3.

Fuel gas system Maintenance Manual for Auxiliaries

Compact gas ramp

Content
Gas filter
Maintaining the gas filter, 1000 Hours......................................................................................................3-5
Instrument air filter
Maintaining the microfilter, 1 Years.......................................................................................................... 3-7
Mass flow meter
Cleaning the flow meter, As required....................................................................................................... 3-9
Clean the flow meter when needed. Replace the seals if necessary.
Gas shut-off valve
Maintaining the ball valve, 2 Years......................................................................................................... 3-11
Overhauling the ball valve, 5 Years........................................................................................................ 3-13
Gas regulating valve
Calibrating the gas regulator, 1 Years.................................................................................................... 3-15
Replacing the packing and gaskets, As required...................................................................................3-17
Replace the packing and gaskets as required by plant operating conditions and national laws.
Gas vent valve
Maintaining the ball valve, 3 Years......................................................................................................... 3-19
Overhauling the ball valve, 5 Years........................................................................................................ 3-21

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Maintaining the gas filter GUID-984C304D-B720-4BF0-8EEF-E678FDC0D8A0

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: SF1040
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Gas filter B001 Manufacturer: Parker

Work Information
JobID: wca2809 Work time: 2 Hours
Type of job: Planned maintenance Stop time: 2 Hours
Interval: 1000 Hours (Only after first start or major overhaul) Service personnel: Mechanical, 1 / Component
4000 Hours Responsibility: Wärtsilä/Elering

Prerequisites

WARNING
Before starting any work on the gas regulating equipment, make sure it is
properly isolated, vented and secured from accidental starting.

Required spareparts

Qty Description
2 Filter element

As required Sealing kit

Replace the filter cartridge after the first 1000 operating hours on a new installation. After
that, replace the cartridge after 4000 hours, or when the pressure difference indicator
shows pressure drop of ≥ 0,2 bar.

Procedure
1 Disassemble the filter.
a Loosen the nuts and remove the cover.
b Unscrew the nut on the centre rod and remove the holder cover.
c Remove the used filter elements.
d Lift off the bottom plate and the spring along the centre rod.
2 Clean the tank, the cover of the tank, the holder cover, and the bottom plate.
3 Check the condition of the O-rings on the cover, in the holder cover, and in the bottom
plate.
Replace the O-rings, if needed.
4 Assemble the filter with new filter elements in opposite order.
5 Check the filter for possible leaks.

Postrequisites

CAUTION
The used filter element is to be treated as hazardous waste.

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Maintaining the microfilter GUID-33C768D9-9379-400B-8A51-05A9FEEC0788

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: G5 XP4
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Instrument air filter B002 Manufacturer: Zander

Work Information
JobID: wca2810 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 1 Years Service personnel: Mechanical, 1 / Component
Responsibility: Wärtsilä

Prerequisites

WARNING
Never remove any parts of the filter, or manipulate in any way when the filter is
pressurized! A sudden escape of pressure may cause serious injuries.

Required spareparts

Qty Description
1 Filter element

1 O-ring

Check the function of the micro filter and replace the filter element.

Procedure
1 Check the function of the condensate trap.

NOTE
The instructions in the following steps do not apply to filters that are equipped
with a manual relief valve.

a Check if a permanent flow noise can be heard when the discharge valve is closed. This
indicates a leakage.
b Turn the knurled screw on the housing bottom to the right in order to open the drain
valve manually.
If the condensate trap:
- works correctly, a small amount of condensate, compressed air or inert gas will
discharge.
- is defective, an unusual amount of condensate discharges.

NOTE
If you have doubts about the correct function of the trap, proceed as described
below:

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3. Fuel gas system Maintenance Manual for Auxiliaries

c Shut off the compressed air or gas supply.

d Open the manual drain valve and depressurize the filter.
e Unscrew the filter bowl as described in the section "Renew filter element".
f Remove the condensate trap, clean or fit a new condensate trap.
g Refit the filter bowl as described in the section "Renew filter element".
h Re-check the operation of the condensate trap.
i Ensure that the knurled nut is tightened so that the automatic drain functions correctly.
2 Replace the filter element.
a Shut off compressed air or gas supply to the filter.
b Depressurize the filter housing.
Operate drain valve as follows:
- for manual drain valves: open manual valve and wait until the pressure has escaped.
- for automatic condensate drains: turn knurled screw to the right and wait until the
pressure has escaped.
- for an electronic condensate drain: press the push button, if necessary several times.
The filter is depressurized when flow noise can no longer be heard.
c Unscrew the filter bowl section and remove it.
d Unscrew the filter element and remove it.

NOTE
New filter elements with external foam socks (series Z, X) should only be
handled by the end caps; otherwise, the foam sock could be damaged.

e Insert the new filter element and O-ring. Tighten the filter element until it is hand tight;
ensure that the O-ring is seated correctly.
f Before the assembly, lightly grease the threads of the housing sections with Molykote or
a comparable lubricant.
g Reconnect the filter bowl to the head and tighten by hand.
h Unscrew the filter bowl by 30°.
This allows the filter to be opened easily even after an extended period of operation and
frequent pressure changes.
i Close the manual or automatic drain.
j Check the housing for leaks.

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Cleaning the flow meter GUID-18C95CC5-AD8D-4D16-8CF3-B20EB88A3BC7

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: Promass 80
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Mass flow meter F001 Manufacturer: Endress+Hauser

Work Information
JobID: wca2811 Work time: 1 Hours
Type of job: Wash/Clean Stop time: 0 Hours
Interval: As required Service personnel: Mechanical, 1 / Component
1 Years Responsibility: Elering

Prerequisites
Required spareparts

Qty Description
As required Seals

Refer to the manufacturer's manual for detailed instructions.

Procedure
1 Clean the flow meter.
When cleaning the exterior of measuring devices, always use cleaning agents that do not
attack the surface of the housing and the seals.
If pigs are used for internal cleaning, it is essential to take the inside diameters of measuring
tube and process connection into account.
2 Replace seals if necessary.

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Maintaining the ball valve GUID-DD46D237-7B96-4A11-94E3-9341A72B20F6

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: Fig Z
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Gas shut-off valve V001, V003, V004, V016 Manufacturer: Pekos

Work Information
JobID: wca3038 Work time:
Type of job: Planned maintenance Stop time:
Interval: 2 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
The valve may be pressurised – before doing maintenance, empty the pipeline
and ball valve body by opening the valve part way to release any pressure.

Required spareparts

Qty Description
1 Sealing set

Procedure
1 Disassemble the valve.
Make alignment marks on the body 1 (1) and the body 2 (2) flanges to ensure correct
reassembly.
Place the parts on a clean surface. To make reassembly easier, arrange the parts in order of
disassembly.
2 Replace the following parts in the ball valve:
4 - Seat
6 - Stem seal
7 - Stem packing 1
7d - Stem packing 2
14 - Body seal 1
31 - Bearing
32 - Bearing disc
34 - Body seal 2
35 - Stem o-ring
165 - Stem bearing
Refer to Fig 3-1for the location of the parts in the valve.
Inspect the other parts and replace any parts that are worn or damaged. Clean the body
cavity and all parts.

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16 A
22
13b 11

13a 17
165
11
50 B
110 9 33
2
8b 31
32
15
8a
7d

14
34
3 C
35 23
4
6
1 24
5
16
20
17
19

A – Valves DN15–DN32, B – Guided ball valves, C – Valves DN125–DN300, 1. Body 1, 2.

Body 2, 3. Ball, 4. Seat, 5. Stem, 6. Stem seal, 7. Stem packing 1, 7d. Stem packing 2, 8a.
Gland packing 1, 8b. Gland packing 2, 9. Spring washer, 11. Cover, 13a. Cover bolt 1, 13b.
Cover bolt 2 (DN40–DN300), 14. Body seal 1, 15. Body bolt, 16. Handle, 17. Handle bolt,
19. Spring, 20. Antistatic ball, 22. Stop pin (DN15–DN32), 23. Handle pin (DN125–DN300),
24. Lengthening handle (DN125–DN300), 31. Bearing, 32. Bearing disc, 33. Support
bearing, 34. Body seal 2, 35. Stem o-ring, 50. Subjection ring, 110. O subjection ring
(DN125–DN300). 165. Stem bearing

Fig 3-1 GUID-ADEAC059-54F7-4B02-AEAE-D5A947CC10F0 v1

3 Assemble the valve with new parts.

Refer to the manufacturer's documentation for instructions.

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Overhauling the ball valve GUID-0650B02F-000E-4F94-ADC9-C4BF111E6188

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: Fig Z
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Gas shut-off valve V001, V003, V004, V016 Manufacturer: Pekos

Work Information
JobID: wca3039 Work time:
Type of job: Planned maintenance Stop time:
Interval: 5 Years Service personnel: Mechanical, 1 / Component

Prerequisites

WARNING
The valve may be pressurised – before doing maintenance, empty the pipeline
and ball valve body by opening the valve part way to release any pressure.

Required spareparts

Qty Description
1 Ball

1 Stem

1 Sealing set

Procedure
1 Disassemble the valve.
Make alignment marks on the body 1 (1) and the body 2 (2) flanges to ensure correct
reassembly.
Place the parts on a clean surface. To make reassembly easier, arrange the parts in order of
disassembly.
2 Replace the following parts in the ball valve:
3 - Ball
5 - Stem
19 - Spring
20 - Antistatic ball
Refer to Fig 3-2for the location of the parts in the valve.
Inspect the other parts and replace any parts that are worn or damaged. Clean the body
cavity and all parts.

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16 A
22
13b 11

13a 17
165
11
50 B
110 9 33
2
8b 31
32
15
8a
7d

14
34
3 C
35 23
4
6
1 24
5
16
20
17
19

A – Valves DN15–DN32, B – Guided ball valves, C – Valves DN125–DN300, 1. Body 1, 2.

Body 2, 3. Ball, 4. Seat, 5. Stem, 6. Stem seal, 7. Stem packing 1, 7d. Stem packing 2, 8a.
Gland packing 1, 8b. Gland packing 2, 9. Spring washer, 11. Cover, 13a. Cover bolt 1, 13b.
Cover bolt 2 (DN40–DN300), 14. Body seal 1, 15. Body bolt, 16. Handle, 17. Handle bolt,
19. Spring, 20. Antistatic ball, 22. Stop pin (DN15–DN32), 23. Handle pin (DN125–DN300),
24. Lengthening handle (DN125–DN300), 31. Bearing, 32. Bearing disc, 33. Support
bearing, 34. Body seal 2, 35. Stem o-ring, 50. Subjection ring, 110. O subjection ring
(DN125–DN300). 165. Stem bearing

Fig 3-2 GUID-ADEAC059-54F7-4B02-AEAE-D5A947CC10F0 v1

3 Assemble the valve with new parts.

Refer to the manufacturer's documentation for instructions.

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Calibrating the gas regulator GUID-FC8DF6FF-E547-425C-AB06-4D4600B19B19

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: GX
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Gas regulating valve V005, V006 Manufacturer: Fisher

Work Information
JobID: wca2812 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 2 Hours
Interval: 1 Years Service personnel: Mechanical, 1 / Component
Responsibility: Wärtsilä

Prerequisites

WARNING
Before starting any maintenance work on the gas regulating equipment, make
sure that it is properly isolated, vented, and secured from accidental starting.

Make an auto calibration of the DVC2000 (travel calibration).

Procedure
1 Re-calibrate the auto positioner.
This calibration must be done when the unit is off-line and the regulator is vented (empty).

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Replacing the packing and gaskets GUID-BD796B24-86BD-49F1-BB65-69C09B01A5D0

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: GX
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Gas regulating valve V005, V006 Manufacturer: Fisher

Work Information
JobID: wca2813 Work time: 2 Hours
Type of job: Overhaul Stop time: 2 Hours
Interval: As required Service personnel: Mechanical, 1 / Component
Responsibility: Wärtsilä/Elering

Prerequisites

NOTE
Before starting any maintenance on the gas regulating equipment, make sure
that it is properly isolated, vented, and secured from accidental starting.

Required spareparts

Qty Description
1 Packing Kit for DN 25 and 50

1 Packing Kit for DN 80

As required Body/Bonnet Gasket Kit for DN 25

As required Body/Bonnet Gasket Kit for DN 40

As required Body/Bonnet Gasket Kit for DN 50

As required Body/Bonnet Gasket Kit for DN 80

Replace the packing and gaskets. Use the appropriate packing and gaskets for the valve
size.

Procedure
Ⴠ Replace the packing, when needed.
Use the appropriate Packing Kit.
Ⴠ Replace the body and valve gaskets.
Use the appropriate Body/Bonnet Gasket Kit.

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Maintaining the ball valve GUID-1EAA73D5-A358-420E-9DEB-AEF394E4484C

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: Master Star
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Gas vent valve V002, V007, V008, V009 Manufacturer: Starline

Work Information
JobID: wca2831 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 3 Years Service personnel: Mechanical, 1 / Component
Responsibility: Elering

Prerequisites
Required spareparts

Qty Description
1 Packing set

Procedure
1 Disassemble the valve.
Place the parts on a clean surface. To make re-assembly easier, arrange the parts in order
of disassembly.
2 Replace the following parts in the ball valve:
3 - Packing ring
7 - Thrust washer
8 - O-ring
10 - Seats
11, 18 - Body seals.
Refer to Fig 3-3 for the location of the parts in the valve.
Inspect the other parts and replace any parts that are worn or damaged.

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1 2A

8
17
7 13 16
5

2B
4
6
3

18
11
9 10
14

12

1. Handle, 2 (A, B) Nut, 3. Packing ring, 4. Spring washer, 5. Antistatic stem, 6. Gland
packing, 7. Thrust washer, 8. O-ring stem, 9 Ball, 10. Seats, 11. Body seal, 12. Body, 13.
End connections, 14. Stop-pin, 16. Bolts, 17. Stop washer, 18. Body seal

Fig 3-3 Parts for ball valve GUID-AA226961-077A-4F34-92DD-1D44B664FDD6 v2

3 Assemble the valve with the new parts.

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Overhauling the ball valve GUID-DFBC1000-32B9-4EEF-99E3-8F0BF187C991

Component
Unit: Compact gas ramp ZAC011, ZAC021, ZAC031, Type: Master Star
ZAC041, ZAC051, ZAC061,
ZAC071, ZAC081, ZAC091,
ZAC101, ZAC111, ZAC121,
ZAC131, ZAC141, ZAC151,
ZAC161, ZAC171, ZAC181,
ZAC191
Component: Gas vent valve V002, V007, V008, V009 Manufacturer: Starline

Work Information
JobID: wca2832 Work time: 1 Hours
Type of job: Planned maintenance Stop time: 1 Hours
Interval: 5 Years Service personnel: Mechanical, 1 / Component
Responsibility: Elering

Prerequisites
Required spareparts

Qty Description
1 Spare part set

Procedure
1 Disassemble the valve.
Place the parts on a clean surface. To make re-assembly easier, arrange the parts in order
of disassembly.
2 Replace the following parts in the ball valve:
2 (a, b) Nuts
4 Spring washer
5 Antistatic stem
9 Ball
17 Stop washer.
Refer to Fig 3-4 for the location of the parts.
Inspect the other parts and replace any parts that are worn or damaged.

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