Loading Arm Testing Interval

The Inspection, Maintenance andTesting of Equipment Installed atPetroleum Installations- Mechanical and Electrical.

Defence Works Services

LONDON : HMSO

© Crown copyright 1994Applications for reproductions should be made to HMSOFirst published 1994

ISBN 0 11 772809 8

Other titles in the Series:

Defence Works Functional Standards 01-Children's Play Area Design Guide

ISBN 0 11 772714 8

Defence Works Functional Standards 02 (Edition 2-1994)Catering Design Guide

ISBN 0 11 772770 9

Defence Works Functional Standards 03-Catering Equipment Specification

ISBN 0 11 772454 8

Defence Works Functional Standards 04-Conservation Manual for Listed Buildings and Scheduled Monuments

ISBN 0 11 772455 6

Defence Works Functional Standards 05-Specification for Specialist Works on Petroleum Installations—Mechanical

ISBN 0 11 772777 6

Defence Works Functional Standards 06-Guide to Airfield Pavement Maintenance

ISBN 0 11 772730 X

Foreword

245267 B*

This document is for the use of Top Level Budget Holders (TLBH's) for application by theProperty Managers (PROM), Establishment Works Consultants (EWC), Works ServiceManagers (WSM) and other parties involved in the undertaking of Mechanical and ElectricalMaintenance, Inspections and Testing of Bulk Petroleum Installations on the MOD estate.

The document was prepared under the direction of the Defence Petroleum DistributionCommittee.

Abbreviations

AP(POL)AP(PET)BSDWSEWCHSEJSPMODPETPROMPOLTLBH,sWSM

Authorised Person POL (Term in current use)Authorised Person Petroleum (POL term to be replaced by PET)British StandardDefence Works ServicesEstablishment Works ConsultantHealth and Safety ExecutiveJoint Service PublicationsMinistry of DefencePetroleumProperty ManagerPetroleum, Oil and LubricantTop Level Budget HoldersWorks Service Manager

Contents

Page No.

General RequirementsIntroductionAimHazardous Area Classification (Petroleum)StandardsSafe WorkingTechnical Authority

Maintenance, Inspection and Testing IndexMechanical IndexElectrical Index

Maintenance, Inspection and Testing ScheduleMechanical ScheduleElectrical Schedule

AppendixTank Inspection Frequency

245267 B*2

2.2.1.2.2.

3.3.1.3.2.

4.4.1.

1.

5.

8.

46.

1.1 .1 .1.2.1.3.1.4.1.5.1.6.

1. General Requirements

Introduction

DWS Functional Standard Number 07 affords guidance and direction on the maintenance andinspection frequencies applicable to equipment used in petroleum installations.The information presented in this document is the basis for the preparation of schedules forthe maintenance of Bulk Petroleum Installations.

Functional Standard Number 07 supersedes the following PSA Maintenance, Inspection andTesting documentation, as applied to Bulk Petroleum Installations:

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 FixedAppliance in Hazardous Areas.

Functional Standard Number 07 applies to fixed equipment found within petroleum installationson the MOD estate, including:

Mechanical equipment in petroleum hazardous areas.

Mechanical equipment which is part of a petroleum system, but is outside of thehazardous area.

Electrical equipment located within the hazardous area.

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 thisdocument. In such cases the manufacturers recommendations should be followed.

Aim

The aim of Functional Standard Number 07 is to :

a. Furnish the Property Manager, Establishment Works Consultant (EWC) and Works ServiceManager (WSM) with an approved set of standards which :

Are required by MOD/NATO for application to Bulk Petroleum Installations.

Comply with the requirements of the relevant British Standards and otherapproved Codes of Practice.

Form the basis for, and therefore facilitate the development of, an inspection andtest programme for installations.

Help ensure that installed mechanical and electrical equipment, continues tofunction in a safe and satisfactory manner.

1.1

1 . 1 . 1 .

1.1.2.

1.1.3.

1.1.4.

1.1.5.

1.2.

1.2.1.

a.

b.

c.

a.

b.

(1).

(2).

(3).

(4).

1

Minimise the risk of ignition, in hazardous caused by inadequatelymaintained apparatus.

Form the basis for the audit of maintenance activities.

b. Consolidate and present inspection, maintenance and testing policy requirements in oneeasy to read document.

Hazardous Area Classification (Petroleum)

The classification of the petroleum hazardous areas is based upon the concept of dealing withthe risk of fire and explosion by area classification. The area classification criteria are given inBS 5345. (see para 1.4.1(d)).

The petroleum hazardous area classifications are :

Zone in which the explosive atmosphere is continuously present, orpresent for long periods.

Zone in which an explosive atmosphere is likely to occur in normaloperation.

Zone in which an explosive atmosphere is not likely to occur in normaloperation, and if it occurs will exist only for a short time.

Hazardous area classification drawings, specific to each installation, should be held by theOperating Authority and the EWC/WSM organisations. These hazardous area classificationdrawings must comply with the requirements of Joint Services Safety Regulations for theStorage 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 FunctionalStandard to determine the maintenance frequencies of electrical equipment and installations.

Standards

Functional Standard Number 07 shall be read in conjunction with the following relevantstandards :

DWS Functional Standard Number 05, Specification for Specialist Works on PetroleumInstallations - Mechanical.

BS 7671, Requirements for Electrical Installations, IEE Wiring Regulations.

BS 5345, Selection, Installation and Maintenance of Electrical Apparatus for use inPotentially Explosive Atmospheres (other than mining applications or explosive processingand 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).

Health & Safety at Work Act 1974 and regulations made thereunder.

Petroleum (Consolidation) Act and Regulations made thereunder.

(5).

(6).

1.3.

1.3.1

1.3.2.

a. Zone 0 -

b. Zone 1 -

c. Zone 2 -

1.3.3.

1.4.

1.4.1.

a.

b.

c.

d.

e.

f.

g.

h.

2

Home Office Model Code of Principles of Construction and Premises Licensed under thePetroleum (Consolidation) Act 1928 and 1936.

MOD Safety Rules and Procedures for Work on Petroleum Installations, (Formally PSAMechanical & Electrical Engineering Guide, Volume 8, Section 53).

MOD Safety Rules and Procedures for Electrical Works, (Formally PSA Mechanical &Electrical Engineering Guide, Volumes, Section 51).

Safe Working

All works on Petroleum installations are controlled under the delegation of the OperatingAuthority, 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 theAP(PET). Works examples that require the issue of electrical permits are given below:

Opening of enclosures of explosion protected equipment.

Testing that could result in incendive sparking occurring in a hazardous area.

Works which might effect the integrity of the explosion protection.

Inspection, maintenance and testing in petroleum hazardous areas should only be undertakenby competent personnel who are :

Familiar with the MOD Safety Rules and Procedures for works on Petroleum Installations.

Experienced in inspection, maintenance and testing within petroleum hazardous areas.

In addition, electrical personnel should be trained and experienced :

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 hazardousareas.

Earth fault loop impedance tests, high current continuity tests and prospective short circuitcurrent tests are not to be carried out in hazardous areas. Such tests can introduce currentand/or voltages in parts of the installation where they might not be expected, due to bondingof extraneous conductive parts and lightning protection systems. This could result in incendivesparking 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 equipmentmust be identified and isolated. Manufacturers recommended isolation procedures are to befollowed prior to testing being undertaken.

Where maintenance, inspection or testing discloses deterioration which may effect the abilityof the equipment or installation to perform safely in a hazardous area, appropriate remedialmeasures should be taken. Replacement equipment shall comply with BS 5345. No alterationsshould be made to any apparatus or installation without the prior approval of a competentelectrical engineer.

Equipment used for testing the electrical installations in hazardous areas shall be intrinsicallysafe.

3

1.5.4.

1.5.5.

1.5.6.

1.5.7.

1.5.3.

1.5

1.5.1.

1.5.2.

i.

j.

k.

a.

b.

c.

a.

b.

c.

d.

e.

The electrical tests given in section 2.0, job numbers 20 to 32 are to be undertaken in numericorder.

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 corrosiveor other adverse atmospheric condition, a high risk of mechanical damage or vibration, andwhere there are other onerous circumstances. The need for more frequent maintenanceinspections 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 bythe hazardous area classification in conjunction with BS 5345, and should be adhered to forthe safe operation of the facility.

Records of all inspection, resulting maintenance works and tests of equipment and systemsinstalled in the hazardous area must be kept and maintained. These records should be keptwith the site layout drawings showing the extent and zone designation of the hazardous area.

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 WorksAuthority, (DWS TA):

Head of Bulk Petroleum InstallationsRoom 121Airfields and Bulk fuels GroupPO Box 1734Sutton ColdfieldWest MidlandsB75 7QB

This DWS Standard, Inspection, Maintenance and Testing of Equipment Installed at PetroleumInstallations - Mechanical and Electrical, has been devised for use of the Crown and of itscontractors in the execution of contracts for the crown and, subject to the Unfair ContractsTerms Act 1977, the Crown will not be liable in any way whatever (including but withoutlimitation negligence on the part of the Crown its servants or agents) where the specificationis used for other purposes.

1.5.8.

1.5.9.

1.5.10.

1.5.11.

1.6

1.6.1.

1.6.2.

2. Maintenance, Inspection and Testing Index

2.1. Mechanical Works

Job No

1.01.1

2.02.12.22.32.42.52.62.72.82.9

2.102.112.12

3.03.13.2

4.04.1

5.05.1

6.06.1

7.07.1

8.08.18.2

9.09.1

10.010.1

11.01 1 . 1

Description of Job and Criteria

Installations (General)Valve Pits, Chambers, Pump Houses & Access Ways

Storage TanksExterior Inspection (General)Interior Inspection (General)Internal Tank InspectionInternal Tank CleaningLow Level Alarm/ControlHigh Level Shut-off Valve Alarm/controlContents GaugePressure/Vacuum ValvesInternal Coils and HeatersFoot Valves and StrainersSwing Arms and Floating Suction UnitLeak Detection

PumpsPump MaintenanceFilters & Strainers at Pumps

Filter Water Separators (FWS)Maintenance of FWS

Fuel MonitorsMaintenance of Fuel Monitors

Pre-coat FiltersMaintenance of Pre-coat Filters

Automatic Control ValvesMaintenance of Automatic Control Valves

Flow MetersMaintenance of Flow MetersAccuracy Testing of Flow Meters

Pressure GaugesCalibration of Pressure Gauges

Manually Operated ValvesMaintenance of Manually Operated Valves

Additive Injection EquipmentMaintenance of Additive Injection Equipment

245267 C*

5

Job No

12.012.1

13.013.1

14.014.114.2

15.015.115.215.3

16.016.1

17.017.1

18.018.1

19.019.119.2

Description of Job & Criteria

Leak Detection EquipmentMaintenance of Leak Detection Equipment

Surge AlleviatorsMaintenance of Surge Alleviators

Pipelines/PipeworkMaintenance of Pipelines/PipeworkPressure Testing of Pipelines/Pipework

Rubber HosesMaintenance of Rubber HosesHose CouplingsHydrant Pit couplings/Valves

Loading Arms & PantographMaintenance of Loading Arms & Pantograph

Cathodic ProtectionMaintenance of Cathodic Protection Equipment

Oil Interceptors/Drain TanksMaintenance of Oil Interceptors and Drain Tanks

Marine FacilitiesOff-shore Unloading FacilitiesShore Facilities ie Jetty, Docks etc

6

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


Visual Inspection

Visual Inspections and Physical Checks

Safety Signs and Notices

Continuity Testing

Correct Polarity Testing

Measurement of Phase and Protective conductor Resistance

Insulation Tests

Electrical Separation of Circuits

Barriers and Enclosures

Earth Electrode tests

Earth Fault Loop Impedance measurements (Ze)

RCD Tests

Zone 0 Equipment & Tests

245267 C*2

7

3. Inspection and Testing Schedule

3.1 Mechanical Works

JobNo

Description of Job and Criteria Interval

1.0

1.1

Petroleum Installations (General)

Valve Pits, Ducts, Chambers, Pump Houses, Dispense/ReceiptPoints 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 andreported

c. Pipework and equipment shall be free from leaks or weeps

d. Access ways are to be free from obstructions

(The above activities shall be carried out when undertaking Jobnumbers 2 to 32)

3 months

3 months

3 months

8

JobNo


2.0

2.1

Storage Tanks

Exterior (General):

a. Visually check exterior of storage including associatedequipment, and access ways for:

3 months

See job 17

2.2 Internal Tank Inspection:

a. Inspect surfaces and seems for signs of leaks, corrosion, pittedplates, breakdown or damage to epoxy coating and sludgedeposits

b. Internal tank equipment shall be inspected as detailed insections 2.3 to 2.10 inclusive

c. After the completion of the inspection/works within the tank afinal inspection of the epoxy lining is required prior to tankdeparture 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:

As detailedin Appendix4, Section4.1

(1)(2)(3)

Date of inspection and/or cleaningCarried out byDate of next inspection

f. Record in the Maintenance record details of any cleaning,repairs or other remedial actions required and subsequent actionto be taken

9

(1)(2)(3)(4)(5)(6)

LeaksCorrosionDamage to steelworkDamage to external protectionDeterioration of equipmentEase of operation of equipment

Special attention should be given to vulnerable areas such aswelded or rivetted seams

b. Cathodic protection systems shall be tested and maintained inaccordance with manufacturers recommendations

JobNo


2.3 Internal Tank Cleaning:

a. Cleaning is to be undertaken when inspection reveals:

There is an accumulation of solid matter, silt or wax onthe tank bottom and fittingsMaintenance and repairs have to be undertaken

The Operating Authority indicate that there is to be achange of productThe tank is being taken out of commission

Requirementdeterminedafter internaltankinspectionSee job 2.2

c. Tank cleaning is to be undertaken by a competent contractor(s)or depot personnel (NAVY) in accordance with MOD/DWSpublications:

Low Level Alarm/Control:

a. Check operation of low level alarm/control when the tank isbeing emptied

b. Ensure pump stops and alarm is given when the liquid leveldrops to the desired pump cut-off level

c. Maintain in accordance with manufacturers recommendations

When tankis beingemptied12 months

10

(1)

(2)

b. Or:

(1)

(2)

MOD Safety Rules and Procedures for Work on POLInstallations

(1)

2.4

JobNo


2.5 High Level Shut-off Valve Alarm/Control:

a. Inspect the float mechanism for: 12 monthsWhen tank isempty

12 monthsCheck the high level shut-off control valve operatesand shuts of the fuel to the tankCheck high and high/high level alarms operates

2.6 Contents Gauge:

a. Inspect sensing heads, probes, floats, wires and other contentsgauge components.

b. Maintain on accordance with manufacturers recommendations

Internal tankequipmentfollowinginternal tankinspection orcleaning oftank

External tankequipment12 months

2.7 Pressure/Vacuum Valves:

a. Remove and service in accordance with manufacturersrecommendations

b. Test operation under simulated pressure condition

12 months

2.8 Internal Coils and Heaters:

a. Inspect coils and heaters for:

Followinginternalinspection orcleaning oftankSee job 2.2

1 1

(1)(2)(3)

Ease of operationCorrosion/DeteriorationFuel in float chamber

b. When tank is being filled:

0)

(2)

c. maintain in accordance with manufacturers recommendations

(1)(2)(3)

DamageCorrosionSecureness of fixing

b. Pressure test coils to 150% of the normal working pressure

JobNo


Foot Valves and Strainers:

a. Inspect foot valve and strainers ensuring that they are:

Followinginternalinspection orcleaning oftank

Swing Arms and Floating Suction Unit:

a. Check and test for:

Internal tankequipmentfollowinginternalinspection orcleaning oftank

External tankequipment12 months

12

2.9

(1)(2)

Clean and free from sludgeOperate freely and seat and seal

b. Maintain in accordance with manufacturers recommendations

(1)(2)(3)(4)(5)

Damage and corrosionFuel in floatEase of operationWinch-rope and anchoragesSafe operation of winch

b. Replace seals in swing arm units

2.10

JobNo


6 months

6 months

12 months

6 months

13

245267 D*

3.0

3.1

Pumps

Pump Maintenance:

a. Pumps shall be maintained in accordance with manufacturersrecommendations. This shall include:

(1)(2)(3)(4)

(5)

Lubrication of bearings, seals and glandsPump coupling alignment and bolt torque settingsPump primer unitCorrect operation of by-pass valve on positivedisplacement pumpOperation of centrifugal pump by circulation or withdelivery valve closed

b. Check correct operation of pumps noting:

(1)(2)(3)(4)(5)(6)

Any leaksExcessive vibrationAbnormal noiseHigh bearing temperaturesOperating pressure and flowLubricant levels

c. Plant Monitoring Systems:

Vibration analysisDebris analysis

(1)(2)

3.2 Filters and Strainers at Pumps:

a. Check for:

(1)(2)(3)

LeaksExternal corrosion and deteriorationExcessive pressure drop across filter/strainer. Pressurereadings should be recorded

JobNo

4.0

4.1


Filter Water Separators

Filter Water Separators (FWS) Maintenance:

a. FWS shall be maintained in accordance with the manufacturersrecommendations. This shall include:

(1) Monitoring the pressure differential

(2) Check for leaks, damage or corrosion

(3) Change FWS cartridge when requested by theOperating Authority. An approved procedure forchanging cartridges is as follows:

a. Isolate pumpsb. Close all product valves to unitc. Open vent valvesd. Drain contents into drain tank or as instructed by

Operatord. Remove cover, seal and cartridgee. Clean interior of unitf. Inspect for internal corrosion and any damage tointernal liningg. Fit new cartridge and cover sealh. Fill unit slowly, ( < 1m/s), to reduce risk fromelectrical static chargesi. Restore to operational conditionj. Dispose of old cartridge in approved mannerk. Stencil on outside of FWS in 25mm letters:

Interval

3 months3 months

Whenrequested byOperatingAuthority

14

(1) Coalester/Separator cartridge replaced(2) Flow meter reading

(4)

(5)

Testing the air eliminator:

a. Listen to ensure that air is being vented during thefilling operationb. Check that there is no leakage of product when theunit is full

Test automatic water drains:a. Close the outlet valve at the filter and run the pumpand note the pressure gauge reading on the pumpb. Inject water through the manual drain until theautomatic drain valve operates. The water injectionpressure should not exceeding 110% of the notedpump gauge readingc. During the procedure the water level at no time torise out of the gauge glassd. Note the water level in the gauge glass when theautomatic water drain valve operates. This should beapproximately one third up the gauge glass

6 months

6 months

JobNo


4.0cont./

Filter Water Separators (FWS) Maintenance:

e. If an automatic fuel discharge valve is fitted, closethe automatic water drain isolating valve and continuewater injection until the automatic fuel discharge valveclosesf. Note the water level in the gauge glass when theautomatic fuel discharge valve closes. This should beapproximately two thirds of the way up the gaugeglass and approximately half way down when it opensg. Ensure that the automatic water drain valve is toclose tight after the discharge of water

Testing of differential pressure gauge

Testing the pressure relief valve to 110% of the normalworking pressure

Note: The criteria for changing the cartridge will be advised bythe Operating Authority. This will be determined in conjunctionwith manufacturers recommendations. Details should be recordedin the Maintenance Record

See job 9.26 months

15

245267 D*2

The above operation should be undertaken in accordance withMOD Safety Rules and Procedures

(6)

(7)

JobNo


5.0

5.1

Fuel

Maintenance of Fuel Monitors:

a. Fuel monitors shall be maintained in accordance withmanufacturers recommendations. This shall include:

(1)(2)(3)

(5)

(6)

(7)(8)

Monitoring the pressure differential across the unitCheck for leaks, damage and corrosionChange fuel monitor cartridge when requested by theOperating Authority. The procedure for changingcartridges is as follows:

a. Isolate pumpsb. Close all product valves to unitc. Open vent valvesd. Drain contents into drain tank or as instructed byOperatord. Remove cover, seal and cartridgee. Clean interior of unitf. Inspect for internal corrosion and any damage tointernal liningg. Fit new cartridge and cover sealh. Fill unit slowly, ( < 1m/s), to reduce risk fromelectrical static chargesi. Restore to operational conditionj. Dispose of old cartridge in approved mannerk. Stencil on outside of fuel monitor in 25mm letters:

(1) Fuel monitor cartridge replaced(2) Flow meter reading

3 months3 months

Whenrequested byOperatingAuthority

Test air eliminator:

a. Listen to ensure that air is being vented during thefilling operationb. Check that there is no leakage of product when theunit is full

Test drain valve

a. Ensure that the valve seats correctly after use andthat there is no leakage

Test differential pressure gaugeTest pressure relief valve to 110% of the normalworking pressure

6 months

6 months

See job 9.26 months

The above operation should be undertaken in accordance withMOD Safety Rules and Procedures

16

JobNo


5.1cont./ Maintenance of Fuel Monitors:

Note: The criteria for changing the cartridge will be advised bythe Operating Authority. This will be determined in conjunctionwith manufacturers recommendations. Details should be recordedin the Maintenance Records

17

JobNo


Pre-coat Filters

Maintenance of Pre-coat Filters:

a. Pre-coat filters shall be maintained in accordance withmanufacturers recommendations. The maintenance procedure willbe decided by the system configuration and type of equipmentinstalled. As a result of the differing types of equipment theprocedure given below may require modification to suit particularinstallations requirements:

Procedure:

Monitor the pressure differential across the unitCheck for leaks, damage and corrosionInspect interior of unit. The procedure is as follows:

a. Isolate unit by closing all product valvesb. Drain all product from unit into drain tank or asdirected by Operating Authorityc. Open cover at handwheel endd. Remove and examine filter media traysd. Clean interior of unite. Inspect for internal corrosion and the condition ofthe liningf. Install filter trays and check for free operationg. Restore to operational conditionh. Fill unit slowly, (> 1m/s), to reduce risk fromelectrical static chargei. Stencil on outside of pre-coat filter in 25mm letters:

(1) Interior inspected and cleaned(2) Flow meter reading

3 months3 monthsAs required

j. Record in maintenance records:

(1) Dates when back flushing/filter media changed(2) Throughput achieved between media changes(3) Dates when off-base supply line to the pre-coat filter is pigged

(4) Test air eliminator

a. Listen to ensure that air is being vented during thefilling operation

b. Check that there is no leakage of product when theunit is full

(5) Test drain valve

a. Ensure that the valve seats correctly after use andthat there is no leakage

6 months

6 months

18

(1)(2)(3)

6.0

6.1

JobNo


6.1cont./

Maintenance of Pre-coat Filters:

Test differential pressure gauge

Test pressure relief valve to 110% of the normalworking pressure.

This operation should be undertaken in accordance with MODSafety Rules and Procedures

Note: Back-flushing and renewing the filter media is theresponsibility of the Operating Authority

See job 9.2

6 months

19

(6)

(7)

JobNo


Automatic Control Valves

Maintenance of Automatic Control Valves:

a. Automatic control valves are to maintained in accordance withmanufacturers recommendations. This shall include checking for:

3 months3 months6 months

20

7.0

7.1

Fuel leaksCorrosion & deterioration on external casingCorrect operation of valve. For example, simulate therequired conditions to evaluate if the valves operatewithin the prescribed criteria:

a. Pressure reducing; to maintain a constant presetpressure in accordance with the operating criteriaregardless of the flow rate

b. Flow control; to maintain preset rate of product flowin accordance with the operating criteria regardless ofthe line pressure to the valve

c. Surge arrestor; to limit the downstream pressurerise to no more than 110% of the normal operatingpressure

d. Excess flow shut off; to cut of the flow at the presetrate of flow

e. Shut off; to provide "full flow" and "shut off" and tolimit the surge pressure to not more than 10% abovethe safe working pressure of the system

f. Pressure relief; to limit the pressure to 110% of thenormal working pressure

g. Check valve; to cause the valve to close againstreverse flow

h. high level control of alarm; to operate at the presetlevel; of fuel in the tank

(1)(2)(3)

JobNo


3 months3 months3 monthsAs required

12 months

21

Flow Meters

Maintenance of Flow Meters:

a. Flow meters shall be maintained in accordance withmanufacturers recommendations. This shall include:

8.0

8.1

0)(2)(3)(4)

Checking for leaksExamination for corrosion and deteriorationLegibility of registerLubrication as required

Accuracy Testing of Meters:

a. Meters shall be tested for accuracy in accordance with theprocedures indicated:

8.2

The meter is to be tested using a master meterconnected in series. Certificate of accuracy should beavailable for the master meter together with correctionfactors for flow, pressure and viscosity

The test conditions, ie flow and pressure shall besimilar to normal operating conditions

Test quantity shall be 4 times the maximum ratedcapacity 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 testb. Serial number of meter under testc. Serial number of master meter including copy ofcalibration certificationd. Rate of flowe. Pressure recorded during testf. Test run quantityg. Master meter reading after testh. Test meter reading after testi. ± ....% of meter under testj. Testers initialsk. Remedial actions required

(1)

(2)

(3)

(4)

(5)

JobNo


12 months

6 months

22

9.0

9.1

9.2

Pressure Gauges

Calibration of Pressure/Vacuum Gauges:

a. Shall be calibrated over its full working range against anapproved master meter or with a suitable test rig

Differential Pressure Gauges

a. Shall be tested on a test rig

b. The gauge is to be tested over its full working range, ie up anddown the scale, comparison readings between gauge under testand master gauge to be noted

c. The gauge is to zero at no pressure differential

d. The maximum permissible error ± 0.5 psi

JobNo


3 months

3 months3 monthsAs required3 months

23

10.0

10.1

(1)(2)(3)(4)

Manually Operated Valves

Maintenance on Manually Operated Valves:

a. Manually operated valves shall be maintained in accordancewith the manufacturers recommendations. This shall include:

Examination for leaksCheck for corrosion and deteriorationLubrication as requiredManually operated to check for ease of operation

JobNo


Additive Injection Equipment

Maintenance of Additive Injection Equipment:

a. Additive injection equipment shall be maintained in accordancewith manufacturers recommendations. This shall include:

6 months

24

(1)(2)(3)

Examination for leaksCheck for corrosion and deteriorationCalibration of injection equipment

11.0

1 1 . 1

JobNo


Surge Alleviators

Maintenance of Surge Alleviators:

a. Surge alleviators shall be maintained in accordance withmanufacturers recommendations. This shall include:

6 months

25

12.0

12.1

(1)(2)

Examination for leaksCheck for corrosion and deterioration

JobNo


Leak Detection Equipment

Maintenance of Leak Detection Equipment:

a. Leak detection equipment shall be maintained in accordancewith manufacturers recommendations. This shall include:

3 months

26

13.0

13.1

(1)(2)

Examination for leaksCheck for corrosion and deterioration

JobNo


Pipelines Below Ground:

a. Check the ground above buried pipework for signs of leakage.For example dead vegetation etc

3 months

3 months6 months

36 months

3 months

27

14.0

14.1

14.2

14.3

Pressure Testing Pipelines/Pipework:

a. Pipelines/pipework shall be pressure tested to 150% of thenormal working pressure

b. Pressure testing is to be undertaken in accordance with DWSFunctional Standard No.5, Specialist Works on PetroleumInstallations - Mechanical

Pipelines

Maintenance of Pipelines/Pipework:

a. The following shall be visually checked:

(1)(2)

(3)(4)

Check for leaks with the system under pressureExamine system for corrosion and deterioration ofpipework and protectionInspect bonding/groundingCheck cathodic protection installation(See job 17.)

JobNo


15.0

15.1

15.2

15.3

3 months

6 months6 months

3 months

3 months

As required

1 month

1 month1 month

1 month3 months(withoutdeadmans)6 months(withdeadmans)

28

Rubber Hoses.

Maintenance of Rubber Hoses:

a. Rubber hoses shall be maintained in accordance withmanufactures recommendations. This shall include:

Hose Couplings:

a. Hose couplings shall be maintained in accordance withmanufacturers recommendations. This shall include:

Hydrant Pit Couplings/Valves:

a. Hydrant pit couplings/valves shall be maintained in accordancewith manufacturers recommendations. This shall include:

(1)

(2)(3)

(4)(5)

Pit box inspection, checking for water, fuel product,condition of lining, pit lid sealChecking valve and components are free from leaksInspection of operating handle and associatedcables/connectionsManually determine the integrity of the main valve sealTest closure time of valve is between 2 & 5 seconds

(1)

(2)

(3)

Checking screw threads and couplings are clean andundamagedMating surfaces and 'O' rings are to be undamaged toensure good sealLubrication is in accordance with manufacturersrecommendations

(1)(2)

(3)

Visual examination for any damage to the hosePressure testing of the hose, (as manufacturersrecommendations)Electrical continuity testing of the hose

JobNo


Loading Arms and Pantographs

Maintenance of Loading Arms and Pantographs:

a. Loading arms and pantographs shall be maintained inaccordance with manufacturers recommendations. This shallinclude:

3 months3 months6 monthsAs required

6 months

29

16.0

16.1

(1)(2)(3)(4)

(5)

Inspection for damage and corrosionCheck for any leaksCheck operation ie free in actionLubricated in accordance with manufacturersrecommendationsPressure test to 150% of normal working pressure

JobNo


Cathodic Protection

Maintenance of Cathodic Protection Equipment:

a. Cathodic protection equipment shall be maintained inaccordance with the manufacturers/installers recommendations.This shall include:

6 months6 months6 months12 months

30

(1)(2)(3)(4)

Check power source for supplyInspect rectifier/anodes for any signs of damageRecord voltage and ampere measurementsUndertake potential measurement survey

17.0

17.1

JobNo


Oil Interceptors and Drain Tanks

Maintenance of Oil Interceptors and Drain Tanks:

a. Oil interceptor and drain tanks should be maintained inaccordance with manufacturers recommendations. This shallinclude:

Weekly

Weekly

3 months3 monthsAs requiredby inspection3 months3 months

31

18.0

18.1

Visually check interceptor outflow for signs ofpetroleum productCheck level petroleum product within interceptorExcessive levels require investigationCheck for leakage and corrosionCheck for sludge and debrisClean when required

Check operation of gauges and high level alarmsSample outflow for petroleum product

(1)

(2)

(3)(4)(5)

(6)(7)

JobNo


Marine Facilities:

Off-shore Unloading Facilities:

a. Inspect navigation aids and mooring buoys for correctoperation and for evidence of damage and possible movement ordragging by vessels, current or winds. Mark wrecks or othernavigational hazards and initiate action for their removal

b. Inspect submarine pipelines and their seaward end for signs ofpetroleum product

c. Inspect mooring hawsers, lines, deck hoses, chain, flangeadaptors, gaskets and other gear used in the mooring of vesselsand in the connecting tanker unloading hoses to the side of thetanker or to the tanker's manifold

d. divers should inspect tanker unloading hoses, navigational andmooring buoys and their mooring chains, shackles and anchorsfor signs of developing failures or signs of rapid wear of partssubject to wave motion or abrasion on the ocean floor

e. Hydrostatically test the entire unloading system to 1.5 times thenormal working pressure

Shore Facilities ie Jetty, Docks etc:

a. Inspect pipelines, valves and dock/jetty hoses for signs ofdamage or deterioration

b. Inspect all mooring lines, cleats, bollards, bits, pulley blocks,steel wire ropes, winches etc for signs of damage

c. Inspect dock/jetty for signs of serious damage

d. Hydrostatically test the entire unloading system to 1.5 times thenormal working pressure

3 months

3 months

3 months

12 months

36 months

3 months

3 months

3 months

36 months

32

19.0

19.1

20.2

3.2 Electrical Works

JobNo

20.0


Visual Inspection

Inspect the complete electrical installation and confirmthat the installation shows no signs of:

a. Mechanical failure

b. Corrosion

c. Damage

d. Overheating

and that :

e. No unauthorised modifications have been made tothe installation or fixed appliances and they are in asafe and satisfactory condition for continued operation

f. The installation, apparatus and fixed appliancescomply with the documentation and that any specialinstallation conditions have been adhered to

g. All apparatus labels and markings are legible, theapparatus is correctly assembled and all fixings (boltsand nuts) are present

h. The enclosures, glasses, glass/metal seals of thelights are satisfactory and the lamp types and ratingsare correct

i. There is no evidence of compound from stopper orcable boxes and there is no obvious damage to cables

j. Flexible cables show no signs of damage,deterioration or overheating and are mechanicallysecured to the apparatus in accordance with theinstallation documentation

k. There is no undue accumulation of dust and dirt andapparatus is adequately protected from weather

l. The installation and the associated equipmentapparatus and fixed appliances function correctly

m. Records of inspections, checks and tests at theprescribed intervals have been kept and the installationconforms with the records

HazardousArea

Zone 1

Zone 2

Interval

6 months

12 months

33

JobNo

Description of Job and Criteria HazardousArea

Interval

21.0 Visual Inspection and Physical Checks

Check that the condition and operation off the electricalequipment and apparatus incorporated in theinstallation. Specific attention should be given to thefollowing:

a. Damage to the enclosure and the enclosure finishes

b. Damage and/or deterioration of insulation ofcomponents and accessories within the enclosures

c. Damage and/or deterioration of the insulatingmaterials and insulating barriers within the enclosures

d. Security of access doors and the condition of anygaskets 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 electricalinterlocks

h. Satisfactory operation of contactors, relays, switchesand other components

i. The correct current rating of fuses and circuit breakers

j. The correct operation of instruments, meters, indicatorlights, alarm and test devices

k. The integrity of locks and/or seals on meters, fusesand special equipment

I. Correct operation of trip switches, emergency stopswitches/push buttons and similar safety devices

Zone 1

Zone 2

12 months

24 months

34

JobNo

22.0


Safety Signs and Notices.

Check safety signs, labels, notices and posters fixed onor adjacent to electrical equipment and appliances are:

a. Securely fixed

b. Clearly readable at normal operating or maintenancepositions and correctly identify the equipment orappliance and/or its purpose

c. In accordance with BS 7671, are fitted to equipmentwithin which a voltage exceeding 250 volts exists andwhere a voltage exceeding 250 volts exists in separateenclosures which, although separated, aresimultaneously accessible

d. In accordance with BS 7671, are fitted at the point ofconnection of every earthing conductor and earthelectrode, the main equipotential bonding and thepoints of connection of every bonding conductor toextraneous conductive part

5. Prominently displayed as specified in MOD SafetyRules and Procedures for Electrical Works

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

35

JobNo

23.0


Continuity Testing of Protective Conductors andEquipotential Bonding

Check and test the protective conductors for damage inaccordance with the following criteria:

a. Test the resistances of the circuit protectiveconductors and bonding conductors using a batterypowered, intrinsically safe ohmmeter to verify as far aspossible that they are electrically sound and correctlyconnected in accordance with the BS 7671

b. Compare the resistance test results with thoseobtained from previous tests and investigate anysignificant changes

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

36

JobNo

24.0


Correct Polarity

A test of polarity shall be made to verify that:

a. Every fuse and single-pole control and protectivedevice is connected in the phase conductor only

b. Centre-contact bayonet and Edison screw lamps toBS 6776 in circuits having an earthed neutral conductorhave the outer or screwed contacts connected to aneutral conductor

c. Wiring has been correctly connected to socket-outletsand similar accessories

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

37

JobNo

25.0


Measurement of (R1+R2)

The measurement of the phase conductor and theprotective conductor is to be undertaken in accordancewith the requirements of BS 7671. This can bemeasured with a low resistance reading ohmmeter. Thearea concerned should be gas free before testing isundertaken (See MOD Safety Rules and Procedures forWork on Petroleum Installations)

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

38

JobNo

26.0


Insulation Tests.

The insulation tests on equipment and wiring shall becarried out as detailed in BS 7671 and undertaken onlyin non-hazardous areas . Insulation testing should becarried out using intrinsically safe test apparatus. Evenwhen using such apparatus, there may be a possibilityof incendive sparking therefore the area concernedshould be gas free before testing is undertaken. Prior toundertaking low voltage insulation tests, equipment thatmay be damaged by such tests must be isolated.Manufacturers recommended isolation procedures mustbe adopted

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

39

JobNo

27.0


Electrical Separation of Circuits.

Where protection is provided by electrical separationcheck and if necessary test in accordance with thefollowing:

a. If the circuits have been modified since the lastinspection, carry out tests to verily compliance BS 7671

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

40

JobNo

28.0


Barriers and Enclosures

Check and if necessary test the barriers and enclosuresin accordance with the following:

a. Check the barriers and enclosures for deterioration,damage and security fixings. If the barriers have beenmodified since the last inspection, carry out the tests toverily compliance with BS 7671

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

41

JobNo

29.0


Earth Electrode(s) Testing

Measure the earth electrode resistance to the generalmass of earth and compare the resistance measuredwith previous resistance tests. Any significant changesin earth electrode resistance should be investigated.Record the test results

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

42

JobNo

30.0


Earth Fault Loop Impedance Measurements (Ze)

The line/earth fault loop impendence is to be measuredat the point of origin of the electrical installation. Thepoint selected for the application of this test should be aconvenient distribution switchboard or switch which isoutside the hazardous area but as close to it aspossible. The test should be undertaken in accordancewith the following:

a. Test the line/earth fault loop impendence of theelectrical installation to prove compliance with BS 7671

b. Test instruments of the current impulse type shallhaver an impulse duration of not greater than 40 msand shall give an indication of polarity and protectivecontinuity before the impulse is applied

c. The earth fault loop impedance (Ze) should bemeasured, recorded and compared with the previousresults. Any significant increases should be highlightedfor investigation and remedial action

d. Bonding, protective conductors temporarilydisconnected for the purposes of the tests should bereconnected

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

43

JobNo

31.0


Residual Current Devices (RCD's)

Test the tripping operation of RCD's with a specialisttester and in accordance with the requirements of BS7671 and the associated IEE Wiring RegulationsGuidance Notes for Inspection and Testing

HazardousArea

Zone 1

Zone 2

Interval

12 months

24 months

44

JobNo

32.0


Zone O Equipment

Equipment located in Zone 0 environments shall bemaintained in accordance with manufacturersrecommendations and the requirements of BS 5345 pt 4& 8 - intrinsically safe apparatus or systems & specialprotection (specifically certified for use in zone 0)

HazardousArea

Interval

AsRequired.

45

4. APPENDIX

Tank Inspection Frequency

Initial tank inspections shall be undertaken to determine the :

Tank Type

Operating Tanks (ietanks which directlyserve refuellingvehicles or hydrantsystems)

Bulk Storage orbuffer tanks

Bulk Storage (bargeor tanker delivery)

Drain Tanks (fuelrecovery unit)

Tank Interior Uncoated

Without inletfilter/separator

3 years

4 years

3 years

With inletfilter/separator

5 years

6 years *5 years **

5 years *

Tank Interior Coated

Without inletfilter/separator

5 years

6 years5 years **

5 years

With inletfilter/separator

8 years5 years **

8 years5 years **

8 years5 years **

Normally inspected and cleaned concurrently with theinspection/cleaning of operating storage tank. (This does not apply tosmall 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 frequentmaintenance and inspections.

Note: Newly constructed tanks must be inspected after one year of initial filling to check thecondition of the interior coating, an item still under warranty.

Tank entry shall only be undertaken where safe access can be achieved. When tankaccess is limited, inspection shall be visually from the tank manhole.

Printed in the United Kingdom for HMSODd 298006 C10 4/94 3245267 19542 46

4.1

4.1.1

4.1.2

Condition of the internal tank lining and hence satisfy fuel quality requirements.

Mechanical integrity of the storage tank and its internal mechanical components.

The frequencies given are for Aviation fuel tanks. The Operating Authority may request that morefrequent inspections are undertaken. This may be due to concerns over the integrity of the tankor the internal equipment located within the tank.

a.

b.

Loading Arm Testing Interval

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