FUEL POLISHING SYSTEM TEST PROCEDURE

Test Procedure for Fuel Polishing System

0 Issue

REV. Date Description Prepared Reviewed Approved

 FUEL POLISHING SYSTEM TEST PROCEDURE

TABLE OF CONTENTS

1. SCOPE

2. REFERENCE DOCUMENTS

3. PERSONNEL QUALIFICATION

4. APPARATUS

5. PREPARATION

6. PROCEDURE

7. TEST REPORT / CHECKLIST

SCOPE
 FUEL POLISHING SYSTEM TEST PROCEDURE

This procedure describes the method followed as per manufacturer recommendations to perform the test of fuel polishing
system. The target is to proof and show the smooth operation of polishing unit

2. REFERENCE DOCUMENTS

• Approved project drawings and specifications.

• Manufacturer's instructions and recommendations for the unit.
• Relevant local regulations, codes and standards.
• Approved Material Submittal.
• Project Specification

3. PERSONNEL

Personnel performing the testing shall be trained to operate the instruments and the test equipment.

4. APPARATUS
4.1 Instruments

• Multimeter for current measurement.

• Hand tools

It is possible to use other instruments if they are equivalent or better.

4.2 Calibration

Instruments shall be periodically checked and calibrated.

5. PREPARATION

5.1 Priming the System

Priming of the system with fuel to the primary filter at the level of the pump inlet is required. If the pump is being run
without
Fuel is being run without fuel pump damage will occur.

Prime the system by using the priming T or by lifting the lid on the primary filter.

The gear pump can build up very high pressures and it is therefore important to make sure the pump is not operated with
the
delivery lines closed (or restricted).

5.2. Programming the Timer

The system can be run on the manual mode or with preset times. The running mode need to set based site condition and
project application. To set the timer of the system to have it run at set times, please take the following steps:
 FUEL POLISHING SYSTEM TEST PROCEDURE

• Check that the emergency stop button is not pressed, the 3-way switch is "OFF" and press the green
• "OK" button on the control panel to reset the alarm
• Use the DOWN button until you get to week clock 1
• Press the ESC button for 2 seconds
• Select the desired day using the DOWN and press OK
• Use the RIGHT, LEFT and DOWN buttons to select the days of the week (“- “means inactive that day)
• In the same fashion select the hour the system should start those days
• And, again in the same way, select the hour the system should stop those same days
• Press “OK” and you are done
• If required you can program two week schedules this way
• Press “ESC” two times to get back to the main screen

5.3. System Operation:

System Operation Turn the AUTO-OFF-MANUAL switch to AUTO and the system will be in stand-by, or start running
when the programmed timer is active. When you put the system in MANUAL mode, the pump will start running until
you turn the knob to OFF or an alarm occurs.

Pump Operation Automatic Mode: Press the ‘MANUAL’ button on the System Controller until ‘AUTO’ is indicated
on the display. When the timer contacts close, the pump will start and run until the scheduled timer setting has expired.
See the Controller section for setting the timer for scheduled run times.

On Mode: Press the ‘MANUAL’ button on the System Controller until ‘ON’ is indicated on the display. The pump
motor will run until the system is switched off, into “Auto” mode, or an alarm has been tripped.

5.3. Alarms:

Alarms featured on the system include:

• Leak Detection (system shutdown, alarm indication)

 Activated when the Float Switch in the system’s drip tray detects a raised liquid level. The system will go into
an alarm state and the pump will not be allowed to be run until the alarm is addressed and cleared.

• High Pressure (system shutdown, alarm indication)

 Activated when the Pressure Switch, placed on the pressure side of the pump set, detects a reading above the
factory set point (15 PSI). The system will go into an alarm state and the pump will not be allowed to run until
the alarm is addressed and reset.
 FUEL POLISHING SYSTEM TEST PROCEDURE

Once triggered alarms are addressed, each alarm can be reset via the System Controller.

6. TEST PROCEDURE

6.1 Pre-Checks

Pre-check procedures for a fuel polishing system involve the following steps:

• Inspect all system components, including pumps, filters, hoses, valves, and control panels, to ensure they are
installed correctly and in good working condition.
• Check electrical connections and ensure that all safety features are operational.
• Verify that the system is properly grounded to prevent electrical hazards.

6.2 Functional Testing

With breakers and power turned on, and pump running, check all alarms for proper operation:

Leak Detection - Manually raise the float switch located at the bottom of the leak-basin. The pump should
immediately turn off and the “Leak Detection” alarm should be indicated on the System Controller. Reset the
alarm by lowering the float switch and pushing or selecting the Alarm Reset button on the enclosure door panel.

Vacuum Alarm - Slowly, partially close the inlet ball valve. The pump should turn off and “CHANGE PRIM.
FILTER…” or “High Vacuum” alarm should be indicated on the System Controller. Open the inlet ball valve again.
Reset the alarm by pushing the Alarm Reset button on the enclosure door panel.

Pressure Alarm - Slowly, partially close the outlet ball valve. The pump should turn off (after a delay of about 1
second) and “CHANGE SEC. FILTER…” or “High Pressure” alarm should be indicated on the System Controller.
Open the outlet ball valve again. Reset the alarm by pushing the Alarm Reset button on the enclosure door panel.

Water Sensor - Jump the Water Detection Sensor Probes by placing a conductor across the two horizontal contacts.
The pump should turn off and “Water Alarm” or “PLS. DRAIN WATER PRIM FILTER …” should be indicated on
the System Controller. Remove the metal and reset the alarm by pushing the Alarm Reset button on the enclosure door
panel.

No Flow Alarm – Ensure green light indicator turns on when the system pump is on (moving fluid) and off when the
system is not running. Disconnect the cable connection on the back of the flow switch. The pump should turn off and
the “No Flow Alarm” or “CHECK FLOW” should be indicated on the System Controller. Use Flow Switch Setting &
Adjustment instructions to return the switch to the proper setting. Reset the alarm by pushing the Alarm Reset button
on the enclosure door panel.

Turn the AUTO-OFF-MANUAL switch to AUTO and the system will be in stand-by, or start running when the
programmed timer is active and monitor the system's performance, including pressure levels and pump operation, to
ensure proper functioning as per programme.

Conduct a fuel sample analysis before and after the polishing process to check for contaminants and verify fuel quality.

7. TEST REPORT
 FUEL POLISHING SYSTEM TEST PROCEDURE

Check list of Fuel polishing System Pre- Commissioning

Checked by Date
S.NO ACTIVITY

1. Check the Schematic reference as per approved drawing

2. Material Installed is as per approved material submittal.

3. MIR procedure completed and materials approved by consultant

Inspect all system components for proper installation and

4.
functioning.
5. Check all electrical terminals and connections for tightness.

6. Check the Manual operation polishing system

7. Check the Auto operation polishing system

8. Hand-Off-Auto Switch function

9. Check the leak alarm

10. Check the water alarm

11. Check the vacuum alarm

12. Check the pressure alarm

13. Check no flow

Check for installation of interface modules with BMS System in

14.
all Fuel Polishing Control Panel
Comments:

QA/QC CONSULTANT EMPLOYERS REPERSENTATIVE

Name: Name: Name:

Sign: Sign: Sign:
Date: Date: Date:
 FUEL POLISHING SYSTEM TEST PROCEDURE

Check list of Fuel polishing System Commissioning

Checked by Date
S.NO ACTIVITY

Check Pre- commissioning procedure completed and approved

1.
by consultant

2. Check the Manual operation polishing system

3. Check the Auto operation polishing system

4. Check the leak alarm

5. Check the water alarm

6. Check the vacuum alarm

7. Check the pressure alarm

8. Check no flow

Comments:

QA/QC CONSULTANT EMPLOYERS REPERSENTATIVE

Name: Name: Name:

Sign: Sign: Sign:
Date: Date: Date:
FUEL POLISHING SYSTEM TEST PROCEDURE