Gas Combustion Unit (GCU) Standard Maintenance File

PartID: OM9016_01

GAS COMBUSTION UNIT (GCU)

STANDARD MAINTENANCE FILE
1 SUMMERY
• General Information
• GCU maintenance manuals

◦ Exhaust Stack, Combustion Chamber, Burner and Accessories

◦ Combustion Air Fan, AVT Fan (if applicable)
◦ Power Cabinet
◦ Control cabinet
◦ Gas Valve Train (GVT)
◦ Air Valve Train (AVT) – if applicable
This document presents a general maintenance program along with the inspection plan procedure for
the Gas Combustion Unit.
This procedure may be updated according to the notified body class requirements, sub-supplier
recommendations, and the end user preferences based on the contact.

CAUTION

Prior to any operation, the operator must read this manual entirely. The product / materiel should
not be deviate of its initial destination.

2 GENERAL INFORMATION
2.1 GENERAL SAFETY PRECAUTIONS
This section provides important safety information for anyone responsible for installing, operating,
adjusting; maintaining, cleaning, repairing or transporting the GCU.
Safe operation of the unit can only be guaranteed if it is properly installed, commissioned and
maintained by a qualified person (who is not under the effect of any drugs or alcohol or any product
which could modify/affect the behavior) in compliance with the operating instructions and the
maintenance file.

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Gas Combustion Unit (GCU) Standard Maintenance File
PartID: OM9016_01

It must also be complied with general installation and safety instructions for pipeline, plant construction
and Liquefied Natural Gas (LNG) carrier operation as well as the proper use of tool and safety
equipment.

2.2 WARNING
Some of units may cause physical injury if it is not handled and disposed of carefully.
Consider whether closing isolating valves will put any other part of the system or personnel at risk.
Danger may include: isolation of vents, protective devices or alarms. Ensure isolation valves are turned
off in gradual way to avoid system shocks.
Before attempting any maintenance:

• Consider what is or may have been in the pipeline (natural gas, nitrogen, fuel oil, inert gas, …)
and follow the safety rules accordingly (wear of protective clothing including gloves and glasses,
measurement of natural gas or oxygen content, …).
• Ensure that any pressure is isolated, and safety vented to atmospheric pressure before attempting
to maintain the units.
• Ensure that the electrical power supply is shut down and all the control and power cabinets are
locked.
Electricity can cause severe injuries. Never open control or power cabinets, never attempt any
maintenance or setting of equipments before shutting down the electrical power supplies of the
installation.
Allow time for temperature to stabilize to ambient temperature after isolation or stop of the installation to
avoid the danger of burns and always consider that protective clothing (including safety glasses) is
required.

IMPORTANT

Any failure to follow these rules regarding "General safety precautions" and "Warning" releases
Alfa Laval Aalborg from all responsibilities.

2.3 REMOVAL OPERATION

After each component removal, flanges must be inspected, cleaned, and seals and gaskets must be
replaced.

IMPORTANT

If the Buyer uses non Alfa Laval Aalborg parts or non Alfa Laval Aalborg approved repairs and
such parts or repairs cause personal injury, death or property damage to third parties, Buyer shall
indemnify and hold harmless Alfa Laval Aalborg from all claims and liabilities associated therewith.

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Gas Combustion Unit (GCU) Standard Maintenance File
PartID: OM9016_01

2.4 GCU MAINTENANCE MANUALS

General remarks

• Objective of visual checking is to point out any change from the origin or from previous inspection
(Rust, lack of paint, crack, deformation, displacement of element, missing part such as screw,
unscrewed nuts, etc).A dye penetrant inspection can complete the visual check.
• At visual checking, in case of abnormal observation, please take pictures and inform Alfa Laval
Aalborg through email: Global ServiceOperation@alfalaval.com.

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 OM9016_02#A.3
GAS COMBUSTION UNIT (GCU) STANDARD MAINTENANCE FILE

Gas Combustion Unit (GCU) Standard Maintenance File

Exhaust Stack, Combustion Chamber, Burner and Accessories

Exhaust Stack, Combustion Chamber, Burner and Accessories

Tag No Operation
Dry Dock
Referenced Description Start-up Every 3 Operation Rem arks
Monthly 1 Year 2 Year Overhaul
P&ID m onths
D133 Visual inspection and flow Check air flow rate for UV cell cooling:
Air Needle valve ((UV Cell Air purging) x
D134 rate measurement Flow rate is defined in operating manual
YARD Flexible Hose (UV Cell Air purging) x Visual inspection Check that it is not damaged
Check opening and closing
D210 Air manual isolating valve x
of the valve
The UVCell is a safety device, any repair work or similar
x Cleaning, connections check shall only be carried out by manufacturer or
D131 other personas appointed by the manufacturer
UV Cell
D132 Replace after 10 years*
replace damaged parts,
x (x) * Viewing port of UV Cell should be cleaned
if present
as well as glass cleaning
Remove the thermocouples for visual inspection
x Visual inspection checking the sensors, cables and connections including
D144 bolts, flange, and cable tray
Exhaust stack Thermocouple
D145
Replacement of Along with the thermocouple replacement, full inspection
x
thermocouple of other parts required, and replacement if necessary

x Visual Check Cleaning if required

D110 View Port Glass with seal
x replaced if required
Visual inspection/
D161 Burner Gas expansion joint x
Replacement if required
Check that the 2 igniters are sparkling properly through the
view port during normal start up.
x Test and Visual inspection The sparkling must be at least at the top of ignitor,
Remarks: Sparks along the rod is acceptable if there is
D316 sparks at the top
Spark igniter
D317 Check the gap between the two electrodes at the top of
Visual inspection Cleaning if
x igniter is from 2 to 3 mm
required
According burner instruction
Replacement of spark
x
igniters

D122 Visual inspection and Check the calibration. The calibration values are indicated
Air differential pressure transmitter x
D123 output signal check in the operating manual

Figure 1 main_ax6267020en.wmf
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GAS COMBUSTION UNIT (GCU) STANDARD MAINTENANCE FILE

Exhaust Stack, Combustion Chamber, Burner and Accessories, part 2

Tag No Operation
Dry Dock
Referenced Description Start-up Every 3 Operation Remarks
Monthly 1 Year 2 Year Overhaul
P&ID months
Through the view port when stop and when running
x Visual inspection Check that there is no visible damage on the burner

Visual inspection inside the chamber of diaphragm, burner

D315 Burner (Burner Head and Burner Body)
and igniters
Visual inspection Cleaning
x Cleaning of burner head if required
(if required)

· Visual inspection (Welding, cracks around the chamber

dilution holes, etc.) and bottom dampers
· Check integrity of raw material. It must be Free of
General corrosion, otherwise inform AlfaLaval.
x Visual inspection and check · Visual inspection of the mixing device and mixing
device support , dampers at the top of the chamber

· Visual inspection (Welding, cracks around the chamber

dilution holes, etc.)
D300 Combustion Chamber
· Check the tightening of the screws of the support, top
and bottom damper, fastening fixation of the burner,
fastening of the mixing device at the top of the chamber
· Check integrity of raw material, important rust
x Full inspection · Measurement of the thickness of the mixing device and
the combustion chamber around the dilution holes
Check the Lower Damper and Upper Damper visual
conditions
It must be Free of General corrosion, otherwise inform
AlfaLaval.

Check the seal of the door, the tightening of wires

D11 Junction box for spark igniter transformer x Visual inspection
connection
Check the seal of the door, the tightening of wires
XD12 Junction box for UV cell x Visual inspection
connection
D144.2 Check the seal of the door, the tightening of wires
Junction box for temperature transmitters x Visual inspection
D145.2 connection
x x Visual inspection Electrical connections to be checked
D235 Flowmeter Main Gas Line (if present)
x Calibration

Figure 2 main_bx6267050en.wmf

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GAS COMBUSTION UNIT (GCU) STANDARD MAINTENANCE FILE

Fan + Air heater fan (If applicable)

Fan + Air heater fan (If applicable)

Tag No Operation
Dry Dock
Referenced Description Start-up Every 3 Operation Rem arks
Monthly 1 Year 2 Year Overhaul
P&ID m onths
Visual inspection including
x
Fan units anti vibration supports Refer to fan manual in the instruction manual
x Cleaning of air inlet
x Visual inspection Check the self closing function of dampers
Outlet non return, damper Protection/Replacement if
x
present Spray CRC or similar corrosion inhibitor on outlet damper
Outlet flexible connection x Visual inspection Check there is no holes in the flexible bellow s
Check if there is no foreign matter inside the fan
Rotate impeller by hand and be sure that it does not
Impeller x Visual inspection
touch the w alls (Pow er to be disconnected before
present action)
Check the tension and
pulley alignment
XD600 Fan Visual inspection including
Drive belts x
Belt guard corrosion and
fitting by screw s fully
tightened
Greasing
Mineral oil cleaning and See quantity per bearing in fan draw ing and
Bearings x
new greasing including grease type in manual
support
Visual Inspection &
Bearing Supports x
Cleaning
Rotor/Shaft x Visual inspection
Drive pulley x Visual inspection
Check sealing of JB cover, cables and cable
Junction Box for Fan motor x Visual inspection
connections.
Cover for fan housing x Visual inspection Check of leaks

General Inspection
Fan Motor Bearings x
Greasing Refer to fan manual in the instruction manual
XD610 Fan Motor

Fan motor ventilation

impeller x Visual inspection Cleaning of impeller

Figure 3 main_cx6267060en.wmf

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GAS COMBUSTION UNIT (GCU) STANDARD MAINTENANCE FILE

Power & control cabinet

POWER CABINET
Tag No Operation
Dry Dock
Referenced Description Start-up Every 3 Operation Rem arks
Monthly 1 Year 2 Year Overhaul
P&ID m onths

xL1 Filters x Clean/Change filters

Air condition filters along w ith connections like drainage

xL1.1 Air condition (if present) x Visual inspection
needs to be visual checked.
Soft start and soft stop unit (if present)
x Replacement
Starter relay

xL1 Cabinet structure and door latch system x Visual inspection

Note 1: One year or start-up, whichever sooner.

Note 2: Before performing present work of present kind on the power cabinet, ensure that the upstream electrical power supply
has been locked out by the operator of the vessel. Request and approve the lockout certi?cate.

Figure 4 main_dx6267070en.wmf

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GAS COMBUSTION UNIT (GCU) STANDARD MAINTENANCE FILE

Gas valve train + Air valve train (If applicable)

GAS VALVE TRAIN + AIR VALVE TRAIN (IF APPLICABLE)

Tag No Operation
Dry Dock
Referenced Description Start-up Every 3 Operation Rem arks
Monthly 1 Year 2 Year Overhaul
P&ID m onths
Flanges & Gaskets Visual inspection Leak test under normal pressure
x
Flanges leak test No visible bubbles w ith leak detector
D220 Manual gas isolating Valve Upstream /dow nstream Pressure test under standard pressure
D260 (Off gas if present) x leak test No visible bubbles w ith leak detector at valve vent outlet
D221 GVT strainer(including off Visual inspection Cleaning
x
D261 gas - if present) or changing if necessary
D222, D282 Gas pressure transmitter
D287, D289 on Gas line
Visual inspection
D291, D293 Air pressure transmitter x
Check the calibration
D214, D216 on exhaust Gas
D262 Off gas line (if present)
D233, D229, x Visual inspection
Gas line pneumatic valve
D270, D272 (if Upstream / dow nstream Leak test under standard pressure
(isolating) x
present) leak test
D228, D232
D230, D234
D257
D237(if present)
D207, D209 (if Visual inspection
present) Solenoid valve
x Upstream / dow nstream
D271, D273 (if Off gas line (if present)
leak test
present)
D275 (if present)
GVT
D267, D269 (if
present)

D241, D244, Pneumatic gas flow Visual inspection and

D238 (if present) x
control valve Check

x Visual inspection
Nitrogen manual lockable
D250 Upstream / dow nstream Leak test under standard pressure
isolating valve x
leak test
D212, D224, Gas & nitrogen & Air
D247 compressed pressure
x Visual inspection
D252, D280 indicator
D264 (if present)
Junction box and electrical Visual inspection and Check that the w ires are not damaged
D10 x
wires check Check the screw tightening for the terminal screw s
D213, D215,
D217, D223,
D283, D225, x Visual inspection Check
D286, D288,
D253, D263, 2 ways manifold
D265, D281,
Pressure test under standard pressure
D248, D290, Upstream /dow nstream
x No visible bubbles w ith leak detector
D292, D125, leak test
at manifold vent outlet
D124

Figure 5 main_ex6271470en.wmf

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GAS COMBUSTION UNIT (GCU) STANDARD MAINTENANCE FILE

Gas valve train + Air valve train (If applicable), part 2

Tag No Operation
Dry Dock
Referenced Description Start-up Every 3 Operation Rem arks
Monthly 1 Year 2 Year Overhaul
P&ID m onths
Flow meter Off Gas (if x Visual inspection Electrical connections to be checked
D276
present) x Calibration
x Visual inspection
D255 Non return valve
x Leak test
x Visual inspection, Cleaning
D251 Nitrogen Strainer
x Changing if required
D231, D227 GVT
D266, D268 (if Gas Vent valve Leak test
present) x

D256, D208
Nitrogen Shut off valve Leak test
D206 (if present)
x
x Visual inspection
D226, D284 Temperature transmitter
x Check of calibration
D805 Manual butterfly valve x Leak test
D804 Heating Element x Visual Inspection
Visual inspection including
D801 Fan
x anti vibration supports
Check in accordance w ith
D802 Fan Motor x general inspection of See Air heater fan motor manual
manual
AVT Visual Inspection,
D810, D808 (if applicable) Instrumentation Calibration, and Changed if
D800 x required
Pressure test under standard pressure
Upstream /dow nstream
D809 2 w ays manifold x No visible bubbles w ith leak detector at manifold vent
leak test
outlet
Check in accordance w ith
D806 Motor Valve x x general inspection of
manual
Junction box's and Visual inspection and
D13 x
electrical w ires check

Note 1: All tag numbers might not be available on all P&ID

Figure 6 main_fx6271480en.wmf

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Gas Combustion Unit (GCU) Quality plan
PartID: OM9016_03

GAS COMBUSTION UNIT (GCU)

QUALITY PLAN
1 INTRODUCTION
This document presents a preliminary general quality control plan (QCP) for the Gas Combustion Unit.
This procedure may be updated according to the class requirements, sub-supplier recommendations.All
imperfections or defects during inspection controls must be mentioned as NCR (Non-Conformity
Report) with the cure action.
Level 1 ................................................................................................................................................................. Sub-Suppliers
Level 2 ............................................................................................................................................................... Alfa Laval Rep
Level 3 ................................................................................................................. Notified Body/ Classification Company
Review (Documentation / Report / Certificate) .............................................................................................................. R
Spot Witness Point ................................................................................................................................................................... S
Witness Point ............................................................................................................................................................................ W
Hold Point .................................................................................................................................................................................... H

2 TABLE OF CONTENT
Phase / Equipment Controls 1 2 3 Remarks
Design Internal drawing review R

Gas Burner Drawings R R

Certificates R R R

Dimensional control and interfaces W S S Assembled inside the

combustion chamber

Gas Valve Unit Drawings R R

Certificates R R R

Welding procedure R R

Dimensional control and interfaces in regard to W S S

the approved drawings

X-ray control R R R According to class requirements

Pressure test R/W R/S W According to class requirements

Leakage test R/W R/S W According to class requirements

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Gas Combustion Unit (GCU) Quality plan
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Phase / Equipment Controls 1 2 3 Remarks

Marking R R S

Weighing R R

Table 1:

Phase / Equipment Controls 1 2 3 Remarks

Control cabinet Electrical drawings R R R

Certificates R R R

Electrical tests R/W R/S W

Functional tests R/W R/S W

Test of the sequence R/W R/S W

Marking R R S

Weighing R R

Power cabinets Electrical drawings R R R

Certificates R R R

Electrical tests R/W R/S W

Functional tests R/W R/S W

Test of the sequence R/W R/S W

Marking R R S

Weighing R R

Combustion chamber Drawings R R

Welding procedure R R

Non destructive examination tests (penetrant test) R/W R/S

Dimensional control and interfaces W W

Marking R R S

Weighing R/W S

Combined air fans and electric motors Drawings and calculation notes R R

Check of welding procedure documentation R R

Dimensional control and interfaces W W

Electric motor certificate (Shaft) R R R

Axial balancing control of the turbine R/W R

Marking R R S

Weighing R/W S

AVT (if any) Drawing R R

Welding Procedure R R

Non destructive examination tests (Only Visual test) R/W R/S

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Phase / Equipment Controls 1 2 3 Remarks

Marking R R S

Welding R/W S

Delivery Packing R R

Site Acceptance Commissioning W

Gas trials W

Documentation Final Documentation R R

Spare Parts Final Documentation R R

Table 2:

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