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Slide 2 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 JTOT Jet A Thermal Oxidation Test Training Memphis Refinery Lab Tools Material Pre-Assembly Assembly Purpose Test Slide 3 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 2 Purpose for JTOT The Jet Fuel Thermal Oxidation Tester JTOT has been designed to produce an accelerated (higher temperature) version of conditions that might be experienced by a fuel flowing through a typical engine system. The test measures the high temperature stability of gas turbine fuels to ensure the Jet fuel meets the quality standards for temperature stability and deposit decomposition products within the fuel system. Slide 4 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 3 Purpose for JTOT During the test, fuel is pumped at a fixed volumetric flow rate through a heater, after which it enters a precision stainless steel filter where fuel degradation products may become trapped. For example, Commercial Jet fuels must be found to be thermally stable at a fuel temperature as high as 163 o C (325 o F). The Fuel is rated by measuring: Pressure drop (mm Hg) Tube deposits. Slide 5 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 4 Safety PPE The operator must comply with all Valero Safety standards and be appropriately dressed with the following: Fire Resistant (FRE) Lab Coat Safety Glasses with Side Shields Solvent Resistant Gloves Slide 6 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 5 Equipment Required Slide 7 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 6 Tools and Equipment 1000 ml Graduated Cylinder Nut Driver Allen Screwdriver Piston Puller 1000 ml Beaker 9/16 Wrench Slide 8 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 7 Materials Required Prior to beginning the test, you must ensure you also have the following: Jet A Sample Appropriate Filters Sample Filters Differential Filter Pre-Filter Appropriate O-Rings Heater Tube Appropriate Insulators Distilled Water Slide 9 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 8 Pre-Assembly Several equipment components must be inspected and pre-assembled for each Jet TOT. These include: Trap Assembly Fuel Reservoir Assembly Filter Funnel Holder Assembly Heater Assembly Pre-Filter Assembly Water Reservoir Assembly Fuel Reservoir Assembly Heater Tube Assembly Filter Section Assembly Remember that new components (heater assembly, o-rings, and filters) are required for each new test. DO NOT REUSE! Assembly of each component will now be discussed. Slide 10 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 9 Trap Assembly This is the trap, it will be filled with distilled water. This is the distilled water reservoir, this is the top to it. Notice it has an O-ring. This will hold the distilled water. These are the six nuts with washers that are used to assemble the top to the O-ring. Slide 11 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 10 Fuel Reservoir Assembly This is the fuel reservoir. Its a piston cylinder. Notice it also has an O-ring. Notice that the bottom of the piston is flush with the bottom of the cylinder at the start of the test. Thats the cap. Thats the stand that holds the Fuel reservoir. This is the filter funnel holder. It attaches to the top of the fuel reservoir when we are ready to filter our sample into the container. Slide 12 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 11 Heater Assembly This is the heater assembly with the insulators. And the nuts that hold the insulators and o-rings in place. Slide 13 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 12 Pre-Filter Assembly This is the pre-filter assembly. Notice it also has an o-ring. It has three nuts that assemble the two pieces. A new 0.45 um millipore filter is installed in it. Slide 14 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 13 Water Reservoir Assembly Filling and assembling the water reservoir. The water reservoir should be clean. The rings should be in place in the groove. You may need to press the o-ring into the groove with your finger. We are going to fill it with distilled water. Be sure to fill it completely to the top of the reservoir. Install the nuts. Ensure they have the washer on prior to assembly otherwise its difficult to take apart later on. Finger tighten all the nuts in a crisscross pattern to secure the lid evenly. You want to go across then skip one. Then go back across, then the next one. Now tighten the nuts with the nut-driver in the same crisscross pattern. Do not overtighten. Slide 15 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 14 Fuel Reservoir Assembly Make sure that the o-ring is intact. You want to feel and make sure that there is no foreign matter on the o-ring surface that could cause the seal to fail. Also ensure the o-ring is secured in the groove at the bottom of the Reservoir. The piston must be level with the bottom of the Fuel Reservoir. Be careful not to pull the piston out of the cylinder. When you place the cylinder in the assembly stand, it will press it up to the proper level. The filter/aeration funnel screws on the top of the Fuel Reservoir in a clockwise rotation. You are ready to put the filter paper in. You are now ready to add the sample through the filter into the Fuel Reservoir. Slide 16 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 15 Heater Tube Another consumable item that we use is going to be the standard heater tube. Its a polished aluminum tube made to the exact specifications of the specified materials, well look at those later on. The tube kit comes with the tube. Inside the tube kit is the differential pressure filter, with a red dot on it and three o-rings. The heater tube has a hole in one end and the other end is solid. The end with the hole in it is where the probe is going to be. Slide 17 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 16 Heater Tube Assembly During the assembly it is essential that you wear gloves. Holding the heater tube at one end, carefully insert it into the heater tube housing. Note that the open end of the heater tube must be oriented up to permit thermocouple insertion (the other end is plugged.) There are four ceramic insulators. The one with the small collar goes in first, then an o-ring goes on top of that. Then a large collar. (reverse Oreo white/black/white) Place the nut on top to lock them in. (finger tight only) When properly installed you will see the white of the last insulator protruding through the nut. Repeat the process on the bottom side. Observe the heater tube through the fuel discharge hole. You should be able to see the holder bisecting the entrance of the tube. Once everything is in position, tighten down the nuts on both ends securely. Confirm that the shoulder of the rod is still in place. Insert the filter with the red side up. Place the 3 rd o-ring on top of the filter. The heater tube section is now completely assembled. Slide 18 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 17 Filter Section Assembly Youll notice that the Millipore filters are packed with one white Millipore filter sandwiched in between two blue guard membranes. You do not want to get the guard membranes into the filter section or the test will fail. Double check to make sure that you do not have the guard membrane on your filter. Ensure the metal backup screen is in place Place the Millipore filter against the metal backup screen. Check to make sure the o-ring is in place and clean. Assemble the two housing pieces, insert the 3 screws and tighten with the nut driver. Connect the pre-filter assembly to the reservoir cover and finger tighten. Slide 19 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 18 Filling the water trap. Fill the water Trap with Distilled water at least to the shoulder. Attach the glass jar to the air trap assembly and place a beaker under the air trap assembly drip line. Slide 20 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 19 Testing Slide 21 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 20 Pre Test Checks Make sure you have that in the right place. Tighten it up. Slide 22 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 21 Initiate Test Aeration Aeration now finished, you are going to blow out the tube. Finish Assembly Start Sample Cylinder Purge Slide 23 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 22 Start Test See the pressure is going up. Now is a good time to observe if you have any leaks. If any leaks are noted, tighten connections immediately. Note if the pressure is not going up there is probably a leak so re-check. When the pressure reaches about 500 psi, the Jet-TOT will automatically: Turn the heater power to ON at 80% initial power Record the time that the heater turned on Increase the temperature to the specified Set Point Begin counting down the Test Timer When the pressure stabilizes the Jet-TOT will automatically Tare to 0 and a large T will appear on the screen. The test will now run automatically and finish in about an hour and 49 minutes. Slide 24 Tools Material Pre-Assembly Assembly Purpose Test 4/24/2015 23 Shut Down and Clean-up