FUNCTION OF A LOADING ARM INSTALLATION From any fixed point (Pier,jetty,ect..),this (Pier jetty ect ) this unit provides loading and unloading facilities for seagoing vessels and river barge. barge 1. Loading arm freedom of movement to : - Follow the high and low water positions for tides and river levels. - Follow the movement of the vessel in the water due to variations in weight as the cargo is loaded or unloaded. - Follow the drift of the vessel (parallel or perpendicular to the quay side) 2. Control equipment necessary for the land operating personnel to : - Supervise loading conditions. - Act quickly in the event of accidents.
YAW
HEAVE
PITCH SWAY ROLL
SURGE
BOAT MOVEMENTS
9
CONTROL SYSTEM & OPERATING PRINCIPLE
The tubing g , flexible hoses and fitting connectors, to interconnect all hydraulic equipments & components
10
CONTROL SYSTEM & OPERATING PRINCIPLE The complete maneuver of the Chiksan arms within the working envelope is effected by means of an electro-hydraulic system. This system y enables independent p movements of the units around their horizontal axis,, and the movement of the complete p assembly y around a vertical axis The control of the arm is achieved by an electric & hydraulic installation composed of: The components which are common to all the arms of a given bank: • One hydraulic power unit , common unit for arms maneuvering, ERS system • The hydraulic power unit delivers the hydraulic power to operate the control valves and arm hydraulic cylinders & hydraulic motors • One PLC cabinet, a jetty head control panel • A remote control units ( radio cordless ) •
P i i Monitoring Position M i i System S (PMS)
• From the jetty head control panel, the operator can fully control of the arms and respond to any signal. Arms movements can also be controlled from the radio remote control panel. It is easier to connect the arm from the tanker's deck with the radio remote control The components which are supplied for each arm : • The h selector l valve l assembly bl with h ERS S accumulator l at the h foot f off each h arm has h the h function f to distribute d b the h hydraulic h d l power on the h right h cylinder l d • The ERS accumulator delivers hydraulic power supply in case of electrical power failure to emergency disconnect the arm • A set of hydraulic cylinders & hydraulic motors (Quickon III hydraulic coupler & style 80 rotation) Hydraulic cylinders power three movements of the RCMA : Slewing of the complete arm Raising and lowering of the inboard section Raising and lowering of the outboard section • The slewing of the complete articulated assembly in a horizontal plane is achieved with one double acting cylinder connected to the female piece of the Style 50 riser swivel. The drive cylinder stem end is connected to the riser • The inboard drive of the arm includes one double acting cylinder, a wire rope, a driving pulley and a return (or idler) pulley arrangement installed on the inboard arm • The outboard drive of the arm includes a double acting cylinder, connected directly to a rack bar which operates a gear connected with the balancing sheave installed on the rear of the inboard arm
11
LOADING ARMS GENERAL KINEMATICS • All loading arms are designed to accommodate six degrees of movement between the ship and the deck. Six swivel joints are used on a loading arm to provide the needed movements as described below: • The first three swivel joints from the base riser to the style 40 apex swivel joint of the loading arm provide the three translations of the end of the loading arm to cover the operating envelope.
3
2
• The three last swivel joints ensure the rotational degrees of freedom, in order to align the coupler flange with the ammonia ship manifold flange. Each of the three swivel joints of the style 80 terminal swivel joint assembly corresponds to a rotational movement of the ammonia ship: The rotation number 4 ensures the freedom for the roll movement of the tanker The rotation number 5 ensures the freedom for the yaw movement of the tanker
4
The rotation number 6 ensures the freedom for the pitch movement of the tanker
1
• Six degrees of possible motion between ship and shore, during transfer: 6 degrees of freedom ► 6 swivel joints
5
Swivels 1 to 3 = > 3 translations Swivel 4=> Roll Swivel S i l 5 => Yaw Y
6
Swivel 6 => Pitch Practically no limit for the roll, pitch and yaw accepted
12
OPERATING ENVELOPE AND SPOTTING LINE(S) • Operating envelope definition : That volume in witch a loading arm presentation flange is required to operate. The volume is based on the range of manifold locations, changes in tides and freeboard,, surge g and sway. y • Spotting line(s) definition : For a single arm connection the spotting line is a line, at a pre-determinate location on the jetty deck which is aligned with the centre-line of the ship’s manifold to which it connect. connect For multi-arm connections the spotting line for each group of connected arm is a line, at a pre-determinate location on the jetty deck which is aligned with the centre-line of the group of ship’s manifold flanges to which they connect.
C
A
HWL LWL
Operating envelope • Terminal de Barra do Riacho _ Drawing N° 2400208129701 • Terminal de Ilha Comprida _ Drawing N° 2400208129702
A
: Flanging area
C
: Drift area
HWL : High water level LWL : Low water level
13
RCMA \ ROUTATING COUNTERWEIGHT MARINE LOADING ARM \ GENERAL VIEW
The RCMA arm is fully balanced in all positions, the counterweights being combined into one rotating assembly to balance both i b inboard d and d outboard tb d arms
14
RCMA - GENERAL VIEWS \ STYLE 50 SECTION Base riser
• This sub-assembly connects the RCMA to dockside piping for fluid transfer. It also provides an i important t t supportt ffunction. ti Th The di dimensions i off the th pipe, i base b plate l t and d gussets t are determined d t i d by b the total deadweight of the arm, wind loading forces, and the weight of the product in the arm. • The inboard arm is connected to the top of the base riser and includes the main counterweight extension. The outboard arm links the inboard arm to the vessel being loaded or unloaded. • This swivel joint connects the top of the base riser to the inboard arm and includes a swivel allowing arm rotation around the base riser riser, a 90 degree elbow and a swivel allowing inboard arm rotation around a horizontal axis.
2
Outboard arm
Inboard arm
Style 50_Trunion
Style 50_Elbow (Removable)
1
Style 50_Riser
Base riser
15
RCMA - GENERAL VIEWS \ STYLE 40 & STYLE 80 SECTIONS STYLE 40 WHEEL ( APEX )
3
• This swivel joint connects the inboard and outboard arm at the apex p of the RCMA. It includes a 90 degree elbow, a swivel allowing the outboard arm to move relative to the inboard arm and another 90 degree elbow.
STYLE 80
4
• This swivel joint connects the outboard arm to the vessel manifold. It includes three swivels connected by three 90 d degree elbows lb to allow ll a wide id range off possible movement when connecting or disconnecting the RCMA.
5 6
16
RCMA - ACCESS LADDERS Access ladders to reach the style 50 & style 40 are installed on the base riser and the inboard arm maintenance platforms
• The technician performing the arm maintenance operations is protected by a harness equipped with safety lanyard and carabineer so that he is permanently attached. The h harness is i attached tt h d to t a retaining carriage which glides freely in the guide rail as the technician climbs or descends. • During the ascent or the descent, the technician exerts a light traction on the retaining carriage from his dorsal position in support. The retaining carriage glides consequently freely in the rail. Without traction, the retaining carriage automatically swings and comes to engage on the nearest notch. notch Any possible fall is avoided.
17
RCMA MARINE LOADING ARM \ MAINTENANCE PLATFORMS
Maintenance platforms located at the style 40 & 50 of the arm levels allow the inspection & light maintenance of the parts
18
Tie-down system y
INBOARD ARM LOCKING DEVICE AND OUTBOARD ARM LOCKING VALVE
1.Purpose It is necessary to mechanically lock the marine loading arm vertically in the rest position to enhance the safety of the operating personnel 2. Description
Hydraulic valve in opening position: Outboard arm free
The FMC mechanical tie-down system has one part located at the end of the inboard arm structure and the other on the base riser of the arm. arm With the arm locked in the vertical stored position, it is neither possible for the complete arm to slew nor for the inboard arm to swing. To lock the outboard arm (located on the front side of selector valve cabinet), a manually operated hydraulic valve is normally used. The tie-down system is designed to withstand the maximum wind speed of the installation.
Hydraulic valve in closing position: O b Outboard d arm llock k
Inboard arm mechanical locking g device
19
INBOARD ARM LOCKING DEVICE Purpose: • The locking device of the inboard arm prevents the slewing and the inboard arm motions when the arm is in parked (stored) position. p the locking g device ? How to operate • Rotate the hand wheel either clockwise or counter clockwise to lift up or to lower the square bar What are the safety locking positions ? • In p parked position, p , always y ensure that square q bar is FULLY inserted into the U-shape of the inboard arm and firmly tighten the hand wheel Warning: • Failure to lock full stroke the locking device of the inboard arm could unlock the arm, cause damage it and bend the locking screw when the arm is in parked position and subjected to wind action
Inboard arm mechanical locking device
20
BALANCE SYSTEM AND PANTOGRAPH ARRANGEMENT Style 40 sheave
Outboard arm
Pantograph cables Outboard counterweights
Pantograph arrangement • The pantograph arrangement is composed of two sheaves (style 40 & balancing sheave) and cables . These cables are strung around the sheaves to transmit the counterweights force to the outboard arm
Balancing sheave
21
BALANCING SYSTEM DESCRIPTION & METHODOLOGY Balancing system •
The arm is balanced by counterweights and pulleys so that it is balanced empty in all conditions without the intervention of any external mechanical force.
For the outboard section and style 80:
By the main counterweights on the balancing sheave beam with the pantograph
For the arm assembly: By the main counterweights / balancing sheave assembly which compensates the weight of inboard, outboard sections and the "Style 80" By the additional counterweights (if necessary) fitted on the beam of inboard arm for making better the inboard section balancing Methodology Proceed as follows : 1.
Adjustment of the parallelism ( outboard arm & outboard counterweight beam ).
2.
Adjustment j of the outboard balancing. g
3.
Adjustment of the inboard balancing.
Mechanical adjustment & tests •
Wire ropes are subject to initial stretching, and may require adjustment of turnbuckles to remove excessive slack ( generally on sea side turnbuckle tu buc e ). )
Check the arm balancing, extending it into the working area and unselect the arm from “selected” mode to “free wheel” mode - Check that the outboard counterweight beam is parallel to the outboard section - Check that the outboard and inboard arm remains fixed once the maneuver is stopped •
A slow l motion ti off outboard tb d and d inboard i b d arm is i acceptable t bl by b consideration id ti off the th mechanical h i l parameters t off the th equipment i t and d the th service i conditions
22
PANTOGRAPH CABLES & WIRE ROPES MAINTENANCE Annual preventive maintenance: • Check condition of cable (greasing,slackness,ect.) • Check lock nuts, coupling sleeves and turnbuckles for looseness • If the sea side pantograph cable is too tight, it would impose undue loads on the style 40 and balancing sheaves swivel joints; if required loose a sea side turnbuckle and check again the parallelism • Periodical lubrication (Minimum yearly greasing ) • Wire rope shall be lubricated. Whenever a lack of lubricant is noted, remove all di t prior dirt i to t lubrication, l b i ti by b using i compressed air or by brushing and grease again Pantograph cables (Upper & lower side) Inboard driving system wire ropes • Setting of pantograph cables parallelism ( after replacement ).
Safety instructions regarding the wire rope • Corrosion : If the wire rope are kept lubricated as noted above, then this will not be a problem. It is essential that corrosion does not take place place. Internal corrosion is not visible and external corrosion may just be pitting, which is not visible to the naked eye. The first sign of corrosion will be rust forming on wire rope. The wire rope should be replaced if too much corrosion occurs. • Loss in diameter : This condition is due to excessive strain, internal corrosion or broken wires and requires replacement of the wire rope. • Broken wires : Each "lay" is made up of strands, and each strand is made up of a group i At A the h first fi sign i off a broken b k wire, i the h off wires. wire rope must be replaced since it is not possible to see broken internal wires.
• Check that the cable section winding round the sheaves are in the middle of the channel and not against one of the flange. • Pantograph cables maintenance ( refer to the maintenance manual / Section § 5 )
Core
Strand Wire rope Wire
23
HYDRAULIC DRIVE CYLINDERS \ DESCRIPTION & PREVENTIVE MAINTENANCE • The hydraulic power unit delivers the hydraulic power to operate the control valves and arm hydraulic cylinders. • The operator controls the arm movements from the main control panel or partially from the remote control p panel. • The selector valve assembly at the foot of the arm has the function to distribute the hydraulic power on the right cylinder. • Three movements of the RCMA are powered by hydraulic cylinders:
Slewing of the complete arm.
Raising and lowering of the inboard section.
Raising and lowering of the outboard section
• The slewing of the complete articulated assembly in a horizontal plane is achieved with one double acting cylinder connected to the female piece of the riser swivel. The drive cylinder stem end is connected to the riser • The inboard drive includes one double acting cylinder or 2 single acting cylinders, a cable and pulley arrangement installed on the inboard arm • The outboard drive includes one double acting cylinder or 2 single acting cylinders installed at the bottom of the inboard arm ► 12” loading arms only
Note: Nuts of hydraulic cylinder casing threaded rods require thread locking adhesive ( Loctite 243)
• The outboard drive of the arm includes a double acting cylinder, connected directly to a rack bar which operates a gear connected with the balancing sheave installed on the rear of the inboard arm ► 6” and 10” loading arms
24
ALL ARMS \ SLEWING HYDRAULIC DRIVE CYLINDER The slewing of the complete articulated assembly in a horizontal plane is achieved with one double acting cylinder connected to the female piece of the riser swivel. The drive cylinder stem end is connected to the riser.
1. Clevis 2. “SKF” Knuckle 3. Clevis pin 4. Split pin 5. Plate washer 6. Cylinder shaft Slewing drive cylinder ( double acting )
7. Spacing ring
Clevis
25
ALL ARMS \ INBOARD HYDRAULIC CYLINDER & INBOARD DRIVING SYSTEM The raising and lowering of the inboard arm / structure assembly of the RCMA is obtained by a double effect drive cylinder fastened on the inboard arm of RCMA and inboard structure of RCMA) witch actuates a cable and sheave arrangement installed along the inboard arm of RCMA and inboard structure of RCMA Free pulley Greasing gp point
Wire ropes & turnbuckle
Double acting cylinder
Style 50 _ fix pulley ( Anchorage point )
26
6” & 12” ARMS \ OUTBOARD CYLINDERS & OUTBOARD DRIVING SYSTEM Outboard drive cylinder (double acting )
Rack bar
Rack pinion system
Rack guides
27
12” ARMS / OUTBOARD CYLINDERS & OUTBOARD DRIVING SYSTEM Outboard drive cylinders (double acting )
Turnbuckle & Sleeves
Wire ropes
Pulley & Anchorage
The outboard drive includes two simple acting cylinders, a cable and pulley arrangement installed on the inboard structure and balancing sheave.
28
HYDRAULIC DRIVE CYLINDER \ DOUBLE ACTING CROSS SECTIONAL VIEW
Hydraulic cylinder location:
Shaft threads assembly with lock thread : Loctite 275
• All RCMA : Slewing, g, Outboard & Inboard driving g system y Hydraulic cylinder seals / Ordering details for spare seals kits: • Use the genuine FMC spare part. Part number available on recommended spare part list • See instruction sheet in Operating & Maintenance Manual for Maintenance and Overhaul of hydraulic drive cylinders
29
HYDRAULIC DRIVE CYLINDER \ SINGLE ACTING CROSS SECTIONAL VIEW
Hydraulic cylinder location:
Shaft threads assembly with lock thread : Loctite 275
• RCMA 12” ONLY : Outboard driving system (Qty 2 per arm ) Hydraulic cylinder seals / Ordering details for spare seals kits: Use the genuine FMC spare part. Part number available on recommended spare part list
30
HYDRAULIC DRIVE CYLINDER \ CROSS SECTIONAL VIEW SEALS REPLACEMENT
• Hydraulic cylinder \ Seals replacement procedure & Preventive maintenance
31
HYDRAULIC DRIVE CYLINDERS \ PREVENTIVE MAINTENANCE Annual preventive maintenance
• Major overhaul / Seals replacement: Between 5 to 7 years ( The need for an major overhaul will normally confirmed by excessive corrosion ,wear of components) • For hydraulic cylinders maintenance , refer to the maintenance manual
32
PRODUCT & STRUCTURE SWIVEL JOINTS DESCRIPTION A swivel i l joint j i t assembly bl • Enabling the loading arm once connected, to follow the movements of the vessel within the working envelope. • Allow the rotation between two items of a product line whilst ensuring no product leakage, even under external pressure. • The heart of a Chiksan marine arm is the swivel joint. ln a standard marine arm there are six i swivel i l joints j i t with ith the th direction di ti off rotation in three planes giving the arm six degrees of freedom. This allows the arm to be manoeuvred to and from the vessel and, once connected, allows the arm to follow ail the motions of the vessel. • Each swivel joint is made up of a male and female part joined by two or three bail bearing raceways allowing the free rotation of the joint. A compression type packing seal is used to seal the two parts of the swivel joint. Packings • Chiksan swivel packing ensure that fluid does not leak. They come in a variety of materials depending on the physical and the chemical characteristics of the product being handled. Specially designed low torque packing are used in the style 80 to enable this swivel joint to be easily moved when connecting to or disconnecting from a vessel.
33
RCMA LOADING ARM – PRODUCT & STRUCTURE SWIVEL JOINTS A Chiksan swivel joint is typically composed of one, two or three th swivels i l which hi h allow ll movementt in i different diff t parts of the RCMA. The swivel consists of a male nipple which turns in a female coupling on two or three rows (races) of ball bearings
3
2
5
4 1
6
7
34
REMOVABLE ELBOWS & PACKING REPLACEMENT Limit of use – Recommendations: Before any maintenance operation on site, ensure that the minimum precautions below are taken into account : •
The jetty must be free of any residual vapour of hazardous products and the maintenance zone clearly posted. Other loading/unloading arms must not be in operation. All other rules specific to the operator, to the local regulations or linked to the products handled will have to be respected
Never attempt any maintenance, disassembly, inspection or repair on a loading arm before to be sure that : •
The arm is empty of product, at ambient temperature and without residual pressure,
•
The arm is locked in up-right position (vertical rest position of inboard arm),
•
The balancing and the parallelism have been accurately carried out and checked,
•
The arm cannot be operated,
•
For a hydraulically-operated arm, it is necessary to lock the arm by the manual selection from the selector valve
•
For a hydraulically-operated arm, switch off power supply and isolate the electric and hydraulic equipment (control panel, panel hydraulic power unit, unit accumulator, accumulator etc
•
Check that all personnel wear protective equipment (minimum : gloves, safety glasses, safety helmet , safety shoes, harness, etc.)
•
Ensure that safe working load of the lifting means is selected according to the weight of the piece to be handled
•
Only the FMC genuine maintenance tools must be used
Style 50
Style 40
35
REMOVABLE ELBOWS & PACKING REPLACEMENT STYLE 50 True removable elbows are installed at the Style y 50 (Riser) ( ) and Style y 40 (Apex). ( p ) Permanent devices being fixed on the loading arm, it is possible to totally remove the elbow in order to inspect and change the packing seal if necessary without the need for lifting equipment, significantly reducing downtime • Required special tools (provided)
• Replacement of Packings at Style 50 •
Lock the arm in vertical position of inboard arm. Use the personal protective equipment (refer to the instructions sheet "Use of the safety equipments"), to climb up to the Style 50. For the arms without platforms or ladders, it is necessary to use a man basket (or aerial lift) or equivalent
•
Install the lifting device (1) using the collar around axis (4)
•
Put in place the winch (2). It must be connected between the welded ring (3) and the lifting device (1). If necessary, use slings between the both ends of the winch
•
Loosen and remove the bolting of the both flanges of the Style 50 spool
• •
With the winch, lift and rotate the elbow around the axis (4) Remove the packing(s) of the Style 50 riser (A) and/or the Style 50 trunion (B) swivel joints
•
Clean the sealing faces & Install the new packing(s)
•
Reinstall the elbow and the bolting and tighten the bolting according to recommended torques (see separate instructions sheet)
•
Remove the winch (2) and the lifting device (1) in the reverser order
36
REMOVABLE ELBOWS & PACKING REPLACEMENT STYLE 40 Replacement of packing at Style 40 •
Lock the arm in vertical position of inboard arm
•
Use the personal protective equipment (refer to the instructions sheet "Use of the safety equipments"), to climb up to the Style 40. For the arms without platforms or ladders, it is necessary to use a man basket (or aerial lift) or equivalent
•
Refer to the Style 50 paragraph for the next steps of the procedure
•
Install the new packing(s) and always replace the spiral wound gasket (5)
In each case, inspect the packing faces on the male piece and on the flange. They must be in perfect condition. Some superficial corrosion may be eliminated by polishing. If more corrosion is present, it cannot be removed that way, it is necessary to replace the swivel pieces (Contact the After Sales Department of FMC). See instruction i i sheet h in Operating & Maintenance Manuall for f Packing k s replacement l
37
REMOVABLE ELBOWS & PACKING REPLACEMENT STYLE 80 Secure the arm •
Operate the arm in such a way that the Style 80 reaches the jetty or the dummy manifold (where available)
•
Secure the arm with slings and wire rope (Tirfor winch) or chain blocks :
•
Fasten the outboard / inboard arm firmly to mooring points on the jetty or base riser gusset (taking up on 3 points). See detailed procedure in the Operating and Maintenance Manual
4
5
Replacement of packing at Style 80 • The swivel joints 4 & 6 are 2 pieces type SWJ’s without flanges. It is necessary to fully dismantle the SWJ’s to be able to replace the packing. For the SWJ 6, it can be easily dismantled by rotating the connecting flange. For the SWJ 4, it will be necessary to disconnect all hydraulic flexible hoses, instrument cables between outboard arm and ERS to ensure that the lower part of the style 80 is secured on dummy manifold. manifold The “split split flange flange” SWJ 5 will be disconnected from the flange and the SWJ 4 will be dismantled by rotating the elbow. •
Style 80 6
The swivel joints 5 is "split flange" type (3 parts swivel joints), a complete disassembly of the ball races to replace the packing is not required. The packing is accessible when the flange is taken apart. Refer to the instructions sheet "Disassembly / Reassembly of swivel joints”
Note: •
Before the disassembly of a Style 80 swivel joints, always ensure that the arm is correctly secured to compensate unbalance. Contact the After Sales Department of FMC for assistance
•
Spare parts must be always available prior to start the maintenance works (Packings, SWJ’s components, electrical insulation components…) Arm in maintenance position Style 80 on the dock
38
SWIVEL JOINTS PREVENTIVE MAINTENANCE Preventive maintenance • Check for abnormal noise during operation( If the sea side pantograph cable is too tight, it would impose undue loads on the style 40 and balancing sheaves bearings; if required loose a sea side turnbuckle and check again the parallelism and/or pantograph sheave bearing may need lubrication,ect...) • Periodical checking all fixing parts (Apply the corresponding torque on bolts, screws ,refer to the maintenance manual). • Periodical touch paint : Check for damage to the painted surfaces and a formation of rust. Where necessary use a suitable paint repair procedure to restore protection. • The need for an major overhaul will normally confirmed by excessive corrosion ,wear of components. • Periodical lubrication manual or centralized greasing system ( bearings and all moving parts ,refer to the maintenance manual ) Grease : Molykote 44 light Packing : AD / SS Procedure • Proper lubrication consists in small amounts of grease, lightly and smoothly applied and evenly distributed through out the bearing chamber. Even distribution can be best achieved by rotating the swivel through 30 to 40 degrees between successive small applications of grease. Swivels should be checked for smooth rotation after lubrication.
Important : • The removal of any parts for maintenance, repair or inspection should only be undertaken by qualified and trained personnel .
39
SWIVEL JOINTS PREVENTIVE MAINTENANCE \ PACKINGS
16” AD\SS Packing
16” AD\SS Packing – Damaged sealing surface & g p particles Presence of foreign
40
CENTRALIZED GREASING SYSTEM & MOBILE LUBRICATION UNIT Centralized greasing system • This system is installed to lubricate the swivel joints at style 50, style 40, balancing sheave and the axis of the return pulley of the inboard drive (only 8” arms) without having to climb the arm to perform this maintenance preventive p p operation. p • The style 80 swivel joints are manually greased. • The filling of the centralised greasing system is effected from the dock by a manual pump. Benefit: Benefit • Provides for better protection against moisture, corrosion, rust the environment guards against g the risk of internal • Limits and g components corrosion • Allows for the lubrication of areas and joints of the arm not easily accessible • Permit continuous functioning of arms and thus saves important intervention time • Reduces the risk of pollution from the lubricant • Prolongs g the life and good g working g condition of the arm • Centralized greasing system Drawing N° 24027081297521A Mobil manual lubrication pump
41
CENTRALIZED GREASING SYSTEM
Measuring valves (4 points)
Style 40
Centralized greasing system:
Inboard pulley
• The greasing pump is connected on two lines dia 18. The grease is pressurized with the pump and delivered inside the li lines. At each h swivel i l joint j i t is i installed i t ll d a measuring i valves l which hi h deliver small quantity of grease and ensure that all swivel joints are lubricated in same time. • While using the manual pump, the grease must be pressurized at approx 120 bars before to be delivered in 1 line. One greasing i cycle l is i achieved hi d when h the th grease has h been b pressurized two times and that the grease has been delivered in the 2 lines. (to be able to be dispatched
Style 50
Annual p preventive maintenance: • Annually inspect the centralised greasing system: Measuring valves, fittings, flexible hoses…(If any) • Protect measuring valves with Densyl tape
Balancing sheave
42
ELECTRIC INSULATION FLANGES \ PRINCIPLE & MAINTENANCE Purpose : • To T isolate i l t and d avoid id sparks k att the th ship/loading hi /l di arm flanges fl connection ti • The isolation flange is an electrical insulation barrier that prevents electrical current flow between the loading arm and tanker during oil loading (stray currents and static electricity ) • The isolation flanges are one of several systems used to minimize current flows between the berth and the tanker Electric insulation test : ( yearly ) • The electric insulation shall be measured though the swivel joint which has no external contact with ground or other metallic part • M Measurementt shall h ll be b performed f d with ith the th arm in i empty t condition diti and d fully f ll dried d i d att ambient temperature • Measure with a Mega ohmmeter the electrical insulation resistance under 20 Volts dc (direct current) . The resistance must be equal to or higher than 1000 ohms ( 1 KΩ After hydrostatic testing ) • Material measurement ► Dielectrometre MC 5 Chauvin Arnoux or equivalent (Equipment calibrated by an independent laboratory) Electric insulation / Annual preventive maintenance : • Th The electric l t i insulation i l ti joint j i t will ill be b disassembled and inspected in case of test failure. The defective elements will be replaced and the insulation joint will be reassembled and re-tested • Check the external coating condition • Check the hydraulic flexible hoses condition ( if any by pass, all flexible hoses at the style 80 section must be electrically insulated type )
Three factors are necessary to initiate an explosion: A. Oxygen B. Gas (from leakages) C. Initiation of sparks
• For value torque, refer to the OMM
43
ELECTRIC INSULATION FLANGES Silicomet "joint blue" packing paste Used for re-sealing the epoxy glass pipes & washer . After fitting the bushes and washers ,fill the remaining cavities with packing paste ( Used as seal to prevent ingress of moisture). moisture)
External coating / Two coats of "Carbo mastic 14" product or equivalent ( Epoxy resin )). The special p black coating g ensures a non-conductive protection for rain Sealing against external agent : Replaced the protective compound if it's damaged or cracked
1
• Item 1 : Isolating washer
2
• Item 2 : Isolating pipe • Item 3 : Isolating plate • Item 4 : Lattygraph seal (both side)
3 Electric insulation disassembly & re-assembly procedure
4
• It is strongly misadvised to carry out the disassembling of the electric insulation flanges without having as a preliminary the spare parts necessary at the reassembly
44
ELECTRIC CONTINUITY ON THE ARM Each arm and his line is fitted with an electrical continuity, the bypass rotations being effected by copper cables. The base is equipped with a bracket to be grounded. Purpose : To ensure the continuity of electric arm to avoid possible damage rotations in contact occasional ball / Snap in the case of a potential difference important. The electrostatic charging of an arm can create a spark if the electrical continuity is not assured. Considering that the static loading arm can occur during loading, due to the flow of product in the pipeline, we must consider an electrical continuity the arm to the grounding. This independently of the joint electrical insulation on the arm (between flange or rotation ST80, which has the function of preventing a spark to establish if the vessel is not at the same potential as the dock upon login / disconnect). disconnect)
Style 40 section
45
MECHANICAL JACK & ANTI-ROTATION SYSTEM ON STYLE 80 Jack has 3 main goals :
Single leg jack
• The mechanical jack is located at the style 80 (terminal) swivel joint of the marine loading arm .The jack partially transfers arm loads to the tankers deck this reducing manifold stresses. • To balance the style 80. If jack is removed, style 80 will be unbalanced, and angle between coupler and manifold flange will be increased. • Prevent the rotation of ERS after an emergency disconnection sequence: Indeed, hydraulic actuator is shifted from flange axis. If arm is designed with a vapour return t li line, th the bending moment is still more important. Friction swivel torque is inferior to the moment of hydraulic actuator(s) ( ) Anti-rotation system is linked to the jack. If jack is removed after a disconnection sequence the Style 80 can fall on vessel deck Preventive maintenance: Twin leg g jjack
• Regularly R l l grease the th jack’s j k’ screws and d anti-rotating ti t ti system t (b (bearing) i )
46
NITROGEN PURGING LINE \ BASE RISER TO APEX 1” nipple 1 Style 40 (apex) swivel joint
Non return valve
Style 50 (riser) swivel joint
Flexible hose
Swivel joint
Style 80 (terminal) swivel joint Line supports
• 1’’ Nitrogen purging line (for 12” arms)_ Drawing N° 2402608129752
Line flange
Nitrogen purging line 1" dia. from base riser to apex (Style 40) \ Purpose : • Drain the arm out with nitrogen injection at style. Product in inboard arm and base riser is pushed back to shore and outboard arm to the ship. Nitrogen draining is used when the product shall not get in contact with open air or to accelerate the draining procedure time • Bypass of the style 50 (riser) swivel joint by a combination of flexible hose coupled to a swivel joint to increase the overall life expectancy • Installed on each arm, it allows filling nitrogen in the outboard arm from the Style 40 of the arm to drain the arm off. This 1" line is fitted with a check-valve at its tops to avoid any ejection of product from the line. • The connection to the nitrogen circuit on the dock is achieved by the 1" 1 ANSI 150 RF flange with a ball valve
47
PURGE SEQUENCE DESCRIPTION WITH NITROGEN LINE FROM BASE RISER TO APEX OF THE ARM Clapet Anti-retour Check valve
Sequence description :
Ligne de chasse azote Nitrogen injection line
e–O
be Int ern e
rn Exte
Tu
T ube
–I nb oa rd
a rm
• After the end of loading (no pressure in product line), with product line valves V1 and V2 open : • Open valve V3 (to inject nitrogen at apex). • The product located in the inboard arm and in the base riser is pushed towards the land, when the outboard arm and style 80 swivel joint is drained (by gravity) towards the tanker. • When the arm is empty, close valves V3, V1 and V2.
Apex
utbo rm ard a
Embase – Base Riser
Vers le terminal To the terminal
Azote Nitrogen Produit Product
C t Customer
Vers le navire To ship tank
V2
V3
Produit Product Customer
V1 Jetée - Jetty
Navire - Ship
48
QUICKON 3 HYDRAULIC COUPLER \ DESCRIPTION General The Quikcon 3 is a hydraulically operated Quick Connect / Disconnect Coupler (QCDC) based on the Chiksan® manual Quikcon coupler. During operation, the jaws of the clamps rotate simultaneously to the correct position as the clamps open or close across the tankers manifold flange. One O-ring seal fitted in a groove of the Quikcon 3 coupler flange insures a positive sealing. sealing Quikcon 3 offers faster mating of flanges than possible through manual flanging operations, another FMC innovation for improved operator safety and lowering tanker dock time. Description Quikcon 3 operates with three (6” and 10” ) or four clamps (12”) assemblies to secure to the ships manifold flange. Designed to work with new, as well as existing, hydraulic pumping units, the coupler may be adjusted to function at different operating pressures Features : • Mechanically locked using irreversible screw and nut mechanism for enhanced safety. • In case of electric power failure, can be opened either hydraulically or manually using a spanner • Reduced turnaround time of vessels
Quikcon 3 hydraulic coupler / ANSI 300 _ OMM
49
QUIKCON III HYDRAULIC QCDC / 6”, 10” & 12” ANSI - 300 FLANGE Quick Connect/Disconnect Coupler Important notice: • Never pressurise the loading arm with the blind flange g installed on the coupler p except p for those which have a safety pressure relief valve or a hole • During a disconnection operation, do not hold the coupler opening switch control until the jaw is full stroke opened. opened Once the jaw of each tightening unit has opened and that the ship manifold flange is free by coupler, the operator shall release the joystick switch (or control panel switch). Do not attempt to open the clamps full stroke at its maximum position • Do not attempt to connect the arm on a ship’s manifold flange having either a different pressure rating or a different diameter than forecasted • Check for connecting manifold or spool flange face condition : it must be clean and free of any scratches. Surface roughness of manifold flange must be of the same type and quality than the one of the coupler • Never attempt to connect the h coupler l on flange fl which do not comply this surface roughness requirements. Otherwise, the coupler may probably leak
50
QUICKON 3 - HYDRAULIC COUPLER DESCRIPTION
QUICKON III closing - Video QUICKON III opening - Video Quikcon III is a hydraulically operated coupling, during operation the jaws of the clamps rotate simultaneously to the correct position as the clamps open or close across the ship’s manifold flange. One “O-ring seal fitted in a groove of the Quikcon III coupling flange insures a positive sealing
51
QUICKON III \ HYDRAULIC COUPLER PREVENTIVE MAINTENANCE \ PRIMARY SEAL REPLACEMENT Primary seals replacement • During the replacement of the primary packing seal, unscrew the M6 screws which maintain the retaining seal brackets. Replace the packing seal and screw the M6 screws. g seal bracket is located as far as possible p from the sealing g face,, to avoid that packing p g comes into brackets during ga • Payy attention to the retaining connection operation. • Check for connecting manifold or spool flange face condition : it must be clean and free of any scratches. Surface roughness of manifold flange must be of the same type and quality than the one of the coupler. • Never attempt to connect the coupler on flange which do not comply this surface roughness requirements. Otherwise, the coupler may probably leak leak.
52
QUIKCON III HYDRAULIC QCDC \ HYDRAULIC SYSTEM PRINCIPLE QCDC control block Q • The aim of this manifold is to control the closing or the opening of the hydraulic coupler, by controlling the 4 hydraulic drives (1 for each clamp) in serial or parallel mode.
Hydraulic schematic
• When closing from an open position :The serial mode is automatically on. on The clamps start to close with the same oil flow, while the pressure is divided by three.
• When one clamp is almost closed: the flow decreases. Then the parallel mode is automatically on. on The clamps continue to close with independent flows, but with the same pressure (190 on each) • Quikcon III is a hydraulically operated coupling, during operation the jaws of the clamps rotate simultaneously to the correct position as the clamps open or close across the ship’s manifold flange. One “O-ring seal fitted in a groove of the Quikcon III coupling flange insures a positive sealing • The closing operation stops in parallel mode, mode when the operator estimates that the coupler is completely closed.
• Hydraulic pressure is not required to maintain the clamping force. The non reversible drive screw system is designed so that this clamping force is maintained automatically • The hydraulic block is composed of metering jets : the hydraulic oil must be clean and without particle to avoid hydraulic trouble shooting
53
QUICKON 3 - HYDRAULIC COUPLER \ PREVENTIVE MAINTENANCE Yearly maintenance • Open the cover, inspect and full grease QCDC driving system • Before reassembling, clean and degrease the polyethylene cover (07) and the plate (06). Spread a blue silicon layer on the cover surface f and d reassemble bl it with ith the 4 screw (21).
Preventive maintenance / Greasing • Every three months, grease each tightening unit of the hydraulic coupler l with ith FMC specified ifi d grease. The Th coupler l mustt be b greasing i in i open position trough items (17) in two places for each module. Insert approximately 100 g of grease • In order to distribute the grease in the whole tightening unit, make a few opening and closing cycles after greasing • If some squealing noises are audible since functioning, grease the hydraulic Quikcon III coupler using the same procedure
Recommended grease: Kubler Isoflex Topas L32
• Regularly check the seal cover condition to avoid increase water inside the mechanism of the QCDC driving system (motorization) and grease the gearing g g system y fullyy g
54
QUICKON III \ HYDRAULIC COUPLER MAINTENANCE BOARD Periodic servicing and routine inspections • Coupler requires little maintenance, but that which is required is essential and must be accomplished if ultimate service life is to be achieved • Each time that the hydraulic coupler is operated, it would be well to quickly check all hydraulic tubing, hoses and hydraulic block for leakage while the clamps are being closing
55
QUICKON III - HYDRAULIC COUPLER \ MANUAL OPERATION Manual operation of the hydraulic coupler is provided as a safety feature for times where hydraulic operation is not possible Recommended procedure by manual operation of hydraulic block • Remove the protecting cover on the hydraulic block • If any (depends of hydraulic bloc generation) , remove the plastic cap fitted on the setting rod, unscrew the counter-nut then screw the rod on the side of the hydraulic block, in order to push the internal distributor. The block is then in parallel position • Unscrew the screw (23) and the washer (22) located on the driving screw then remove the plug (9) with the V-seal V seal ring (14). (14) • Release each clamps independently, operating each driving screw (3) with a standard 21 mm wrench in the correct direction of rotation • The driving screw (3) has a left handed thread. Screw clockwise to open the clamp • After having unlocked each clamp, unscrew the rod of the hydraulic block in order to bring it back to its initial position. The hydraulic block is returned in serial position • Operate the screw of one of the motorizations using the wrench. All clamps open simultaneously (the hydraulic flow drives all the motors together). The shaft has to be fully turned approximately 25 times to get it from its closed position to the opened position • Reassemble the plug (9) with V-seal ring (14), the washer (22) and the screw (23)
56
QUICKON 3 - HYDRAULIC COUPLER \ MANUAL OPERATION Manual operation in case of electric power failure or hydraulic failure • Drain the arm and check that it is empty • Remove the main screw gear plug (9) and parts (14), (21) and (23). • Remove the square key (25 & 24) • Use 21 mm socket wrench to actuate coupler manually (either opening or closing) Hydraulic functioning recovering • Reassemble the square key (24), the gear plug (09) and the screw (21-22)
For more information, refer to: Quikcon 3 / Operating & Maintenance manual
57
QUICKON III \ HYDRAULIC COUPLER MANUAL OPERATION
Manual operation in case of electric power failure or hydraulic failure • Remove the main screw gear plug • Remove the square key • Use 21 mm socket wrench to actuate coupler manually (either opening or closing) Hydraulic functioning recovering • Reassemble the square key the gear plug and the screw
58
EMERGENCY RELEASE SYSTEM (E.R.S.) \ PRINCIPLE • The h Double-Disco bl i Valves/Emergency l / Release l Coupler l (DDV/ERC) ( / ) provides id the h means to isolate the flow of product and disconnect the marine loading arm from the tanker in the event of an emergency. • Upon disconnection, the loading arm side valve remains part of and isolates the marine loading arm. The ship side valve remains attached to the tanker flange isolating the tanker manifold. Spillage of product is therefore prevented from both the arm and tanker manifold. manifold • The DDV/ERC is activated by the FMC control system. The speed of the operation of the DDV/ERC, opening/closure of disco valves and disconnection of ERC, is adjusted by controlling the flow rate of hydraulic oil from the hydraulic power unit. Two independent p functions are integrated g in the ERS actuator:
ERS Valves actuation
PERC release
• Mechanical & hydraulic Interlocks between the 2 functions. When the ERS valves are opened p or not fullyy closed: Impossible p to release the PERC without closing g completely p y the double valves • The two disco valves are actuated simultaneously, through a parallelogram link system, as used on hundreds of FMC ERS systems in service. • All the parts of this actuator are protected against corrosion, using the same materials as on Chiksan Marine Loading Arm and hydraulic QC/DC. QC/DC
• FMC / 6” DDV / PERC_Drawing N° 24KTV030630Y • FMC / 10” 10 DDV / PERC Drawing N° N 24KTV031030Y • FMC / 12” DDV / PERC drawing N° 24KTV1312200 • FMC / DDV / PERC / Operating & Maintenance manual
59
ERS TANDEM DESCRIPTION \ DDV & PERC ASSEMBLY
60
ERS TANDEM DESCRIPTION \ DDV & PERC ASSEMBLY
61
ERS TANDEM - DDV \ PERC CLAMPS DESCRIPTION The ERC consists Th i off two clamps l connected d by b rods forming a collar around the ball valve middle flanges (Face plates). The shape of the clamps acting on the profile of the middle flanges exerts a force holding them together. • Complete Assembly A embl in stainless t inle steel teel • Spring Energized (Belleville washers) PERC to ensure proper opening under 25mm ice coating – OCIMF 1999 • Easier to reconnect after a disconnection: no specific equipment required Maintenance facilities: • Possible to simulate a disconnection without releasing the PERC: removing of the PERC axis • Possible to release the PERC without separating the double valves: use of maintenance clamps Belleville spring washers: • Assembling of the 8 Belleville washer in 4 places
General assembly of the 2 clamps PERC assembled on the two valves
62
ERS TANDEM - DDV \ PERC CLAMPS DESCRIPTION The PERC collar is energized by Belleville washers located inside the two clamps in order to break the ice layer and open properly the PERC. A shear pin prevents PERC from unexpected release.
PERC in closed and opened position
Belleville spring washers: • Assembling of the 8 Belleville washer in 4 places Shear pin: • A shear pin is fitted in the releasing fork for added security by preventing accidental release of the Perc ((Onlyy use FMC shear pin). • Regularly check that the shear pin is in position and undamaged. • The correct shear pin position guarantee that the PERC clamps and release fork is well positioned
Picture N°2 PERC axis in operating position
Picture N°1 Shear pin with safety pin
63
TANDEM HYDRAULIC CYLINDER / ESD1 SEQUENCE Vidéo
Picture N°3 / ERS Double ball valves opened / PERC closed
Picture N N°4 4 / ERS Double ball valves closed / PERC closed (ESD1)
ESD1 / Stop loading sequence description: • The first part of the tandem cylinder stroke is used for closing the valves (ESD1 sequence). For this, the yoke pushes the roller of the operating lever and the upper valve is closed. Simultaneously, the lower valve is closed by the connecting rods linked to the second operating lever.
64
TANDEM HYDRAULIC CYLINDER / ESD2 SEQUENCE ESD2 routine test \ Vidéo
ESD2 Vidéo
Picture N°5 / ERS Double ball valves closed / PERC released after emergency disconnection sequence (ESD2) ESD2 / Emergency disconnection sequence description: • The second part of the tandem cylinder stroke is used to release the PERC by pushing the PERC axis via the pusher (ESD2 sequence). At this stage, t th the upper valve l iis free f from f th the llower operating ti lever. l
65
ERS ACTUATOR \ TANDEM HYDRAULIC CYLINDER \ PRINCIPLE Description:
A
B
C
D
E
• Very simple (few moving parts) and very light Mechanical interlock: • Impossible to release the PERC without closing completely l l the h double d bl valves. l • Meet OCIMF and EN1474: disconnection in two sequences: 1. Closing of the valves 2 Disconnection 2. Di ti • Use of a tandem cylinder which is composed of two cylinders overlapped • Two hydraulic valves to control this actuator: 1 One for manoeuvring the double valves 1. 2. One for releasing the PERC Design: • Composed of 2 oil chambers and 2 movable parts Functioning steps: • A: valves in opened position • B: valves in closed position • C: PERC release • D: valves re-opening after disconnection • E: valves in opened position
66
TANDEM HYDRAULIC CYLINDER \ ESD2 SEQUENCE
Picture N°6 / Valves closed
Picture N°7 / PERC releasing / Breaking shear pin
67
TANDEM HYDRAULIC CYLINDER \ ESD2 SEQUENCE
Picture N°8 / PERC releasing / Opening the DBV clamps
Picture N°9 / The PERC collar is energized by Belleville washers located inside the two clamps
68
ACTUATOR DESCRIPTION \ DDV IN OPEN POSITION DDV hydraulic cylinder
PERC clamps
Pusher
DDV connecting rods
PERC Ca axis s: • Installed: PERC can be activated •
PERC axis removed
Removed: PERC cannot nnot be activated ti ted
69
ACTUATOR DESCRIPTION \ DDV CLOSE & PERC OPEN DBV hydraulic cylinder
DBV in closing position & PERC activated (PERC clamps open)
PERC clamps
Pusher
PERC axis : • Installed: PERC activated
70
DDV & PERC ASSEMBLY \ PERC LOCKING VALVE • Hydraulic y circuit for PERC control is equipped q pp with a manually operated locking valve, installed directly at triple swivel assembly ( Style 80) • It has to be opened at time of connection and closed at time of disconnection. • A control switch detects its position "opened“ Position "closed“ or “Perc valve not armed” : • The manoeuvring of the arm is possible • Disconnection of the PERC during manoeuvring or rest position of the arm is not possible Position "opened" opened or “Perc Perc valve armed armed”:: • The manoeuvring of the arm is not possible (selection of the arm is automatically disable by the FMC logic when the Perc valve is armed) • The disconnection of the PERC is possible in case of emergency after closing of ERS valves. Important : • This PERC locking valve must be imperatively opened for the PERC to be operational. • The PERC valve is manually operated after arm connection to the ship’s p manifold and stayy in opening p g position during all loading time. This PERC valve must be closed before to disconnect the arm. • When the PERC valve is in open position ( PERC armed, arm in “Loading” selection), the arm is automatically unselected by the logic, it’s means the arm is in free wheel and cannot be operated. p Preventive maintenance: • Regularly check the inductive proximity switch and manual operation valve efficiency • Check manual operation valves efficiency and grease the mechanism
71
INDUCTIVE PROXIMITY SWITCHES ON DDV & PERC ASSEMBLY PERC collar detection
One proximity switch to indicate if the PERC clamps are full closed and tightened (Show PERC collar in correct closing position_ When Perc collar is fully open after ESD2 ► Open DDV operation is disabled )
One inductive proximity switch to ensure that th t th the axis i PERC is i placed. Removing this axis enables to carry out ESD2 (Emergency disconnection sequence) simulation without releasing the PERC ((Show without PERC axis))
Show on this picture PERC axis installed \ PERC in operating condition
Inductive proximity switch DBV detection in opening position
Inductive proximity switch DBV detection in closing position
72
INDUCTIVE PROXIMITY SWITCHES ON DDV & PERC ASSEMBLY Picture N°10 / PERC hydraulic valve not armed (valve closed) PERC disconnection not allowed Control light on jetty control panel “Arm ready for loading” is “Off”
Picture N°11 / Switch two position / To inform the FMC logic (green control light on jetty control panel) and DCS (customer info) that the QCDC is closed and arm in operating condition (Operator action) Picture N° 12 / Inductive proximity switch PERC axis detection / PERC axis removed PERC not in operating condition
Picture N°13 / Inductive proximity switch PERC axis detection / PERC axis installed PERC in operating condition
73
EMERGENCY RELEASE SYSTEM \ SAFETY & RE-ASSEMBLY RODS The 4 safety/re-assembly rods must be installed : • For testing the closing of the DDV and activation of the ERC • During maintenance works on the DDV/ERC assembly • For the re-assembly of the DDV after emergency disconnection • At the end of the loading/unloading operations, after closing the PERC valve and prior to disconnect the arm from the ship • These safety rods should be stored on the berth if possible
4 places
74
DDV/PERC – EMERGENCY DISCONNECTION SEQUENCE
FMC factory yard test \ September 2009
ERS valves closed, PERC activated
Loading arm hydraulically blocked in position
ESD2 sequence _ Closing of ERS valves and PERC activation video
75
SECURING THE LOADING ARMS FOLLOWING AN EMERGNECY DISCONNECTION SEQUENCE (ESD2) Manoeuvre the arm after emergency disconnection : Warning / Major safety issue : It is forbidden to reset an ESD2 emergency disconnection sequence before having stored and secured all the emergency disconnected loading arms on parked position or connected again on the ship. This would put the disconnected arms out of all control and could cause serious personal injury or death (the ESD reset switch key must be removed from the switch). During all operations putting the personal in contact with the products, this personal should be equipped with the safety clothes adapted to the product . • Select manually all emergency disconnected arms, from selector valve cabinet (imperatively), See Picture N°23: • Following an emergency disconnection (DDV close & PERC collar opened), two different alternatives are possible, depending the situation on the berth. The first one is to drain, store and secure the loading arm; the second one is to directly reconnect the loading arm on the ship • From the main control panel, select radio cordless mode for the loading arm operation
Picture N°23/ Selector valve manual command with locking device ( show on this picture in selected mode, Arm hydraulically blocked)
76
DOUBLE VALVES / PERC RE-ASSEMBLY AFTER ESD2
•
•
•
• • • •
•
•
•
PERC re-assembly procedure for one emergency disconnected arm: From selector valve assembly: Manually select the emergency disconnected arm as indicated in Slide 76 From remote control, re-select re select the emergency disconnected arm ( See instructions and procedure at the next page) If possible, operate the arm / Style 80 near the ship deck or on the jetty and install a rope on the outboard arm (to secure the arm) and close the PERC hydraulic isolating valve Move the inboard arm to the vertical position and lock it with the mechanical locking device Operate the outboard arm 10° above the horizontal position (see the drawing) The outboard arm will be also drained by gravity inside the inboard arm product line Open the 1” valve nitrogen purging line (located on the base riser) and open drain valve (customer process). The product inside the inboard arm and the base riser product line will be drained on shore side (slop tank) After complete draining, bring back the outboard arm to the park position and secure it with the temporary rope and close the outboard valve (located on selector valve assembly). As soon as all emergency disconnected arms are drained and secured, it is possible to reset the ESD2 sequence. The ESD2 sequence can be reset only when all arms are drained and secure
Drain valve
77
RE-CONNECTING THE LOADING ARMS AFTER ESD2 Reconnection of the loading arm on the ship: • Thi This second d solution l i allow ll the h reconnection i off the h loading arm full of product directly on the ship when possible to be able to start again the loading/unloading sequences.
Clapet Anti-retour Check valve Style 40 Style 40 - Apex
Ligne de chasse azote Nitrogen injection line
The steps are as follow: • The V1 valve is closed during the emergency disconnection sequence (ESD1)
Tube Interne Inboard arm
• Select the loading arm from the cordless remote control or from the control panel
Style 50 Style 50
Tube Externe Outboard Arm
• IImperatively ti l manually ll select l t the th disconnected di t d loading l di arms for safety reasons (as indicated slide 71) • Ensure that the ship is positioned in the correct working area. PERC (fermé) PERC (closed)
• Bring back the loading arm on the ship • Close the PERC valve • Reconnect the PERC collar between the DDV’s. (see the ERS reconnection procedure starting slide 74) • Unselect the loading arm (electrically and manually) • Proceed to the same operation for all disconnected loading arms
Vers le terminal To the terminal
Embase Base Riser
Customer
Azote Nitrogen Produit Product
Vers le navire To ship tank
V3 Produit Product
V1
Customer
V2
• Reset the ESD2 sequence. • The key switch “Reset Reset ESD sequences” sequences can be used only when all loading arms are stored and secured.
ERS (Vannes ouvertes) ERS (Opened valves)
Jetée - Jetty
Navire - Ship
• Open the V1 valve • Restart the loading/unloading operations.
78
RECONNECTION OF THE DDV/ERC SYSTEM Reconnection arm per arm
TOP VIEW
• This operation can be done on the ship (lower valve still connected on the ship) or on the jetty (free of ship and lower valve connected on dummy manifold) • When the alarm sequence has been reset and if the hydraulic PERC locking valve is still armed (unlocked), it is therefore impossible to select the arm from the electric or radio remote control panels •
It is then necessary to operate the loading arm from the directional control valves (by using the manual command) after selected manually the loading arm
4 places
• Ensure that the ship is in the correct working area • Start the hydraulic pump • Select electrically the loading arm from the remote control • Select manually the loading arm from the selector valve for safety reasons (see picture on slide 76)
Re-assembly & safety rods
• After an emergency disconnection, the loading arm is operated unbalanced • Remove the safety sling from the outboard arm (if installed before) • Remove the stow locks and operate the loading arm and upper valve so that the middle iddl flanges fl are approximately i t l 300mm 300 apart. t It may be b necessary to t attach tt h a rope to the upper valve so as to bring the middle flanges parallel • Ensure that the seal area between the PERC flanges is clean, dry and free from foreign matter and that the seals are in a perfect condition and correctly installed. The seals should be replaced if any damage or scratching – even minor, is detected. Th seall groove area should The h ld also l be b perfectly f tl clean l and d free f from f any scratching t hi • Install the re-assembly & safety threaded rods as shown on picture • Close the PERC valve (if not done before) Chain blocks can also be used in addition on instead of the threaded rods
79
RECONNECTION OF THE DDV/ERC SYSTEM •
Using the re-assembly threaded rods, or with the chain blocks line up the valves and adjust adj st the th threaded eaded rods ods o or hoists so that the middle flanges are ae approximately aligned and parallel, maintaining a distance of 300mm between the flanges
•
Manually unselect the arm from selector valve assembly and from the remote control, switch to “0” position). The arm will be in free wheeling mode and will move with the ship’s motion
•
Replace the PERC gasket (between ERS flanges)
•
Bring the two disco valves together by adjusting the hoist and ensuring that: The notch in the middle flange of the upper valve is oriented and aligned with the notch in the middle flange of the lower valve (see Picture N°19). Check that the cross linkage’s linkage s ‘Y’ Y shaped connections are engaging correctly around the pins on the ship side lower valve lever (see Picture N°20) The spigot in the middle flanges is correctly engaged( see Picture N°18)
•
Position the PERC collar around the disco valves middle flanges ensuring that the p position is correct. Picture N°19 _ DDV notch alignment
Picture N°18 DDV/ Flanges alignment
Pi t Picture N°20 _ Reassembly R bl DDV/ERC cross li linkage k
80
RECONNECTION OF THE DDV/ERC SYSTEM • Once both valves flanges are together, remove the PERC axe if not done before • Un tight g the PERC collar of ½ turn using g the adjustable j screw with nut welded • Position the PERC around the flanges PERC and engage the came (See Pictures N°30) • Re-tight the screw, as recommended torque value • The tightening torque value is different for each double valve/Perc diameter. Refer to the table on the following slide for the torque value of each loading arm • Reinstall a new shear pin in the releasing fork for added security by preventing accidental release of the Perc (Only use FMC shear pin) • The correct shear pin position guarantee that the PERC clamps and release fork is well positioned (See Picture N°30)
PERC clamps position
Adjustable screw Came in position
Shear pin installed back
Picture 30: Perc collar re-assembly
Picture 24: Tightening Perc collar
81
RECONNECTION OF THE DDV/ERC SYSTEM Adjustable screw
Warning: The tightening torque value is different for each double valve/Perc diameter. Refer to the table on the following slide for the torque value of each loading arm
82
RECONNECTION OF THE DBV/ERC SYSTEM •
Reconnect the QCDC coupler hydraulic lines via the snap connectors (Pi (Picture 27)
•
Unlock the DDV driving system by pulling the locking disk (see pictures in slide 79 )
Shear pin
• Start the hydraulic pump of the HPU and re open the ERS valves (DDV) using the command on the control panel or on the cordless remote control •
As soon as all PERC / ERS valves are reassembled, carry out a pneumatic pressure test as indicated in operating and maintenance manual as indicated in section 4 ( DDV flange N² leak test at 6 bar)
R Repeat t the th above b procedure d for f the th remaining i i loading l di arms Option 1 ► After ERS\DDV reconnection \ Restart the transfer: •
As soon as all the conditions of loading are joined, all ERS\DDV reconnected :
•
If it iis nott done, d manually ll deselect d l t the th arm ( Arm A in i free f wheel h l mode). Unselect this arm from the selector valve assembly (see Picture 27) by unscrewing the manual selection and from the remote or local control panel
Picture N°25b \ Torque wrench for PERC re-assembly
• Remove the re-assembly & safety rods. Install the ERS in working condition diti (S (See Pi Picture t 25 : ERS ready d for f operation ti (PERC axis i installed) • Open the PERC isolating valve on all connected arms ► The loading arms are now back in normal operation mode •
Restart the p product transfer (refer ( to the normal operating p g procedure p \ OMM “Operating instruction) Quick coupling/ Picture 27
83
RECONNECTION OF THE DDV - MECHANICAL LOCKING SYSTEM Unlock the DDV driving system by pulling the locking disk (disengage the locking pin from the housing)
DDV in opening position
DDV in closing position y locked Mechanically
Pull the locking disk to unlocked the DDV
84
RECONNECTION OF THE DDV/ERC SYSTEM Option 2 ► Disconnect and bring back the arm in storage position: • If it is not done, manually deselect the arm ( Arm in free wheel mode). Unselect this arm from the selector valve assembly (see Picture 27) by unscrewing the manual selection and from the remote or local control panel •
Start the hydraulic pump, reselect the arm and open the hydraulic coupler (From radio cordless)
•
Disconnect the arm from the tanker manifold and open the hydraulic coupler, replace the coupler face plate cover
• Operate the arm and manoeuvre it back to the stowed / parked position and lock this arm (Mechanical device for the inboard arm and manual valve on the hydraulic line of the outboard arm) •
Unselect the arm from jetty control panel or from the radio cordless unit
Repeat the above procedure for the remaining loading arms
Pusher connected to the tandem cylinder
Perc axis Shear pin with safety split pins
Picture 27: Arm manually deselected
Picture 25: ERS ready for operation
Perc axis in position: ERS ready for operation
85
DDV/PERC ASSEMBLY / INSPECTIONS AND TESTING 1. Routine inspection (Every three months) Refer R f to t th the preventive ti maintenance i t b board d 2. Routine testing • ERS valves close/open tests (Operation from local control panel or from cordless remote control) After the inspection & before the arrival of each tanker • ERS valves closure testing by ESD1 activation (Stop loading sequence) After the inspection before the arrival of the first tanker, this test must be performed monthly or before each loading. • PERC hydraulic cylinder routine testing by ESD2 activation (Emergency disconnection sequence) After the inspection before the arrival of the first tanker, this test must be performed monthly or before each loading • PERC hydraulic valve testing • After the inspection before the arrival of the first tanker, this test must be performed every year • PERC controlled release testing • After the inspection before the arrival of the first tanker, this test must be performed every year Warning – Very important / Actions to be carry out before any routing testing •
The key switch “maintenance override” must be on position 1 and the yellow light “Maintenance Override Activated” must be “On” (stop automatic retraction)
•
Prior to operating the unloading arm or opening the hydraulic coupler check that the loading arm is empty of product
•
The loading arm is equipped with an emergency release system (Double Disco Valves/PERC assembly). Before maneuvering the loading arm check that the PERC locking valve located on style 80 is closed to prevent any opening of the PERC . On Jetty control panels , all green light “Arm ready for loading” must be “Off” on all arms
•
Ensure that the 4 safety and re-assembly rods are installed as indicated in Slide N°74
•
During this test ensure that there are no personnel within a three meter radius of the style 80
•
With the radio control unit maneuver the loading arm so that the style 80 is accessible to jetty
•
Manually select the arm to be tested as indicated in slide N°76
•
Remove the PERC axis from the PERC collar as indicated here and on slide 73
PERC axis removed ERS system ready for routine tests
86
FUNCTIONNING TEST \ ERS VALVES CLOSE This test will be performed from the local control panel or from the cordless remote control: • Check h k that h conditions d indicated d d slide lid 86 are achieved h d • Start the hydraulic motor pump (if not running yet) • When the loading arms is in parked position or in manoeuvring mode, the ERS valves should be opened and the corresponding green light “ERS VALVES OPENED” should be “ON” on the local control panel Close the ERS valves using the rotating switch on local control panel (direct command) or using the switch button on the cordless remote control after corresponding loading arm has been selected • The corresponding red light “ERS VALVE CLOSED” should lights “On” on the local control panel Open the ERS valves using the rotating switch on local control panel (direct command) or using the switch button on the cordless remote control after corresponding loading arm has been selected • The corresponding red green “ERS VALVE OPENED” should lights “On” on the local control panel When the Wh h di disco valves l are iin iintermediate di position, i i both b h lights li h « ERS VALVES OPENED » and d « ERS VALVES CLOSED » are flashing
Radio cordless transmitter “Open DDV”
“Close DDV”
Synoptic jetty control panel
87
ESD1 - STOP LOADING SEQUENCE ROUTING TEST PROCEDURE Warning – Very important / Actions to be carry out before any routing testing as indicated in slide 86
• The hydraulic pump is automatically started. The corresponding lamp "Pump running" lights up on the local control panel.
Check that the maintenance override key switch is on position 1 and that the yellow light “maintenance override activated” is “On”
• The solenoid valve SV10 in the HPU to release the pressure of the accumulator is energized.
• These tests can be done from push buttons on the local control panel and from equivalent customer device • Deselect the arm (Arm selector switch in position “0” on local and remote control panel). Arm will then be in free wheeling. The "Arm p lights g “Off” selected" lamp • For safety reasons, the arms will be kept indicated on slide 76
manually selected as
• The hydraulic pump is stopped • The local control panel is kept under power • Ensure that the PERC axis is removed from the PERC collar as indicated in slide 73: ERS operation - Routine testing (Actuator with PERC axis removed from the PERC)) in order to prevent an inadvertent release of the PERC
• A time delay starts (corresponding to the time closing of the main shut off valve and stopping pp g of the pump). p p) T1: 0 seconds. Can be adjusted during pre-commissioning/commissioning. • At the end of this time delay T1 (average timing: 5 seconds), a new time delay starts (corresponding to the closing time of the ERS valves) and the solenoid valve “DDV closing” is energised ((Temporisation p T2: 6 seconds); ); The first section of the piston p rod extend to close the DDV’s (The closing/opening time of the DDV is adjusted with the flow control valves installed on each selector valve assembly). • Once the DDV are closed (red control light “ERS VALVE CLOSED” lights “On”, cancel the sequence: key operated switch "ESD reset" • The red lamp "ESD1 / Stop loading", the external audible and visual alarms go “Off” • Re-open the ERS valve from the local control panel
ERS valves closure testing by "ESD1 ESD1 / Stop loading loading” • Open the PERC locking valve located on style 80 ►The lamp on the local control panel “Arm ready for loading” for the arm under test lights up .
PERC hydraulic cylinder routine testing by “ESD1/ Stop loading”
• Press the push button "ESD1 ESD1 / Stop loading loading" on the local control panel • The red lamp "ESD1 / Stop loading" flashes on the local control panel • The external audible and visual alarms give an intermittent signal
88
PERC HYDRAULIQUE VALVE TESTING Warning – Very important / Actions to be carry out before any routing testing as indicated in slide 86
PERC valve to be tested (shown in closed position)
• This test is done with the manual drives of the ERS and PERC valves directional control valves on the selector valves assembly • This test is to control the efficiency of the hydraulic interlock on the PERC valve • For safety reasons, reasons the arms will be kept manually selected as indicated on slide 76 • Start the hydraulic pump • Ensure that the PERC valve is closed. The green light “Arm ready for loading” must be “Off” • Ensure that the PERC axis is removed from the PERC collar as indicated in slide 73: ERS operation - Routine testing (Actuator with PERC axis removed from the PERC)) in order to prevent an inadvertent release of the PERC. Close the ERS valves from the local control panel or from the cordless remote control • Check that the corresponding red light “ERS VALVE CLOSED” is “On”
Perc axis removed Closing of the ERS valves
Opening of the ERS valves
• Remove the PERC manual drive safety pin on the selector valve assembly (solenoid valve TAG # UNCOUPLE) Fully press the manual drive of the PERC valve directional control valve on the selector valve assembly • The second section of the tandem cylinder’s piston rod must not extend. The piston rod must remain at same position • Re-open the ERS valve from local control panel or from the cordless remote control • Install back the PERC manual drive safety pin on the selector valve assembly • If the second section of the tandem cylinder’s piston rod extend, the PERC valve at the style 80 must be immediately replaced
Activation of the PERC
89
ESD2 - EMERGENCY DISCONNECTION SEQUENCE ROUTINE TEST PROCEDURE Warning – Very important / Actions to be carry out before any routing testing as indicated in slide 86 Check that the maintenance override key switch is on position 1 and that the yellow light “maintenance override activated” is “On” • These tests can be done from push buttons on the local control panel and from equivalent customer device i PERC hydraulic cylinder routine testing by “ESD2/ Emergency disconnection” • Open p the PERC locking g valve located on style y 80 ►The lamp p on the local control panel “Arm ready for loading” for the arm under test lights up
• At the end of the time lag and if the ERS valves of the arm are closed, the second section of the piston rod of the double acting hydraulic cylinder extends but not open the PERC collar (actuator with PERC axis removed from the PERC) and a new delay starts (corresponding to the opening of the PERC). Temporisation T3: 2seconds • The arm is automatically blocked by selection Since the maintenance override is activated, there is no automatic retraction after ESD2 • Cancel the sequence: key operated switch "ESD reset“ reset
• Press the push button "ESD2/ Emergency disconnection" on the local control panel
• The red lamp "ESD1 / Stop loading“ and red lamp "ESD2/ Emergency disconnection" , the external audible and visual alarms goes “Off”
• The red lamp "ESD1/ Stop loading" flashes on the local control panell
• Re-open p the ERS valve from the local control p panel or from the cordless remote control
• The red lamp "ESD2/ Emergency disconnection" lights up on the local control panel • The external audible and visual alarms give a continuous signal • The hydraulic pump starts. The corresponding lamp "Pump running" i " lights li h up on the h electric l i controll panell • The solenoid valve SV10 in the HPU to release the pressure of the accumulator is energized • A time delay starts (corresponding to the time closing of the main shut off valve and stopping of the pump). T1: 0 seconds start • At the end of this time delay T1 (average timing: 5 seconds, a new time delay starts (corresponding to the closing time of the ERS valves) and the solenoid valve “DDV closing” is energised (Temporisation T2: 6 seconds); The first section of the piston rod extends to close the DDV’s (The closing/opening time of the DDV is adjusted with the flow control valves installed on each selector al e assembly) assembl ) valve
• Close the PERC locking valve. The lamp "Arm ready for loading" of the tested arm goes off on the local control panel After these checks • Bring back the arm in parked position and lock it • If not, unselect the arm by unscrewing the manual handle on the selector valve assembly • Stop the Hydraulic Power Unit • Switch off the local control panel
PERC hydraulic cylinder routine testing by “ESD2/ Emergency disconnection”
90
EMERGENCY RELEASE SYSTEM PERC CONTROLLED RELEASE TESTING Warning – Very important / Actions to be carry out before any routing testing as indicated in slide 86 Check that the maintenance override key switch is on position 1 and that the yellow light “maintenance override activated” is “On” • These tests can be done from push buttons on the local control panel and from equivalent customer device i • After the inspection before the arrival of the first tanker, this check will be made every one year or prior to seal change out or other maintenance • D During i th operation the ti off the th disconnection, di ti ensure no personnell within a two meter radius • If needed, install the 4 hoists between upper and lower valves : Used to separate PERC flange in case of DDV Seal replacement • For the reconnection, see the above paragraph “Reassembly after the emergency disconnection disconnection” PERC controlled disconnection”
release
testing
by
“ESD2
/
Emergency
• Temporary remove shear pin from PERC collar as indicated in slide 76 • Put in place PERC axis on PERC collar as indicated in Picture N°29 (PERC in operating condition) • Open the PERC locking valve located on style 80 ►The lamp on the local control panel “Arm ready for loading” for the arm under test lights up • Press the push button "ESD2 / Emergency disconnection" on the local control panel • The red lamp "ESD1 ESD1 / Stop loading loading" flashes on the local control panel • The red lamp "ESD2/ Emergency disconnection" lights up on the local control panel
Picture N°29_ N°29 Temporary clamping device & PERC in operating condition
• The external audible and visual alarms give a continuous signal • The hydraulic pump starts. The corresponding lamp "Pump running" lights up on the electric control panel
91
EMERGENCY RELEASE SYSTEM PERC CONTROLLED RELEASE TESTING • The solenoid valve SV10 in the HPU to release the pressure of the accumulator is energized • A time delay starts (corresponding to the time closing of the main shut off valve and stopping of the pump). T1: Average timing 5 seconds start • At the end of this time delay T1, a new time delay starts (corresponding to the closing time of the ERS valves) and the solenoid valve “DDV closing” is energised (Temporisation T2: 6 seconds); The first section of the piston rod extends to close the DDV’s (The closing/opening time of the DDV is adjusted with the flow controll valves l i installed ll d on each h selector l valve l assembly) bl ) • At the end of the time lag and if the ERS valves of the arm are closed, the second section of the piston rod of the double acting hydraulic cylinder extends but not open the PERC collar (actuator with PERC axis removed from the PERC) and a new delay starts (corresponding to the opening of the PERC) PERC). Temporisation T3: 2 seconds • The arm is automatically blocked by selection • Since the maintenance override is activated, there is no automatic retraction after ESD2 • The four temporary safety & re-assembly rods will prevent the separation of the ERS valves when the emergency release coupler is opened To reset the system : • Stop the alarm : key button "ESD reset" on the Local Control Panel.. Allll the h signals l and d the h motor stops • Remove the PERC axis from PERC clamps Picture N°30_ DDV closed & PERC clamps open in controlled release
92
EMERGENCY RELEASE SYSTEM PERC CONTROLLED RELEASE TESTING • Un tighten PERC collar of 1/2 turn the screw with nut welded welded. To move the screw screw, a nut is welded on it (see Picture N°31) N 31) • Position the PERC around the flanges PERC and engage the came as indicated in slide 80 • Re-tighten the screw, at the corresponding torque value • The tightening torque value is different for each double valve/Perc diameter. Refer to the table on the following slide for the torque value of each loading arm(as indicated in table slide 82) • Reinstall a new shear pin in the releasing fork for added security by preventing accidental release of the Perc (Only use FMC shear pin) • The correct shear pin position guarantee that the PERC clamps and release fork is well positioned as indicated in slide 81 • If installed, remove the hoists • Unlock the DDV driving system by pulling the locking disk (disengage the locking pin from the housing) as indicated in slide 84 • Operate in opening position the ERS valve using the local control panel or cordless remote control • Bring back the arm in parked position and lock it and remove the manual selection from the selector valve
Picture N°31_ PERC collar Adjusting screw
93
DDV & PERC \ GOOD PRACTICE AND PREVENTIVE MAINTENANCE • After prolonged service, the DDV/ERC will need to be completely overhauled. The interval between such overhauls will vary from between 5 and 7 years, dependent upon the operating conditions, standard of maintenance and the inspection reports. • The need for an overhaul will normally be confirmed by excessive corrosion, wear of components, or difficulty in operation . • Only minor repairs will be carried out on the coupler in jetty. Major maintenance task should be performed in repair shop in a clean working area by qualified, trained and authorized FMC personnel. • The use of non-FMC OEM (Original Equipment Manufacturer) parts voids all design, type, case, test and quality approvals by third-party certifying authorities and may void product warranty. • Major maintenance tasks should be carried out by suitably experienced personnel in a clean area, where the components can be properly documented, repaired or replaced and tested before being reinstalled. Good practice • • • •
Never test operate the ERC unit unless the ship side ball valve is fully supported or the temporary clamping device installed on PERC clamps Always ensure that the personnel are at least two meters away from the unit prior to operating the ERC For low temperature DBV/ERC systems it is important that the ball valves are never rotated when there is ice formation on the sphere. Water wash must no be used to disperse the ice Ensure maintenance and production personnel operating this equipment read and understand the FMC operating & maintenance manual
Preventive maintenance •
Routine testing as per FMC operating & maintenance manual ( It is suggested that the routine test is carried out prior to every cargo transfer )
•
Check for oil leaks on hydraulic actuators , cylinders, sequence valve and hydraulic Perc valve
•
Ensure all hydraulic fittings and hoses are free from oil leaks and are undamaged
•
Check that all pins and washers are in position, secure and undamaged
•
Check that the ‘Y’ shaped connections on the cross linkages are well greased and in correct position
•
Check that the shear pin is in position and undamaged
•
Check hydraulic sequence valve efficiency ( plunger sticky…)
•
Yearlyy greasing g g all DDV and PERC actuator moving g parts p (Rail ( guide, g , guiding g g rod,, pushing p g rod,, mechanical interlocks ect..))
94
FMC EQUIPMENTS DDV & PERC \ GOOD PRACTICE Important p note: • The double valves are only designed for the events of Emergency Disconnection. • FMC does not recommend using the double valves as process valves • Storage of the arms with the double valves closed presents risks that an accidental disconnection occurs • FMC declines d li all ll responsibilities ibiliti for f using i the th double d bl valves l as process piping i i valves l Warning / Major safety issue : • These double ball valves are supposed stay all time in opening position (When the arms are in storage position or in motion). The ERS/DDV are “Emergency valves” and not process valves. When the ERS/DDV are in open position, the tandem cylinder is fully retracted and do not allow operating the ERC when the ERS valves are opened. These entire safety devices are in place to secure the operators against any miss operation. I remind you that the MLA’s must be operated empty of product and without pressure into the product line. • In case the terminal operating policy requires that the ERS valves of FMC loading arms are closed whilst the arms are in stored position, FMC highlights the fact that this creates a potential risks to accidentally pressurize the loading arms. If for any y reason the jetty j y ESD valves are leaking, g, having g the ERS valves closed will not allow operation p people p p to detect this leak. Proper terminal procedures shall be put in place to ensure it has been checked the arms are empty and out of any pressure before the operators manoeuvre the arms and /or open the ERS valves. Non respect of this advice could lead to major accident and FMC will not be responsible for the consequences of such unsafe operations. Warning: • Any removal of any parts of the DDV/PERC for inspection, maintenance and repair, disassembly or reassembly of major arm components should be only undertaken by qualified personnel and with great precaution and care as to avoid handling accidents. • For better safety, these operations should be preferable performed under supervision of FMC personnel. • Never attempt any inspection or repair on a loading arm before having make sure: That the arm is empty and without pressure That the arm is locked That the arm cannot be operated
95
MAINTENANCE BOARD FOR ARM / MECHANICAL PART
FMC Option
Visual checks General look
Standard Maintenance Board Day Week Month 3 Mon 6 Mon Year *
Paint Anchor bolts
* *
Pantograph / Inboard & outboard wire ropes
*
Structure arm
*
Structure bearing & Swivel joints
*
Parking locking system
Check the tighteness of all fixing parts ( use the torque wrench / refer to FMC maintenance manual for torque values ) : structure bearing ,c/w beams, ect…
Check the screws tightening of product line flanges ( Refer to the maintenance manual for torque requirement / use a torque wrench ) Regulary check proximity switch condition and adjustment (If any)+ Regulary test effeciency and grease mechanisum
*
Electrical insulation flanges
*
Parrallelisum & inboard / outboard balancing
Detailed check of the arm, look for leakages, corrosion, and control hydraulic flexible hoses Touch ups where needed Check for anti corrosion protection Check for anti corrosion protection and tension / Visually inspect the cable for damage / Check loosen turnbuckle lock nuts ( protect them with "Densyl tape") & check the tightening attachement
Grease every 6 months, depends of working frequency / Check for abnormal noise during operation (Manual grease pump and/or centralized greasing system)
*
Product line
Comments
Test and verify the resistance value( 1 Kohm/1000 Vdc) / Check the condition of the insulated hydraulic flexible hoses/Inspect for wears tears and cracks.Check if leakages / control the tightening bolts ( use torque wrench )& re-coating the flange yearly Check the parrallelisum of the outboard c/w beam and the outboard arm and arm balancing .Select and extend the arm over the sea, control tendency to raise or faaling down or stabilize , re-adjust if necessary .
*
Counterweights ( primary & secondary )
*
Check for corrosion and threaded rod tightness.(protect them with "Densyl tape")
Ladders
*
Inspect for corrosion .Check the trolleys , check all fixing parts ( tighteness )
Plarforms
*
Mechanical jack
*
Centralised greasing system Balancing wheel / Style 50
*
p for corrosion , check all fixing gp parts ( tighteness g ) Inspect
*
Check before each loading & regulary greasing all moving parts
*
Check the good functionning of all measuring valves ( protect them with "Densyl tape") & check the flexible hose condition (inspect for wears tears and cracks) Lubricate the bearing (Manual grease pump and/or centalised greasing system )
96
MAINTENANCE BOARD FOR ALL ARMS / MECHANICAL PART Option
Visual checks
Day Week Month 3 Mon 6 Mon Year
Inboard hydraulic cylinder
outboard hydraulic cylinder
slewing hydraulic cylinder
Comments
*
Regulary check the hydraulic flexible hoses, pipework and hydraulic fittings condition. Check the shafts condition (wearness, leaks and tears on the rods) .Check movement and look out for weird noises.Checks the tightening of the hydraulic cylinders fixing parts,pivots, couling sleeves,turnbuckles & lock nuts and grease .Check if any misalignement & regulary grease the inboard wire ropes
*
Regulary check the hydraulic flexible hoses, pipework and hydraulic fittings condition Check the shafts condition (wearness, leaks and tears on the rods)wearness, leaks and tears on the rods .Check movement and look out for weird noises.Checks the tightening of the hydraulic cylinders fixing parts (Pivots) & lock nuts and grease .Check if any misalignement
*
Regulary check the hydraulic flexible hoses, pipework and hydraulic fittings condition Check the shafts condition (wearness, leaks and tears on the rods)wearness, leaks and tears on the rods .Check movement and look out for weird noises.Checks the tightening of the hydraulic cylinders fixing parts (Pivots) & lock nuts and grease .Check if any misalignement
Inboard movement
*
Check movement & speed and look out for weird noises, grease up if necessary.
Outboard movement
*
Check movement & speed and look out for weird noises, grease up if necessary.
Rotation movement
*
Check movement and & speed look out for weird noises, grease up if necessary.
Open/Close QUIKCON III Hydraulic coupler
*
Check functionning and look out for weird noises, grease up bearings and all moving parts. Check the functionning of the proximity switches
QUIKCON III Hydraulic coupler
*
At each loading ,check the seals condition on QCDC face
QUIKCON III / Hydraulic coupler (QCDC)
*
Inspect for corrosion / Greasing all moving parts / Check that all bearings and bushings are in good condition and where is necessary are proprely greased / Deterioration and corrosion. Regulary check the hydraulic flexible hoses, pipework and hydraulic fittings condition ( refer to the FMC maintenance manual ) / Check the alignment cone condition and fixing part
97
MAINTENANCE BOARD FOR ALL ARMS / MECHANICAL PART Option
Visual checks
Day Week Month 3 Mon 6 Mon Year
Product line swivel joints
N/A
Nitrogen drying swivel joints (LNG arms)
*
Centralized greasing system
*
Check for leakage on primary packing
*
Check at each loading the N² inlet pressure & the outlet flow at the last swivel joint on style 80 ( N°6) / Inspect the flexible hoses for wear tears and cracks ;Check if leakages and check the condition of the N² N lines , fittings and fixing parts .
*
Check the good functionning of all measuring valves ( protect them with "Densyl tape") & check the flexible hose condition (inspect for wears tears and cracks)
Nitrogen g p purging g g line
*
Vacuum breaker
Comments
Check all flexible hoses condition Inspect for corrosion, Check all fixing parts ( tighteness ) / Regulary check the greasing condition of spring return valve & valve / Inspect and replace if necessary the vacuum breaker wire rope / Anually full grease valve and spring return valve
*
*
Routing testing as per FMC manual ( test ESD1 & ESD2 sequences on dummy manifold or on the ship with safety bolts on DV & Perc in routine test position )
*
Test the ESD1 & ESD2 in automatic sequence ( from proximity switches ) and by manual activation from the selector valve cabinet ( switch off the electric motors power supply , test has to be done with accumulators only / on dummy manifold only with safety bolts on DV)
DV & PERC system
*
Open the PERC collar in control release and check DV flanges ( upper & lower ) if any moisture or damage /Open the release fork spring box's cover and greasing the belville spring washers & re-sealing/ Check the shear pin condition / ERC maintenance to be done on dummy manifold only with the ERC safety device installed
DV & PERC system
*
Inspect for corrosion , check all fixing parts ( tighteness) / Visually inspect DV & PERC actuator conditions / Check and test the hydraulic ERS sequence valve / Check the proximity switches condition and test effeciency.
DV & PERC / Routine testing
DV & PERC / ESD automatic sequences and manual activativation / Routine testing
*
*
98
MAINTENANCE BOARD FOR HYDRAULIC & ELECTRIC CONTROL SYSTEMS Hydraulic y system y on the arm Hydraulic tubings & fittings & fixing parts
*
Inspect for corrosion, leakages and damages.Check all fixing parts
Hydraulic flexible hoses
*
Inspect for wears tears and cracks.Check if leakages / Checks the cable ties condition, replace if necessary
Hydraulic cylinders cylinders, motors motors, actuators
*
Inspect for corrosion, leakages and damages.Check all fixing parts
Hydraulic sequence valve on DBV
Check the functionning and grease the piston plugger on the hydraulic control valve ,look for hydraulic oil leakages
*
p g ((locared Quick disconnect coupling on style 80 / Used for QCDC)
Electric system on the arm
*
Proximity switches
PERC manual locking valve on style 80
Alarm system on arm
Check the condition of the electric conduits and fixing parts , electric cables , cable glands, junction boxes ( check if any moisture and re-sealing ) check & test all proximity switches .
*
Check the condition of the electric conduits and fixing parts , electric cables , cable glands, junction boxes ( check if any moisture and re-sealing ) check & test all proximity switches .
*
Check the good functionning / Checks the proximity switch condition (if any moisture inside) and resealing if necessary / Check the two positions valve condition and grease mechanisum Check functionning of the overeach alarm , operate the arm outsisde the working area and test the first alarm and second alarm extention & slewing right/left .Verify the setting of the extention & slewing alarm ( refer to the FMC drawing for the angles calibration)
*
PMS / P Potentiometric t ti t i sensors Parking locking system / Inboard arm locking device (If any)
Check the effeciency & look for hydraulic oil leakage
*
* *
Check the functionning and grease the axis driving system and cahain (slewing sensors) / Check all fixing parts Check proximity switch adjustment / Regulary test proximity switch (Inspect if any moisture inside)
99
MAINTENANCE BOARD FOR HYDRAULIC CONTROL SYSTEMS Option p
Visual checks
Dayy Week Month 3 Mon 6 Mon Year
HYDRAULIC POWER UNIT General look Paint Tubings & fittings Electric cables
* * * *
Comments Check for corrosion Touch ups Pressure test for leaks, check for crushed tubings Check connections, avoid moisture
Main pressure
*
Check before each loading and adjust if necessary ( 190 bar )
Hydraulic oil level
*
Check before each loading and refill the tank if necessary
*
*
Before each loading check if any hydraulic oil leakage ( visit door , ect…) / Yearly ,open and drain & clean oil hydraulic tank ( drain all accumulators first ) / Clean or replace strainer filters on two hydraulic pumps and pneumatic pump / Take hydraulic oil sample
*
Check efficiency / Set point: Hight temperature alarm ► 60°C
Hydraulic oil tank
N/A
Oil temperature transmitter 4-20 Ma
*
N/A
Hydraulic oil level transmitter 4-20 Ma
*
Pressure & return line hydraulic oil cartridge filters Moisture filter / air dryier system Manual emergency hand pump Electric motors pump Pressure gauge / Main pressure Hydraulic bloc & set of hydraulic valves
*
Check efficiency / Set point: Low oil level alarm ► 15 mb ( Corresponding at more or less 30% of total oil tank capacity) Before each loading ,check the visual clogging indicator on both oil filters / Yearly replace by new both cartridge filters ( dont try to clean up !!!!) Inspect the dissecant cartridge ( when the dissecant change into rose color , the dissecant element must be replaced )
*
*
Check effeciency and regulary grease the moving parts
*
Check the good functionning / Grease bearing every 5 years *
* *
Pressure = 190 bar / recalibrate every year Check for corrosion , leaks or damages
Control directional valves and solenoid valves for "Accumulator release pressure"
*
Greasing the manual command and check if efficiency
Accumulators nitrogen pressure into bladder
*
Check the N² pressure every six months = P : 130 bar / Refill if necessary
HPU accumulator / 20 litters
*
Check accumulator vessel condition (corrosion and/or damages) / Checks for leaks
100
MAINTENANCE BOARD FOR HYDRAULIC CONTROL SYSTEMS Option
Visual checks
Day Week Month 3 Mon 6 Mon Year
Comments
Hydraulic power unit Pressure transmitter / Oil low pressure accumulator for ERS system
*
*
Check the good functionning : Alarm low oil pressure below 175 bar / recalibrate every year
Pressure transmitter accumulator hydraulic pressure regulation for ERS system
*
*
Check the good functionning : start hydraulic pump at 178 bar & stop pump at 180 bar / recalibrate every year
Selector Valve Assy.
*
Check for leaks corrosion and damages
Control directional valves and solenoid valves for ERS/DV, Arm movements & selection
*
Greasing the manual command and check if efficiency
Throttle valves & flow regulators
*
Greasing the screws adjustment ( both sides )
Selector valve
*
Greasing the manual command and check if efficiency / Check the inductive proximity switch condition and check the effeciency
ERS manual command ( for ESD2 in case of power failure)
*
Check the good functionning and grease regulary he mechanisum
Pressure transmitter / Abnormal pressure into ERS lines
*
*
Pressure gauge / Check if any abnormal oil pressure into ERS line
*
*
Accumulator Pack (for ERS) Pressure gauge / Check Accumulators Acc m lators nitrogen press pressure re into bladder
Pressure = 0 bar or less than 40 bar / recalibrate every year Check for leaks corrosion and damages
* *
Check the good functionning : Alarm abnormal oil pressure alarm at 40 bar / recalibrate every year
*
Pressure = 178 to 180 bar / recalibrate every year Check the N² pressure every six months = P : 135 bar / Refill if necessary
*
ERS accumulator / 32 liters
*
Check accumulator vessel condition (corrosion and/or damages) / Checks for leaks
Hydraulic bloc & set of hydraulic valves
*
Check for corrosion , leaks or damages
101
MAINTENANCE BOARD FOR ELECTRIC CONTROL SYSTEMS Option N/A
Visual checks
Day Week Month 3 Mon 6 Mon Year
Comments
Remote Control Pendant Work test
*
*
Check the good functionning / Every year, open transmitter box and check for humidity ,sealness of connections,if the presence of moisture inside the pendant ,dry it up with hair dryer and clean the connection terminal ,and re-sealing .
*
*
Check the cable & connector's conditions
RADIO CORDLESS
*
Battery
*
Before each use, recharge and install new battery / Check the battery condition Activate the "battery test" at each use (LED must "On" steady light)
*
Before to power "On" the radio transmitter, position all the switches in neutral or "0" position. pos t o Radio ad o co cordless d ess po portable tab e ttransmitter a s tte ccheck ec tthe e co communication u cat o status with t tthe e shore, if Radio base unit is ok , the lamp "radio cordless in operation" must be "On" on the radio cordless cabinet and LED transmitter must "On" (steady light), If not refer to the operating & maintenance manual
Communication C i ti (t (transmitter itt to t base unit receiver)
N/A
Check the good functionning / Every year, open transmitter box and check for humidity ,sealness of connections,if the presence of moisture inside the pendant ,dry it up with hair dryer and clean the connection terminal ,and re-sealing .
Work test
CONTROL PANEL General look Paint Electric cable Check power Lamp test Pressurization system Working test Power "On" electric control panel
*
* * * * * * * *
Check labels, plates, and lamps Touch ups Avoid moisture Check continuity and insulation Before every unloading Regulary verify the inlet pressure : 7 bar / Check efficiency Check all functions No alarm must be activated, if yes, checks the corresponding indicating alarm light ► Report and ask the maintenance department to intervene
102
PREVENTIVE MAINTENANCE / MAJOR OVERHAUL ITEM
DESIGNATION
1
M arine lo ading arms & assio ciated co ntro l systems
2
3
LOCATION /
FREQUENCY
REMARKS
Fo r mo re details, refer to the standard preventive maintenance bo ard and to Weekly / M o nthly the o pearting & maintenance manual supplied with the equipments Yearly The need fo r an o verhaul will no rmally be co nfirmed by excessive co rro sio n, wear o f co mpo nents, o r difficulty in o peratio n .
A fter pro lo nged service, the DV/ERC will need to be co mpletely o verhauled. Yearly / M ajo r The interval between such o verhauls will vary fro m between 2 and 5 years Emergency release system M arine lo ading arms o verhaul every five ,dependent upo n the o perating co nditio ns, standard o f maintenance and the ERC & DV Style 80 years inspectio n repo rts.
QCDC hydraulic co upler
pro lo nged g service, the QCDC will need to be co mpletely p y o verhauled. The A fter p Yearly / M ajo r M arine lo ading arms interval between such o verhauls will vary fro m between 3 and 5 years o verhaul every five Style 80 ,dependent upo n the o perating co nditio ns, standard o f maintenance and the years inspectio n repo rts.
4
A fter pro lo nged service, the structure bearing will need to be co mpletely Yearly / M ajo r Strure bearings & Structure o verhauled. verhauled The interval between such o verhauls will vary fro m between 20 and M arine lo ading arms o verhaul every five swivel jo ints 22 years ,dependent upo n the o perating co nditio ns, standard o f maintenance years and the inspectio n repo rts.
5
A fter pro lo nged service, the pro duct line swivel jo int will need to be co mpletely Yearly / M ajo r o verhauled. The interval between such o verhauls will vary fro m between 10 and M arine lo ading arms o verhaul every five 15 years ,dependent upo n the o perating co nditio ns, standard o f maintenance years and the inspectio n repo rts.
P ro duct line swivel jo int
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PREVENTIVE MAINTENANCE / MAJOR OVERHAUL ITEM
DESIGNATION
LOCATION
6
Hydraulic system
Hydraulic po wer unit + selecto r valve assemblies + accumulato r pack + h d li sytem hydraulic t on M LA 's
7
Hydraulic o n M arine lo ading arms
Hydraulic cylinders + hydraulic mo to r & actuato rs + hydraulic flexible ho ses
FREQUENCY
REMARKS
Co mplete draining accumulato rs and o il tank and cleaning all hydraulic pump strainer filters Draining the hydraulic circuit (do ck lines and o n the lo ading arm lines). Yearly / M ajo r Overhaul o f the hydraulic po wer unit and selecto r valve assembly , ERS cabinet o verhaul every five and accumulato r pack ► Dismantling, cleaning all hydraulic internal years y co mpo nents t and d replacing l i gaskets k t and d “ o ” rings. i Overhaul o f all hydraulic cylinders and hydraulic actuato rs (ERS and hydraulic co upler), Hydraulic blo cking valves and sequence valves ► Cleaning internal chamber and replace all seals ,” o ” rings, ect... Overhaul the hydraulic limit sto p (A pex limit angle, Inbo ard arm limit angle), parking p g lo ck valve,, P ERC & Hydraulic y co upler p interlo ck valves : Dismantling, g, cleaning all internal co mpo nents and replacing all gaskets and “ O” rings, check fo r co rrect adjustment and functio ning, check fo r co rro sio n, apply to uch paint if necessary. Replacement o f all hydraulic flexible ho ses o n lo ading arm. A ccumulato r envelo pe : A n internal inspectio n must be carried o ut every five years and an external visual inspectio n every two years ( Fo r further Yearly / M ajo r info rmatio n, refer to the “ P ressure vessels regulatio ns” and “ Safety o verhaul every five regulatio ns “ in acco rdance with the co ncerned co untry ). years A ccumulato r bladders & pisto n seals replacement . Refill the hydraulic o il tank with new o il Flushing g and purging g g the hydraulic y circuit with new hydraulic y o il. Greasing the bearing o f the electric mo to r ( hydraulic pump HP U). Recalibrate the pressure gauges and pressure and temperature switches. Checks the visit do o r gasket Check fo r damage to the painted surfaces and a fo rmatio n o f rust. Where necessary use a suitable paint repair pro cedure to resto re pro tectio n ( On all hydraulic equipments) equipments).
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