The Inspection, Maintenance and Testing of Equipment Installed at Petroleum Installations - Mechanical and Electrical.

Defence Works Services

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 03Catering Equipment Specification ISBN 0 11 772454 8

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. 1.1. 1.2. 1.3. 1.4. 1.5. 1.6. 2. 2.1. 2.2.

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.

Electrical equipment located within the hazardous area.

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).

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

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

Hazardous Area Classification (Petroleum)

The classification of the petroleum hazardous areas is based upon the concept of dealing with the risk of fire and explosion by area classification. The area classification criteria are given in BS 5345. (see para 1.4.1(d)). The petroleum hazardous area classifications are :
a. Zone 0 Zone in which the explosive atmosphere is continuously present, or present for long periods.

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.

Petroleum (Consolidation) Act 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.

Opening of enclosures of explosion protected equipment.

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

c.
1.5.3.

Works which might effect the integrity of the explosion protection.

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.

In addition, electrical personnel should be trained and experienced :

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.

Maintenance, Inspection and Testing Index

Mechanical Works
Job No

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

6.0 6.1 7.0 7.1

Pre-coat Filters Maintenance of Pre-coat Filters

Automatic Control Valves Maintenance of Automatic Control Valves

Flow Meters Maintenance of Flow Meters Accuracy Testing of Flow Meters

8.0 8.1 8.2 9.0 9.1

10.0 10.1

Pressure Gauges Calibration of Pressure Gauges

Manually Operated Valves Maintenance of Manually Operated Valves Additive Injection Equipment Maintenance of Additive Injection Equipment

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

Description of Job & Criteria

Leak Detection Equipment Maintenance of Leak Detection Equipment
Surge Alleviators Maintenance of Surge Alleviators

Pipelines/Pipework Maintenance of Pipelines/Pipework Pressure Testing of Pipelines/Pipework

Rubber Hoses Maintenance of Rubber Hoses Hose Couplings Hydrant Pit couplings/Valves

16.0 16.1 17.0 17.1 18.0 18.1 19.0 19.1 19.2

Loading Arms & Pantograph Maintenance of Loading Arms & Pantograph

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

Description of Job and Criteria 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

28.0
29.0 30.0 31.0 32.0

Barriers and Enclosures

Earth Electrode tests Earth Fault Loop Impedance measurements (Ze)
RCD Tests

Zone 0 Equipment & Tests

245267 C*2

3.
3.1

Inspection and Testing Schedule

Mechanical Works

Job No 1.0 1.1

Description of Job and Criteria

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)

Job No 2.0 2.1

Description of Job and Criteria

Interval

Storage Tanks
Exterior (General):

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

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

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

As detailed in Appendix 4, Section 4.1

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)

Date of inspection and/or cleaning Carried out by Date of next inspection

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

Description of Job and Criteria

Interval

Internal Tank Cleaning: a. Cleaning is to be undertaken when inspection reveals:

(1)
(2)

There is an accumulation of solid matter, silt or wax on the tank bottom and fittings Maintenance and repairs have to be undertaken

Requirement determined after internal tank inspection See job 2.2

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

Low Level Alarm/Control:

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

When tank is being emptied 12 months

10

Job No
2.5

Description of Job and Criteria

Interval

High Level Shut-off Valve Alarm/Control:

a. Inspect the float mechanism for: (1)

(2) (3)

Ease of operation Corrosion/Deterioration Fuel in float chamber

12 months When tank is empty

b. When tank is being filled:

1 2 months

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

c. maintain in accordance with manufacturers recommendations

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

a. Remove and service in accordance with manufacturers recommendations

b. Test operation under simulated pressure condition

2.8

Internal Coils and Heaters:

a. Inspect coils and heaters for: (1)

(2) (3)

Damage Corrosion Secureness of fixing

Following internal inspection or cleaning of tank See job 2.2

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

11

Job No

Description of Job and Criteria

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

Following internal inspection or cleaning of tank

b. Maintain in accordance with manufacturers recommendations

2.10

Swing Arms and Floating Suction Unit:

a. Check and test for:

(1) (2) (3) (4) (5)
Damage and corrosion Fuel in float Ease of operation Winch-rope and anchorages Safe operation of winch

Internal tank equipment following internal inspection or cleaning of tank External tank equipment 12 months

b. Replace seals in swing arm units

12

Job No Pumps

Description of Job and Criteria

Interval

3.0 3.1

Pump Maintenance:
a. Pumps shall be maintained in accordance with manufacturers recommendations. This shall include: 6 months

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

(5)

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

b. Check correct operation of pumps noting:

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

Any leaks Excessive vibration Abnormal noise High bearing temperatures Operating pressure and flow Lubricant levels 12 months

c. Plant Monitoring Systems:

(1)
(2)

Vibration analysis Debris analysis

3.2

Filters and Strainers at Pumps: a. Check for: 6 months

(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

Description of Job and Criteria

Interval

Filter Water Separators

Filter Water Separators (FWS) Maintenance: a. FWS shall be maintained in accordance with the manufacturers recommendations. This shall include: (1) (2) (3) Monitoring the pressure differential Check for leaks, damage or corrosion Change FWS cartridge when requested by the Operating Authority. An approved procedure for changing cartridges is as follows:
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 FWS in 25mm letters:

3 months 3 months

When requested by Operating Authority

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

6 months
(4)

Testing the air eliminator:

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

Job No 4.0 cont./

Description of Job and Criteria

Interval

Filter Water Separators (FWS) Maintenance:

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 of differential pressure gauge

See job 9.2 6 months

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

Description of Job and Criteria

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)

Test air eliminator:

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

See job 9.2

6 months

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

16

Job No
5.1 cont./

Description of Job and Criteria

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:

3 months 3 months As required

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

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 precoat filter is pigged (4) Test air eliminator 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 (5) Test drain valve 6 months 6 months

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

18

Job No 6.1 cont./

Description of Job and Criteria

Interval

Maintenance of Pre-coat Filters:

(6)
(7)

Test differential pressure gauge Test pressure relief valve to 110% of the normal working pressure.

See job 9.2 6 months

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

Description of Job and Criteria

Interval

Automatic Control Valves

Maintenance of Automatic Control Valves: a. Automatic control valves are to maintained in accordance with manufacturers recommendations. This shall include checking for:

(1) (2) (3)

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

3 months 3 months 6 months

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

Description of Job and Criteria

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

3 months 3 months 3 months 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

Description of Job and Criteria

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

Differential Pressure Gauges

a. Shall be tested on a test rig

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

Description of Job and Criteria

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

3 months 3 months As required 3 months

23

Job No

Description of Job and Criteria

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

Description of Job and Criteria

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

Examination for leaks Check for corrosion and deterioration

25

Job No
13.0 13.1

Description of Job and Criteria

Interval

Leak Detection Equipment

Maintenance of Leak Detection Equipment:

a. Leak detection equipment shall be maintained in accordance with manufacturers recommendations. This shall include:
(1) (2)

3 months

Examination for leaks Check for corrosion and deterioration

26

Job No

Description of Job and Criteria

Interval

14.0
14.1

Pipelines
Maintenance of Pipelines/Pipework:

a. The following shall be visually checked: (1) (2)

(3) (4) Check for leaks with the system under pressure Examine system for corrosion and deterioration of pipework and protection Inspect bonding/grounding Check cathodic protection installation (See job 17.)

3 months 3 months 6 months

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

Pipelines Below Ground:

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

3 months

27

Job No

Description of Job and Criteria

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

Hydrant Pit Couplings/Valves:

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

1 month 1 month 1 month

1 month 3 months (without deadmans) 6 months (with deadmans)

28

Job No

Description of Job and Criteria

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

3 months 3 months 6 months As required

6 months

29

Job No

Description of Job and Criteria

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

6 months 6 months 6 months 1 2 months

30

Job No

Description of Job and Criteria

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

Description of Job and Criteria

Interval

19.0 19.1

Marine Facilities:

Off-shore Unloading 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

navigational hazards and initiate action for their removal

b. Inspect submarine pipelines and their seaward end for signs of petroleum product
c. Inspect mooring hawsers, lines, deck hoses, chain, flange adaptors, gaskets and other gear used in the mooring of vessels and in the connecting tanker unloading hoses to the side of the tanker or to the tanker's manifold

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

normal working pressure

20.2

Shore Facilities ie Jetty, Docks etc:

a. Inspect pipelines, valves and dock/jetty hoses for signs of

damage or deterioration

3 months

b. Inspect all mooring lines, cleats, bollards, bits, pulley blocks,

steel wire ropes, winches etc for signs of damage

3 months

3 months c. Inspect dock/jetty for signs of serious damage

d. Hydrostatically test the entire unloading system to 1.5 times the
36 months

normal working pressure

32

3.2

Electrical Works

Job No

Description of Job and Criteria

Hazardous Area Zone 1

Zone 2

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

Description of Job and Criteria

Hazardous Area

Interval

21.0

Visual Inspection and Physical Checks

Check that the condition and operation off the electrical equipment and apparatus incorporated in the installation. Specific attention should be given to the following:

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

h. Satisfactory operation of contactors, relays, switches and other components

i. The correct current rating of fuses and circuit breakers

j. The correct operation of instruments, meters, indicator lights, alarm and test devices
k. The integrity of locks and/or seals on meters, fuses and special equipment

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

34

Job No
22.0

Description of Job and Criteria

Hazardous Area Zone 1

Zone 2

Interval

Safety Signs and Notices.

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

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

Description of Job and Criteria

Hazardous Area Zone 1 Zone 2

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

Description of Job and Criteria

Hazardous Area Zone 1

Zone 2

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

Description of Job and Criteria

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

Description of Job and Criteria

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

Description of Job and Criteria

Hazardous Area Zone 1

Zone 2

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

Description of Job and Criteria

Hazardous Area Zone 1 Zone 2

Interval

Barriers and Enclosures

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

Description of Job and Criteria

Hazardous Area Zone 1

Zone 2

Interval

29.0

Earth Electrode(s) Testing

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

Description of Job and Criteria

Hazardous Area
Zone 1

Interval

30.0

Earth Fault Loop Impedance Measurements (Ze)

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

43

Job No
31.0

Description of Job and Criteria

Hazardous Area Zone 1 Zone 2

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

Description of Job and Criteria

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)

45

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

46