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JFTOT II J

UEL

HERMAL

XIDATION

ESTER

October 2003
Version 2.1 or later

59297

300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA

TELEPHONE: 281-580-0339 • FAX: 281-580-0719

Summary of Contents for Alcor JFTOT II

Page 1: ...JFTOT II JET FUEL THERMAL OXIDATION TESTER October 2003 Version 2 1 or later 59297 300 BAMMEL WESTFIELD ROAD HOUSTON TEXAS 77090 USA TELEPHONE 281 580 0339 FAX 281 580 0719...

Page 2: ...of PAC This manual and all information disclosed herein shall not be used to manufacture construct or fabricate the goods disclosed herein shall not be exploited or sold shall not be copied or otherw...

Page 3: ...r of this equipment to establish appropriate safety and health practices and to determine applicabilitylimitationspriortouse For safe operation this equipment must be electri cally grounded by way of...

Page 4: ...nting up Failure to ship the MCRT with legs up will damage the MCRT Remove all samples and accessories from the MCRT remove and clean the glass jar remove any loose depos its from the oven lid or exha...

Page 5: ...ch using either one or two Ps The JFTOT 230 is used to perform the standard quality control tests in the refinery laboratory The JFTOT II JFTOT 230 240 has had several names Included are UFTOT UFTOT 2...

Page 6: ...essage to become scrambled To refresh the display and unscramble messages press the REFRESH key ABBREVIATIONSAND GLOSSARY These manuals use certain units abbreviations shown WARNING HOT SURFACES durin...

Page 7: ...red handled repaired altered or operated contrary to current API PAC recommendations Warranty will not be granted for removal and installation of parts components or accessories or for normally requir...

Page 8: ...JFTOT II User s Manual Rev C Page viii THISPAGEINTENTIONALLYBLANK...

Page 9: ...JFTOT II JET FUEL THERMAL OXIDATION TESTER Operation Manual October 2003 Version 2 1 or later 300 BAMMEL WESTFIELD ROAD HOUSTON TEXAS 77090 USA TELEPHONE 281 580 0339 FAX 281 580 0719...

Page 10: ...JFTOT II Operation Manual Rev C JFTOT II Operation Manual Rev C Page 2 THISPAGEINTENTIONALLYBLANK...

Page 11: ...nstall aeration tube and dryer 7 2 7 Pan Installation 7 2 8 First Time Power ON 7 3 GENERALOPERATIONALINFORMATION 9 3 1 Computer Display Screen and Keypad 9 3 2 Main Operations 10 4 PERFORMINGATEST 17...

Page 12: ...Method 29 6 APPENDICES 31 A1 Precautionary Statements For Hazardous Materials 31 A2 JFTOT Equipment Description 32 A3 Heater Tube Temperature Profile 41 A4 Routine Maintenance 41 A5 Materials Supplies...

Page 13: ...for a test such as assembling the hardware aerating the sample and bleeding air from the system With these exceptions the JFTOT is operated by entering parameters and other test setup data into the c...

Page 14: ...is an optional feature as is the time reactor Future work with this device can be expected to yield details for require ments and specifications on operation Currently it is an option for use in resea...

Page 15: ...77 cm wide by 88 cm high by 52 cm deep plus clearances 6 cm in front for knobs and 15 cm on right side for fan Mounting feet 72 cm wide by 35 cm deep Printer size 38 cm wide 2 1 2 Weight 115 Kg inclu...

Page 16: ...JFTOT II Operation Manual Rev C Page 4 FIG2 1 FRONTVIEWOFTHEJFTOT FIG2 2 LOWERRIGHTHANDSIDEVIEWOFTHEJFTOT...

Page 17: ...JFTOT II Operation Manual Rev C Page 5 FIG2 3 ACCESSORYCOMPONENTSPACKAGEDWITHJFTOTII...

Page 18: ...es are not provided but are required for normal operation See MATERI ALS SUPPLIES AND SPARES in the Appen dix 2 3 REAR PANEL INSPECTION The fluid level in the coolant reservoir should be about 50 Chec...

Page 19: ...tool Plug the thermocouple into the socket of the sliding scale assembly and plug the lead into the thermocouple receptacle on the cabinet 2 6 INSTALL AERATION TUBE AND DRYER Connect the fitting of th...

Page 20: ...JFTOT II Operation Manual Rev C Page 8 THISPAGEINTENTIONALLYBLANK...

Page 21: ...the center of the key using slow and deliberate actions This prevents accidental selections from being made and prevents messages or values from scrolling too quickly When making a menu selection the...

Page 22: ...d screen to a printer or computer via the serial interface REFRESH rewrite the current display screen Remember this manual is applicable to both the JFTOT 230 and JFTOT 240 Therefore references and di...

Page 23: ...nless the system is not calibrated the clock is stopped or there is a test fragment in memory If this configuration is not correct the JFTOT will consider it a hardware failure e Hardware failures If...

Page 24: ...ata Then press ENTER again for the TEST RUNNING display to restart the test 3 2 2 View Test Data Operation The VIEW TEST HISTORY menu allows the important DP1 test data to be viewed without the need f...

Page 25: ...Operation The Autocal TC menu allows the operator to calibrate the thermocouple and temperature measurement system to known calibration standards a Ice at 0 C b Freezing point of Tin 232 C c Freezing...

Page 26: ...ntains memory power for all calibration information and test data Battery Life When the clock is off and the JFTOT is powered on the clock will start automatically and the CLOCK MENU will be displayed...

Page 27: ...JFTOT II Operation Manual Rev C Page 15 FIGURE3 1 EXAMPLEOFTESTDATAWHENREAL TIMETRANSMITISSETTO TIMED...

Page 28: ...JFTOT II Operation Manual Rev C Page 16 THISPAGEINTENTIONALLYBLANK...

Page 29: ...of skin irritation from solvents WARNING These solvents will irritate the skin after a short time Use rubber gloves It is recommended that gloves not be reused The solvent is flammable and harmful if...

Page 30: ...center section see Section 5 Heater Tube Deposit Rating Reject any tube showing scratches unpolished area or other visual defects b examine the tube for straightness Roll the tube on a flat surface an...

Page 31: ...k for proper mating Matching numbers are stamped on the inside sur faces of the caps and bus bar These numbers must match and face each other To ensure consistent reassembly the caps are normally not...

Page 32: ...ass jar with distilled water then attach to air trap assembly Place a 1000mL beaker under the air trap assembly dripline 4 7 PREPARATION OF TEST FUEL NOTE Test method results are known to be sensitive...

Page 33: ...general purpose retentive qualitative filter paper b prevents spillage during fuel aeration Measure about 600 ml of test fuel using a clean graduated cylinder Place the filter paper in the funnel Pou...

Page 34: ...any fuel Screw the fuel reservoir on to the drive assembly Attach the reservoir outlet line to the top of the prefilter and finger tighten snugly Attach the reservoir outlet line to the heater tube h...

Page 35: ...EST RUNNING display Turn the FLOW CONTROL SELECTOR VALVE s to the RUN position The system fuel pressure will increase At about 300 psig the bypass valve s will cycle close and open NOTE the bypass val...

Page 36: ...pear in the lower right corner of the display when the P values have been tared The JFTOT will record automatically the P If the P exceeds 250mmHg the JFTOT will open the appropriate bypass valve When...

Page 37: ...ll start down automatically and the MAIN MENU willbedisplayed To request a manual termination of a test press EXIT A message will appear asking if the test is to be terminated Press EXIT to terminate...

Page 38: ...ion Using tweezers remove the test filter and O ring from the discharge chamber and discard Remove the hex nuts and shoulder insulators Slide the heater tube out of the housing Do not touch the tube i...

Page 39: ...and empty the fuel and water in the jar into the appropri ate waste container Check the pan underneath the JFTOT for evidence of fuel leaks If fuel is found check the reservoir lip seal for damage and...

Page 40: ...JFTOT II Operation Manual Rev C Page 28...

Page 41: ...r tube such that the side with the maximum deposit is visible If necessary remove adapter and rotate heater tube slightly in holder to better reveal the maximum deposit 5 1 7 Compare the maximum heate...

Page 42: ...y these and do not attempt to estimate a numerical grade Example 1 a heater tube has a maximum deposit falling between Color Standard Codes 2 and 3 with no other colors present The overall tube rating...

Page 43: ...wing surfaces or electric arcs A1 3 Iso Propanol 2 Propanol Keep away from heat sparks and open flame Keep container closed use with adequate ventilation Avoid buildup of vapors and eliminate sourceso...

Page 44: ...ant value by maintaining a constant leak The control is precise because the regulator is only exposed to water which is displaced by the test fuel An absolute pressure transducer measures the fuel pre...

Page 45: ...t is matched to the electrical resistance of the heater tube The JFTOT provides both temperature indication MAN mode and automatic control AUTO mode The input signal to the JFTOT computer is from a th...

Page 46: ...s The computer contains a crystal oscillator to maintain accurate time The time remaining in the test is displayed in minutes and sec onds A2 7 Technical Specifications Setpoint range 180 C to 380 C F...

Page 47: ...Air Bleed 17621 10 Drip Flow Water 11 Water Beaker 17643 12 Water Reservoir 63320 13 Water Outlet Fitting 28351 14 Water Reservoir Vent Line 43931 15 Water Reservoir Inlet Line 43930 16 AdditionalFitt...

Page 48: ...JFTOT II Operation Manual Rev C Page 36 FIGUREA2 2 1 ASSEMBLYDRAWINGOFHEATERTUBETESTSECTION...

Page 49: ...JFTOT II Operation Manual Rev C Page 37 FIGUREA2 2 3 HEATERSECTIONANDTIMEREACTOR WITHOUTINSULATION 2 P 240ONLY FIGUREA2 2 2 HEATERSECTIONWITHNOTIMEREACTOR 1 P MODEL230OR240...

Page 50: ...JFTOT II Operation Manual Rev C Page 38 FIGUREA2 2 4 TIMEDELAYREACTOR MODEL240ONLY 35375 PLUSLINE 43925...

Page 51: ...JFTOT II Operation Manual Rev C Page 39 FIGUREA2 3 SYRINGEPUMPANDFUELRESERVOIR...

Page 52: ...JFTOT II Operation Manual Rev C Page 40 FIGUREA2 4 WATERRESERVPOR 63320...

Page 53: ...ed more than 2 C from the initial value readjust the HEATER POWER and begin again at the 56 mm position If drift is less than 2 C proceed to position 32 mm A3 5 Return the thermocouple to the 39 mm po...

Page 54: ...ssue AluminumFoil Tweezers Rubber Squeeze Bulb Silicone Grease Gearbelt Beaker 1000 ml plastic A5 3 The following items are required to be replaced after each test and therefore must be stocked in acc...

Page 55: ...lowing additional items are not supplied with the JFTOT but are required for normal operation ALCOR Visual Tuberator Solvent may be technical grades of n heptane or2 2 4 trimethylpen tane technical gr...

Page 56: ...38012 DisposableGloves 100 box 83033 Filter Paper Box of 100 27052 Fuse 6 25 amp 29726 Fuse 6 amp 29685 Fuse 2 amp 29706 Fuse 750 amp 29725 Gearbelt 31287 Heater Tube and Filter Kit 10 Box 91652 Insu...

Page 57: ...JFTOT II JET FUEL THERMAL OXIDATION TESTER D3241 Manual October 2003 Version 2 1 or later 300 BAMMEL WESTFIELD ROAD HOUSTON TEXAS 77090 USA TELEPHONE 281 580 0339 FAX 281 580 0719...

Page 58: ...JFTOT II D3241 Manual Rev C Page 2 THISPAGEINTENTIONALLYBLANK...

Page 59: ...est Section 6 2 5 Assembly and Installation of Pre Filter 9 2 6 Assembly of Water Reservoir 10 2 7 Assembly of Air Trap 10 2 8 Preparation of Test Fuel 10 2 9 Assembly of Fuel Reservoir Section 13 3 T...

Page 60: ...JFTOT II D3241 Manual Rev C Page ii THISPAGEINTENTIONALLYBLANK...

Page 61: ...nt If a test is accidentally terminated after aerating the fuel sample restarting the D3241 test requires the fuel be aerated again However the CUSTOM test will recognize if an aeration has been perfo...

Page 62: ...JFTOT II D3241 Manual Rev C Page 2 THISPAGEINTENTIONALLYBLANK...

Page 63: ...seal mating surface for scratches To prevent leaks there must be a proper seal between the piston and lip seal CAUTION The lip seal is made from virgin Teflon and is very soft Use extreme care when h...

Page 64: ...sh all surfaces of the piston and lip seal with solvent Do not remove the lip seal from the piston 7 Flush inside surface of the fuel reservoir cover with solvent and scrub with a nylon brush Then flu...

Page 65: ...ver lines with solvent and thoroughly blow dry using a squeeze bulb 15 Flush the reservoir outlet line with solvent and thoroughly blow dry using a squeeze bulb 16 Flush the heater section outlet line...

Page 66: ...with solvent 2 4 ASSEMBLY OF HEATER TUBE TEST SECTION 1 A new ALCOR heater tube test filter and three high temperature O rings are required for each test NOTE Heater tubes should not be re used Tests...

Page 67: ...eject the tube as the deposit forming characteristics on the tube will be affected 4 Onto one end of the heater tube sequentially install a tapered insulator wide end out high temperature O ring shoul...

Page 68: ...ed check for proper mating Numbers are stamped on the inside faces and these must be the same and face each other To ensure consistent reassem bly the caps are normally not completely re moved from th...

Page 69: ...25 mm diameter 2 Using a clean flat bladed unserrated tweezers install the filter element back up screen in the pre filter housing recess 3 Using a clean tweezers place the 0 45 m white membrane filt...

Page 70: ...o the water reservoir cover holes and tighten uniformly with the nut driver 5 Put the water reservoir over the quick connect fitting on the test platform and press down firmly until seated A snap will...

Page 71: ...e drive pump is at the bottom 4 Lubricate the lip seal with fuel Place the piston in the center of fuel reservoir stand Press the reservoir down over the piston until seated 5 Place the O ring in the...

Page 72: ...ure is to set the reservoir containing the filtered fuel into a hot or cold water bath as required to bring the fuel temperature within the limits Record the temperature of the test fuel 11 Attach the...

Page 73: ...ver in place taking care the O ring stays in the groove Remove the fuel reservoir from the stand and wipe the outside of the reservoir to remove any fuel 3 Screw the fuel reservoir onto the drive asse...

Page 74: ...JFTOT II D3241 Manual Rev C Page 14 JFTOTIIREADYFORD3241TEST...

Page 75: ...to confirm 3 2 VENTING THE FUEL SYSTEM 1 Turn the FLOW CONTROL SELECTOR VALVE to the SYSTEM VENT position On the Model 240 leave the bottom P2 valve set to the RUN position 2 Press F3 to turn the Driv...

Page 76: ...n on the coolant pump WARNING HOT SURFACES the heater test section and lines are heated Do not touch 6 Remove the beaker from under the drip line and replace with a clean beaker 7 Adjust coolant flow...

Page 77: ...ation Press any key except EXIT to save the test data NOTE Test number 8 is used as an example in the following displays 4 A message will be displayed to vent the system pressure below 0 35MPa 50 psig...

Page 78: ...inting by pressing EXIT twice Correct the problem then press F1 to print the report 4 When the JFTOT has finished transmitting data to the printer the VIEW TEST HISTORY screen will be displayed Press...

Page 79: ...F4 F5 F6 F7 F8 F9 F10 PE 3 Disconnect and remove the heater section outlet line 4 Disconnect the heater section bypass line fitting 4 DISASSEMBLY 5 Raise the heater tube thermocouple to the top of th...

Page 80: ...er tube with solvent 13 After the solvent has evaporated from the heater tube place the heater tube in the original plastic container and seal it with a cap Mark it with the appropriate identification...

Page 81: ...19 Disconnect the water reservoir push down the collar on the quick connect fitting to release the fitting Remove the reservoir from the apparatus and place it in a cleaning pan 20 Remove the water re...

Page 82: ...er tube deposit rating s Maximum recorded pressure drop across the filter or the time required to reach a pressure differential of 25 mmHg NOTE The tube rating and P criteria are a means of deciding w...

Page 83: ...JFTOT II JET FUEL THERMAL OXIDATION TESTER Calibration Manual October 2003 Version 2 1 or later 300 BAMMEL WESTFIELD ROAD HOUSTON TEXAS 77090 USA TELEPHONE 281 580 0339 FAX 281 580 0719...

Page 84: ...JFTOT II Calibration Manual Rev C JFTOT II Calibration Manual Rev C Page 2 THISPAGEINTENTIONALLYBLANK...

Page 85: ...ev C Page i TABLE OF CONTENTS 1 INTRODUCTION 1 2 CALIBRATION OF HEATERTUBETEMPERATURE CONTROLLER 3 3 CHECKING VALIDITYOF PTRANSDUCER DPT 13 4 CHECKING VALIDITYOF FUELFLOW RATE 17 5 CHECKINGAERATION FL...

Page 86: ...JFTOT II Calibration Manual Rev C Page ii THISPAGEINTENTIONALLYBLANK...

Page 87: ...accurate to determine if there is a problem with a transducer Basically the air is removed from the lines throughout the system and the transducer is zeroed Then a measured height of fuel is added and...

Page 88: ...JFTOT II Calibration Manual Rev C Page 2 SAMPLEOFQUICKREFERENCECARD...

Page 89: ...ding with the AUTOCAL to allow for temperature stabilization and warm up of JFTOT 2 3 The screen will display the MAIN MENU 2 4 Press F6 AUTOCAL TC for the PERFORM CALIBRATION screen The display will...

Page 90: ...you are asked whether or not you want to keep the value for determining correction Press any key except EXIT to keep the temperature value If you keep the value you will proceed with the Tin Calibrati...

Page 91: ...the PERFORM CALIBRATION AUTOCAL TC display You must keep retain in temporary memory a valid ice water calibration tempera ture to continue to the Tin Calibration point 2 9 If a proper ice bath tempera...

Page 92: ...is time the screen will display the prompt INSERT THERMOCOUPLE Carefully lower the thermocouple to the bottom of the well noting the total distance of travel on the slide assembly scale Raise it 2 5 m...

Page 93: ...error message is displayed The Tin Calibration must be repeated proceed to Step 2 23 2 20 The thermocouple may be removed when the temperature reaches 262 C The display will display the prompt REMOVE...

Page 94: ...e Mainte nance Manual Repeat AUTOCAL procedure Computer is not adjusted properly Contact your authorized Alcor service representative 2 23 If a Tin freezing point temperature was NOT detected and kept...

Page 95: ...heated The screen will display Please wait while the Lead is heated If the thermocouple is already inserted into the Lead proceed to Step 2 33 2 31 Adjust the COOLING FLOW to the center of the green...

Page 96: ...cted freezing point The drop in tempera ture below the freezing point and the abrupt reversal is due to the super cooling characteris tic of Lead If the temperature does not remain constant long enoug...

Page 97: ...emperature is more than 10 C from the reference you can not keep the value Press any key Check the Lead Calibrator then repeat the AUTOCAL TC The value of 341 C is used here as an example NOTE failure...

Page 98: ...date and the temperature detected for each calibration point will be displayed 2 42 1 If the thermocouple was not properly removed and is still inserted stuck in solid Tin or Lead then press F1 to tur...

Page 99: ...ning when not in use 3 3 Remove the Air Trap glass jar Place a beaker under the drip tubes Cap the spent fuel outlet port and P2 port 240 only 3 4 Perform the test with the heater test section disconn...

Page 100: ...imizingairleftinline 3 10 Turn the FLOW CONTROL SELECTOR VALVE to the P VENT position and raise the bottle The bottle will push fuel and any air through the system to the air trap drip tube 3 11 Hold...

Page 101: ...the bottle stays above the fitting on the bottom of the bottle 3 16 When air bubbles no longer emerge turn the FLOW CONTROL SELECTOR VALVE to the RUN position 3 17 Lower the bottle so that the level...

Page 102: ...0 gms ml density at a height of 400 mm and the familiar JFTOT bias on P of 6 0 800gms ml 400mm Theoretical P 25 16mmHg 13 53 94 If there is a difference between the actual and theoretical values of gr...

Page 103: ...OM test place a clean beaker under the drip tube when the heater turns on Remove the beaker when the heater turns off Record the elapsed time the heater is on 4 CHECKING VALIDITY OF FUEL FLOW RATE 4 3...

Page 104: ...JFTOT II Calibration Manual Rev C Page 18 THISPAGEINTENTIONALLYBLANK...

Page 105: ...long the air pump is on This time should be 6 min 1 4 sec 5 CHECKING AERATION FLOW TIMER AND COOLANT FLOW 5 2 3 While running a D3241 or CUSTOM test use a calibrated timer or stop watch to time how lo...

Page 106: ...JFTOT II Calibration Manual Rev C Page 20 THISPAGEINTENTIONALLYBLANK...

Page 107: ...JFTOT II JET FUEL THERMAL OXIDATION TESTER Maintenance Manual October 2003 Version 2 1 or later 300 BAMMEL WESTFIELD ROAD HOUSTON TEXAS 77090 USA TELEPHONE 281 580 0339 FAX 281 580 0719...

Page 108: ...JFTOT II Maintenance Manual Rev C Page 2 THISPAGEINTENTIONALLYBLANK...

Page 109: ...acement 5 3 2 AutoCal Calibrator Lead Replacement 5 3 3 Thermocouple Replacement and PositionAdjustment 6 3 4 Cleaning Bus Bar Contacts 6 3 5 Aeration Dryer Replacement 7 3 6 Lubricating Drive PumpAss...

Page 110: ...JFTOT II Maintenance Manual Rev C Page ii THISPAGEINTENTIONALLYBLANK...

Page 111: ...th associated equipment for controlling and measuring the heater tube temperature A differential pressure transducer is used to measure P across the test filter The maintenance routine and repair of t...

Page 112: ...JFTOT II Maintenance Manual Rev C Page 2 THIS PAGE INTENTIONALLY BLANK...

Page 113: ...me at 3 mL min is 166 min Fuel aeration timer 6 minutes Aeration Flowrate 1 5 L Min Green Coolant Flowrate 10 Gal Hr Green Heater tube temperature profile timer 30 min after heater tube temperature is...

Page 114: ...JFTOT II Maintenance Manual Rev C Page 4 THIS PAGE INTENTIONALLY BLANK...

Page 115: ...thermocouple to apply power to melt the Tin When the Tin has melted raise the thermocouple to remove it from the Tin The JFTOT will turn the heater off and display the initial AutoCal screen Clean th...

Page 116: ...socket The thermocouple plug is polarized and will fit into the socket only one way 4 Adjust the top of the slide assembly so that it is even with the top of the reference mark on the scale top of th...

Page 117: ...tom bearings of the drive pump assembly replace the drive column o ring Turn the plunger shaft counter clockwise ccw to unscrew the shaft from the nut Pull the plunger shaft out of the column to expos...

Page 118: ...rom a the blue green display screen b the keypad 3 9 CLEANING THE JFTOT II CABINET 1 Clean the stainless steel cabinet with a soft clean cloth and a stainless steel cleaner NOTE DO NOT use the stainle...

Page 119: ...JFTOT II Maintenance Manual Rev C Page 9 4 TROUBLESHOOTING...

Page 120: ...JFTOT II Maintenance Manual Rev C Page 10 THISPAGEINTENTIONALLYBLANK...

Page 121: ...JFTOT II JET FUEL THERMAL OXIDATION TESTER ISO 9000 Manual October 2003 Version 2 1 or later 300 BAMMEL WESTFIELD ROAD HOUSTON TEXAS 77090 USA TELEPHONE 281 580 0339 FAX 281 580 0719...

Page 122: ...JFTOT II ISO 9000 Manual Rev C Page 2 THISPAGEINTENTIONALLYBLANK...

Page 123: ...JFTOT II ISO 9000 Manual Rev C Page i TABLE OF CONTENTS 1 INTRODUCTION 1 2 PREPARATION FORTEST 4...

Page 124: ...JFTOT II ISO 9000 Manual Rev C Page ii THISPAGEINTENTIONALLYBLANK...

Page 125: ...forms provide for recording of Calibration Verification and Mainte nance as required by the JFTOT Manual An ex ample work instruction is provided to assist recording Heater Tube rating results on the...

Page 126: ...JFTOT II ISO 9000 Manual Rev C Page 2...

Page 127: ...JFTOT II ISO 9000 Manual Rev C Page 3...

Page 128: ...JFTOT II ISO 9000 Manual Rev C Page 4...

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Summary of Contents for Alcor JFTOT II

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Summary of Contents for Alcor JFTOT II

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