Refueller Module Commissioning Checklist - local copy

• Refueller Module Commissioning Checklist

• Document No.

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

• Product ID

• Manufacturer

• Unit Type

  Hydrant Dispenser

  Refueller

• Capacity

  12KL

  16KL

  25KL

  40KL

• Flowrate

  300 GPM

  600 GPM

• Type Fuel

01. Tank

• Part Number / Model

• Serial No.

02. Filter Monitor

• Part Number / Model

• Serial No.

03. PCV / Deadman Valve

• Part Number / Model

• Serial No.

04. Deadman Handswitch

• Part Number / Model

• Serial No.

05. Bulk Meter

• Part Number / Model

• Serial No.

06. Meter Register

• Part Number / Model

• Serial No.

07. Flexible Joints

• Part Number / Model

• Serial No.

08. Product Pump

• Part Number / Model

• Serial No.

09. Product Pump Motor

• Part Number / Model

• Serial No.

10. Hose Reel Motor

• Part Number / Model

• Serial No.

11. Reel Hose Coupling

• Part Number / Model

• Serial No.

12. HEPCV Regulator

• Part Number / Model

• Serial No.

13. Bottom Load Coupling

• Part Number / Model

• Serial No.

14. Fuel Sampler

• Part Number / Model

• Serial No.

15. Large LED Display

• Part Number / Model

• Serial No.

16. Reel Hose

• Part Number / Model

• Serial No.

16. Deck Hose (Platform)

Deck Hose (Left)

Deck Hose (Right)

2.1. GENERAL

2.1.1. Flow Features

• Hydrostatic Test or Certificate Test for piping system and all components of the meter valves will be designed for a hydrostatic test pressure 16 bar

  Yes

  No

• Open depressurisation spring loaded return valve and check pressure on piping system. These lines will be fitted with check valves and isolating ball valves

  Yes

  No

2.1.2. Drain Valves and Plug

• Is drain valves and plug grouped, labeled, and using spring loaded return ball valves?

  Yes

  No

2.1.3. Sample Points

• Check sampling from Aljac sample jar, is it illuminated, height, hydrometer and thermometer fittings?

  Yes

  No

2.2. SAFETY

2.2.1. Interlock

• a. Unstow equipment on interlock test point and check for interlock LED indicator flashing / individual LED flashing / amber light above panel flashing

• b. Push Interlock Override, check Red light above panel flashing

• Underwing coupling

• Bonding

• Bottom Loading (Left)

• Bottom Loading (Right)

• Handrail of Tank

• Seal interlock override button after test

  Off

  On

2.2.2. Emergency Fuel Stop

• While the fuel is running, press emergency fuel stop button, fuel must be stop flowing

  Yes

  No

2.3. ELECTRICAL

2.3.1. Battery Isolation Switch

• Check battery isolation switch is operational. This should isolate all the electrics, including engine

  Yes

  No

2.3.2. Area classification

• Vapour proof, double pole wiring, according NFPA70 code for the use of electrical apparatus in potentially explosive atmosphere

  Yes

  No

2.3.3. Explosion Proof Light

• Installed on meter, sample jar, control panel, deadman light, refuellinh activity, and LED panel meter

  Yes

  No

2.3.4. Bonding

• Vapour proof, double pole wiring, according NFPA70 code for the use of electrical apparatus in potentially explosive atmosphere

  Yes

  No

2.4. HYDRAULIC

• Check for operation all hydraulic lines, check of indication of leaking

  Yes

  No

2.5. FUELLING

2.5.1. Sampling

• Perform filter inlet and low point drains (2 liter jar) and note the results. Continue draining until clear

  Yes

  No

2.5.2. DP Gauge

• Note Filter Differential Pressure (DP) reading and check for full scale deflection

• Full scale deflection

  Off

  On

2.5.3. Engine Emergency Stop

• With the vehicle running activate the "Engine Emergency Stop" button. Engine should be stopped immediately

  Yes

  No

2.5.4. Hoses

• Check all hose for bulge, kinking or coupling slippage

• Manufacturer

• Date of manufacture

  Date

• Date fitted

  Date

• Hose type

• Hose size

• Test report

  Available

  N/A

• Coupling type

  Underwing Coupling

  Overwing Nozzle

3.1. PRESSURE AND PERFORMANCE TEST

• Engine (RPM)

• Flowrate (LPM)

• Pump Pressure (kPa)

• PCV/Venturi Monitor (kPa)

• Air Reference (kPa)

3.1.1 Performance Test

Max Specified Rate 100%

• Flowrate (LPM)

• Backpressure (kPa)

• Pump Pressure (kPa)

• PCV Monitor (kPa)

• Engine (RPM)

Max Specified Rate 50% (Backpressure applied)

• Flowrate (LPM)

• Backpressure (kPa)

• Pump Pressure (kPa)

• PCV Monitor (kPa)

• Engine (RPM)

Max Specified Rate 25% (Backpressure applied)

• Flowrate (LPM)

• Backpressure (kPa)

• Pump Pressure (kPa)

• PCV Monitor (kPa)

• Engine (RPM)

Zero Flow (dead head)

• Flowrate (LPM)

• Backpressure (kPa)

• Pump Pressure (kPa)

• PCV Monitor (kPa)

• Engine (RPM)

Surge Pressure (2 second closure)

• Flowrate (LPM)

• Backpressure (kPa)

• Pump Pressure (kPa)

• PCV Monitor (kPa)

• Engine (RPM)

Valve Leakage / Creep (@ 1 minute dead head)

• Flowrate (LPM)

• Backpressure (kPa)

• Pump Pressure (kPa)

• PCV Monitor (kPa)

• Engine (RPM)

3.2. DEADMAN CONTROL CHECK

• Max. Test Flowrate (LPM)

• Against Rig Pressure P.3 (Bar/Psi)

3.2.1. Deadman

• A. Opening - time from start of flow to maximum flow (minimum 5 second)

• B. Closing - time from initial flow reduction to zero flow (minimum 2 second)

• C. Overshoot - volume passed from deadman release to zero flow (lower of 5% of flowrate per minute or 200 liters / 53 usg max)

• Result under limit?

  Yes

  No

3.3. HEPCV TEST

3.3.1. Primary Surge/Pressure Control

• 1. Set refueller Pump Speed at maximum

• 2. Set Reference Pressure to 100 Psi (6.9 bar)

• 3. Read pressure on Test Rig Gauge P.3

• 4. Do surge control first

Front Reel

• 1. Peak pressure during 2 seconds closure from full flow - P.3 (Max 120 Psi/8.3 Bar)

• 2. Maximum pressure during reduction from full to very low flow over approximately 30 seconds - very low flow is 5% of normal max flowrate (Max 50 Psi/3.5 Bar)

• 3. Pressure when flow stops - zero flow (Max 60 Psi/4.15 Bar)

• 4. Pressure 30 seconds after flow stop (record value)

• 5. Pressure Creep (Max increase of 5 Psi/0.35 Bar)

Deck Hose (Left)

• 1. Peak pressure during 2 seconds closure from full flow - P.3 (Max 120 Psi/8.3 Bar)

• 2. Maximum pressure during reduction from full to very low flow over approximately 30 seconds - very low flow is 5% of normal max flowrate (Max 50 Psi/3.5 Bar)

• 3. Pressure when flow stops - zero flow (Max 60 Psi/4.15 Bar)

• 4. Pressure 30 seconds after flow stop (record value)

• 5. Pressure Creep (Max increase of 5 Psi/0.35 Bar)

Deck Hose (Right)

• 1. Peak pressure during 2 seconds closure from full flow - P.3 (Max 120 Psi/8.3 Bar)

• 2. Maximum pressure during reduction from full to very low flow over approximately 30 seconds - very low flow is 5% of normal max flowrate (Max 50 Psi/3.5 Bar)

• 3. Pressure when flow stops - zero flow (Max 60 Psi/4.15 Bar)

• 4. Pressure 30 seconds after flow stop (record value)

• 5. Pressure Creep (Max increase of 5 Psi/0.35 Bar)

3.3.2. Secondary Pressure Control

• Reset Air Reference to the normal operating setting, block HEPCVs Open and Measure Pressure on Test Tig Gauge P.3

• Maximum Test Flowrate Established (LPM)

SPCV

• 1. Highest pressure during reduction to zero flow (Max 55 Psi/3.8 Bar)

• 2. Pressure when flow stops/zero flow (Max 80 Psi/5.5 Bar)

• 3. Pressure 30 seconds after flow stops (record value)

• 4. Pressure Creep (Max increase of 5 Psi/0.35 Bar)

• 5. Refueller pump/Hydrant pressure - zero flow (Minimum 90 Psi/6.2 Bar)

• 6. Air Reference Pressure (record value)

3.4. ITEM CHECKS FOR LEAKS

3.4.1. Fuelling

3.4.2. Hydraulic

• PTO

• Pump

• Hand controllers - Module

• Oil Filter

• Reservoir

• Hose reel motors

• Product Pump Motor

3.5. DEFUELLING

• Check operation of defuelling and defuelling flowrate

  Yes

  No

Signature

• 1st Commissioner

  Sign

• 2nd Commissioner

  Sign

Other Remarks