Professional Documents
Culture Documents
SO# VC-9152957
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CAUTION
PLANT OPERATING PERSONNEL SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITH
THE CONTENT OF THIS MANUAL, THE PHYSICAL INSTALLATION, AND EQUIPMENT
PROVIDED BEFORE ATTEMPTING TO ENERGIZE AND OPERATE THE SYSTEM. IT IS
RECOMMENDED THAT AN AUTHORIZED JOHN ZINK COMPANY FIELD REPRESENTATIVE BE
RETAINED FOR INITIAL SYSTEM COMMISSIONING AND PLANT PERSONNEL TRAINING.
Requests for field service and spare parts can be made during our normal office hours from 8:00 a.m. to 4:30 p.m. (CST)
Monday through Friday. Please reference the John Zink Sales Order number when requesting service.
For assistance, please contact John Zink Company as follows:
Service
(918) 234-2962
Spare Parts (918) 234-2749
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CONFIDENTIALITY STATEMENT
INFORMATION CONTAINED IN THIS MANUAL IS CONSIDERED TO BE CONFIDENTIAL AND
PROPRIETARY PROPERTY OF THE JOHN ZINK COMPANY AND IS NOT TO BE DISCLOSED TO
OTHERS WITHOUT WRITTEN PERMISSION.
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Table of Contents
I. GENERAL NOTICES ......................................................................................................................................................... 5
II. INTRODUCTION .............................................................................................................................................................. 7
III. SAFETY ............................................................................................................................................................................ 8
IV. INSTALLATION............................................................................................................................................................ 10
V. DESIGN BASIS AND PERFORMANCE GUARANTEE .............................................................................................. 12
VI. SYSTEM SUMMARY AND DESCRIPTION ............................................................................................................... 13
VII. DSU SYSTEM OPERATION ....................................................................................................................................... 15
Pre-Operation ..................................................................................................................................................................... 15
Testing and Calibration ...................................................................................................................................................... 16
System De-Pressure ............................................................................................................................................................ 18
Start-up ............................................................................................................................................................................... 19
Normal Operation ............................................................................................................................................................... 19
Process Shutdown............................................................................................................................................................... 20
Normal Shutdown............................................................................................................................................................... 21
Emergency Shutdown......................................................................................................................................................... 21
VIII. TROUBLESHOOTING ............................................................................................................................................... 23
Problem: Vapor High or High-High Oxygen Content ....................................................................................................... 23
Problem: Vapor Low, Low-Low, High or High-High Pressure ........................................................................................ 23
Problem: Dock Detonation Arrester High Differential Pressure ....................................................................................... 24
Problem: Valve Sequence.................................................................................................................................................. 24
Problem: Dock Detonation Arrestor High Temperature.................................................................................................... 24
Problem: Vapor Backflow ................................................................................................................................................. 24
Problem: Oxygen Analyzer Low-Low Flow ..................................................................................................................... 24
IX. SYSTEM TESTING ....................................................................................................................................................... 25
Dock Arrestor High Temperature (TSH-101) .................................................................................................................... 25
Valve Sequence .................................................................................................................................................................. 26
X. PREVENTATIVE MAINTENANCE .............................................................................................................................. 27
XI. SET POINTS AND CONFIGURATION SHEETS ........................................................................................................ 28
XII. ELECTRICAL-MECHANICAL DRAWINGS ............................................................................................................. 29
XIII. SPECIFICATION SHEETS ......................................................................................................................................... 30
XIV. PLC LOGIC ................................................................................................................................................................. 31
XV. TECHNICAL SERVICE AGREEMENT ..................................................................................................................... 32
XVI. STANDARD TERMS AND CONDITIONS ............................................................................................................... 33
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I. GENERAL NOTICES
WARNING
Instructions provided in this Manual were prepared to serve as a
general guide. It is intended for use by qualified personnel with
knowledge about Equipment of this type. It is not intended to
cover all possible variations in Equipment or to provide for
specific operating problems which may arise. If additional
information is required, please contact the Service Department
listed on page 2. Remember, STOP, THINK, AND ASK.
WARNING
Each person referring to this Manual is responsible for its proper
use in accordance with its terms and conditions, along with
adhering to all warnings or cautions provided in the Manual.
WARNING
In addition to any general safety measures provided in this
Manual, each person must comply with all current national, state,
local, and company safety regulations at all times.
Any person using this Manual will accept, and agree to be bound by, the following terms and conditions.
NOTE
The following terms and conditions are subject to, and are
superseded by, any contract between the individual and
COMPANY regarding the sale of Equipment.
1.
NO WARRANTIES: This Manual is provided on an "as is", "where is" basis without any warranty or guarantee
of any kind, whether express of implied, written or oral. COMPANY EXPRESSLY DISCLAIMS ALL EXPRESS
AND IMPLIED WARRANTIES REGARDING THE MANUAL, INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE.
2.
INDEMNIFY AND HOLD HARMLESS: Individuals understand there are certain risks inherent in using the
Equipment, including, without limitation, bodily injury, death, and damage to personal property, including the
various risks described in the Manual under Caution, Warning, or Danger text. Individuals understand these risks
may result from a variety of circumstances including, but not limited to, the use or misuse of the Manual or the
Equipment. As a material consideration for the right to use this Manual, each person agrees to indemnify, assume
and hold COMPANY and its parent company, subsidiaries and affiliates, and each of their officers, directors,
employees and agents (collectively the "Seller Parties"), harmless from any and all injuries, losses, damages, costs,
and expenses which may arise out of, or result from, the Manual or the Equipment, including, but not limited to,
risks of personal injury, death, and property loss or other damages.
3.
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LIMITATION, LOST PROFITS AND LOST REVENUE, REGARDLESS OF THE FORM OF ACTION,
WHETHER IN CONTRACT, TORT, NEGLIGENCE, STRICT PRODUCT LIABILITY, OR OTHERWISE,
EVEN IF THE COMPANY PARTIES WERE INFORMED OF OR ARE AWARE OF THE POSSIBILITY OF
ANY SUCH DAMAGES IN ADVANCE. EACH INDIVIDUAL ACKNOWLEDGES AND AGREES THE
FOREGOING ALLOCATION OF RISK WAS ACKNOWLEDGED, AGREED, AND FOUND REASONABLE,
AND THAT THE FOREGOING LIMITATIONS ARE AN ESSENTIAL BASIS OF THEIR RIGHT TO USE
THIS MANUAL.
4.
GENERALLY: The foregoing provisions may not be waived or amended unless in writing signed by an officer of
COMPANY. These Terms shall be governed by the laws of the State of Kansas, without regard to its conflicts of
law rules.
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II. INTRODUCTION
The John Zink Dock Safety Unit (DSU) is a fully automatic system that is designed to incinerate a
mixture of hydrocarbon vapors and air and operate remotely in either an automatic or manual mode.
The system starts and stops in response to external electrical control signals received by the control
logic system.
The combustion system is controlled by a programmable logic controller (PLC) which has an internal
pre-designed operating logic sequence. The PLC receives and transmits control signals in response
to operating pressures and temperatures. In the event that a component fails or if the process
conditions vary beyond the prescribed operating parameters, the control system will respond by
stopping the flow of hydrocarbon vapor and shutting down the combustion system in a safe and
sequenced order.
As part of the safety system design to prevent a flame flashback from the burner assembly, i.e., antiflashback burners and detonation arrestors have been provided. Each item is designed to stop the
propagation of a flashback to the source of the hydrocarbon vapor flow.
In addition to the anti-flashback equipment, various pressure switches, temperature switches, and
thermocouples are also used to monitor and protect personnel and equipment from a mis-operation or
system malfunction. The vapor combustor system consists of the following equipment and safety
devices:
1.
Oxygen Analyzers
Detonation Arrestors
Control Panels
Vapor Piping, Instruments, and Valves
Enrichment Gas Piping and Instruments
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III. SAFETY
WARNING
All operating and maintenance personnel must read and become familiar with this operating
instruction manual. Operation of the dock safety unit must be strictly in accordance with John
Zink Company operating and maintenance instructions. IMPROPER OPERATION OF THE
EQUIPMENT CAN RESULT IN EQUIPMENT DAMAGE AND/OR INJURY OR POSSIBLE LOSS OF
LIFE TO OPERATING PERSONNEL.
This documentation does not replace any existing company safety operating procedures and/or
instructions. All normal safety precautions should be followed when operating vapor combustor and
fuel systems. Consult your plant operations and safety authorities for complete details.
CAUTION
FIRE AND EXPLOSION HAZARDS
1.
Smoking, welding or open flames should be prohibited around the unit as long as it
contains hydrocarbon vapors. Leaks should be repaired as soon as possible to prevent
accumulation of spilled combustibles. Spillage should be cleaned up promptly.
2.
The marine loading system vapor piping contains hydrocarbon vapor that released in
air may become explosive. Extreme caution must be exercised when opening the
system for inspection and service. Smoking, welding, or open flame must be prohibited
whenever the system is opened to the atmosphere.
ELECTRICAL HAZARDS
1.
Potentially dangerous voltages exist in control cabinets and electrically actuated control
components. These components should only be serviced when system power is removed
and only be qualified electrical/instrument servicemen.
2.
High voltage (120 VAC) capable of causing severe injury or death is used on this
equipment.
3.
MECHANICAL EQUIPMENT
1.
2.
Keep hands, loose articles of clothing, and jewelry away from operating rotating
machinery. Since the system starts up automatically, power should be disconnected
prior to performing maintenance on the equipment.
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SAFETY EQUIPMENT
*1.
*2.
*3.
*4.
*5.
Never expose piping, vessels, or equipment to pressures higher than their design
pressure. Excessive pressure can result in vessels or lines leaking, bursting, or rupturing,
or in other types of dangerous pressure release. Be aware of the design pressures of the
equipment you are working with and the gas pressure present.
2.
Keep gas connections tight. Leaking gas containing hydrocarbon vapors presents the
danger of fire or explosion. A flanged or threaded connection just tight enough to hold a
vacuum or a few pounds pressure may leak at higher pressure. Always use an
appropriate thread sealant on threaded connections, and make sure gaskets are in good
condition and properly positioned to provide full surface contact.
3.
Always be sure the pressure is relieved before opening any piping or vessel connections.
4.
Do not vent gas pressure by loosening a component connection. Use vent and drain
valves provided for this purpose. Even at low pressure, the pressure on components can
be great enough to pose a hazard.
5.
Protect your hearing. Pressurized gas being vented may produce a very loud, high
frequency sound which may not be uncomfortable but can cause damage. When working
around such a vent, use ear plugs or other suitable hearing protection.
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IV. INSTALLATION
INSTALLATION
Installation of the Dock Safety Unit (DSU) is the responsibility of the customer. Prior to installation,
this manual and all related documentation for this project should be reviewed. Any questions about
the installation or the equipment should be addressed to the John Zink Vapor Control Service
Department referenced on the first page of this manual. Also if alignment or fit-up problems are
encountered during the assembly procedure, John Zink Company, Vapor Control Department, must
be contacted prior to making any changes or alterations to the equipment.
Note: It is John Zink Company's policy to require verbal and written
notification of equipment problems. John Zink will review the
situation and determine the course of action necessary to resolve any
and all field problems. Should the customer or contractor make
changes or alterations to the DSU system without prior approval by John
Zink Company, any and all claims for field service repair charges will be
declined and returned to the individual companies. Review John Zink
Company's Warranty and standard Terms of Sale.
Personnel performing the installation work must review all drawings provided by John Zink Company
in order to properly reassemble the vapor combustion system. Drawings to be reviewed for this
installation are:
Drawing Number
Description
D-VC-9152957-150
D-VC-9152957-201
D-VC-9152957-202 (1-4)
D-VC-9152957-401 - 407
D-VC-9152957-440
If the system is going to be stored outside for more than ten days in wet weather conditions, power
should be applied to the main control panel and the heater turned on to protect delicate control
instruments and help prevent corrosion inside the panel. John Zink personnel should inspect all
control enclosures prior to start-up for systems stored more than 90 days. Failure to properly protect
the control panel from moisture and corrosion could invalidate all manufacturer and John Zink
warranties on electrical components inside the main control panel.
The following must be performed to install the Dock Safety Unit (DSU).
1.
Carefully remove the skid from the transport truck using provided lifting lugs. Only qualified
equipment operators should supervise, remove, and install the combustion equipment..
2.
Set the skid on properly designed platforms and foundations. Level and grout with nonshrinking grout.
3.
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DSU SKID
a. Install pressure/vacuum safety vent, PSV-101, to inlet to DSU skid piping. Install all
pressure and vacuum weights provided. Bundles are tagged pressure and vacuum
and should be installed on their corresponding side of the vent valve.
b. Install dock skid warning lights (AL-2) and alarm light (AL-1) within sight of dock
operator and run control wire into control panel CE-1.
c. Install oxygen analyzer probe in main vapor piping downstream of enrichment mixer.
The probe needs to be between 10 and 30 pipe diameters from the injection mixer,
MX-1. Install 1/2 stainless steel tubing from probe to oxygen analyzer sample
connection.
d. Install rain-shield on Oxygen Analyzer panel.
e. Install rain-shield on panel rack.
4.
Customer conduit and electrical wiring hookups. Note that this list is only a summary. See
Drawings B-VC-9152957-401 through 407 for details. Note that dashed lines indicate
customer supplied wire.
a.
b.
c.
d.
5.
Confirm that all pipe fittings and flanges, electrical wiring connections and electrical conduit
fittings are tight.
Note: Do Not Pour electrical seals until the vapor combustion system has been
checked, started and placed in service by a John Zink field service engineer.
6.
Confirm that external electrical control and power wiring is correctly sized and the system
has correct overload protection.
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1.
3.
The design basis assumes that there is negligible H2S and mercaptan. Higher
concentrations may require additional precautions to protect against corrosion in
the stack and vapor piping.
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2.
3.
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2.
3.
OFF
OFF
OFF
Open
Open
Open
Closed
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4.
Turn the system Power switch on control panel CE-1 to the ON position and confirm that
the system power on light is illuminated.
5.
Press the Lamp Test button on control panel CE-1 and confirm that all lights are
illuminated.
6.
Press the System Reset button at the dock to confirm that all faults are clear. If a fault is
present it must be corrected before proceeding.
7.
Inspect loading hose between loading vessel and dock for possible problems.
8.
2.
Press the Combustor Start button on CE-1.The green Combustor Started light will begin
to flash. Once the customer combustor is ready to accept vapors the light will turn a solid
green.
3.
Turn the Dock Mode switch to the TEST position. Isolate PIT-101, PIT-102, and PDIT101 from the process line and open the instruments to the test manifold using the ball
valves located at each instrument.
4.
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d. Confirm that the fault activated at the proper pressure determined for each loading
operation.
e. Relieve the vacuum on the line to clear the fault.
5.
6.
7.
8.
9.
Test the Dock Filter High Differential Pressure (PDAH-101) fault as follows:
a. Using the test manifold located on the dock skid apply pressure on high side of PDIT101.
b. Slowly increase the pressure until the alarm is activated.
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c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and the
appropriate control panel light is illuminated.
d. Confirm that the fault activated at the proper pressure determined for each loading
operation.
e. Relieve the pressure on the line to clear the fault.
10.
11.
Test the Oxygen Analyzer Low Sample Flow (FSLL-101) fault as follows:
a. Reduce sample flow using adjustable flow meter inside the analyzer cabinet.
b. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate
control panel light is illuminated.
c. Place sample flow back to original position.
12.
13.
System De-Pressure
Before loading begins, the vessel being filled should be de-pressured close to atmospheric pressure.
This is accomplished as follows:
1.
Install the vapor hose to the loading vessel. Insure that the vessel block valve is not open
at this time.
2.
If the customer combustor is not already running press the Combustor Start button on
CE-1. The green Combustor Started light will begin to flash. Once the customer
combustor is ready to accept vapors the light will turn a solid green.
3.
4.
The PLC will ignore the DSU High Pressure Shutdown during the De-Pressure Mode.
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5.
Press the Vessel Depressure button and the Depressure Enable light will begin to flash.
6.
7.
Vessel operator can begin to slowly open the vessel vapor header block valve to bleed
pressure into the line. If this step is done too quickly the pressure may be high enough to
lift the pressure relief valve.
8.
The pressure control valve, PCV-101, will open to a set output of approximately 15%.
9.
The PCV-101 PID loop will be active but not affect the PCV valve position until the PID
loop demand exceeds 15%.
10.
As the pressure inside the vessel begin to drop the vessel operator can begin to open the
block valve more. This step is repeated until the valve is full open.
11.
The DSU will de-pressure the vessel until the pressure drops to 2 WC.
12.
At this point, the De-Pressure Enable light will go solid, the PCV-101 valve will go closed
and the customer vapor blower should stop.
13.
DSU Dock Mode switch can be moved to the RUN position and loading can commence.
Note: During Depressure operation, after the pressure has dropped below the highhigh pressure shutdown set point, the DSU mode switch can be moved to the RUN
mode de-activating the depressure mode and allowing loading to commence.
Start-up
The start-up stage starts the system and consists of stack purge, pilot ignition, and ready-to-load. The
following instructions assume the testing and calibration stage has been completed. The steps to be
performed are:
1.
2.
3.
Press the Combustor Start push-button. The green Combustor Started light will stop
flashing and turn solid once the customer combustor is ready to accept vapors, indicating
loading can start.
Normal Operation
The Normal Operation stage starts and stops the loading of the marine vessel. The following
instructions assume the Start-up stage has been completed. The steps to be performed are:
1.
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2.
3.
Press the Dock Start push-button located on the DSU panel CE-1.
a. The customer liquid valve opens.
b. Customer vapor blowers can begin operation.
c. Pressure control of the DSU system is accomplished by pressure valve PCV-101
working in tandem with PIT-101. The transmitter PIT-101 monitors the operating
pressure and passes the pressure on to PIC-101, which increases or decreases the
position of the valve.
4.
5.
To stop loading, press the Dock Stop push-button located on the DSU panel CE-1.
a.
b.
c.
d.
Several alarms may occur during normal operation that will not shut down the system. The cause of
any alarm should be immediately investigated and corrected if necessary. The following will alarm
only:
Vapor High Oxygen Content (ASH-101)
Vapor Low Pressure (PSL-101)
Vapor High Pressure (PSH-101)
Filter High Differential Pressure (PDAH-101)
Note: The control panel lights are programmed with a first out feature. The light for
the fault causing the alarm or shutdown will be flashed. The lights for any faults
that may result from the first one will be illuminated steadily.
Process Shutdown
The process shutdown stage is a partial, intermediate shutdown that allows faster restarts. When a
process shutdown fault occurs, the dock skid will stop and customer vapor blower should shut down
while the combustor continues to operate. The following faults will cause a process shutdown:
Vapor Low-Low Pressure (PSLL-102)
Vapor High-High Pressure (PSHH-102)
Vapor High-High Oxygen Content (ASHH-101)
Oxygen Analyzer Low Flow (FALL-101)
Dock Detonation Arrester Backflow (PDAL-101)
Vapor Valve Position Failure
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Note: The control panel lights are programmed with a first out feature. The light for
the fault causing the alarm or shutdown will be flashed. The lights for any faults
that may result from the first one will be illuminated steadily.
1.
2.
The shutdown (red) strobe light will flash and the horn will sound.
The light for the fault causing the shutdown will be flashed.
The lights for any faults resulting from the first one will be illuminated steadily.
Customer vapor blowers should stop.
Vapor shutdown valve PCV-101 will close.
The customer liquid valve will close.
Normal Shutdown
The normal shutdown stage is a controlled, complete shutdown that can be initiated at any time during
the start-up, normal operation or process shutdown stages.
1.
2.
The control panel lights for any faults resulting from the shutdown will be illuminated.
The customer liquid loading valve will close.
The DSU vapor shutdown valve PCV-101 will close.
Customer vapor blowers should stop.
The Dock Started light will be extinguished.
The Combustor Started light will be extinguished.
Emergency Shutdown
The emergency shutdown stage is an immediate, complete shutdown that occurs when unsafe
conditions are detected.
An emergency shutdown can be initiated by pushing the Emergency Stop button located on CE-1.
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2.
3.
The shutdown (red) strobe light will flash and the horn will sound.
The light for the fault causing the shutdown will flash.
The customer liquid loading valve will close.
The DSU vapor shutdown valve PCV-101 will close.
Customer vapor blowers should stop.
The Dock Started light will be extinguished.
The customer combustor should shutdown.
The Combustor Started light will be extinguished.
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VIII. TROUBLESHOOTING
WARNING
This equipment has 480 VAC and 120 VAC electricity that can shock or kill
personnel. Extreme caution must be used when servicing this equipment.
This equipment contains vapors within the explosive mixture range.
Extreme caution must be used when servicing this equipment.
Preventative maintenance and repairs should only be performed by qualified service
personnel who are familiar with all safety and operations procedures. Read Section II,
Cautions and Warnings before proceeding with any maintenance operations.
This troubleshooting section is only intended to be a guide in solving equipment faults. It lists
potential problems with possible causes and solutions, and is not a detailed list of all possible
problems. Reference should be made to the vendor literature section of the operating manual to
troubleshoot problems with specific component items of this system. It is recommended that only
qualified service personnel should perform repairs. Contact the John Zink Company at 1-800755-7252 if a system fault cannot be corrected. The following items are discussed in this section.
1.
2.
3.
4.
5.
6.
7.
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Valve Sequence
a.
b.
c.
d.
e.
f.
g.
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X. PREVENTATIVE MAINTENANCE
WARNING
This equipment has 120 VAC electricity that can shock or kill
personnel. Extreme caution must be used when servicing this equipment.
This equipment contains vapors within the explosive mixture range.
Extreme caution must be used when servicing this equipment.
Preventative maintenance and repairs should only be performed by qualified service
personnel who are familiar with all safety and operations procedures. Read Section II,
Cautions and Warnings before proceeding with any maintenance operations.
1. The detonation arrestors should be checked once every six months to verify that they
are free from foreign matter, which could restrict hydrocarbon vapor flow.
2. All safety shutdown devices should be tested for correct operation and verified a
minimum of once every three months.
3. Review Section VIII, System Testing, to assist in preventative maintenance.
4. Check calibration and operation of all instruments in accordance with vendor literature
in Section XVIII.
5. Refer to vendor literature for specific maintenance requirements of various
components.
6. Thermocouples should be checked for accuracy once every year.
Note: The above preventative maintenance summary is only designed as a guideline and
does not include all areas that must be checked. A preventative maintenance program
must be designed, based upon existing company policy, operational experience,
vendor data requirements, maintaining an adequate supply of spare parts and an
operation-maintenance log book. John Zink has many field technicians across the
world that can provide Preventative Maintenance assistance with documented checks
and corrections. For a detailed PM quote please contact 918-234-5718.
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(*)
(*)
-10 w.c.
20 w.c.
8% O2
9% O2
200F
30-40 psig
-1 w.c.
10 w.c.
* These values are dependent on the vessel to be loaded. Refer to 33 CFR 154.814.
TABLE 1:
OXYGEN ANALYZER SET POINTS NON-INERT
TYPE OF CARGO
O2 CONTROL %
O2 ALARM % (ASH)
O2 SHUTDOWN % (ASHH)
N/A
N/A
N/A
N/A
TYPE OF CARGO
Crude Oil
TABLE 2:
OXYGEN ANALYZER SET POINTS INERT
O2 ALARM % (ASH)
O2 SHUTDOWN % (ASHH)
O2 CONTROL %
7.0%
8.0%
9.0%
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Description
Piping and Instrument Diagram
Nozzle Legend and General Notes
General Arrangement Dock Safety Skid
Schematic Wiring Diagrams DSU
Test Panel Layout
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Manufacturer
Air / Gas Filter (Filter)
Asco (Solenoid Valve)
Bettis / PMV (Actuator / Positioner)
Enardo (Arrestor, Pressure / Vacuum Relief Valve)
Fisher (Regulator, Flow Control Valve)
Flowseal (Butterfly Valve)
McDaniel (Pressure Gauge)
Mueller (Strainer)
Neo-Dyn (Pressure Switch)
Servomex (Oxygen Analyzer)
Thermo-Sensor (Thermocouple)
Yokogawa (Pressure Transmitter)
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