Pr oj ect : Upgr adi ng DPS & B- Bl ock Faci l i t i es

Cl i ent Ref . : AD122 / L- 017

Our Ref . : M- 304942
Equi pment Tag No: A- 1243


I NSTALLATI ON & OPERATI ON &
MAI NTENANCE MANUAL FOR FOAM
PROPORTI ONI NG SYSTEM (DPS)






A 21.11.2011 M.SASON E.SEN
REV

DATE

NOTES

PREPARED
BY
APPROVED
BY
CUSTOMER
APPROVAL

DATE






DOAN YANGIN
Sndrme San ve Tic. A..


DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 2 / 10


HEALTH AND SAFETY

All work to be carried out in accordance with site rules and national regulations.
The equipment is designed to withstand normal operating conditions and
pressures. When properly used and maintained by trained personnel it
represents minimal risk to health and safety.
It is the responsibility of the person installing or erecting any items of equipment
to ensure that it is installed in compliance with the instructions and to ensure that
the equipment is safe for use under normal operating conditions.

WARNING
Where appropriate, components and equipment under pressure and
electrical connections should be isolated from supply before undertaking
any servicing or maintenance.


DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 3 / 10


INSTALLATION

- Locate DPS Foam Proportioning Skid (Pack No:2) onto the concrete foundation
and remove 4 off heightening legs from the skid frame.
- Drain case of the Pelton wheel (P-1254A) should be aligned with the drain channel
which is opened previously on the foundation.
- Locate the 950 L. Foam Tank (Pack No:6) onto the concrete foundation according
to the Dogan Yangin drawing 304942-PGL-002.
- Take out Skid Interconnection Pipes from the Pack No:3.
- 2 off interconnecting pipes are needed to connect the skid to the foam tank. All
corresponding pipe ends are marked with a number for easy matching.
- Connect the skid to the tank by the help of interconnecting pipes.
- Mark the foundation bolt positions.
- Take out interconnecting pumps and lift the skid and foam tank to give access for
drilling.
- Refer to the chemical bolt manufacturers instructions for drilling, installation and
torque details.
- After allowing sufficient time for the bond to cure, tighten the anchor bolts to the
torque setting recommended in the manufacturers instructions.
- Adjust the height of the packing with shims in each bolt position until piping is
Horizontal and all flanges are Vertical.
- Locate the skid & foam tank on the foundation and connect by using interconnecting
pipes again.
- Locate DPS Skid Outlet Manifold (Pack No:7) and connect the manifold to the skid
according to the Dogan Yangn drawing 304942-PGL-002
- Connect 2 off solenoid coils (can be found attached on the skid frame) to the deluge
valves pre-installed in the manifold.
- Connect 1 conduit (which can be found attached on the skid frame) to the bottom
of the foam tank by the help of the pipe clamps found bottom of the tank.
- Connect the wires to the low level gauge.
- Locate 1 off 4 OS&Y Gate Valve and 1off 4 Y Type Strainer (Pack No:4) and
install to the inlet of the skid according to the Dogan Yangin drawing 304942-PGL-
002
- Locate Magnetic Level Gauge and valves (Pack No:3) and connect to
flanges on Foam Tank. For detailed instructions refer to the manufacturers manual.
- Connect 4 inlet piping (by Others) to the 4 OS&Y Gate Valve.
- Connect 3 T-1201 Foam Solution Piping (by Others) to outlet flange of the 3
Deluge Valve (DV-478).


DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 4 / 10


- Connect 4 T-1241 Foam Solution Piping (by Others) to the outlet flange of the 4
Deluge Valve (DV-477).
- If remote start function will be used, remove temporary link from the terminals 1 & 2
in the control panel and connect wires from remote start button (by Others).
- If remote stop function will be used, connect wires to the Terminals 2 & 3 in the
control panel from remote stop button (by Others)
- If Pump Running signal will be supervised, connect wires to the terminals 4 & 5 in
the control panel (by Others).
- If Electric Pump Fault signal will be supervised, connect wires to the terminals 6 &
7 in the control panel (by Others).
- If Electric Pump Trip function will be used, connect wires to the terminals 10 & 11
in the control panel (by Others).
- For remote operation of the Deluge Valve (DV-477), connect wires (24 Vdc) from
DCS to the terminals 12 & 13 in the control panel (by Others).
- For remote operation of the Deluge Valve (DV-478), connect wires (24 Vdc) from
DCS to the terminals 14 & 15 in the control panel (by Others).
- For remote operation of the Deluge Valve (PV-475), connect wires (24 Vdc) from
DCS to the terminals 16 & 17 in the control panel (by Others).
- For remote operation of the valve (DV-476), connect wires (24 Vdc) from DCS to
the terminals 18 &19 in the control panel (by Others).
- Connect 415V supply to the terminal R, S, T, N terminal in the control panel and
make sure all three lamps are ON.
- Connect air pressure to the valves DV-476, DV-477 and DV-478.
- Fill the foam tank with FP-350 foam supplied.
- Bleed air from the system by opening High Point Vent Valves (From the flush
valves of the pressure gauges located at each Foam pumps discharge).



DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 5 / 10


OPERATION

Remote Operation from DCS;
- For valve numbers, please refer to the drawing attached to this manual.
- The following skid mounted valves should be in normally CLOSED position;
o 14 16 17
- The following skid mounted valves should be in normally OPEN position;
o 1 2 4 6 8 9 10 11 12 15 18
- The following skid mounted valves should be air pressurized;
o 5 7 - 13
- Ensure the ex-proof control panel has no alarm condition.
- The water pressure inlet of the proportioner should be minimum 9 bar.
- Remotely start electric motor driven foam pump (P-1254B).
- In the event of having problem with electric motor driven foam pump (P-1254B);
activate the spare pelton wheel driven foam pump (P-1254A) by energizing the
solenoid of the deluge valve #3.
- The foam discharge pressure of the foam pump should be minimum 11 bar.
- Supervise the foam concentrate capacity from magnetic level gauge and low
level switch.

WARNING: The pumps shall not be run without Foam Concentrate

- Note that during all these operations one person needs to be in the foam
pumping station to supervise systems while working.
- Energize the solenoid of the #13 pneumatic controlled ball valve (DV-476).
- Foam concentrate should now be fixing with fire water to produce correct
proportioning of foam solution.
- Energize the solenoid of the Deluge Valve controlling the foam discharge (#5 or
#7) of the related tank in fire.
- Examine the duplex gauge of the Balance Valve. Foam (Black) and water (red)
pressures should be equal.
- After extinguishing the fire, de-energize the solenoid of the deluge valve #5 or #7.
- De-energize the solenoid of the pneumatic controlled ball valve (#13).
- If electric motor driven foam pump (P-1254B) is running, remotely Stop the foam
pump.
- If pelton driven foam pump (P-1254A) is running, de-energize the solenoid of the
deluge valve #3.
- Ensure the foam solution and foam concentrate pressures drop to zero by
examining the pressure gauges.


DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 6 / 10


Emergency Operation (If Remote Operation Fails);
- For valve numbers, please refer to the drawing attached to this manual.
- The following skid mounted valves should be in normally CLOSED position;
o 14 16 17
- The following skid mounted valves should be in normally OPEN position;
o 1 2 4 6 8 9 10 11 12 15 18
- The following skid mounted valves should be air pressurized;
o 5 7 - 13
- Ensure the ex-proof control panel has no alarm condition.
- The water pressure inlet of the proportioner should be minimum 9 bar.
- Start electric motor driven foam pump (P-1254B) from the control panel located
on the skid.
- In the event of having problem with electric motor driven foam pump (P-1254B);
activate the spare pelton wheel driven foam pump (P-1254A) by opening the
emergency manual control valve of the deluge valve #3.
- The foam discharge pressure of the foam pump should be minimum 11 bar.
- Supervise the foam concentrate capacity from magnetic level gauge and low
level switch.

WARNING: The pumps shall not be run without Foam Concentrate

- Manually open the #13 pneumatic control valve from the top of the actuator by
the help of wrench.
- Foam concentrate should now be fixing with fire water to produce correct
proportioning of foam solution.
- Open the Deluge Valve controlling the foam discharge (#5 or #7) of the related
tank in fire manually by opening emergency manual control valve.
- Examine the duplex gauge of the Balance Valve. Foam (Black) and water (red)
pressures should be equal.
- After extinguishing the fire, close the emergency valve of the deluge valve #5
or #7.
- Close pneumatic controlled ball valve (#13) manually.
- If electric motor driven foam pump (P-1254B) is running, Stop the foam pump
from the local control panel.
- If pelton driven foam pump (P-1254A) is running, close the emergency
manual valve of the deluge valve #3.
- Ensure the foam solution and foam concentrate pressures drop to zero by
examining the pressure gauges.



DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 7 / 10


ROUTINE MAINTENANCE TESTING

Testing Electric Motor Driven Foam Pump Operation (Monthly);
- For valve numbers, please refer to the drawing attached to this manual.
- The following skid mounted valves should be in normally CLOSED position;
o 14 16 17
- The following skid mounted valves should be in normally OPEN position;
o 1 2 4 6 8 9 10 11 12 15 18
- The following skid mounted valves should be air pressurized;
o 5 7 - 13
- Ensure the ex-proof control panel has no alarm condition.
- The water pressure inlet of the proportioner should be minimum 9 bar.
- Start electric motor driven foam pump (P-1254B) from the control panel located
on the skid.
- The foam discharge pressure of the foam pump should be minimum 11 bar.
- Supervise the foam concentrate capacity from magnetic level gauge and low
level switch.

WARNING: The pumps shall not be run without Foam Concentrate

- Run the foam pump at least 15 minutes.
- Stop the electric motor driven foam pump (P-1254B) from the control panel
located on the skid.
- This test should be performed each month.

Testing Water Motor (Pelton) Driven Foam Pump Operation (Monthly);
- For valve numbers, please refer to the drawing attached to this manual.
- The following skid mounted valves should be in normally CLOSED position;
o 14 16 17
- The following skid mounted valves should be in normally OPEN position;
o 1 2 4 6 8 9 10 11 12 15 18
- The following skid mounted valves should be air pressurized;
o 5 7 - 13
- Ensure the ex-proof control panel has no alarm condition.
- The water pressure inlet of the proportioner should be minimum 9 bar.
- Start Pelton wheel driven foam pump (P-1254A) by opening the emergency
manual control valve of the deluge valve #3.
- The foam discharge pressure of the foam pump should be minimum 11 bar.


DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 8 / 10


- Supervise the foam concentrate capacity from magnetic level gauge and low
level switch.

WARNING: The pumps shall not be run without Foam Concentrate

- Run the foam pump at least 15 minutes.
- Stop Pelton wheel driven foam pump (P-1254A) by closing the emergency
manual control valve of the deluge valve #3.
- This test should be performed each month.

Testing Foam Proportioning System (Annually);
- For valve numbers, please refer to the drawing attached to this manual.
- The following skid mounted valves should be in normally CLOSED position;
o 14 16 17
- The following skid mounted valves should be in normally OPEN position;
o 1 2 4 6 8 9 10 11 12 15 18
- The following skid mounted valves should be air pressurized;
o 5 7 - 13
- Ensure the ex-proof control panel has no alarm condition.
- The water pressure inlet of the proportioner should be minimum 9 bar.
- Start electric motor driven foam pump (P-1254B) from the control panel located
on the skid.
- The foam discharge pressure of the foam pump should be minimum 11 bar.
- Supervise the foam concentrate capacity from magnetic level gauge and low
level switch.

WARNING: The pumps shall not be run without Foam Concentrate

- Manually open the #13 pneumatic control valve from the top of the actuator by
the help of wrench.
- Foam concentrate should now be fixing with fire water to produce correct
proportioning of foam solution.
- Close the OS&Y gate valve controlling the foam pourer of the relevant tank.
- Connect fire hose and a low expansion foam branchpipe to the 2 landing valve
of the foam solution hydrant located at the downstream of the deluge valve (#5 or
#7).
- Open the Deluge Valve controlling the foam discharge (#5 or #7) of the related
tank manually by opening emergency manual control valve.


DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 9 / 10


- Examine the duplex gauge of the Balance Valve. Foam (Black) and water (red)
pressures should be equal.
- Slowly open 2 landing valve of the foam solution hydrant and collect the foam
according to the NFPA-11A. Measure expansion, concentration and 25
drainage time according to the NFPA-11A.
- Close 2 landing valve of the foam solution hydrant.
- Close pneumatic controlled ball valve (#13) manually.
- Close the Deluge Valve controlling the foam discharge (#5 or #7) of the related
tank manually by closing emergency manual control valve.
- Stop the electric foam pump from the local control panel.
- Disconnect fire hose and low expansion branchpipe from the foam solution
hydrant.
- Open the OS&Y gate valve controlling the foam pourer of the relevant tank.
- Ensure the foam solution and foam concentrate pressures drop to zero by
examining the pressure gauges.
- Repeat same test for pelton wheel driven foam pump.

Flushing Foam Proportioning System (If Required);
- The following skid mounted valves should be in normally CLOSED position;
o 8 9 10 11 15 18
- The following skid mounted valves should be in normally OPEN position;
o 1 2 4 6 14
- Open 16 17 and drain valves on the foam concentrate pipelines to drain the
foam.
- Connect one end of the fire hose to the nearby fire hydrant and connect the other
end to the valve #16.
- Connect one end of the fire hose to the valve #17 and locate the other end to the
nearby drain.
- Close the drain valves, and open the hydrant valve slowly.
- Run the electric motor driven foam pump (P-1254B) and ensure the water
discharge from the hose outlet of the #17 valve.
- Stop the pump after 30 seconds and close 16 17.
- Repeat same for pelton wheel driven pump (P-1254A).
- Do not flush each pump more than 1 minute.
- Disconnect hoses from the fire hydrant and valves #16 17.
- Make sure the valves are in position below;
o CLOSE: 14 16 17
o OPEN: 1 2 4 6 8 9 10 11 12 15 18
o AIR PRESSURIZED: 5 7 - 13


DOAN YANGIN
Sndrme San ve Tic A
DALEEL PETROLEUM L.L.C.
UPGRADING DPS & B-BLOCK
FACILITIES PROJECT


INSTALLATION & OPERATION &
MAINTENANCE MANUAL FOR FOAM
PROPORTIONING SYSTEM (DPS)
Date 18.11.2011
Ref. AD122 / L017
Revision - A -
Page No 10 / 10