ariel hp booster user manual

Pipeline & Specialty Services

Ariel HP Booster User Manual 21

st May 2009

Compiled by : D.Wood Reviewed by: A. Denham Approved by: P.Kirby

Ariel HP Booster 4-Stage, High Pressure, Zone II, JGA-4 Unit

User Manual

Disclaimer: Although all technical content has been subject to a review and sign off process Oilennium accepts no responsibility for the content of this Manual or for the consequences of any actions taken on the basis of the information provided.

Ariel HP Booster

Ariel HP Booster User Manual 21st May 2009

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This manual has been extracted from the online training Manual shown below.

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Contents Introduction .................................................................................................................... 7

1. Safety ......................................................................................................................................... 8 1.1. Noise ...................................................................................................................................... 8 1.2. Pressure Relief Valves ........................................................................................................... 8 1.3. Oily Water Drain ..................................................................................................................... 8 1.4. Rotating Machinery ................................................................................................................ 9 1.5. Scrubber Drain ....................................................................................................................... 9 1.6. Hot Surfaces .......................................................................................................................... 9 1.7. High Pressure ...................................................................................................................... 10

2. Understanding the Booster Layout ....................................................................................... 11 2.1. Inlet ...................................................................................................................................... 11 2.2. Scrubber Drain Valve ........................................................................................................... 12 2.3. Stage 1 Scrubber Pot ........................................................................................................... 12 2.4. Stage 1 Cylinder .................................................................................................................. 12 2.5. Stage 1 PRV ........................................................................................................................ 12 2.6. Stage 1 Aftercooler .............................................................................................................. 12 2.7. Stage 2 Scrubber Pot ........................................................................................................... 12 2.8. Stage 2 Cylinder .................................................................................................................. 13 2.9. Stage 2 PRV ........................................................................................................................ 13 2.10. Stage 2 Aftercooler ......................................................................................................... 13 2.11. Stage 3 Cylinder .............................................................................................................. 13 2.12. Stage 3 PRV ................................................................................................................... 13 2.13. Stage 3 Aftercooler ......................................................................................................... 13 2.14. Stage 4 Cylinder .............................................................................................................. 13 2.15. Stage 4 PRV ................................................................................................................... 13 2.16. Stage 4 Aftercooler ......................................................................................................... 13 2.17. Vent to Atmosphere ........................................................................................................ 13 2.18. Discharge Outlet ............................................................................................................. 14

3. Control Panel Layout .............................................................................................................. 15 3.1. Inlet Suction Pressure Gauge .............................................................................................. 16 3.2. Stage 1 Discharge Pressure ................................................................................................ 16 3.3. Stage 2 Discharge Pressure ................................................................................................ 17 3.4. Stage 3 Discharge Pressure ................................................................................................ 17 3.5. Discharge Pressure Gauge .................................................................................................. 17 3.6. Ariel AMOT Indicators .......................................................................................................... 18 3.7. Exhaust Gas Temperature ................................................................................................... 18 3.8. Engine RPM Display ............................................................................................................ 18 3.9. Engine Oil Pressure ............................................................................................................. 19 3.10. Engine Water Temperature ............................................................................................. 19 3.11. Engine AMOT Indicators ................................................................................................. 19 3.12. Emergency Stop Button .................................................................................................. 20 3.13. Commissioning Valve ...................................................................................................... 20 3.14. Engine Start Button ......................................................................................................... 20 3.15. Engine Stop Button ......................................................................................................... 21

4. Engine Speed & Fan Controls ............................................................................................... 22 4.1. Engine Speed Control (Throttle) .......................................................................................... 22 4.2. Aftercooler Fan Control ........................................................................................................ 22

5. Understanding the AMOT Functions .................................................................................... 23 5.1. Air Supply............................................................................................................................. 23 5.2. Control Air Loop ................................................................................................................... 24 5.3. Calibration ............................................................................................................................ 24 5.4. Pressure Sensors ................................................................................................................ 24 5.5. Vibration Sensors ................................................................................................................. 25 5.6. Temperature Probes ............................................................................................................ 25 5.7. Engine Over Speed .............................................................................................................. 25 5.8. Air Intake Damper ................................................................................................................ 26 5.9. Engine Fuel Rack ................................................................................................................. 26 5.10. Ariel Lubricating Oil ......................................................................................................... 26

6. Rigging Up............................................................................................................................... 27 6.1. Additional Rig-Up Equipment ............................................................................................... 27 6.2. Positioning the Unit .............................................................................................................. 27

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6.3. Engine Air Start Connection ................................................................................................. 28 6.4. Fuel Line Connection ........................................................................................................... 28 6.5. Ariel Suction Inlet ................................................................................................................. 28 6.6. Booster Discharge Outlet ..................................................................................................... 29 6.7. Ground Out to Earth ............................................................................................................. 29

7. Pre-Start Checks ..................................................................................................................... 30 7.1. Ariel Cylinder Drain Tank ..................................................................................................... 30 7.2. Engine Oil ............................................................................................................................ 30 7.3. Engine Cooling Water .......................................................................................................... 30 7.4. Hydraulic Oil Level ............................................................................................................... 31 7.5. Ariel Lubricating Oil Level .................................................................................................... 31 7.6. Aftercooler Fan Header Tank Level ..................................................................................... 31 7.7. Air Start Supply .................................................................................................................... 32 7.8. Fuel Supply .......................................................................................................................... 32 7.9. Air Filter Indicators ............................................................................................................... 33 7.10. 24-Volt ESD System ....................................................................................................... 33

8. Starting the Unit ...................................................................................................................... 34 8.1. Air Supply............................................................................................................................. 34 8.2. Control Panel Commissioning Valve .................................................................................... 34 8.3. Ariel Oil Lubricating Commissioning Valve........................................................................... 35 8.4. Engine Throttle Control ........................................................................................................ 35 8.5. Aftercooler Fan Control ........................................................................................................ 35 8.6. Engine Stop Button .............................................................................................................. 36 8.7. Fuel Supply .......................................................................................................................... 36 8.8. Fuel Priming ......................................................................................................................... 36 8.9. Inlet Valve ............................................................................................................................ 37 8.10. Discharge Valve .............................................................................................................. 37 8.11. Emergency Stop Button .................................................................................................. 37 8.12. Ariel Hand Prime Oil Pump ............................................................................................. 38 8.13. Starting the Engine .......................................................................................................... 38

9. Unit Running Checks ............................................................................................................. 39 9.1. Inlet Pressure ....................................................................................................................... 39 9.2. Monitoring Unit Outputs ....................................................................................................... 39 9.3. Scrubber Pot Drains ............................................................................................................. 39 9.4. Ariel Lubricating Oil Catch Tank Drain ................................................................................. 40 9.5. Air Filter Indicators ............................................................................................................... 40 9.6. Check for Leaks ................................................................................................................... 40 9.7. Pipework and Hoses ............................................................................................................ 41

10. Stopping the Unit .................................................................................................................... 42 10.1. Venting or By-passing ..................................................................................................... 42 10.2. Reduce the Engine Speed .............................................................................................. 42 10.3. Activate the Stop Button .................................................................................................. 42 10.4. Draining the Scrubber Pots ............................................................................................. 43 10.5. Aftercooler Fan ................................................................................................................ 43 10.6. Draining the Ariel Lubricating Oil Tank ............................................................................ 43 10.7. Isolate the Unit ................................................................................................................ 44

11. Engine Maintenance ............................................................................................................... 45 11.1. Engine Oil Filter ............................................................................................................... 45 11.2. Adding Engine Oil ........................................................................................................... 46 11.3. Engine Air Filter ............................................................................................................... 46 11.4. Engine Primary Fuel Filter ............................................................................................... 47 11.5. Engine Secondary Fuel Filters ........................................................................................ 47 11.6. Engine Water Conditioner Filter ...................................................................................... 48 11.7. Coolant Additive .............................................................................................................. 48 11.8. Run Up Checks ............................................................................................................... 48 11.9. Housekeeping ................................................................................................................. 49

12. Ariel Maintenance ................................................................................................................... 50 12.1. Ariel Lubrication Pump .................................................................................................... 50 12.2. Lubrication Oil Filter ........................................................................................................ 50 12.3. Ariel Air Filter ................................................................................................................... 51 12.4. Hydraulic Aftercooler Oil.................................................................................................. 51 12.5. Cylinder Lubricating Catch Tank ..................................................................................... 52

13. Troubleshooting ..................................................................................................................... 53 13.1. Listening for Leaks .......................................................................................................... 53 13.2. Looking for Leaks ............................................................................................................ 54

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13.3. No Air to the Control Panel .............................................................................................. 54 13.4. Engine Turns Over but will not Start ................................................................................ 55 13.5. Starter Engages but Engine will not Turn Over ............................................................... 55 13.6. Unit Shuts Down after Start Up ....................................................................................... 56 13.7. High Operating Temperature ........................................................................................... 56

Notes .................................................................................................................................................. 57

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THINK!

Working with unfamiliar equipment can lead to uninformed injuries.

The use of this equipment is subject to certain hazards, which cannot be

protected against by mechanical means or product design.

If there is something in this course you do not understand, ask your

supervisor, or learning department, to explain it to you.

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Introduction

This training Manual will cover the Zone ll Ariel JGA-4, 4-stage, High Pressure

Discharge Booster.

Specifically unit B5653LP which produces 1000scfm (28m³/min) flow@3100psi

(213bar) maximum discharge.

However you should always take the time to study the particular unit that you

are operating as you may find that there are some subtle changes from

machine to machine.

The aim of this Manual is to show you how to set up, run and operate the unit

safely.

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1. Safety

1.1. Noise

When the unit is running there will be high noise levels from both the Ariel

compressor and the engine unit, so ear protection must be worn at all times.

Remember that there may be other units running in close proximity to you

and just a short period of exposure to high noise levels can damage your

hearing.

1.2. Pressure Relief Valves

Each stage of the compressor

discharge pipe work has a Pressure

Relief Valve (PRV) fitted,

pre-set to the Maximum Allowable

Working Pressure (MAWP) for

that particular stage.

They are designed to discharge

any excessive pressure to

protect the operator, the

equipment and the client

process system.

They are all piped into a 1" (25mm) common line which vents to

atmosphere above the aftercooler assembly. Although these should not

vent under normal operation be aware of their location and the possibility

of a sudden release of air.

1.3. Oily Water Drain

During the compression process the

cylinders of the Ariel are lubricated

with oil to prevent seizure, this

creates an oily waste fluid.

This oily waste is collected in a

receiving tank in the center of the

unit and requires periodical draining

via the drain hose, pictured right.

All oily fluids or waste oil must be

disposed of using the correct waste

management procedures and QHSSE

guidelines.

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1.4. Rotating Machinery

The unit is fitted with two rotating

fans, one at either end of the unit.

One for the engine radiator and one

for the air end aftercoolers.

Remember that:

All guards should be in place

before operating the unit.

Any missing or damaged

guards should be reported to the

supervisor or the safety department

as soon as possible.

The unit should not be operated if any of the guards are damaged or

missing.

1.5. Scrubber Drain

During the compression of the air an oily fluid will

also be produced from each of the scrubber pots,

located on the top of each of Stage 1 and Stage 2

cylinders only.

Each of these will require periodical draining (approx

every 2hrs) when the unit is running, via the drain line

on the bottom of each vessel.

The fluids must be disposed of using the correct

Weatherford and client QHSSE waste management

procedures.

1.6. Hot Surfaces

There will be many hot and exposed

surfaces on the unit, such as the

exhaust bellows in the image on the

left. Not all of these surfaces may be

clearly marked due to their location

or physical size and may not have

guards fitted.

Therefore care should be taken

when carrying out any checks or

routine maintenance and always try

to plan maintenance when the unit

has been shut down and allowed to cool off.

Note: always wear full PPE and keep exposed areas of the body to a

minimum.

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1.7. High Pressure

The booster unit has many areas of

pressurized pipe work and vessels,

every effort should be made to keep

clear of these as much as possible

when operating the unit.

Always depressurize the system

before attempting any repairs no

matter how small or quick the repair

might seem.

NEVER WORK ON PRESSURIZED VESSELS OR LINES!

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2. Understanding the Booster Layout

Understanding the Booster layout helps when operating and troubleshooting

the unit.

The booster takes in low pressure air, knocks out the moisture using the

scrubber pots on cylinders 1 and 2 and compresses the air before delivery to

the next stage of compression.

This is repeated until the 4th stage reaches the final discharge pressure.

2.1. Inlet

Low pressure, 3" inlet connection.

Pressure range from 10psig to

160psig (0.6 bar to 10 bar).

1

3

2

4 5

6

7

8 9

10

11

13

15 14

16

17

12

18

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2.2. Scrubber Drain Valve

Each Scrubber Pot, on Stages 1 and 2, is fitted with a manually operated valve

for draining off waste oily fluids created when the air cools down.

Drain off into a secure container and dispose of using the correct

Weatherford and client environmental procedures.

2.3. Stage 1 Scrubber Pot

This vessel is used to remove the

airborne moisture from the supply

air and is fitted with internal baffle

plates which helps to collect the

moisture.

2.4. Stage 1 Cylinder

Ariel compressor, 1st Stage of compression, 363psig (43.7bar) Maximum

Allowable Working Pressure (MAWP).

2.5. Stage 1 PRV

Stage 1 preset 1" (25mm) PRV vented to Atmosphere.

Each stage has a PRV (Pressure Relief Valve) fitted to the discharge side of the

cylinder.

Each PRV is calibrated on a regular basis, usually a period of 6 months, a

maximum being a 12 month period.

2.6. Stage 1 Aftercooler

After each compression process the air is passed through an aftercooler

before compression by the next stage.

This is repeated on all four stages of compression.

2.7. Stage 2 Scrubber Pot

Stage 2 Scrubber Pot.

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Second Stage of compression, 843psig (58bar) Maximum Allowable Working

Pressure (MAWP).

2.9. Stage 2 PRV

Stage 2 compression 1" (25mm) PRV.


Second Stage compression aftercooler.


Third Stage Compression, 2010psig (138bar) Maximum Allowable Working

Pressure (MAWP).

2.12. Stage 3 PRV



Stage 3 aftercooler.


Fourth Stage Compression, 3100psig (213bar) Maximum Allowable Working

Pressure (MAWP).

2.15. Stage 4 PRV



Stage 4 compression aftercooler.

2.17. Vent to Atmosphere

1" (25mm) common vent line piped to discharge above the aftercooler

assembly.

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2.18. Discharge Outlet

2" (50mm), 3100psig (213bar) Maximum Allowable Working Pressure

(MAWP), final discharge outlet.

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3. Control Panel Layout

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To remove the control panel

protection bars, remove the

lock pins at either end of the

bars before lifting them out of

the retaining pockets. Turn the

cabinet door latches clockwise

to gain access to the controls;

the door can be lifted off its

hinges for better access if

required.

Store the crash bars in a safe

location as they must be re-fitted before transportation or shipping back to

the Weatherford location.

3.1. Inlet Suction Pressure Gauge

The Inlet Suction gauge has a range of 0-300psi (0-20

bar) and displays the inlet pressure being supplied to

the Booster unit.

3.2. Stage 1 Discharge Pressure

This gauge displays the maximum pressure, in psi

(pounds per square inch), discharged from the Stage 1

cylinder which is then delivered to the second stage

for further compression with a gauge range of 0-

600psi (0-41bar).

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This gauge displays the Stage 2 maximum discharge

pressure being delivered to Stage 3, also displayed in

psi, with a gauge range of 0-1000psi (0-69bar).


This is a 0 to 3000psi (0-206bar) gauge and once again it

displays the maximum discharge pressure from the 3rd

stage.

3.5. Discharge Pressure Gauge

The Discharge Pressure gauge displays the final 4th Stage

maximum discharge pressure, exiting the 2" (50mm)

discharge outlet of the unit.

It is located at the top right hand side of the panel face

and is a dual scale gauge reading a maximum of 6000psi

(400bar).

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3.6. Ariel AMOT Indicators

All the Ariel

compressor AMOT

indicators are in

two banks, situated

across the middle

of the control

panel face.

The display will

highlight any errors

with a Red chevron; and as shown in this picture they will turn to Green if

the system is error free.

Take some time to study these and locate the relevant probe on the unit.

3.7. Exhaust Gas Temperature

The Exhaust Gas Temperature gauge is located to the

left of the engine rev counter.

The reading is displayed in both Fahrenheit and Celsius.

3.8. Engine RPM Display

This gauge has a digital read out but an analogue

display rev counter can be found mounted directly

under the control panel unit. The engine speed is

displayed in RPM, Revolutions per Minute.

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3.9. Engine Oil Pressure

This gauge displays the engine oil pressure in both psi

and KPa (Kilopascal).

The gauge allows a visual reading to be taken and the

pressure monitored when the unit is operational.

3.10. Engine Water Temperature

The Water Temperature gauge is displayed in

Fahrenheit and is located on the control panel face,

alongside the oil pressure gauge.

3.11. Engine AMOT Indicators

The Engine AMOT indicators can be found at the bottom of the control panel

face.

These are shutdown indicators for the following alarms;

Low Engine oil pressure.

High Engine water temperature.

High Engine exhaust temperature.

Engine over-speed.

Yellow alert.

The yellow alert indicates a failure or loss of air on the AMOT system.

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3.12. Emergency Stop Button

The large Red emergency stop button

should only be used for emergency stopping

of the unit.

Using this stop button other than in an

emergency can cause damage to the engine

unit.

3.13. Commissioning Valve

Before the unit can be started the

commissioning valve has to be placed

into the set position.

This is the toggle like switch located

in-between the emergency stop and

the general engine stop button.

3.14. Engine Start Button

The White, Engine Start button, is

on the right hand side of the control

panel.

When starting the unit push the

button firmly, releasing it when the

unit fires up and runs.

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3.15. Engine Stop Button

The Black Engine Stop button must

be pushed and held down to

complete the unit shutdown

sequence.

This button must be used for all

general shutdowns of the unit.

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4. Engine Speed & Fan Controls

There are two controls that are not

included on the control panel, the

engine throttle and the aftercooler

fan speed control.

Both these controls are mounted

separately, directly underneath the

control panel.

4.1. Engine Speed Control (Throttle)

The large black knurled Engine

Throttle control requires turning in

a clockwise direction to increase the

engine revs and anti clockwise to

decrease the engine revs.

Note: as this control is a

pneumatically controlled unit there is

a slight delay in response time.

Therefore be patient when adjusting

the revs and give the engine time to

respond.

4.2. Aftercooler Fan Control

To control the air discharge

temperature a hydraulically driven

fan is mounted directly in line with

the Aftercoolers.

The variable speed fan is throttled

and speed adjusted by using the Fan

Throttle control lever mounted

directly underneath the control

panel.

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5. Understanding the AMOT Functions

Throughout this training Manual you will read reference to the AMOT control

system. It comprises of pre-set sensors which limit over-pressure, controls

vibration levels, and temperature control.

Although it is not necessary to have detailed knowledge of the system, it is

advisable to have a basic understanding of how the system controls the

operation of the unit.

5.1. Air Supply

A low pressure air signal, taken from

the air start supply is looped via

colored coded nylon tubing to the

AMOT pressure, temperature and

vibration switches.

If any of the AMOT sensors trip they

will exhaust the air, break the looped

system causing the unit to shutdown

or prevent the start up process.

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5.2. Control Air Loop

The control air is linked from the

AMOT sensor to the status

indicators on the control panel.

Should one indicator on the control

panel change to Red the

commissioning sequence will be

halted until it is reset or the error

has been corrected.

Reset the commissioning valve to

complete a full commissioning check and return the indicators to Green.

During this process a small amount of air will exhaust each time this is

functioned, but don't worry this is quite normal.

5.3. Calibration

All the AMOT probes and sensors

require periodical calibration to be

able to control and protect the unit

safely.

This is usually completed on a 6

month cycle, 12 months being the

maximum period between re-

calibration.

Each AMOT unit will have a unique

calibration plate detailing the sensor

number and the calibration date.

5.4. Pressure Sensors

There are five pressure sensors

positioned on the Ariel Compressor.

They are:

Hi Discharge Pressure Stage

1, Stage 2, Stage 3 and Stage 4

Low Inlet Suction Pressure.

Each sensor has an instrument air

feed via a flexible nylon pipe, this

loops the signal to the indicator on

the control panel, which then sends the signal to the next sensor.

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5.5. Vibration Sensors

There are two vibration sensors on the Ariel unit:

One on the Ariel compressor block

One on the Aftercooler fan.

Any excessive vibration will send the unit into shutdown and must be rectified

before start up can be achieved. Each sensor has an indicator on the control

panel, Green for pass, Red for fail.

5.6. Temperature Probes

All four Ariel cylinders have a

high temperature probe as does

the Ariel lubricating oil.

These are all looped into the

same instrument air supply and

will fail to initiate the next stage

of the commissioning process if

the Red fail mode is displayed

on the control panel.

5.7. Engine Over Speed

The engine over speed is also linked into the same

AMOT air system via the over speed control unit,

located centrally on the top of the engine.

Should the engine speed (RPM) go above the designed

limits the air signal will be exhausted and the unit will

shut down.

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5.8. Air Intake Damper

The engine air intake is fitted with a

damper system, which when

activated by the emergency stop will

close and places the engine into

shutdown.

This is a function controlled by the

AMOT system and until reset the

unit can not be commissioned.

5.9. Engine Fuel Rack

As part of the general shutdown

function, the fuel rack is also

controlled by an air operated piston,

activated by the black stop button on

the control panel.

Again this must be in the set position

before the commissioning sequence

can be completed to allow the start

up of the unit.

5.10. Ariel Lubricating Oil

The Ariel low lubricating oil pressure

sensor is situated on the top of the

lubricating oil reservoir tank, located

at the end of the Ariel main frame.

The Ariel also has protection from:

Loss of lubricating oil pressure

High lubricating oil temperature

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6. Rigging Up

Before rigging up confirm that:

All certification is valid and in date

All the equipment and hand tools needed to complete the rig up are on

site

All pipe work and connections are compatible with the unit connections

The layout of the equipment is correct

The equipment has arrived undamaged and fit for purpose

The client is familiar with the equipment and the rig up requirements.

6.1. Additional Rig-Up Equipment

Due to the size and construction of the Booster Unit there are a few ancillary

items that have to be transported separately. It is important to locate these

items during the early stages of the rig up process:

Check that the exhaust rain covers have been removed

Check the inlet and discharge crossovers are on site and are of the correct

specification

Locate and inspect the air start PRV assembly

Make sure that all crossover assembly bolts and gaskets have been

dispatched.

Should any of these items be missing it will not be possible to run the unit, so

make sure any missing items are reported immediately.

6.2. Positioning the Unit

When positioning the unit a few basic checks should be applied.

Check the site for a solid level surface. You may need wooden leveling

blocks

Allow enough access to the Unit for daily operational maintenance

Check for possible over head obstructions

Check exhaust routes; make sure there is a clear free flow away from the

work area and combustible materials

Check that the site is capable of withstanding the weight of the unit,

spreader beams may be required.

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6.3. Engine Air Start Connection

The 2" (50mm) Fig 200 hammer

union air start inlet connection can

be located low level on the opposite

side to the control panel, towards

the radiator end of the base frame.

Install the 2" air start line making

sure to include the Pressure

Regulating Valve, PRV, pre-set to

120psi (8bar) max, this prevents

damage to the air start motor.

The starting air also supplies the

AMOT Shutdown Control System with a positive pressure and is essential to

the start up of the unit.

6.4. Fuel Line Connection

The Booster unit does not have a

fuel tank storage facility but has two

quick connect snap-tite connections

for fuel supply and return.

The upper male fitting is the

fuel supply line.

The lower female fitting is the

fuel return line.

The fittings are arranged in this way to help reduce the chance of incorrect

connection.

The unit can be supplied from a pumped or gravity feed system, although if a

pumped fuel system is to be used it must not exceed 40psi (3bar).

6.5. Ariel Suction Inlet

Located on the same side of the unit as the

control panel the Suction Inlet has a

crossover and can be either of the following

two connections.

A 3" (76mm) raised face bolted flange

connection.

or

A 3"(76mm) fig 200 Hammer Union.

Again, always use whip check safety lines on all hose connections.

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6.6. Booster Discharge Outlet

The Discharge Outlet from the

booster is a removable crossover

which is bolted to the 2" (50mm)

2500lb RTJ (Ring Type Joint) outlet

flange found at low level, on the

aftercooler end of the unit, make

sure that all bolts are installed prior

to testing or running of the unit.

The crossover has to be removed

for shipping and transportation as it

protrudes past the boundary of the

protection frame and would be damaged if left in position.

6.7. Ground Out to Earth

The Booster unit should be

grounded to earth, using the earthing

points around the unit skid frame.

Alternatively a clamp system can be

used but a clean bare metal surface is

required to make a good contact.

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7. Pre-Start Checks

Checking all lubricating and cooling fluid levels on the Booster is essential.

Failing to check any of the levels as instructed in this next section could have

very serious consequences on the successful operation of the unit.

7.1. Ariel Cylinder Drain Tank

Make sure that the Ariel cylinder

drain tank valve is closed and placed

in the storage location.

7.2. Engine Oil

The engine oil dip stick on the

Caterpillar 3412DITA can be found

on the same side of the unit as the

Control/Start Panel.

Remove the dip stick and check that

oil level is between the upper and

lower marks.

Use a clean dry cloth to wipe the dip

stick before replacing it firmly back

into its holder, top up the level as

necessary making sure not to mix

grades of oil. This can be done via the fill point located on top of the engine.

7.3. Engine Cooling Water

The cooling fluid level sight glass can

be located on the very top right hand

corner of the radiator above the

control panel.

Ensure that the unit is not hot as this

will have an effect on the cooling

fluid level which should read halfway

across the sight glass face.

Note: the cooling system is a

pressurized system and should

therefore never be opened until the

unit has cooled down.

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7.4. Hydraulic Oil Level

The hydraulic oil storage tank is located

on the opposite side of the unit to that

of the Control Panel.

The hydraulic fluid is used to supply the

hydraulic motor which drives the

variable speed aftercooler fan.

The oil level should be kept between the

upper Black marker and the lower Red

marker on the sight glass.

7.5. Ariel Lubricating Oil Level

The level of the oil should be kept

two thirds of the way up the sight

glass and should only be topped up

when the unit is shutdown.

Use a good grade of diesel engine oil,

usually a 15/40w and more often the

same grade and type used on the

Caterpillar engine unit.

Note: it is good practice to never

mix different grades or types of oil,

so check before filling.

7.6. Aftercooler Fan Header Tank Level

Once then purge cycle is complete

on the Zone ll panel, power will be

sent to the main distribution panel.

Select the correct fan speed Hertz,

turn the "OFF/ON" switch to the

ON position and press the white

POWER ON button.

Now turn the Air Cooler fan on

using the green twist switch.

Note it is important at this stage to

check for phase reversal and the correct rotation of the Air Cooler fan.

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7.7. Air Start Supply

The engine air start supply serves

two purposes, in that it supplies

enough air to start the unit and also

supplies air to the AMOT Shutdown

Control Panel System.

A total loss of air supply or

insufficient supply will not allow the

unit to start.

Check that the hose connections are

fitted correctly and that the safety

whip check lines are fitted during

assembly.

Make sure that the hose is certified to the correct working pressure and is in

good condition. The unit will require 900scfm@125psi (25m³/min@8bar) air

supply to allow the unit to start.

7.8. Fuel Supply

Be sure to:

Check that the fuel lines are

secure and the flow and return lines

are fitted to the correct

connections on the unit

Follow the lines to place all

valves in the correct position

Visually check that the lines

are free from damage or kinks

Check for crushed or trapped

lines which will prevent flow

Have catch trays and spill kits where required and check that all

connections are leak free.

Remember any fuel spills must be reported and cleaned up using the correct

environmental and QHSSE procedures.

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7.9. Air Filter Indicators

Check the filter status indicator and reset using the yellow reset button on

the top of the indicator.

If the indicator doesn't reset then

further investigation is required. The

unit may require an air filter change

before proceeding. How to do this

will be covered in the maintenance

section of this training manual.

7.10. 24-Volt ESD System

The ESD (Emergency Shut Down)

Solenoid is located just below the

Control Panel, the 24volt solenoid is

looped into the air supply feeding the

Booster AMOT Control System,

which then receives a 24volt signal

from the site or installation ESD

system.

If the 24volt signal is lost the air will

be vented and the unit will

shutdown.

If this application is not required on site it can be by-passed by looping out the

air supply. This action will not change the effectiveness of the Booster unit's

integral protection system in any way.

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8. Starting the Unit

Before attempting to start the unit, walk the perimeter of the unit making

sure that there have been no changes to the rig up that may have an impact

on the safe operation of the unit.

Make sure that all walkways and access areas are clear of obstructions.

8.1. Air Supply

Make sure that the air supply hose is

connected and all valves are in the

open position.

Visually inspect that all connections

have safety whip checks fitted and

that the hose is not trapped or

crushed.

8.2. Control Panel Commissioning Valve

The toggle type commissioning

switch must be placed in the up

position, which overrides the AMOT

system until the engine oil has

reached operating pressure.

Once the unit has successfully

reached normal running conditions

the toggle will drop and be reliant

solely on the engine integral oil

pressure.

Should the oil pressure fail when the unit is running the unit will shut down.

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8.3. Ariel Oil Lubricating Commissioning Valve

The Ariel compressor has the same type of commissioning toggle switch that

must be placed in the set position prior to starting. Lift the toggle in an

upwards motion until it locks in position.

This will stay in the commission position until the unit lubricating oil pressure

has risen sufficiently.

Failure to set this switch will not allow the AMOT safety shutdown system to

complete the system checks and will lock out the start up process.

The commissioning switch is located on the same side as the air start inlet to

the rear of the unit and at the base of the Aftercooler assembly.

8.4. Engine Throttle Control

Check that the throttle control has

been backed off in an anticlockwise

direction until no resistance is felt.

This will prevent the unit being

started with excessive revs placed on

the engine.

Once started the engine it will have

an idle speed of approximately 900

to 1000rpm.

8.5. Aftercooler Fan Control

Set the Aftercooler fan control lever

to the 5 o'clock position.

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8.6. Engine Stop Button

The engine stop button must be set in

the run position by pulling it out lightly

until a positive pressure is felt.

Do not exert too much force when

resetting as this may damage the control

button.

8.7. Fuel Supply

Follow the fuel lines and double

check that they are connected

correctly, have no kinks or damage

and have all the necessary valves

open to supply and return fuel.

The engine fuel system will always

draw more fuel than needed, so it is

very important to make sure that the

return line is installed correctly.

8.8. Fuel Priming

It may be necessary to prime the fuel system the

first time that the unit is started. To do this make

sure that the fuel lines are connected and that

the supply and return line valves are open. Turn

the black plunger located on top of the

secondary fuel filter housing in a clockwise

direction to extract the plunger.

Pump the plunger until a firm resistance is felt,

this may take several pumps, be patient.

Return the plunger back in the locked position by

pushing in firmly and turning in an anticlockwise

direction.

This operation may need to be repeated until all

air is removed from the system.

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8.9. Inlet Valve

Visually check that all the

compressor inlet feed valves are

open to the booster, making sure

that all connections are secure and

have suitable whip checks fitted.

Check that there are no sharp turns

or kinks in the lines and no potential

for crushing or restriction of flow.

8.10. Discharge Valve

Check the status of all the valves on

the discharge pipe work and that the

unit is lined up correctly for the job

process.

8.11. Emergency Stop Button

Pull the emergency stop button to

make sure that it is set in the run

position.

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8.12. Ariel Hand Prime Oil Pump

Just before starting the unit, the Ariel

compressor lubricating system will

require priming. This simply means

that the oil needs circulating by

means of the hand pump until

pressure is seen on the filter housing

gauges.

This prevents the unit bearings and

crank shaft from being started in a

run dry condition and causing

excessive wear or even seizure.

The hand pump is located on the end of the compressor housing on the

control panel side of the unit. No more than a few strokes of the hand pump

should be required until pressure build up can be seen on the filter gauges.

8.13. Starting the Engine

Placing the palm of the hand on the

start button, push it in sharply until

the engine unit fires and the RPM

gauge is showing clear indication of

engine revs.

Do not hold the starter button for

long periods as this could cause

damage to the starter motor.

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9. Unit Running Checks

There are several periodical checks required during the operation of the unit.

Failing to complete the checks can result in an unplanned shutdown of the unit

or even worse, equipment failure.

9.1. Inlet Pressure

Monitor the inlet pressure, should

this fall below 10psi (0.68bar) or rise

above 160psi (11bar) the unit will

shutdown.

During some operations it may be

necessary to install an adjustable

PCV (Pressure Control Valve) on the

booster inlet which will require

periodical adjustments. Make any

adjustments in small increments and

allow the system time to stabilize.

9.2. Monitoring Unit Outputs

Before placing the unit into full load operation,

allow the unit to warm up for approximately 30

minutes to reach its operating temperature.

Under normal conditions the water temperature

for the booster will be between 170-180°

Fahrenheit (76-82° Celsius) but this will vary with

the ambient temperature of the location.

It is good practice to take note of the unit's normal

operating temperatures and pressures as this may

help diagnose any issues at a later stage.

9.3. Scrubber Pot Drains

It is important that the scrubber pots are drained at

least once every two hours, although this can be done

as frequently as deemed necessary.

Failing to drain the scrubbers can result in oily fluid

carry over to the compressor cylinder which could

result in cylinder valve failure.

Note: It may be necessary to drain the scrubbers

more frequently if the operation of the unit is of a high

demand. Always follow the site and company QHSSE

environmental policies on contaminated waste fluids

disposal.

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9.4. Ariel Lubricating Oil Catch Tank Drain

Each compressor cylinder is

lubricated during running operations

and therefore creates excess waste

oil that is drained into the catch

tank.

The catch tank will require draining a

minimum of every six hours and this

can be done via the hose and valve

assembly, located at the end of the

unit on the control panel side.

9.5. Air Filter Indicators

During operation visually check the

filter status indicators, especially if

you are on an exposed dusty or

sandy location.

Should there be a need to change

out the filter the unit will have to be

shutdown and taken off line. This

may have an impact on the project

operation and will require some

notice and planning, to avoid down

time on the job.

9.6. Check for Leaks

Take the time to "walk" the unit,

checking the perimeter of the unit

making sure that there are no fluid

or air leaks.

Visually check that the engine unit

cooling pipes and hoses are leak free.

Look for any colored fluids, such as

coolant, usually blue in color,

hydraulic oil, usually red in color and

diesel fuel which can be either a clear

or red fluid.

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9.7. Pipework and Hoses

Visually check all pipe work and

hoses ensuring that they are secure,

free from crushing and clear of all

walkways.

Make sure that all safety whip checks

and hose restraints are in place.

When the unit is running there may

be some level of vibration, make

sure that all pipe work and hoses are

supported or braced to help reduce

this as much as possible.

Excessive vibration can cause metal fatigue and eventually failure.

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10. Stopping the Unit

Visually check all pipe work and hoses ensuring that

they are secure, free from crushing and clear of all

walkways.

Make sure that all safety whip checks and hose

restraints are in place.

When the unit is running there may be some level of

vibration, make sure that all pipe work and hoses are

supported or braced to help reduce this as much as

possible.

Excessive vibration can cause metal fatigue and

eventually failure.

10.1. Venting or By-passing

If the process system has been fitted with a re-circulation or by-pass vent

system, this must be placed in the correct status before stopping the unit.

10.2. Reduce the Engine Speed

Use the engine speed throttle

control and slowly turn in an

anticlockwise direction, to lower the

engine speed.

Allow the unit to come off load and

idle for approximately 30 minutes.

10.3. Activate the Stop Button

Stop the unit by pushing and holding

down the Black engine stop button

until the engine has come to a

controlled stop.

Note: Make sure to stop the unit

with the Black stop button and not

the Red emergency stop button for

this operation.

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10.4. Draining the Scrubber Pots

Drain the scrubber pots and dispose

of the fluids following the correct

environmental QHSSE procedures.

Remember to drain the Scrubber

Pots on all four stages of the unit.

10.5. Aftercooler Fan

Turn the Aftercooler fan control

lever to the central, off position.

10.6. Draining the Ariel Lubricating Oil Tank

Drain the Ariel lubricating catch

tank, containing and disposing of the

fluids using the correct QHSSE

procedures.

This tank is not a pressurized system,

so it may take some time to drain

down.

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10.7. Isolate the Unit

Finally once the unit has stopped, isolate the:

Inlet valve

Discharge valve

Air start supply valves

All fuel supply and return line valves

If the unit is to stand idle for a long period, it might be worth fitting the

weather protection cover to the exhaust outlet.

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11. Engine Maintenance

This section will cover onsite routine operational maintenance, based on a

250 hour duty period; this will require the use of basic hand tools and the

assistance from another operator to complete.

Always ensure that the unit has cooled down and has been isolated before

attempting any maintenance.

Note: wear the correct PPE and dispose of all oils, filters and cleaning

materials following the correct environmental QHSSE procedures.

11.1. Engine Oil Filter

The engine oil filters are mounted

under the exhaust cooler, so due to

their very restricted location, ask

another operator for help.

The filters are a disposable canister

type (Cat part No IR-0716) and

unscrew in a clockwise direction, use

a filter strap to undo the canisters

and try to avoid puncturing them,

remember the oil may still be quite

warm.

Before fitting the new filters partially fill them with clean engine oil, this

prevents the engine dry starting after the maintenance work is complete.

Clean the filter sealing area, give the o-ring seal a light coating of oil to reduce

the friction and tighten in an anticlockwise direction.

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11.2. Adding Engine Oil

To replace or top up the engine oil,

the filler cap is central to the engine

and is best accessed from the air

filter side of the engine.

Unscrew the center lever on

top of the cap in an anticlockwise

direction to loosen.

Lift out the filler cap.

Add the desired quantity of

oil.

Check the engine dip stick for

the correct oil level.

Reinstate the cap and tighten the center lever in a clockwise direction to

secure.

Try to use manageable quantities of oil when filling the unit. Keep the oil in

sealed containers until ready to use, this will help you to control spillages,

keep the oil free from contamination and ease manual handling difficulties.

11.3. Engine Air Filter

The engine air filter (Cat part number

S4N-0015) is a disposable element

type and is mounted at high level on

the unit. The outer cover of the

housing is a hinged cover type,

secured with snap fit clips, make sure

that the clips are firmly in place after

changing the air filter.

Clean the filter housing before

installing the new element and check

the housing seal for tears or damage.

Never attempt to change the air filter on a unit that is running, this could

result in serious injury and equipment failure.

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11.4. Engine Primary Fuel Filter

Isolate all fuel lines and have the

necessary spill prevention equipment

to hand.

Unscrew the center bolt on the top

of the filter housing in an

anticlockwise direction, remove the

re-usable filter element and clean

thoroughly.

When replacing the element make

sure that the filter housing o-ring

seal is in good condition and seated

correctly. If possible half fill the canister with clean diesel fuel and tighten the

center hexagon bolt, in a clockwise direction checking that the canister is

centered and level.

11.5. Engine Secondary Fuel Filters

Before removing the filters make sure that the fuel lines are isolated and that

all the necessary spill prevention equipment is to hand.

Use a filter strap to unscrew the filters (Cat part No

IR-0749) in a clockwise direction from the filter

housing, place them in a secure container for disposal.

Prime the new filter elements with clean fuel prior to

installing them, to approximately ⅔ rd's full and smear

the o-ring seal with fuel. Screw the filter onto the

housing and hand tighten, use the filter strap to

further tighten until resistance is felt.

Note: do not use excessive leverage when using the

filter strap to tighten the filters.

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11.6. Engine Water Conditioner Filter

Changing of the coolant filters (Cat

part No SN9-3368) is much the

same as the other disposable

cartridge type canisters found on the

unit and they require the same

removal and installation process.

They are a disposable filter element

and screw off in clockwise direction.

The coolant fluids will require

replacing with the recommended

fluid type once the unit has been run

up.

11.7. Coolant Additive

Use a recommended coolant with a

50/50 ratio of water to coolant

additive. This must be added after

any repairs to the water cooling

system or water filter replacement

and can be done via the radiator filler

cap.

Check the sight glass on the radiator,

the level should be approximately

half way across the face of the glass.

11.8. Run Up Checks

Following any service or major repairs, the unit should be run up and checked

thoroughly after a short run period. Check all fluid levels, the water cooling

system may have pockets of air trapped within it, which may only circulate out

of the system when it is running.

Make sure that all filters are tight, make sure that all hose and pipe supports

are in place and check for signs of fluid leaks.

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11.9. Housekeeping

As with any maintenance work there

will be packaging, cleaning cloths and

replacement parts used for the

maintenance work.

Before attempting any equipment run

up, always insure that all materials

used are cleaned up and disposed of

using the correct environmental and

QHSSE procedures.

Good housekeeping is an essential part of any job.

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12. Ariel Maintenance

To ensure that the Ariel unit runs trouble free during operation, there are a

few maintenance tasks that can be completed and should be classed as

essential. As an operator the level of experience required to carry out these

tasks is minimal, however should any of the tasks be above your skill level, ask

the site supervisor for assistance.

It is worth noting that it is good practice, where possible, to always "prime" or

"charge" the newly installed filter with a sensible level of fluid prior to fitting.

This helps to prevent dry starts and reduces the introduction of air within the

fluid systems.

12.1. Ariel Lubrication Pump

The Ariel lubricating pump oil level

should be reading approximately half

way up the sight glass.

This oil level is fed from the Header

tank positioned above the

aftercoolers and is usually the same

grade and type as that used for the

Caterpillar engine.

12.2. Lubrication Oil Filter

The Ariel lubricating oil filter, located on the crank

case housing (part No A661 or FL667) is a

disposable cartridge type and is removed by turning in

a clockwise direction.

When installing a new filter again always prime the

filter with clean oil before installing.

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12.3. Ariel Air Filter

The Ariel crankcase breather and air filter is an oil bath type located in the

center of the crank case housing.

Depending on location this may need

regular cleaning, for instance in a

dusty, desert location the filter

would require a more regular

cleaning cycle.

Undo the center retaining nut and

remove the cover, lift out the metal

gauze filter and wash thoroughly with

a suitable cleaning fluid before

replacing. Fill the filter bath to the

level indicator inside the filter

housing making sure that the filter element is pre-oiled.

12.4. Hydraulic Aftercooler Oil

The hydraulic system is fitted with a

disposable screw on, canister type

filter element (Part No, Baldwin BT-

8308-MPG).

Before changing the filter isolate the

oil feed valve at the bottom of the

tank then unscrew the filter in a

clockwise direction to remove it. Be

careful though, there will be residual

oil in the system so have spill kits or

catch trays ready.

Installing the filter is the reverse procedure but make sure to "prime" the filter

with oil before fitting, with Shell Donax TA or an equivalent.

Note: the mixing of oils should be avoided unless 100% compatibility is

assured.

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12.5. Cylinder Lubricating Catch Tank

After every 48hrs of continuous

running drain the cylinder lubricating

catch tank into a suitable spill proof

container and dispose of following

the correct QHSSE and

Environmental procedures.

The tank is fitted with a drain hose

located on the end of the unit, make sure that after completing this task, the

valve is fully closed and stored in the correct position.

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13. Troubleshooting

This section will endeavor to cover as many scenarios as possible, however

for a more detailed troubleshoot seek expert advice.

Before beginning a thorough investigation always check the services to the

unit, it may help in reducing operational down time.

For example:

sufficient air supply

fuel supply isolation valves are in the open position

Ariel inlet supply is above the minimum low inlet shut down pressure 10psi

(0.6bar)

all inlet and discharge valves are in the correct operating position.

all transport or shipping blanks have been removed.

13.1. Listening for Leaks

If the unit has shut down or

stopped and it is possible to do

so, listen for air leaks on the

AMOT control system.

Be systematic in checking for

leak paths, for example:

make sure that the control

panel is not indicating an

AMOT failure

check the air start line for

leaks or crushed hoses

make sure that the air supply has not been inadvertently isolated

check that the instrument air tubing is connected to all the sensors and

probes.

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13.2. Looking for Leaks

Take the time to inspect the unit for fluid leaks, isolate and report any leaks

found on the unit and do not attempt a re-start until repaired.

Fluid leaks may be indicated by color, this list may help but it should be used

as an indicator only:

water will be of a blue or green color, due to the cooling/anti freeze

additive

hydraulic oil is usually clear or red in color

diesel fuel is either slightly yellowish or red in color

engine oil will be a black color

visually check the nylon tubing for splits or damage

use a soapy water mix to highlight possible air leak paths.

13.3. No Air to the Control Panel

If there is no air to the control panel,

check the following:

air start supply line is charged

air supply is present to the

bottom inlet on the control panel

no audible leaks can be heard

within the control panel

check that the control panel

commissioning valve is set

check that the Ariel Lube oil

commissioning valve is set.

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13.4. Engine Turns Over but will not Start

If the unit fails to start, use this list to

check the following.

Check that:

the fuel supply and return valves

are in the open position

both commissioning valves are in

the set position

both the emergency stop and

general stop buttons are in the

run position

the engine shutdown dampers are in the run position

there is sufficient air supply to start the unit, minimum requirement

is 900scfm@125psi (25m³/[email protected]).

13.5. Starter Engages but Engine will not Turn Over

If the engine starting system is

initiated but the starter motor does

not engage, it is safe to assume that

the starter motor has jammed.

This might be resolved by isolating

the air supply and spraying a suitable

lubricant into the starter,

reconnecting the air line and

initiating the start sequence.

Should this fail then the next option

would be to remove the starter for

repair or replacement.

Make sure that all isolations are in place before doing any major

maintenance on the unit.

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13.6. Unit Shuts Down after Start Up

If the unit starts but will not run for

more than 3-5minutes check the

following:

engine air filter indicator status

for blocked filter

check for sufficient fuel supply

the unit requires

28.5gallon/hr@full load

(130liter/hr@full load)

check that the fuel hoses are not

crushed or trapped, restricting flow

check that the engine air intake is not restricted or blocked

make sure that there is no restriction to the air start supply

visually check all instrument AMOT nylon tubing and connections.

13.7. High Operating Temperature

If the Booster unit has a sudden

increase in temperature, check the

following items:

check the water cooled

exhaust bellows is not leaking

check for blocked or

obstructed air intake

check that the engine cooling

fan is receiving clean cool air

make sure that the engine is

not over-revving

visually check for broken fan blades on the engine cooling fan

visually check the radiator sight glass for fluid level

check for a rise in the ambient temperature.

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Notes

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Important Information Take time to read this manual thoroughly. If you are uncertain about any of the information presented in the

manual, please refer to Weatherford UK Ltd. for clarification before operation.

Any comments on this Manual please send to:

[email protected]

Prepared by Oilennium Ltd on behalf of Weatherford UK Ltd. www.oilennium.co.uk

www.oilennium.co.uk

ariel hp booster user manual

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