Documente Academic
Documente Profesional
Documente Cultură
LONDON : HMSO
Crown copyright 1994 Applications for reproductions should be made to HMSO First published 1994 ISBN 0 1 1 772809 8
Other titles in the Series: Defence Works Functional Standards 01Children's Play Area Design Guide ISBN 0 1 1 772714 8
Defence Works Functional Standards 02 (Edition 2-1994) Catering Design Guide ISBN 0 1 1 772770 9
Defence Works Functional Standards 04Conservation Manual for Listed Buildings and Scheduled Monuments ISBN 0 1 1 772455 6
Defence Works Functional Standards 05Specification for Specialist Works on Petroleum InstallationsMechanical ISBN 0 1 1 772777 6
Defence Works Functional Standards 06Guide to Airfield Pavement Maintenance ISBN 0 11 772730 X
Foreword
This document is for the use of Top Level Budget Holders (TLBH's) for application by the Property Managers (PROM), Establishment Works Consultants (EWC), Works Service Managers (WSM) and other parties involved in the undertaking of Mechanical and Electrical Maintenance, Inspections and Testing of Bulk Petroleum Installations on the MOD estate. The document was prepared under the direction of the Defence Petroleum Distribution Committee.
245267 B*
Abbreviations
AP(POL) AP(PET) BS DWS EWC HSE JSP MOD PET PROM POL TLBH,s WSM
Authorised Person POL (Term in current use) Authorised Person Petroleum (POL term to be replaced by PET) British Standard Defence Works Services Establishment Works Consultant Health and Safety Executive Joint Service Publications Ministry of Defence Petroleum Property Manager Petroleum, Oil and Lubricant Top Level Budget Holders Works Service Manager
Contents
Page No.
General Requirements Introduction Aim Hazardous Area Classification (Petroleum) Standards Safe Working Technical Authority
1.
Maintenance, Inspection and Testing Index Mechanical Index Electrical Index Maintenance, Inspection and Testing Schedule Mechanical Schedule Electrical Schedule Appendix Tank Inspection Frequency
5.
3. 3.1. 3.2.
4. 4.1.
8.
46.
245267
B*2
1.
General Requirements
1.1 1.1.1.
Introduction DWS Functional Standard Number 07 affords guidance and direction on the maintenance and inspection frequencies applicable to equipment used in petroleum installations. The information presented in this document is the basis for the preparation of schedules for the maintenance of Bulk Petroleum Installations. Functional Standard Number 07 supersedes the following PSA Maintenance, Inspection and Testing documentation, as applied to Bulk Petroleum Installations: a. PSA Mechanical and Electrical Engineering Guide, (MEG), Volume 4, Section 1.101, Maintenance of Fuel Storage (POL) Installations. MEG Volumes, Section 24.101, Inspection and Testing of Electrical Installations and Fixed Appliance in Hazardous Areas.
1.1.2.
b.
1.1.3.
Functional Standard Number 07 applies to fixed equipment found within petroleum installations on the MOD estate, including:
a. b.
Mechanical equipment in petroleum hazardous areas. Mechanical equipment which is part of a petroleum system, but is outside of the hazardous area.
c.
1.1.4. 1.1.5.
Functional Standard Number 07 does not apply to Kerbside Pump installations. In certain circumstances there may be equipment installed which is not referred to in this document. In such cases the manufacturers recommendations should be followed.
Aim The aim of Functional Standard Number 07 is to :
1.2.
1.2.1.
a.
Furnish the Property Manager, Establishment Works Consultant (EWC) and Works Service Manager (WSM) with an approved set of standards which :
(1).
(2).
Comply with the requirements of the relevant British Standards and other approved Codes of Practice. Form the basis for, and therefore facilitate the development of, an inspection and test programme for installations. Help ensure that installed mechanical and electrical equipment, continues to function in a safe and satisfactory manner.
(3).
(4).
(5). (6).
Minimise the risk of ignition, in hazardous maintained apparatus. Form the basis for the audit of maintenance activities.
caused by inadequately
b. Consolidate and present inspection, maintenance and testing policy requirements in one easy to read document.
1.3.
1.3.1
1.3.2.
b. Zone 1 -
Zone in which an explosive atmosphere is likely to occur in normal operation. Zone in which an explosive atmosphere is not likely to occur in normal operation, and if it occurs will exist only for a short time.
c.
Zone 2 -
1.3.3.
Hazardous area classification drawings, specific to each installation, should be held by the Operating Authority and the EWC/WSM organisations. These hazardous area classification drawings must comply with the requirements of Joint Services Safety Regulations for the Storage and Handling of Fuels and Lubricants, (JSP 317), unless specific exemption is given. The hazardous area classification drawings shall be used in conjunction with this Functional Standard to determine the maintenance frequencies of electrical equipment and installations.
1.4. 1.4.1.
Standards Functional Standard Number 07 shall be read in conjunction with the following relevant standards :
a.
DWS Functional Standard Number 05, Specification for Specialist Works on Petroleum Installations - Mechanical.
BS 7671, Requirements for Electrical Installations, IEE Wiring Regulations.
b. c.
BS 5345, Selection, Installation and Maintenance of Electrical Apparatus for use in Potentially Explosive Atmospheres (other than mining applications or explosive processing and manufacture). BS 6651, Protection of Structures Against Lightning.
BS 7430, Code of Practice for Earthing. The Electricity at Works Regulations 1989 (advice is given in HSE Guidance Booklet HS(R) 25).
d. e. f.
g.
h.
Health & Safety at Work Act 1974 and regulations made thereunder.
i.
Home Office Model Code of Principles of Construction and Premises Licensed under the Petroleum (Consolidation) Act 1928 and 1936.
j.
MOD Safety Rules and Procedures for Work on Petroleum Installations, (Formally PSA Mechanical & Electrical Engineering Guide, Volume 8, Section 53).
MOD Safety Rules and Procedures for Electrical Works, (Formally PSA Mechanical & Electrical Engineering Guide, Volumes, Section 51).
k.
1.5
1.5.1.
Safe Working
All works on Petroleum installations are controlled under the delegation of the Operating Authority, by the Authorised Person, AP (PET). Associated permits will be issued by the AP (PET).
Electrical permits are issued by the Authorised Person Electrical in coordination with the AP(PET). Works examples that require the issue of electrical permits are given below:
1.5.2.
a.
b.
c.
1.5.3.
Inspection, maintenance and testing in petroleum hazardous areas should only be undertaken by competent personnel who are : a. b. Familiar with the MOD Safety Rules and Procedures for works on Petroleum Installations. Experienced in inspection, maintenance and testing within petroleum hazardous areas.
c.
d.
In the principles and details of the various types of explosion protection. In related installation practice. On the general principles of the selection of equipment for installations in hazardous areas.
e.
1.5.4.
Earth fault loop impedance tests, high current continuity tests and prospective short circuit current tests are not to be carried out in hazardous areas. Such tests can introduce current and/or voltages in parts of the installation where they might not be expected, due to bonding of extraneous conductive parts and lightning protection systems. This could result in incendive sparking in areas or parts of the installation not covered by the permit to work. Electronic equipment can be damaged by certain electrical tests, therefore such equipment must be identified and isolated. Manufacturers recommended isolation procedures are to be followed prior to testing being undertaken. Where maintenance, inspection or testing discloses deterioration which may effect the ability of the equipment or installation to perform safely in a hazardous area, appropriate remedial measures should be taken. Replacement equipment shall comply with BS 5345. No alterations should be made to any apparatus or installation without the prior approval of a competent electrical engineer.
1.5.5.
1.5.6.
1.5.7.
Equipment used for testing the electrical installations in hazardous areas shall be intrinsically safe.
3
1.5.8.
The electrical tests given in section 2.0, job numbers 20 to 32 are to be undertaken in numeric order. The maintenance, inspection and testing frequencies given in section 2.0. are the minimum. More frequent and/or more detailed inspections will be necessary where there is a corrosive or other adverse atmospheric condition, a high risk of mechanical damage or vibration, and where there are other onerous circumstances. The need for more frequent maintenance inspections will be determined by specific site conditions, and this is a site responsibility. It should be noted that electrical maintenance and inspection frequencies are determined by the hazardous area classification in conjunction with BS 5345, and should be adhered to for the safe operation of the facility. Records of all inspection, resulting maintenance works and tests of equipment and systems installed in the hazardous area must be kept and maintained. These records should be kept with the site layout drawings showing the extent and zone designation of the hazardous area.
1.5.9.
1.5.10.
1.5.11.
1.6
1.6.1.
Technical Authority
Technical advice and assistance on MOD Petroleum matters can be obtained from DWS. Approaches may be through local DWS offices or directly to the petroleum Technical Works Authority, (DWS TA): Head of Bulk Petroleum Installations Room 121 Airfields and Bulk fuels Group PO Box 1734 Sutton Coldfield West Midlands B75 7QB
1.6.2.
This DWS Standard, Inspection, Maintenance and Testing of Equipment Installed at Petroleum Installations - Mechanical and Electrical, has been devised for use of the Crown and of its contractors in the execution of contracts for the crown and, subject to the Unfair Contracts Terms Act 1977, the Crown will not be liable in any way whatever (including but without limitation negligence on the part of the Crown its servants or agents) where the specification is used for other purposes.
2.
2.1.
Description of Job and Criteria Installations (General) Valve Pits, Chambers, Pump Houses & Access Ways Storage Tanks Exterior Inspection (General) Interior Inspection (General) Internal Tank Inspection Internal Tank Cleaning Low Level Alarm/Control High Level Shut-off Valve Alarm/control Contents Gauge Pressure/Vacuum Valves Internal Coils and Heaters Foot Valves and Strainers Swing Arms and Floating Suction Unit Leak Detection
1.0 1.1
2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12
3.0 3.1 3.2 4.0 4.1
5.0 5.1
Pumps Pump Maintenance Filters & Strainers at Pumps Filter Water Separators (FWS) Maintenance of FWS
Fuel Monitors Maintenance of Fuel Monitors
11.0
11.1
5
245267 C*
Job No
12.0 12.1
13.0 13.1 14.0 14.1 14.2
15.0 15.1 15.2 15.3
Cathodic Protection Maintenance of Cathodic Protection Equipment Oil Interceptors/Drain Tanks Maintenance of Oil Interceptors and Drain Tanks
Marine Facilities Off-shore Unloading Facilities Shore Facilities ie Jetty, Docks etc
2.2.
Electrical Works
Job No
20.0
21.0 22.0 23.0
24.0 25.0 26.0
27.0
28.0
29.0 30.0 31.0 32.0
245267 C*2
3.
3.1
Interval
Petroleum Installations (General) Valve Pits, Ducts, Chambers, Pump Houses, Dispense/Receipt Points and Access ways a. Shall be clear from combustible materials, explosive hazards, loose equipment and materials
b.Corrosion and damage to installation shall be monitored and reported c. Pipework and equipment shall be free from leaks or weeps
3 months
3 months 3 months
d. Access ways are to be free from obstructions (The above activities shall be carried out when undertaking Job numbers 2 to 32)
Interval
Storage Tanks
Exterior (General):
including associated
3 months
Leaks Corrosion Damage to steelwork Damage to external protection Deterioration of equipment Ease of operation of equipment
Special attention should be given to vulnerable areas such as welded or rivetted seams b. Cathodic protection systems shall be tested and maintained in accordance with manufacturers recommendations See job 17
2.2
Internal Tank Inspection: a. Inspect surfaces and seems for signs of leaks, corrosion, pitted plates, breakdown or damage to epoxy coating and sludge deposits
b. Internal tank equipment shall be inspected as detailed in sections 2.3 to 2.10 inclusive
c. After the completion of the inspection/works within the tank a final inspection of the epoxy lining is required prior to tank departure and replacing the manhole
d. After inspection replace manhole cover (using new gaskets) Clean and grease bolts before replacement e. Stencil in 25mm letters the following on the manhole cover:
(1) (2) (3)
f. Record in the Maintenance record details of any cleaning, repairs or other remedial actions required and subsequent action to be taken
Job No
2.3
Interval
There is an accumulation of solid matter, silt or wax on the tank bottom and fittings Maintenance and repairs have to be undertaken
b. Or: (1)
(2) The Operating Authority indicate that there is to be a change of product The tank is being taken out of commission
c. Tank cleaning is to be undertaken by a competent contractor(s) or depot personnel (NAVY) in accordance with MOD/DWS publications: (1)
MOD Safety Rules and Procedures for Work on POL Installations
2.4
a. Check operation of low level alarm/control when the tank is being emptied
b. Ensure pump stops and alarm is given when the liquid level drops to the desired pump cut-off level c. Maintain in accordance with manufacturers recommendations
10
Job No
2.5
Interval
0)
(2)
Check the high level shut-off control valve operates and shuts of the fuel to the tank Check high and high/high level alarms operates
2.6
Contents Gauge:
a. Inspect sensing heads, probes, floats, wires and other contents gauge components. b. Maintain on accordance with manufacturers recommendations
Internal tank equipment following internal tank inspection or cleaning of tank External tank equipment 1 2 months
2.7
Pressure/Vacuum Valves:
12 months
2.8
11
Job No
Interval
2.9
Foot Valves and Strainers: a. Inspect foot valve and strainers ensuring that they are:
(1) (2)
Clean and free from sludge Operate freely and seat and seal
2.10
Internal tank equipment following internal inspection or cleaning of tank External tank equipment 12 months
12
Job No Pumps
Interval
3.0 3.1
Pump Maintenance:
a. Pumps shall be maintained in accordance with manufacturers recommendations. This shall include: 6 months
Lubrication of bearings, seals and glands Pump coupling alignment and bolt torque settings Pump primer unit Correct operation of by-pass valve on positive displacement pump Operation of centrifugal pump by circulation or with delivery valve closed
6 months
(1)
(2) (3) (4) (5) (6)
Any leaks Excessive vibration Abnormal noise High bearing temperatures Operating pressure and flow Lubricant levels 12 months
(1)
(2)
3.2
(1)
(2) (3)
Leaks External corrosion and deterioration Excessive pressure drop across filter/strainer. Pressure readings should be recorded
13
245267 D*
Job No
4.0
4.1
Interval
3 months 3 months
6 months
(4)
a. Listen to ensure that air is being vented during the filling operation b. Check that there is no leakage of product when the unit is full
6 months
(5)
Test automatic water drains: a. Close the outlet valve at the filter and run the pump and note the pressure gauge reading on the pump b. Inject water through the manual drain until the automatic drain valve operates. The water injection pressure should not exceeding 110% of the noted pump gauge reading c. During the procedure the water level at no time to rise out of the gauge glass d. Note the water level in the gauge glass when the automatic water drain valve operates. This should be approximately one third up the gauge glass
14
Interval
e. If an automatic fuel discharge valve is fitted, close the automatic water drain isolating valve and continue water injection until the automatic fuel discharge valve closes f. Note the water level in the gauge glass when the automatic fuel discharge valve closes. This should be approximately two thirds of the way up the gauge glass and approximately half way down when it opens g. Ensure that the automatic water drain valve is to close tight after the discharge of water
(6)
(7)
Testing the pressure relief valve to 110% of the normal working pressure
The above operation should be undertaken in accordance with MOD Safety Rules and Procedures
Note: The criteria for changing the cartridge will be advised by the Operating Authority. This will be determined in conjunction with manufacturers recommendations. Details should be recorded in the Maintenance Record
15
245267 D*2
Job No
5.0
5.1
Interval
Fuel
Maintenance of Fuel Monitors: a. Fuel monitors shall be maintained in accordance with manufacturers recommendations. This shall include:
(1) (2) (3) Monitoring the pressure differential across the unit Check for leaks, damage and corrosion Change fuel monitor cartridge when requested by the Operating Authority. The procedure for changing cartridges is as follows:
3 months 3 months
When requested by Operating Authority
a. Isolate pumps b. Close all product valves to unit c. Open vent valves d. Drain contents into drain tank or as instructed by Operator d. Remove cover, seal and cartridge e. Clean interior of unit f. Inspect for internal corrosion and any damage to internal lining g. Fit new cartridge and cover seal h. Fill unit slowly, ( < 1m/s), to reduce risk from electrical static charges i. Restore to operational condition j. Dispose of old cartridge in approved manner k. Stencil on outside of fuel monitor in 25mm letters:
(1) Fuel monitor cartridge replaced (2) Flow meter reading
(5)
6 months
a. Listen to ensure that air is being vented during the filling operation b. Check that there is no leakage of product when the unit is full
(6)
Test drain valve a. Ensure that the valve seats correctly after use and that there is no leakage
6 months
(7) (8)
Test differential pressure gauge Test pressure relief valve to 110% of the normal working pressure
6 months
The above operation should be undertaken in accordance with MOD Safety Rules and Procedures
16
Job No
5.1 cont./
Interval
Maintenance of Fuel Monitors: Note: The criteria for changing the cartridge will be advised by the Operating Authority. This will be determined in conjunction with manufacturers recommendations. Details should be recorded in the Maintenance Records
17
Job No
6.0 6.1
Description of Job and Criteria Pre-coat Filters Maintenance of Pre-coat Filters: a. Pre-coat filters shall be maintained in accordance with manufacturers recommendations. The maintenance procedure will be decided by the system configuration and type of equipment installed. As a result of the differing types of equipment the procedure given below may require modification to suit particular installations requirements: Procedure:
(1) (2)
(3)
Interval
Monitor the pressure differential across the unit Check for leaks, damage and corrosion Inspect interior of unit. The procedure is as follows: a. Isolate unit by closing all product valves b. Drain all product from unit into drain tank or as directed by Operating Authority c. Open cover at handwheel end d. Remove and examine filter media trays d. Clean interior of unit e. Inspect for internal corrosion and the condition of the lining f. Install filter trays and check for free operation g. Restore to operational condition h. Fill unit slowly, (> 1m/s), to reduce risk from electrical static charge i. Stencil on outside of pre-coat filter in 25mm letters:
a. Ensure that the valve seats correctly after use and that there is no leakage
18
Interval
(6)
(7)
Test differential pressure gauge Test pressure relief valve to 110% of the normal working pressure.
This operation should be undertaken in accordance with MOD Safety Rules and Procedures
Note: Back-flushing and renewing the filter media is the responsibility of the Operating Authority
19
Job No
7.0 7.1
Interval
Fuel leaks Corrosion & deterioration on external casing Correct operation of valve. For example, simulate the required conditions to evaluate if the valves operate within the prescribed criteria:
a. Pressure reducing; to maintain a constant preset pressure in accordance with the operating criteria regardless of the flow rate b. Flow control; to maintain preset rate of product flow in accordance with the operating criteria regardless of the line pressure to the valve
c. Surge arrestor; to limit the downstream pressure rise to no more than 110% of the normal operating pressure d. Excess flow shut off; to cut of the flow at the preset rate of flow e. Shut off; to provide "full flow" and "shut off" and to limit the surge pressure to not more than 10% above the safe working pressure of the system f. Pressure relief; to limit the pressure to 110% of the normal working pressure g. Check valve; to cause the valve to close against reverse flow h. high level control of alarm; to operate at the preset level; of fuel in the tank
20
Job No
Interval
8.0
8.1
Flow Meters Maintenance of Flow Meters: a. Flow meters shall be maintained in accordance with manufacturers recommendations. This shall include:
0) (2) (3) (4)
Checking for leaks Examination for corrosion and deterioration Legibility of register Lubrication as required
8.2
Accuracy Testing of Meters: a. Meters shall be tested for accuracy in accordance with the procedures indicated: 12 months
(1)
The meter is to be tested using a master meter connected in series. Certificate of accuracy should be available for the master meter together with correction factors for flow, pressure and viscosity The test conditions, ie flow and pressure shall be similar to normal operating conditions Test quantity shall be 4 times the maximum rated capacity of the meter Aviation bulk fuel meters are to be accurate to 0.1% at the test flow rate Record in the maintenance record: a. Date of test b. Serial number of meter under test c. Serial number of master meter including copy of calibration certification d. Rate of flow e. Pressure recorded during test f. Test run quantity g. Master meter reading after test h. Test meter reading after test i. ....% of meter under test j. Testers initials k. Remedial actions required
(2)
(3)
(4)
(5)
21
Job No
9.0
9.1
Interval
Pressure Gauges
Calibration of Pressure/Vacuum Gauges: a. Shall be calibrated over its full working range against an approved master meter or with a suitable test rig
12 months
9.2
6 months
b. The gauge is to be tested over its full working range, ie up and down the scale, comparison readings between gauge under test and master gauge to be noted c. The gauge is to zero at no pressure differential d. The maximum permissible error 0.5 psi
22
Job No
Interval
10.0 10.1
Manually Operated Valves Maintenance on Manually Operated Valves: a. Manually operated valves shall be maintained in accordance with the manufacturers recommendations. This shall include:
(1) (2) (3) (4)
3 months
Examination for leaks Check for corrosion and deterioration Lubrication as required Manually operated to check for ease of operation
23
Job No
Interval
11.0 11.1
Additive Injection Equipment Maintenance of Additive Injection Equipment: a. Additive injection equipment shall be maintained in accordance with manufacturers recommendations. This shall include:
(1)
(2) (3)
6 months
Examination for leaks Check for corrosion and deterioration Calibration of injection equipment
24
Job No
12.0 12.1
Interval
Surge Alleviators
Maintenance of Surge Alleviators: a. Surge alleviators shall be maintained in accordance with manufacturers recommendations. This shall include:
(1)
(2)
6 months
25
Job No
13.0 13.1
Interval
a. Leak detection equipment shall be maintained in accordance with manufacturers recommendations. This shall include:
(1) (2)
3 months
26
Job No
Interval
14.0
14.1
Pipelines
Maintenance of Pipelines/Pipework:
14.2
Pressure Testing Pipelines/Pipework: a. Pipelines/pipework shall be pressure tested to 150% of the normal working pressure
b. Pressure testing is to be undertaken in accordance with DWS Functional Standard No.5, Specialist Works on Petroleum Installations - Mechanical 36 months
14.3
a. Check the ground above buried pipework for signs of leakage. For example dead vegetation etc
3 months
27
Job No
Interval
15.0 15.1
Rubber Hoses.
Maintenance of Rubber Hoses: a. Rubber hoses shall be maintained in accordance with manufactures recommendations. This shall include: (1) (2)
(3)
Visual examination for any damage to the hose Pressure testing of the hose, (as manufacturers recommendations) Electrical continuity testing of the hose
3 months
6 months 6 months
15.2
Hose Couplings:
a. Hose couplings shall be maintained in accordance with manufacturers recommendations. This shall include: (1)
(2)
(3)
Checking screw threads and couplings are clean and undamaged Mating surfaces and 'O' rings are to be undamaged to ensure good seal Lubrication is in accordance with manufacturers recommendations
3 months
3 months
As required
15.3
a. Hydrant pit couplings/valves shall be maintained in accordance with manufacturers recommendations. This shall include: (1)
(2) (3)
(4) (5)
Pit box inspection, checking for water, fuel product, condition of lining, pit lid seal Checking valve and components are free from leaks Inspection of operating handle and associated cables/connections Manually determine the integrity of the main valve seal Test closure time of valve is between 2 & 5 seconds
28
Job No
Interval
16.0 16.1
Loading Arms and Pantographs Maintenance of Loading Arms and Pantographs: a. Loading arms and pantographs shall be maintained in accordance with manufacturers recommendations. This shall include:
(1) (2) (3) (4)
(5)
Inspection for damage and corrosion Check for any leaks Check operation ie free in action Lubricated in accordance with manufacturers recommendations Pressure test to 150% of normal working pressure
29
Job No
Interval
17.0 17.1
Cathodic Protection
Maintenance of Cathodic Protection Equipment:
a. Cathodic protection equipment shall be maintained in accordance with the manufacturers/installers recommendations. This shall include:
(1) (2)
(3) (4)
Check power source for supply Inspect rectifier/anodes for any signs of damage Record voltage and ampere measurements Undertake potential measurement survey
30
Job No
Interval
18.0 18.1
Oil Interceptors and Drain Tanks Maintenance of Oil Interceptors and Drain Tanks:
a. Oil interceptor and drain tanks should be maintained in accordance with manufacturers recommendations. This shall include:
(1) (2)
(3) (4) (5)
(6) (7)
Visually check interceptor outflow for signs of petroleum product Check level petroleum product within interceptor Excessive levels require investigation Check for leakage and corrosion Check for sludge and debris Clean when required
Check operation of gauges and high level alarms Sample outflow for petroleum product
Weekly
Weekly
3 months 3 months As required by inspection 3 months 3 months
31
Job No
Interval
19.0 19.1
Marine Facilities:
a. Inspect navigation aids and mooring buoys for correct operation and for evidence of damage and possible movement or dragging by vessels, current or winds. Mark wrecks or other
3 months
3 months
3 months
d. divers should inspect tanker unloading hoses, navigational and mooring buoys and their mooring chains, shackles and anchors for signs of developing failures or signs of rapid wear of parts subject to wave motion or abrasion on the ocean floor e. Hydrostatically test the entire unloading system to 1.5 times the
12 months
36 months
3 months
3 months
32
3.2
Electrical Works
Job No
Interval
20.0
Visual Inspection
6 months
12 months
Inspect the complete electrical installation and confirm that the installation shows no signs of:
a. Mechanical failure
b. Corrosion
c. Damage
d. Overheating and that : e. No unauthorised modifications have been made to the installation or fixed appliances and they are in a safe and satisfactory condition for continued operation f. The installation, apparatus and fixed appliances comply with the documentation and that any special installation conditions have been adhered to g. All apparatus labels and markings are legible, the apparatus is correctly assembled and all fixings (bolts and nuts) are present h. The enclosures, glasses, glass/metal seals of the lights are satisfactory and the lamp types and ratings are correct
i. There is no evidence of compound from stopper or cable boxes and there is no obvious damage to cables j. Flexible cables show no signs of damage, deterioration or overheating and are mechanically secured to the apparatus in accordance with the installation documentation
k. There is no undue accumulation of dust and dirt and apparatus is adequately protected from weather l. The installation and the associated equipment apparatus and fixed appliances function correctly m. Records of inspections, checks and tests at the prescribed intervals have been kept and the installation conforms with the records
33
Job No
Hazardous Area
Interval
21.0
Zone 1
Zone 2
12 months
24 months
a. Damage to the enclosure and the enclosure finishes b. Damage and/or deterioration of insulation of components and accessories within the enclosures c. Damage and/or deterioration of the insulating materials and insulating barriers within the enclosures d. Security of access doors and the condition of any gaskets on the access doors and panels e. Corrosion, overheating and tightness of connections f. Corrosion, overheating and pitting of contacts g. Satisfactory operation of electrical and/or electrical interlocks
I. Correct operation of trip switches, emergency stop switches/push buttons and similar safety devices
34
Job No
22.0
Interval
12 months 24 months
a. Securely fixed
b. Clearly readable at normal operating or maintenance positions and correctly identify the equipment or appliance and/or its purpose c. In accordance with BS 7671, are fitted to equipment within which a voltage exceeding 250 volts exists and where a voltage exceeding 250 volts exists in separate enclosures which, although separated, are simultaneously accessible d. In accordance with BS 7671, are fitted at the point of connection of every earthing conductor and earth electrode, the main equipotential bonding and the points of connection of every bonding conductor to extraneous conductive part 5. Prominently displayed as specified in MOD Safety Rules and Procedures for Electrical Works
35
Job No
23.0
Interval
Continuity Testing of Protective Conductors and Equipotential Bonding Check and test the protective conductors for damage in accordance with the following criteria: a. Test the resistances of the circuit protective conductors and bonding conductors using a battery powered, intrinsically safe ohmmeter to verify as far as possible that they are electrically sound and correctly connected in accordance with the BS 7671 b. Compare the resistance test results with those obtained from previous tests and investigate any significant changes
12 months
24 months
36
Job No
Interval
24.0
Correct Polarity
12 months
24 months
A test of polarity shall be made to verify that: a. Every fuse and single-pole control and protective device is connected in the phase conductor only b. Centre-contact bayonet and Edison screw lamps to BS 6776 in circuits having an earthed neutral conductor have the outer or screwed contacts connected to a neutral conductor c. Wiring has been correctly connected to socket-outlets and similar accessories
37
Job No
Hazardous Area
Interval
25.0
Measurement of (R1+R2)
The measurement of the phase conductor and the protective conductor is to be undertaken in accordance with the requirements of BS 7671. This can be measured with a low resistance reading ohmmeter. The area concerned should be gas free before testing is undertaken (See MOD Safety Rules and Procedures for Work on Petroleum Installations)
Zone 1
Zone 2
12 months
24 months
38
Job No
Hazardous Area
Interval
26.0
Insulation Tests.
Zone 1
Zone 2
12 months
24 months
The insulation tests on equipment and wiring shall be carried out as detailed in BS 7671 and undertaken only in non-hazardous areas . Insulation testing should be carried out using intrinsically safe test apparatus. Even when using such apparatus, there may be a possibility of incendive sparking therefore the area concerned should be gas free before testing is undertaken. Prior to undertaking low voltage insulation tests, equipment that may be damaged by such tests must be isolated. Manufacturers recommended isolation procedures must be adopted
39
Job No
27.0
Interval
Electrical Separation of Circuits. Where protection is provided by electrical separation check and if necessary test in accordance with the following: a. If the circuits have been modified since the last inspection, carry out tests to verily compliance BS 7671
12 months
24 months
40
Job No
28.0
Interval
12 months
Check and if necessary test the barriers and enclosures in accordance with the following: a. Check the barriers and enclosures for deterioration, damage and security fixings. If the barriers have been modified since the last inspection, carry out the tests to verily compliance with BS 7671
24 months
41
Job No
Interval
29.0
12 months
Measure the earth electrode resistance to the general mass of earth and compare the resistance measured with previous resistance tests. Any significant changes in earth electrode resistance should be investigated. Record the test results
24 months
42
Job No
Hazardous Area
Zone 1
Interval
30.0
12 months 24 months
The line/earth fault loop impendence is to be measured at the point of origin of the electrical installation. The point selected for the application of this test should be a convenient distribution switchboard or switch which is outside the hazardous area but as close to it as possible. The test should be undertaken in accordance with the following:
a. Test the line/earth fault loop impendence of the electrical installation to prove compliance with BS 7671
Zone 2
b. Test instruments of the current impulse type shall haver an impulse duration of not greater than 40 ms and shall give an indication of polarity and protective continuity before the impulse is applied c. The earth fault loop impedance (Ze) should be measured, recorded and compared with the previous results. Any significant increases should be highlighted for investigation and remedial action d. Bonding, protective conductors temporarily disconnected for the purposes of the tests should be reconnected
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Job No
31.0
Interval
Residual Current Devices (RCD's) Test the tripping operation of RCD's with a specialist tester and in accordance with the requirements of BS 7671 and the associated IEE Wiring Regulations Guidance Notes for Inspection and Testing
12 months 24 months
44
Job No
32.0
Hazardous Area
Interval
Zone O Equipment
As Required.
Equipment located in Zone 0 environments shall be maintained in accordance with manufacturers recommendations and the requirements of BS 5345 pt 4 & 8 - intrinsically safe apparatus or systems & special protection (specifically certified for use in zone 0)
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4.
APPENDIX
4.1
4.1.1
Tank Inspection Frequency Initial tank inspections shall be undertaken to determine the :
a. b.
Condition of the internal tank lining and hence satisfy fuel quality requirements. Mechanical integrity of the storage tank and its internal mechanical components.
4.1.2
The frequencies given are for Aviation fuel tanks. The Operating Authority may request that more frequent inspections are undertaken. This may be due to concerns over the integrity of the tank or the internal equipment located within the tank.
Tank Interior Uncoated Tank Type Without inlet filter/ separator With inlet filter/ separator
Tank Interior Coated Without inlet filter/ separator With inlet filter/ separator
Operating Tanks (ie tanks which directly serve refuelling vehicles or hydrant systems) Bulk Storage or buffer tanks Bulk Storage (barge or tanker delivery) Drain Tanks (fuel recovery unit)
3 years
5 years
5 years
8 years 5 years **
4 years
6 years * 5 years **
6 years 5 years **
8 years 5 years **
3 years
5 years *
5 years
8 years 5 years **
Normally inspected and cleaned concurrently with the inspection/cleaning of operating storage tank. (This does not apply to small drain or slops tanks with limited access)
* **
If a filter/separator or micromic filter is installed in the receipt system. The shorter interval applies if the equipment installed in the tank requires more frequent maintenance and inspections.
Note:
Newly constructed tanks must be inspected after one year of initial filling to check the condition of the interior coating, an item still under warranty.
Tank entry shall only be undertaken where safe access can be achieved. When tank access is limited, inspection shall be visually from the tank manhole.
Printed in the United Kingdom for HMSO Dd 298006 C10 4/94 3245267 19542
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