PRESSURIZATION INSTRUCTIONS OF BOOTSTRAP SYSTEM (& STUFFING BOX)

REF: DWG D0033305 THE PURPOSE OF THE BOOTSTRAP IS TO HYDRAULICALLY LOAD THE ENTIRE HEAD ASSEMBLY STACK CONSISTING OF THE BOOTSTRAP PLATE, OIL HEAD, PROCESS HEAD, ANTI ROTATION PLATE AND MAIN NUT WITH ENOUGH PRESSURE TO INSURE PROPER CLOSURE INTEGRITY. WHEN PRESSURIZED THE BOOTSTRAP PERFORMS SIMILAR TO A HYDRAULIC RAM. PROCEDURE: THERE ARE 3 HAND OPERATED VALVES WITHIN THE PIPING SYSTEM OF THE BOOTSTRAP. DESCRIPTION: BOOTSTRAP PUMP BLEED VALVE #1 IS LOCATED DIRECTLY ON THE HAND PUMP AND MUST BE CLOSED TO INSURE HAND PUMP FUNCTION. WHEN THIS VALVE IS OPEN PRESSURE WILL BE ALLOWED BACK INTO THE HAND PUMP RESERVOIR. CLOSE VALVE TO ENABLE THE HAND PUMP AND ONCE AT 27,500 PSI CLOSE VALVE #2 AND OPEN VALVE #1 TO RELIEVE THE PRESSURE ON THE HAND PUMP. BOOTSTRAP BLOCK VALVE #2 (HV-631) IS LOCATED JUST AFTER THE HAND PUMP AND IS USED AS AN ISOLATION VALVE ONCE THE BOOTSTRAP SYSTEM IS PRESSURIZED. PRESSURIZE BOOTSTRAP TO 27,500 PSI THEN CLOSE THIS VALVE. BOOTSTRAP CAVITY BLEED VALVE #3 (HV-634) IS LOCATED ON THE OTHER SIDE OF THE STUFFING BOX. THIS VALVE IS USED TO PURGE HYDRAULIC FLUID THRU THE BOOTSTRAP AREA INSURING THE BOOTSTRAP IS FULL OF OIL. WHEN INITIALLY PRESSURIZING THE BOOTSTRAP PRESSURIZE TO 5000 PSI THEN SLOWLY OPEN THIS VALVE TO LET PRESSURE DOWN AND REPEAT 3 TIME FINALLY KEEPING THE VALVE CLOSED AND PLUGGED THEN PRESSURIZE TO 27,500 PSI

MAINTENANCE INSTRUCTIONS OF DIAPHRAGM AND O-RING IN STUFFING BOX

DE-PRESSURIZE THE FOLLOWING: 1. PROCESS GAS 2. OPEN OIL BYPASS VALVE 3. ELECTRICAL SYSTEM 4. WATER SYSTEM LOCK OUT UNIT PROCEDURE: ONCE SATISFIED THE SYSTEM IS DE-ENERGIZED, 1. SLOWLY OPEN THE BOOTSTRAP BLOCK VALVE TO LET THE PRESSURE OFF THE BOOTSTRAP. FOR LATER USE, LOCATE AND IDENTIFY MATCH MARKS ON THE MAIN NUT / STUFFING BOX TOP. 2. REMOVE THE PROCESS CHECK VALVES AND BACKERS. 3. REMOVE THE COOLING PIPING NIPPLES. 4. WITH TOMMY BARS, LIFTING EYE AND CHAIN HOIST SUPPLIED REMOVE THE MAIN NUT. 5. REMOVE THE BRASS THRUST WASHER. 6. USING LIFTING EYE, HEAD REMOVAL TOOL AND CHAIN HOIST SUPPLIED, REMOVE THE PROCESS HEAD. 7. REMOVE THE OLD O-RINGS AND DIAPHRAGMS. THERE ARE FOUR O-RINGS TOTAL, TWO FOR THE LEAK DETECTION LOCATED ON THE SIDE OF EACH HEAD AND A OIL & PROCESS O-RING 8. CLEAN THE PROCESS HEAD, O-RINGS AND DIAPHRAGMS AND INSTALL WITH NEW PARTS. 9. INSTALL PROCESS HEAD AND ONCE THE HEAD IS IN PLACE, SCREW THRU THE STUFFING BOX INTO THE COOLING HOLES THE ANTI-ROTATION BARS SUPPLIED. 10. INSTALL THE BRASS THRUST WASHER AND MAIN NUT. 11. ONCE THE MAIN NUT IS CLOSE TO BOTTOMING OUT ALIGN MATCH MARKS LOCATED ON THE MAIN NUT AND TOP OF STUFFING BOX. 12. INSTALL CHECK VALVES, BACKERS, COOLING PIPING. 13. PRESSURIZE THE BOOTSTRAP.

14. PRESSURE TEST THE LEAK DETECTION SYSTEM FOR INTEGRITY. 15. COMPRESSOR IS READY TO PRIME.