Installation and Maintenance of the Microfilter for Natural Gas {1261} Caterpillar

Engine:

G3304 (S/N: N4F1-UP)

G3306 (S/N: JCA1-UP; G6X1-UP)

G3306B (S/N: R6S1-UP)

G3406 (S/N: 4FD1-UP; 1RK1-UP; KAR1-UP)

G3408 (S/N: 6NB1-UP; 6RJ1-UP)

G3412 (S/N: R7A1-UP; 7DB1-UP)

G3412C (S/N: 6ZM1-UP)

G3508 (S/N: 4WD1-UP; 9TG1-UP; CPJ1-UP; WPM1-UP; WPN1-UP; DLR1-UP; CPS1-UP)

G3508B (S/N: RBK1-UP)

G3512 (S/N: 5JD1-UP; 7NJ1-UP; CSP1-UP; WPR1-UP; GNS1-UP)

G3512E (S/N: SSR1-UP)

G3516 (S/N: ZBA1-UP; 8LD1-UP; 4EK1-UP; WPS1-UP; WPT1-UP; WPW1-UP; CSZ1-UP; ZAZ1-UP)

G3516B (S/N: ZBB1-UP; ZBC1-UP; JEF1-UP)

G3516C (S/N: GSB1-UP; GZC1-UP; GZZ1-UP)

G3516E (S/N: GAS1-UP; SLY1-UP)

G3520 (S/N: HET1-UP)

G3520B (S/N: TPC1-UP; GLF1-UP; GZP1-UP)

G3520C (S/N: GZA1-UP; HEA1-UP; GZB1-UP; HEB1-UP; GZL1-UP; GZM1-UP; GZN1-UP; B9P1-UP; CWW1-UP; CWY1-UP)

G3520E (S/N: GZG1-UP; GZH1-UP; SXY1-UP)

G3606 (S/N: 4ZS1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

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Gas under pressure. Rapid discharge from disconnecting or disassembly could cause personal injury or death. See service manual before relieving pressure or charging.

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Keep hands clear of hot surfaces and pipes while engine is running and soon after switch is off.

The described filters must be only used for filtering natural gas or used for filtering methane gas from a coal mine. The technical data that is specified on the information plate must be observed. Please contact the manufacturer if you plan to use the filter for any gases that not are indicated on the information plate.

These filters are suited for explosive areas outside the housing. The interior of the housing must never contain any explosive gas mixture.

The filters are conductive. The operator must make sure that grounding is maintained under all circumstances. The operator must also make sure that the grounding is not impaired by any attachments. The conductivity must be tested and approved after each service.

Components and Reference Dimensions

G-Series Filters

Illustration 1	g01998394
(1) Locking screw (2) Upper housing (3) O-ring seal (4) O-ring seal (5) Threaded rod (6) Filter element (7) Lower housing

Illustration 2	g01872320
Refer to Table 1 for reference dimensions.

Table 1

Filter Assembly	Dimensions				Weight	Filter Element
G-Series	A	B	C	D
321-6969	130 mm (5.1 inch)	495 mm (19.5 inch)	43 mm (1.7 inch)	335 mm (13.2 inch)	5.5 kg (12.1 lb)	322-4981
321-6970	164 mm (6.5 inch)	685 mm (27 inch)	48 mm (1.9 inch)	520 mm (20.5 inch)	9.6 kg (21.2 lb)	322-4984
321-6971	250 mm (9.8 inch)	1061 mm (41.8 inch)	74 mm (2.9 inch)	750 mm (29.5 inch)	26.6 kg (58.6 lb)	322-4985

F-Series Filters

Illustration 3	g01998414
(1) Upper Housing (2) Flat seal (3) Filter element (4) Lower housing

Illustration 4	g01872153
Refer to Table 2 for reference dimensions.

Table 2

Filter Assembly	Dimensions				Weight	Filter Element
F-Series	A	B	C	D
326-6199	500 mm (19.7 inch)	1372 mm (54.0 inch)	258 mm (10.2 inch)	400 mm (15.7 inch)	102 kg (224.9 lb)	316-0680
311-5944	790 mm (31.1 inch)	1640 mm (64.6 inch)	336 mm (13.2 inch)	480 mm (18.9 inch)	230 kg (507.1 lb)	316-0680

Safety

Handling Natural Gas

Natural gas poses a considerable risk and incidents must be prevented by all means. Ensure that all notes on hazardous substances are heeded when natural gas is filtered.

• The appropriate safety precautions must be performed.

• Flush the respective section of the pipe and the filter with an inert gas prior to all work.

• Verify the absence of an explosive atmosphere.

Transportation and Storage

• The transportation of filters of natural gas must be carried out by specialized personnel.

• Filters that are damaged must not be installed.

• Filters and filter elements must not be opened prior to use. Store the filter and filter elements in the original packing.

Long periods of storage must meet the following conditions:

• Inside

• Dry

• Free of dust

• An ambient minimum temperature of 1° C (34° F)

Note: When the filter is stored for long periods the threads must be checked for corrosion.

Grounding

Filters for natural gas must be grounded. Establish the appropriate bond for grounding by using the flange connection. Insulating materials must not be used. Check the conductivity and document the conductivity.

Filter Operation

• Do not perform any unapproved modifications on the filters. Unapproved modifications will endanger the operational safety. Unapproved modifications may cause damage or personal injury.

• Avoid sudden pressure fluctuations. If the pressure increases too quickly or the pressure drops too quickly, damage to the filter may occur.

• The use of accessories with an external power supply creates a hazard from electrical voltage. Heed the operating instructions for the electrical accessories. Work on electrical accessories only when the accessories are de-energized.

Maintenance

• Always maintain the prescribed service intervals. Failure to comply with prescribed service intervals may cause the filter to function incorrectly.

• Maintenance must be performed by specialized personnel only.

• Only use suitable tools when you work in an explosive environment.

Disassembly and Disposal

• Flush the entire system with an inert gas before disassembling filters.

• Always read the material safety data sheet of the respective gas. Dispose of all components of the filter according to the applicable regulations.

Filter Installation

Preparation

Note: The filter must always be used at the location with the lowest temperature of the gas in the system.

• Ensure that the system of the pipeline is free of any contamination.

• A pressure regulator and a temperature regulator must be used. The regulators must make sure that the limit values are not exceeded.

• A suitable device for the release of pressure must be installed for the filter. The device for the release of pressure must prevent natural gas from escaping into the atmosphere.

• If necessary, flush the section of the pipe with an inert gas.

• Depressurize the system.

• Check the filter for possible damage that occurred during the transport. Do not install a damaged filter.

• If necessary, construct a device for support. Ensure that the device can bear the weight of a filter that is completely filled with liquid.

Installation

• Check the direction of the flow of the gas when the filter is installed in the pipeline. The gas must flow through the filter in the direction that is indicated by the arrow on the upper housing.

• The filter must always have a vertical installation.

• Ensure that sufficient clearance below the filter so that the filter can be easily disassembled.

• Integrate the filter into the ground plane by using the ground lugs.

• Make sure that there is a metallic connection between the ground lugs and the customer's piping.

• Remove all nonconductive materials until the base material becomes visible on the connections.

• Never use materials that would act as an isolator.

• Make sure that the ground connection has continuity. Keep a record of each measurement.

• Establish an electrical connection for any electronic accessories.

• Make sure that any electrical connection meets all electrical codes.

• Flush filters with an inert gas in order to expel atmospheric oxygen.

• Repressurize the section of the pipe and check the section of the pipe for leaks.

Maintenance Work and Intervals

Table 3

Component	Maintenance	Maintenance Interval
		Daily	Weekly	6 months	Yearly (1) (2) (3)
Entire filter	Clean the outside of the filter.		X
Conductivity	Verify			X
Housing for G-Series filter	Check the threads for a proper fit.			X
Filter Element	Replace				X
Housing	Replace the O-ring or the flat seal.				X

( 1 )	Replace regardless of the operating hours
( 2 )	Replace the element when the differential pressure reaches 0.35 bar (5.1 psi) for a low pressure filter.
( 3 )	Replace the element when the differential pressure reaches 0.6 to 0.8 bar (8.7 to 11.6 psi) for a high pressure filter.

Preparation for Maintenance

Follow these guidelines before performing maintenance on the filters.

• Flush the section of the pipe with an inert gas.

• Verify the absence of an explosive atmosphere.

• Shut off the gas supply to the filter.

• Depressurize the filter housing. Ensure that the pressure has been positively relieved.

• Allow the filter to cool down.

Draining the Condensate

• Take appropriate measures in order to prevent the gas from escaping into the atmosphere.

• Check and drain any condensate in the filter if liquid contamination is suspected in the fuel.

Cleaning the Filter Housing

Note: Beware of static charges. Clean the filter housing with a moist cloth. Using a dry cloth to clean the filter housing could represent a source of ignition due to the accumulation of a static charge.

Dust that has collected on the filter can pose a potential risk. The filter housing must be cleaned regularly. The intervals of cleaning depends on the concentration of dust in the air. Higher concentrations of dust will require more frequent cleaning.

• Wipe the filter housing with a moist cloth at regular intervals.

• Moisten the cloth with water only. Remove excess water from the cloth and do not use detergent.

Verifying the Conductivity

• Measure the electrical conductivity between the piping and the filter housing at six month intervals.

• Restore the conductivity as often as necessary.

• Document the conductivity after every measurement.

Replacing the Filter Element

Note: Use the proper tools to open and close the filter housing. Do not apply the tool to the threaded area. Do not damage the threads.

G-Series Filters

Illustration 5	g01885494
(1) O-ring for the filter element (2) Filter element (3) O-ring for the filter housing (4) Lower housing

1. Perform the preparations for maintenance.

2. Unscrew the lower housing (4) and remove the housing.

3. Unscrew the filter element (2) and O-ring (1) as an unit. Discard the filter element and discard the O-ring.

4. Discard O-ring (3) .

5. Insert a new filter element (2) and O-ring (1) as an unit.

6. Ensure that the O-ring is seated and hand tighten the filter element.

7. Insert a new O-ring (3) for the housing. Ensure that the O-ring is properly seated.

8. If necessary, apply a thin coat of grease on the threads on the housing. Ensure that the grease does not contact the O-rings or the sealing surfaces.

9. Connect the upper housing to the lower housing. Hand tighten the housings until the alignment arrows align.

10. Close the manual drain valve.

11. Test conductivity and document the results.

12. Check the housing for tightness.

F-Series Filters

A filter housing can accommodate a maximum of ten filter elements. The following instructions apply to a single filter element per filter housing. These instructions could also apply to several filter elements.

Illustration 6	g01886337
(1) Flat seal (2) O-ring for the filter element (3) Filter element (4) Lower housing

1. Perform the preparations for maintenance.

2. Remove the nuts from the lower housing.

3. Remove lower housing (4) .

4. Remove flat seal (1) and discard the seal.

5. Unscrew the filter element (3) and remove the filter element. Discard O-ring (2) .

6. Insert a new filter element (3) and O-ring (2). Ensure that the O-ring is properly seated.

7. Insert a new flat seal (1). Ensure that the flat seal is properly seated.

8. Reassemble the filter housing. Tighten the screws.

9. Close the manual drain valve.

10. Test and document conductivity.

11. Check the housing for leakages.

Check the Threads for a Proper Fit

1. Perform the preparations for maintenance.

2. Open the filter housing at regular intervals.

3. Check that the threads are sufficiently greased. Ensure that the threads have a proper fit.

4. If necessary, apply a thin coat of grease on the threads of the housing.

5. Reassemble the filter housing.

6. Check the filter housing for leakages.

Disposing of Filter Elements

The filter element might have been contaminated by the filtered substances. Consult the notes on hazardous substances for the filtered gas. Ensure that the applicable regulations for disposal are followed when you dispose of any filter elements.

Correcting Faults

Procedure for Pressure Spikes

A pressure spike can occur when valves are opened suddenly. The filter element may still be usable after a pressure spike. The filter element must be checked for damage. A damaged filter element must be replaced.

1. Flush the section of the pipe and the filter with an inert gas.

2. Verify the absence of an explosive atmosphere.

3. Block the supply of gas to the filter.

4. Depressurize the filter housing. Make sure that the pressure has been positively relieved.

5. Allow the filter housing to cool.

6. Remove the filter element and check the filter element for damage.

7. Discard any damaged filter element.

Note: Contact the manufacturer if the blowing of the pressure occurs frequently.

Insufficient Capacity of Filtration

If the capacity of filtration is insufficient with regular maintenance, then the ambient conditions of use may not be matched to the filter that is used. Also, the rating of filter may not be sufficient. Contact the manufacturer.