 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of Ignition Fuel from Flowmeter attached
Store Ignition Fuel from Flowmeter in the storage box labelled GS04
Disconnect FBA09 from BV01 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FBA09 attached
Store FBA09 in the storage box labelled GS04
Disconnect BV01 from Ignition Flame using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of BV01 attached
Store BV01 in the storage box labelled GS04
Disconnect Coflow Air from Flowmeter from CV05 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of Coflow Air from Flowmeter attached
Store Coflow Air from Flowmeter in the storage box labelled GS04
Disconnect CV05 from FS09 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of CV05 attached
Store CV05 in the storage box labelled GS04
Disconnect FS09 from FS08 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FS09 attached
Store FS09 in the storage box labelled GS04
Disconnect FS08 from BV07 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FS08 attached
Store FS08 in the storage box labelled GS04
Disconnect the drain from BV07 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners attached to BV07
Store the drain in the storage box labelled GS04
Disconnect BV07 from Air Inlet using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of BV07 attached
Log stage in the disassembly documentation form
Stage 4.2: remove pressure switched and gauges from the pressure vessel
Disconnect PS27 from PS24 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PS27 attached
Store PS27 in the storage box labelled GS04
Disconnect PS24 from Air Inlet using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PS24 attached
Store PS24 in the storage box labelled GS04
Disconnect PS28 from PS25 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PS28 attached
Store PS28 in the storage box labelled GS04
Disconnect PS25 from Ignition Flame using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PS25 attached
Store PS25 in the storage box labelled GS04
Disconnect PG09 from PG03 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG09 attached
Store PG09 in the storage box labelled GS04
Disconnect PG03 from PG02 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG03 attached
Store PG03 in the storage box labelled GS04
Disconnect PG02 from Combustor using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG02 attached
Store PG02 in the storage box labelled GS04
Disconnect PS26 from PS23 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PS26 attached
Store PS26 in the storage box labelled GS04
Disconnect PS23 from Combustor using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PS23 attached
Store PS23 in the storage box labelled GS04
Log stage in the disassembly documentation form
Stage 5: Remove the exhaust peripherals (Block 5: GS05)
Disconnect the Flue Gas Vent from PRV01 using a spanner
a. Record any fasteners used in the additional components form
Store the Flue Gas Vent in the storage box labelled GS05
Disconnect PRV01 from PC400 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners upstream and downstream of PRV01 attached
Store PRV01 in the storage box labelled GS05
Disconnect EBV06 from PC400 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners upstream and downstream of EBV06 attached
Store EBV06 in the storage box labelled GS05
Disconnect PG12 from FIL14 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG12 attached
Store PG12 in the storage box labelled GS05
Disconnect FIL14 from the control air inlet using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the control air inlet attached
Store FIL14 in the storage box labelled GS05
Disconnect PG05 from the control air inlet using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of PG05 attached
Store PG05 in the storage box labelled GS05
Disconnect the Alicat Pressure Controller from the Control Air Outlet using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the Alicat Pressure Controller attached
Store Control Air Outlet in the storage box labelled GS05
Disconnect the Alicat Pressure Controller from the Control Air Inlet using a spanner
a. Record any fasteners used in the additional components form
Store the Alicat Pressure Controller in the storage box labelled GS05
Disconnect Control Air Inlet from Equilibar
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the Control Air Inlet attached
Store Control Air Inlet in the storage box labelled GS05
Disconnect the Main Exhaust from FIL13 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the Main Exhaust attached
Disconnect FIL13 from Equilibar using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL13 attached
Store FIL13 in the storage box labelled GS05
Disconnect Equilibar from EBV05 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of Equilibar attached
Store Equilibar in the storage box labelled GS05
Disconnect the Main Exhaust from FIL12 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the Main Exhaust attached
Store the Main Exhaust in the storage box labelled GS05
Disconnect FIL12 from EBV05 using a spanner
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of FIL12 attached
Store FIL12 in the storage box labelled GS05
Disconnect EBV05 from PC700
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of EBV05 attached
Store EBV05 in the storage box labelled GS05
Disconnect emergency exhaust from SV09
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the emergency exhaust attached
Store emergency exhaust in the storage box labelled GS05
Disconnect SV09 from PC700
a. Record any fasteners used in the additional components form
b. Keep the fasteners downstream of the emergency exhaust attached
Store SV09 in the storage box labelled GS05
Log stage in the disassembly documentation form
Burner Subsystem
Burner Subsystem
Labelling Procedures:
Labelling Procedures:
Prior to commencing the disassembly of the burner system, multiple components will need to be labelled. Ensure the PC600s and PC700s still have the correct labels, as discussed in a previous procedure. Ensure the unistrut frame is labelled in the procedure below.
Unistrut Labelling
Print off Unistut Document. It is in the Disassembly: Combustor printable pdf above and shown to the right.
Using wide masking tape, attach tape in a loop around a piece of unistrut frame. Ensure that the tape is looped in a way that ensures that it is touching itself, and cannot be peeled off the frame piece.
On this tape label the piece a number.
Write the corresponding number onto the piece represented in the unistrut document.
Repeat steps 2-3 for all unistrut pieces.
Submit a photo or scan of the unistrut document completed to the disassembly progress form.
Disassembly Procedure:
Disassembly Procedure:
For the disassembly of this subsystem, multiple people will be required. This is due to the size and weight of the system. For some pieces having at least one other person will ensure a safer disassembly process. For other pieces, such as PC500, it is not possible for one person to move.
Stage 1: Remove Vertical Exhaust System (Block 6: BS06)
Take photos of arrows lined up at the connections listed below and submit a photo submission form (or upload later).
a. PC600 #3 and PC700 #4
b. PC700 #4 and PC700 #5
c. PC700 #5 and PC700 #6
d. PC700 #6 and PC800
Using an iterative bolt loosening process, remove the bolts and nuts connecting PC700 #4 and PC700#5. Store bolts and nuts in a large zip lock bag. Ensure the zip lock bag is labelled appropriately (e.g. PC700 #4 -PC700 #5 connection) and place into bolt storage box.
Repeat step 1 for the connection between PC700 #5 and PC700#6.
Remove PC700 #5, ensuring that PC700s #4 and #6 are not damaged and still supported. Place PC700 #5 on storage pallet.
Using an iterative bolt loosening process, remove the bolts and nuts connecting PC600 #3 and PC700 #4 whilst supporting PC700 #4.
a. Lower PC700 #4 carefully and store on pallet.
b. Store bolts and nuts in a large labelled zip lock bag and place bag into bolt storage box.
Using an iterative bolt loosening process, remove the bolts and nuts connecting PC700 #6 and PC800 whilst supporting PC700 #6.
a. Lift and remove PC700 #6 carefully and store on pallet.
b. Store bolts and nuts in a large labelled zip lock bag and place bag into bolt storage box.
Stage 2: Remove Horizontal Exhaust System (Block 5: BS05)
Take photos of arrows lined up at the connections (listed below) and the structure being supported. Submit a photo submission form (or upload later).
a. PC500 and PC600 #1
b. PC600 #1 and PC700 #2
c. PC700 #2 and PC600 #3
d. PC700 #2 being supported by the unistrut frame
Using an iterative bolt loosening process, remove the bolts and nuts connecting PC700 #2 and PC600#3. Keep supporting PC600 #3 throughout the process.
a. Lower PC600 #3 down carefully and store on the pallet with the other exhaust system components.
b. Store bolts and nuts in a large zip lock bag. Ensure the zip lock bag is labelled appropriately and place into bolt storage box.
Iteratively loosen and remove the bolts and nuts connecting PC600 #1 and PC700#2. Ensure PC700 #2 is supported throughout the process to avoid damage to bolts.
a. Carefully lower PC700 #2 down and store on the pallet with the other exhaust system components.
b. Store bolts and nuts in a large zip lock bag. Ensure the zip lock bag is labelled appropriately and place into bolt storage box.
Iteratively loosen and remove the bolts and nuts connecting PC600 #1 to PC500.
a. Carefully lower PC600 #1 down and store on the pallet with the other exhaust system components.
b. Store bolts and nuts in a large zip lock bag. Ensure the zip lock bag is labelled appropriately and place into bolt storage box.
Stage 3: Remove the End of the Exhaust Subsystem (Block 7: BS07)
Take photos of arrows lined up at the connection of PC800 to PC900. Submit a photo submission form (or upload later).
Iteratively loosen and remove the bolts and nuts connecting PC800 to PC900.
a. Remove both PC800 and 900 from PC1200 and store on the pallet with the other exhaust system components.
b. Store bolts and nuts in a large zip lock bag. Ensure the zip lock bag is labelled appropriately and place into bolt storage box.
Stage 4: Remove the Unistrut Extension Frame (Block 7: BS07 and Block 8: BS08)
Take photos of the structure from multiple angles and submit a photo submission form (or upload later).
Dismantle the unistrut appropriately from top to bottom. Store all unistrut pieces collectively on a pallet. Collect all bolts and nuts appropriately in labelled zip lock bags which in turn will be stored in the bolt storage box.
a. Start with the horizontal pieces a top of the frame that are no longer bearing any load.
b. Once all top pieces removed, start removing the diagonal pieces connected to the vertical pieces attached to PC1200.
c. Next remove the horizontal beams between vertical pieces attached to PC1200.
d. Remove the vertical beams attached to PC1200.
e. Remove the vertical beams attached to PC1100.
Remove PC1200 from PC1100.
a. Store bolt connections in a zip lock bag. Ensure bag is labelled appropriately and place into bolt storage box.
b. Place PC1200 on a storage pallet with PC800 and PC900.
Stage 5: Remove the Pressure Vessel Exhaust Assembly (Block 4: BS04)
Note: This section will require the forklift.
Take photos of arrows lined up at the connection of PC400 to PC500. Submit a photo submission form (or upload later).
Collect two piece of unistrut which are slightly longer than the gap in the blue supporting frame.
Attach the unistrut pieces to the flange at the top of PC500 by bolting the opposite holes of the flange to the unistrut pieces. Note, keep the open section of the unistrut facing upwards.
Iteratively loosen and remove the bolts and nuts connecting PC400 to PC500. Keep 3 bolts and nuts loosely attached to keep secure to PC400. Store bolts and nuts in a container. Label the container appropriately.
Using the forklift, position the blue supporting frame for the forklift underneath the unistrut bars. To achieve positioning, the frame may need to be tilted around the unistrut bars.
Lift the forklift tines so the rectangular guides of the frame lift up and the unistrut bars sit across the frame.
a. If needed, attach to the unistrut bars to the lifting frame for extra security.
Remove the final 3 bolts and store in the container for the bolts of this connection.
a. Place this container next to the bolt storage box.
Lift PC500 off from PC400 using a forklift. Place PC500 on a pallet.
a. If frame was attached to the unistrut bars, detach frame and store frame near PC500.
Stage 6: Remove the Internal Components of Combustion Chamber and the inlet assembly (Block 1: BS01 and Block 3: BS03)
Loosen the M6 screws connecting the inlet cap to PC100 flange.
a. Slowly allow the jet to slide out and touch the ground.
With the jet on the ground, use the forklift to support the PC1100 frame, with PC 100, 200, 300 and 400 all still attached.
a. The forklift tines should support the upper cross beams of PC1100, which is just above the bottom flange of PC400.
Whilst supporting the jet, the forklift should lift PC1100 above the jet allowing the jet to be removed. Then lower the structure back on to the ground.
a. Place the jet in a safe storage location ensuring that is protected and will not be broken.
Carefully remove the top quartz by pulling it out from the top of the scaffolding.
a. Place in a safe storage location ensuring that is protected and will not be broken.
Remove the screws near the top of the PC400. Store in a labelled zip lock bag. Place bag into a box for internal components parts.
Remove the top superwool and discard.
Reach into the internal components and remove the following.
a. Ceramic alumina tubing.
i. Collect all pieces, wrap up in and protective material and store in a safe location.
b. Stetight ceramic balls.
i. Collect in a zip up bag, label bag and store with internal components.
Iteratively loosen and remove the bolts and nuts connecting PC100 to PC200, and place PC100 on a pallet.
a. Store bolts and nuts in a a zip lock bag. Label the bag appropriately and store in the bolt container.
Iteratively loosen and remove the bolts and nuts connecting PC200 to PC300.
a. Carefully lower PC200 onto a hydraulic scissor lift trolley. Transport to a pallet for storage.
i. Be careful for any loose components missed in step 7.
b. Store bolts and nuts in a zip lock bag. Label the bag appropriately and store in the bolt container.
Iteratively loosen and remove the bolts and nuts connecting PC300 to PC400.
a. Two people will carefully lower PC300 onto a hydraulic scissor lift trolley.
i. Be careful for any loose components missed in step 7.
b. Remove the bottom quartz cylinder and superwool from PC300.
c. Transport to a pallet for storage.
d. Store bolts and nuts in a container. Label the container appropriately and store next to the bolt box.
Place the scissor lift, with the ‘pot plant holder’ on it, underneath the bottom flange of PC400.
a. Lift the scissor lift platform so the ‘pot plant holder’ touches the internal components.
b. Remove the M10 studs supporting the firebrick. Store studs in a labelled plastic bag and store in internal components box.
c. Lower the scissor lift down gradually to remove the fire brick, alumina blocks and superwool.
d. Dispose of the superwool, but keep the firebrick for the purpose of modelling the next firebrick.
Stage 7: Finalise the disassembly of the Main Combustion Chamber (Block 2: BS02)
For a window section loosen and remove the screws and nuts holding the assembly. Use the order from 'Window Hex Nut and Screw Ordering' document to ensure the quartz window does not break.
a. Collect all nuts and screws in zip lock bag. Label the bag and store in the window components box.
b. Carefully remove the window cap (PC406), the two window gaskets and the quartz window.
c. Sort the 3 components into three different containers for protection and for future cleaning.
Repeat step 1 for the second window section on the window assembly.
Repeat step 1 and 2 for the three other window assemblies.
Remove all thermal fuse plugs attached to PC400.
a. Place all plugs into a zip lock bag and label. Store bag with the thermocouple electrical components.
The final structure remaining is the PC400 with PC1100. Move with forklift to wherever the assembly will be stored before cleaning and maintenance.
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