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RAK Mobile Filling Station Operation Manual

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Al-Rakeb Oil, Electricity & Construction Services
Company
Operation Manual for Mobile Filling Station
No part of the operation manual may be reproduced or transmitted by any without prior permission of Al-Rakeb Company Oil, Electricity &
Construction Services
Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait

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  • Page 1 Al-Rakeb Oil, Electricity & Construction Services Company Operation Manual for Mobile Filling Station No part of the operation manual may be reproduced or transmitted by any without prior permission of Al-Rakeb Company Oil, Electricity & Construction Services Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 2: Nomenclature

    Nomenclature MFS Mobile Filling Station Feet International Organization for Standardization Liters Millimeters Kilogram Cubic Meter Underwriters Laboratories Volt Hertz Inch health, safety and environment Direct Current Voltage Alternating Current Inch Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 3: Overview

    Overview This operation manual explains briefly all aspects of the Mobile Filling Station (MFS) from operation, safeness, maintenance, etc. This product is designed and manufactured to service sites that are far from gas station and to eliminate that factor of having an above/underground ground storage tank.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS NOMENCLATURE ..............................2 OVERVIEW ..................................3 TABLE OF CONTENTS .............................4 LIST OF FIGURES ..............................6 LIST OF TABLES ................................7 1. SAFTEY ..................................8 1.1 I ..............................8 NTRODUCTION 1.2 I ......................8 NFORMATION AND ARNING ABELS 1.3 L ................10 IST OF ARTS LONG WITH ESCRIPTIVE IGURES 1.4 S...
  • Page 5 3.1 I ..............................34 NTRODUCTION 3.2 T ........................34 RANSPORTATION AND OGISTICS 3.3 L ............................34 IFTING OF THE 3.4 I ..............................34 NSTALLATION 3.5 E ..............................34 LECTRICAL 3.6 O ................................35 PERATION 3.6.1 General Setup............................35 3.6.2 Filling the Tank ............................37 3.6.3 Filling Vehicles and other Machinery......................39 3.6.4 Navigating through ProGauge Console and Digimon Unit Console ............40 3.6.4.1 ProGauge Console ...............................

  • Page 6: List Of Figures

    LIST OF FIGURES ........................8 IGURE AIN SPECIFICATIONS LABEL 2. N .................................8 IGURE 3. N ............................9 IGURE O SMOCKING SIGN 4. E ..........................9 IGURE XPLOSIVE ATMOSPHERE 5. N ............................9 IGURE O CELL PHONES 6. T MFS........................10 IGURE HE REAR SIDE OF THE 7.

  • Page 7: List Of Tables

    LIST OF TABLES 1. S ....................16 ABLE HOW ALL PARTS LISTING AND NUMBERS 2. S ......................19 ABLE HOWS THE EXPLOSION PROOF PARTS 3. E .......................21 ABLE MERGENCY VENT DISTRIBUTION 4. F .........................32 ABLE UEL TYPES AND DENSITIES 5.

  • Page 8: Saftey

    1. SAFTEY 1.1 Introduction To ensure safe operation and usage of the product, safety instructions and guidelines must be followed. Guidelines and instructions include labels, procedure, and operation. 1.2 Information and Warning Labels Figure 1.Main specifications label. Figure 2. No Fire. Copyright 2020, Al-Rakeb Oil, Electricity &...

  • Page 9: Figure 3. No Smocking Sign

    Figure 3. No smocking sign. Figure 4. Explosive atmosphere. Figure 5. No cell phones. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 10: List Of Parts Used Along With Descriptive Figures

    1.3 List of Parts Used Along with Descriptive Figures Figure 6. The rear side of the MFS. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 11 Figure 7. Station Dispensing Section. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 12: Figure 8. Control Room Entrance

    Figure 8. Control room entrance. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 13: Figure 9. Shows The Control Room

    Figure 9. Shows the control room. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 14: Figure 10. Other View Of The Control Room

    Figure 10. Other view of the control room. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 15: Figure 11. Top Side Of The Mfs Through The Maintenance Door

    Figure 11. Top side of the MFS through the maintenance door. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 16: Table 1. Show All Parts Listing And Numbers

    Table 1. Show all parts listing and numbers. Part Part Name Infeed line Digimon Console ATEX Tank Status Monitoring Servo Motor with Butterfly Flange Anti-explosion light unit Smoke detector Emergency Vent for Outer shell Automatic Fire extinguisher Overfilling Alarm Light Unit Switch Emergency Shutdown Buttons Ground Reel Manual Fire Extinguisher...

  • Page 17: Safety Features

    1.4 Safety Features 1.4.1 Fire Extinguishers The MFS is supported by 3 automatic fire extinguishers (Sprinkler) and 2 manual fire extinguishers. Two of the automatic fire extinguishers are fixed at the top of the dispenser cabin and the third will be attached to the top of the rear cabin where the infeed line is located. The fire extinguishers will be operating when it detects any sign of heat letting the extinguisher valve to open and operate.

  • Page 18: First Aid Kit

    1.4.3 First Aid Kit A first aid kit is also installed in the control room right next to the fire blanket. It is positioned in way that if the operator facing the electrical box it shall be behind the operator. Section 1.3 shows the location of the first aid kit inside the control room.

  • Page 19: Explosion Proof Parts

    Figure 14. Smoke detector inside the control room. As shown from figure 14, the location of the smoke detector inside the control room is attached to the ceiling of the room. 1.4.5 Explosion Proof Parts The product contains explosion proof parts such as the light units, the Digimon console, and the electrical box.

  • Page 20: Pressure / Vacuum Vent 2'' + Flame Arrestor

    1.4.6 Pressure / Vacuum Vent 2'' + Flame Arrestor The MFS is provided with pressure vent 2'' and flame arrestor. This device allow the breathing of the tank during filling and suction process. Figure 15. Pressure / Vacuum Vent 2'' + Flame Arrestor. 1.4.7 Retention Tray A retention tray is used in the MFS to prevent any fuel spillage form occurring during the tank filling process.

  • Page 21: Emergency Vents

    to perform a maintenance operation on the tank. The suction port is located at the top of the MFS and can be accessed using the maintenance door at the top. Refer to section 1.3 part number 31. 1.4.9 Emergency Vents As of UL standards, the tank should be provided with an emergency vent for above ground storage tanks.

  • Page 22: Level Switch

    Figure 16. Shows the how the level indicator will measure the tank level. Figure 17. Shows the Paste used to measure the tank fluid level. 1.4.12 Level Switch A level switch is installed at the top section of the MFS where it can be accessed using the maintenance door.

  • Page 23: Overfilling Alarm

    1.4.13 Overfilling Alarm A overfill alarm will be installed in order to alarm the operator that if either of the tanks is filled. The device is installed in the rear section of the MFS where the infeed line is located. Refer to section 1.3 part number 8 to locate the overfill alarm.

  • Page 24: Safe Installation

    Figure 19. Corner casting locations. 1.5.2 Safe Installation When installing the MFS please make sure that the station is to be placed on a flat surface preferably concrete to prevent any instability from occurring. Please make sure to install the MFS in a position that avoids any kind of traffic and moving vehicles to ensure safeness and not to impede traffic.

  • Page 25: Manhole Operations

    1.5.7 Manhole Operations Whenever using the manhole in the MFS please inform the Safety officer (HSE) about the action in case any unexpected situation takes place that might affect negatively the safety of the MFS operator. Refer to section 1.3 part number 34 to locate the manhole. 1.5.8 Emergency Shutdown Buttons Note that the MFS is installed with six emergency shutdown buttons.

  • Page 26: Product Description

    2. PRODUCT DESCRIPTION 2.1 Introduction This section of the manual describes the all aspects of the products. It goes over several types of descriptions that will be discussed in all sections listed below. 2.2 General System Description The MFS is a rebuilt 40 ft ISO standard container. This product can store 2 types of fuel by having 2 separate tanks with a capacity of 20,000 L each that are separated by a bypass flange.

  • Page 27: Figure 21. Shows The Isometric View Of The Station

    Figure 21. Shows the Isometric view of the station. Figure 22. Top view of the station. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 28: Designation Plate

    Figure 23. Elevation view of the station. 2.3 Designation Plate A label with all main specifications of the MFS will also be hanged on the rear door of the MFS. Figure 24. Location of the specification label. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 29: General Description And Overview Of The Mfs Layout

    Figure 25. Main specifications label. 2.4 General Description and Overview of the MFS Layout Figure 26. Shows the general layout of the MFS (not to scale). Figure 26 shows the general layout of the of the MFS and how sections are divided and where every cabin is located.

  • Page 30: Air-Conditioning Unit

    that can let you have access to all compartments located at the top such as the manhole to perform any kind of preventive of breakdown maintenance. Figure 27. Shows the maintenance 2.4.2 Air-Conditioning Unit The front side also contains the condenser unit of the AC installed for the cabin and a ladder that can let you have access to the top of the MFS.

  • Page 31: Power Distribution Unit

    Figure 28. Shows the portable thermostat. 2.4.3 Power Distribution Unit The MFS is equipped with four 240 V power distribution units with a circuit breaker for each. The power distribution unit is located in the control room in case the operator is in need for source of power.

  • Page 32: Mfs Weight Scenarios

    Figure 29. Dimensions of the MFS. 2.5.2 MFS Weight Scenarios Table 4. Fuel types and densities. Fuel Density Type (kg/m 747.5 Diesel Table 5. Volume Scenarios. Volume Scenarios (m Volume (m Volume 1 Volume 2 Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 33: Table 6. Fuel Type, Weight, And Different Volume Scenarios

    Table 6. Fuel type, weight, and different volume scenarios Fuel Type Vol = 20 m Vol = 40 m 91 Octane Fuel Weight (kg) 14,760 29,520 95 Octane Fuel Weight (kg) 14,950 29,900 98 Octane Fuel Weight (kg) 15,200 30,400 Diesel Weight (kg) 16,640 33,280...

  • Page 34: Operation And Setup Instructions

    3. OPERATION AND SETUP INSTRUCTIONS 3.1 Introduction This section of the user’s manual describes the appropriate and safest way to operate the MFS. All sorts of sections are listed below and shall be explained in detail. Please follow the “Operation and Setup Instructions”...

  • Page 35: Operation

    supported by a voltage stabilizer inside the cabin in order to stabilize the power that is fed to the MFS. Table 8. Parts numbers and names Part Number Name Power input plug Ground Reel 3.6 Operation 3.6.1 General Setup. 1. Make sure that the MFS is settled on Flat surface as mentioned in section 3.5 “Installation”. 2.

  • Page 36: Figure 31. The Switch In The Electrical Box

    4 are located in the dispenser section, 2 on every dispenser. The sixth is located in control cabin where the electrical box is located. Figure 31. The switch in the electrical box. 5. Lights can be turned on by turning the switch located in the rear cabin and the control room.

  • Page 37: Filling The Tank

    3.6.2 Filling the Tank 1. Turn on the switch that is located in the electrical box inside the control cabin. Place the switch to the position (Up) shown in figure 31, as it is the start position. To turn the operation off, flip the switch to the opposite side (Down).

  • Page 38: Figure 33. Shows The Retention Tray

    Figure 33. Shows the retention tray. 4. While pumping operation is taking place the inline check valve 4'' is activated to prevent the fuel from returning back to the fuel conveying truck. Make sure that the cut valve 4'' is fully opened.

  • Page 39: Filling Vehicles And Other Machinery

    8. There is a leak detecting alarm located in the control room of the cabin. The role of this device is to alarm the operator in case there was any leakage detected in the tank. The alarm should specify which tank is leaking by showing a LED light next to the word “leak 1” or “leak 2”.

  • Page 40: Navigating Through Progauge Console And Digimon Unit Console

    3. If the tank was intended to be filled with two products, guns color coding is to be used. Product Color Color Identification Petrol Yellow Diesel Black 4. The rest of the operation can be treated like a regular gas station fuel pumping. 5.

  • Page 41: Figure 36. The Switch At The Bottom Side Of The Progauge

    Figure 36. The switch at the bottom side of the ProGauge. Figure 37. ProGauge main menu. • Once in the main menu, the console can show the 2 tanks simultaneously with all their main statuses such as volume, height, and temperature. The main menu is shown in figure •...

  • Page 42: Table 9. Detailed Pages

    • Table 9. Detailed pages. Number Page Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 43 Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 44: Digimon Console

    • The wide arrows located at the left and right side of the monitor is to silent and ignore any alarm notification • If the operator is willing to go back to the main menu, the operator shall press the button labeled with the number 2 in figure 37.

  • Page 45: Figure 39. The Digimon Console

    Figure 39. The Digimon console. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 46: Table 10. Detailed Status Pages

    Table 10. Detailed status pages. Number Page Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 47: Maintenance

    4. Maintenance 4.1 Introduction This section of the operation manual explains briefly on how to perform a safe and efficient preventive maintenance on the MFS. Avoiding these series of maintenance procedure can cause serious damages to the MFS and prevent it from operating safely and efficiently. 4.2 Mechanical 4.2.1 Emergency Vents Table 11.

  • Page 48: Electrical

    4.3 Electrical 4.3.1 Wiring When any physical damage to the wiring system can be seen, replace immediately. The wire replacement shall be with wires with the same quality of the wires used in the MFS. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 49: Troubleshooting

    5. TROUBLESHOOTING Table 12. Troubleshooting table. Issue Diagnose Solution check the that hose of truck is actually make sure it is actually working or the delivering truck it working. Sometimes there might not be delivering the product. might be a problem in the filling truck.
  • Page 50 Issue Diagnose Solution servo motor is still Check the level switch if it is working If it not working properly properly since the level switch is replace level switch. opened. connected to the electrical box and the electrical box is connected to the electrical actuator.
  • Page 51 Issue Diagnose Solution Check if the light unit is actually burned If burned out, replace. out. Check conductivity of the emergency If it is not working replace the switch. Check the conductivity of the emergency switch or wires cables. depending on what parts is not operating properly.
  • Page 52 Issue Diagnose Solution Check electric connection and power If damaged, replace. If it is not cables connection. connected, connect. Check power card inside the dispenser. If damaged, replace. Dispenser has no power thus monitor is Check the circuit breaker of the dispenser If it is off turn it on.

  • Page 53: Refrences

    6. REFRENCES 6.1 Websites • https://www.navacqs.nl/producten/container-lashing-equipment/corner-castings/ • https://www.youtube.com/watch?v=CK-d5NGx0wI • https://www.alibaba.com/product-detail/Used-40-feet-High-Cube- Container_60295969929.html Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 54: Contact Information

    7. CONTACT INFORMATION Company Address West Shuaiba Industrial Area, Block 5, St. C1 plot 151-152-167 E-mail Info@rak.com.kw mfs.technical-support@rak.com.kw mfs.spare-parts@rak.com.kw wahab@rapico.com.kw mohammad.ibrahim@rak.com.kw Khaled.Najjar@rak.com.kw Phone Numbers Office 1: +965 23260472 Office 2: +965 23260572 Abdulwahab Albabtain: +965 66769444 Khaled AlNajjar: +965 52554346...

  • Page 55: Appendix A Tank Volume

    8. Appendix A Tank Volume Tank in Inner Dimensions for Single Tank Width 2.00 Length 4.38 Height 2.35 Ruler length 90 228.6 2.286 Ruler Length Volume Volume (L) Volume (Gallon) (in) 0.00 0.61 613.20 161.99 1.00 0.84 835.70 220.77 2.00 1.06 1,058.21 279.55...
  • Page 56 Ruler Length Volume Volume (L) Volume (Gallon) (in) 23.00 5.73 5,730.79 1,513.91 24.00 5.95 5,953.30 1,572.69 25.00 6.18 6,175.80 1,631.47 26.00 6.40 6,398.30 1,690.25 27.00 6.62 6,620.81 1,749.03 28.00 6.84 6,843.31 1,807.81 29.00 7.07 7,065.82 1,866.59 30.00 7.29 7,288.32 1,925.37 31.00 7.51 7,510.82...
  • Page 57 Ruler Length Volume Volume (L) Volume (Gallon) (in) 59.00 13.74 13,740.94 3,629.97 60.00 13.96 13,963.44 3,688.75 61.00 14.19 14,185.94 3,747.53 62.00 14.41 14,408.45 3,806.31 63.00 14.63 14,630.95 3,865.09 64.00 14.85 14,853.46 3,923.87 65.00 15.08 15,075.96 3,982.65 66.00 15.30 15,298.46 4,041.43 67.00 15.52 15,520.97...
  • Page 58 Ruler Ruler Ruler Height + Height + Height + Volume Volume Volume Length Length Length Calibration Calibration Calibration (Gallon) (in) (cm) (cm) (in) 0.000 0.000 0.000 7.000 2.756 0.070 0.613 613.200 161.990 1.000 2.540 0.025 9.540 3.756 0.095 0.836 835.704 220.770 2.000 5.080...
  • Page 59 Ruler Ruler Ruler Height + Height + Height + Volume Volume Volume Length Length Length Calibration Calibration Calibration (Gallon) (in) (cm) (cm) (in) 36.000 91.440 0.914 98.440 38.756 0.984 8.623 8,623.344 2,278.046 37.000 93.980 0.940 100.980 39.756 1.010 8.846 8,845.848 2,336.825 38.000 96.520...
  • Page 60 Ruler Ruler Ruler Height + Height + Height + Volume Volume Volume Length Length Length Calibration Calibration Calibration (Gallon) (in) (cm) (cm) (in) 75.000 190.500 1.905 197.500 77.756 1.975 17.301 17,301.000 4,570.440 76.000 193.040 1.930 200.040 78.756 2.000 17.524 17,523.504 4,629.219 77.000 195.580 1.956...
  • Page 61 Volume Vs. Ruler Reading 22,000 20,000 18,000 16,000 14,000 12,000 10,000 8,000 6,000 4,000 2,000 Ruler Reading (in) Volume vs. Ruler Reading 6,000 5,600 5,200 4,800 4,400 4,000 3,600 3,200 2,800 2,400 2,000 1,600 1,200 Ruler Reading (in) Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 62: Appendix B Firefighting Instruments Location

    9. Appendix B Firefighting Instruments Location Appendix B shows the location of all firefighting instrumentation. Instrumentation includes fire extinguisher, automatic fire extinguisher, smoke detector, fire blanket, and first aid kit. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 63 Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 64 Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

  • Page 65: Appendix C Piping & Instrumentation Diagram

    Appendix C Piping & Instrumentation Diagram This section includes the piping & Instrumentation Diagram Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 66 Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 67 Appendix D Top View Design Drawing Appendix D shows the top view design drawing of the mobile fuel station Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 68 Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 69 This page was intended to be blank. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...
  • Page 70 This page was intended to be blank. Copyright 2020, Al-Rakeb Oil, Electricity & Construction Services Company | Kuwait...

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