User manual FLUKE GB-75

[. . . ] Operation and Maintenance Manual GB-75TM and GB-152TM Gas Booster With Control Kit ©1998-2008 DH Instruments, a Fluke Company GB-75TM AND GB-152TM OPERATION AND MAINTENANCE MANUAL This equipment described in this manual is designed and manufactured for the intended purpose of generating high pressure gas. Certain precautions need to be followed during installation and operation of this device. Reading and understanding the material is essential to the safe and correct operation of the unit. Pressurized equipment is potentially dangerous. The equipment described in this manual generates and controls very high gas pressures. [. . . ] Set the drive pressure to the maximum desired high pressure output divided by the booster ratio (75 for GB-75, 152 for GB-152). For example, if the desired high pressure output of a GB-152 is 70 MPa (10 000 psi), set the drive air pressure to 70 MPa/152 = 460 kPa (67 psi). Remember that when the SHUTOFF valve is in the ON position, the booster will operate until the high pressure output is equal to the drive air setting times the booster ratio. The DRIVE ADJUST regulator is NOT self venting so it cannot be used to set pressure lower than the current pressure when the SHUTOFF valve is OFF. If you overshoot the desired set point, set the SHUTOFF valve to ON until the DRIVE pressure is lower than your desired setting. Then set the SHUTOFF valve to OFF and use the regulator to adjust the pressure in the ascending direction. The booster will begin to cycle and will continue to cycle until it stalls. When it stalls, the high pressure output is roughly equal to the drive pressure setting times the booster's ratio (75 or 152). ©1998-2008 DH Instruments, a Fluke Company Page 12 3. OPERATION 3. 3. 1 OPERATION GENERAL OPERATING PRINCIPLE AND INFORMATION Refer to Figure 3. The purpose of the GB booster is to automatically boost gas pressure to very high pressure. The value of very high pressure that is generated depends on the drive air pressure setting. The unit generates high pressure using a Pneumatically Operated Gas Booster Pump and a Drive Air Control Kit. GAS BOOSTER PUMP The booster pump is a Pascal press utilizing two pistons connected together on the same axis having a normal area ratio of 75:1 (GB-75) or 152:1 (GB-152). The booster is a two-stroke, single stage reciprocating pump that generates gas pressures 75 or 152 times greater than the shop drive air applied to the pump. The pump operates automatically, provided drive air is supplied to the DRIVE ADJUST regulator and the regulator is set to at least 140 kPa (20 psig). Operation is continuous until the outlet pressure is 75 (GB-75) or 152 (GB-152) times the shop drive air pressure. At this point, the opposing forces within the pump reach equilibrium and the pump stalls. For example, using a GB-75 with the drive air pressure set to 500 kPa (73 psig), the pump will run until the high pressure output reaches 75 x 0. 5 = 37. 5 MPa (5 450 psig). The Shop Drive Air section (low pressure) consists of a piston, cylinder, air cycling valve, pilot valve and vent section. This section provides the reciprocating action and compression force needed to operate the booster and generate the high pressure gas. Drive air is channeled to the appropriate side of the piston (compression or suction stroke) by the air cycling valve. When the piston reaches full stroke, a pilot valve is mechanically activated causing the air cycling valve to change position. Shop drive air is routed to the opposite side of the piston reversing piston direction where a second pilot valve is activated repeating the process. [. . . ] Repair or replace leaking regulators. · · Never tighten a fitting while it is under pressure. If pressure is in the system and the fitting should fail while being tightened, you or those around you may be injured. Do not over-torque the DH500 fittings that are inside the booster. It is possible that a leak exists in the high pressure section of the gas booster. If no leaks can be found following the above procedures, it is likely the problem is within the booster. [. . . ]