Attachment 4 - Commissioning results - checklist and summary.pdf

Check‐List and steps for the commissioning MKAB ‐ System Commissioning ‐ with water

Date:_____________

Ref Description Completed Remarks

0 Coordinate operations with Base CE

1 Inspection of the Truck Fill Stand Area (joint sealants 100% replaced)

Inspection of the tank 1 interior:

Internal floating roof, Fill Nozzle, Vents

3 Close Tank 1 After inspecting the interior

Inspection of the tank 1 interior:

Internal floating roof, Fill Nozzle, Vents

5 Close Tank 2 After inspecting the interior

Open filter vessels. Remove and store cartiges:

Issue F/S 1

Issue F/S 2

Receipt F/S 1

Receipt F/S 2

Carefull not to damage door seals.

If damaged use a gasket sealant to reseal the filter door.

7 Install thin mesh (sock) inside the basket strainers (4 units)

8 Built temporary support for water hose Must go over fence and concrete wall

Connect hose from fire hydrant to tank 1 (hose goes over the fence and concrete wall suported by a temporary structure) Coordinate with base CE and Fire Dep. before

10 Partially fill tank with 360 m3 of water (5,07 m) Once complete infor Base CE that filling stopped

During tank filling, survey the floating pan from the roof to confirm that it's floating

12 Disconnect and prepare to install it from TFS 1 to off‐loading rack. Ensure path remains cleared for trucks

13 Fill pipes with water and bleed off all air vents

Hydrostatic test pipe sections, with PRTs isolated from the system.

Replace gaskets as needed.

Test at 175 PSI

Verify that each pump rotation is in the correct direction:

Pump 1

Pump 2

Pump 3

Pump 4

PRT Pump (Tk1)

PRT Pump (Tk2)

Drain Tk pump

Close nearly complete the valves downstream the main pumps. When starting the first run, monitor the AMPs to target the correct flow.

Main pumps should work at 42.2 Amps. If higher than

45 throlte down the valve. If lower than 35 open slowly.

Run pumps a few minutes to check pressure and vibration:

Pump 1

Pump 2

Pump 3

Pump 4

PRT Pump (Tk1)

PRT Pump (Tk2)

Drain Tk pump

Circulate fuel using only tank 1, with the hose connected from TFS 1 to off‐loading rack.

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TLopes Text Box Tank area was cleaned from vegetation

TLopes Text Box All gaskets seals were in good condition. All filter elements were protected with plastic and delivered to KBR for local storage

TLopes Text Box Not required. All basket strainers were thin mesh and in good condition.

TLopes Text Box Hose path was passed under the (reinforced) fence and over the wall.

TLopes Text Box The system has severe lack of vents and drain points.

TLopes Text Box All pumps were rotating in the opposite direction. All were corrected. Some pumps were initially stuck and were rotated by hand (with power off).

PRT pump 1 and Drain Tank pump were gripped and it was not possible to unlock them.

PRT pump 2 had the switch defective due to corrosion. The switch from PRT pump 1 was swapped and the pump confirmed to work correctly (also after correcting the rotation)

TLopes Text Box PRT pump 1 and Drain Tank pump don't work.

TLopes Text Box All flow switches have writing issues (i.e turning one pump and the opposite flow switch light goes on), tests were performed by manually override and verification of flow.

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TLopes Text Box 4 - 8 June 2018

Flush offloading piping using 4 pumps simultaneously, for 30 min, checking the basket strainers DP every 10 min.

Record pressures and DP at the basket strainers.

Monitor Amps and adjust valves accordingly.

Circulate fuel using only tank 1, with the hose connected from TFS 1 to off‐loading rack. Flushing is complete when no more dirt (grains/chunks) are captured in the basket

19 Connect TFS 1 and 2 Pantographs in closed‐loop mode.

Flush off‐loading piping using all 4 pumps simultaneously, for 30 min, checking the basket strainers DP every 10 min.

Record pressures and DP at the basket strainers.

Monitor Amps and adjust valves accordingly.

Circulate fuel using only tank 1, with the hose connected from TFS 1 to off‐loading rack. Flushing is complete when no more dirt (grains/chunks) are captured in the basket

21 After water is sufficiently clean, re‐install flow meters. Temporary flow meter to be installed at the Tank inlet.

22 Install temporary flow meter at the Tank 1 inlet.

Circulate water with one pump, and calibrate meters:

TFS 1 meter

TFS 2 meter

Off‐loading meter

24 Transfer water into tank 2

During tank 2 filling, survey the floating pan from the roof to confirm that it's floating

If client is satisfied, drain all water through the drainage:

Vents

Low‐points

Pump Sump drains

Flanges at trapped locations

27 Clean Tank 1, 28 Clean Tank 2

29 Dry all piping with Air compressor

During the drying process monitor humidiy of air coming out of the pipe and record.

Replace Pump Seals:

Pump 1

Pump 2

Pump 3

Pump 4

PRT Pump (Tk1)

PRT Pump (Tk2)

Drain Tk pump

32 Clean‐up and De‐mobilize

Notes:

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TLopes Text Box It was confirmed that the meter are working, but due to the time loss on fixing the pumps, the meter calibration was not performed. This operation can easily be performed once the system has clean fuel inside.

TLopes Text Box All Control Valves and meters were reinstalled in position. The spool pieces were also delivered to KBR for storage.

Water hoses (large fire fighting type) were donated to the local Fire Department.

TLopes Text Box Due to loud noise of the pumps, a complete refurbishment of pump and electrical motor is preferred than to only replaced the seals.

ECC delivered all mechanical seals from the original pump manufacturer, for all 7 pumps. ECC had also acquired and delivered the new bearings for the 4 main pumps. These were also delivered to KBR for local storage.

TLopes Text Box In addition to the previously listed deficiencies and recommended repairs, the following lists the deficiencies detected during commissioning and their respective repair actions:

1 - The system has no LPD (Low-Point Drains), nor HPV (High-Point Vents). This makes all system filling and draining extremely complex. It's highly recommended to install several LPD and HPVs. It's estimated that about 7 LPD and 7 HPV will be necessary.

2 - Recommend replacement of PRT Pump 1 ( Blackmer XL 1.25B; SN:817252 ) and Drain Tank Pump (MP Pump, Mod: 36427-UX SN: P90725), which are gripped.

3 - Due to resistance to rotation, it's recommended a full refurbishment of the main pumps (seals and bearings) and including electrical motors (bearings and final alignments) at a qualified work-shop. The mechanical seals are already on-site as well the pump bearings. (Gorman-Rupp Pumps RD 3A32-BAR SN: 1413014N, 1413015N, 1413016N and 1413017N).

4 - All flow switches had wiring issues, such as turning the pump off immediately (no lag) or turning on the light of the other pumps (cross wiring). It's recommended the pump control panels (one at the loading pumps and another at the off-loading pumps) to have their wiring redone by a qualified electrician with experience in fuel pump control systems.

5 - The CLA-VAL dry connectors, at the end both pantographs have the seals damaged. It's recommended to replace the seals.

6 - Tank 1, roof access hatch has it's manual lock stuck. It's recommended to unlock it and to grid the excess material to allow proper operation.

7 - Truck Fill Stand 1, the junction box that supplies energy to the meter has a damaged cable gland. It's recommended it's replacement.

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