Installation, Operation and Maintenance Instructions
Hughes Zero Power Cooler® (ZPC)
The following guide provides instructions for site personnel on the safe handling, start-up, installation and maintenance of the ZPC.
Please note:
The ZPC is transported to the customer site without being charged with water. It is the responsibility of site personnel to ensure that the ZPC exchangers are filled with potable water when installed at the final site location. If the exchanger is not fully charged, the cooling process will not work efficiently.
It is the responsibility of the customer to ensure that all site safety procedures and risk assessments are carried out and adhered to, most notably for working at height.
Personnel/operatives should read and fully understand this document to have a clear understanding of how to fill and maintain the ZPC safely.
This manual provides instructions for the safe handling, start up, installation and maintenance of the Zero Powered Chiller and is
applicable to the personnel who will be responsible for the installation, commissioning and maintenance of the ZPC,
The purpose of this document is to provide all instructions in order to guarantee the correct installation of materials provided
Scope
Purpose
with the ZPC
Installation / Commissioning
Remove any dust and possible debris from the ZPC exchangers Remove all protection from the internal/external exchangers. Using the appropriate sling secure ZPC at the 4 off external eyebolts (free issue) and a trained operator shall carefully
position / align the flanges of the external exchanger above the internal exchanger as shown.
Installation and Commissioning
External exchanger
M16 x 80mm fasteners
• Remove any dust and debris from the ZPC
exchangers.
Tank shower lid for ZPC complete with inspection hatch and pipewor cover plates
• Remove any packaging from the external
exchangers.
This manual provides instructions for the safe handling, start up, installation and maintenance of the Zero Powered Chiller and is applicable to the personnel who will be responsible for the installation, commissioning and maintenance of the ZPC,
Internal exchanger
The purpose of this document is to provide all instructions in order to guarantee the correct installation of materials provided
Installation / Commissioning
Scope
Purpose
with the ZPC
Remove any dust and possible debris from the ZPC exchangers Remove all protection from the internal/external exchangers. Using the appropriate sling secure ZPC at the 4 off external eyebolts (free issue) and a trained operator shall carefully
position / align the flanges of the external exchanger above the internal exchanger as shown.
The ZPC is usually dispatched assembled - in the event it is supplied unassembled Connect the exchangers via x3 flanges by interposing the relevant gasket. Using the four M16x80 fasteners (included in please follow the fittings procedure below:
the kit) bolt the flanges together until tight.
•
A trained site operative should carefully position the flanges of the external exchanger so they align with the internal exchanger below.
• Connect the exchangers via the three flanges by interposing the
relevant gasket.
• Using the four M16x80 fasteners provided, bolt the flanges together
until tight.
Connect the exchangers via x3 flanges by interposing the relevant gasket. Using the four M16x80 fasteners (included in
the kit) bolt the flanges together until tight.
REFER TO DRAWING 02 37 049 10415 for detailed views of assembly instructions - P:\02 37 049 10415 - Shortcut.lnk
REFER TO DRAWING 02 37 049 10415 for detailed views of assembly instructions - P:\02 37 049 10415 - Shortcut.lnk
Filling the ZPC
Remove filler plugs
Filling options:
• Remove the filler plugs from the top of the exchanger using a
spanner.
(Ensure the filler plugs are kept in a safe place until required for fitting and sealing.)
Connect hose loosely into the expansion vase
• Use a suitable small diameter hose and fit loosely into the
expansion vase.
• Connect to the mains water supply, or a water tanker.
Note: to assist with the filling procedure the water can be directed into the exchanger using a funnel
F
i l l i
n g
h o s e
OR
Mains water supply
F
i l l i
n g
h o s e
Water
• Do not leave the exchanger unattended while filling. Check the unit for leaks both inside and outside the tank
shower water tank. If any leaks are observed, stop and tighten the joints.
•
•
Filling is complete when the water flows out of the filling connection.
Ensure all the air has been expelled. and when the water comes out without any bubbles, shut off the water supply.
• Remove the hose and check that the water level inside the expansion vase is 40mm below the filling
connection.
• Replace the filler plugs into the exchanger taking care not to overtighten or damage the threads.
Note: The water level in the expansion vase must be checked after approximately 24 hours. If necessary, add water and check that the water level inside the expansion vase is 40mm below the filling connection.
Maintenance
A maintenance logbook should be created to record regular checks, and if necessary, repairs performed.
A liquid level check should be performed at least every 6 months:
•
Access the ZPC, ensuring that all site safety procedures and risk assessments are carried out when working
at height.
• Check the water level inside the expansion vase is not less than 40mm below the vase entrance.
•
•
Add water if required.
Ensure the external tank exchanger fins are clear and free of debris. If necessary, clean between the external
fins using a brush. For internal cleaning use either compressed air or pressurized water to remove any debris.
In the event that the ZPC needs to be emptied:
• Remove the expansion vase filler plug.
•
Insert a hose loosely and empty the tank using a vacuum pump until empty.
• Disconnect the three flanges to allow disassembly of the heat exchanger.
• Once the heat exchanger has been removed, drain the tank shower water tank and remove the lid.
• Disconnect the internal exchanger flange at the bottom of the tank to fully drain the internal exchanger.
•
Ensure the internal flange connection is re-tightened.
If you require further assistance please contact us: T: +44(0)161 430 6618 E: sales@hughes-safety.com
Project: Q-21699 - Saipem COMP2 Folder: to send in TC-01 response