Rak Mobile filling station User manual

Al-Rakeb Oil, Electricity & Construction Services

Company

Operation Manual for Mobile Filling Station

No part of the operation manual may be reproduced or transmitted by any without prior permission of Al-Rakeb Company Oil, Electricity &

Construction Services

Nomenclature

MFS

Mobile Filling Station

Feet

ISO

International Organization for Standardization

Liters

Millimeters

Kilogram

Cubic Meter

Underwriters Laboratories

Volt

Hertz

Inch

HSE

health, safety and environment

Direct Current

VAC

Voltage Alternating Current

Inch

Overview

This operation manual explains briefly all aspects of the Mobile Filling Station (MFS) from

operation, safeness, maintenance, etc. This product is designed and manufactured to service sites

that are far from gas station and to eliminate that factor of having an above/underground ground

storage tank. For instance, those sites can be oil rigs, boat docks, and any sites that lacks a

convenient petrol station.

This product also helps in monitoring fuel consumption in sites by having a built-in

dispenser that contains flow meter. This product can also store 2 types of fuel by having 2 separate

tanks with a capacity of 20,000 Liters each that are separated by a bypass flange. The flange can

be opened letting the operator have a full capacity of 40,000 Liters. The cabin is fully

accommodated with an AC unit to ensure comfortableness of the operator and to keep all electrical

components including the control box and monitoring unit cool.

The product follows the UL-142 and DNV-GL standards and have already been certified.

This certification followed a series steps of testing procedures to ensure safeness and quality of

the product being manufactured.

TABLE OF CONTENTS

NOMENCLATURE ......................................................................................................................................................2

OVERVIEW ..................................................................................................................................................................3

TABLE OF CONTENTS .............................................................................................................................................4

LIST OF FIGURES ......................................................................................................................................................6

LIST OF TABLES ........................................................................................................................................................7

1. SAFTEY .....................................................................................................................................................................8

1.1 INTRODUCTION ....................................................................................................................................................8

1.2 INFORMATION AND WARNING LABELS ..............................................................................................................8

1.3 LIST OF PARTS USED ALONG WITH DESCRIPTIVE FIGURES ...........................................................................10

1.4 SAFETY FEATURES ............................................................................................................................................17

1.4.1 Fire Extinguishers .....................................................................................................................................17

1.4.2 Fire Blanket ...............................................................................................................................................17

1.4.3 First Aid Kit ...............................................................................................................................................18

1.4.4 Smoke Detectors ........................................................................................................................................18

1.4.5 Explosion Proof Parts ...............................................................................................................................19

1.4.6 Pressure / Vacuum Vent 2'' + Flame Arrestor .........................................................................................20

1.4.7 Retention Tray ...........................................................................................................................................20

1.4.8 Suction Port ...............................................................................................................................................20

1.4.9 Emergency Vents .......................................................................................................................................21

1.4.10 Leak Detection Alarm .............................................................................................................................21

1.4.11 Level Indicators .......................................................................................................................................21

1.4.12 Level Switch .............................................................................................................................................22

1.4.13 Overfilling Alarm ....................................................................................................................................23

1.4.14 Emergency Shutdown Buttons ................................................................................................................23

1.5 SAFETY INSTRUCTIONS .....................................................................................................................................23

1.5.1 Safe Lifting ................................................................................................................................................23

1.5.2 Safe Installation ........................................................................................................................................24

1.5.3 Traffic Warnings .......................................................................................................................................24

1.5.4 MFS and Vehicles Filling .........................................................................................................................24

1.5.5 Grounding and Earthing ...........................................................................................................................24

1.5.6 Smocking and Fire Sources. .....................................................................................................................24

1.5.7 Manhole Operations ..................................................................................................................................25

1.5.8 Emergency Shutdown Buttons ..................................................................................................................25

2. PRODUCT DESCRIPTION ..................................................................................................................................26

2.1 INTRODUCTION ..................................................................................................................................................26

2.2 GENERAL SYSTEM DESCRIPTION .....................................................................................................................26

2.3 DESIGNATION PLATE .........................................................................................................................................28

2.4 GENERAL DESCRIPTION AND OVERVIEW OF THE MFS LAYOUT ...................................................................29

2.4.1 Doors and Entrances .................................................................................................................................29

2.4.2 Air-Conditioning Unit ...............................................................................................................................30

2.4.3 Power Distribution Unit ............................................................................................................................31

2.5 DIMENSIONS OVERVIEW ...................................................................................................................................31

2.5.1 MFS dimensions ........................................................................................................................................31

2.5.2 MFS Weight Scenarios .............................................................................................................................32

3. OPERATION AND SETUP INSTRUCTIONS ...................................................................................................34

3.1 INTRODUCTION ..................................................................................................................................................34

3.2 TRANSPORTATION AND LOGISTICS ..................................................................................................................34

3.3 LIFTING OF THE TANK ......................................................................................................................................34

3.4 INSTALLATION ...................................................................................................................................................34

3.5 ELECTRICAL ......................................................................................................................................................34

3.6 OPERATION ........................................................................................................................................................35

3.6.1 General Setup. ...........................................................................................................................................35

3.6.2 Filling the Tank .........................................................................................................................................37

3.6.3 Filling Vehicles and other Machinery. .....................................................................................................39

3.6.4 Navigating through ProGauge Console and Digimon Unit Console ......................................................40

3.6.4.1 ProGauge Console ............................................................................................................................................... 40

3.6.4.2 Digimon Console .................................................................................................................................................. 44

4. MAINTENANCE ....................................................................................................................................................47

4.1 INTRODUCTION ..................................................................................................................................................47

4.2 MECHANICAL ............................................................................................................................................47

4.2.1 Emergency Vents .......................................................................................................................................47

4.2.1.1 Maintenance Procedure ...................................................................................................................................... 47

4.2.2 Manhole .....................................................................................................................................................47

4.3 ELECTRICAL ......................................................................................................................................................48

4.3.1 Wiring ........................................................................................................................................................48

5. TROUBLESHOOTING .........................................................................................................................................49

6. REFRENCES ..........................................................................................................................................................53

6.1 WEBSITES ............................................................................................................................................................53

7. CONTACT INFORMATION ................................................................................................................................54

Company Address ...............................................................................................................................................54

E-mail ..................................................................................................................................................................54

Phone Numbers ..................................................................................................................................................54

8. APPENDIX A TANK VOLUME .....................................................................................................................55

9. APPENDIX B FIREFIGHTING INSTRUMENTS LOCATION ................................................................62

10. APPENDIX C PIPING & INSTRUMENTATION DIAGRAM ..............................................................65

LIST OF FIGURES

FIGURE 1.MAIN SPECIFICATIONS LABEL. .....................................................................................................................8

FIGURE 2. NO FIRE. ........................................................................................................................................................8

FIGURE 3. NO SMOCKING SIGN. .....................................................................................................................................9

FIGURE 4. EXPLOSIVE ATMOSPHERE. ...........................................................................................................................9

FIGURE 5. NO CELL PHONES. .........................................................................................................................................9

FIGURE 6. THE REAR SIDE OF THE MFS. ....................................................................................................................10

FIGURE 7. DISPENSER ROOM OF THE MFS. ......................................................... ERROR! BOOKMARK NOT DEFINED.

FIGURE 8. CONTROL ROOM ENTRANCE. .....................................................................................................................12

FIGURE 9. SHOWS THE CONTROL ROOM. ....................................................................................................................13

FIGURE 10. OTHER VIEW OF THE CONTROL ROOM. ...................................................................................................14

FIGURE 11. TOP SIDE OF THE MFS THROUGH THE MAINTENANCE DOOR. ................................................................15

FIGURE 12.CLOSE VIEW TO THE FIRE BLANKET. ........................................................................................................17

FIGURE 13. CLOSE LOOK TO THE FIRST AID KIT. ........................................................................................................18

FIGURE 14. SMOKE DETECTOR INSIDE THE CONTROL ROOM. ...................................................................................19

FIGURE 15. PRESSURE / VACUUM VENT 2'' + FLAME ARRESTOR. .............................................................................20

FIGURE 16. SHOWS THE HOW THE LEVEL INDICATOR WILL MEASURE THE TANK LEVEL. .......................................22

FIGURE 17. SHOWS THE PASTE USED TO MEASURE THE TANK FLUID LEVEL. ...........................................................22

FIGURE 18. CLOSE LOOK OF THE OVERFILL ALARM. .................................................................................................23

FIGURE 19. CORNER CASTING LOCATIONS. ................................................................................................................24

FIGURE 20. SHOWS A SIMPLE FLOW DIAGRAM OF THE MFS. ....................................................................................26

FIGURE 21. SHOWS THE ISOMETRIC VIEW OF THE STATION. .....................................................................................27

FIGURE 22. TOP VIEW OF THE STATION. .....................................................................................................................27

FIGURE 23. ELEVATION VIEW OF THE STATION. .........................................................................................................28

FIGURE 24. LOCATION OF THE SPECIFICATION LABEL. .............................................................................................28

FIGURE 25. MAIN SPECIFICATIONS LABEL. .................................................................................................................29

FIGURE 26. SHOWS THE GENERAL LAYOUT OF THE MFS (NOT TO SCALE). ..............................................................29

FIGURE 27. SHOWS THE MAINTENANCE ......................................................................................................................30

FIGURE 28. SHOWS THE PORTABLE THERMOSTAT. ....................................................................................................31

FIGURE 29. DIMENSIONS OF THE MFS. .......................................................................................................................32

FIGURE 30. VOLTAGE STABILIZER. .............................................................................................................................35

FIGURE 31. THE SWITCH IN THE ELECTRICAL BOX. ...................................................................................................36

FIGURE 32. CLOSE LOOK WHERE TO PARK THE CONVEYING TRUCK. .......................................................................37

FIGURE 33. SHOWS THE RETENTION TRAY. ................................................................................................................38

FIGURE 34. LOCATION OF BOTH INLINE CHECK VALVE AND THE CUT VALVE. .........................................................38

FIGURE 35. SHOWS THE BY-PASS FLANGE. ..................................................................................................................39

FIGURE 36. THE SWITCH AT THE BOTTOM SIDE OF THE PROGAUGE. .......................................................................41

FIGURE 37. PROGAUGE MAIN MENU. ..........................................................................................................................41

FIGURE 38. INFO BUTTON MENU. ................................................................................................................................44

FIGURE 39. THE DIGIMON CONSOLE. ..........................................................................................................................45

LIST OF TABLES

TABLE 1. SHOW ALL PARTS LISTING AND NUMBERS. ..................................................................................................16

TABLE 2. SHOWS THE EXPLOSION PROOF PARTS. .......................................................................................................19

TABLE 3. EMERGENCY VENT DISTRIBUTION. ..............................................................................................................21

TABLE 4. FUEL TYPES AND DENSITIES. ........................................................................................................................32

TABLE 5. VOLUME SCENARIOS. ...................................................................................................................................32

TABLE 6. FUEL TYPE, WEIGHT, AND DIFFERENT VOLUME SCENARIOS ......................................................................33

TABLE 7. FUEL SCENARIOS AND WEIGHT ....................................................................................................................33

TABLE 8. PARTS NUMBERS AND NAMES .......................................................................................................................35

TABLE 9. DETAILED PAGES. .........................................................................................................................................42

TABLE 10. DETAILED STATUS PAGES. ..........................................................................................................................46

TABLE 11. EMERGENCY VENT DISTRIBUTION TABLE. ................................................................................................47

TABLE 12. TROUBLESHOOTING TABLE. ......................................................................................................................49

1. SAFTEY

1.1 Introduction

To ensure safe operation and usage of the product, safety instructions and guidelines must be

followed. Guidelines and instructions include labels, procedure, and operation.

1.2 Information and Warning Labels

Figure 1.Main specifications label.

Figure 2. No Fire.

Figure 3. No smocking sign.

Figure 4. Explosive atmosphere.

Figure 5. No cell phones.

1.3 List of Parts Used Along with Descriptive Figures

Figure 6. The rear side of the MFS.

Figure 7. Station Dispensing Section.

Figure 8. Control room entrance.

Figure 9. Shows the control room.

Figure 10. Other view of the control room.

Figure 11. Top side of the MFS through the maintenance door.

Table 1. Show all parts listing and numbers.

Part

Part Name

Qty

Infeed line

Digimon Console ATEX Tank Status Monitoring

Servo Motor with Butterfly Flange

Anti-explosion light unit

Smoke detector

Emergency Vent for Outer shell

Automatic Fire extinguisher

Overfilling Alarm

Light Unit Switch

Emergency Shutdown Buttons

Ground Reel

Manual Fire Extinguisher

Retention Tray

Cut Off Valve for inlet Control

AC unit

Aluminum Door to Control Room

Power Input Plug

Fire Blanket

First Aid Kit

Power Distribution Unit with Circuit breaker

Electrical Box

Leak Alarm Console

ProGauge Console

Submersible pump

Level Switch

Level Probe

Depth plug

Junction Box

Vent Port

Emergency Vent

Suction Port

Spare

Inlet Port

Manhole

Solenoid Valve 2’’

cutoff valve 2’’

Venting fans

1.4 Safety Features

1.4.1 Fire Extinguishers

The MFS is supported by 3 automatic fire extinguishers (Sprinkler) and 2 manual fire

extinguishers. Two of the automatic fire extinguishers are fixed at the top of the dispenser cabin

and the third will be attached to the top of the rear cabin where the infeed line is located. The fire

extinguishers will be operating when it detects any sign of heat letting the extinguisher valve to

open and operate. The other two fire extinguishers are manual and will be attached to the rear door

of the MFS and inside the control room. Please refer to section 1.3 in order to see the locations of

all fire extinguishers. Automatic ones are labeled with number 7 and the manual ones are labeled

with number 12.

Section 1.3 shows the location of the fire extinguishers located in the rear side of the MFS where

the infeed line is located. The fire extinguisher that is hanged on the right-side door is the manual

one, and the other that is attached to the ceiling of the room is the automatic one.

Section 1.3 Shows the locations of the automatic fire extinguishers inside the dispenser room. All

extinguishers are attached on the ceiling of the dispenser cabin. Section 1.3 shows the location of

the manual fire extinguisher located in the control room.

Note: check and test that all extinguishers are reliable and check dates on all fire extinguishers.

1.4.2 Fire Blanket

Inside the control cabin there is a fire blanket that is attached to the wall. It is positioned in way

that if the operator facing the electrical box, it shall be to the operator right. Section 1.3 shows the

location of the fire blanket in located in the control room and it is labeled with the number 18.

Figure 12.Close view to the fire blanket.

1.4.3 First Aid Kit

A first aid kit is also installed in the control room right next to the fire blanket. It is positioned in

way that if the operator facing the electrical box it shall be behind the operator. Section 1.3 shows

the location of the first aid kit inside the control room. It is labeled with the number 19.

Figure 13. Close look to the first aid kit.

1.4.4 Smoke Detectors

There are six smoke detectors in the MFS. The first one is located inside the rear cabin that leads

to the infeed section. The second is located in the dispenser section of the MFS. The third is located

in the control room. Section 1.3 shows the location of the smoke detector in the MFS rear section.

One smoke detector is placed on the maintenance door. Two smoke detectors are located between

the wall of the container and the tank. It is labeled with the number 5. For the exact location of

smoke detectors please refer to Appendix B. Appendix B shows the exact location of all smoke

detectors.

Figure 14. Smoke detector inside the control room.

As shown from figure 14, the location of the smoke detector inside the control room is attached

to the ceiling of the room.

1.4.5 Explosion Proof Parts

The product contains explosion proof parts such as the light units, the Digimon console, and the

electrical box. This was done in order for the MFS to meet the UL-142 Safety code. All Explosion

proof parts are listed in section 1.3. table 2 Shows the number of all parts in order to refer to them

in section 1.3 and locate them.

Table 2. Shows the explosion proof parts.

Part Number

Name

Digomon Console

Anti-explosion light unit

Electrical Box

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