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SPPBSO# VC-9152957 Page 1

Operation and Maintenance Manual

John ZinkDock Safety Unit

Customer: CITT

End User:SPB

Location:Cartagena, Colombia

Purchase Order No.:1102

John Zink Shop Order No.: VC-9152957

Model No.: DSU #1

CAUTION

PLANT OPERATING PERSONNEL SHOULD THOROUGHLY FAMILIARIZE THEMSELVES WITHTHE CONTENT OF THIS MANUAL, THE PHYSICAL INSTALLATION, AND EQUIPMENTPROVIDED BEFORE ATTEMPTING TO ENERGIZE AND OPERATE THE SYSTEM. IT IS

RECOMMENDED THAT AN AUTHORIZED JOHN ZINK COMPANY FIELD REPRESENTATIVE BERETAINED FOR INITIAL SYSTEM COMMISSIONING AND PLANT PERSONNEL TRAINING.

Requests for field service and spare parts can be made during our normal office hours from 8:00 a.m. to 4:30 p.m. (CST)

Monday through Friday. Please reference the John Zink Sales Order number when requesting service.

For assistance, please contact John Zink Company as follows:

Service (918) 234-2962 Emergency (918) 234-1800

Spare Parts (918) 234-2749 Facsimile (918) 234-1968

John Zink Company

11920 East Apache Street

Tulsa, Oklahoma 74116-1300

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CONFIDENTIALITY STATEMENT

INFORMATION CONTAINED IN THIS MANUAL IS CONSIDERED TO BE CONFIDENTIAL ANDPROPRIETARY PROPERTY OF THE JOHN ZINK COMPANY AND IS NOT TO BE DISCLOSED TO

OTHERS WITHOUT WRITTEN PERMISSION.

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I. GENERAL NOTICES ......................................................................................................................................................... 5

II. INTRODUCTION .............................................................................................................................................................. 7

III. SAFETY ............................................................................................................................................................................ 8

IV. INSTALLATION ............................................................................................................................................................ 10

V. DESIGN BASIS AND PERFORMANCE GUARANTEE ........... .......... ........... .......... ........... ........... .......... ........... ......... 12

VI. SYSTEM SUMMARY AND DESCRIPTION .......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ...... 13

VII. DSU SYSTEM OPERATION .......... .......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ........... ......... 15

Pre-Operation ..................................................................................................................................................................... 15

Testing and Calibration ...................................................................................................................................................... 16

System De-Pressure ............................................................................................................................................................ 18

Start-up ............................................................................................................................................................................... 19Normal Operation ............................................................................................................................................................... 19

Process Shutdown............................................................................................................................................................... 20

Normal Shutdown............................................................................................................................................................... 21

Emergency Shutdown ......................................................................................................................................................... 21

VIII. TROUBLESHOOTING ............................................................................................................................................... 23

Problem: Vapor High or High-High Oxygen Content ......... ........... .......... ........... ........... .......... ........... .......... ........... ......... 23

Problem: Vapor Low, Low-Low, High or High-High Pressure .......... ........... .......... ........... .......... ........... .......... ........... .... 23

Problem: Dock Detonation Arrester High Differential Pressure ........... .......... ........... ........... .......... ........... .......... ........... .. 24

Problem: Valve Sequence............ ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........ 24Problem: Dock Detonation Arrestor High Temperature............ .......... ........... .......... ........... .......... ........... .......... ........... .... 24

Problem: Vapor Backflow ......... ........... .......... ........... .......... ........... .......... ........... .......... ........... ........... .......... ........... ......... 24

Problem: Oxygen Analyzer Low-Low Flow ......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ........... .. 24

IX. SYSTEM TESTING ....................................................................................................................................................... 25

Dock Arrestor High Temperature (TSH-101) .................................................................................................................... 25

Valve Sequence .................................................................................................................................................................. 26

X. PREVENTATIVE MAINTENANCE .......... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... . 27

XI. SET POINTS AND CONFIGURATION SHEETS .......... ........... .......... ........... .......... ........... ........... .......... ........... ......... 28

XII. ELECTRICAL-MECHANICAL DRAWINGS .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .... 29

XIII. SPECIFICATION SHEETS .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... ........... .......... . 30

XIV. PLC LOGIC ................................................................................................................................................................. 31

XV. TECHNICAL SERVICE AGREEMENT ......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ........... .. 32

XVI. STANDARD TERMS AND CONDITIONS .......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ...... 33

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XVII. VENDOR LITERATURE ......... ........... .......... ........... .......... ........... .......... ........... ........... .......... ........... .......... ........... .. 34

XVIII. OPERATIONAL-MAINTENANCE NOTES .......... .......... ........... .......... ........... ........... .......... ........... .......... ........... .. 35

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I. GENERAL NOTICES

WARNINGInstructions provided in this Manual were prepared to serve as a

general guide. It is intended for use by qualified personnel withknowledge about Equipment of this type. It is not intended to

cover all possible variations in Equipment or to provide for

specific operating problems which may arise. If additional

information is required, please contact the Service Department

listed on page 2. Remember, STOP, THINK, AND ASK.

WARNINGEach person referring to this Manual is responsible for its proper

use in accordance with its terms and conditions, along with

adhering to all warnings or cautions provided in the Manual.

WARNINGIn addition to any general safety measures provided in this

Manual, each person must comply with all current national, state,

local, and company safety regulations at all times.

Any person using this Manual will accept, and agree to be bound by, the following terms and conditions.

NOTEThe following terms and conditions are subject to, and are

superseded by, any contract between the individual andCOMPANY regarding the sale of Equipment.

1. NO WARRANTIES: This Manual is provided on an "as is", "where is" basis without any warranty or guarantee

of any kind, whether express of implied, written or oral. COMPANY EXPRESSLY DISCLAIMS ALL EXPRESS

AND IMPLIED WARRANTIES REGARDING THE MANUAL, INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR USE.

2. INDEMNIFY AND HOLD HARMLESS: Individuals understand there are certain risks inherent in using the

Equipment, including, without limitation, bodily injury, death, and damage to personal property, including the

various risks described in the Manual under Caution, Warning, or Danger text. Individuals understand these risks

may result from a variety of circumstances including, but not limited to, the use or misuse of the Manual or the

Equipment. As a material consideration for the right to use this Manual, each person agrees to indemnify, assume

and hold COMPANY and its parent company, subsidiaries and affiliates, and each of their officers, directors,employees and agents (collectively the "Seller Parties"), harmless from any and all injuries, losses, damages, costs,

and expenses which may arise out of, or result from, the Manual or the Equipment, including, but not limited to,

risks of personal injury, death, and property loss or other damages.

3. LIMITATION OF LIABILITY: IN NO EVENT SHALL COMPANY NOR ITS AFFILIATES (INCLUDING

THEIR RESPECTIVE OFFICERS, DIRECTORS, EMPLOYEES AND AGENTS, COLLECTIVELY, THE

"COMPANY PARTIES") BE LIABLE OR OBLIGATED TO ANY PERSON OR ANY OTHER PARTY

IN ANY MANNER FOR ANY SPECIAL, NON-COMPENSATORY, CONSEQUENTIAL, INDIRECT,

INCIDENTAL, STATUTORY, OR PUNITIVE DAMAGES OF ANY KIND, INCLUDING WITHOUT

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LIMITATION, LOST PROFITS AND LOST REVENUE, REGARDLESS OF THE FORM OF ACTION,

WHETHER IN CONTRACT, TORT, NEGLIGENCE, STRICT PRODUCT LIABILITY, OR OTHERWISE,

EVEN IF THE COMPANY PARTIES WERE INFORMED OF OR ARE AWARE OF THE POSSIBILITY OF

ANY SUCH DAMAGES IN ADVANCE. EACH INDIVIDUAL ACKNOWLEDGES AND AGREES THE

FOREGOING ALLOCATION OF RISK WAS ACKNOWLEDGED, AGREED, AND FOUND REASONABLE,

AND THAT THE FOREGOING LIMITATIONS ARE AN ESSENTIAL BASIS OF THEIR RIGHT TO USE

THIS MANUAL.

4. GENERALLY: The foregoing provisions may not be waived or amended unless in writing signed by an officer of

COMPANY. These Terms shall be governed by the laws of the State of Kansas, without regard to its conflicts of

law rules.

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II. INTRODUCTION

The John Zink Dock Safety Unit (DSU) is a fully automatic system that is designed to incinerate amixture of hydrocarbon vapors and air and operate remotely in either an automatic or manual mode.The system starts and stops in response to external electrical control signals received by the controllogic system.

The combustion system is controlled by a programmable logic controller (PLC) which has an internalpre-designed operating logic sequence. The PLC receives and transmits control signals in responseto operating pressures and temperatures. In the event that a component fails or if the processconditions vary beyond the prescribed operating parameters, the control system will respond bystopping the flow of hydrocarbon vapor and shutting down the combustion system in a safe andsequenced order.

As part of the safety system design to prevent a flame flashback from the burner assembly, i.e., anti-flashback burners and detonation arrestors have been provided. Each item is designed to stop thepropagation of a flashback to the source of the hydrocarbon vapor flow.

In addition to the anti-flashback equipment, various pressure switches, temperature switches, andthermocouples are also used to monitor and protect personnel and equipment from a mis-operation orsystem malfunction. The vapor combustor system consists of the following equipment and safetydevices:

1. Dock Skid with:

a. Oxygen Analyzersb. Detonation Arrestorsc. Control Panelsd. Vapor Piping, Instruments, and Valvese. Enrichment Gas Piping and Instruments

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III. SAFETY

WARNING

All operating and maintenance personnel must read and become familiar with this operating

instruction manual. Operation of the dock safety unit must be strictly in accordance with JohnZink Company operating and maintenance instructions. IMPROPER OPERATION OF THE

EQUIPMENT CAN RESULT IN EQUIPMENT DAMAGE AND/OR INJURY OR POSSIBLE LOSS OFLIFE TO OPERATING PERSONNEL.

This documentation does not replace any existing company safety operating procedures and/orinstructions. All normal safety precautions should be followed when operating vapor combustor andfuel systems. Consult your plant operations and safety authorities for complete details.

CAUTION

FIRE AND EXPLOSION HAZARDS

1. Smoking, welding or open flames should be prohibited around the unit as long as itcontains hydrocarbon vapors. Leaks should be repaired as soon as possible to preventaccumulation of spilled combustibles. Spillage should be cleaned up promptly.

2. The marine loading system vapor pipingcontains hydrocarbon vapor that released inair may become explosive. Extreme caution must be exercised when opening thesystem for inspection and service. Smoking, welding, or open flame must be prohibitedwhenever the system is opened to the atmosphere.

ELECTRICAL HAZARDS

1. Potentially dangerous voltages exist in control cabinets and electrically actuated controlcomponents. These components should only be serviced when system power is removedand only be qualified electrical/instrument servicemen.

2. High voltage (120 VAC)capable of causing severe injuryor deathis used on thisequipment.

3. Insure all skids and flare stack are properly grounded.

MECHANICAL EQUIPMENT

1. This vapor combustion system contains pneumatically operated control components,(control valves, block valves). Never operate this equipment unless guides, shields, orcovers are in place.

2. Keep hands, loose articles of clothing, and jewelry away from operating rotatingmachinery. Since the system starts up automatically, power should be disconnectedprior to performing maintenance on the equipment.

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SAFETY EQUIPMENT

*1. Approved safety shoes.*2. Safety goggles or glasses.

*3. Fire retardant coveralls.*4. Ear plugs.*5. Hard hat.

*Verify requirements with Safety Management personnel.

REPROGRAMMING WARNING

The Programmable Logic Controller (PLC) is the computer controlling the Dock Safety Unit (DSU).The PLC is programmed by John Zink Company to ensure proper DSU operation. Accidental orunauthorized reprogramming of the PLC may result in unsafe or dangerous operation of the MVCS.

John Zink Company is not responsible for any damages or expenses incurred as a result ofunauthorized reprogramming of the PLC. Unauthorized reprogramming could be hazardous topersonnel, damage the equipment, and/or void the system equipment warranty.

PRESSURIZED GAS

Gas under pressure can be dangerous. The following guidelines for working around pressurizedequipment must be followed:

1. Never expose piping, vessels, or equipment to pressures higher than their designpressure. Excessive pressure can result in vessels or lines leaking, bursting, or rupturing,or in other types of dangerous pressure release. Be aware of the design pressures of the

equipment you are working with and the gas pressure present.

2. Keep gas connections tight. Leaking gas containing hydrocarbon vapors presents thedanger of fire or explosion. A flanged or threaded connection just tight enough to hold avacuum or a few pounds pressure may leak at higher pressure. Always use anappropriate thread sealant on threaded connections, and make sure gaskets are in goodcondition and properly positioned to provide full surface contact.

3. Always be sure the pressure is relieved before opening any piping or vessel connections.

4. Do not vent gas pressure by loosening a component connection. Use vent and drainvalves provided for this purpose. Even at low pressure, the pressure on components can

be great enough to pose a hazard.

5. Protect your hearing. Pressurized gas being vented may produce a very loud, highfrequency sound which may not be uncomfortable but can cause damage. When workingaround such a vent, use ear plugs or other suitable hearing protection.

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IV. INSTALLATION

INSTALLATION

Installation of the Dock Safety Unit (DSU) is the responsibility of the customer. Prior to installation,this manual and all related documentation for this project should be reviewed. Any questions aboutthe installation or the equipment should be addressed to the John Zink Vapor Control ServiceDepartment referenced on the first page of this manual. Also if alignment or fit-up problems areencountered during the assembly procedure, John Zink Company, Vapor Control Department, mustbe contacted prior to making any changes or alterations to the equipment.

Note: It is John Zink Company's policy to require verbal and writtennotification of equipment problems. John Zink will review thesituation and determine the course of action necessary to resolve anyand all field problems. Should the customer or contractor makechanges or alterations to the DSU system without prior approval by JohnZink Company, any and all claims for field service repair charges will bedeclined and returned to the individual companies. Review John ZinkCompany's Warranty and standard Terms of Sale.

Personnel performing the installation work must review all drawings provided by John Zink Companyin order to properly reassemble the vapor combustion system. Drawings to be reviewed for thisinstallation are:

Drawing Number Description

D-VC-9152957-150 Piping and Instrument DiagramD-VC-9152957-201 Nozzle Legend and General NotesD-VC-9152957-202 (1-4) General Arrangement Dock Safety SkidD-VC-9152957-401 - 407 Schematic Wiring Diagrams DSUD-VC-9152957-440 Test Panel Layout

If the system is going to be stored outside for more than ten days in wet weather conditions, powershould be applied to the main control panel and the heater turned on to protect delicate controlinstruments and help prevent corrosion inside the panel. John Zink personnel should inspect allcontrol enclosures prior to start-up for systems stored more than 90 days. Failure to properly protectthe control panel from moisture and corrosion could invalidate all manufacturer and John Zinkwarranties on electrical components inside the main control panel.

The following must be performed to install the Dock Safety Unit (DSU).

1. Carefully remove the skid from the transport truck using provided lifting lugs. Only qualifiedequipment operators should supervise, remove, and install the combustion equipment..

2. Set the skid on properly designed platforms and foundations. Level and grout with non-shrinking grout.

3. Install the following ship loose components:

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DSU SKID

a. Install pressure/vacuum safety vent, PSV-101, to inlet to DSU skid piping. Install allpressure and vacuum weights provided. Bundles are tagged pressure and vacuumand should be installed on their corresponding side of the vent valve.

b. Install dock skid warning lights (AL-2) and alarm light (AL-1) within sight of dock

operator and run control wire into control panel CE-1.c. Install oxygen analyzer probe in main vapor piping downstream of enrichment mixer.

The probe needs to be between 10 and 30 pipe diameters from the injection mixer,MX-1. Install 1/2 stainless steel tubing from probe to oxygen analyzer sampleconnection.

d. Install rain-shield on Oxygen Analyzer panel.e. Install rain-shield on panel rack.

4. Customer conduit and electrical wiring hookups. Note that this list is only a summary. SeeDrawings B-VC-9152957-401 through 407 for details. Note that dashed lines indicatecustomer supplied wire.

a. 120 VAC to overfill panel, VOC-101,b. 120 VAC to alarm light, AL-1, and shutdown light, AL-2.c. 120 VAC to control panel CE-1.d. Run communication cable between all control cabinets in a dedicated communication

conduit.

Note: See electrical drawings for the type of wire to be used. Final selection of wiresizes and types is the responsibility of the customer in order to comply with thelocal and NEC codes.

5. Confirm that all pipe fittings and flanges, electrical wiring connections and electrical conduit

fittings are tight.

Note: Do Not Pour electrical seals until the vapor combustion system has beenchecked, started and placed in service by a John Zink field service engineer.

6. Confirm that external electrical control and power wiring is correctly sized and the systemhas correct overload protection.

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V. DESIGN BASIS AND PERFORMANCE GUARANTEE

DESIGN BASIS

Number of Docks ................................................ Two (1 current / 1 future)Number of Loading Berths .................................................... One per dockVessels Loaded ................................................................................ ShipsVessels Atmospheres ..................................................................... InertedOxygen Content of Inerted Vessels .......................................Less than 5%Number of Docks Loaded Simultaneously ................................................ 2Inerted and Non-Inerted Atmospheres Loaded Simultaneously ............. NoMaximum Loading Rate .......................................................... 5,500 m3/hrChemicals ................................................................................... Crude OilProduct True Vapor Pressure(1)..................................... 3.4 psia maximumArea Electrical Classification

DSUs .................................................... Class I, Division 2, Group C, DMotor Type .................................................................................. TEFCEnclosure Type .................................................................... NEMA 4X

Detonation Arrestor Classification ................................................. Group D

Elevation .......................................................................................... 50 ftAmbient Temperature ................................................................... 15-40CElectrical Power ........................................................... 120 V, 1 Ph, 60 HzNitrogen ..........................................................................................80 psigVapor Piping..ANSI B31.3Valves and Flanges..ANSI B16.5

%

%

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VI. SYSTEM SUMMARY AND DESCRIPTION

SYSTEM SUMMARY

This Dock Safety Unit (DSU) is designed to capture hydrocarbon vapors generated and displacedfrom liquid hydrocarbons loading of cargo ships. The maximum loading rate is 5,500 m3/hr. Thevapors are drawn into the DSU safety spool through a loading hose from the vessel's cargo tank.Detonation arresters protect against a fire or explosion in the vapor line spreading to other parts of thesystem or to the ship.

SYSTEM DESCRIPTION

1. Equipment Control Panels

Control panels associated with major equipment systems are located throughout the DSU.They contain indicator lights and switches associated with individual panel status.

2. Programmable Logic Controller (PLC)

An Allen Bradley industrial computer controls the automated processes of the DSU.

3. Safety Spool/Dock Saftey Unit (See drawing D-VC-9152957-150)

A safety spool assembly is located on a skid at the barge loading site. The safety spoolhelps protect the barge and loading facility from flashbacks originating from either side ofthe safety spool. A loading arm is used to connect the dock safety spool to the vesselbeing loaded.

a. Pressure/Vacuum Relief Valve with Flame Screen (PSV-101)

The pressure/vacuum relief valve provides protection from both excessive vacuum andexcessive pressure to protect against damage to the barge in the event of a controlmalfunction. If pressure is low, one valve opens to allow air to be drawn in and reducethe vacuum. If pressure is excessive, the other valve opens to release vapor to theatmosphere and so lower the line pressure. A flame screen in the vacuum relief valveprotects against flame being drawn in.

b. Intake Vapor Pressure Transmitters (PIT-101,PIT-102)

These transmitters trigger high and low pressure alarms for operator attention, andhigh-high and low-low alarms with a shutdown.

c. Detonation Arrester (DA-101)

This Coast Guard-accepted device restricts flashback by reducing the flametemperature below the ignition point of the vapor. A detonation is halted by slowing thepropagation of the flame-front to subsonic velocity. Both functions are accomplishedby routing the vapors through a fine honeycomb of vapor channels which serve toabsorb heat and decrease vapor pressure/velocity.

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d. Differential Pressure Switch (PDSH-101)

A differential pressure transmitter measures the line pressure difference between thesystem strainer and the detonation arrester. It triggers a shutdown when a backflow ofvapors toward the barge causes a specific pressure difference. It also triggers analarm if it senses excessive forward pressure drop indicating a dirty filter element.

e. Temperature Switch (TSH-101)

A thermocouple placed at the outlet of the safety spool detonation arrester monitorsDA-101 Temperature and TSH-101 triggers a shutdown if a high temperature isdetected.

f. Oxygen Analyzer (ASH-101, ASHH-101)

To avoid having an explosive mixture of vapors in the system, the oxygen content ofthe vapor is continuously analyzed during loading operations. To ensure that theinerted vapors stay outside the explosive range, the oxygen content of the enriched

vapor is measured by two oxygen analyzers to ensure that the concentration of oxygenremains below 7% for all cargoes. An alarm is triggered if the oxygen concentration isabove 8%. A shutdown will be triggered if analyzer flow is blocked or the oxygenconcentration reaches 9%.

The Oxygen Analyzer sampling point is located at a point far enough downstream ofthe enrichment gas injection site to allow adequate mixing of the gases prior tosampling.

The Oxygen Analyzer has a 2-hour warm-up period during which its readings may beinvalid. Therefore, it must be turned on at least 2 hour before pre-transfer calibration isto be done.

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VII. DSU SYSTEM OPERATION

The operation of the Dock Safety Unit consists of the following stages:

Pre-operationTesting and CalibrationVessel De-PressureStart-upNormal OperationProcess ShutdownNormal ShutdownEmergency Shutdown

The pre-operation stage ensures the system is ready and safe to start up. The testing and calibrationstage consists of tests and calibrations of the system. The start-up stage starts the system and bringsit to the ready-to-load status. The normal operation stage starts and stops the loading of the marinevessel. The process shutdown stage is a partial, intermediate shutdown that allows faster restarts.The normal shutdown stage is a controlled, complete shutdown. The emergency shutdown stage isan immediate, complete shutdown that occurs when unsafe conditions are detected. These stagesare described in detail in the following pages. The instructions do not, however, include the additionalsteps necessary during the initial system start-up and operation when personnel from John ZinkCompany are required.

The control of this system is highly integrated with the customers control system. The operatingdescription and instructions in this manual describe the integrated control as we understand it. Theyshould be reviewed to ensure their accuracy and should be used to develop overall operatinginstructions for the complete system.

Pre-Operation

The Pre-operation stage ensures the system is ready and safe to start up. The following instructionsassume the system is in a Normal Shutdown status. The steps to be performed are:

1. Confirm that the following switches are in the position shown:

System Power (CE-1) OFFDock Mode (CE-1) OFFCustomer-supplied power disconnects OFF

2. Confirm that the following valves are in the positions shown:

Analyzer valves OpenPressure gauge valves OpenPressure transmitter valves OpenVapor shutdown valves Closed

3. Turn on the customer-supplied power disconnect to CE-1.

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4. Turn the system Power switch on control panel CE-1 to the ON position and confirm thatthe system power on light is illuminated.

5. Press the Lamp Test button on control panel CE-1 and confirm that all lights areilluminated.

6. Press the System Reset button at the dock to confirm that all faults are clear. If a fault ispresent it must be corrected before proceeding.

7. Inspect loading hose between loading vessel and dock for possible problems.

8. Insure hand valve HV-101 located on the dock skid is closed.

Testing and Calibration

The Testing and Calibration stage consists of the testing and calibration that the USCG requires to beperformed within 24 hours prior to the start of loading. Reference: 33 CFR 154.2150 (c). The

following faults must be tested on the DSU chosen for loading purposes.

Vapor Low Pressure (PSL-101)Vapor High Pressure (PSH-101)Vapor Low-Low Pressure (PSLL-102)Vapor High-High Pressure (PSHH-102)Vapor Backflow (PDAL-101)Dock Filter High Differential Pressure (PDAH-101)Vapor High Oxygen Content (ASH-101/102)Vapor High-High Oxygen Content (ASHH-101/102)Oxygen Analyzer Low Sample Flow (FSLL-101)

Additional routine testing of the system is also required and is described in Section VIII, SystemTesting. The following instructions assume the Pre-operation stage has been completed. The stepsto be performed are:

1. Confirm that the switches system Power (CE-1) is in the ON position.

2. Press the Combustor Start button on CE-1.The green Combustor Started light will beginto flash. Once the customer combustor is ready to accept vapors the light will turn a solidgreen.

3. Turn the Dock Mode switch to the TEST position. Isolate PIT-101, PIT-102, and PDIT-101 from the process line and open the instruments to the test manifold using the ball

valves located at each instrument.

4. Test the Vapor Low Pressure (PSL-101)fault as follows:

a. Using the test manifold located on the dock skid, pull a vacuum on PIT-101.b. Slowly decrease the pressure until the alarm is activated.c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and the

appropriate control panel light is illuminated.

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d. Confirm that the fault activated at the proper pressure determined for each loadingoperation.

e. Relieve the vacuum on the line to clear the fault.

5. Test the Vapor High Pressure (PSH-101)fault as follows:

a. Using the test manifold located on the dock skid apply pressure to PIT-101.b. Slowly increase the pressure until the alarm is activated.c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and the

appropriate control panel light is illuminated.d. Confirm that the fault activated at the proper pressure determined for each loading

operation.e. Relieve the pressure on the line to clear the fault.

6. Test the Vapor Low-Low Pressure (PSLL-102)fault as follows:

a. Using the test manifold located on the dock skid pull a vacuum on PIT-102.b. Slowly decrease the pressure until the alarm is activated.

c. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriatecontrol panel light is illuminated.



7. Test the Vapor High-High Pressure (PSHH-102)fault as follows:

a. Using the test manifold located on the dock skid apply pressure to PIT-102.b. Slowly increase the pressure until the alarm is activated.c. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate

control panel light is illuminated.d. Confirm that the fault activated at the proper pressure determined for each loading

operation.e. Relieve the pressure on the line to clear the fault.

8. Test the Vapor Backflow (PDAL-101)fault as follows:

a. Using the test manifold located on the dock skid apply vacuum on the high side ofPDIT-101.

b. Slowly increase the vacuum until the alarm is activated.c. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate

control panel light is illuminated.



9. Test the Dock Filter High Differential Pressure (PDAH-101)fault as follows:

a. Using the test manifold located on the dock skid apply pressure on high side of PDIT-101.

b. Slowly increase the pressure until the alarm is activated.

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c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and theappropriate control panel light is illuminated.


e. Relieve the pressure on the line to clear the fault.

10. Calibrate Oxygen Analyzer

a. Use vendor supplied procedure in Section XVI

11. Test the Oxygen Analyzer Low Sample Flow (FSLL-101)fault as follows:

a. Reduce sample flow using adjustable flow meter inside the analyzer cabinet.b. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate

control panel light is illuminated.c. Place sample flow back to original position.

12. Test the Vapor High Oxygen Content (ASH-101/102)as follows:

a. Gradually open needle valve located on the side of the oxygen analyzer to allowambient air into the sample stream.

b. Increase the amount of air into the sample until the alarm is activated.c. Confirm that the alarm (amber) strobe light flashes, the horn sounds, and the

appropriate control panel light is illuminated.d. Close needle valve.

13. Test the Vapor High-High Oxygen Content (ASHH-101/102) as follows:

a. Gradually open located on the side of the oxygen analyzer to allow ambient air into thesample stream.

b. Increase the amount of air into the sample until the alarm is activated.c. Confirm that the alarm (red) strobe light flashes, the horn sounds, and the appropriate

control panel light is illuminated.d. Close needle valve.

System De-Pressure

Before loading begins, the vessel being filled should be de-pressured close to atmospheric pressure.This is accomplished as follows:

1. Install the vapor hose to the loading vessel. Insure that the vessel block valve is not open

at this time.

2. If the customer combustor is not already running press the Combustor Start button onCE-1. The green Combustor Started light will begin to flash. Once the customercombustor is ready to accept vapors the light will turn a solid green.

3. Turn the Dock Mode switch to TEST.

4. The PLC will ignore the DSU High Pressure Shutdown during the De-Pressure Mode.

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5. Press the Vessel Depressure button and the Depressure Enable light will begin to flash.

6. The customer vapor blowers should go to a fixed minimal output.

7. Vessel operator can begin to slowly open the vessel vapor header block valve to bleed

pressure into the line. If this step is done too quickly the pressure may be high enough tolift the pressure relief valve.

8. The pressure control valve, PCV-101, will open to a set output of approximately 15%.

9. The PCV-101 PID loop will be active but not affect the PCV valve position until the PIDloop demand exceeds 15%.

10. As the pressure inside the vessel begin to drop the vessel operator can begin to open theblock valve more. This step is repeated until the valve is full open.

11. The DSU will de-pressure the vessel until the pressure drops to 2 WC.

12. At this point, the De-Pressure Enable light will go solid, the PCV-101 valve will go closedand the customer vapor blower should stop.

13. DSU Dock Mode switch can be moved to the RUN position and loading can commence.

Note: During Depressure operation, after the pressure has dropped below the high-high pressure shutdown set point, the DSU mode switch can be moved to the RUNmode de-activating the depressure mode and allowing loading to commence.

Start-up

The start-up stage starts the system and consists of stack purge, pilot ignition, and ready-to-load. Thefollowing instructions assume the testing and calibration stage has been completed. The steps to beperformed are:

1. Go to DSU control panel.

2. Turn the Dock Mode switch to the RUN position.

3. Press the Combustor Start push-button. The green Combustor Started light will stopflashing and turn solid once the customer combustor is ready to accept vapors, indicatingloading can start.

Normal Operation

The Normal Operation stage starts and stops the loading of the marine vessel. The followinginstructions assume the Start-up stage has been completed. The steps to be performed are:

1. Ensure the Combustor Started light is illuminated.

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2. Confirm manual vapor valve HV-101 is open.

3. Press the Dock Start push-button located on the DSU panel CE-1.

a. The customer liquid valve opens.

b. Customer vapor blowers can begin operation.c. Pressure control of the DSU system is accomplished by pressure valve PCV-101

working in tandem with PIT-101. The transmitter PIT-101 monitors the operatingpressure and passes the pressure on to PIC-101, which increases or decreases theposition of the valve.

4. Operators should monitor the following items:

a. Pressures, temperatures and levels.b. Performance of the pressure, temperature and oxygen content controller loops.

5. To stop loading, press the Dock Stop push-button located on the DSU panel CE-1.

a. Customer liquid valve closes.b. The vapor shutdown valve at the dock PCV-101 will close.c. Customer vapor blowers should stop.d. The Combustor Started light will stay illuminated.

Several alarms may occur during normal operation that will not shut down the system. The cause ofany alarm should be immediately investigated and corrected if necessary. The following will alarmonly:

Vapor High Oxygen Content (ASH-101)Vapor Low Pressure (PSL-101)

Vapor High Pressure (PSH-101)Filter High Differential Pressure (PDAH-101)

Note: The control panel lights are programmed with a first out feature. The light forthe fault causing the alarm or shutdown will be flashed. The lights for any faultsthat may result from the first one will be illuminated steadily.

Process Shutdown

The process shutdown stage is a partial, intermediate shutdown that allows faster restarts. When a

process shutdown fault occurs, the dock skid will stop and customer vapor blower should shut downwhile the combustor continues to operate. The following faults will cause a process shutdown:

Vapor Low-Low Pressure (PSLL-102)Vapor High-High Pressure (PSHH-102)Vapor High-High Oxygen Content (ASHH-101)Oxygen Analyzer Low Flow (FALL-101)Dock Detonation Arrester Backflow (PDAL-101)Vapor Valve Position Failure

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1. When a process shutdown occurs, the following will occur.

a. The shutdown (red) strobe light will flash and the horn will sound.b. The light for the fault causing the shutdown will be flashed.c. The lights for any faults resulting from the first one will be illuminated steadily.d. Customer vapor blowers should stop.e. Vapor shutdown valve PCV-101 will close.f. The customer liquid valve will close.

2. After a process shutdown occurs, the steps to be performed are:

a. Correct the fault causing the shutdown. See section VII, Troubleshooting.b. Press the System Reset button located on the DSU panel, CE-1 and confirm that the

alarm clears.c. Press the Dock Start button on the DSU panel CE-1.d. The liquid loading valve will open.e. Vapor shutdown valve PCV-101 will open and the customer vapor blower should start

the loading process again.

Normal Shutdown

The normal shutdown stage is a controlled, complete shutdown that can be initiated at any time duringthe start-up, normal operation or process shutdown stages.

1. A normal shutdown is initiated by:

a. Pushing the Dock Stop button on the DSU panel CE-1.b. Pushing the Combustor Stop button on the DSU panel CE-1.

2. When a Normal Shutdown is initiated, the following will occur.

a. The control panel lights for any faults resulting from the shutdown will be illuminated.b. The customer liquid loading valve will close.c. The DSU vapor shutdown valve PCV-101 will close.d. Customer vapor blowers should stop.e. The Dock Started light will be extinguished.

f. The Combustor Started light will be extinguished.

Emergency Shutdown

The emergency shutdown stage is an immediate, complete shutdown that occurs when unsafeconditions are detected.

An emergency shutdown can be initiated by pushing the Emergency Stop button located on CE-1.

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1. The following faults will cause an Emergency Shutdown:

a. Dock Arrestor High Temperature (TSH-101)b. Combustor Global Shutdownc. Vapor Arrestor Backflow (PDAL-101)

d. Valve Position Failure


2. When an emergency shutdown occurs, the following will occur.

a. The shutdown (red) strobe light will flash and the horn will sound.b. The light for the fault causing the shutdown will flash.c. The customer liquid loading valve will close.d. The DSU vapor shutdown valve PCV-101 will close.

e. Customer vapor blowers should stop.f. The Dock Started light will be extinguished.g. The customer combustor should shutdown.h. The Combustor Started light will be extinguished.

3. After an emergency shutdown occurs, the steps to be performed are:

a. Investigate and correct the fault. See section VII, Troubleshooting.b. Press the Fault Reset button and confirm that all alarms are clear.c. Restart the system as described in the start-up section.

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VIII. TROUBLESHOOTING

WARNING

This equipment has 480 VAC and 120 VAC electricity that can shock or kill

personnel. Extreme caution must be used when servicing this equipment.

This equipment contains vapors within the explosive mixture range.Extreme caution must be used when servicing this equipment.

Preventative maintenance and repairs should only be performed by qualified servicepersonnel who are familiar with all safety and operations procedures. Read Section II,

Cautions and Warnings before proceeding with any maintenance operations.

This troubleshooting section is only intended to be a guide in solving equipment faults. It listspotential problems with possible causes and solutions, and is not a detailed list of all possibleproblems. Reference should be made to the vendor literature section of the operating manual to

troubleshoot problems with specific component items of this system. It is recommended that onlyqualified service personnel should perform repairs. Contact the John Zink Company at 1-800-755-7252 if a system fault cannot be corrected. The following items are discussed in this section.

1. Vapor High or High-High Oxygen Content.2. Vapor Low, Low-Low, High or High-High Pressure.3. Dock Detonation Arrester High Differential Pressure.4. Valve Sequence.5. Dock Detonation Arrester High Temperature.6. Vapor Backflow.7. Oxygen Analyzer Low-Low Flow.

Problem: Vapor High or High-High Oxygen Content

Potential Causes:

a. Oxygen analyzer not working properly.b. Enrichment gas valve is closed.c. Strainer is plugged.d. Regulator is set too low.

Problem: Vapor Low, Low-Low, High or High-High Pressure

Potential Causes:

a. Strainer is plugged.b. Arrestor is plugged.c. Vapor blower is not operating properly.

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Problem: Dock Detonation Arrester High Differential Pressure

Potential Causes:

a. Arrestor is plugged.b. Strainer is plugged.

Problem: Valve Sequence

Potential Causes:

a. Automatic shutdown valve has failed.b. Automatic shutdown valve limit switch has failed.

Problem: Dock Detonation Arrestor High Temperature

Potential Causes:

a. High temperature at the arrestor.b. Temperature switch set point is incorrect.

Warning: If a high detonation arrestor temperature occurs, the equipment shouldnot be operated until the reason for the fault condition is found and remedied. JohnZink personnel should be contacted immediately.

Problem: Vapor Backflow

Potential Causes:

a. Enrichment valve has failed open.

Problem: Oxygen Analyzer Low-Low Flow

Potential Causes:

a. Bad sample pump.b. Sample lines closed.c. Sample lines plugged.d. Flow meters out of adjustment.

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IX. SYSTEM TESTING

WARNING

This equipment has 120 VAC electricity that can shock or kill


This equipment contains hydrocarbon vapors within the explosive mixturerange. Extreme caution must be used when servicing this equipment.



Periodic testing of the safety alarms and shutdowns is of the utmost importance to insure properoperation and safety protection for personnel and equipment. This testing is in addition to theUSCG required testing described in Section V. A formal testing schedule that incorporates both

calendar and usage requirements should be implemented. Testing every three months or twelveloadings, whichever occurs first, is one recommended schedule. Instructions for testing thefollowing items are provided in this section.

1. Dock Arrestor High Temperature (TSH-101)2. Valve Sequence

Note: System testing will require that certain control instruments be removed from thevessels and combustor to verify correct calibration set points and operation.Controls shall be reinstalled and a complete system check should be performed toverify the proper operation of the control wiring. When performing a completesystem check, do notsimulate operation by installing jumper wires.

Dock Arrestor High Temperature (TSH-101)

a. Remove cap from thermocouple TE-101.b. Turn the System Power switch off.c. Replace thermocouple TE-101 with a thermocouple simulator.d. Turn the System Power switch on.e. Press the Reset button and confirm that all fault lights are extinguished.f. Increase the thermocouple simulator until the temperature switch activates.

g. Confirm the switch de-activates at 200F.h. Confirm the correct fault light illuminates.i. Decrease the thermocouple simulator.

j. Confirm the switch de-activates at 200F.k. Press the Reset Button.l. Confirm that the fault light clears.m. Reinstall the thermocouple TE-101

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Valve Sequence

a. Turn the System Power switch on.b. Press the Reset button and confirm all that fault lights are extinguished.c. Manually open automatic shutdown valve PCV-101.d. Confirm that the correct fault light illuminates.

e. Manually close the valve that was opened.f. Press the Reset button.g. Confirm that the fault light clears.

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X. PREVENTATIVE MAINTENANCE

WARNING

This equipment has 120 VAC electricity that can shock or kill


This equipment contains vapors within the explosive mixture range.Extreme caution must be used when servicing this equipment.



1. The detonation arrestors should be checked once every six months to verify that theyare free from foreign matter, which could restrict hydrocarbon vapor flow.

2. All safety shutdown devices should be tested for correct operation and verified a

minimum of once every three months.3. Review Section VIII, System Testing, to assist in preventative maintenance.4. Check calibration and operation of all instruments in accordance with vendor literature

in Section XVIII.5. Refer to vendor literature for specific maintenance requirements of various

components.6. Thermocouples should be checked for accuracy once every year.

Note: The above preventative maintenance summary is only designed as a guidelineanddoes not include all areas that must be checked. A preventative maintenance programmust be designed, based upon existing company policy, operational experience,vendor data requirements, maintaining an adequate supply of spare partsand an

operation-maintenance log book. John Zink has many field technicians across theworld that can provide Preventative Maintenance assistance with documented checksand corrections. For a detailed PM quote please contact 918-234-5718.

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XI. SET POINTS AND CONFIGURATION SHEETS

The following set points are for start-up purposes and may require adjusting during start-up to matchspecific operating conditions.

Vapor Low Pressure (PSL-101) (*)Vapor High Pressure (PSH-101) (*)Vapor Low-Low Pressure (PSLL-102) -10 w.c.Vapor High-High Pressure (PSHH-102) 20 w.c.Vapor High Oxygen Content (ASH-101) 8% O2Vapor High-High Oxygen Content (ASHH-101) 9% O2

Dock Arrestor High Temperature (TSH-101) 200FNitrogen Purge Gas Pressure 30-40 psigVapor Backflow (PDAL-101, PDAL-301) -1 w.c.Filter Blockage (PDAH-101) 10 w.c.

* These values are dependent on the vessel to be loaded. Refer to 33 CFR 154.814.

TABLE 1: OXYGEN ANALYZER SET POINTS NON-INERT

TYPE OF CARGO O2CONTROL % O2ALARM % (ASH) O2SHUTDOWN % (ASHH)

N/A N/A N/A N/A

TABLE 2: OXYGEN ANALYZER SET POINTS INERT

TYPE OF CARGO O2CONTROL % O2ALARM % (ASH) O2SHUTDOWN % (ASHH)

Crude Oil 7.0% 8.0% 9.0%

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XII. ELECTRICAL-MECHANICAL DRAWINGS

Drawing Number Description

D-VC-9152957-150 Piping and Instrument DiagramD-VC-9152957-201 Nozzle Legend and General NotesD-VC-9152957-202 (1-4) General Arrangement Dock Safety SkidD-VC-9152957-401 - 407 Schematic Wiring Diagrams DSUD-VC-9152957-440 Test Panel Layout

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XIII. SPECIFICATION SHEETS

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XIV. PLC LOGIC

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XV. TECHNICAL SERVICE AGREEMENT

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XVI. STANDARD TERMS AND CONDITIONS

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XVII. VENDOR LITERATURE

Tab Manufacturer1 Air / Gas Filter (Filter)2 Asco (Solenoid Valve)3 Bettis / PMV (Actuator / Positioner)4 Enardo (Arrestor, Pressure / Vacuum Relief Valve)5 Fisher (Regulator, Flow Control Valve)6 Flowseal (Butterfly Valve)7 McDaniel (Pressure Gauge)8 Mueller (Strainer)9 Neo-Dyn (Pressure Switch)10 Servomex (Oxygen Analyzer)11 Thermo-Sensor (Thermocouple)12 Yokogawa (Pressure Transmitter)

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XVIII. OPERATIONAL-MAINTENANCE NOTES

Documents

1. DSU O&M (SPPB)