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Operation and Maintenance Manual John Zink Dock Safety Unit Customer: CITT End User: SPB User: SPB Location: Cartagena, Location: Cartagena, Colombia Purchase Order No.: 1102 No.: 1102 John Zink Shop Order No.: VC-9152957 Model No.: DSU #1
CAUTION PLANT OPERATING PERSONNEL SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH THE CONTENT OF THIS MANUAL, THE PHYSICAL INSTALLATION, AND EQUIPMENT PROVIDED BEFORE ATTEMPTING TO ENERGIZE AND AND OPERATE THE SYSTEM. SYSTEM. IT IS RECOMMENDED THAT AN AUTHORIZED JOHN ZINK COMPANY FIELD REPRESENTATIVE BE RETAINED FOR INITIAL SYSTEM COMMISSIONING AND PLANT PERSONNEL TRAINING. Requests for field service and spare parts can be made during our normal office hours from 8:00 a.m. to 4:30 p.m. (CST) Monday through Friday. Please reference the John Zink Sales Order number when when requesting service. For assistance, please contact John Zink Company as follows: Service (918) 234-2962 Spare Parts (918) 234-2749
Emergency (918) 234-1800 Facsimile (918) 234-1968
John Zink Company 11920 East Apache Street Tulsa, Oklahoma 74116-1300
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CONFIDENTIALITY STATEMENT INFORMATION CONTAINED IN THIS MANUAL IS CONSIDERED TO BE CONFIDENTIAL AND PROPRIETARY PROPERTY OF THE JOHN ZINK COMPANY AND IS NOT TO BE DISCLOSED TO OTHERS WITHOUT WRITTEN PERMISSION.
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����� �� �������� I. GENERAL GENERAL NOTICES....................................... ..................................................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................ .. 5 II. INTRODUCTION INTRODUCTION ............................ .......................................... ............................ ............................ ............................ ............................ ........................... ........................... ............................ ............................ ................... ..... 7 III. SAFETY............................ .......................................... ............................ ............................ ............................ ............................ ............................ ........................... ........................... ............................ ............................ ................... ..... 8 IV. INSTALLATION INSTALLATION............................ .......................................... ............................ ............................ ............................ ............................ ........................... ........................... ............................ ............................ ................. ... 10 V. DESIGN BASIS AND PERFORMANCE GUARANTEE ........... .......... ........... .......... ........... ........... .......... ........... ......... 12 VI. SYSTEM SUMMARY AND DESCRIPTION .......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ...... 13 VII. DSU SYSTEM OPERATION .......... .......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ........... ......... 15 Pre-Operati Pre-Operation on ........................... ......................................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ .......................... ............ 15 Testing and Calibration ...................................................................................................................................................... 16 System De-Pressure ............................................................................................................................................................ 18 Start-up Start-up ............................ .......................................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ..................... ....... 19 Normal Operation Operation............................ .......................................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................... ..... 19 Process Process Shutdown....... Shutdown..................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ .......................... ............ 20 Normal Shutdown....... Shutdown..................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ .......................... ............ 21 Emergency Shutdown ......................................................................................................................................................... 21 VIII. TROUBLESHOOTI TROUBLESHOOTING NG .......................... ........................................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ................... ..... 23 Problem: Vapor High or High-High Oxygen Content ......... ........... .......... ........... ........... .......... ........... .......... ........... ......... 23 Problem: Vapor Low, Low-Low, High or High-High Pressure .......... ........... .......... ........... .......... ........... .......... ........... .... 23 Problem: Dock Detonation Arrester Arrester High Differential Pressure ........... .......... ........... ........... .......... ........... .......... ........... .. 24 Problem: Valve Sequence............ ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........ 24 Problem: Dock Detonation Arrestor High Temperature............ .......... ........... .......... ........... .......... ........... .......... ........... .... 24 Problem: Vapor Backflow .................... ......... ........... .......... ........... .......... ........... .......... ........... .......... ........... ........... .......... ........... ......... 24 Problem: Oxygen Analyzer Low-Low Flow ......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ........... .. 24 IX. SYSTEM TESTING ........................... ......................................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ .......................... ............ 25 Dock Arrestor High Temperature (TSH-101) .................................................................................................................... 25 Valve Sequence Sequence ........................... ......................................... ............................ ............................ ............................ ............................ ............................ ........................... ........................... ............................ ........................ .......... 26 X. PREVENTATIVE MAINTENANCE .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... . 27 XI. SET POINTS AND CONFIGURATION SHEETS .......... ........... .......... ........... .......... ........... ........... .......... ........... ......... 28 XII. ELECTRICAL-MECHANICAL DRAWINGS .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .... 29 XIII. SPECIFICATION SHEETS .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... . 30 XIV. PLC LOGIC ............................ .......................................... ............................ ............................ ............................ ............................ ............................ ............................ ............................ ............................ ..................... ....... 31 XV. TECHNICAL SERVICE AGREEMENT ......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ........... .. 32 XVI. STANDARD TERMS AND CONDITIONS .......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ...... 33
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XVII. VENDOR LITERATURE .......................................................................................................................................... 34 XVIII. OPERATIONAL-MAINTENANCE NOTES ........................................................................................................... 35
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I. GENERAL NOTICES
WARNING Instructions provided in this Manual were prepared to serve as a general guide. It is intended for use by qualified personnel with knowledge about Equipment of this type. It is not intended to cover all possible variations in Equipment or to provide for specific operating problems which may arise. If additional information is required, please contact the Service Department listed on page 2. Remember, STOP, THINK, AND ASK.
WARNING Each person referring to this Manual is responsible for its proper use in accordance with its terms and conditions, along with adhering to all warnings or cautions provided in the Manual.
WARNING In addition to any general safety measures provided in this Manual, each person must comply with all current national, state, local, and company safety regulations at all times. Any person using this Manual will accept, and agree to be bound by, the following terms and conditions.
NOTE The following terms and conditions are subject to, and are superseded by, any contract between the individual and COMPANY regarding the sale of Equipment. 1.
NO WARRANTIES: This Manual is provided on an "as is", "where is" basis without any warranty or guarantee of any kind, whether express of implied, written or oral. COMPANY EXPRESSLY DISCLAIMS ALL EXPRESS AND IMPLIED WARRANTIES REGARDING THE MANUAL, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE.
2.
INDEMNIFY AND HOLD HARMLESS: Individuals understand there are certain risks inherent in using the Equipment, including, without limitation, bodily injury, death, and damage to personal property, including the various risks described in the Manual under Caution, Warning, or Danger text. Individuals understand these risks may result from a variety of circumstances including, but not limited to, the use or misuse of the Manual or the Equipment. As a material consideration for the right to use this Manual, each person agrees to indemnify, assume and hold COMPANY and its parent company, subsidiaries and affiliates, and each of their officers, directors, employees and agents (collectively the "Seller Parties"), harmless from any and all injuries, losses, damages, costs, and expenses which may arise out of, or result from, the Manual or the Equipment, including, but not limited to, risks of personal injury, death, and property loss or other damages.
3.
LIMITATION OF LIABILITY: IN NO EVENT SHALL COMPANY NOR ITS AFFILIATES (INCLUDING THEIR RESPECTIVE OFFICERS, DIRECTORS, EMPLOYEES AND AGENTS, COLLECTIVELY, THE "COMPANY PARTIES") BE LIABLE OR OBLIGATED TO ANY PERSON OR ANY OTHER PARTY IN ANY MANNER FOR ANY SPECIAL, NON-COMPENSATORY, CONSEQUENTIAL, INDIRECT, INCIDENTAL, STATUTORY, OR PUNITIVE DAMAGES OF ANY KIND, INCLUDING WITHOUT
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LIMITATION, LOST PROFITS AND LOST REVENUE, REGARDLESS OF THE FORM OF ACTION, WHETHER IN CONTRACT, TORT, NEGLIGENCE, STRICT PRODUCT LIABILITY, OR OTHERWISE, EVEN IF THE COMPANY PARTIES WERE INFORMED OF OR ARE AWARE OF THE POSSIBILITY OF ANY SUCH DAMAGES IN ADVANCE. EACH INDIVIDUAL ACKNOWLEDGES AND AGREES THE FOREGOING ALLOCATION OF RISK WAS ACKNOWLEDGED, AGREED, AND FOUND REASONABLE, AND THAT THE FOREGOING LIMITATIONS ARE AN ESSENTIAL BASIS OF THEIR RIGHT TO USE THIS MANUAL. 4.
GENERALLY: The foregoing provisions may not be waived or amended unless in writing signed by an officer of COMPANY. These Terms shall be governed by the laws of the State of Kansas, without regard to its conflicts of law rules.
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II. INTRODUCTION The John Zink Dock Safety Unit (DSU) is a fully automatic system that is designed to incinerate a mixture of hydrocarbon vapors and air and operate remotely in either an automatic or manual mode. The system starts and stops in response to external electrical control signals received by the control logic system. The combustion system is controlled by a programmable logic controller (PLC) which has an internal pre-designed operating logic sequence. The PLC receives and transmits control signals in response to operating pressures and temperatures. In the event that a component fails or if the process conditions vary beyond the prescribed operating parameters, the control system will respond by stopping the flow of hydrocarbon vapor and shutting down the combustion system in a safe and sequenced order. As part of the safety system design to prevent a flame flashback from the burner assembly, i.e., antiflashback burners and detonation arrestors have been provided. Each item is designed to stop the propagation of a flashback to the source of the hydrocarbon vapor flow. In addition to the anti-flashback equipment, various pressure switches, temperature switches, and thermocouples are also used to monitor and protect personnel and equipment from a mis-operation or system malfunction. The vapor combustor system consists of the following equipment and safety devices: 1.
Dock Skid with: a. b. c. d. e.
Oxygen Analyzers Detonation Arrestors Control Panels Vapor Piping, Instruments, and Valves Enrichment Gas Piping and Instruments
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III. SAFETY WARNING All operating and maintenance personnel must read and become familiar with this operating instruction manual. Operation of the dock safety unit must be strictly in accordance with John Zink Company operating and maintenance instructions. IMPROPER OPERATION OF THE EQUIPMENT CAN RESULT IN EQUIPMENT DAMAGE AND/OR INJURY OR POSSIBLE LOSS OF LIFE TO OPERATING PERSONNEL.
This documentation does not replace any existing company safety operating procedures and/or instructions. All normal safety precautions should be followed when operating vapor combustor and fuel systems. Consult your plant operations and safety authorities for complete details.
CAUTION FIRE AND EXPLOSION HAZARDS 1.
Smoking, welding or open flames should be prohibited around the unit as long as it contains hydrocarbon vapors. Leaks should be repaired as soon as possible to prevent accumulation of spilled combustibles. Spillage should be cleaned up promptly.
2.
The marine loading system vapor piping contains hydrocarbon vapor that released in air may become explosive. Extreme caution must be exercised when opening the system for inspection and service. Smoking, welding, or open flame must be prohibited whenever the system is opened to the atmosphere.
ELECTRICAL HAZARDS 1.
Potentially dangerous voltages exist in control cabinets and electrically actuated control components. These components should only be serviced when system power is removed and only be qualified electrical/instrument servicemen.
2.
High voltage (120 VAC) capable of causing severe injury or death is used on this equipment.
3.
Insure all skids and flare stack are properly grounded.
MECHANICAL EQUIPMENT 1.
This vapor combustion system contains pneumatically operated control components, (control valves, block valves). Never operate this equipment unless guides, shields, or covers are in place.
2.
Keep hands, loose articles of clothing, and jewelry away from operating rotating machinery. Since the system starts up automatically, power should be disconnected prior to performing maintenance on the equipment.
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SAFETY EQUIPMENT *1. *2. *3. *4. *5.
Approved safety shoes. Safety goggles or glasses. Fire retardant coveralls. Ear plugs. Hard hat.
*Verify requirements with Safety Management personnel. REPROGRAMMING WARNING The Programmable Logic Controller (PLC) is the computer controlling the Dock Safety Unit (DSU). The PLC is programmed by John Zink Company to ensure proper DSU operation. Accidental or unauthorized reprogramming of the PLC may result in unsafe or dangerous operation of the MVCS. John Zink Company is not responsible for any damages or expenses incurred as a result of unauthorized reprogramming of the PLC. Unauthorized reprogramming could be hazardous to personnel, damage the equipment, and/or void the system equipment warranty. PRESSURIZED GAS Gas under pressure can be dangerous. The following guidelines for working around pressurized equipment must be followed: 1.
Never expose piping, vessels, or equipment to pressures higher than their design pressure. Excessive pressure can result in vessels or lines leaking, bursting, or rupturing, or in other types of dangerous pressure release. Be aware of the design pressures of the equipment you are working with and the gas pressure present.
2.
Keep gas connections tight. Leaking gas containing hydrocarbon vapors presents the danger of fire or explosion. A flanged or threaded connection just tight enough to hold a vacuum or a few pounds pressure may leak at higher pressure. Always use an appropriate thread sealant on threaded connections, and make sure gaskets are in good condition and properly positioned to provide full surface contact.
3.
Always be sure the pressure is relieved before opening any piping or vessel connections.
4.
Do not vent gas pressure by loosening a component connection. Use vent and drain valves provided for this purpose. Even at low pressure, the pressure on components can be great enough to pose a hazard.
5.
Protect your hearing. Pressurized gas being vented may produce a very loud, high frequency sound which may not be uncomfortable but can cause damage. When working around such a vent, use ear plugs or other suitable hearing protection.
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IV. INSTALLATION INSTALLATION Installation of the Dock Safety Unit (DSU) is the responsibility of the customer. Prior to installation, this manual and all related documentation for this project should be reviewed. Any questions about the installation or the equipment should be addressed to the John Zink Vapor Control Service Department referenced on the first page of this manual. Also if alignment or fit-up problems are encountered during the assembly procedure, John Zink Company, Vapor Control Department, must be contacted prior to making any changes or alterations to the equipment. Note: It is John Zink Company's policy to require verbal and written notification of equipment problems. John Zink will review the situation and determine the course of action necessary to resolve any and all field problems. Should the customer or contractor make changes or alterations to the DSU system without prior approval by John Zink Company, any and all claims for field service repair charges will be declined and returned to the individual companies. Review John Zink Company's Warranty and standard Terms of Sale. Personnel performing the installation work must review all drawings provided by John Zink Company in order to properly reassemble the vapor combustion system. Drawings to be reviewed for this installation are: Drawing Number
Description
D-VC-9152957-150 D-VC-9152957-201 D-VC-9152957-202 (1-4) D-VC-9152957-401 - 407 D-VC-9152957-440
Piping and Instrument Diagram Nozzle Legend and General Notes General Arrangement Dock Safety Skid Schematic Wiring Diagrams DSU Test Panel Layout
If the system is going to be stored outside for more than ten days in wet weather conditions, power should be applied to the main control panel and the heater turned on to protect delicate control instruments and help prevent corrosion inside the panel. John Zink personnel should inspect all control enclosures prior to start-up for systems stored more than 90 days. Failure to properly protect the control panel from moisture and corrosion could invalidate all manufacturer and John Zink warranties on electrical components inside the main control panel. The following must be performed to install the Dock Safety Unit (DSU). 1.
Carefully remove the skid from the transport truck using provided lifting lugs. Only qualified equipment operators should supervise, remove, and install the combustion equipment..
2.
Set the skid on properly designed platforms and foundations. Level and grout with nonshrinking grout.
3.
Install the following ship loose components:
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DSU SKID a. Install pressure/vacuum safety vent, PSV-101, to inlet to DSU skid piping. Install all pressure and vacuum weights provided. Bundles are tagged “pressure” and “vacuum” and should be installed on their corresponding side of the vent valve. b. Install dock skid warning lights (AL-2) and alarm light (AL-1) within sight of dock operator and run control wire into control panel CE-1. c. Install oxygen analyzer probe in main vapor piping downstream of enrichment mixer. The probe needs to be between 10 and 30 pipe diameters from the injection mixer, MX-1. Install 1/2” stainless steel tubing from probe to oxygen analyzer sample connection. d. Install rain-shield on Oxygen Analyzer panel. e. Install rain-shield on panel rack.
4.
Customer conduit and electrical wiring hookups. Note that this list is only a summary. See Drawings B-VC-9152957-401 through 407 for details. Note that dashed lines indicate customer supplied wire. a. b. c. d.
120 VAC to overfill panel, VOC-101, 120 VAC to alarm light, AL-1, and shutdown light, AL-2. 120 VAC to control panel CE-1. Run communication cable between all control cabinets in a dedicated communication conduit. Note: See electrical drawings for the type of wire to be used. Final selection of wire sizes and types is the responsibility of the customer in order to comply with the local and NEC codes.
5.
Confirm that all pipe fittings and flanges, electrical wiring connections and electrical conduit fittings are tight. Note: Do Not Pour electrical seals until the vapor combustion system has been checked, started and placed in service by a John Zink field service engineer.
6.
Confirm that external electrical control and power wiring is correctly sized and the system has correct overload protection.
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V. DESIGN BASIS AND PERFORMANCE GUARANTEE DESIGN BASIS Number of Docks ................................................ Two (1 current / 1 future) Number of Loading Berths .................................................... One per dock Vessels Loaded ................................................................................ Ships Vessels Atmospheres ..................................................................... Inerted Oxygen Content of Inerted Vessels .......................................Less than 5% Number of Docks Loaded Simultaneously................................................ 2 Inerted and Non-Inerted Atmospheres Loaded Simultaneously ............. No Maximum Loading Rate .......................................................... 5,500 m3/hr Chemicals ................................................................................... Crude Oil Product True Vapor Pressure (1) ..................................... 3.4 psia maximum Area Electrical Classification DSUs.................................................... Class I, Division 2, Group C, D Motor Type ..................................................................................TEFC Enclosure Type .................................................................... NEMA 4X Detonation Arrestor Classification .................................................Group D Elevation .......................................................................................... ≤ 50 ft Ambient Temperature ................................................................... 15-40°C Electrical Power ........................................................... 120 V, 1 Ph, 60 Hz Nitrogen ..........................................................................................80 psig Vapor Piping…………………………………………………….….ANSI B31.3 Valves and Flanges………………………………………………..ANSI B16.5
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VI. SYSTEM SUMMARY AND DESCRIPTION SYSTEM SUMMARY This Dock Safety Unit (DSU) is designed to capture hydrocarbon vapors generated and displaced from liquid hydrocarbons loading of cargo ships. The maximum loading rate is 5,500 m3/hr. The vapors are drawn into the DSU safety spool through a loading hose from the vessel's cargo tank. Detonation arresters protect against a fire or explosion in the vapor line spreading to other parts of the system or to the ship. SYSTEM DESCRIPTION 1.
Equipment Control Panels Control panels associated with major equipment systems are located throughout the DSU. They contain indicator lights and switches associated with individual panel status.
2.
Programmable Logic Controller (PLC) An Allen Bradley industrial computer controls the automated processes of the DSU.
3.
Safety Spool/Dock Saftey Unit (See drawing D-VC-9152957-150) A safety spool assembly is located on a skid at the barge loading site. The safety spool helps protect the barge and loading facility from flashbacks originating from either side of the safety spool. A loading arm is used to connect the dock safety spool to the vessel being loaded. a. Pressure/Vacuum Relief Valve with Flame Screen (PSV-101) The pressure/vacuum relief valve provides protection from both excessive vacuum and excessive pressure to protect against damage to the barge in the event of a control malfunction. If pressure is low, one valve opens to allow air to be drawn in and reduce the vacuum. If pressure is excessive, the other valve opens to release vapor to the atmosphere and so lower the line pressure. A flame screen in the vacuum relief valve protects against flame being drawn in. b. Intake Vapor Pressure Transmitters (PIT-101,PIT-102) These transmitters trigger high and low pressure alarms for operator attention, and high-high and low-low alarms with a shutdown. c. Detonation Arrester (DA-101) This Coast Guard-accepted device restricts flashback by reducing the flame temperature below the ignition point of the vapor. A detonation is halted by slowing the propagation of the flame-front to subsonic velocity. Both functions are accomplished by routing the vapors through a fine honeycomb of vapor channels which serve to absorb heat and decrease vapor pressure/velocity.
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d. Differential Pressure Switch (PDSH-101) A differential pressure transmitter measures the line pressure difference between the system strainer and the detonation arrester. It triggers a shutdown when a backflow of vapors toward the barge causes a specific pressure difference. It also triggers an alarm if it senses excessive forward pressure drop indicating a dirty filter element. e. Temperature Switch (TSH-101) A thermocouple placed at the outlet of the safety spool detonation arrester monitors DA-101 Temperature and TSH-101 triggers a shutdown if a high temperature is detected. f.
Oxygen Analyzer (ASH-101, ASHH-101) To avoid having an explosive mixture of vapors in the system, the oxygen content of the vapor is continuously analyzed during loading operations. To ensure that the inerted vapors stay outside the explosive range, the oxygen content of the enriched vapor is measured by two oxygen analyzers to ensure that the concentration of oxygen remains below 7% for all cargoes. An alarm is triggered if the oxygen concentration is above 8%. A shutdown will be triggered if analyzer flow is blocked or the oxygen concentration reaches 9%. The Oxygen Analyzer sampling point is located at a point far enough downstream of the enrichment gas injection site to allow adequate mixing of the gases prior to sampling. The Oxygen Analyzer has a 2-hour warm-up period during which its readings may be invalid. Therefore, it must be turned on at least 2 hour before pre-transfer calibration is to be done.
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VII. DSU SYSTEM OPERATION The operation of the Dock Safety Unit consists of the following stages: Pre-operation Testing and Calibration Vessel De-Pressure Start-up Normal Operation Process Shutdown Normal Shutdown Emergency Shutdown The pre-operation stage ensures the system is ready and safe to start up. The testing and calibration stage consists of tests and calibrations of the system. The start-up stage starts the system and brings it to the ready-to-load status. The normal operation stage starts and stops the loading of the marine vessel. The process shutdown stage is a partial, intermediate shutdown that allows faster restarts. The normal shutdown stage is a controlled, complete shutdown. The emergency shutdown stage is an immediate, complete shutdown that occurs when unsafe conditions are detected. These stages are described in detail in the following pages. The instructions do not, however, include the additional steps necessary during the initial system start-up and operation when personnel from John Zink Company are required. The control of this system is highly integrated with the customer’s control system. The operating description and instructions in this manual describe the integrated control as we understand it. They should be reviewed to ensure their accuracy and should be used to develop overall operating instructions for the complete system. Pre-Operation The Pre-operation stage ensures the system is ready and safe to start up. The following instructions assume the system is in a Normal Shutdown status. The steps to be performed are: 1.
Confirm that the following switches are in the position shown: System “Power” (CE-1) “Dock Mode” (CE-1) Customer-supplied power disconnects
2.
Confirm that the following valves are in the positions shown: Analyzer valves Pressure gauge valves Pressure transmitter valves Vapor shutdown valves
3.
OFF OFF OFF
Turn on the customer-supplied power disconnect to CE-1.
Open Open Open Closed
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4.
Turn the system “Power” switch on control panel CE-1 to the ON position and confirm that the system power on light is illuminated.
5.
Press the “Lamp Test” button on control panel CE-1 and confirm that all lights are illuminated.
6.
Press the “System Reset” button at the dock to confirm that all faults are clear. If a fault is present it must be corrected before proceeding.
7.
Inspect loading hose between loading vessel and dock for possible problems.
8.
Insure hand valve HV-101 located on the dock skid is closed.
Testing and Calibration The Testing and Calibration stage consists of the testing and calibration that the USCG requires to be performed within 24 hours prior to the start of loading. Reference: 33 CFR 154.2150 (c). The following faults must be tested on the DSU chosen for loading purposes. Vapor Low Pressure (PSL-101) Vapor High Pressure (PSH-101) Vapor Low-Low Pressure (PSLL-102) Vapor High-High Pressure (PSHH-102) Vapor Backflow (PDAL-101) Dock Filter High Differential Pressure (PDAH-101) Vapor High Oxygen Content (ASH-101/102) Vapor High-High Oxygen Content (ASHH-101/102) Oxygen Analyzer Low Sample Flow (FSLL-101) Additional routine testing of the system is also required and is described in Section VIII, System Testing. The following instructions assume the Pre-operation stage has been completed. The steps to be performed are: 1.
Confirm that the switches system “Power” (CE-1) is in the ON position.
2.
Press the “Combustor Start” button on CE-1.The green “Combustor Started” light will begin to flash. Once the customer combustor is ready to accept vapors the light will turn a solid green.
3.
Turn the “Dock Mode” switch to the TEST position. Isolate PIT-101, PIT-102, and PDIT101 from the process line and open the instruments to the test manifold using the ball valves located at each instrument.
4.
Test the Vapor Low Pressure (PSL-101) fault as follows: a. Using the test manifold located on the dock skid, pull a vacuum on PIT-101. b. Slowly decrease the pressure until the alarm is activated. c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated.
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d. Confirm that the fault activated at the proper pressure determined for each loading operation. e. Relieve the vacuum on the line to clear the fault. 5.
Test the Vapor High Pressure (PSH-101) fault as follows: a. Using the test manifold located on the dock skid apply pressure to PIT-101. b. Slowly increase the pressure until the alarm is activated. c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated. d. Confirm that the fault activated at the proper pressure determined for each loading operation. e. Relieve the pressure on the line to clear the fault.
6.
Test the Vapor Low-Low Pressure (PSLL-102) fault as follows: a. Using the test manifold located on the dock skid pull a vacuum on PIT-102. b. Slowly decrease the pressure until the alarm is activated. c. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated. d. Confirm that the fault activated at the proper pressure determined for each loading operation. e. Relieve the vacuum on the line to clear the fault.
7.
Test the Vapor High-High Pressure (PSHH-102) fault as follows: a. Using the test manifold located on the dock skid apply pressure to PIT-102. b. Slowly increase the pressure until the alarm is activated. c. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated. d. Confirm that the fault activated at the proper pressure determined for each loading operation. e. Relieve the pressure on the line to clear the fault.
8.
Test the Vapor Backflow (PDAL-101) fault as follows: a. Using the test manifold located on the dock skid apply vacuum on the high side of PDIT-101. b. Slowly increase the vacuum until the alarm is activated. c. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated. d. Confirm that the fault activated at the proper pressure determined for each loading operation. e. Relieve the vacuum on the line to clear the fault.
9.
Test the Dock Filter High Differential Pressure (PDAH-101) fault as follows: a. Using the test manifold located on the dock skid apply pressure on high side of PDIT101. b. Slowly increase the pressure until the alarm is activated.
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c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated. d. Confirm that the fault activated at the proper pressure determined for each loading operation. e. Relieve the pressure on the line to clear the fault. 10.
Calibrate Oxygen Analyzer a. Use vendor supplied procedure in Section XVI
11.
Test the Oxygen Analyzer Low Sample Flow (FSLL-101) fault as follows: a. Reduce sample flow using adjustable flow meter inside the analyzer cabinet. b. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated. c. Place sample flow back to original position.
12.
Test the Vapor High Oxygen Content (ASH-101/102) as follows: a. Gradually open needle valve located on the side of the oxygen analyzer to allow ambient air into the sample stream. b. Increase the amount of air into the sample until the alarm is activated. c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated. d. Close needle valve.
13.
Test the Vapor High-High Oxygen Content (ASHH-101/102) as follows: a. Gradually open located on the side of the oxygen analyzer to allow ambient air into the sample stream. b. Increase the amount of air into the sample until the alarm is activated. c. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate control panel light is illuminated. d. Close needle valve.
System De-Pressure Before loading begins, the vessel being filled should be de-pressured close to atmospheric pressure. This is accomplished as follows: 1.
Install the vapor hose to the loading vessel. Insure that the vessel block valve is not open at this time.
2.
If the customer combustor is not already running press the “Combustor Start” button on CE-1. The green “Combustor Started” light will begin to flash. Once the customer combustor is ready to accept vapors the light will turn a solid green.
3.
Turn the “Dock Mode” switch to TEST.
4.
The PLC will ignore the DSU High Pressure Shutdown during the De-Pressure Mode.
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5.
Press the “Vessel Depressure” button and the “Depressure Enable” light will begin to flash.
6.
The customer vapor blowers should go to a fixed minimal output.
7.
Vessel operator can begin to slowly open the vessel vapor header block valve to bleed pressure into the line. If this step is done too quickly the pressure may be high enough to lift the pressure relief valve.
8.
The pressure control valve, PCV-101, will open to a set output of approximately 15%.
9.
The PCV-101 PID loop will be active but not affect the PCV valve position until the PID loop demand exceeds 15%.
10.
As the pressure inside the vessel begin to drop the vessel operator can begin to open the block valve more. This step is repeated until the valve is full open.
11.
The DSU will de-pressure the vessel until the pressure drops to 2” WC.
12.
At this point, the “De-Pressure Enable” light will go solid, the PCV-101 valve will go closed and the customer vapor blower should stop.
13.
DSU “Dock Mode” switch can be moved to the RUN position and loading can commence. Note: During Depressure operation, after the pressure has dropped below the highhigh pressure shutdown set point, the DSU mode switch can be moved to the RUN mode de-activating the depressure mode and allowing loading to commence.
Start-up The start-up stage starts the system and consists of stack purge, pilot ignition, and ready-to-load. The following instructions assume the testing and calibration stage has been completed. The steps to be performed are: 1.
Go to DSU control panel.
2.
Turn the “Dock Mode” switch to the RUN position.
3.
Press the “Combustor Start” push-button. The green “Combustor Started” light will stop flashing and turn solid once the customer combustor is ready to accept vapors, indicating loading can start.
Normal Operation The Normal Operation stage starts and stops the loading of the marine vessel. The following instructions assume the Start-up stage has been completed. The steps to be performed are: 1.
Ensure the “Combustor Started” light is illuminated.
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2.
Confirm manual vapor valve HV-101 is open.
3.
Press the “Dock Start” push-button located on the DSU panel CE-1. a. The customer liquid valve opens. b. Customer vapor blowers can begin operation. c. Pressure control of the DSU system is accomplished by pressure valve PCV-101 working in tandem with PIT-101. The transmitter PIT-101 monitors the operating pressure and passes the pressure on to PIC-101, which increases or decreases the position of the valve.
4.
Operators should monitor the following items: a. Pressures, temperatures and levels. b. Performance of the pressure, temperature and oxygen content controller loops.
5.
To stop loading, press the “Dock Stop” push-button located on the DSU panel CE-1. a. b. c. d.
Customer liquid valve closes. The vapor shutdown valve at the dock PCV-101 will close. Customer vapor blowers should stop. The “Combustor Started” light will stay illuminated.
Several alarms may occur during normal operation that will not shut down the system. The cause of any alarm should be immediately investigated and corrected if necessary. The following will alarm only: Vapor High Oxygen Content (ASH-101) Vapor Low Pressure (PSL-101) Vapor High Pressure (PSH-101) Filter High Differential Pressure (PDAH-101)
Note: The control panel lights are programmed with a first out feature. The light for the fault causing the alarm or shutdown will be flashed. The lights for any faults that may result from the first one will be illuminated steadily.
Process Shutdown The process shutdown stage is a partial, intermediate shutdown that allows faster restarts. When a process shutdown fault occurs, the dock skid will stop and customer vapor blower should shut down while the combustor continues to operate. The following faults will cause a process shutdown: Vapor Low-Low Pressure (PSLL-102) Vapor High-High Pressure (PSHH-102) Vapor High-High Oxygen Content (ASHH-101) Oxygen Analyzer Low Flow (FALL-101) Dock Detonation Arrester Backflow (PDAL-101) Vapor Valve Position Failure
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Note: The control panel lights are programmed with a first out feature. The light for the fault causing the alarm or shutdown will be flashed. The lights for any faults that may result from the first one will be illuminated steadily. 1.
When a process shutdown occurs, the following will occur. a. b. c. d. e. f.
2.
The shutdown (red) strobe light will flash and the horn will sound. The light for the fault causing the shutdown will be flashed. The lights for any faults resulting from the first one will be illuminated steadily. Customer vapor blowers should stop. Vapor shutdown valve PCV-101 will close. The customer liquid valve will close.
After a process shutdown occurs, the steps to be performed are: a. Correct the fault causing the shutdown. See section VII, Troubleshooting. b. Press the “System Reset” button located on the DSU panel, CE-1 and confirm that the alarm clears. c. Press the “Dock Start” button on the DSU panel CE-1. d. The liquid loading valve will open. e. Vapor shutdown valve PCV-101 will open and the customer vapor blower should start the loading process again.
Normal Shutdown The normal shutdown stage is a controlled, complete shutdown that can be initiated at any time during the start-up, normal operation or process shutdown stages. 1.
A normal shutdown is initiated by: a. Pushing the “Dock Stop” button on the DSU panel CE-1. b. Pushing the “Combustor Stop” button on the DSU panel CE-1.
2.
When a Normal Shutdown is initiated, the following will occur. a. b. c. d. e. f.
The control panel lights for any faults resulting from the shutdown will be illuminated. The customer liquid loading valve will close. The DSU vapor shutdown valve PCV-101 will close. Customer vapor blowers should stop. The “Dock Started” light will be extinguished. The “Combustor Started” light will be extinguished.
Emergency Shutdown The emergency shutdown stage is an immediate, complete shutdown that occurs when unsafe conditions are detected. An emergency shutdown can be initiated by pushing the “Emergency Stop” button located on CE-1.
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The following faults will cause an Emergency Shutdown: a. b. c. d.
Dock Arrestor High Temperature (TSH-101) Combustor Global Shutdown Vapor Arrestor Backflow (PDAL-101) Valve Position Failure Note: The control panel lights are programmed with a first out feature. The light for the fault causing the alarm or shutdown will be flashed. The lights for any faults that may result from the first one will be illuminated steadily.
2.
When an emergency shutdown occurs, the following will occur. a. b. c. d. e. f. g. h.
3.
The shutdown (red) strobe light will flash and the horn will sound. The light for the fault causing the shutdown will flash. The customer liquid loading valve will close. The DSU vapor shutdown valve PCV-101 will close. Customer vapor blowers should stop. The “Dock Started” light will be extinguished. The customer combustor should shutdown. The “Combustor Started” light will be extinguished.
After an emergency shutdown occurs, the steps to be performed are: a. Investigate and correct the fault. See section VII, Troubleshooting. b. Press the “Fault Reset” button and confirm that all alarms are clear. c. Restart the system as described in the start-up section.
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VIII. TROUBLESHOOTING WARNING This equipment has 480 VAC and 120 VAC electricity that can shock or kill personnel. Extreme caution must be used when servicing this equipment. This equipment contains vapors within the explosive mixture range. Extreme caution must be used when servicing this equipment. Preventative maintenance and repairs should only be performed by qualified service personnel who are familiar with all safety and operations procedures. Read Section II, Cautions and Warnings before proceeding with any maintenance operations. This troubleshooting section is only intended to be a guide in solving equipment faults. It lists potential problems with possible causes and solutions, and is not a detailed list of all possible problems. Reference should be made to the vendor literature section of the operating manual to troubleshoot problems with specific component items of this system. It is recommended that only qualified service personnel should perform repairs . Contact the John Zink Company at 1-800755-7252 if a system fault cannot be corrected. The following items are discussed in this section. 1. 2. 3. 4. 5. 6. 7.
Vapor High or High-High Oxygen Content. Vapor Low, Low-Low, High or High-High Pressure. Dock Detonation Arrester High Differential Pressure. Valve Sequence. Dock Detonation Arrester High Temperature. Vapor Backflow. Oxygen Analyzer Low-Low Flow.
Problem: Vapor High or High-High Oxygen Content Potential Causes: a. b. c. d.
Oxygen analyzer not working properly. Enrichment gas valve is closed. Strainer is plugged. Regulator is set too low.
Problem: Vapor Low, Low-Low, High or High-High Pressure Potential Causes: a. Strainer is plugged. b. Arrestor is plugged. c. Vapor blower is not operating properly.
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Problem: Dock Detonation Arrester High Differential Pressure Potential Causes: a. Arrestor is plugged. b. Strainer is plugged. Problem: Valve Sequence Potential Causes: a. Automatic shutdown valve has failed. b. Automatic shutdown valve limit switch has failed. Problem: Dock Detonation Arrestor High Temperature Potential Causes: a. High temperature at the arrestor. b. Temperature switch set point is incorrect. Warning: If a high detonation arrestor temperatu re occurs, the equipment should not be operated until the reason for the fault condition is found and remedied. John Zink personnel should be contacted immediately. Problem: Vapor Backflow Potential Causes: a. Enrichment valve has failed open. Problem: Oxygen Analyzer Low-Low Flow Potential Causes: a. b. c. d.
Bad sample pump. Sample lines closed. Sample lines plugged. Flow meters out of adjustment.
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IX. SYSTEM TESTING WARNING This equipment has 120 VAC electricity that can shock or kill personnel. Extreme caution must be used when servicing this equipment. This equipment contains hydrocarbon vapors within the explosive mixture range. Extreme caution must be used when servicing this equipment. Preventative maintenance and repairs should only be performed by qualified service personnel who are familiar with all safety and operations procedures. Read Section II, Cautions and Warnings before proceeding with any maintenance operations. Periodic testing of the safety alarms and shutdowns is of the utmost importance to insure proper operation and safety protection for personnel and equipment. This testing is in addition to the USCG required testing described in Section V. A formal testing schedule that incorporates both calendar and usage requirements should be implemented. Testing every three months or twelve loadings, whichever occurs first, is one recommended schedule. Instructions for testing the following items are provided in this section. 1. 2.
Dock Arrestor High Temperature (TSH-101) Valve Sequence Note: System testing will require that certain control instruments be removed from the vessels and combustor to verify correct calibration set points and operation. Controls shall be reinstalled and a complete system check should be performed to verify the proper operation of the control wiring. When performing a complete system check, do not simulate operation by installing jumper wires.
Dock Arrestor High Temperature (TSH-101) a. b. c. d. e. f. g. h. i. j. k. l. m.
Remove cap from thermocouple TE-101. Turn the System Power switch off. Replace thermocouple TE-101 with a thermocouple simulator. Turn the System Power switch on. Press the Reset button and confirm that all fault lights are extinguished. Increase the thermocouple simulator until the temperature switch activates. Confirm the switch de-activates at 200 °F. Confirm the correct fault light illuminates. Decrease the thermocouple simulator. Confirm the switch de-activates at 200 °F. Press the Reset Button. Confirm that the fault light clears. Reinstall the thermocouple TE-101
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Valve Sequence a. b. c. d. e. f. g.
Turn the System Power switch on. Press the Reset button and confirm all that fault lights are extinguished. Manually open automatic shutdown valve PCV-101. Confirm that the correct fault light illuminates. Manually close the valve that was opened. Press the Reset button. Confirm that the fault light clears.
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X. PREVENTATIVE MAINTENANCE WARNING This equipment has 120 VAC electricity that can shock or kill personnel. Extreme caution must be used when servicing this equipment. This equipment contains vapors within the explosive mixture range. Extreme caution must be used when servicing this equipment. Preventative maintenance and repairs should only be performed by qualified service personnel who are familiar with all safety and operations procedures. Read Section II, Cautions and Warnings before proceeding with any maintenance operations. 1. The detonation arrestors should be checked once every six months to verify that they are free from foreign matter, which could restrict hydrocarbon vapor flow. 2. All safety shutdown devices should be tested for correct operation and verified a minimum of once every three months. 3. Review Section VIII, System Testing, to assist in preventative maintenance. 4. Check calibration and operation of all instruments in accordance with vendor literature in Section XVIII. 5. Refer to vendor literature for specific maintenance requirements of various components. 6. Thermocouples should be checked for accuracy once every year. Note: The above preventative maintenance summary is only designed as a guideline and does not include all areas that must be checked. A preventative maintenance program must be designed, based upon existing company policy, operational experience, vendor data requirements, maintaining an adequate supply of spare parts and an operation-maintenance log book. John Zink has many field technicians across the world that can provide Preventative Maintenance assistance with documented checks and corrections. For a detailed PM quote please contact 918-234-5718.
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XI. SET POINTS AND CONFIGURATION SHEETS The following set points are for start-up purposes and may require adjusting during start-up to match specific operating conditions. Vapor Low Pressure (PSL-101) Vapor High Pressure (PSH-101) Vapor Low-Low Pressure (PSLL-102) Vapor High-High Pressure (PSHH-102) Vapor High Oxygen Content (ASH-101) Vapor High-High Oxygen Content (ASHH-101) Dock Arrestor High Temperature (TSH-101) Nitrogen Purge Gas Pressure Vapor Backflow (PDAL-101, PDAL-301) Filter Blockage (PDAH-101)
(*) (*) -10” w.c. 20” w.c. 8% O 2 9% O 2 200 °F 30-40 psig -1” w.c. 10” w.c.
* These values are dependent on the vessel to be loaded. Refer to 33 CFR 154.814. TABLE 1: OXYGEN ANALYZER SET POINTS NON-INERT TYPE OF CARGO O 2 CONTROL % O2 ALARM % (ASH) O2 SHUTDOWN % (ASHH) N/A N/A N/A N/A TABLE 2: OXYGEN ANALYZER SET POINTS INERT TYPE OF CARGO O 2 CONTROL % O2 ALARM % (ASH) O2 SHUTDOWN % (ASHH) Crude Oil 7.0% 8.0% 9.0%
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XII. ELECTRICAL-MECHANICAL DRAWINGS Drawing Number D-VC-9152957-150 D-VC-9152957-201 D-VC-9152957-202 (1-4) D-VC-9152957-401 - 407 D-VC-9152957-440
Description Piping and Instrument Diagram Nozzle Legend and General Notes General Arrangement Dock Safety Skid Schematic Wiring Diagrams DSU Test Panel Layout
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XIII. SPECIFICATION SHEETS
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XIV. PLC LOGIC
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XV. TECHNICAL SERVICE AGREEMENT
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XVI. STANDARD TERMS AND CONDITIONS
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XVII. VENDOR LITERATURE Tab 1 2 3 4 5 6 7 8 9 10 11 12
Manufacturer Air / Gas Filter (Filter) Asco (Solenoid Valve) Bettis / PMV (Actuator / Positioner) Enardo (Arrestor, Pressure / Vacuum Relief Valve) Fisher (Regulator, Flow Control Valve) Flowseal (Butterfly Valve) McDaniel (Pressure Gauge) Mueller (Strainer) Neo-Dyn (Pressure Switch) Servomex (Oxygen Analyzer) Thermo-Sensor (Thermocouple) Yokogawa (Pressure Transmitter)
