O&m Kul 14 Project

OPERATION AND
MAINTENANCE FUEL
SYSTEM
Table of Contents
1. Brief System Description....................................................................................................4
1.1 Introduction.................................................................................................................4
2. List of Equipment................................................................................................................7
2.1 List of Major Equipment.............................................................................................7
3. Manufacturing Literature..................................................................................................11
4. Spare Parts List.................................................................................................................13
4.1 Spare Parts List..........................................................................................................13
5. Operating Procedures........................................................................................................15
5.1 System Operation......................................................................................................15
5.2 Emergency Operation Procedure (EOP)....................................................................22
6. Maintenance Procedures & Servicing Records.................................................................27
6.1 Sevicing & Maintenance Procedures.........................................................................27
6.2 Fuel Pump Control Panel...........................................................................................28
7. Disposal Instructions.........................................................................................................31
7.1 Disposal instructions and waste management...........................................................31
8. Factory Test Certificates, Site Testing & Commissioning Reports..................................33
8.1 Factory Test Certificates............................................................................................33
8.2 Site Testing & Commissioning Reports....................................................................40
9. Modifications....................................................................................................................43
9.1 To be furnished later upon completion of as-built drawings.....................................43
10. As built Drawings..........................................................................................................45
10.1 To be furnished later upon completion of as-built drawings.....................................45
SECTION 1
BRIEF SYSTEM DESCRIPTION
1. Brief System Description
1.1 Introduction
The fuel oil system consists of new 2 Underground Fuel Storage Tanks (UST) with 24 hours
of fuel storage capacity from adjacent side of the building, fuel transfer pump room housing
two fuel transfer pump sets (N+N), pump control panel, 1000L fuel storage Day tank in each
generator container, fuel distribution pipe system.
The UST is completed with filling station, vent point and fuel level content gauge for ease of
refilling of fuel.
Each filling station shall be provided with dedicated main fill line connecting to individual
fuel underground storage tank. The fuel fill port assembly shall be complete with powder
coated steel enclosure, control panel complete with fuel management and inventory system
level, gauges, and meter, camlock hose connection, isolation valve, and a strainer.
An underground concrete chamber outside the building that is buried below the service
road is provided for each UST. Each will be provided with sump to allow a portable sump
pump to be dropped below this sump to drain in case of water accumulation.
Each UST has two (2) nos. of access hatches to house associated tanks accessories such as
the interstitial leak detection cable, level switch, level sensor, valves, etc. In addition, each
UST is provided with its own fill port, complete with camlock, dedicated fill line to the UST,
and fuel management and inventory system. All fuel fill points are located centrally and
housed in a secured room outside the building.
Using transfer tank system, the fuel pump system will provide fuel distribution to the Day
tank of each individual Generator Set. In the fuel pump room, bund wall is constructed to
cover full pump room for the safe operations and maintenance of the system and a point
leak detection system will be provided in the pump room.
Fuel oil supply pipe of UST is routed underground and rise above ground within the fuel
pump room where it connects to the fuel transfer pump suction ring header with isolation
valve and strainer. Two fuel transfer pumps (N+N) are within the fuel pump room. Both
pumps are connected in parallel to the suction header and supply two fuel supply risers
feeding day tanks, complete with sectionalizing valves.
Each generator double walled Day tank has a 1000L of installed capacity, dedicated fuel
level controllers, two fuel inlet pipes, two motorized isolation valves, a drain (dump) pipe
with fusible link valve and leak detection sensor provided by the generator manufacturer.
Each Day tank has dual feeds from the fuel transfer risers for concurrently maintainability. A
manual isolation valve is located at each fuel feed line. Under normal condition both manual
ball valves will remain open. If a leak is noticed in either supply pipe the operator can
manually isolate the leaking pipe by closing the manual isolation valves.
The Day tank motorized fill including its level switches & sensors, shall be monitored, and
controlled by the Day tank control panel provided by the generator manufacturer which
shall communicate, via open communication protocol (Modbus TCP / BACNET TP/IP), with
the generator control panel and fuel oil system controller.
The fuel oil system controller shall be provided with primary and redundant Programmable
Logic Controllers (PLCs). The fuel oil system controller shall communicate with the fuel
management and inventory system, generator day tank control panels, and the fuel transfer
pump control panels via open communication protocol (Modbus TCP / BACNET TP/IP).
1.2 Underground Fuel Tank

The underground storage tank is storage unit designed to hold liquids safely below ground
level. Two (2) unit Double FRP Underground Storage Tank is supplied which required to
supply diesel for fuel system required from this project. Fiberglass-Reinforced Plastic (FRP):
known for its resistance to corrosion and compatibility with a wide range of substances. This
Underground Storage Tank have 106000-liter effective capacity for one (1) tank. Each
underground storage tank is consisting of fuel level transmitter, leak sensor, fuel level
switches and sufficient valve to allow maintenance. Underground storage tank has fuel
piping system connected with transfer pump and fuel/water separator installed to ensure
clean diesel were supplied for generator set operations. The Underground storage tank set
is designed to be operated manually or automatically depending on operating conditions.
Control panel can be set to switch either manual mode, automatic mode and off mode
based on situation. In standard operation, underground storage tank system shall be in auto
mode which operate based on situation from sequence of operation.
SECTION 2
LIST OF EQUIPMENTS
2. List of Equipment
2.1 List of Major
Equipment Underground
Storage Tank
No. Descriptions Brand Model
1 Underground Storage Tank AllTank T106
TTK Leak
Detection FG-NET
2 Interstitial Leak Detector
Systems
Rochester
T/LL70 Series
3 Level Switches Sensors
4 Level Transmitter
TTK Leak
Detection FG-NET
5 Tank Sump Leak Detector
Systems
Mainhole cover FL100, FL120, FL7A,

6 Fiberlite
FL100- SK12, FL120-
SK12
7 Valves Thinktank
8 Pressure vacuum vent with flame Thinktank
arrestor
9 Check valves Thinktank
10 Y strainer Thinktank Y - Type : PN16
Fuel System
1 Motorize valve Thinktank BN008,BN020,BN040,BN010
Daytank
TTK Leak
Detection FG-NET
2 Leak Detector
Systems
Rochester
T/LL70 Series
4 Level Transmitter
5 Filtration Filtertechnik LPCPF-1-SIZE2-2-BSPF-

B-3-V-SS
TT42C150P/R
6 Pressure relief valve Thinktank
7 Ball valves Thinktank ASME - Flanged Ball Valve
8 Pressure vacuum vent with flame

arrestor
9 Check valves
11 Side entry float switches HEBEI Steel Pipe

12 Stainless steel braided flexible hose
List Key Suppliers and Key Contacts

Item Name of Address Contact Number Remarks
Supplier
1. AllTank Lot 4009, Jln. Klinik, 03 5161 9152 Underground
Solutions Sdn Kg Bkt. Naga, Bt. 6 Storage Tank
Bhd 1/2, Jln. Bkt. and Accessories
Kemuning, 42450 parts
Klg, Selangor
Malaysia
2. Franklin Fueling Min.Chua@franklinfueling.c Fuel Pump,
System om Distribution &
THsu@franklinfueling.com Fuel Inventory
salessea@gilbarco.com
System
3. Simens Malaysia Cp Tower, 11, Jalan 03 7952 5555 Leak Detection
Sdn.Bhd 16/11, Seksyen 16, System
46350 Petaling Jaya,
Selangor
4. Hilti Malaysia Tower 3, Brunsfield 1-800-88-0985 Fire Seal
Sdn.Bhd Oasis, Oasis Square,
Level 8, 2, Jalan
PJU 1A/7A, Oasis
Ara Damansara,
47301 Petaling Jaya,
Selangor
5. Bina Plastic New Village 03-7800 0355 HDPE PN10
Industries Industrial Estate, Lot
Sdn.Bhd 4844, Jalan KPB
11A
Balakong, 43300 Seri
Kembangan, Selangor
6. Weida Unit C-05-03 & Unit 03-6143 0988 Double Wall
Marketing C-05-03A 5th Floor, Subsoil
Sdn.Bhd Sunway Nexis Biz Drainage Pipe
Suites, Jalan PJU
5/1, Kota
Damansara, 47810
Petaling Jaya,
Selangor
7. United U-LI No.33, Jalan Kartunis 03-5569 5999 HDG Trunking
Corporation Bhd U1/47, Temasya
Industrial Park,
Section U1, 40150
Shah Alam,
Selangor
8. Southern Steel 5, Jalan Utas 15/7, 03-5510 5166 GI Conduit
Pipe Sdn.Bhd Seksyen 15, 40200
Shah Alam,
Selangor
9. Fibrelite Hedgeford Innovation 03-7847 1888 Manhole Cover
Park, Jalan Tandang,
46400, Petaling Jaya,
Selangor, 46050
10. All Tank Lot 4009, Jalan 03-5161 9152 Undergorund
Solutions Klinik, Kg Tank
Sdn.Bhd Bkt.Naga, Bt.6 1/2,
Jln.
Bkt.Kemuning, 42450
Klg, Selangor, 40460
11. Pantech L3, Jalan 03-5192 7995 Stainless Steel
Corporation Trompet 33/8, Pipe
Seksyen 33,
40400 Shah
Alam, Selangor
Emergency Contact List

Item Name Designations Email Contact
Numbers
1 Abdul Raof Project Manager raof@eipt.com.my 016-2339928
Project Admin &
2 Fakhrul Iman Iman@eipt.com.my 016-7129908
Procurement
3 Zul Hazwan Assistant Engineer zul.hazwan@eipt.com.my 012-7746114
4 Zawirul Faiz Engineer zawirul.faiz@eipt.com.my 017-6952680
SECTION 3
MANUFACTURER LITERATURE
3. Manufacturing Literature
SECTION 4
SPARE PARTS LIST
4. Spare Parts List
4.1 Spare Parts List
Underground Storage
Tank
1 Underground Storage Tank AllTank T106
TTK Leak
Detection FG-NET
2 Interstitial Leak Detector
Systems
Rochester
T/LL70 Series
4 Level Transmitter
TTK Leak
Detection FG-NET
5 Tank Sump Leak Detector
Systems
Mainhole cover FL100, FL120, FL7A,

6 Fiberlite
FL100- SK12, FL120-
SK12
7 Valves Thinktank
8 Pressure vacuum vent with flame Thinktank
arrestor
9 Check valves Thinktank
Fuel System

1 Motorize valve Thinktank BN008,BN020,BN040,BN010
Daytank
TTK Leak
Detection FG-NET
2 Leak Detector
Systems
Rochester
T/LL70 Series
4 Level Transmitter
5 Filtration Filtertechnik LPCPF-1-SIZE2-2-BSPF-
6 Pressure relief valve

7 Ball valves
8 Pressure vacuum vent with flame
arrestor
9 Check valves
10 Y strainer
11 Side entry float switches
12 Stainless steel braided flexible hose

SECTION 5
OPERATING PROCEDURES
5. Operating Procedures
5.1 System Operation
A) FUEL TRANSFER PUMP SYSTEM

SCENARIO 1: Low fuel level 50% (Lead fill request) and High fuel level 85% (Lead fill stop)
 Duty selector switches to be in “AUTO” position at Transfer Pump Control Panel.

 Sequence for all day tank as below:
 When the fuel level any one of the day tank reaches at low fuel level it will initialize the
filling sequence.
 The tank with low fuel level the motorized valve – OPEN
 For example, day tank No. 1 and 3 is low level, tank No. 2 and No. 4 is high level, the motorized
valve for tank No.1 and No.3 will OPEN and Day Tank No. 2 and No.4 will remain CLOSE.
 U/G tank No.1, Fuel suction & return motorized valve - OPEN
 Fuel pump start running.
 If day tank No.1 reach high level and day tank No.3 not reach high level, day tank No.1 motorized
valve will CLOSE and day tank No. 3 will remain OPEN until reach the high level. The pump
continues running.
 If all the day tank reach the high level then pump immediately stop.
 An alarm status will send to control panel/HMI with warning alarm transmit to BMS
 U/G tank No.1, Fuel suction motorized valve – CLOSE
 U/G tank No.1, Return motorized valve - CLOSE (Time delay 30min)
SCENARIO 2: Low fuel level (50%) (If faulty situation on level sensor & no flow)
 When fuel “Low Level” alarm is initiated – whereby pump Start level sensor faulty or
insufficient flow detected
 “Low Level” alarm will be triggered on the fuel pump control panel with pre-emptive
warning alarms, but fuel transfer pump will not start
 If pump failure or ‘No Flow’ fuel in the pipe system alarm will be triggered on the fuel pump
control panel with warning alarms,
 The system will changeover to standby system B including the Pump and Motorized
Valves Operator/crew to attend: - to acknowledge alarm and attend the faulty
SCENARIO 3: Low low level 30% (Lag fill request)
 When “Low Low Level” (Lag fill request – “Level Alarm”) is initiated – whereby pump Start
“level sensor” are faulty or insufficient flow detected
 When the “Low Low Level” alarm triggered, the alarm not affected/interrupted the operation
of generator during the auto power fail or manual operation.
 Lag fill request – “Level Alarm” will be triggered, both system (A) and (B) take over and lead
fuel transfer pump and motorized valves will run and open to fill the day tank.
 If one of the day tank reaches “Low Level” the respective motorized valve system (B) will close.
The others day tank that has not reach “Low Level” will remain open for both motorized valve
system (A) and (B).
 The standby system (B) will stop when all the day tank reaches “Low level” but the duty system
(A) will continue running until filling process completed.
Valves. Operator/crew to attend: - to acknowledge alarm and attend the faulty
SCENARIO 4: Critical low low level (15%)
 When “Critical Low Low Level” (Level Alarm) is initiated – whereby low fuel level and lag fill
request sensor faulty or insufficient flow detected
 Lag fill request – “Level Alarm” will be triggered, both system (A) and (B) take over and lead fuel
transfer pump and motorized valves will run and open to fill the day tank.
 If one of the day tank reaches “Low Level” the respective motorized valve system (B) will close.
The others day tank that has not reach “Low Level” will remain open for both motorized valve
system (A) and (B).
 The standby system (B) will stop when all the day tank reaches “Low level” but the duty system
(A) will continue running until filling process completed.
Valves Operator/crew to attend: - to acknowledge alarm and attend the fault / manually reset
SCENARIO 5: High High Fuel Level Alarm (95%)
 Fuel transfer pump fail to stop due to lead fill request level switch malfunction; “High High Level”
alarm will be activated, and motorized valve will cut-off and stop supply for the affected day
tank only.
 Fuel transfer operation will not affect any fuel supply to other remaining day tanks.
 Fuel transfer pump (system A & B) will stop when fuel level reaches to “High Level” (lead fill
“Stop Level” sensor) in the day tank.
 In the event of “High High Level” (Level Alarm) switch faulty, and the pump none stop
pumping transfer the fuel, the overflow fuel from day tank will flow back to bulk fuel storage
tank.
 An alarm status will send to control panel/HMI with warning alarm transmit to
BMS Operator/crew to attend: - to acknowledge alarm and attend the fault / manually
reset
SCENARIO 6: Day Tank Leak
 If any fuel leak is detected in the containment tank (drip pan for each day tank inside bund wall).
The leak sensor will be activated, a warning alarm will send to control panel/HMI with alarm
transmit to BMS. Operator/crew to conduct the physical inspection to check leakage occurred.
 During the pump running, if the surrounded drip pans of the respective day tank fuel leak
detection activated, the respective supply pipe’ motorized valve will close and cut off fuel
supply.
 At the same time any other day tank demanded the fuel, the pump will start and continue to top
up the fuel into the respective day tank.
 Fuel transfer system operation will not affect the fuel supply to other remaining day tanks.
 If the transfers fuel pipeline detected fuel leaking during the critical time where the day tank
demand fuel, the respective fuel line motorize valve will be closed, and then system will initiates
command the secondary fuel transfer pump (B) to take over the duty with continue refilling fuel
from storage tank to respective day tank without interrupted the fuel transfer system above.
 If a particular day tank leak is detected, that day tank will close the motorized valves both
system (A) and (B) and stop filling. The others day tank which are not affected will continue the
filling sequence. No changeover to system (B) for the day tank leakage.
 An alarm status will send to control panel/HMI with warning alarm transmit to
Operator/crew to attend: - to acknowledge alarm and attend the fault / manually reset
SCENARIO 7: Lead system Pump Trip
 If System (A) lead fuel transfer pump overload or trips, an alarm status will send to control panel
/HMI with warning alarm transmit to BMS.
 Hence, lag fuel transfer pump (B) will take over duty automatically
Operator/crew to attend: - to acknowledge alarm and attend the fault & manually reset
SCENARIO 8: Lead Pump No Flow
 If lead fuel transfer pump (A) starts but flow switch detected no fuel inside the fuel pipe within 1
minute, alarm will send to control panel/HMI with warning alarm transmit to BMS where system
(A) lead pump will stop.
 Hence, lag fuel transfer pump (B) will take over duty automatically.
 If suddenly “no flow’’ occurs in any day tank primary fuel pipe due to pipe clogged, the fuel
transfer pump (A) will stop, and system will initiates start the fuel transfer pump (B) to take over
the duty and continue refilling fuel from storage tank to respective day tank without interrupted
the fuel transfer system above.
SCENARIO 9: Fuel Transfer Pump (A) Power Loss, Fuel Transfer Pump (B) take over (Change
over)
 If fuel transfer pump (A) fails to running within 1 minute.

 An alarm status will send to control panel/HMI with alarm transmit to BMS
 Hence, Lag fuel transfer pump (B) will take over duty automatically
 To check the transfer pump at system (A) and reset alarm at control panel
Operator/crew to attend: - to acknowledge alarm and attend the defect & manually
reset
SCENARIO 10: Panel system (A) Power Loss, Panel System (B) take over (Change over)
 If System (A) fuel pump control main incoming power loss (failure of pump control panel main
supply) An alarm status will send to control panel/HMI with alarm transmit to BMS.
 Hence, System (B) fuel transfer pump will take over to transfer fuel when fuel level reaches to
Low Level (Lead fill request Level)
SCENARIO 11: Motorized Valve Failure
 If fuel supply line motorized valve fails to close within 1 minute in system A,
 An alarm status will send to control panel/HMI with alarm transmit to BMS, to check the alarm
on pump control panel and to rectify the valve
 System (B) fuel transfer pump will take over and start transfer fuel when fuel level reaches (Lag
fill request – Level) in day tank
 If fuel storage tank No.1 or No.2 suction & return’ motorized valve fails to open within 1 minute
in system (A), the system will changeover to system (B) including the Day tank motorized valve
and pump.
 If air lock/trap in pipeline where result the pump (A) is not operating or pressure relief valve
malfunction during the critical time
 An alarm status will send to control panel/HMI with alarm transmit to BMS, Crew to check the
alarm status on pump control panel, check the valve and pipeline condition with rectify the
issues
 System (B) fuel transfer pump will take over and start transfer fuel when fuel level reaches (Lag
fill request – Level) in day tank.
 In the event when happened the air lock/trap, the pressure air increases in the pipe fuel line.
PRV will function to opening high pressure air out and recloses when the pressure drops below
the opening pressure (operation pressure).
Operator/ crew to attend: - to acknowledge alarm and attend the defect & manually reset
SCENARIO 12: In the Event of Fire
 When there is a fire, the fuel transfer system will not be affected.
SCENARIO 13: System(A) PLC Failure, Backup System (B) Take Over
 There are standalone of independence PLC system in Control Logic integrate with respective
pump set.
 If fuel pump control panel (A) PLC “Failure” due to power loss or interruption
 Hence, System (B) fuel pump will take over duty, start transfer when fuel level reaches (lag fill
request – “Level Sensor”) in the day tank
SCENARIO 14: To Cut-In Next Fuel Storage Tank 25% (Low Low Level)- Change over
between FST 1 & 2
 During fuel transfer operation where bulk fuel storage tank 1 fuel level drops to “Low Low
Level” which is (25% of bulk tank capacity).
 “Low Low Level” alarm initiated to alert both system fuel transfer pump control panel and lead
pump were continuous pumping.
 Bulk fuel storage tank 2 suction and return motorized valve will open before Bulk fuel storage
tank 1 suction and return motorized valve will close. (To ensure set to Auto mode for both
panel)
 Fuel transfer pump will continue operation transferred from bulk fuel storage tank 2 and fuel
storage tank 1 will lock out (HMI screen at Panel will indicate lock out when bulk storage is
below 25%)
SCENARIO 15: Failure of Day Tank Motorized Valve
 During fuel transfer operation, where fuel demanded day tank’ motorized valve fail/unable to
open at system (A)
 It will result the suction pipeline pressure increase over the designed suction head pressure.
 However, external pressure relief valve setting has been set 10% higher than the
designed suction head pressure.
 Fuel external pressure relief valve will open when pressure is 10% higher than the designed
suction head pressure. The supply fuel will release and flow back to bulk tank.
 Fuel external pressure relief valve pipe fuel flow switch will activate the alarm (10sec time delay).
 And alarm status will send to control panel/HMI with alarm transmit to BMS
 The affected lead fuel transfer pump (system A) will stop immediately, and switch to lag
fuel pump (system B) shall take over the duty.
 The affected fuel external pressure relief valve pipe fuel flow switch alarm will auto normalize
after faulty devices being rectified.
 If the motorized valve in system (A) failure, the system (B) will take over.
 Lead (system A) fuel transfer pump and motorized valves will resume back duty after the
affected day tank motorized valve being rectified (the faulty parts require to rectify / replaced
prior back on duty), the system will continue on system (B) until the next cycle process.
 Fuel transfer operation should not affect any of the fuel supply to other remaining day tanks.
SCENARIO 16: Manual Mode
 The fuel transfer pump control selector switches to “MANUAL” Position

 Fuel suction pipe motorized valve selector switches to “MANUAL” Position
 Return pipe motorized valve selector switches to “MANUAL” Position
 Motorized valve for day tank switches to “MANUAL” Position
 Select the day tank that require filling. Switch the motorized valve selector switch to “OPEN”
position for day tank selected.
 Switch the return pipe motorized valve selector switch – “OPEN” (verify at touch screen before
proceed)
 Switch the fuel suction pipe motorized valve selector switch – “OPEN” (verify at touch screen
before proceed for check motorize valve status)
 Push button the fuel transfer pump “START” (proceed start pump after 5 sec open motorize
valve)
 During manual fuel transfer process, the operator/ crew should standby and monitor the fuel
distribution.
 After the fuel transfer or distribution finish, manual push the “STOP” button and pump will stop.
 Immediately after pump “STOP” switch the fuel suction pipe motorized valve selector switch
to– “CLOSE” position for prevent fuel pipe airlock.
 Switch the return pipe motorized valve selector switch to– “CLOSE” position.
 Switch the motorized valve for day tank selector switch to– “CLOSE” position.
 At last, turn back the selector switches back to “AUTO” Position for fuel pump and for all
motorize valve.
 An alarm status will send to control panel/HMI with alarm transmit to
BMS Operator/ crew to attend: - to acknowledge alarm and attend the
faulty
B) FUEL POLISHING PUMP SYSTEM
The fuel polishing system is to remove water, microbiological growth and other
contaminants from diesel to maintain the fuel quality at all times. The fuel polishing pump
2(N) will operate alternately (take turn basic) to complete a cycle of the entire tank volume
for storage period 7days basic (weekly). Two units of proposed fuel polishing pump (take
turn basic) able to carry out the fuel polishing through fuel suction pipe with foot valve to
be installed closer to the bottom of the storage tank for suction. The fuel return from the
polishing pump will be discharged horizontally into the fuel tank.
The fuel polishing system is designed for each underground fuel storage tank, and the
system capable to polish and maintain the fuel quality. After the fuel is polished, the
polished fuel will release flow back to another underground fuel tank through fuel polish
return pipe that connected with common return pipe. The system can be operated
automatically/ manually to maintain the fuel quality. The fuel polishing system control is
integrated with fuel transfer pump control panel at pump room. When fuel transfer pumps
start, fuel polishing pumps shall cease operations and shut down the polishing cycle.
Besides, the said polish pump able to transfer the fuel within the underground tank 1 with
underground tank 2 for fuel balancing purpose.
The fuel polishing system is consisting of the following:
 Polishing pump
 Filter at the outlet to the pump
 Deferential pressure gauge
 Flow meter
 Water detection Automatic Tank Gauging (ATG).
High Level interface is provided for the BMS to monitor the following:
 Fuel polishing pump Start/ Stop
 Fuel polishing pump Auto/Manual
 Fuel polishing pump Trip Alarm.
 Fuel polishing pump Power Loss-Status
 Fuel polishing pump flow status
 Water detection alarm
SCENARIO 17: Auto Mode
 The polish pump selector switches to be in AUTO Position.

 The timer (weekly digital base) will start the fuel polishing according to the allotted
time schedule.
 When the timer contacts close.
Operation of underground fuel storage tank
 Fuel polish suction pipe motorized valve - OPEN
 Return pipe motorized valve - OPEN
 The fuel polishing pump will start accordance to timer schedule has set.
 During the fuel polishing through the fuel water separator (Fuel Filter), this filter
separates contaminants and water from fuel.
 If any of the day tank request for fuel transfer from the storage tank during on the fuel
polishing operation, the fuel polishing operation shall be immediately stopping the
motor pump, once the fuel transfer pump finish the operation, the fuel polishing pump
will be continued start automatically (as per the timer program).
 Auto mode operation polishing pump will stop balancing between underground tank
when fuel level reach “Low Low Level”.
 If any water detected, fuel transfer pump will stop, and alarm status will send to control
panel/HMI with alarm transmit to BMS. Operator/crew to attend and acknowledge
alarm and manually reset.
Fuel pump polishing operation
Similar follow the other side underground storage tank polishing sequence.
 Fuel polish suction pipe motorized valve - CLOSE
 Fuel Return pipe motorized valve – CLOSE (Time delay 30 minutes)
SCENARIO 18: Manual Mode
 The polish pump selector switches to “MANUAL” Position

 Manual push the pushbutton and pump will start.
Underground fuel storage tank
 Fuel polish suction pipe motorized valve - OPEN

 Return pipe motorized valve - OPEN
 The fuel polishing pump will start.
 During manual fuel polishing, the operator/ crew should standby and monitor the
whole process.
 After the polishing cycle finish, manual push the stop button and pump will stop.
 Hence, fuel suction pipe motorized valve – CLOSE
 Fuel return pipe motorized valve – CLOSE (Time Delay 30minute)
 At last, duly switch off and turn back the selector switches back to “AUTO” Position
During the fuel polishing process (Auto), and where any of fuel day tank call for fuel, hence
alarm will activate with signal notify fuel polishing pumps should stop and cease
operations to shut down the polishing cycle. Fuel transfer pumps will take duty to start
pumping the fuel to day tank. During in manual mode process, if any day tank request
filling, polishing pump will immediately cut-off by interlock from relays to stop the
polishing pump.
Operation of Fuel Monitoring Control Panel System A & B
 The Fuel Monitoring Control Panel was to monitor the fuel level for underground
tank and day tank, as well as for monitoring of fuel and water leak at tank
chamber area.
 The Fuel Monitoring Control Panel consist of a main monitoring module,
ProGauge Maglink LX4 with a touch screen display and capable to interface with
32 level sensor probes.
 The Maglink LX console was propriety and robust design with Linux base
software for a reliable and stability for used in oil and gas industrial. Hence, the
fuel system design was with a primary Fuel Monitoring Control Panel in the
services line and a secondary system in manual operation for backup in case of
primary unit fail.
5.2 Emergency Operation Procedure (EOP)
Manual Mode
1. Assess the requirement.

Which Day Tank to fill, Daytank 1 to 37? Example: Daytank 1
Which Underground Tank (UG) to pump from, UG Tank 1, 2, 3 or 4? Example: UG Tank 1
Which Transfer Pump to use, A or B? Example: Transfer Pump A
2. Check UG Tank 1 level. Put mode selector switch for UG Tank 1 Supply MOV to
Manual
3. Put mode selector switch for Day Tank 1 and 2 Supply MOV to Manual. Put
command switch to Open
4. Put mode selector switch for Transfer Pump A to Manual
5. Press Pump Start button and confirm pump is running. put UG Tank 1 MOV
command switch to Open
6. Confirm there is flow in the line by hearing the line being filled and observe at Day Tank 1
and that level is increasing. WHEN LEVEL REACH HIGH LEVEL, be ready to close
Day Tank 1 Supply MOV and Stop the Pump. CRITICAL POINT : PLEASE BEWARE
7. WHEN LEVEL REACH HIGH LEVEL, put Day Tank 1 Supply MOV command switch to
Close
8. After Day Tank 1 Supply MOV have been closed, immediately switch UG Tank 1
Supply MOV to Close. Then immediately press Stop for Transfer Pump A. [Immediate
close UG Tank 1 Supply MOV and Stop Transfer Pump after last Day Tank MOV is
closed to prevent overpressure in the line]
9. Manual Fuel Transfer process in complete.
Emergency Shutdown
 The fuel transfer system can be shut off anytime by pressing emergency stop button at both system
panel. Any panel in emergency lock out mode will lockthe system until both of emergency button is
released. System won’t run if any panel in lock out mode.
SECTION 6
MAINTENANCE PROCEDURES &
SERVICING RECORDS
6. Maintenance Procedures & Servicing Records
6.1 Servicing & Maintenance
Procedures Underground Fuel Storage
Tanks
 Make sure fill cover present, not broken or damaged

 Fill covers are identified by color and located on the correct tank
 Check the leak detection monitor
 No cracks, bulges or holes in the spill containment manhole
 Below-grade containment manhole properly latched (if present)
 Below-grade containment manhole contains oils-absorbent material
 Fill cap in good condition, seals tightly
 No obstruction inside the fill pipe
 Check the leak detection monitor
 Water level sensor
Accessories for UGT

 The good operation the sump must be visually inspected simultaneously
with underground tank
 Check manhole cover, skirting and frame from rusty
 Make sure handle have on site for open and close manhole cover
Valves
 Check all valve flow for any accumulated oil. Clean it if necessary
 Motorized valve - Check visual operation
 Check voltage supply plug, contact plug and auto / manual declutching
 Check automatic indoor temperature control
 Check 360 visual position indicator well function
 Check drain valve well functioned
Fuel Transfer Pump
 Make sure internal gear pump well function
 Check if rotor motor pump can run
 Check diesel from between the gear and discharge port. Clean if necessary
 Make sure diesel constant smooth flow with no pulsations
Filtration
 Check filter housing for any oil accumulation. Clean the filter
 Check and clean in out pipe before and after filter
 Check filter absorbs. Replace if necessary
Fuel Pump Control Panel

 Measure the incoming voltage
 Measure the DC Power Supply
 Check panel light is working
 Check panel fan is working
 Check pilot lamp is working
 Check digital power meter reading correctly
 Check PLC run LED
 Check PLC error LED
 Check PLC Maintain LED
 Check PLC I/O module Diagram LED
 Check ethernet switch port is power on
 Check ethernet switch port is working
 Check Touchscreen is communicating with the PLC by checking the graphics
are having active readings
 Check the power switching is working by turning off MCCB 1
 Check the power switching is working by turning off MCCB 2
 Select manual for all pumps and valves at the control panel
 Press starts to run the pumps. Observe if touchscreen is showing the correct
pump status
 Select open to manually open the valves. Observe if touchscreen is showing the
open and close status
 Check Reading instruments at touchscreen
 Remove dust or dirt build up in the panel
 Check Panel filter for any dust accumulation. Clean or replace as necessary
 Check panel fan for any dust accusation. Clean the fan
 Check for any damage to the electrical components
 Check for any loose connection on equipment
SECTION 7
DISPOSAL INSTRUCTIONS
7. Disposal Instructions
7.1 Disposal instructions and waste
management To be furnished later

SECTION 8
FACTORY TEST CERTIFICATES, SITE TESTING
& COMMISSIONING REPORTS
8. Factory Test Certificates, Site Testing & Commissioning Reports
8.1 Factory Test Certificates
CORRUGATED PIPE
MAINHOLE COVER
TEST REPORT
FL100 EN124 D400 Cover Test

Date: 12/09/12
Client: Fibrelite Composites Ltd.
Cover
The cover supplied is a round FL100 and of composite construction. (See photo.
1) No. on cover –
The cover was tested in a composite

frame. Frame No.
Photo. 1
-1-
Test Rig
The test rig consists of a ‘giant mecanno’ frame bolted to the floor and supporting the
Enerpac 50 tonne hydraulic cylinder. (Photo 2)
Photo. 2
The cover and frame were sat on steel channels and plates with steel shims to pack
and level.
Test
The test was carried out in accordance with BS EN 124, Class D400.
The load was applied to the cover through a 250mm diameter by 45mm thick steel
block with a 250mm diameter by 25mm rubber pad between the block and cover.
The load was measured using a 1000kN load cell (serial no. 3243N) and digital
load indicator (serial no. D.I.B.1).
The deflection was measured at the centre on the underside of the cover using a dial
indicator.
The cover was loaded to 2/3 of the test load and then released. This was repeated five
times. It was then loaded to try and achieve the test load.
-2-
Results
Load (kN) Deflection Remarks

(mm)
0 0.00
267 19.95 Light cracking noises from
30kN onwards for the
1stcycle.
0 1.00
267 20.45
0 0.95
267 21.05
0 1.10
267 21.08 .
0 1.17
267 21.15
0 1.21
20 3.40
42 5.08
60 6.50
80 8.05
101 9.67
123 11.28
140 12.56
160 14.03
180 15.49
200 16.90
220 18.28
240 19.65
260 21.07
284 22.64
300 24.07
320 25.70
340 27.90
360 29.70
380 31.90
400 33.70
400 (10 34.12
seconds)
-3-
400 (20 34.46
seconds)
400 (30 34.55
seconds)
0 2.41
400 35.12
420 37.52 Louder cracking.
440 39.89 Loud
cracking/tearing
noises.
442 41.25 Lou bang! – failure.
360 42.75
.
FL100 EN124 D400 Test

500
450
400
350
300
Load
250
200
150
100
50
0
0 5 10 15 20 25 30 35 40 45
Deflection (mm)
-4-
FL100 EN124 D400 Test
500
450
400
350
300
250
200
Load
150
100
50
0
0 50 100 150 200 250 300 350 400 450

Time (seconds)
The cover held the test load of 400kN for the required 30 seconds so therefore passed the EN124 D40
In accordance with EN124 Clause 8.3.1 the permanent set of the cover was 1.21mm which is within th
The cover therefore passed the permanent set test also.
After the cover had passed the EN124 D400 test, the load was released from the
400kN and after waiting two minutes for the cover to settle, the permanent set was
recorded at 2.41mm
The cover was then loaded again until failure at 442kN
The cover was then removed from the test rig and inspected for damage.
-5-
On the top surface there was a large crack running from the outside edge of the
cover towards the centre. (Photo.3)
Photo.3
There were no signs of any cracking to the bottom surface of the cover or any damage
to the frame.
M.A.Salisbury
Senior Technician
-6-
STAINLESS STEEL PIPE
BALL VALVE
Shanghai Thinktank Process Management Co,.Ltd
TEST & INSPECTION REPORT
Customer: EI Power Technologies Sdn.
PO 00009566 Date: 30th Aug, 2023 Model Q941F-150LB-080
Bhd. (913886-A)
No.:
Chemical Component (%) Mechanical Properties
Parts Product Name Material Material QTY δb δs Stat
C Si Mn P S Cr Ni Mo Cu V (Mpa) (Mpa)
δ% Ψ% HB e
Body WCB 0.20 0.42 0.84 0.018 0.018 0.039 0.046 0.008 0.018 0.002 288 501 26 / /
Motorized Ball Valve-DN80 6
Ball CF8M 0.070 0.66 0.99 0.030 0.010 18.30 9.00 2.10 / / 264 518 38 / /
Body WCB 0.23 0.058 0.9 0.031 0.041 0.46 0.48 0.18 / 0.027 250 485 35 / /
Manual 2 Pieces Ball Valve-
8
Ball DN15 CF8 0.055 0.84 1.29 0.034 0.008 18.15 8.310 0.12 / / 205 485 35 / /
Body WCB 0.23 0.058 0.9 0.031 0.041 0.46 0.48 0.18 / 0.027 250 485 35 / /
Manual 2 Pieces Ball Valve-
40
Ball DN40 CF8 0.055 0.84 1.29 0.034 0.008 18.15 8.310 0.12 / / 205 485 35 / /
Performance Test
Inspection Item Shell Test(MPa) Leakage Seal Test（MPa） Air Seal Test（MPa）
Pressure Rate 150LB / 150LB / 150LB /
Test Pressure 3.0Mpa / 2.2Mpa / 0.6Mpa /
Test Medium Water / Water / Air /
Times 120S / 120S / 60S /
Result Conformity / Conformity / Conformity /
QC Supervisor Inspector Auditor

Customer: EI Power Technologies Sdn. Bhd.
PO 00009566 Date: 30th Aug, Model Q941F-150LB-080
(913886-A)
No.: 2023
Parts Item Front Back Nameplate Actuator
Motorized Ball
1
Valve
Inspector 郑浩忠
Test Result Conformity
Approved By 王雪涛
PO 00009566 Date: 30th Aug, Model Q41F-1000WOG-015
(913886-A)
No.: 2023
Parts Item Photos
Manual 2
1 Pieces Ball
Valve
Inspector 郑浩忠
Customer: EI Power Technologies Sdn.
PO 00009566 Date: 30th Aug, Model Q41F-150LB-040
Bhd. (913886-A)
No.: 2023
Parts Item Photos
Manual 2
1 Pieces Ball
Valve
Inspector 郑浩忠
FLAME ARRESTOR WITH VENT DN80
PO No.: 00009566 Date: 26th Aug, 2023 Model 7110+FA-S-080
(913886-A)
Parts Product Name Material QTY T.S. Y.S. State
C Si Mn P S Cr Ni / / EL% HB /
(Mpa) (MPa)
Body SS304 0.054 0.475 1.480 0.026 0.002 17.520 8.140 / / 650.0 / 55.0 85.0 /
Flame Arrestor With Vent-
2
DN80
Trim SS316 0.046 0.410 1.077 0.025 0.011 18.090 14.020 / / 780.0 / 75.0 87.0 /
Performance Test (Design Temp: 200℃, Design Pressure: 150LB/20Bar)
Inspection Item Air Pressure
Design Pressure -300/ +1350Pa

Test Pressure -300/ +1350Pa
Test Medium Air
Times/ Temperature 60s/ Atmospheric Temperature
Result Conformity
QC Supervisor Inspector Auditor Erplosion Group: IIA-MESG:0.9mm

PO No.: 00009566 Date: 26th Aug, Model 7110+FA-S-080
(913886-A)
2023
Parts Item Valve, nameplate, packing Photo
Flame Arrestor
1 With Vent-
DN80
Inspector 郑浩忠
Result Conformity
PRESSURE RELIEF VALVE
Customer: EI Power Technologies Sdn. Bhd. (913886-A) PO 00009566 Date: 30th Aug, 2023 Model TTA42C-150LB-C-080
No.:
Hea
Parts Product Name Material QTY δb δs State
t C Si Mn P S Cr Ni V MO
(Mpa) (Mpa)
δ% Ψ% HB
No.
Valve body WCB 0.21 0.51 0.4 0.017 0.023 0.1 0.06 0.01 0.03 505 260 25 42 / /
Trim Pressure Relief Valve SS304 3123 2 0.07 0.8 1.6 0.044 0.025 18.5 9 / / 540 230 36 / / /
Spring 50CrVA 0.48 0.25 0.51 0.017 0.025 1 0.2 0.1 / 1305 1130 13 21 / /
Production No. 23081956-23081957 Manufacturing permit：TS733018-2024 Parameters
Seq. Inspection Item Requirements Result Product Type TTA42C Nominal Pressure 2.0 Mpa
1 Major part material By the rules of ASTM A351/A351M-2000 Measure up Nominal Diameter 2”x2” Pressure Level 0.25-4 Mpa
Thread precision &
2 roughness By confirmed drawing Measure up Set Pressure 0.3 Mpa Lifting Height 8 mm
3 Main connection size Comply API 526 Standard Measure up Runner Diameter 32 mm Discharge Coefficient 0.7
4 Spring Proceeding of fatigue test and stiffness inspection Measure up Discharge Pressure 0.33 Mpa Return Pressure 0.26 Mpa
5 Strength test 1.5PN（Testing medium：water） Measure up Service Temperature 300°C, Applicable medium:Water, oil, Steam
6 Set pressure (Mpa) 0.3±3%( Testing medium：Air) Measure up

The drawing pattern of the product has passed ASME VIII
7 Imperviousness ≤20 bubble/min.(Testing medium：Air) Measure up standard, and is permitted to deliver.

2 Bar
b'
Z'-
6 Cap WCB
5 Spring 50CrVa
4 Bonnet WCB
D
D
N
2
'
3 Disc SS304
L
2 Seat SS304
f'
1 Body WCB
b
Z-Ød
f
DN
No. Name Material
D2
D1
D
L
Pressure Relief Valve DRAWING
Size: DN5
Pressure Rating: 150LB
50 150 120.7 92 18 2 4-Ø18 50 150 120.7 92 18 2 4-Ø18 135 120
DN D D1 D2 b t Z-Ød DN' D' D1' D2' b' t' Z'-Ød L L1
Model: TTA42C-150LB-C-050
Customer: EI Power Technologies Sdn. Bhd. (913886-A) PO 00009566 Date: 30th Aug, 2023 Model TTA42C-150LB-C-080
No.:
Parts Item Photos
1 Pressure Relief Valve
Inspector 郑浩忠
SINGLE DISC SWING CHECK VALVE
& WAFER CHECK VALVE
PO 00009566 Date: 29th Aug, 2023
(913886-A)
No.:
Parts Product Name Size Material QTY δb δs State
C Si Mn P S Cr Ni Mo Cu V (Mpa) (Mpa)
δ% Ψ% HB
Body Y Strainer Valve DN80 WCB 4 0.253 0.041 0.810 0.350 0.031 0.310 0.420 0.210 0.350 0.021 495 290 30 / /
Body Wafer Check Valve DN50 WCB 4 0.252 0.042 0.810 0.350 0.031 0.300 0.420 0.220 0.350 0.021 495 290 30 / /
Single Disc Swing

Body DN50 A105 4 0.240 0.290 0.880 0.028 0.036 / / / / / 529 266 32 48 /
Check Valve
Single Disc Swing

Body DN80 A105 6 0.250 0.280 0.880 0.027 0.037 / / / / / 529 266 32 48 /
Check Valve
Performance Test
Inspection Item Shell Test(MPa) Leakage Test（MPa） Low Pressure Seal Test （MPa）
Pressure Rate 150LB / 150LB / 150LB /
Test Pressure 3.0Mpa / 2.2Mpa / 0.6Mpa /
Test Medium Water / Water / Air /
Times 120S / 120S / 60S /
Result Conformity / Conformity / Conformity /

PO 00009566 Date: 29th Aug, 2023
(913886-A)
No.:
Parts Item Single Disc Swing Check Valve | Wafer Check Valve
Single Disc
Swing Check
1
Valve & Wafer
Check Valve
Inspector 郑浩忠
Y-STRAINER
PO 00009566 Date: 29th Aug, 2023
(913886-A)
No.:
Parts Item Valve's Photo and Packing Photo
1 Y-Strainer
Inspector 郑浩忠
TRANSFER PUMP
8.2 Site Testing & Commissioning Reports
To be furnished later upon completion of testing CX1-CX5
SECTION 9
MODIFICATIONS
9. Modifications
9.1 To be furnished later upon completion of as-built drawings

SECTION 10
AS-BUILT DRAWINGS
10. As built Drawings
10.1 To be furnished later upon completion of as-built drawings

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OPERATION AND

1.2 Underground Fuel Tank

2.1 List of Major

Mainhole cover FL100, FL120, FL7A,

5 Filtration Filtertechnik LPCPF-1-SIZE2-2-BSPF-

7 Ball valves Thinktank ASME - Flanged Ball Valve

8 Pressure vacuum vent with flame

10 Y strainer Thinktank Y - Type : PN16

11 Side entry float switches HEBEI Steel Pipe

List Key Suppliers and Key Contacts

Emergency Contact List

4.1 Spare Parts List

Mainhole cover FL100, FL120, FL7A,

No. Descriptions Brand Model

5 Filtration Filtertechnik LPCPF-1-SIZE2-2-BSPF-

6 Pressure relief valve

12 Stainless steel braided flexible hose

5.1 System Operation

A) FUEL TRANSFER PUMP SYSTEM

 Duty selector switches to be in “AUTO” position at Transfer Pump Control Panel.

SCENARIO 3: Low low level 30% (Lag fill request)

SCENARIO 4: Critical low low level (15%)

SCENARIO 5: High High Fuel Level Alarm (95%)

SCENARIO 6: Day Tank Leak

SCENARIO 7: Lead system Pump Trip

SCENARIO 8: Lead Pump No Flow

 If fuel transfer pump (A) fails to running within 1 minute.

SCENARIO 11: Motorized Valve Failure

SCENARIO 12: In the Event of Fire

SCENARIO 15: Failure of Day Tank Motorized Valve

 The fuel transfer pump control selector switches to “MANUAL” Position

 The polish pump selector switches to be in AUTO Position.

 The polish pump selector switches to “MANUAL” Position

Underground fuel storage tank

 Fuel polish suction pipe motorized valve - OPEN

Operation of Fuel Monitoring Control Panel System A & B

1. Assess the requirement.

9. Manual Fuel Transfer process in complete.

6.1 Servicing & Maintenance

Procedures Underground Fuel Storage

 Make sure fill cover present, not broken or damaged

Accessories for UGT

Fuel Pump Control Panel

7.1 Disposal instructions and waste

management To be furnished later

8.1 Factory Test Certificates

FL100 EN124 D400 Cover Test

The cover was tested in a composite

Load (kN) Deflection Remarks

FL100 EN124 D400 Test

0 50 100 150 200 250 300 350 400 450

The cover therefore passed the permanent set test also.

The cover was then loaded again until failure at 442kN

Pressure Rate 150LB / 150LB / 150LB /

Test Pressure 3.0Mpa / 2.2Mpa / 0.6Mpa /

Test Medium Water / Water / Air /

Times 120S / 120S / 60S /

Result Conformity / Conformity / Conformity /