RAK Mobile Filling Station User manual

Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait
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

Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait
2
Nomenclature
MFS
Mobile Filling Station
Ft
Feet
ISO
International Organization for Standardization
L
Liters
mm
Millimeters
kg
Kilogram
m3
Cubic Meter
UL
Underwriters Laboratories
V
Volt
Hz
Hertz
''
Inch
HSE
health, safety and environment
DC
Direct Current
VAC
Voltage Alternating Current
in
Inch

Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait
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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.

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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

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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

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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

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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

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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.

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Figure 3. No smocking sign.
Figure 4. Explosive atmosphere.
Figure 5. No cell phones.

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1.3 List of Parts Used Along with Descriptive Figures
Figure 6. The rear side of the MFS.
37

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Figure 7. Station Dispensing Section.

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Figure 8. Control room entrance.

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Figure 9. Shows the control room.

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Figure 10. Other view of the control room.

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

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Table 1. Show all parts listing and numbers.
Part
No
Part Name
Qty
1
Infeed line
2
2
Digimon Console ATEX Tank Status Monitoring
1
3
Servo Motor with Butterfly Flange
2
4
Anti-explosion light unit
3
5
Smoke detector
6
6
Emergency Vent for Outer shell
2
7
Automatic Fire extinguisher
3
8
Overfilling Alarm
1
9
Light Unit Switch
2
10
Emergency Shutdown Buttons
6
11
Ground Reel
1
12
Manual Fire Extinguisher
2
13
Retention Tray
1
14
Cut Off Valve for inlet Control
2
15
AC unit
1
16
Aluminum Door to Control Room
1
17
Power Input Plug
1
18
Fire Blanket
1
19
First Aid Kit
1
20
Power Distribution Unit with Circuit breaker
1
21
Electrical Box
1
22
Leak Alarm Console
1
23
ProGauge Console
1
24
Submersible pump
2
25
Level Switch
2
26
Level Probe
2
27
Depth plug
2
28
Junction Box
5
29
Vent Port
2
30
Emergency Vent
2
31
Suction Port
2
32
Spare
4
33
Inlet Port
2
34
Manhole
2
35
Solenoid Valve 2’’
4
36
cutoff valve 2’’
4
37
Venting fans
2

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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.

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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.

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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
2
Digomon Console
4
Anti-explosion light unit
21
Electrical Box

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1.4.6 Pressure / Vacuum Vent 2'' + Flame Arrestor
The MFS is provided with pressure vent 2'' and flame arrestor. This device allow the breathing of
the tank during filling and suction process.
Figure 15. Pressure / Vacuum Vent 2'' + Flame Arrestor.
1.4.7 Retention Tray
A retention tray is used in the MFS to prevent any fuel spillage form occurring during the tank
filling process. The retention tray is provided with a valve to have ensure safe drainage of the
excess fuel that was spilled in the operation of filling the tank. The retention tray is able to slide in
and out to have an easy maneuver when opening the valve located at the bottom of the retention
tray. Refer to section 1.3 in order to locate the retention tray. It is labeled with the number 13.
1.4.8 Suction Port
The MFS is provided with suction port. Each tank has its own suction port to ensure that the tank
is prevented from overfilling. The Suction port was also added to simplify the emptying of the
tank operation in order to transport it. This was also added incase emptying was needed in order