Transcript Slide 1

FUEL SYSTEM SERVICES
SEMPER PROGRAM LLC
A “Service Disabled Veteran Owned Small Business”
www.semper1.com
This document contains information which may be confidential or privileged. The
information is intended to be only for the use of the individual presented with this document
by Semper Group LLC. Any disclosure, copying, distribution or use of the contents of this
information is prohibited.
S.E.M.P.E.R. PROGRAM
INTRODUCTION
SEMPER stands for Service Extended Maintenance Program and Equipment
Repair and serves military and privatized operations at petroleum storage and
distribution systems worldwide. SEMPER significantly increases the life-span of
existing fuel systems and components.
SEMPER provides on-demand readiness on both a national and international
scale. The dual-use training of our technicians on technologies of military and
commercial equipment is integrated throughout SEMPER. Not only does SEMPER
provide experienced repair services on existing fuel equipment, SEMPER
technicians can provide refreshment training and calibration services as well. With
newly privatized POL / LFM programs becoming more of a norm, repair and
training is becoming crucial to operational readiness.
SEMPER opens options for Military Joint Services capability over all ground,
aviation, and marine facilities or bases. System longevity is increased when all
equipment is calibrated, tuned, and running in peak operational condition.
“Service Disabled Veteran Owned Small Business”
DISCIPLINES AND LOGISTICS
Since SEMPER was derived from four unique specialties from the fuels
infrastructure industry, we have the capability to satisfy a number of repair and
tune-up needs across a wide variety of fuel handling systems.
Those four entities are:
Air Force Liquid Fuels Maintenance Veteran
Air Force POL Veteran
Military Fuel Systems Controls Company
Military Fuel System Parts and Equipment Supplier
This union has created one of the most capable, expedient, and competitive service
companies in existence. The following pages will show services offered. Our
website shows the most current experience and any of the listed locations can
provide testimony that SEMPER provided outstanding service.
Visit us at www.semper1.com
CORE CONCEPT
SEMPER’s core competency is fuel system maintenance. The original ideas of
constant pressure hydrant system tune-ups and recurring maintenance programs are
our core concepts and capabilities. A dire need from the military fuels career field was
a motivating factor to move forward to satisfy this need. Although resident Liquid
Fuels Maintenance crews are quite capable, their career fields have recently been
plagued with deployments, personnel cuts, multi-tasking, and system malfunctions
beyond their capabilities. SEMPER has completely satisfied the call to make up that
difference. We stand ready to respond on short notice to equipment malfunctions and
maintenance programs both mechanical and controls, so the war fighter can continue
its mission without interruption. SEMPER has a history of consistent competitive
pricing as a Service Disabled Veteran Owned Small Business.
PROGRAM BENEFITS:
SPEED and PRICE!
The SEMPER Program is managed under a creative and flexible technical
architecture that shares test equipment, facilities and personnel. The customer needs
to contact only one provider, yet all services, regardless as to the region, are available
to the customers’ demands. This integrated service platform can reduce costs in
multiple contract administration, multiple source qualification processes and the
need for the customer to maintain multiple stocks of repair parts inventory. A lean
logistics effort by SEMPER will shrink the customers’ logistics ‘footprint’ while
maintaining sustainable capabilities. Requirements for base-level service or repair
personnel, test equipment and test facilities are correspondingly reduced.
The anxiety of dependence on newly privatized personnel at fuel depots and overtaxed Liquid Fuel Maintenance personnel can be reduced if supported by SEMPER.
This will save tax dollars, reduce military spending and provide top rated technicians
to support petroleum storage and distribution responsibilities with military services
around the world.
SEMPER’S supplier is a fully authorized manufacturer distributor for pumps,
control valves, flow meters and instrumentation. Strategic locations of warehousing,
test equipment and volumetric flow meter calibration provers in the USA and in
Dubai support the regions they serve.
Petro Chem Technologies is our “Single System Supplier”.
During nearly 60 years of their history, they have been either an
Authorized Service Center, Authorized Distributor, Representative or
OEM for these companies
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ACTARIS – flow meters
BARTON – flow meters and pressure measurement
BRODIE METER – positive displacement meters and control valves
BROOKS INSTRUMENT – flow meters
CAMERON – DB&B plug valves
CIM-TEK FILTRATION - filtration
CIVICON – point level control and grounding for trucks and storage tanks
CLA-VAL COMPANY – control valves, nozzles and adapters
CONVAULT TANK – storage tanks
CORKEN – positive displacement pumps and compressors
DANIEL- aviation refueler control valves and flow measurement
DWYER – pressure and temperature instrumentation, flow switches
EMCO WHEATON – truck & marine loading arms, swivels and floating suction assembly
EMERSON – aviation refueler control valves and flow measurement
ENRAF – level gauging and additive injection systems
FACET / M.E. INDUSTRIES – aviation filter separators, micronic filters, monitors
FILLRITE / TUTHILL – electric and hand operated pumps and dispensers
FUELMASTER – ground fuel management and controls
GASBOY – ground fuel dispensers and pumps
GATE CITY – additive injection systems
GENERAL VALVE – DB&B plug valves
GORMAN-RUPP – straight centrifugal, self-priming, positive displacement pumps
GREEN MANUFACTURING – loading racks, canopy, safety stairs, dike stairs
HALLIBURTON SPECIAL SERVICES – flow meters, pumps and valves
HANSACONSULT – leak detection systems and testing
HIGHLAND TANK – storage tanks and oil water separators
IDEX – flow meters, pumps and valves
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LANE CANOPY – ground fuel station overhead canopy
LIQUID CONTROLS – positive displacement, turbine and mass flow meters
L&J TECHNOLOGIES – storage tank fittings and level measurement
MERCOID – temperature, pressure and level instrumentation
NATIONAL PUMP – API 610 vertical turbine pumps
NEPTUNE MEASUREMENT – positive displacement and mass flow meters
OCV – diaphragm automatic control valves
OPW – loading arms, swivel joints, sight flow indicators
PNEUMERCATOR – point level and tank gauging instrumentation
RED JACKET – submersible turbine pumps
ROSEMOUNT – flow meters, level, temperature and pressure instrumentation
SCHLUMBERGER – positive displacement and mass flow meters
SCULLY SIGNAL – point level control and grounding for trucks and tanks
SMITH METER – positive displacement and turbine meters, control valves
TAYLOR VALVE – ASME pressure relief valves
TPC – system controls and complete control panels
UNION PUMP – API 610 centrifugal pumps
VEEDER ROOT – tank level instrumentation, mechanical flow meter readout
WARRICK CONTROLS – tank level instrumentation
WATTS ACV – diaphragm automatic control valves
WHITTAKER CONTROLS – commercial and military aviation equipment
WORTHINGTON PUMP- API 610 centrifugal pumps
SERVICES OFFERED by SEMPER:
 Fuel System Tune-ups
 Recurring Maintenance Programs
 Type III Hydrant System Safety Solutions
 Control Valve Repair/Troubleshooting
 Control Panel Repair/Upgrades
 Complete Additive Injection Packages
 Meter Calibration Services
 Ground Fuel System Repair/Upgrades
 New System Start-up Support
 Startup Training for LFM and POL
Fuel System Tuneups
Complex hydrant refueling systems cannot go without at least annual calibration
checks and adjustment. Through daily use, these systems experience drift of original
settings, both mechanically and electronically and thus bringing their operation out of
its original, efficient state. Complaints of operating pressure loss, idle pressure loss,
and timing of lead and lag pump starts are just a few things that happen when these
system go without care for an extended period. We have developed a complete
sample statement of work for the customer to see exactly what we do during a full
tune-up.
Sample Statement of
Work
Purpose
This sample Statement of Work (SOW) was devised to aid prospective customers in
identifying and defining requirements of a full tune-up of their automated or mechanical
fueling system. Although this SOW applies mainly to constant pressure hydrant fueling
systems, it covers many aspects of other fuel handling systems such as a mechanical
storage system. The tune-up consists mainly of two parts; Mechanical and Controls.
Scope of Work
Using one controls specialist and one mechanical specialist, contractor will test and
calibrate controls, instrumentation, and applicable mechanical equipment for Type II,
III, IV, and V Hydrant Fueling Systems. Only minor repairs of equipment during this
tune-up fall under this scope of work as long as the repair does not detract from the
timeline of the tune-up. Repairs above and beyond minor repair will be communicated
to a government representative and contracted separately from this SOW.
Description of Services
Contractor shall perform inspection, testing and calibration of all controls,
instrumentation, control valves, and equipment for base fueling systems including
ancillary equipment used. Excluded are testing/inspection of tanks, inventory systems,
piping/tank cathodic protection systems, oil water separators and annual meter proving.
Specific components and duties are as listed in Appendix 1 and attachments. Intent of
this contract is to provide for and ensure the safe, effective, and continuous operation of
the referenced fueling system. Contractor shall comply with all applicable federal, state,
local laws and regulations, and the Base Hazardous Waste Management Plan. The
contractor shall perform its work in accordance with commercial industry standards and
as indicated by Department of Defense standards. Note: These services are to
supplement the normal activities of the localized maintenance activity.
Scheduling
Although a tune-up can be performed on a one-time basis, scheduling of annual visits are
strongly encouraged to maintain the health and efficient operation of microprocessor
controlled fueling systems. Recurring visits are to be a result of consultation with base
personnel and must allow for negotiation of annual dates to accommodate for potential
conflicts with contractor’s other obligations.
Base/Activity Support
The base or activity representative shall provide base or DOD passes for contractor
access to systems and/or required escorts for secured areas. Base maintenance personnel
will be required to assist the contractor in system testing and air elimination and provide
data or history on problems experienced. In addition, system as-built data will be made
available to aid in inspection/calibration/testing of systems and components. Upon
request of the contractor, any fuel evacuation from equipment or piping for the purpose
of repairs shall be done by base personnel. Operators shall be responsible for providing
equipment for the purpose of testing system dispensing components. Contractor, in
performance of inspection, calibration, and testing, shall work with the operators to
minimize system downtime in order to maintain base mission readiness.
Records
The contractor shall maintain records of services in performance of this content. The
records will be used to create a report, which shall include identification of component,
location, maintenance work performed, condition of component, date of
inspection/calibration, statement of repairs needed, if any, with an estimated cost of
repairs. Reports shall be submitted within 30 days after the tune-up visit. If an urgent
repair situation arises during the tune-up, contractor will immediately report to the
authorized government representative on-site at the time of discovery for authorization or
advisement of repairs.
Government Furnished Property
There is no government furnished property provided in the contract.
Quality Control
The contractor shall utilize commercial quality control procedures. The records of tuneup shall be kept and made available to the government throughout the contract
performance period.
Performance of Services, During Crisis as Declared by the National Command
Authority or Applicable Combatant Commander
The contractor shall provide services outlined in the contract. However, base workload
may significantly increase during wartime contingencies, and response times could be
impacted. Government representatives will advise contractor of any work stoppage as it
pertains to potential interference with DOD mission objectives.
Security Requirements
The contractor shall make available personnel data for background checks if required for
clearance into secured areas.
Qualifications
The contractor must have experience as a fuels “system supplier” representative as
defined by the DOD standards for pressurized hydrant fueling systems – Type III
specification.
Full Tune-up Checklist
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Complete system walk-thru with customer, Discuss significant problems.
Run the system through 3-5 complete cycles in Auto mode.
Check PLC processor for proper running conditions.
Perform system operation test using primary and back-up control systems.
Verify each digital input and output point.
Calibrate each analog input and output and recalibrate as necessary.
Check all PLC power supplies for proper running condition.
Examine all local hardware i.e. switches, displays, lights, and relays.
Check out HMI PC and alarm printer as applicable.
Check out HMI software program, If update is required, advise customer.
Check all spare parts and make recommendations for what is required.
Check out each local Uninterrupted Power Supply, verify battery status.
Verify all wire connections and tighten as necessary.
Inspect, test, calibrate instrumentation.
Inspect starter/motor controls.
Inspect all PLC related components.
Verify all audible/visual alarm devices.
Check and calibrate flow switches.
Check and calibrate flow transmitters.
Check and calibrate pressure transmitters.
Check and calibrate level transmitters (non-inventory).
Inspect/adjust valve position switches.
Inspect/adjust Motor Operated Valves.
Inspect/adjust level switches.
Verify tank level alarms (Low, High, High-High).
Verify emergency stop stations.
Inspect flow meters.
Verify/adjust operation of hydraulic control valves.
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Check and verify all manual valve operation.
Observe filter separator operation and adjust as necessary.
Verify proper operation of the entire Scully system.
Observe loading and unloading systems/equipment.
Inspect pumps for vibration, bearing temperatures, lubrication levels, alignment,
noise, and cleanliness.
Verify Product Recovery tank functions and adjust as necessary.
Verify pressure gauges.
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Provide training of base personnel on system operation, maintenance, and
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emergency operation modes. See following training outlines.
 Investigate any other related problems as requested by customer.
CONTROL VALVE CHECKLIST
1).
Receipt Pump Control Valves (300 GPM, 600 GPM)
a) Rate of flow setting (GPM)
b) Pressure control setting (psi)
c) Pressure relief (psi)
d) Closing speed (Turns)
e) Opening speed (Turns)
2).
Filter Separator Control Valves (300 GPM, 600 GPM)
a)
b)
c)
d)
e)
3).
Truck Loading Control Valves (300GPM, 600 GPM)
a)
b)
c)
d)
e)
4).
Issue Pump Control Valves (300 GPM, 600 GPM)
a)
b)
c)
d)
e)
5).
Filter Separator Control Valves (hydrant, 600 GPM, 1200 GPM)
a)
b)
c)
d)
e)
6).
Hydrant Control Valves (4in., 6in., pneumatic, hydraulic)
a)
b)
c)
d)
e)
7).
Pantograph Control Valves (3, 4, 6in.)
a)
b)
c)
d)
e)
8).
Pressure Control Valve
a)
b)
c)
d)
e)
9).
Back Pressure Control Valve
a)
b)
c)
d)
e)
10).
Defuel / Flush Valve
a)
b)
c)
d)
e)
11).
High Level Shut-Off Valve
a)
b)
c)
d)
e)
Control Valve Repair, Upgrade,
Trouble-Shooting
SEMPER technicians are factory
trained and proven. They have
responded to some tough
challenges in this area and have
only become more proficient. No
matter if it’s Cla-Val, OCV,
Watts, or other, they can repair,
tune, or add features to your
existing valves. Ask us about
improving your filter or pump
control valves to better control
those components.
Control Panels
Telemetry and Process
Controls, Inc. (TPC) of Minnesota
provides all control system
and electrical consultation,
service and training.
Repairs and calibrations of
Type III Hydrant system
controls to simple motor
starters. Factory certification
is provided in the following
hardware and software:
G.E. Fanuc – Control Software
(CIM-VAR) – Partner, G.E.
Fanuc – PLC Software
(FASTRAC) – Partner, Allen
Bradley – RS View (Factory
Trained) – FIX Intellution –
System Integrator Program –
Wonderware – System
Integrator Program,
Rotork/Pakscan, Siemens
Step-7 PLC
Field Calibration,
Instrumentation & Repair
Electrical and
instrumentation technicians
are qualified by
manufacturer training for
service on pump control
panels, Scully tank high
level controls, truck
grounding and point level
control, pressure and
temperature transmitters and
control valves.
In-House Parts Support
Field technicians are
supported by
strategically located
warehouse facilities
with a current
inventory of repair
parts.
Flow Meter Calibration & Proving
SEMPER can provide
reliable meter proving
services at competitive
prices. 200-gallon and 1500gallon mobile volumetric
proving trucks are available.
Ground Fuels
Ground fuel repair and
calibration for mogas, diesel
and bio fuel systems. Will
address pumps, dispensers,
filtration, tank integrity,
gauging and automation
controls. Repairs span
equipment concerns from the
fuel nozzle to the inventory
management system.
Additive Injection
SEMPER is versed in so many aspects of fuel system repair, including additive
injection . Trained and certified the hard way, our proficiency came from places
like PSAB in Saudi Arabia when the US Forces had to make JP-8 from Jet-A1in
the 1990s. Several Hammonds injectors had to be maintained in the austere
desert environment or aircraft didn’t fly. Our current technicians were there
learning the hard way. They have kept abreast of the latest products and can
provide the customer with whatever is needed in this area.
Refresher Training
Refresher training is
second nature to our
technicians. With their
prior military background,
they are no stranger to the
training process and
lesson plan creation. See
our sample lesson plans
later in this booklet.
Mechanical Training Outline
Developed by veteran POL and LFM personnel.
1)
OVERALL CONCEPT OF OPERATION
2)
STORAGE TANKS
Level Alarms High, High-High and Low
Water Draw – Off System Tape Gauge
3)
PUMPS
Alignment, Oil (type,amount), Grease,
(type, how to) Vibration, Temperature
4)
CONTROL VALVES
Components, Features, Adjustments,
Trouble-shooting
5)
FILTER SEPERATORS
Elements, Water, Connection to control
valve, Float
6)
METERS
Calibration, Adjustments
7)
TRANSMITTERS
Calibration, Air
8)
MANUAL VALVES
Types (ball, double block and bleed plug)
Adjustments, Packing Glands, Reliefs
9)
VALVE POSITIONING
How new system affects checklists
10)
FLOW SWITCHES
Paddle Adjustments, Trouble-shooting
11)
THERMAL SWITCHES
Type, Operation, Trouble-shooting
12)
STRAINERS
Mesh, DP
13)
PRESSURE RELIEF
14)
PRT SYSTEM
Operation, Pump-back
15)
PANTOGRAPHS
Valve Settings, Maintenance
16)
OUTLETS
Components, Pit Draining, E-stops
Setting per location
Pump Control Panel
Training Plan
Provided by Telemetry & Process Controls
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1).
Introduction – All personnel, 30 minutes
A. Introduction
B. Company Information
2).
Operation of the Panel – All personnel, 1-2 hours
A. Components, exterior
1. Switches
a. Mode select switch
b. Pump select switch
c. E-stop button
d. E-stop reset button
e. System select switch
2. Lights
a. Power
3. Annunciator
a. Acknowledge button
b. Test button
c. Windows
4. Graphic Panel
5. Chart Recorder
a. Configuring
b. Screen Navigation
c. Storing data
6. Horn
B. Operation of Truck Fill Mode
1. Prior to switching modes
a. Valve position
b. Lead Select
c. Input Select
2. Putting the switch into Automatic
3. When pumps should start and stop
a. Flow and pressure set points
b. Timers for starts, stops and fails
4. What are the normal operating conditions
a. Pressure
b. Flow rates with number of pumps running
5. Disables
a. High and low levels
b. E-stop
c. Valve position
6. Alarms
a. Critical
b. Non Critical
C. HMI
1. Starting the PC
2. Starting the project
3. Navigating screens
4. What each screen does
5. How to use HMI to troubleshoot
6. Stopping the project
7. Users Manual
8. Proper Shutdown
3). Basic Troubleshooting – All personnel 1-2 hours
A. Components, interior
1. Primary PLC
a. CPU Rack
b. First Expansion Rack
c. Second Expansion Rack
2. Backup PLC
a. Power CPU Rack
b. First Expansion Rack
c. Second Expansion Rack
3. Power Supplies
a. AC
b. DC
4. UPS’s
5. Scully Level Alarm modules
6. Modem for Remote Service
7. Field Terminals
8. Circuit Breakers
9. Fuses
10. Switches
11. Relays
B. Analyzing the problem with the HMI
C. Checking lights
4). Advanced Troubleshooting and Maintenance – LFM and Electrical, 2 - 3 hours
A. Interior Components
1. PLC Rack Components
a. Primary PLC racks
b. Backup PLC racks
c. Power Supplies
d. Processors
e. I/O modules, Redundant and Non-Redundant
2. Power Supplies
a. AC power conditioners and surge suppressor
b. 24 volt DC
3. Terminals
a. Field terminals
b. TPC connections
4. Fans
a. Fans
b. Thermostats
B. Power Switches
1. Breakers
2. Component Switches
C. Lights for correct operation
1. PLC power supply
2. Communication module
3. Digital input and output module
4. Analog input and output
5. Annunciator
6. Changing bulbs
D. Cable connections
1. Computers to PLC
2. Computers to keyboard and mouse extenders
3. Viewer to Server HMI
E. Voltage and Current readings
1. Checking voltage outputs and inputs to the power
conditioners
2. Voltage readings on digital inputs and outputs
3. Current and Voltage readings on analog modules
F. How to read drawings
1. How to tell what drawing to look at based on a terminal number
2. What are field connections and what are in the panel
3. Relay connections
4. Module wiring
G. Checking to field devices connected to the panel
1. Determine if problem is in the panel or in the field
2. Bypassing a device
H. Troubleshooting the Automatic operation
1. Using HMI to troubleshoot
2. Using the trending option
3. Determining if the PLC is making the correct decisions
I. How to replace parts
1. PLC modules
2. Power supplies
3. Batteries
J. Program Changes
1. PLC with Versa Pro
2. HMI with Simplicity
K. Basics Test
1. Primary and Backup
2. Lights
3. Voltages
L. How to read and use the “O and M manual”
M. Generator switch over – To be completed by Electrician
5). PLC and HMI programming – Programmers, 2 - 3 hours
A. Starting Laptop
B. PLC editor
1. Getting online
2. Editing logic
3. Troubleshooting PLC problems
a. Starting HMI Editor
b. Starting the project developer
c. Selecting the project
d. Editing the project
e. Loading the project to the PC
f. Starting the Project and testing
Steve Voce: President
34 Ians Way
Rochester, NH 03867
603-833-0192
E-mail: [email protected]
Steven Rommel: Vice President
110 Gardengate Rd
Camden, DE 19934
302-535-6769
E-mail: [email protected]
Petro Chem Technologies
Greg Savage
752 Route 518
Skillman, NJ 08558
Tele 609-924-3334
Fax 609-924-7774
E-mail: [email protected]
Telemetry & Process Controls
Jim Edison
11320 Upper 33rd Street North
Lake Elmo, MN 55042
Tele 651-430-0435
Fax 651-430-0783
E-mail: [email protected]
Visit our website at: www.semper1.com
Visit our website at: www.semper1.com