This reassembly webpage is the fourth and final procedural webpage dedicated to the decommissioning and recommissioning of the CP-JHC burner. The reassembly procedure aims to support the user in assembling all subsystems and their components to form the CP-JHC burner. The reassembly procedures include processes that verify subsystem assembly and validate subsystem functionality.
The subsystem reassembly order is as follows:
Burner subsystem
Gas subsystem
Water subsystem
Electrical Subsystem
For the reassembly 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 reassembly process. For other pieces, such as PC500, it is not possible for one person to move and machinery is required.
Stage 1: Prepare main combustor chamber for reassembly by reattaching window assemblies (Block 2 and Block 3)
Note this section will require a gantry lift.
Move PC1100 with PC400 into place over the central jet hole using the gantry lift system or some other kind of machinery.
Prepare components for a window assembly section so components can be re-attachment.
a) Place a window gasket on into a weld pad (PC 405).
b) Follow the gasket carefully with a quartz window pane and another gasket.
c) Whilst supporting the gaskets and pane, place the window cap on.
d) Insert the screws and nuts. Tighten iteratively using the order from Hex Nut and Screw Ordering Sheet. Tighten each nut to the same torque, to the point at which the window assembly is secure.
Repeat step 1 for the second section of the window assembly.
Repeat step 1 and 2 for the other three assemblies.
Then iteratively go through each window assembly until all nuts are tightened to 10Nm.
Stage 2: Prepare main combustor chamber for reassembly by inserting firebrick assembly (Block 2 and Block 3)
Note this section will require a scissor lift.
Shift the scissor lift under the PC400 flange.
a) Place the ‘pot plant holder’ under the flange on the scissor lift.
b) Place the firebrick, superwool boards and alumina brick assembly on top of the ‘pot plant holder’.
c) Take a photo of this assembly and upload it to the photo submission form.
d) Use the scissor lift to lift the firebrick, superwool boards and alumina brick assembly into PC400.
e) If necessary, adjust the assembly to the optimal arrangement.
f) Insert the M10 bolts into PC400 so the internal assembly is supported.
Lower the scissor lift back down.
Place PC200 on the scissor lift.
Using two people, place the PC300 flange onto the PC200 flange.
a) Ensure the ignitor and pilot jet are correctly aligned, and the arrows on the flange align.
b) Whilst supporting PC300, carefully place bolts into the flange holes and connect PC200 to PC300.
c) Iteratively tighten bolts using the bolt tightening procedures.
d) Take photos of arrows lined up at the connection and submit a photo submission form (or upload later).
Ensure the scissor lift is located in the correct position so PC300 and PC400 flange arrows align when the platform is lifted.
Carefully insert the bottom quartz cylinder into the internal components. Ensure that it is not going to fall out in the following steps.
Using the scissor lift, lift PC300 so its flange aligns with the PC 400 flange.
a) Double-check check the arrows on the flanges align.
b) Iteratively place bolts into the connection of PC300 to PC400.
c) Iteratively tighten bolts using the bolt tightening procedures.
d) Take photos of arrows lined up at the connection and submit a photo submission form (or upload later).
Stage 3: Inset Central Jet and reattach Inlet Assembly to Main Combustion Chamber (Block 1 and 2)
Insert the central jet into the hole in the lab. Ensure that it is supported whilst in the ground so it does not break.
Carefully manoeuvre PC100 underneath the combustor chamber and over the central jet hole. Ensure that the jet will be able to be inserted into PC100.
Lift PC100 and attach to PC200.
a) Ensure the arrows on the flanges align.
b) Iteratively place bolts into the connection of PC100 to PC200.
c) Iteratively tighten bolts using bolt tightening procedure.
d) Take photos of arrows lined up at the connection and submit a photo submission form (or upload later).
Carefully lift the jet into place. Tighten the M6 screw on the inlet cap to hold the jet in place.
From the top of PC400, gently cup in Stetight ceramic balls around the bottom of the central jet.
From the top of PC400, carefully slide the ceramic alumina tubing down the central jet tube.
Insert the central quartz tube.
Place the top super wool board on top of the internal assembly. Secure by inserting the screws back into the top of the PC400
Stage 4: Attach Pressure Vessel Exhaust assembly (Block 4)
Note this section will require a gantry lift.
Using the two-piece unistrut lifting 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.
Slowly lift PC500 off of the pallet using the gantry lift, and move over PC400.
Slowly lower PC500 onto PC400, ensuring that the arrows line up on the flanges.
Collect the bolt and nuts bag for the PC400 to PC500 connection.
Slide bolts into all the holes so that PC400 and PC500 are connected.
Then loosely attach all nuts to the bolt.
Iteratively go and tighten the bolts using the standard bolt-tightening procedures.
Once PC 500 is securely attached to PC400, remove the unistrut lifting frame. Keep unistrut pieces and connectors for the next stage.
Take photos of arrows lined up at the connection and submit a photo submission form (or upload it later).
Stage 5: Attach Exhaust End Frame and Unistrut Frame (Block 7 and Block 8)
To complete this stage of the procedure retrieve the unistrut labelling document. This document will help identify which pieces are needed and where.
Collect the dismantled unistrut pieces (pallet) and the nuts and bolts bag (bolt/fastener storage box).
Collect PC 1200 from the end exhaust pallet, and collect PC1100 to PC1200 bolt connections zip lock bag.
Reattach PC1200 to PC 1100.
Next, the unistrut frame will be reattached to PC1100 and PC1200. Use a document to ensure the right pieces are connected. To resolve any confusion look at photo submission from disassembly. Iterative stages of attachment tightening should be used when necessary to ensure the best structure angles.
a) Start by attaching the vertical beams attached to PC 1100. Ensure vertical by using a bubble spirit level. Check nuts and bolts are appropriately tight.
b) Attach the vertical beams to PC1200. Again ensure vertical and fasteners tight.
c) Attach the horizontal beams which are attached to PC 1200. Ensure horizontal by using a bubble spirit level. Check nuts and bolts are appropriately tight.
d) Attach diagonal pieces connected to the vertical pieces. Check nuts and bolts are appropriately tight.
e) Finally, attach horizontal pieces that exist at the top of the frame. Check nuts and bolts are appropriately tight.
Once all unistrut pieces are connected, double-check it all nuts and bolts are tight.
Take photos of the final structure from multiple angles and submit the photo form or upload it to Google Drive.
Compare photos to disassembly photos where there should be a strong similarity. There might be a slight difference in angles as some unstrut beams currently are off by approximately 5 degrees.
Stage 6: Attach the End of the Exhaust Subsystem
Collect PC800 and PC900 from the exhaust pallet.
Collect the appropriate Ziploc bag containing the bolt and nuts for this connection.
Place PC800 and PC900 on PC1200.
Align the arrows on the PC800 and PC900 flanges. Ensure the lines on PC800 and PC900, are in line with the lines on PC1200.
Attach the nuts and bolts of this connection in an iterative process ensuring that arrows and lines remain aligned.
Once all bolts and nuts are attached, ensure all are appropriately tightened. Use the bolt tightening procedure.
Take photos of arrows lined up at the connection and submit a photo submission form (or upload it later).
Stage 7: Attach the Horizontal Exhaust Subsystem
Collect PC600#1, PC600#3, and PC700#2.
Collect nuts and bolt bags for connections: PC500-PC600#1, PC600#1-PC700#2 and PC700#2-PC600#3.
Stop by placing PC600#1 on PC500. Align the arrows at the connection, and loosely connect using the appropriate nuts and bolts. Do not tighten yet.
Place PC700#2 on the unistrut frame so that the end aligns with PC600#1. The correct end is facing the PC600#1.
Making sure that PC700#2 remains well supported, move it to the point that the bolts at the PC600#1-PC700#2 can easily slide in and out.
Lightly attach the nuts and bolts.
Iteratively tighten the nuts and bolts at connections PC500-PC600#1 and PC600#1-PC700#2. Use an altered version of the bolt-tightening procedure. Ensure PC700#2 remains supported and that the bolts at PC600#1-PC700#2 are not placed under excessive load that could cause failure.
Align PC600#3 to PC700#2, and connect using the nuts and bolts. Iteratively tighten using use the bolt-tightening procedure.
Ensure all connections are appropriately tight.
Take photos of arrows lined up at each connection and submit a photo submission form (or upload it later).
Stage 8: Attach the Vertical Exhaust Subsystem
Collect PC700#4, PC700#5, PC700#6.
Collect the nuts and bolts bags for connections: PC600#3-PC700#4, PC700#4-PC700#5, PC700#5-PC700#6, and PC700#6-PC800.
Carefully lift PC700#6 on top of PC800. Ensure the correct end of PC700#6 is facing PC800 and that the arrows line up at the flanges. Whilst supporting PC700#6, attach using the bolts for the connection.
Using multiple people, carefully lift PC700#4 to PC600#3. Ensure the correct end of PC700#4 is facing PC600#3. Align the arrows at the flanges and connect the two components using the connection's nuts and bolts. Ensure PC700#4 is supported in such a way that it does not move the horizontal exhaust system and of course extra stress at the other connections.
While supporting PC700#4 and PC700#6, slide PC700#5 between the two. Make sure that PC700#5 has the correct orientation.
Confirm that PC700#5 is supported by PC700#6 and supports PC700#4.
Ensuring the arrows up both connections are aligned, attach the nuts and bolts at connections PC700#4-PC700#5 and PC700#5-PC700#6.
Go through and iteratively tighten all nuts and bolts at the connections using the bolt-tightening procedure. The connections are listed below:
PC600#3-PC700#4
PC700#4-PC700#5
PC700#5-PC700#6
PC700#6-PC800
Confirm that the vertical and horizontal exhaust system is appropriately supported visually.
Check all connections are appropriately tight.
Take photos of arrows lined up at each connection and submit a photo submission form (or upload it later).
Stage 9: Final Checks
Check all nuts and bolts for all connections are secure and appropriately tight. Below is a checklist of all connections to be crossed off once sure the connection is secure.
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-PC1200
PC1100-PC1200
Check all photos from the disassembly process match the reassembled structure. Checklist below:
a) Unistrut frame structure.
b) All arrows at the following connections
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-PC1200
Check all labelled components match the label diagrams completed in disassembly.
a) PC600s and PC700s
b) Unistrut frame
Check that there are no leftover nuts and bolts, or any other kind of fasteners.
For any issues in steps one to four, fix them appropriately and complete a documentation form.
Take any photos necessary to document the final structure.
Thread tape (white and yellow)
Spanner
Ladder
Stage 1: Reassemble 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)
Retrieve hose assembly HA01 from the storage box labelled GS01
a. Ensure the fasteners upstream of HA01 are attached b. Verify that the hose inlet is labelled "inlet" with masking tape
Wrap thread tape around the inlet of HA01
Reconnect hose assembly HA01 to the natural gas mains using a spanner
Retrieve ball valve BV08 from the storage box labelled GS01
a. Ensure the fasteners downstream of HA01 are attached
b. Verify that the hose outlet is labelled "outlet" with masking tape
Wrap thread tape around the outlet of HA01 and the inlet of BV08
Reconnect hose assembly HA01 to manual ball valve BV08 using a spanner
Retrieve filter FIL03 from the storage box labelled GS01
a. Ensure the fasteners downstream of BV08 are attached
Wrap thread tape around the outlet of BV08 and the inlet of FIL03
Reconnect ball valve BV08 to filter FIL03 using a spanner
Retrieve PG13 from the storage box labelled GS01
a. Ensure the fasteners downstream of FIL03 are attached
Wrap thread tape around the inlet of PG13
Reconnect filter FIL03 to PG13 using a spanner
Retrieve SV04 from the storage box labelled GS01
a. Ensure the fasteners downstream of FIL03 are attached
Wrap thread tape around the outlet of FIL03 and the inlet of SV04
Reconnect filter FIL03 to SV04 using a spanner
Retrieve SV05 from the storage box labelled GS01
a. Ensure the fasteners downstream of SV04 are attached
Wrap thread tape around the outlet of SV04 and the inlet of SV05
Reconnect SV04 to SV05 using a spanner
Retrieve CV46 from the storage box labelled GS01
a. Ensure the fasteners downstream of SV05 are attached
Wrap thread tape around the outlet of SV05 and the inlet of CV46
Reconnect SV05 to control valve CV46 using a spanner
Retrieve CV47 from the storage box labelled GS01
a. Ensure the fasteners downstream of CV46 are attached
Wrap thread tape around the outlet of CV46 and the inlet of CV47
Reconnect control valve CV46 to CV47 using a spanner
Retrieve HA02 from the storage box labelled GS01
a. Ensure the fasteners downstream of CV47 are attached to the hose
Wrap thread tape around the outlet of CV47 and the inlet of HA02
Reconnect CV47 to hose assembly HA02 using a spanner
Log stage in the reassembly documentation form
Stage 2: Reassemble the gas booster (Block 2: GS02)
Stage 2.1: From NG Isolation valve train to vent
Retrieve BV34 from the storage box labelled GS02.
a. Verify that the fasteners downstream of BV34 are attached.
Retrieve SN01 from the storage box labelled GS02.
a. Verify that the fasteners downstream of SN01 are attached.
Wrap thread tape around the connection.
Reconnect BV34 to SN01 using a spanner.
Retrieve PS19+20 from the storage box labelled GS02.
a. Verify that the fasteners downstream of PS19+20 are attached.
Wrap thread tape around the connection.
Reconnect SN01 to PS19+20 using a spanner.
Retrieve BV04 from the storage box labelled GS02.
a. Verify that the fasteners downstream of BV04 are attached.
Wrap thread tape around the connection.
Reconnect PS19+20 to BV04 using a spanner.
Retrieve the vent component from the storage box labelled GS02.
a. Verify that the fasteners downstream of the vent component are attached.
Wrap thread tape around the connection.
Reconnect BV04 to the vent using a spanner.
Stage 2.2: From reticulated NG supply to gas booster
Retrieve FIL04 from the storage box labelled GS02.
a. Verify that the fasteners downstream of FIL04 are attached.
Wrap thread tape around the connection.
Reconnect FIL04 to CV04 using a spanner.
Retrieve CV04 from the storage box labelled GS02.
a. Verify that the fasteners downstream of CV04 are attached.
Wrap thread tape around the connection.
Reconnect CV04 to EBV01 using a spanner.
Retrieve EBV01 from the storage box labelled GS02.
a. Verify that the fasteners downstream of EBV01 are attached.
Wrap thread tape around the connection.
Reconnect EBV01 to its connection.
Stage 2.3: From compressed air to gas booster
Retrieve Compressed air from the storage box labelled GS02.
a. Verify that the fasteners downstream of Compressed air are attached.
Wrap thread tape around the connection.
Reconnect Compressed air to EBV03 using a spanner.
Retrieve EBV03 from the storage box labelled GS02.
a. Verify that the fasteners downstream of EBV03 are attached.
Wrap thread tape around the connection.
Reconnect EBV03 to BV06 using a spanner.
Retrieve BV06 from the storage box labelled GS02.
a. Verify that the fasteners downstream of BV06 are attached.
Wrap thread tape around the connection.
Reconnect BV06 to FIL02 using a spanner.
Retrieve FIL02 from the storage box labelled GS02.
a. Verify that the fasteners downstream of FIL02 are attached.
Wrap thread tape around the connection.
Reconnect FIL02 to REG01 using a spanner.
Retrieve REG01 from the storage box labelled GS02.
a. Verify that the fasteners downstream of REG01 are attached.
Wrap thread tape around the connection.
Reconnect REG01 to PG10 using a spanner.
Retrieve PG10 from the storage box labelled GS02.
a. Verify that the fasteners downstream of PG10 are attached.
Wrap thread tape around the connection.
Reconnect PG10 to CV02 using a spanner.
Retrieve CV02 from the storage box labelled GS02.
a. Verify that the fasteners downstream of CV02 are attached.
Wrap thread tape around the connection.
Reconnect CV02 to CV03 using a spanner.
Retrieve CV03 from the storage box labelled GS02.
a. Verify that the fasteners downstream of CV03 are attached.
Wrap thread tape around the connection.
Reconnect CV03 to PG07 using a spanner.
Retrieve PG07 from the storage box labelled GS02.
a. Verify that the fasteners downstream of PG07 are attached.
Wrap thread tape around the connection.
Reconnect PG07 to the gas booster using a spanner.
Retrieve the air vent from the storage box labelled GS02.
a. Verify that the fasteners downstream of the air vent are attached.
Wrap thread tape around the connection.
Reconnect the air vent to the gas booster using a spanner.
Stage 2.4: From gas booster to vent
Retrieve the Gas booster from the storage box labelled GS02.
a. Verify that the fasteners downstream of the Gas booster are attached.
Wrap thread tape around the connection.
Reconnect the Gas booster to PG08 using a spanner.
Retrieve PG08 from the storage box labelled GS02.
a. Verify that the fasteners downstream of PG08 are attached.
Wrap thread tape around the connection.
Reconnect PG08 to PS09+10 using a spanner.
Retrieve PS09+10 from the storage box labelled GS02.
a. Verify that the fasteners downstream of PS09+10 are attached.
Wrap thread tape around the connection.
Reconnect PS09+10 to the Receiver tank using a spanner.
Retrieve the Receiver tank from the storage box labelled GS02.
a. Verify that the fasteners downstream of the Receiver tank are attached.
Wrap thread tape around the connection.
Reconnect the Receiver tank to CV01 using a spanner.
Retrieve CV01 from the storage box labelled GS02.
a. Verify that the fasteners downstream of CV01 are attached.
Wrap thread tape around the connection.
Reconnect CV01 to EBV02 (also reconnect to HP natural gas outlet here) using a spanner.
Retrieve EBV02 from the storage box labelled GS02.
a. Verify that the fasteners downstream of EBV02 are attached.
Wrap thread tape around the connection.
Reconnect EBV02 to the HP natural gas outlet.
Reconnect EBV02 to BV05.
Retrieve BV05 & SNB02 from the storage box labelled GS02.
a. Verify that the fasteners downstream of BV05 & SNB02 are attached.
Wrap thread tape around the connection.
Reconnect BV05 and SNB02 (permanently joined) to the vent.
Retrieve the vent component from the storage box labelled GS02.
a. Verify that the fasteners downstream of the vent component are attached.
Wrap thread tape around the connection.
Reconnect the vent component to its connection.
Log stage in the reassembly documentation form
Stage 3: Reassemble the flow meter board (Block 3: GS03)
Stage 3.1: Natural gas from booster lines
Retrieve REG02 from the storage box labelled GS03.
a. Verify that the fasteners downstream of REG02 are attached.
Wrap thread tape around the connection.
Reconnect RED02 to natural gas from the booster using a spanner.
Retrieve SV01 from the storage box labelled GS03.
a. Verify that the fasteners downstream of SV01 are attached.
Wrap thread tape around the connection.
Reconnect REG02 to SV01 using a spanner.
Retrieve FIL06 from the storage box labelled GS03.
a. Verify that the fasteners downstream of FIL06 are attached.
Wrap thread tape around the connection.
Reconnect SV01 to FIL06 using a spanner.
Retrieve MFC05 from the storage box labelled GS03.
a. Verify that the fasteners downstream of MFC05 are attached.
Wrap thread tape around the connection.
Reconnect FIL06 to MFC05 using a spanner.
Retrieve SNB03 from the storage box labelled GS03. a. Verify that the fasteners downstream of SNB03 are attached.
Wrap thread tape around the connection.
Reconnect MFC05 to SNB03 using a spanner.
Retrieve CV09 from the storage box labelled GS03.
a. Verify that the fasteners downstream of CV09 are attached.
Wrap thread tape around the connection.
Reconnect SNB03 to CV09 using a spanner.
Retrieve SV02 from the storage box labelled GS03.
a. Verify that the fasteners downstream of SV02 are attached.
Wrap thread tape around the connection.
Reconnect CV09 to SV02 using a spanner.
Retrieve FIL07 from the storage box labelled GS03.
a. Verify that the fasteners downstream of FIL07 are attached.
Wrap thread tape around the connection.
Reconnect SV02 to FIL07 using a spanner.
Retrieve MFC06 from the storage box labelled GS03.
a. Verify that the fasteners downstream of MFC06 are attached.
Wrap thread tape around the connection.
Reconnect FIL07 to MFC06 using a spanner.
Retrieve CV10 from the storage box labelled GS03.
a. Verify that the fasteners downstream of CV10 are attached.
Wrap thread tape around the connection.
Reconnect MFC06 to CV10 using a spanner.
Wrap thread tape around the connection.
Reconnect CV10 to the Rings using a spanner.
Retrieve FIL11 from the storage box labelled GS03.
a. Verify that the fasteners downstream of FIL11 are attached.
Wrap thread tape around the connection.
Reconnect the Rings to FIL11 using a spanner.
Retrieve MFC09 from the storage box labelled GS03.
a. Verify that the fasteners downstream of MFC09 are attached.
Wrap thread tape around the connection.
Reconnect FIL11 to MFC09 using a spanner.
Retrieve CV08 from the storage box labelled GS03.
a. Verify that the fasteners downstream of CV08 are attached.
Wrap thread tape around the connection.
Reconnect MFC09 to CV08 using a spanner.
Stage 3.2: Air from compressor lines
Retrieve EBV04 from the storage box labelled GS03.
a. Verify that the fasteners downstream of EBV04 are attached.
Wrap thread tape around the connection.
Reconnect EBV04 to Air from the compressor using a spanner.
Retrieve FIL04 from the storage box labelled GS03.
a. Verify that the fasteners downstream of FIL04 are attached.
Wrap thread tape around the connection.
Reconnect EBV04 to FIL04 using a spanner.
Wrap thread tape around the connection.
Reconnect FIL04 to the Equilibar using a spanner.
Retrieve FIL08 from the storage box labelled GS03.
a. Verify that the fasteners downstream of FIL08 are attached.
Wrap thread tape around the connection.
Reconnect the Equilibar to FIL08 using a spanner.
Retrieve MFC10 from the storage box labelled GS03.
a. Verify that the fasteners downstream of MFC10 are attached.
Wrap thread tape around the connection.
Reconnect FIL08 to MFC10 using a spanner.
Retrieve CV06 from the storage box labelled GS03.
a. Verify that the fasteners downstream of CV06 are attached.
Wrap thread tape around the connection.
Reconnect MFC10 to CV06 using a spanner.
Stage 3.3: Hydrogen Cylinder lines
Retrieve SV07 from the storage box labelled GS03.
a. Verify that the fasteners downstream of SV07 are attached.
Wrap thread tape around the connection.
Reconnect SV07 to the Hydrogen Cylinder's BOC 135G using a spanner.
Retrieve FIL10 from the storage box labelled GS03.
a. Verify that the fasteners downstream of FIL10 are attached.
Wrap thread tape around the connection.
Reconnect SV07 to FIL10 using a spanner.
Retrieve MFC04 from the storage box labelled GS03.
a. Verify that the fasteners downstream of MFC04 are attached.
Wrap thread tape around the connection.
Reconnect FIL10 to MFC04 using a spanner.
Retrieve CV07 from the storage box labelled GS03.
a. Verify that the fasteners downstream of CV07 are attached.
Wrap thread tape around the connection.
Reconnect MFC04 to CV07 using a spanner.
Wrap thread tape around the connection.
Reconnect CV07 to the Ring using a spanner.
Retrieve FIL05 from the storage box labelled GS03.
a. Verify that the fasteners downstream of FIL05 are attached.
Wrap thread tape around the connection.
Reconnect the Ring to FIL05 using a spanner.
Retrieve MFC07 from the storage box labelled GS03.
a. Verify that the fasteners downstream of MFC07 are attached.
Wrap thread tape around the connection.
Reconnect FIL05 to MFC07 using a spanner.
Retrieve CV11 from the storage box labelled GS03.
a. Verify that the fasteners downstream of CV11 are attached.
Wrap thread tape around the connection.
Reconnect MFC07 to CV11 using a spanner.
Keep the physical board with the storage box GS03.
Log stage in the reassembly documentation form
Stage 4: Reassemble the main pressure vessel (Block 4: GS04)
Stage 4.1: Reattach inlets to the pressure vessel
Retrieve FBA03 from the storage box labelled GS04.
a. Verify that the fasteners downstream of FBA03 are attached.
Wrap thread tape around the connection and reconnect the Main Jet Fuel from the Flowmeter(s) to FBA03 using a spanner.
Retrieve BV08 from the storage box labelled GS04.
a. Verify that the fasteners downstream of BV08 are attached.
Wrap thread tape around the connection and reconnect FBA03 to BV08 using a spanner.
Wrap thread tape around the connection and reconnect BV08 to the Main Jet using a spanner.
Retrieve FS07 from the storage box labelled GS04.
a. Verify that the fasteners downstream of FS07 are attached.
Wrap thread tape around the connection and reconnect Rake Air from Flowmeter to FS07 using a spanner.
Wrap thread tape around the connection and reconnect FS07 to Rake using a spanner.
Retrieve FBA08 from the storage box labelled GS04.
a. Verify that the fasteners downstream of FBA08 are attached.
Wrap thread tape around the connection and reconnect the Ring Burner Fuel from Flowmeter(s) to FBA08 using a spanner.
Retrieve BV02 from the storage box labelled GS04.
a. Verify that the fasteners downstream of BV02 are attached.
Wrap thread tape around the connection and reconnect FBA08 to BV02 using a spanner.
Wrap thread tape around the connection and reconnect BV02 to the Ring Burner using a spanner.
Retrieve FBA09 from the storage box labelled GS04.
a. Verify that the fasteners downstream of FBA09 are attached.
Wrap thread tape around the connection and reconnect the Ignition Fuel from the Flowmeter to FBA09 using a spanner.
Retrieve BV01 from the storage box labelled GS04.
a. Verify that the fasteners downstream of BV01 are attached.
Wrap thread tape around the connection and reconnect FBA09 to BV01 using a spanner.
Wrap thread tape around the connection and reconnect BV01 to Ignition Flame using a spanner.
Retrieve CV05 from the storage box labelled GS04.
a. Verify that the fasteners downstream of CV05 are attached.
Wrap thread tape around the connection and reconnect Coflow Air from Flowmeter to CV05 using a spanner.
Retrieve FS09 from the storage box labelled GS04.
a. Verify that the fasteners downstream of FS09 are attached.
Wrap thread tape around the connection and reconnect CV05 to FS09 using a spanner.
Retrieve FS08 from the storage box labelled GS04.
a. Verify that the fasteners downstream of FS08 are attached.
Wrap thread tape around the connection and reconnect FS09 to FS08 using a spanner.
Retrieve BV07 from the storage box labelled GS04.
a. Verify that the fasteners downstream of BV07 are attached.
Wrap thread tape around the connection and reconnect FS08 to BV07 using a spanner.
Retrieve the drain from the storage box labelled GS04.
a. Verify that the fasteners downstream of the drain are attached.
Wrap thread tape around the connection and reconnect the drain to BV07 using a spanner.
Wrap thread tape around the connection and reconnect the BV07 to the air inlet using a spanner.
Stage 4.2: Reattach pressure switches and gauges to the pressure vessel
Retrieve PS27 from the storage box labelled GS04.
a. Verify that the fasteners downstream of PS27 are attached.
Retrieve PS24 from the storage box labelled GS04.
a. Verify that the fasteners downstream of PS24 are attached.
Wrap thread tape around the connection and reconnect PS27 to PS24 using a spanner.
Wrap thread tape around the connection and reconnect PS24 to Air Inlet using a spanner.
Retrieve PS28 from the storage box labelled GS04.
a. Verify that the fasteners downstream of PS28 are attached.
Retrieve PS25 from the storage box labelled GS04.
a. Verify that the fasteners downstream of the PS25 are attached.
Wrap the thread tape around the connection and reconnect PS28 to PS25 using a spanner.
Wrap thread tape around the connection and reconnect PS25 to Ignition Flame using a spanner.
Retrieve PG09 from the storage box labelled GS04.
a. Verify that the fasteners downstream of PG09 are attached.
Retrieve PG03 from the storage box labelled GS04.
a. Verify that the fasteners downstream of PG03 are attached.
Wrap thread tape around the connection and reconnect PG09 to PG03 using a spanner.
Retrieve PG02 from the storage box labelled GS04.
a. Verify that the fasteners downstream of PG02 are attached.
Wrap thread tape around the connection and reconnect PG03 to PG02 using a spanner.
Wrap thread tape around the connection and reconnect PG02 to the combustor using a spanner.
Retrieve PS26 from the storage box labelled GS04.
a. Verify that the fasteners downstream of PS26 are attached.
Retrieve PS23 from the storage box labelled GS04.
a. Verify that the fasteners downstream of PS23 are attached.
Wrap thread tape around the connection and reconnect PS26 to PS23 using a spanner.
Wrap thread tape around the connection and reconnect PS23 to the Combustor using a spanner.
Log stage in the reassembly documentation form.
Stage 5: Reassemble the exhaust (Block 5: GS05)
Retrieve the Flue Gas Vent from the storage box labelled GS05.
a. Verify that the fasteners downstream of the Flue Gas Vent are attached.
Retrieve PRV01 from the storage box labelled GS05.
a. Verify that the fasteners upstream and downstream of PRV01 are attached.
Wrap thread tape around the connection and reconnect the Flue Gas Vent to PRV01 using a spanner.
Wrap thread tape around the connection and reconnect PRV01 to PC400 using a spanner.
Retrieve EBV06 from the storage box labelled GS05.
a. Verify that the fasteners upstream and downstream of EBV06 are attached.
Wrap thread tape around the connection and reconnect EBV06 to PC400 using a spanner.
Retrieve PG12 from the storage box labelled GS05.
a. Verify that the fasteners downstream of PG12 are attached.
Retrieve FIL14 from the storage box labelled GS05.
a. Verify that the fasteners downstream of FIL14 are attached.
Wrap thread tape around the connection and reconnect PG12 to FIL14 using a spanner.
Wrap thread tape around the connection and reconnect FIL14 to the control air inlet using a spanner.
Retrieve PG05 from the storage box labelled GS05.
a. Verify that the fasteners downstream of PG05 are attached.
Wrap thread tape around the connection and reconnect PG05 to the control air inlet using a spanner.
Retrieve the Alicat Pressure Controller from the storage box labelled GS05.
a. Verify that the fasteners downstream of the Alicat Pressure Controller are attached.
Wrap thread tape around the connection and reconnect the Alicat Pressure Controller to the Control Air Outlet using a spanner.
Retrieve the Control Air Outlet from the storage box labelled GS05.
Wrap thread tape around the connection and reconnect Control Air Outlet to Alicat Pressure Controller using a spanner.
Retrieve the Control Air Inlet from the storage box labelled GS05.
a. Verify that the fasteners downstream of Control Air Inlet are attached.
Wrap thread tape around the connection and reconnect the Control Air Inlet to Equilibar using a spanner.
Retrieve the Main Exhaust from the storage box labelled GS05.
a. Verify that the fasteners downstream of Main Exhaust are attached.
Wrap thread tape around the connection and reconnect Main Exhaust to FIL13 using a spanner.
Retrieve FIL13 from the storage box labelled GS05.
a. Verify that the fasteners downstream of FIL13 are attached.
Wrap thread tape around the connection and reconnect FIL13 to Equilibar using a spanner.
Retrieve Equilibar from the storage box labelled GS05.
a. Verify that the fasteners downstream of Equilibar are attached.
Wrap thread tape around the connection and reconnect Equilibar to EBV05 using a spanner.
Retrieve Main Exhaust from the storage box labelled GS05.
a. Verify that the fasteners downstream of Main Exhaust are attached.
Wrap thread tape around the connection and reconnect the Main Exhaust to FIL12 using a spanner.
Retrieve FIL12 from the storage box labelled GS05.
a. Verify that the fasteners downstream of FIL12 are attached.
Wrap thread tape around the connection and reconnect FIL12 to EBV05 using a spanner.
Retrieve EBV05 from the storage box labelled GS05.
a. Verify that the fasteners downstream of EBV05 are attached.
Reconnect EBV05 to PC700.
Retrieve emergency exhaust from the storage box labelled GS05.
a. Verify that the fasteners downstream of the emergency exhaust are attached.
Wrap thread tape around the connection and reconnect emergency exhaust to SV09.
Retrieve SV09 from the storage box labelled GS05.
a. Verify that the fasteners downstream of SV09 are attached.
Wrap thread tape around the connection and reconnect SV09 to PC700.
Log stage in the reassembly documentation form.
Stage 6: Verify and validate the natural gas isolation valve train (Block 1: GS01)
Use the gas system flow charts on pages 1 and 2 to check that the components are assembled in the correct order for each system.
Perform a visual inspection of all connections and fasteners to ensure they are properly tightened and oriented.
Complete a soapy water test using the soapy water test checklist to ensure all connections are checked.
a. Spray soapy water at the connection point and flow air or gas through the system.
b. Look for bubbling, as this indicates a potential gas or air leak.
c. Verify that there are no visible bubbles at any connection points.
d. If bubbles are observed, identify the source of the leak and address it by tightening the connection or reapplying thread tape
Log stage in the reassembly documentation form.
Stage 7: Verify and validate the gas booster (Block 2: GS02)
Use the gas system flow charts on page 3 to check that the components are assembled in the correct order for each system.
Perform a visual inspection of all connections and fasteners to ensure they are properly tightened and oriented.
Complete a soapy water test using the soapy water test checklist to ensure all connections are checked.
Spray soapy water at the connection point and flow air or gas through the system.
Look for bubbling, as this indicates a potential gas or air leak.
Verify that there are no visible bubbles at any connection points.
If bubbles are observed, identify the source of the leak and address it by tightening the connection or reapplying thread tape
Log stage in the reassembly documentation form.
Stage 8: Verify and validate the flow meter board (Block 3: GS03)
Use the gas system flow charts on page 4 to check that the components are assembled in the correct order for each system.
Perform a visual inspection of all connections and fasteners to ensure they are properly tightened and oriented.
Complete a soapy water test using the soapy water test checklist to ensure all connections are checked.
Spray soapy water at the connection point and flow air or gas through the system.
Look for bubbling, as this indicates a potential gas or air leak.
Verify that there are no visible bubbles at any connection points.
If bubbles are observed, identify the source of the leak and address it promptly by tightening the connection or reapplying thread tape
Log stage in the reassembly documentation form.
Stage 9: Verify and validate the main pressure vessel (Block 4: GS04)
Use the gas system flow charts on pages 5 and 6 to check that the components are assembled in the correct order for each system.
Perform a visual inspection of all connections and fasteners to ensure they are properly tightened and oriented.
Complete a soapy water test using the soapy water test checklist to ensure all connections are checked.
Spray soapy water at the connection point and flow air or gas through the system.
Look for bubbling, as this indicates a potential gas or air leak.
Verify that there are no visible bubbles at any connection points.
If bubbles are observed, identify the source of the leak and address it promptly by tightening the connection or reapplying thread tape
Log stage in the reassembly documentation form.
Stage 10: Verify and validate the exhaust (Block 5: GS05)
Use the gas system flow charts on page 7 to check that the components are assembled in the correct order for each system.
Perform a visual inspection of all connections and fasteners to ensure they are properly tightened and oriented.
Complete a soapy water test using the soapy water test checklist to ensure all connections are checked.
Spray soapy water at the connection point and flow air or gas through the system.
Look for bubbling, as this indicates a potential gas or air leak.
Verify that there are no visible bubbles at any connection points.
If bubbles are observed, identify the source of the leak and address it promptly by tightening the connection or reapplying thread tape
Log stage in the reassembly documentation form.
spanner
ladder
Stage 1: Reinstall the Red loop (Block 2: WS02)
Retrieve the red loop pipes R1, R2, and R3 from the water system pallet.
Starting with R1, attach the outlet of R1 to the base of PC700 #6 using a spanner. Ensure that the Swagelok connector is secure.
a. Note that this connection should have one red zip tie and one white zip tie.
Attach the inlet of R2 to the top of PC700 #7 using a spanner.
a. Note that this connection should have two red zip ties.
At the bottom of PC1003, attach the outlet of R2 using a spanner.
a. Note that this connection should have two zip ties and one white zip tie.
Attach the inlet of R3 to the top of PC1003 using a spanner.
a. Note that this connection should have three red zip ties.
Leave the inlet of R1 and the outlet of B3 detached at this stage.
Log this stage in the the reassembly documentation form.
Stage 2: Reinstall the Blue loop (Block 3: WS03)
Retrieve the blue loop pipes: B1, B2, and B3 from the water system pallet.
Begin by attaching B1 to the base of the middle PC700 #5 using a spanner.
a. Note that this connection should have one blue zip tie and one white zip tie.
Attach the inlet of B2 to the top of the same PC700 #5 piece using a spanner.
a. Note that this connection should have two blue zip ties.
At the bottom of PC500, attach the outlet of B2 using a spanner.
a. Note that this connection should have two blue zip ties and one white zip tie.
Attach the inlet of B3 to the top of PC500 using a spanner.
a. Note that this connection should have three blue zip ties.
Leave the inlet of B1 and the outlet of B3 detached at this stage.
Log this stage in the reassembly documentation form.
Stage 3: Reinstall the Yellow loop (Block 4: WS04)
Retrieve the yellow loop pipes: Y1, Y2, and Y3 from the water system pallet.
Attach Y1 to the base of the middle PC700 using a spanner.
a. Note that this connection should have one yellow zip tie and one white zip tie.
Attach the inlet of Y2 to the top of the same PC700 piece using a spanner.
a. Note that this connection should have two yellow zip ties.
In the inner mid-point of PC500, attach the outlet of Y2 using a spanner.
a. Note that this connection should have two yellow zip ties and one white zip tie.
Attach the inlet of Y3 to the top of PC500 using a spanner.
a. Note that this connection should have three yellow zip ties.
Leave the inlet of Y1 and the outlet of Y3 detached at this stage.
Log this stage in the reassembly documentation form.
Stage 4: Reinstall the Green loop (Block 5: WS05)
Retrieve the green loop pipes: G1, G2, G3, and G4 from the water system pallet.
Attach G1 to the side of PC600 #3 using a spanner.
a. Note that this connection should have one green zip tie and one white zip tie.
Attach the inlet of G2 on PC600 #3 using a spanner.
a. Note that this connection should have two green zip ties.
On PC700 #2, attach the outlet of G2 using a spanner.
a. Note that this connection should have two green zip ties and one white zip tie.
On the same PC700 #2 piece, attach the inlet of G3 using a spanner.
a. Note that this connection should have three green zip ties.
On PC600 #1, attach the outlet of G3 using a spanner.
a. Note that this connection should have three green zip ties and one white zip tie.
On PC600 #1, attach the inlet of G4 using a spanner.
a. Note that this connection should have four green zip ties.
Leave the inlet of G1 and the outlet of G3 detached at this stage.
Log this stage in the reassembly documentation form.
Stage 5: Reinstall the Water Manifold Board (Block 1: WS01)
Retrieve the water manifold board from the dedicated water system pallet and the bolts from the water system Ziplock bag.
Reattach the water manifold board to the main frame using the bolts and a spanner.
Begin reattaching the hoses to the inlet side of the board with a spanner. Follow the sequence from left to right: G1, Y1, B1, R1 (Green → Yellow → Blue → Red).
a. Note that these hoses should have one zip tie each, with the colour indicating the loop.
Move to the outlet side of the board and reattach the hoses: R3, B3, Y3, G4 (Red → Blue → Yellow → Green) with a spanner.
a. Note that these hoses should have two zip ties each, one with the colour indicating the loop and one white, indicating they are the outlet.
Reference the photo on the water manifold board during disassembly, check that the system has been reassembled correctly.
Double-check all connections for tightness and proper labelling.
Reconnect the laboratory hose to the inlet and outlet of the water system.
Log this stage in the the reassembly documentation form.
Stage 6: Verify the Red loop (Block 2: WS02)
Using a spanner, check that each connection is tightened in the following order
a. R1 inlet
b. R1 outlet
c. R2 inlet
d. R2 outlet
e. R3 inlet
f. R3 outlet
Run water through red loop and check for leaks or dripping at each connection.
a. If a leak occurs assess the situation and either tighten the connection or replace the Swagelok.
Log stage in the reassembly documentation form.
Stage 7: Verify the Blue loop (Block 3: WS03)
Using a spanner, check that each connection is tightened in the following order
B1 inlet
B1 outlet
B2 inlet
B2 outlet
B3 inlet
B3 outlet
Run water through blue loop and check for leaks or dripping at each connection.
If a leak occurs assess the situation and either tighten the connection or replace the Swagelok.
Log stage in the reassembly documentation form.
Stage 8: Verify the Yellow loop (Block 4: WS04)
Using a spanner, check that each connection is tightened in the following order
Y1 inlet
Y1 outlet
Y2 inlet
Y2 outlet
Y3 inlet
Y3 outlet
Run water through yellow loop and check for leaks or dripping at each connection.
If a leak occurs assess the situation and either tighten the connection or replace the Swagelok.
Log stage in the reassembly documentation form.
Stage 9: Verify the Green loop (Block 5: WS05)
Using a spanner, check that each connection is tightened in the following order
G1 inlet
G1 outlet
G2 inlet
G2 outlet
G3 inlet
G3 outlet
G4 inlet
G4 outlet
Run water through green loop and check for leaks or dripping at each connection.
If a leak occurs assess the situation and either tighten the connection or replace the Swagelok.
Log stage in the reassembly documentation form.
For the reassembly of this subsystem, care is required. Without this system being functional, the CP-JHC burner cannot function in a safe manner. Take extra care with electrical loops.
Stage 1: Attach Thermal Loop (Block 1: ES01)
Reference the electrical loop labelling table and labelling diagram.
First, attach all thermal couple fuses using the following process:
a. Collect the thermal fuse zip lock bag
b. Collect the two wires which connect to the thermal fuse (refer to thermal loop table document).
c. Loosely but carefully reassemble washer, resistor, thermocouple and screw. Include LED light for those with it in the bag.
d. Whilst supporting the collection of components, screw into the gasket.
e. Using a multimeter, check the circuit:
i. Check the circuit against the body of the pressure vessel.
ii. If short-circuiting, loosen the screw, rearrange the components and retighten.
iii. Complete steps e and d until the no longer short-circuiting.
g. Attach one of the wires. Tick off wire on table.
h. Check for flow with multimeter using step e.
i. Repeat steps g and h for the other wire.
j. Carefully secure both wires so they are out of the way.
k. Repeat steps a to j for all thermal couple fuses.
Referencing the wire order in the loop labelling table, connect all the wires in series.
a. During this process iteratively check the circuit using a multimeter.
Secure all loose wires or previously secured wires with zip ties.
Double check the wire loop labels against the table and most recent electrical diagram.
Remove all wire labels.
Complete a final circuit check if possible with a voltmeter.
Stage 2: Attach Low Pressure Loop (Block 2: ES02)
Reference the electrical loop labelling table and labelling diagram.
First, attach wires to sensors using the following process:
a. Collect the two wires which connect to the sensor (refer to thermal loop table document).
b. Attach one of the wires. Tick off wire on table.
c. Attach the other wire. Tick off wire on table.
d. Using a multimeter, check the circuit:
i. Check the current flow through the wires and sensor.
ii. If short-circuiting, remove wires. Test functionality of both wires, and the sensor.
iii. Replace faulty wire or replace sensor.
e. Repeat steps a to d for all sensors in the loop.
Referencing the wire order in the loop labelling table, connect all the wires in series.
a. During this process iteratively check the circuit using a multimeter.
Secure all loose wires or previously secured wires with zip ties.
Double check the wire loop labels against the table and most recent electrical diagram.
Remove all wire labels.
Complete a final circuit check if possible with a voltmeter.
Stage 3: Attach High Pressure Loop (Block 3: ES03)
Reference the electrical loop labelling table and labelling diagram.
First, attach wires to sensors using the following process:
a. Collect the two wires which connect to the sensor (refer to thermal loop table document).
b. Attach one of the wires. Tick off wire on table.
c. Attach the other wire. Tick off wire on table.
d. Using a multimeter, check the circuit:
i. Check the current flow through the wires and sensor.
ii. If short-circuiting, remove wires. Test functionality of both wires, and the sensor.
iii. Replace faulty wire or replace sensor.
e. Repeat steps a to d for all sensors in the loop.
Referencing the wire order in the loop labelling table, connect all the wires in series.
a. During this process iteratively check the circuit using a multimeter.
Secure all loose wires or previously secured wires with zip ties.
Double check the wire loop labels against the table and most recent electrical diagram.
Remove all wire labels.
Complete a final circuit check if possible with a voltmeter.
Stage 4: Reconnect Ignition Controllers (Block 4: ES04)
Collect the 'flame supervision unit and handset' box.
Unwind and reconnect the handset cables. Place hands out and desired location.
Reconnect all cables running to and from the flame supervision unit. Place the unit in the desired location.
Remove the storage box.
Stage 5: Connect Main electrical board (Block 5: ES05)
Wheel the main electrical board to the desired location by the reassembled burner.
Unpack the 'board to burner' box. Reconnect the cables from the board to the burner. These connections have unique plug and socket connectors to avoid any cross-connection.
Unpack the 'mains to board' box. Reconnect the cables from the board to the mains, whilst the mains power switch is off. Do not turn on the power until commencing final system checks.
Remove the boxes from the setup.
Stage 6: Reconnect CCTV system (Block 6: ES06)
Retrieve CCTV camera and equipment box, and any extra containers or equipment.
Remove all cameras and equipment from the box.
Perform a trial run of camera communication with the CCTV system. This is here to make sure that each camera can work with the CCTV system in the new laboratory space and is functional.
a. Complete any documentation forms relevant if a CCTV camera is non-operational.
After the trial run, place any equipment where desired. This assumes that the cameras and equipment are stored between sessions of the burner experiments. Do not place any equipment or cameras around the burner until completion of all stages of reassembly.
The cameras, equipment and CCTV system will be set up and used during the validation session.
Stage 7: Validation of Electrical System
Ensure all blocks are connected to the electrical system.
Using the CCTV computer system go through and test cameras for:
Connection to system
Image quality
Light sensitivity
To test the rest of the system, going to need to iteratively go through the burner pre-checks and perform a small trial start. This can largely be controlled and monitored by MATLAB. Using the computer systems go through and test the following:
Main electrical board (ensure it connects all components and turns on burner systems).
MATLAB system (required to sense and monitor sensors).
Handset controls (circuits for ignition, and links to low pressure loop).
Flame Supervision Unit (connection to controls flame supervision and safety features function, interacts with handset and thermal loop)
Electrical loops: Low pressure loop, High pressure loop , Thermal loop
(Need to check each sensor is functionable and monitorable).