ASTON TEMPSET-1600
Operations & Maintenance Manual
ASTON TEMPEST Operations and Maintenance Manual
Contents
1
2
3
4
5
Introduction ....................................................................................................................................... 5
1.1
Objective .................................................................................................................................... 5
1.2
This Operation & Maintenance Manual (OMM) ......................................................................... 5
1.3
Terminology ............................................................................................................................... 5
OHS & WARNINGS .......................................................................................................................... 5
2.1
About this manual ...................................................................................................................... 5
2.2
Safety ........................................................................................................................................ 6
2.2.1
Do Not Open Electrical Cabinets ....................................................................................... 6
2.2.2
Equipment Labels .............................................................................................................. 6
2.2.3
Environmental Warning ...................................................................................................... 6
2.2.4
Cleaning Chemicals ........................................................................................................... 6
2.2.5
Completion of Permit to Work documentation ................................................................... 7
2.2.6
Completion of JSERA ........................................................................................................ 7
2.3
Permits and Documentation ...................................................................................................... 8
2.4
Isolations ................................................................................................................................... 8
2.5
Personal Protective Equipment (PPE) ...................................................................................... 8
EQUIPMENT DESCRIPTION ......................................................................................................... 10
3.1
Diesel Engine (if equipped) ..................................................................................................... 10
3.2
Battery Cabinet (if equipped)................................................................................................... 10
3.3
HMI and Electrical Cabinet ...................................................................................................... 10
3.4
Hydraulic Pump ....................................................................................................................... 11
3.5
Hydraulic Tank......................................................................................................................... 11
3.6
Hose Reel (if equipped) ........................................................................................................... 11
3.7
Floating Pontoons (if equipped) .............................................................................................. 11
3.8
Aston Atomizer Framework ..................................................................................................... 11
3.9
Aston Atomizer Heads ............................................................................................................. 12
3.10
Hydraulic Water Pump and Pickup........................................................................................ 12
Control Panel Description ............................................................................................................... 13
4.1
E-Stop ...................................................................................................................................... 13
4.2
Electrical Isolator ..................................................................................................................... 13
4.3
Human Interface Screen (HMI) ............................................................................................... 13
Installation and Commissioning ...................................................................................................... 15
5.1
Positioning on Site ................................................................................................................... 15
5.2
Setup of Atomizer Floating Unit ............................................................................................... 16
5.2.1
5.3
Setup ................................................................................................................................ 16
Connections............................................................................................................................. 20
5.3.1
Unspooling the Hose Reel (if equipped) .......................................................................... 20
ASTON TEMPEST Operations and Maintenance Manual
5.3.2
6
5.4
Setting Water Pump Position .................................................................................................. 22
5.5
Placing the Floating Atomizer Unit .......................................................................................... 23
OPERATING PHILOSOPHY & START-UP .................................................................................... 24
6.1.1
6.2
START-UP PROCEDURE ...................................................................................................... 25
Start-up Precautions ........................................................................................................ 25
6.2.2
ASTON START-UP PROCEDURE STEPS ..................................................................... 25
6.2.3
Physical Line Checks ....................................................................................................... 25
6.2.4
Services ........................................................................................................................... 26
6.2.5
Placement of plant equipment ......................................................................................... 26
6.2.6
Bleed Hydraulic Lines ...................................................................................................... 26
6.2.7
Start-up ............................................................................................................................ 27
6.2.8
Setpoints (if equipped with AIM system) ......................................................................... 28
6.2.9
Start / Stop the Atomizer’s ............................................................................................... 29
6.2.10
Configuring the Atmospheric Intelligence Module (AIM) (if equipped) .......................... 30
SHUTDOWN PROCEDURE ................................................................................................... 31
6.3.1
6.4
6.5
E-Stop System ................................................................................................................. 31
Alarms ..................................................................................................................................... 31
DATA LOGGING............................................................................................................................. 32
7.1.1
7.2
Documentation ................................................................................................................. 32
Logging of Plant Data .............................................................................................................. 33
7.2.1
Record Keeping for Condition Monitoring ........................................................................ 33
7.2.2
Start-Up Report ................................................................................................................ 33
MAINTENANCE .............................................................................................................................. 34
8.1
Routine Maintenance .............................................................................................................. 34
8.1.1
Maintenance Log.............................................................................................................. 34
8.1.2
Operator Activities ............................................................................................................ 34
8.2
Minor and Major Maintenance ................................................................................................. 34
8.2.1
Defining a Maintenance Activity ....................................................................................... 35
8.2.2
Management of Minor Maintenance Activity .................................................................... 35
8.2.3
Management of Major Maintenance Activity .................................................................... 36
8.3
General Routine Maintenance................................................................................................. 36
8.3.1
Hydraulic Oil Filter Change Procedure ............................................................................ 38
8.3.2
Water In-Line Filter Change Procedure ........................................................................... 41
8.4
9
Shutdown Description ...................................................................................................... 31
Emergency Shutdown ............................................................................................................. 31
6.4.1
8
OPERATING PHILOSOPHY ........................................................................................... 24
6.2.1
6.3
7
Connection of the Hydraulic and Electrical Fittings ......................................................... 21
Recommended Spares List ..................................................................................................... 43
Appendix ......................................................................................................................................... 43
ASTON TEMPEST Operations and Maintenance Manual
ASTON TEMPEST Operations and Maintenance Manual
1 Introduction
1.1 Objective
The objective of this document is to describe the operational functionality of the ASTON TEMPEST.
1.2 This Operation & Maintenance Manual (OMM)
This document describes the operational and maintenance requirements for the enhanced evaporation ASTON
TEMPEST. The description, operation, and maintenance of the following major components are described within this
document:
The document will also cover general maintenance requirements for routine maintenance of the ASTON TEMPEST
over prescribed periods.
The document will cover basic safety requirements of the ASTON TEMPEST to ensure safe operation of equipment
used on the plant.
1.3 Terminology






OMM
SWMS
HMI
PLC
JSERA
PTW
-
Operations & Maintenance Manual
Safe Work Method Statement
Human Machine Interface
Programmable Logic Controller
Job Safety Engineering Risk Assessment
Permit to Work
2 OHS & WARNINGS
Please read this Operator Manual before connecting and using any of the ASTON TEMPEST equipment.
Familiarisation with this manual prior to operation of the system ensures operational safety and maximisation of the
systems benefits.
Failure to operate this equipment as set out in this manual will void any warranty and/or any claims against Aston
Evaporative Services.
The plant has fully automatic functionality incorporated within it, meaning that the ASTON TEMPEST will run on
demand with little user input required. This must be remembered when operating this plant and/or performing
maintenance on it. Standard lock out and isolation procedures must be carried out to ensure that safe maintenance
can be undertaken.
The system features a Machine Interface (HMI) to read and use display screens which display operational
parameters, and active alarms/warnings. These displays will indicate such things as modes of operation, system
parameters, trended data, and alarms and warnings. The display of alarm status will facilitate rapid trouble-shooting
capabilities.
The Human HMI display is located the control cabinet, which is located on the pump skid.
2.1 About this manual
The following pages detail the safety issues concerned with the operation and basic maintenance of the ASTON
TEMPEST.
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ASTON TEMPEST Operations and Maintenance Manual
Any technical intervention with the system must only be performed with reference to the Maintenance Manual and
should ONLY be carried out by trained authorised personnel.
2.2 Safety
The ASTON TEMPEST must be operated in accordance with the instructions contained within this operations manual
to ensure the highest level of safety at all times. Throughout this manual BOLD LETTERING is used to identify labels
on equipment, safety issues, and qualifying statements.
The WORK SAFETY SYMBOL is found with all safety instructions for which
personal injury may occur. Please observe these instructions carefully and carry
out all procedures with care! At the same time, all appropriate laws in force and
general safety and accident regulations must be carefully observed.
CAUTION: means that advice is given which should be especially noted, this is to ensure that the correct operating
procedures are observed to prevent damage to the ASTON TEMPEST.
The CAUTION SYMBOL is found throughout the manual and provides
additional information about items that may be of concern and advises
additional care may be required in this section.
.
NOTE: This means that advice is given with information on how to make optimal use of the ASTON TEMPEST or how
a correct operating procedure is carried out
Before operating the ASTON TEMPEST it is important that this manual be read and understood. If you are unsure
about any aspect within the manual, please contact your Aston agent for further clarification.
Please safely retain this manual with the ASTON TEMPEST for future reference and for the training of new operators.
2.2.1 Do Not Open Electrical Cabinets
WARNING: Only Site Authorised Electricians or Aston Certified Trained
Technicians shall open the electrical cabinets. Do not operate the ASTON
TEMPEST with the cabinet doors opened.
2.2.2 Equipment Labels
WARNING: Do not under any circumstance remove any Caution, Warning or
any other descriptive labelling from the ASTON TEMPEST.
2.2.3 Environmental Warning
WARNING: Do not under any circumstance operate the ASTON TEMPEST in
an explosive or flammable environment.
2.2.4 Cleaning Chemicals
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ASTON TEMPEST Operations and Maintenance Manual
WARNING: Obey all PPE requirements detailed on the MSDS’s of the
chemicals used for any cleaning or operating purposes.
2.2.5 Completion of Permit to Work documentation
WARNING: Always complete a Permit to Work before any maintenance or
work is carried out on the ASTON TEMPEST. Adherence to additional site
regulations will also be required during installation and whenever scheduled
or unscheduled maintenance is carried out.
2.2.6 Completion of JSERA
WARNING: When conducting work that is not regular maintenance or familiar
tasks during installation, and when work is carried out through Aston, a Job
Safety & Environment Risk Analysis (JSERA) must be conducted in addition
to a Permit to Work (PTW).
Work carried out that is instructed by the site will need to comply with all site
regulations and procedures.
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ASTON TEMPEST Operations and Maintenance Manual
2.3 Permits and Documentation
Prior to any work being carried out on the ASTON TEMPEST, the correct permits and documentation MUST be
completed prior to any work commencing.
A Permit to Work (PTW) must be completed prior to work being carried, from which a Safe Work Method Statement
(SWMS) is created covering the tasks involved. This SWMS MUST be read and signed by ALL personnel involved in
the task prior to any work being carried out. A Job Safety & Environment Risk Analysis will also be required whenever
work is carried out that is not familiar or differs from usual tasks. Further information is provided in section 0. Always
contact Aston for further information if unsure of any permits required.
2.4 Isolations
During the course of routine and scheduled maintenance, there may be a requirement to isolate certain systems or
equipment prior to maintenance being carried out.
Isolations prevent unplanned movement or operations of the equipment that is being inspected / worked on. This is for
the safety of the operator and any surrounding personnel, and also to protect the equipment from possible damage.
The use of isolations prevents risk of the following energy sources found on the ASTON TEMPEST site:

Electrical Energy,

Hydraulic Energy,

Kinetic Energy,

Spring Energy,

Thermal energy,

Gravitational Energy; and,

Explosive Energy.
To prevent these forms of energy from causing harm to personnel and equipment, ensure items are LOCKED in their
off or discharged position. The locks will have a DANGER tag attached identifying the reason why it is locked off and
by whom.
WARNING: ONLY THE PERSON WHO APPLIED THE LOCKING DEVICE
IS AUTHORISED TO REMOVE THE LOCK!
ALL isolations are to be carried in accordance with local approved Isolation Process.
WARNING: No isolations are to be performed without familiarisation of where
the isolations points are located!
All isolations must be listed in the SWMS for that task and ALL personnel who are working on that task MUST use
Personal Isolation Locks where required. Isolations are to prevent unplanned movement or operations of equipment
that is being inspected / worked on. This is for the personnel safety of the operator and any surrounding personnel,
and to also protect the equipment from possible damage.
2.5 Personal Protective Equipment (PPE)
It is recommended by Aston that the operator, or anyone, interacting with the chemicals MUST be aware of the
minimum Personal Protective Equipment (PPE) requirements. The ASTON TEMPEST will require the following
minimum PPE:
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ASTON TEMPEST Operations and Maintenance Manual

Long sleeved shirt;

Trousers;

Safety Glasses;

Safety boots; and

PVC gloves.
Optional equipment may also include:


Face Shield;
Ear Muffs / Plugs
This equipment must be inspected prior to every use to ensure it is in good condition and functions correctly.
WARNING: Appropriate PPE must be worn at all times when handling
chemicals!
Afterwards, thoroughly clean all items and inspect them to ensure that they are still in good condition.
If there are any doubts with the condition of any pieces of the PPE, then do not
use it and replace the faulty item immediately!
If there are any doubts with the condition of any pieces of the PPE then do not use it and replace the faulty item
immediately!
The operation of the ASTON TEMPEST may produce noise levels at which hearing protection is required; this will be
indicated in the affected area. Ear protection MUST be worn in these areas or when operating noisy equipment.
WARNING: Ear protection MUST be worn in indicated areas or when using
noisy equipment.
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ASTON TEMPEST Operations and Maintenance Manual
3 EQUIPMENT DESCRIPTION
The following section gives a brief description of various processes and their function within the ASTON TEMPEST.
The ASTON TEMPEST is broken down into the following major modules:


Skid Portion
Floating Atomizer Unit
These two major modules contain the following items:
Skid Portion

Diesel Engine if equipped

Electric Motor if equipped

Battery Cabinet if equipped

HMI and Electrical Cabinet

Hydraulic Pump

Hydraulic Tank

Hose Reel if equipped
Floating Atomizer Unit

Floating Pontoons

Aston Atomizer Framework

Aston Atomizer Heads

Hydraulic Water Pump and Pickup
The operation of these items will be described in further detail in later sections of the manual.
3.1 Diesel Engine (if equipped)
The John Deer E4045HF285 is a 4 cylinder Diesel engine used to run the hydraulic pump and charge the 12V battery
system that runs the HMI and associated electrical hardware. The diesel engine is contained within a metal cabinet
on the Skid Portion.
3.2 Battery Cabinet (if equipped)
The battery cabinet is constructed in stainless steel and contains two 12V batteries wired in parallel that provide
cranking power for the diesel engine and power to run the HMI. The cabinet is the lower of two stainless steel units
located on the Skid Portion located adjacent to the to the engine cabinet.
On the exterior of the Battery Cabinet is the Electrical Disconnect Switch, which provides positive isolation for the
batteries, preventing the ASTON TEMPEST engine and Human Machine Interface (HMI) from being started.
3.3 HMI and Electrical Cabinet
The HMI is attached to the outside of the Electrical Cabinet and is the primary means of controlling the ASTON
TEMPEST. The HMI is used for starting and stopping the unit as well as monitoring weather, diagnosing alarms, and
changing set points. Further information on the HMI and operating the ASTON TEMPEST can be found in Section 4.3
Underneath the HMI is the Emergency Stop (E-Stop), used to shut down the HMI and diesel generator in case of
emergency.
The Electrical Cabinet contains the fuses, Programmable Logic Controller (PLC), Modem Dialler and other associated
electrical hardware. During normal operation, the Electrical Cabinet will not need to be opened.
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ASTON TEMPEST Operations and Maintenance Manual
3.4 Hydraulic Pump
The hydraulic pump is a Sauer Danfoss Series 45 Axial Piston Open Circuit pump. It is set to provide a maximum
pressure of 16.6MPa (2400Psi) to primarily operate the Aston Atomizers and water pump, as well as providing
hydraulic energy to wind and unwind the hose reel (if equipped) on the Pump Skid.
The hydraulic pump is equipped with a pressure relief valve on the output (high pressure) side of the pump in the
cause of a fault developing within the pump.
3.5 Hydraulic Tank
The hydraulic tank supplies hydraulic fluid for the operation of the hydraulic equipment and provides a reservoir for
return fluid to go. Given the location of the hydraulic equipment, a special grade hydraulic fluid is used to ensure that
any spills will not have an adverse effect on the water in the ground or supply dam. It is important to top up hydraulic
oil with the same type or equivalent specifications found in Appendix F of this document noting that the oil used is a
specific vegetable or petroleum grade.
3.6 Hose Reel (if equipped)
The hose reel is used to store the hydraulic and electrical hose bundle that connects to the Floating Atomizer Unit
during transportation. Upon commissioning on site, the Hose Reel can be unwound and wound using hydraulic hand
controls on the Skid Portion. Once the correct length is obtained, the reel does not need wound or unwound during
normal operations of the ASTON TEMPEST.
3.7 Floating Pontoons (if equipped)
There are two floating pontoons that lie parallel to each other and provide buoyancy for the Floating Atomizer Unit.
These pontoons are hollow in construction and care must be taken upon installation not to puncture them when
placing them from the embankment into the water.
3.8 Aston Atomizer Framework
The Aston Atomizer Framework is constructed in such a manner that it is collapsible to allow for ease of transport.
This includes the collapse of the pontoon framework and Atomizer Heads. The procedure for assembling the
framework into its operating position prior to commissioning is contained in Section 5.2.
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ASTON TEMPEST Operations and Maintenance Manual
3.9 Aston Atomizer Heads
The ASTON TEMPEST-800 or 1600 Floating Atomizer Unit comprises either 8 or 16 Atomizer Heads that vaporize
and disperse the water into the atmosphere. The Atomizer Heads have two major functions: Atomize the water and
disperse it into the atmosphere. Water is pumped into the Atomizer Heads (see section 3.10) and plastic hydraulically
driven fan blades hydraulically disperse the vaporized water.
The Atomizer Heads are mounted on a framework that must be set up in the operating position after transport.
3.10 Hydraulic Water Pump and Pickup
Water from the dam or pond is pumped into the Atomizer Heads using a hydraulically driven water pump. The speed
of the pump is controlled using the PLC and feedback from a water flow meter located in a stainless container on the
Floating Atomizer Unit (if equipped with AIM system).
If no AIM system the water pump will have a manual control valve mounted near the pump.
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ASTON TEMPEST Operations and Maintenance Manual
4 Control Panel Description
4.1 E-Stop
The Emergency Stop is a Red push button, which isolates the electrical system in case of emergency. This is the main
method for isolating the system in an emergency, or in the case of serious faults. This button is located underneath
the HMI screen on the upper stainless steel cabinet on the Skid Portion.
To activate the Emergency Stop, the button will lock into position after it has been pushed. This will cause the E-Stop
system to activate, which will shutdown ALL electrical equipment and the diesel engine or electric motor and cause
the hydraulic pump to cease operating. To reset the system, the button needs to be twisted clockwise or pulled out;
the button will then release.
Note that there will be a time delay between pressing the E-Stop and all of the kinetic energy from the hydraulic pump
being dissipated (as the pump must stop operating as the diesel engine shuts down).
WARNING: You must not use this as a form of electrical isolation! The E-Stop
does not provide positive isolation to cabinets or equipment; it does not prevent
the equipment from becoming energised if the system is reset inadvertently.
4.2 Electrical Isolator
Isolation of the ASTON TEMPEST is performed using the disconnect isolation switch located on diesel option outside
the battery panel. This switch is to be used as the effective isolation once the unit is shutdown, before any work is
commenced on the unit.
If electric motor option then a disconnect will be needed per Country and local requirements and this will act as the
isolator.
4.3 Human Interface Screen (HMI)
This is the interface to the PLC and control systems and displays all of the operating parameters and system status
information for the entire ASTON TEMPEST. The ASTON TEMPEST system does not rely on the HMI screen for
normal operation, as the system is fully automated and therefore can still operate without the screen.
Due to the inherent dangers to property and personnel, the ASTON TEMPEST is not to be operated unless
trained/authorised to have this permission.
The selection of various options and settings on the HMI is carried out by pressing the appropriate button on the HMI
touch screen.
The HMI has been configured to provide six (6) various “screens” that can be selected by pressing alternative buttons
at the top of the screen. The available options are (if equipped):






Main (Logo Screen)
Engine
Water
Weather
Setpoints
Alarms
There are 5 (five) available buttons at the top of the HMI screen that can be selected. This is in addition to the
currently displayed screen which displays its function at the top left. Figure 1 illustrates this further.
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ASTON TEMPEST Operations and Maintenance Manual
Current screen
selection
Different
“screens”
available for
selection on HMI
Figure 1- HMI display for Diesel Engine Option
Further information on the operation and functions of the HMI can be found in Section 6.2 of this document.
Figure 1(a) – HMI display for electric motor
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ASTON TEMPEST Operations and Maintenance Manual
5 Installation and Commissioning
5.1 Positioning on Site
The correct site for the ASTON TEMPEST unit shall be determined by Aston engineers’ as well as representatives of
the site. This location shall be in an area that is not subject to flooding, has firm ground not subject to landslides, and
is suitable for the spray of water that will be emitted from the ASTON TEMPEST floating portion.
Both the floating portion and the skid portion will need to be positioned using a suitably sized crane or forklift.
The Hydraulic Hoses and Electrical fittings (if equipped) must be connected
prior to placing the floating portion in the water.
Position the skid portion on a flat section of ground, close to the water’s edge. Consider the location of the fuel filling
point of the diesel engine, as well as the location of the HMI with respect to where the floating portion will be. Ideally,
the operator of the HMI should be able to see the floating portion from the HMI. Further information of the ideal
location can be supplied by contacting Aston.
Ensure that there is room to unroll the hose from the skid portion to connect to the floating portion. This must happen
before the floating portion is placed in the water.
The equipment used to position the skid will need to be used to place the floating unit on the water after the
connections have been made (see the following sections).
Figure 2 – Determining a Suitable Location for Skid and Floating Portion
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ASTON TEMPEST Operations and Maintenance Manual
5.2 Setup of Atomizer Floating Unit
The Floating Portion of the ASTON TEMPEST is transported in a collapsed state. It must be constructed before it can
be placed in water and operated. The following section describes the steps to set the floating portion up.
WARNING: There is potential for damage to equipment and injury to personnel
when setting the Floating Atomizer Portion from its transportable state. In order to
identify hazards and their associated risks with this task, a Job Safety Engineering
Risk Assessment (JSERA) must be completed by Aston Engineers’ in conjunction
with a Permit to Work (PTW) prior to any work commencing.
5.2.1 Setup
1. Ensure a minimum of three (3) people are available to unfold the pontoon and have appropriate PPE as
determined by the completed JSERA.
2. Set the Floating Atomizer Portion on a flat surface
3. Place SLING over and around middle of Pontoon and secure to Crane or Forklift.
4. Locate & Remove the retaining bolts securing the pontoons during shipping see Figure 33 below
Figure 3 – Bolts Securing Pontoons During Shipping
5. Unfold and lower the pontoons carefully USING a CRANE or FORKLIFT in conjunction with a properly rated
SLING so they are resting on the ground
6. Attach an appropriate lifting harness a fixed, load bearing section of the Floating Atomizer Unit and secure this
to the crane or forklift.
7. Gradually lift the Floating Atomizer Unit off the ground until the retaining bolts can be inserted into the
framework to hold the pontoons in the operating position. See Figure 4 on page 16.
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ASTON TEMPEST Operations and Maintenance Manual
Figure 4 – Bolts used to secure the Pontoon Arms in their Operating Position
8. Visually inspect all flan blades on each Atomizer fan assembly to ensure they are set correctly. For details on
setting the fan blade pitch angle, see Appendix A and Figure 5 below.
The top notch should align with center line. This
is the max blade pitch setting.
Figure 5 – Setting each Fan Blade Pitch
9. Remove Bolts from each fan cradle arm. This is done in order to allow each fan arm to be lifted into position
(step 9). See Figure 6 & Figure 7 for more details.
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ASTON TEMPEST Operations and Maintenance Manual
Remove bolt from fan cradle
arm
Figure 6 – Bolt Removal Prior to Lifting Fan Arms into Position
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ASTON TEMPEST Operations and Maintenance Manual
10. Lift atomizer fan arm into position and insert retaining bolt back into position, while supporting the atomizer fan
arm. Apply nickel based anti seize to each threaded portion of the bolt and torque nut onto bolt until secure.
The nuts supplied should be nylon threaded to reduce the likelihood of them loosening. If not, consider using
spring washers. Once the nut is in place and torque up, the bolt can now support the arm. Figure 7 illustrates
this further.
Figure 7 Atomizer Fan Arm Resting on Retaining Bolt
11. Remove bolt from the head end of each atomizer fan arm. This bolt is then inserted into one of three predrilled bolt holes. The appropriate bolt hole alters the fan head angle and is determined by consulting with
Aston engineers, and is determined by the specific application of the unit. Once the bolt has been reinserted,
coat the threaded portion with a nickel based anti-seize and torque up the nut with a wrench. The nuts
supplied should be nylon threaded to reduce the likelihood of them loosening. If not, consider using spring
washers. See Figure 8 below.
Figure 8 – Possible fan head mounting angles
12. Check all remaining nuts/bolts on the atomizer floating portion framework. Ensure every bolt is torque tightly
with a wrench. Special attention must be paid to the bolts/nuts holding the 4 fan assemblies to the arms.
Ensure these bolts/nuts are tight and that the atomizer fan is positioned perpendicular to the arm. See Figure
9 for details.
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ASTON TEMPEST Operations and Maintenance Manual
Bolts/Nuts attaching Atomizer
Fan Assembly
Perpendicular Alignment
between Atomizer Fan
Assembly and Arm
Figure 9 – Bolts/Nuts that must be checked under each Fan Assembly and Alignment
5.3 Connections
5.3.1 Unspooling the Hose Reel (if equipped)
The ASTON TEMPEST (if equipped) features a hydraulically operated hose reel to allow for quick hydraulic
connection of the hoses from the skid to the floating portion.
WARNING: The Hose Reel is driven by a chain and sprocket mechanism. This is
shielded, however, bystanders must be aware of the hazard this presents and the
operator is to ensure that guard is in place and properly attached.
The hose can be unspooled from the reel as follows:
1. Ensure the ASTON TEMPEST Engine or Motor has started and is in IDLE state.
2. Ensure the hose spool valve handle is in its “home” (middle) position
3. Open the Parker Shutoff Valve gradually and ensure that there is no movement from the hydraulic pump
driving the hose reel then close the valve
4. Repeat step 4
5. Open the Parker Shutoff Valve gradually
6. Slowly move the Hose Spool Valve handle towards the “Unspool” direction (see Figure 10)
7. Observe the hose reel unwinding in the correct direction
8. Once hose reel is unwound close Parker Shutoff Valve
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ASTON TEMPEST Operations and Maintenance Manual
Valve to operate
the hose reel
spool/unspool
function
Figure 10 – Valve operation of Hose Spool/Unspool
5.3.2 Connection of the Hydraulic and Electrical Fittings
This section details the connection of the hydraulic and electrical fittings. Care must be taken to ensure the skid
portion is not energised and that effective isolations are in place.
WARNING: If the ASTON TEMPEST skid portion has been operated in order to
unspool the hose from the reel, there may be residue hydraulic oil in parts of the
line. The ASTON TEMPEST must be shut down, isolated and verified that there is
no potential energy stored as pressure within the hydraulic lines. This must be
undertaken before connecting the skid portion to the floating portion.
1. Align the hoses from the hose reel up to the Floating portion. Spin the butterfly union onto the threaded end
on each hose.
2. Ensure the hose connections are firmly attached by using a rubber mallet to ensure that the butterfly unions
are securely attached. Illustrates this.
3. Attach the electrical connection (if equipped) by aligning the cable end with the pins on the socket end (on the
floating portion).
4. Push the cable into the socket and screw the thread until the cable is firmly into the socket (see Figure 1313
and Figure 1414).
Figure 11 – Butterfly Union end Aligned with Screw Fitting
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ASTON TEMPEST Operations and Maintenance Manual
Figure 12 – Screw the Butterfly Union onto the Screw End
Figure 13 – Align the Electrical Cable into the Socket on the Floating Portion (if equipped)
Figure 14 – Secure the Connection by Screwing the Cable end into the Floating Portion (if equipped)
5.4 Setting Water Pump Position
The Water Pump assembly must be adjusted so that the pickup will be adequately under water. To do this, ensure
that the atomizer floating portion is still supported above the ground as described in section 5.2.1.
Remove the position bolt holding the water pump and strainer and replace the position bolt in the location that closest
matches the position so that the pump assembly is just below the centre line of the pontoon, see Figure 15. Verify
that no more than the pump assembly is submerged once the atomizer floating portion is placed in the water.
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ASTON TEMPEST Operations and Maintenance Manual
Height of Pump Aligned With
Centreline of Pontoons
Setting the Water Pump Suction Height
Figure 15 – Setting Water Pump Suction Height
5.5 Placing the Floating Atomizer Unit
The following precautions will need to be followed before placing the Floating Atomizer Unit into the water:
1. Ensure that it is adequately supported from the framework by the lifting machinery.
2. Appropriate tie down points will need to be established to hold the Floating Atomizer Unit in place from each
corner of the unit.
3. Tie the Floating Atomizer Unit off and ensure that it is securely fastened and stable. Consult with Aston
engineers to ensure that the method of securing the Floating Atomizer Unit is satisfactory.
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ASTON TEMPEST Operations and Maintenance Manual
6 OPERATING PHILOSOPHY & START-UP
6.1.1 OPERATING PHILOSOPHY
The system is fully automated for stand-alone operation. The ASTON TEMPEST is designed to be a continuously
operating plant.
Automated operation of the ASTON TEMPEST is controlled by a number of sequences as defined in the Functional
Description Specification document and is summarised as follows:
PLC START-UP
ENGINE START
IDLE
STOP
RUN
IDLE
STOP
PLC START-UP
Power is supplied and the PLC will boot up
ENGINE START
The diesel engine/electric motor is started and set to IDLE.
IDLE
The plant is not performing any activities under sequence control.
RUN
When RUN is selected by an operator, on the HMI, the plant enters the RUN state. In
the RUN state, the sequence performs its defined activities as required and starts the
process of opening the soft start hydraulic value to begin atomizing water.
IDLE
The Atomizers shut down and the diesel engine/electric motor returns to idle and the
soft start hydraulic valve closes. Engine slows to Idle speed and electric motor stays
running at appropriate RPM.
STOP
The diesel engine/electric motor will shut down.
The system controls and operation of the ASTON TEMPEST is provided via the HMI screen which indicates the
following control information:





System status
Alarm status and event viewer
Engineering information of set points and control parameters
Trend and pop up screens for system information
Operator prompts for manual plant operations.
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ASTON TEMPEST Operations and Maintenance Manual
6.2 START-UP PROCEDURE
This section will describe the process by which to start up the ASTON TEMPEST. If the plant has stopped as a result
of a critical alarm, or is coming back to service after maintenance the process below is to be followed.
6.2.1 Start-up Precautions
Prior to start up of any of the ASTON TEMPEST system, it is important that ALL maintenance work has been
completed and ALL manually operated valves are in their correct position for normal operations. These positions are
listed in each subsection of the start up procedures in Section 5.
Aston strongly advises that the correct position of ALL valves is determined and
confirmed prior to starting any part of the ASTON TEMPEST; failure to do so may
result in damage to the equipment.
As the start up process is fully automatic, ALL personnel in or around the ASTON TEMPEST MUST be advised of the
intended operation of the UNIT/plant prior to initiating the start sequence.
It recommended that NO personnel be in the areas where equipment is to be started; if observation is required then
the observer is to remain outside where possible, or remain well away from any pumps.
WARNING: This plant may start at any time so ALL personnel are to be informed
of this and ensure ALL safety precautions are taken before ANY work is carried
out.
While the plant is starting up, it is recommended that the process be followed on the HMI screen. In doing this, the
start up sequence can be monitored and stopped if any issues are noted. Close monitoring of any alarms/warning that
may occur in the start up sequence is also recommended.
On completion of any start up, it is recommended that a walk-around of the ASTON TEMPEST is carried out to ensure
correct operation has occurred and that there are no unmonitored events occurring.
6.2.2 ASTON START-UP PROCEDURE STEPS
The following areas within this section outline the normal process that should be undertaken before pressing the
“Start” and “Run” button on the HMI which will start the diesel engine/electric motor and run the plant. Pressing “RUN”
will take the system out of IDLE State.
6.2.3 Physical Line Checks
It is STRONGLY recommended that after any maintenance, commissioning or work is undertaken at the plant, that a
physical “walking” of the pipe work and valves is undertaken to ensure that no valves are mistakenly left in an
incorrect position, which could cause damage to equipment and endanger human life.
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ASTON TEMPEST Operations and Maintenance Manual
6.2.4 Services
Check that the following services are available and present at all times before starting the ASTON TEMPEST.
Item
Service
Description
1
Diesel
For John Deere Diesel Engine
2
Engine Oil
Check Diesel Engine Oil Level
3
Water
Raw Water is available and suction filter is under
water
4
Communications
HMI system is functioning
5
Hydraulic Fluid
Vegetable Grade/Petroleum based Hydraulic Fluid
is in reservoir tank and is correct level
6.2.5 Placement of plant equipment
The location floating portion of the ASTON TEMPEST and the location of the skid should be determined prior to
delivery. The skid portion should be placed on a solid level surface, within close reach to the location to where the
floating portion will lie. There is limited length for the hydraulic hoses to reach between the floating portion and the
skid.
6.2.6 Bleed Hydraulic Lines
Before starting the ASTON TEMPEST ensure hydraulic lines are full of the required hydraulic oil and the pump is
prepared for running. See Appendix B for further information on the start-up procedure.
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ASTON TEMPEST Operations and Maintenance Manual
6.2.7 Start-up
Prior to start-up of the diesel engine and operation of the hydraulic system, ensure
correct PPE is used by all personnel nearby, including hearing protection and eye
protection.
The plant requires power to run the HMI before it can be started. The HMI will start up automatically once the
electrical isolation swich has been closed. After the HMI has loaded, select the overview screen (if not already on
overview screen) by pressing the “Main” button on the HMI screen. Once the plant is ready to run it will display
“Ready” at the lower left of the engine screen. See Figure 16 for further details.
The engine screen provides information about the engine and hours of operation.
To start the diesel engine select the “start” button on the “Main” screen of the HMI. The plant will start assuming there
are no critical alarms preventing it from running. Once it is running it will assume the “IDLE” state.
Plant “Start”
button
Plant “Main”
button
Engine
Status
Figure 16- Plant Overview Screen.
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6.2.8 Setpoints (if equipped with AIM system)
Plant “Setpoints” button
Figure 17 – Selecting the Setpoints Screen
Certain setpoints need to be programmed into the HMI before operating the uni and altered to fine tune the ASTON
TEMPEST to suit local conditions. Once the plant is operating in the “IDLE” state (see section 0), select the setpoints
screen. It is recommeneded that initially the setpoints are set as follows, by pressing inside the numerical box,
relevant to the setpoint that needs to be set or altered, entering the numerical value, and pressing ENT to set the
value. Figure 18 & Figure 19 illustrate this. The setpoints should be set as follows:


Motor Run Speed (rpm): 2000-2400
Water Valve Run Position(%): 50
Other setpoints should be set in consultation with representatives from of ASTON.
Figure 18 – Setpoints screen
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ASTON TEMPEST Operations and Maintenance Manual
Figure 19 – Entering Setpoints
6.2.9 Start / Stop the Atomizer’s
The following proceedure must be used when starting the Atomizers.
1. Press the blue “RUN” button on the “ENGINE” or “MOTOR” screen
There will be an approximate 30 second delay for the soft start valve to open slowly and allow hydraulic to flow to the
atomizers on the float. The atomizer fans will ramp up to their set pressure (between 1800-2200Psi). Check the
pressure gauge mounted within the soft start valve (see Figure 201).
Figure 20 – Location of the pressure gauge
Once the operating pressure has been reached, there will also be a delay before water starts spraying from the
atomizers.
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ASTON TEMPEST Operations and Maintenance Manual
To stop the Atomizers press the yellow “IDLE” button on the “ENGINE” or “MOTOR” screen of the HMI. Once the
system has returned to an IDLE state, the diesel engine or electric motor can be shut down by pressing the red “OFF”
button. To shut down the HMI, open the isolation switch or shut off the main electric disconnect.
In an emergency use the E-Stop button (under the HMI panel) to shut down the diesel engine or electric motor and
cease operation of the hydraulic pumps. Note that this will take some time for the kinetic energy to dissapate from the
hydraulic system.
6.2.10 Configuring the Atmospheric Intelligence Module (AIM) (if equipped)
The atomspheric intelligence module (AIM) is used to configure the settings between the weather station and the HMI.
The weather station must be calibrated as follows before use:

Set the Vaisala weather station heading to North (verify using a compass) using the arrow on the bottom of
the weather station as a reference point
Pressing the “WEATHER” button on the HMI will bring up the weather screen displaying climatic conditions, as
observed from the Vaisala weather station. Figure 21 illustrates this further.
The WEATHER screen also provides the following information:





Wind Direction
Wind Speed
Air Temperature
Humidity
Barometric Pressure
Figure 21 – HMI WEATHER Screen
Pressing the “SETPOINTS” button on the HMI will display the adjustable setpoints relating to weather as well as
engine speed and water valve position. The following settings can be fine-tuned in conjunction with Aston:
“MAX WIND SPEED” is the maximum speed the ASTON TEMPEST will operate at before the Water Valve position
will be reduced to the value set in “WATER VALVE ALARM POSITION”. The purpose of these two functions is to
ensure that the water spray from the ASTON TEMPEST will not travel further than the desired spray range.
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ASTON TEMPEST Operations and Maintenance Manual
A start point for these two setpoints could be used as in conjunction with advice and fine-tuning from Aston:
 MAX WIND SPEED (MPH) – 45
 WATER VALVE ALARM POSITION (%) – 10
Wind direction shutdown setpoints need to be calibrated by Aston engineers and should be fine-tuned to suit local
weather conditions.
6.3 SHUTDOWN PROCEDURE
6.3.1 Shutdown Description
The ASTON TEMPEST shutdown sequence is fully automatic and the PLC will command different sections of the
plant to shutdown as required by the PLC program.
The ASTON TEMPEST will either completely or partially shut down when certain parameters or events occur. Further
information on these parameters can be found in Appendix C – ASTON TEMPEST Alarm Table Appendix C. A fault
tree analysis can be found in Appendix G.
Once any of the above alarms or events occurs, the plant will be automatically shut down by the PLC and will go into
standby mode.
The ASTON TEMPEST can be shut down at any time by the user, providing they have the required access level. In
an emergency the operator can use the emergency stop (E-Stop) to shut down the plant.
To manually shut down select the “ENGINE” or “MOTOR” screen on the HMI then press the Red “STOP” button.
6.4 Emergency Shutdown
6.4.1 E-Stop System
The plant is shut down in an emergency using the Emergency Stop “E-Stop” button. This button is located below the
HMI screen.
The E-Stop button is a simple device which when the button is pressed will break a Control Loop circuit connected to
an E-Stop Controller.
When an E-Stop button has been activated, this controller will immediately shut down the diesel engine, which will
cause the hydraulic pump to cease providing pressure to drive the evaporation fans and sprayer.
Once an E-Stop has been activated, the system will remain in a stopped state with alarms activated; even if the button
has been reset, the system will still be in the alarm activated mode until the alarm has been reset on the “Alarm”
screen of the HMI.
The button, once pressed, will remain depressed until it is reset. To reset the E-Stop button, all that is required is for
the button to be twisted clockwise or pulled out; it will then pop out and return to its normal position.
6.5 Alarms
In the case of a plant alarm and/or a plant shutdown due to an alarm, the fault that caused the alarm can be viewed by
pressing the “Alarm” button on the HMI. See Figure 2223 below for more details.
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ASTON TEMPEST Operations and Maintenance Manual
Figure 22 – Alarm screen
In order to restart the plant after it has shutdown due to an alarm the “Acknowledge” button must first be pressed. The
plant cannot be restarted unless the user has the required level of access. This is to ensure that alarms can be
diagnosed by personnel with the required level of knowledge before the plant is restarted.
A list of alarms, their cause and the action taken by the ASTON TEMPEST can be found in Appendix C.
7 DATA LOGGING
The following references to safety apply to recording of plant data and routine maintenance activities. This plant is a
fully automated plant and will start and stop when required by the PLC programming. As a result care MUST be taken
when moving around or working on the plant.
ALL safety documentation and Lockouts MUST be completed before ANY maintenance work is carried out on this
plant; failure to do so may result in damage to the plant and/or serious injury to personnel.
WARNING: The plant or equipment may start at any time so ALL personnel
must be aware of this and ensure ALL safety precautions are taken before
ANY work is carried out. Failure to do so may result in damage to the plant
and/or serious injury to personnel!
7.1.1 Documentation
Prior to any work being carried out on the ASTON TEMPEST, all safety documentation for the task involved MUST be
filled out and read and acknowledged by all personnel involved in the task.
All documentation MUST be completed prior to commencement of work on the ASTON TEMPEST.
All routine processes and tasks will have a procedure detailing the task and the process involved in the task.
For tasks outside of these routine tasks, a safety analysis and work statement must be completed, read and signed by
all members of the work party.
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ASTON TEMPEST Operations and Maintenance Manual
7.2 Logging of Plant Data
This section provides details of the data logs required for monitoring the performance of the ASTON TEMPEST and
are required to be completed and lodged as started.
7.2.1
Record Keeping for Condition Monitoring
In order to be able to monitor and maintain the performance of the ASTON TEMPEST, it is necessary to ensure that
all relevant data is collected, recorded, and kept on file.
Apart from monitoring the plants performance, the log sheets are also valuable tools for troubleshooting, and may be
needed in the cases of warranty claims.
7.2.2
Start-Up Report
At the commencement of operations of the ASTON TEMPEST, it is important to collect ALL initial data from the plant.
This data will include:



Setpoints for the ASTON TEMPEST including for the Weather Station, engine RPM, water flow rates, water
valve %, and hydraulic oil level.
Record initial performance of the ASTON TEMPEST
Daily Plant Log
The ASTON TEMPEST records all of the critical parameters for the successful operation of the plant.
In addition to the data logging system, the plant operator(s) must complete a weekly plant log and maintain them, as it
will allow them to keep themselves familiar with the current state of their plant.
Diligent analysis of the data and of the trends in this data will result in early detection of potential problems. This can
mean that early action could be taken and, as a result, a possible failure could be prevented before it occurs.
The following data shall be recorded and logged into an appropriate log-sheet once per week, unless otherwise
stated:
Date, time and hours of operation.
Operating Time of the ASTON TEMPEST
Water Flow Rate
Oil Level in Hydraulic Tank
Water & Oil Level of Diesel Engine
Greasing at grease nipple locations.
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ASTON TEMPEST Operations and Maintenance Manual
8 MAINTENANCE
This section will discuss the maintenance requirements of the ASTON TEMPEST and will be broken up into the
following sections:


Routine maintenance
Major Maintenance
8.1 Routine Maintenance
8.1.1 Maintenance Log
A maintenance log for the plant should be kept as well, in which can be found recorded details of maintenance carried
out on the plant, replacement of any items, as well as any calibrations carried out. This is a useful tool in the early
detection of possible issues and early failures of equipment on the plant.





Record routine maintenance.
Record mechanical failures and replacements.
Record replacements or additions to ASTON TEMPEST devices.
Record calibration of all gauges and meters.
Record cleaning of filters.
8.1.2 Operator Activities
While the ASTON TEMPEST is an automatically operated plant, there are some activities that need to be carried out
on a regular basis.
These activities are to be carried out by the plant operators and details of these activities need to be kept, along with
the weekly data logs. This information can provide useful tools in the early detection of possible issues and early
failures of equipment on the plant.
Within this section, the minimum requirements that the operator needs to maintain for the operation of the plant are
listed, and it also provides the operator with general material to check performance of the ASTON TEMPEST.
It includes a weekly checklist for the operator onsite and a checklist of tasks with a frequency other than weekly.
8.1.2.1
Weekly Checklists
The weekly checklists are used to provide the operator with an easier to follow list of weekly checks that need to be
carried out on the ASTON TEMPEST. Once completed, they are to be added to the Maintenance Task Checklist and
Data Log Sheet and site in the ASTON TEMPEST site folder.
8.2 Minor and Major Maintenance
For major maintenance activities, there will need to be shutdown of the plant and precautions need to be taken to
ensure that the maintenance activities do not damage nearby equipment or alter operating settings.
For minor maintenance activities, where there is no interruption, some critical steps need to be followed to create a
safe working environment for maintenance operators.
The distinction between a major and minor maintenance activity will be discussed briefly. This document provides
general material to be considered in the event of a maintenance activity.


Management of Minor Maintenance Activity
Management of Major Maintenance Activity
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ASTON TEMPEST Operations and Maintenance Manual
8.2.1 Defining a Maintenance Activity
Major Maintenance Activities usually have the following characteristics.
1.
They obstruct:
 Access to the ASTON TEMPEST and/or
 Access to process lines, valves, pump, tank, power outlet, fire hydrant, safety shower and any other
critical equipment.
2.
3.
They significantly detract from the existing safety designs.
They limit the performance of the ASTON TEMPEST to such an extent that the controllable parameters are
no longer within the sound operating range (envelope)
The maintenance activity may cause damage to the ASTON TEMPEST.
The following are examples of major maintenance activities:
 Repair or replacement of a tank
 Repair or replacement of a pump
 Repair or replacement of plant pipe work
4.
5.
8.2.2 Management of Minor Maintenance Activity
During minor maintenance, normal plant operation may continue. In the event that a maintenance activity is not
considered a minor maintenance activity, the ASTON TEMPEST will need to be stopped. In that event, refer to
Managing of Major Maintenance Activity in Table 22 below. Attempting to continue with normal operation may cause
operating problems and raise safety issues.
Care must be taken when handling plant and equipment to avoid contact with skin and eyes. PPE must be worn at all
times when handling plant and equipment. The minimum PPE requirements are listed in Table 11 below:
Table 1 – Minimum PPE requirements for Major and Minor Maintenance Activities
Description
Instruction and Explanation
1
Provide appropriate PPE
Provide well fitting PPE for maintenance workers
2
Safety plan
Discuss the onsite safety plan with maintenance workers.
Discuss a course of action for the following events;
3
Contact details

fire

chemical spill

Has a JSA and SWMS been completed and reviewed
by everyone in the work group?
Provide the maintenance workers with the onsite
operator’s contact details.
Provide the maintenance workers with contact details in
case of emergency.
4
Remove
objects
obstructive
Remove unnecessary and obstructive objects in and
around the work area.
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ASTON TEMPEST Operations and Maintenance Manual
8.2.3 Management of Major Maintenance Activity
During a major maintenance activity, the effected train or ASTON TEMPEST should be shutdown. In order to minimise
downtime after the completion of a major maintenance activity, instructions in Table 22 should be followed.
Specifically, downtime needs to be minimised where major maintenance activity obstructs:


Entrance to the ASTON TEMPEST area and/or
Access to process lines, valves, pump, tank, power outlet, fire hydrant, safety shower and any other critical
equipment.
Care must be taken when handling plant and equipment to avoid contact with skin and eyes. PPE must be worn at all
times when handling plant and equipment. The minimum PPE requirements are listed in section 2.5.
Table 2 - Instructions for Management of a Major Maintenance Activity
Description
Instruction and Explanation
1
Critical planning
Create a plan to manage the maintenance procedure:
 Do the damaged items need to be removed or can they
be repaired where they are?
 If requiring removal, how will the items be removed? Do
nearby items need to be removed as well to clear a path
or avoid damage?
 How much space do the maintenance workers need
(including room for tools and workers)?
 Are the existing facilities compatible with
maintenance workers’ tools; i.e. power outlet?
the
2
Provide appropriate PPE
Provide good fitting PPE for maintenance workers
3
Safety plan
Discuss the onsite safety plan with maintenance workers.
Discuss a course of action when there is:
 fire
 chemical spill
 Has a JSA and SWMS been completed and reviewed by
everyone in the work group?
4
Contact details
Provide the maintenance workers with the onsite operator’s
contact details.
Provide the maintenance workers with contact details in case
of emergency.
8.3 General Routine Maintenance
The following preventative maintenance should be carried out to minimise downtime due to normal service wear and
tear and to maximise service life of the major subsystem.
Please note:
The list below is a summary of major maintenance points only.

For detailed instructions of each action, please consult the individual component manuals, which are included
with this document.

For maintenance instructions for individual equipment consult the manufactures service manuals provided.

Please refer to the spare parts list for spare parts referenced below.
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ASTON TEMPEST Operations and Maintenance Manual

Please refer to the Equipment List documentation and P&ID documentation for identification of equipment
listed below.

If any maintenance points below are unclear, please contact Aston.
The various sections below provide an outline of general routine maintenance tasks for the skid portion. The list of
tasks and their frequency are contained within Table 3 below.
Table 3 – Regular Maintenance Tasks to Skid Portion
Maintenance Item
Detail
Hydraulic Oil Filters
Inspection Items
Frequency
Checked for dirt, clogged or torn
filters
Weekly
Hydraulic Oil Level
Check & Top Up
Inspection of Pump
Inspection of Inline Water
Filter
Check for Leaks
Check, Clean or
Replace
Check for level, cleanliness and
contaminants
Check for leaks & wear
Check for level, cleanliness and
contaminants
Inspection of Hydraulic &
Water Lines
Check & Replace
Check for leaks & wear
Weekly
Inspection of Atomizer Fan
Assembly
Check & Replace
Check for cracks, impacts,
rubbing
Weekly
Inspection of Wear items:
Fain Blades, screen, hose
connection, nuts and bolts,
red vibration mounts
Check & Replace
Check for cracks, impacts,
rubbing
Weekly
Diesel Engine Oil / Coolant
Level
Check and Top
Up
Check for level, cleanliness and
contaminants
Daily
Diesel Engine Oil & Filter
Replace
Drain old fluid, change filter
Engine Coolant
Replace
Drain, flush, replenish
Overhaul
Check & Replace
Visual inspection of all
equipment, check operating
tolerances, replace fluids
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Weekly
Weekly
Weekly
As per Engine Manual
(or 250 hours if in
doubt)
As per Engine Manual
(or 2000 hours if in
doubt)
Yearly
ASTON TEMPEST Operations and Maintenance Manual
8.3.1 Hydraulic Oil Filter Change Procedure
1. Loosen four bolts on top of filter housing as per Figure 23 below
Figure 23 – Loosen Four Filter Housing Bolts
2. Turn top lid portion counter clockwise by 15 degrees and the lid will slide off. Note that the boles do not need to
be completely withdrawn as per Figure 24.
Figure 24 – Sliding Filter Lid Off
3. Remove Lid and contained filter out of housing. Beware of residue hydraulic fluid on filter.
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ASTON TEMPEST Operations and Maintenance Manual
Figure 25 – Removal of Filter Housing and Filter
4. Observe fluid contained within the lower (fixed) filter housing and check for additional dirt within unit that may
require draining and refilling reservoir with new fluid. See Figure 26 for more details. If filter housing is
excessively dirty, remove and clean.
Observe this area for
debris/dirt.
Figure 26 – Observing the Filter Housing for Dirt and Debris
5. Lift out filter housing liner and remove any debris and dirt. Replace back into tank after cleaning. Ensure the
two tabs on the side of the housing liner are aligned when re-inserting into the housing. See Figure 27 and
Figure 28 for details.
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ASTON TEMPEST Operations and Maintenance Manual
Figure 27 – Removing Filter Housing Lining
Figure 28 – Filter Housing Lining Removed
6. Insert a new filter onto the bottom of the filter housing as shown. Ensure that the filter seats into the housing.
Replace the new filter and top housing back into the tank as per Figure 29 below.
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ASTON TEMPEST Operations and Maintenance Manual
Figure 29 – Affixing new Filter onto Housing Top
7. Insert entire housing back into the tank. A small amount of force may be required to seat the filter. Once
seated, turn the housing clockwise so it is captive by the bolts and re-torque the bolts. Figure 30 illustrates this
further.
Figure 30 – Lowering the Filter and Housing Top in place
8.3.2 Water In-Line Filter Change Procedure
1. Remove Filter cap by releasing the two retainers on each side of the cap (cam lock) and pull off the top cap.
The screen is located inside. Remove and clean if necessary. See Figure 31 & Figure 32.
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Figure 31 – Removal of Inline Filter Cap
Figure 32 – Removal of Filter
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ASTON TEMPEST Operations and Maintenance Manual
8.4 Recommended Spares List
Item
Atomizer Heads
Atomizer Motors
Hydraulic Pump
Atomizer Straps
Atomizer Screen (SS)
Atomizer Blades
Water Restrictors
Upper Hydraulic Filter
Water Pump
Type
Quantity
AS-100
2
AS-200
2
FFR074
1
Strap
8
Screen
2
6"
Blades
2 sets
R5.0
2
UHF
2
HP9303S
1
9 Appendix
Appendix A – ASTON FURY/TEMPEST Atomizer User Guide V1.2
Appendix B – Sauer Dunfoss Hydraulic Pump Series 45 Frame F Service Manual
Appendix C – ASTON TEMPEST Alarm Table
Appendix D – ASTON TEMPEST Electrical Schematics
Appendix E – ASTON TEMPEST Limited Warranty
Appendix F – Hydraulic Oil Type and Supplier Quote
Appendix G – Fault Tree Analysis
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