NGL/LPG METERING TRANSLOADER INSTALLATION, OPERATION, & MAINTENANCE MANUAL

Transcription

1 NGL/LPG METERING TRANSLOADER INSTALLATION, OPERATION, & MAINTENANCE MANUAL

2 TABLE OF CONTENTS Disclaimer... 3 What is a transloader and advantages?... 4 How does it work? First Time Usage Preparations & Setup General Maintenance & Inspection Guidelines Purpose and Objectives Maintenance Manuals Maintenance Procedures Maintenance Record Keeping Maintenance Personnel - Training Physical Protection of Equipment Safety Devices Emergency Shutoff Valves Hose Inspection and Maintenance... 16

3 DISCLAIMER As an industry leader in providing bulk storage and transfer solutions within LPG, NGL, and SNG markets, TransTech Energy, LLC, makes the valiant effort to create a semi-custom operations manual for each client that may need basic guidance in future operation and maintenance. Though most systems ultimately serve the same purpose, components within each system vary based upon many facets, including but not limited to, location, availability, cost, customer preferences, and project specifications. To better assist each client in operating and maintaining each system to the fullest of its capabilities, TransTech Energy, LLC provides the client at their request, a simple baseline to create their own procedures and practices for routine operational requirements. Within this Operation and Maintenance Manual, TransTech Energy, LLC will cover areas such as general product information, emergency procedures, basic operations, maintenance, and inspection checklists. Each manual s length is directly related to the complexity of the overall purpose and design of the system provided to each client. Each manual created may incorporate by reference, procedures, codes, regulations, and additional suggestive materials from PERC, NPGA, GPA, and NFPA. Nevertheless, all systems are designed specifically for direct compliance with the most current or applicable NFPA-58 Liquefied Petroleum Gas Code. Any other codes, standards, or governing bodies pertaining to any system or design produced by TransTech Energy, LLC may not be considered during the creation process of this Operations & Maintenance Manual. TransTech Energy, LLC and its members disclaim any liability for any personal injury, property damage, business losses or other damages of any nature whatsoever, whether special, indirect, consequential or compensatory, directly or indirectly resulting from the publication, use, or reliance on this document, or any information, apparatus, method, process, or similar item disclosed in this document. This disclaimer of liability shall apply even if such loss or damage results, in whole or in part, from any acts or omissions of or by any negligence on the part of TransTech Energy, LLC and its members any persons who contributed to the development of the information contained in this document. TransTech Energy, LLC and its members make no warranty or guarantee as to the accuracy or completeness of any information published in this document. The procedures and information in this document are intended to implement the standards set forth in the documents referenced with capabilities of the personnel and equipment available. It does not create new standards or criteria for compliance. The order of steps in any procedure may or may not be of importance. Users of this document should consult the law of their individual jurisdictions for codes, standards, and legal requirements applicable to them. This document is not intended nor should it be construed to: Set forth new policies or procedures to be used as industry standard Prevent the user from using different methods to implement applicable codes, standards or legal requirements. By disseminating or publishing this document TransTech Energy, LLC and its members are not undertaking to render any professional or other service to or on behalf of any person or entity. TransTech Energy, LLC and its members are not undertaking to perform any duty owed by any person or entity to any third party. Anyone reading or using this document should rely on his or her own judgment, company policies or, as appropriate, should seek the advice of a competent professional in determining the exercise of reasonable care in any and all individual set of circumstances.

4 WHAT IS A TRANSLOADER AND ADVANTAGES? A transloader is defined as a mobile system created specifically to transfer product from a typical rail car unit to a typical transport unit. The importance of a transloader design has revolutionized the industry by bypassing the process of needing available storage to move product from rail to highway from virtually any location with an energy source compatible such as a diesel engine or generator. This system can allow any bulk distributor of product to continuously be competitive during any of the following scenarios: When markets are not favorable for storage of large quantities of fuel If rail tower construction is not cost effective for smaller operations During unexpected plant shutdowns During planned plant maintenance operations Peak season times when transfer operations must happen faster HOW DOES IT WORK? Whether the transloader is a towable or motorized unit, its mobility allows for it to be setup at any desired location within a site or plant facility that has level ground. The transloader is connected to the railcar and then connected to transport after the initial setup of the transloader. The unit is connected to a power source that either can be an electrical source or supplied diesel engine to drive the compressor. Once connected to a source of power the transfer process begins until the transport is full or the desired amounts of product are removed from the railcar. The system is then disconnected and repeated as many times as necessary.

5 CONNECT HOSES FROM TRANSLOADER PLATFORM TO RAIL TANKER TRANSTECH ENERGY TRANSLOADER 20 PROCESS DIAGRAM P0 SYSTEM ATTACHMENT TRANSLOADER 20 COMPONENTS RAIL TANKER(FULL) VALVES LOCATED FLUSH W\PLATFORM DECK MC331 LPG/NGL TRANSPORT (EMPTY) I ICON LEDGEND CHECK VALVE W\FLOW INDICATOR VALVE STATUS BALL VALVE CLOSED BALL VALVE GLOBE VALVE LOADING\UNLOADING HOSE SCHEDULE 80 PIPE (VAPOR) GLOBE VALVE CLOSED BALL VALVE OPEN GLOBE VALVE OPEN CONNECT HOSES FROM TRANSLOADER STANCHION TO MC331 LPG/NGL TRANSPORT 4 WAY VALVE FOR SWITCHING COMPRESSOR FLOW DIRECTION SCHEDULE 80 PIPE (LPG) SIGHT FLOW INDICATOR EMERGENCY SHUTOFF VALVE DSK FLOW METER W\RECIEPT PRINTER(OPTIONAL) CORKEN D691 COMPRESSOR

6 TRANSTECH ENERGY TRANSLOADER 20 PROCESS DIAGRAM P1 SYSTEM VAPOR PRESSURE EQUALIZATION PRESSURE EQUALIZATION TRANSLOADER 20 COMPONENTS RAIL TANKER VALVES LOCATED FLUSH W\PLATFORM DECK MC331 LPG/NGL TRANSPORT (EMPTY) I ICON LEDGEND CHECK VALVE W\FLOW INDICATOR BALL VALVE GLOBE VALVE LOADING\UNLOADING HOSE SCHEDULE 80 PIPE (VAPOR) SCHEDULE 80 PIPE (LPG) SIGHT FLOW INDICATOR EMERGENCY SHUTOFF VALVE VALVE STATUS BALL VALVE CLOSED GLOBE VALVE CLOSED BALL VALVE OPEN GLOBE VALVE OPEN 4 WAY VALVE FOR SWITCHING COMPRESSOR FLOW DIRECTION DSK FLOW METER W\RECIEPT PRINTER (OPTIONAL) CORKEN D691 COMPRESSOR FLOW DIRECTION ARROW

7 TRANSTECH ENERGY TRANSLOADER 20 PROCESS DIAGRAM P2 SYSTEM LPG PRESSURE EQUALIZATION TRANSLOADER 20 COMPONENTS RAIL TANKER VALVES LOCATED FLUSH W\PLATFORM DECK MC331 LPG/NGL TRANSPORT (EMPTY) I ICON LEDGEND CHECK VALVE W\FLOW INDICATOR BALL VALVE GLOBE VALVE LOADING\UNLOADING HOSE SCHEDULE 80 PIPE (VAPOR) SCHEDULE 80 PIPE (LPG) SIGHT FLOW INDICATOR EMERGENCY SHUTOFF VALVE VALVE STATUS BALL VALVE CLOSED GLOBE VALVE CLOSED BALL VALVE OPEN GLOBE VALVE OPEN 4 WAY VALVE FOR SWITCHING COMPRESSOR FLOW DIRECTION DSK FLOW METER W\RECIEPT PRINTER (OPTIONAL) CORKEN D691 COMPRESSOR FLOW DIRECTION ARROW

8 TRANSTECH ENERGY TRANSLOADER 20 PROCESS DIAGRAM P3A LIQUID TRANSFER (BEGINNING) TRANSLOADER 20 COMPONENTS RAIL TANKER MC331 LPG/NGL TRANSPORT (EMPTY) I ICON LEDGEND VALVE STATUS CHECK VALVE W\FLOW INDICATOR BALL VALVE CLOSED BALL VALVE GLOBE VALVE CLOSED GLOBE VALVE BALL VALVE OPEN LOADING\UNLOADING HOSE GLOBE VALVE OPEN SCHEDULE 80 PIPE (VAPOR) SCHEDULE 80 PIPE (LPG) SIGHT FLOW INDICATOR EMERGENCY SHUTOFF VALVE DSK FLOW METER W\RECIEPT PRINTER (OPTIONAL) CORKEN D691 COMPRESSOR FLOW DIRECTION ARROW 4 WAY VALVE FOR SWITCHING COMPRESSOR FLOW DIRECTION

9 TRANSTECH ENERGY TRANSLOADER 20 PROCESS DIAGRAM P3B LIQUID TRANSFER (END) TRANSLOADER 20 COMPONENTS RAIL TANKER MC331 LPG/NGL TRANSPORT (EMPTY) I ICON LEDGEND VALVE STATUS CHECK VALVE W\FLOW INDICATOR BALL VALVE CLOSED BALL VALVE GLOBE VALVE CLOSED GLOBE VALVE BALL VALVE OPEN LOADING\UNLOADING HOSE GLOBE VALVE OPEN SCHEDULE 80 PIPE (VAPOR) SCHEDULE 80 PIPE (LPG) SIGHT FLOW INDICATOR EMERGENCY SHUTOFF VALVE DSK FLOW METER W\RECIEPT PRINTER (OPTIONAL) CORKEN D691 COMPRESSOR FLOW DIRECTION ARROW 4 WAY VALVE FOR SWITCHING COMPRESSOR FLOW DIRECTION

10 TRANSTECH ENERGY TRANSLOADER 20 PROCESS DIAGRAM P4 VAPOR RECOVERY (OPTIONAL PROCESS) TRANSLOADER 20 COMPONENTS RAIL TANKER MC331 LPG/NGL TRANSPORT (EMPTY) I ICON LEDGEND CHECK VALVE W\FLOW INDICATOR BALL VALVE GLOBE VALVE VALVE STATUS BALL VALVE CLOSED GLOBE VALVE CLOSED BALL VALVE OPEN LOADING\UNLOADING HOSE SCHEDULE 80 PIPE (VAPOR) SCHEDULE 80 PIPE (LPG) SIGHT FLOW INDICATOR EMERGENCY SHUTOFF VALVE GLOBE VALVE OPEN 4 WAY VALVE FOR SWITCHING COMPRESSOR FLOW DIRECTION DSK FLOW METER W\RECIEPT PRINTER (OPTIONAL) CORKEN D691 COMPRESSOR FLOW DIRECTION ARROW

11 1. FIRST TIME USAGE PREPARATIONS & SETUP The first time setup of a transloader will be different from any other time unless the transloader must be moved to another location using any highway system. The following steps are to assist in the first time usage and setup for a transloader unit: Move the transloader to the designated level location in which it will be used. Upon arrival of the destination, chock all the wheels as appropriate (See Photo Below) WARNING: If the unit is not on level ground and the wheels chocked before setting the system up for use, the transloader can shift unexpectedly, causing serious injury or property damage as a result. Above: Chocks placed at the base of the wheels to ensure minimal shift of the transloader due to rolling.

12 Extend all of the outrigger arms out and begin lowering landing gears to ensure stability Disconnect the transloader from the truck towing the system (if the system is not a truck mounted unit) once landing gears and outrigger arms are set in place to begin leveling the transloader. Ensure the transloader is stable enough before disconnecting it from the truck towing the system (if the system is not a truck mounted unit). WARNING: Before disconnecting from the truck towing the system (if the system is not a truck mounted unit), ensure there is not too much uplift pressure on the connection point as this may cause an unexpected shift of the truck towing the system (if the system is not a truck mounted unit) and/or the transloading system. Above left: Landing gear at the front of the transloader is in extension ensure stability. Above right: Landing gear at rear of the transloader is in extension to ensure stability.

13 Once the truck towing the system (if the system is not a truck mounted unit) is disconnected from the transloader, begin the full stabilization of the transloading system. Begin removing the handrails from the mobile storage location on the unit Begin installing them in the designated locations on the transloader platform area at the top of the unit. Upon Installation of the handrails in the designated locations, the catwalk can now be elevated to the desired height for transfer operations. Once the desired height is reached, the catwalk needs to be bolted into the stationary platform using the (4) ¾ bolts provided (the unit is equipped with (6) ¾ bolts upon request). WARNING: Serious injury or unexpected shifts during transfer operations can result from not properly securing the catwalk to the stationary platform. Above: Notice (4) ¾ bolts securing the catwalk to the platform. Notice (2) nuts for the ¾ bolts are welded to the outside of the mounting bracket for an easier installation once the catwalk is at the required elevation to be secured to the platform.

14 Connect hoses to the transloader using the proper acme adapters provided. Begin the connections of the provided hoses and emergency shutoff valves to the railcar. Ensure all valves from the railcar are in the closed position before connections are made. WARNING: Serious injury or property damage can result if the railcar valves are not closed during the connection process. Begin connecting hoses provided to the transport. Ensure all valves from the transport are in the closed position before connections are made. WARNING: Serious injury or property damage can result if the transport valves are not closed during the connection process. Above left: Notice the individual setting up the railcar for transfer after connecting the provided hoses. Above right: The personnel have checked the system before starting transfer operation of fuels at the transport.

15 Connect inert gas to the actuator system for the emergency shut-off valves and ensure regulator and inert gas tank is set between 30 and 50 psi for the ME980 series actuators o Ensure the ME983 railcar emergency shutoff valves are connected properly to the quick disconnect air hoses provided with a psi range no higher than 50 psi as that is the maximum functioning pressure allowed o Ensure the emergency shutoff valves are functioning properly before starting the offloading process by opening and closing the valves from the remote stations Connect the system to the correct energy source for the compressor usage o Electrical connections are 3 phase/480v WARNING: Serious injury or property damage may result if electrical systems are connected incorrectly. Slowly open valves to charge the system It is best practice to start at the railcar and work down to the transport when opening valves to charge the system (See Images Below For Valve Sequence) Above: The (3) valves to be opened are located within the hatch of the railcar. Valve sequence shall start with the valve on the rear side of the hatch across from the pressure relief valve. The following valves shall be opened in a clockwise sequence.

16 Above: the yellow handle Jomar valves shown shall be opened and closed as shown, inline with the 4-way valve at the compressor. The 3 Jomar ball valve must be opened to allow liquid product to pass from the railcar to the transport. Above: The (2) outside globe valves shall be opened starting with the vapor line which is designated by the color yellow.

17 Above: The (2) globe valves connected to the transport are to be opened, starting with the vapor line. When operating with the optional meter begin with the railcar line to start transfer operations All meters must be calibrated before starting the transfer operations to ensure accuracy of fuels transferred. This will ensure the meter registers as quickly as possible Then open the liquid piping in line to the transport then the vapor line Ensure the vapor suction and discharge valves are open at the compressor (See Images Above For Guidance) WARNING: Serious injury or property damage can occur if the valves are not opened properly at the compressor. Ensure rail and transport pressures are translated to the correct compressor gauges. o If the correct pressures are not translated to the correct gauges,all the necessary valves may not be open. WARNING: Serious injury or property damage can occur if the valves are not opened properly at the compressor.

18 Press the start button on the electrical panel and monitor the system until transport is full Use truck gauge or gallons on meter to determine filled capacity of the transport Upon completion shut system down by closing the valves at the transport and switching the system start switch into the off position. Close valves all the system valves in the reverse order in which they were opened. Valves should be closed from the bottom of the transport to the top of the railcar. See Previous (4) Images Above For Valve Sequence Disconnect hoses from the transport and rail car appropriately. If there is pressure on the system, slowly relieve the pressure on the hoses after all the system valves are closed. WARNING: Propane has a low temperature for vaporization, if the valves are not closed throughout the system, pressure within the charged system can result in frostbite and other serious injuries or property damage. After closing the inert gas valve, disconnect the airlines from the emergency shutoff valves at the rail car system If the emergency shut-off valves are disconnected from the system without the correct valves being closed can cause an unexpected release of energy from the system

19 WARNING: Ensure all the proper valves are closed before disconnecting the emergency shut-off valves as this may cause unintentional release of energy from the system, which can result in a fire, property damage, and/or serious injury. Store all materials for future operation in the secure location provided on the unit. Raise cat walk from the rail car so the railcar or the transloader can be moved Handrails do not have to be removed unless they are required to make certain clearances from location to location on site. Handrails must be removed to travel on any public highways due to height restrictions If the transloader is being moved to another location, the catwalk should be lowered to the original position and the handrails should be removed. The landing gears should also be adjusted so the transloader can be connected to the powered unit properly before being relocated.

20 2. GENERAL MAINTENANCE & INSPECTION GUIDELINES PURPOSE AND OBJECTIVES This section of the guideline is intended to provide owners or operators of LPG/NGL systems the information necessary to comply with the general requirements of NFPA 58 ( the Code ) for maintaining the mechanical integrity of LP-Gas system components through maintenance manuals and the incorporated procedures. MAINTENANCE MANUALS Written maintenance procedures provided by equipment manufacturers may be used as maintenance manuals for the related equipment. MAINTENANCE PROCEDURES Maintenance procedures are in written form in order to be used as the basis for maintaining the mechanical integrity of LPG/NGL system. Refer to Manufacturer s Specifications. Whenever a change in equipment or the system occurs, the affected procedure(s) must be updated Propane compressor: Inspect belts, change oil and filter (Per/ Manufacturer Recommendations). Hoses: Inspect for cracks, cuts, gouges, wear and other noticeable damages (Per company policy). Note: All maintenance shall be performed according to manufacturer specifications and company policy. Routine maintenance checks are a regimen that is a best practice for the industry. MAINTENANCE RECORD KEEPING Maintenance records provide the tracking and documented verification that the facility is being properly maintained and in a safe condition in accordance with NFPA 58. Record Storage - Maintenance records for all fixed equipment used to store and transfer LP-Gas must be kept at each facility. For unattended facilities, these records can be maintained at the unattended facility or another designated location. Accessibility These records must be available to maintenance personnel at all times and to an authority having jurisdiction at any time during normal business hours. Retention Maintenance records must be retained for the life of the equipment, Troubleshooting- Refer to Manufacturer Manual on valves, pumps, electrical starter switches, etc.

21 MAINTENANCE PERSONNEL - TRAINING Individuals performing maintenance on the LP-Gas systems must be trained in the hazards of the system. Maintenance personnel also must be trained in the maintenance and testing procedures applicable to the systems or equipment on which they are working. In order to perform the maintenance procedures, all maintenance contractors must train the personnel under their supervision as noted in the previous two requirements, or ensure that personnel working on a system or equipment are under the supervision of a properly trained individual. PHYSICAL PROTECTION OF EQUIPMENT The following LPG/NGL equipment must be protected against physical damage due to impact from vehicles: Storage Tanks /Containers Above ground piping, which also must be properly supported Dispensers SAFETY DEVICES Additional maintenance requirements for system safety devices are as follows: Pressure Relief Valves and discharge piping must be protected to minimize the entrance of water or extraneous materials using rain caps or any other effective means that do not affect their operability\ EMERGENCY SHUTOFF VALVES Emergency shutoff valves (ESVs) and backflow check valves that are required by the Code must be tested annually for their functionality. ESVs must be specifically tested for: o Automatic shutoff associated with thermal (fire) actuation. o Manual shutoff from a remote location. o Manual shutoff at the valve The results of these tests must be documented. The Code does not set requirements for the retention and maintenance of these test results. Therefore, you should check with established company policy and applicable regulations for the manner in which and the length of time that these records should be kept. Temperature-sensitive elements (i.e., thermal links) cannot be painted nor have any ornamental finishes applied after they have been manufactured.

22 HOSE INSPECTION AND MAINTENANCE Hose assemblies used for liquid transfer must be inspected prior to each use for leakage or any damage that could impair their integrity, and no less than annually. When inspecting the hose assembly, look for: Damage to the outer cover that exposes the reinforcement Kinked or flattened hose Soft spots or bulges in the hose Damaged couplings (including loose bolts, missing parts and slippage) Leakage Leaking or damaged hose assemblies must be immediately repaired or removed from service. The Code does not set requirements for the documentation, retention and maintenance of hose inspection results. Therefore, you should check with established company policy.