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FUNCTION OF A LOADING ARM INSTALLATION

From any fixed point (Pier,jetty,ect..),this


(Pier jetty ect ) this unit provides loading and unloading facilities for seagoing vessels and river barge.
barge

1. Loading arm freedom of movement to :


- Follow the high and low water positions for tides and river levels.
- Follow the movement of the vessel in the water due to variations in weight as the cargo is loaded or unloaded.
- Follow the drift of the vessel (parallel or perpendicular to the quay side)

2. Control equipment necessary for the land operating personnel to :


- Supervise loading conditions.
- Act quickly in the event of accidents.

YAW

HEAVE

PITCH

SWAY

SURGE
ROLL

BOAT MOVEMENTS

9
CONTROL SYSTEM & OPERATING PRINCIPLE

The tubing g , flexible hoses


and fitting connectors, to
interconnect all hydraulic
equipments & components

10
CONTROL SYSTEM & OPERATING PRINCIPLE
The complete maneuver of the Chiksan arms within the working envelope is effected by means of an electro-hydraulic system.
This system
y enables independent
p movements of the units around their horizontal axis,, and the movement of the complete
p assembly
y
around a vertical axis
The control of the arm is achieved by an electric & hydraulic installation composed of:
The components which are common to all the arms of a given bank:
One hydraulic power unit , common unit for arms maneuvering, ERS system
The hydraulic power unit delivers the hydraulic power to operate the control valves and arm hydraulic cylinders & hydraulic motors
One PLC cabinet, a jetty head control panel
A remote control units ( radio cordless )
P i i Monitoring
Position M i i System
S (PMS)
From the jetty head control panel, the operator can fully control of the arms and respond to any signal. Arms movements can also be controlled
from the radio remote control panel. It is easier to connect the arm from the tanker's deck with the radio remote control
The components which are supplied for each arm :
The
h selector
l valve
l assembly
bl with
h ERS
S accumulator
l at the
h foot
f off each
h arm has
h the
h function
f to distribute
d b the
h hydraulic
h d l power on the
h right
h cylinder
l d
The ERS accumulator delivers hydraulic power supply in case of electrical power failure to emergency disconnect the arm
A set of hydraulic cylinders & hydraulic motors (Quickon III hydraulic coupler & style 80 rotation)
Hydraulic cylinders power three movements of the RCMA :
Slewing of the complete arm
Raising and lowering of the inboard section
Raising and lowering of the outboard section
The slewing of the complete articulated assembly in a horizontal plane is achieved with one double acting cylinder connected to the female piece of
the Style 50 riser swivel. The drive cylinder stem end is connected to the riser
The inboard drive of the arm includes one double acting cylinder, a wire rope, a driving pulley and a return (or idler) pulley arrangement installed on
the inboard arm
The outboard drive of the arm includes a double acting cylinder, connected directly to a rack bar which operates a gear connected with the balancing
sheave installed on the rear of the inboard arm

11
LOADING ARMS GENERAL KINEMATICS

All loading arms are designed to accommodate six degrees of


movement between the ship and the deck. Six swivel joints are
used on a loading arm to provide the needed movements as
described below:
The first three swivel joints from the base riser to the style 40
apex swivel joint of the loading arm provide the three
translations of the end of the loading arm to cover the operating
3 2
envelope.
The three last swivel joints ensure the rotational degrees of
freedom, in order to align the coupler flange with the ammonia
ship manifold flange. Each of the three swivel joints of the style
80 terminal swivel joint assembly corresponds to a rotational
movement of the ammonia ship:
The rotation number 4 ensures the freedom for the roll movement of
the tanker
The rotation number 5 ensures the freedom for the yaw movement
of the tanker
4
The rotation number 6 ensures the freedom for the pitch movement
of the tanker
1
Six degrees of possible motion between ship and shore,
during transfer: 6 degrees of freedom 6 swivel joints
Swivels 1 to 3 = > 3 translations
5
Swivel 4=> Roll
Swivel
S i l 5 => Yaw
Y 6
Swivel 6 => Pitch
Practically no limit for the roll, pitch and yaw accepted

12
OPERATING ENVELOPE AND SPOTTING LINE(S)

Operating envelope definition :

That volume in witch a loading arm presentation flange is required to


operate. The volume is based on the range of manifold locations, changes in
tides and freeboard,, surge
g and sway.
y

Spotting line(s) definition :

For a single arm connection the spotting line is a line, at a pre-determinate


location on the jetty deck which is aligned with the centre-line of the ships
manifold to which it connect.
connect

For multi-arm connections the spotting line for each group of connected arm
is a line, at a pre-determinate location on the jetty deck which is aligned with
the centre-line of the group of ships manifold flanges to which they connect.

C A

HWL
LWL

A : Flanging area
Operating envelope
C : Drift area
Terminal de Barra do Riacho _ Drawing N 2400208129701
Terminal de Ilha Comprida _ Drawing N 2400208129702 HWL : High water level

LWL : Low water level

13
RCMA \ ROUTATING COUNTERWEIGHT MARINE LOADING
ARM \ GENERAL VIEW

The RCMA arm is fully balanced in all positions, the counterweights being combined into one rotating assembly to balance both
i b
inboard
d and
d outboard
tb d arms

14
RCMA - GENERAL VIEWS \ STYLE 50 SECTION

Base riser

This sub-assembly connects the RCMA to dockside piping for fluid transfer. It also provides an
i
important
t t supportt ffunction.
ti Th
The di
dimensions
i off the
th pipe,
i base
b plate
l t and
d gussets
t are determined
d t i d by
b
the total deadweight of the arm, wind loading forces, and the weight of the product in the arm.

The inboard arm is connected to the top of the base


riser and includes the main counterweight extension. The
outboard arm links the inboard arm to the vessel being
loaded or unloaded. Outboard arm

This swivel joint connects the top of the base riser to the
Inboard arm
inboard arm and includes a swivel allowing arm rotation
around the base riser
riser, a 90 degree elbow and a swivel allowing
inboard arm rotation around a horizontal axis.

2 Style 50_Trunion

Style 50_Elbow
(Removable)

1
Style 50_Riser

Base riser

15
RCMA - GENERAL VIEWS \ STYLE 40 & STYLE 80 SECTIONS

STYLE 40 WHEEL ( APEX )


3
This swivel joint connects the inboard
and outboard arm at the apex
p of the
RCMA. It includes a 90 degree elbow, a
swivel allowing the outboard arm to
move relative to the inboard arm and
another 90 degree elbow.

STYLE 80

This swivel joint connects the outboard 4


arm to the vessel manifold. It includes
three swivels connected by three 90
d
degree elbows
lb to allow
ll a wide
id range off
possible movement when connecting or
disconnecting the RCMA.
5

16
RCMA - ACCESS LADDERS
Access ladders to reach the style 50 & style 40 are installed on the base riser and the inboard arm maintenance platforms

The technician performing


the arm maintenance
operations is protected by a
harness equipped with
safety lanyard and
carabineer so that he is
permanently attached. The
h
harness is
i attached
tt h d tot a
retaining carriage which
glides freely in the guide rail
as the technician climbs or
descends.
During the ascent or the
descent, the technician
exerts a light traction on the
retaining carriage from his
dorsal position in support.
The retaining carriage glides
consequently freely in the
rail. Without traction, the
retaining carriage
automatically swings and
comes to engage on the
nearest notch.
notch Any possible
fall is avoided.

17
RCMA MARINE LOADING ARM \ MAINTENANCE PLATFORMS

Maintenance platforms located at the style 40 & 50 of the arm levels allow
the inspection & light maintenance of the parts

18
INBOARD ARM LOCKING DEVICE
AND OUTBOARD ARM LOCKING VALVE
Tie-down system
y

1.Purpose

It is necessary to mechanically lock the marine loading arm vertically in the rest position to
enhance the safety of the operating personnel
Hydraulic valve in
2. Description opening position:
Outboard arm free
The FMC mechanical tie-down system has one part located at
the end of the inboard arm structure and the other on the base
riser of the arm.
arm With the arm locked in the vertical stored
position, it is neither possible for the complete arm to slew nor
for the inboard arm to swing.

To lock the outboard arm (located on the front side of selector


valve cabinet), a manually operated hydraulic valve is normally
used. The tie-down system is designed to withstand the
maximum wind speed of the installation.

Hydraulic valve in
closing position: Inboard arm mechanical locking
g device
O b
Outboardd arm llock
k

19
INBOARD ARM LOCKING DEVICE
Purpose:
The locking device of the inboard arm prevents the slewing
and the inboard arm motions when the arm is in parked
(stored) position.
p
How to operate the locking
g device ?
Rotate the hand wheel either clockwise or counter
clockwise to lift up or to lower the square bar
What are the safety locking positions ?
In p
parked position,
p , always
y ensure that square
q bar is FULLY
inserted into the U-shape of the inboard arm and firmly
tighten the hand wheel

Warning:
Failure to lock full stroke the locking device of the
inboard arm could unlock the arm, cause damage it
and bend the locking screw when the arm is in parked
position and subjected to wind action

Inboard arm mechanical locking device

20
BALANCE SYSTEM AND PANTOGRAPH ARRANGEMENT

Style 40 sheave

Outboard arm

Pantograph cables

Outboard counterweights

Pantograph arrangement
The pantograph arrangement is composed of two sheaves (style
40 & balancing sheave) and cables . These cables are strung Balancing sheave
around the sheaves to transmit the counterweights force to the
outboard arm

21
BALANCING SYSTEM DESCRIPTION & METHODOLOGY
Balancing system
The arm is balanced by counterweights and pulleys so that it is balanced empty in all conditions without the intervention of any external
mechanical force.
For the outboard section and style 80:
By the main counterweights on the balancing sheave beam with the pantograph
For the arm assembly:
By the main counterweights / balancing sheave assembly which compensates the weight of inboard, outboard sections and the "Style 80"
By the additional counterweights (if necessary) fitted on the beam of inboard arm for making better the inboard section balancing
Methodology
Proceed as follows :
1. Adjustment of the parallelism ( outboard arm & outboard counterweight beam ).
2. Adjustment
j of the outboard balancing.
g
3. Adjustment of the inboard balancing.
Mechanical adjustment & tests
Wire ropes are subject to initial stretching, and may require adjustment of turnbuckles to remove excessive slack ( generally on sea side
turnbuckle
tu buc e ).
)
Check the arm balancing, extending it into the working area and unselect the arm from selected mode to free wheel mode
- Check that the outboard counterweight beam is parallel to the outboard section
- Check that the outboard and inboard arm remains fixed once the maneuver is stopped
A slow
l motion
ti off outboard
tb d and
d inboard
i b d arm is
i acceptable
t bl by
b consideration
id ti off the
th mechanical
h i l parameters
t off the
th equipment
i t and
d the
th service
i
conditions

22
PANTOGRAPH CABLES & WIRE ROPES MAINTENANCE

Annual preventive maintenance:

Check condition of cable


(greasing,slackness,ect.)

Check lock nuts, coupling sleeves and


turnbuckles for looseness
Safety instructions regarding the wire
If the sea side pantograph cable is too tight, it rope
would impose undue loads on the style 40 and
balancing sheaves swivel joints; if required Corrosion : If the wire rope are kept lubricated
loose a sea side turnbuckle and check again as noted above, then this will not be a problem.
the parallelism It is essential that corrosion does not take place
place.
Internal corrosion is not visible and external
Periodical lubrication (Minimum yearly corrosion may just be pitting, which is not visible
greasing ) to the naked eye. The first sign of corrosion will
Wire rope shall be lubricated. Whenever be rust forming on wire rope. The wire rope
a lack of lubricant is noted, remove all should be replaced if too much corrosion occurs.
di t prior
dirt i tot lubrication,
l b i ti by
b using
i
Loss in diameter : This condition is due to
compressed air or by brushing and excessive strain, internal corrosion or broken
grease again wires and requires replacement of the wire rope.
Pantograph cables (Upper & lower side) Broken wires : Each "lay" is made up of
strands, and each strand is made up of a group
Inboard driving system wire ropes off wires.
i At
A the
h first
fi sign
i off a broken
b k wire, i the
h
wire rope must be replaced since it is not
Setting of pantograph cables parallelism ( after possible to see broken internal wires.
replacement ).

Check that the cable section winding round the Core


sheaves are in the middle of the channel and
not against one of the flange.

Pantograph cables maintenance ( refer to the Strand


maintenance manual / Section 5 ) Wire rope
Wire

23
HYDRAULIC DRIVE CYLINDERS \ DESCRIPTION &
PREVENTIVE MAINTENANCE
The hydraulic power unit delivers the hydraulic power to
operate the control valves and arm hydraulic cylinders.
The operator controls the arm movements from the
main control panel or partially from the remote control
p
panel.
The selector valve assembly at the foot of the arm has
the function to distribute the hydraulic power on the
right cylinder.
Three movements of the RCMA are powered by
hydraulic cylinders:
Slewing of the complete arm.
Raising and lowering of the inboard section.
Raising and lowering of the outboard section
The slewing of the complete articulated assembly in a
horizontal plane is achieved with one double acting
cylinder connected to the female piece of the riser
swivel. The drive cylinder stem end is connected to the
riser
The inboard drive includes one double acting cylinder or
2 single acting cylinders, a cable and pulley arrangement
installed on the inboard arm
The outboard drive includes one double acting cylinder
or 2 single acting cylinders installed at the bottom of Note: Nuts of hydraulic cylinder casing threaded rods require
the inboard arm 12 loading arms only thread locking adhesive ( Loctite 243)
The outboard drive of the arm includes a double acting
cylinder, connected directly to a rack bar which operates
a gear connected with the balancing sheave installed on
the rear of the inboard arm 6 and 10 loading arms

24
ALL ARMS \ SLEWING HYDRAULIC DRIVE CYLINDER

The slewing of the complete articulated assembly in a horizontal plane is


achieved with one double acting cylinder connected to the female piece of
the riser swivel. The drive cylinder stem end is connected to the riser.

1. Clevis

2. SKF Knuckle

3. Clevis pin

4. Split pin

5. Plate washer

6. Cylinder shaft

Slewing drive cylinder ( double acting ) 7. Spacing ring

Clevis

25
ALL ARMS \ INBOARD HYDRAULIC CYLINDER & INBOARD
DRIVING SYSTEM
The raising and lowering of the inboard arm /
structure assembly of the RCMA is obtained by
a double effect drive cylinder fastened on the
inboard arm of RCMA and inboard structure of
RCMA) witch actuates a cable and sheave
arrangement installed along the inboard arm of
RCMA and inboard structure of RCMA

Free pulley
Greasing
gppoint

Wire ropes & turnbuckle

Double acting cylinder

Style 50 _ fix pulley ( Anchorage point )

26
6 & 12 ARMS \ OUTBOARD CYLINDERS & OUTBOARD
DRIVING SYSTEM

Outboard drive cylinder (double acting )

Rack bar

Rack pinion
system

Rack guides

27
12 ARMS / OUTBOARD CYLINDERS & OUTBOARD DRIVING SYSTEM

Outboard drive cylinders


(double acting )

Turnbuckle & Sleeves

Wire ropes

Pulley & Anchorage

The outboard drive includes two simple acting cylinders, a cable and pulley arrangement
installed on the inboard structure and balancing sheave.

28
HYDRAULIC DRIVE CYLINDER \ DOUBLE ACTING
CROSS SECTIONAL VIEW

Hydraulic cylinder location:


Shaft threads assembly with lock thread : Loctite 275
All RCMA : Slewing,
g, Outboard & Inboard driving
g system
y

Hydraulic cylinder seals / Ordering details for spare seals kits:

Use the genuine FMC spare part. Part number available on recommended spare part list

See instruction sheet in Operating & Maintenance Manual for Maintenance and Overhaul of hydraulic drive cylinders

29
HYDRAULIC DRIVE CYLINDER \ SINGLE ACTING
CROSS SECTIONAL VIEW

Hydraulic cylinder location:


Shaft threads assembly with lock thread : Loctite 275
RCMA 12 ONLY : Outboard driving system (Qty 2 per arm )

Hydraulic cylinder seals / Ordering details for spare seals kits:

Use the genuine FMC spare part. Part number available on recommended spare part list

30
HYDRAULIC DRIVE CYLINDER \ CROSS SECTIONAL VIEW
SEALS REPLACEMENT

Hydraulic cylinder \ Seals replacement procedure & Preventive maintenance

31
HYDRAULIC DRIVE CYLINDERS \ PREVENTIVE MAINTENANCE
Annual preventive maintenance

Major overhaul / Seals replacement: Between 5 to 7 years ( The need for an major
overhaul will normally confirmed by excessive corrosion ,wear of components)

For hydraulic cylinders maintenance , refer to the maintenance manual

32
PRODUCT & STRUCTURE SWIVEL JOINTS DESCRIPTION
A swivel
i l joint
j i t assembly
bl
Enabling the loading arm once connected, to
follow the movements of the vessel within
the working envelope.

Allow the rotation between two items of a


product line whilst ensuring no product
leakage, even under external pressure.

The heart of a Chiksan marine arm is the


swivel joint. ln a standard marine arm there
are six
i swivel
i l joints
j i t with
ith the
th direction
di ti off
rotation in three planes giving the arm six
degrees of freedom. This allows the arm to be
manoeuvred to and from the vessel and, once
connected, allows the arm to follow ail the
motions of the vessel.
Each swivel joint is made up of a male and
female part joined by two or three bail bearing
raceways allowing the free rotation of the
joint. A compression type packing seal is used
to seal the two parts of the swivel joint.

Packings
Chiksan swivel packing ensure that fluid
does not leak. They come in a variety of
materials depending on the physical and the
chemical characteristics of the product being
handled. Specially designed low torque
packing are used in the style 80 to enable
this swivel joint to be easily moved when
connecting to or disconnecting from a vessel.

33
RCMA LOADING ARM PRODUCT & STRUCTURE SWIVEL JOINTS
A Chiksan swivel joint is typically composed of one, two
or three
th swivels
i l which
hi h allow
ll movementt in
i different
diff t
parts of the RCMA. The swivel consists of a male nipple
which turns in a female coupling on two or three rows 3
(races) of ball bearings

5 4

6 7

34
REMOVABLE ELBOWS & PACKING REPLACEMENT

Limit of use Recommendations:


Before any maintenance operation on site, ensure that the minimum
precautions below are taken into account :

The jetty must be free of any residual vapour of hazardous products and the
maintenance zone clearly posted. Other loading/unloading arms must not be
in operation. All other rules specific to the operator, to the local regulations
or linked to the products handled will have to be respected

Never attempt any maintenance, disassembly, inspection or repair on a loading


arm before to be sure that :
The arm is empty of product, at ambient temperature and without residual pressure,
The arm is locked in up-right position (vertical rest position of inboard arm),
The balancing and the parallelism have been accurately carried out and checked, Style 50
The arm cannot be operated,
For a hydraulically-operated arm, it is necessary to lock the arm by the manual
selection from the selector valve
For a hydraulically-operated arm, switch off power supply and isolate the electric and
hydraulic equipment (control panel,
panel hydraulic power unit,
unit accumulator,
accumulator etc
Check that all personnel wear protective equipment (minimum : gloves, safety glasses,
safety helmet , safety shoes, harness, etc.)
Ensure that safe working load of the lifting means is selected according to the weight Style 40
of the piece to be handled
Only the FMC genuine maintenance tools must be used

35
REMOVABLE ELBOWS & PACKING REPLACEMENT STYLE 50
True removable elbows are installed at the Style
y 50 (Riser)
( ) and Style
y 40 (Apex).
( p )
Permanent devices being fixed on the loading arm, it is possible to totally remove the
elbow in order to inspect and change the packing seal if necessary without the need for
lifting equipment, significantly reducing downtime

Required special tools (provided)

Replacement of Packings at Style 50


Lock the arm in vertical position of inboard arm. Use the personal protective equipment (refer to the
instructions sheet "Use of the safety equipments"), to climb up to the Style 50. For the arms without
platforms or ladders, it is necessary to use a man basket (or aerial lift) or equivalent
Install the lifting device (1) using the collar around axis (4)
Put in place the winch (2). It must be connected between the welded ring (3) and the lifting device
(1). If necessary, use slings between the both ends of the winch
Loosen and remove the bolting of the both flanges of the Style 50 spool
With the winch, lift and rotate the elbow around the axis (4)
Remove the packing(s) of the Style 50 riser (A) and/or the Style 50 trunion (B) swivel joints
Clean the sealing faces & Install the new packing(s)
Reinstall the elbow and the bolting and tighten the bolting according to recommended torques (see
separate instructions sheet)
Remove the winch (2) and the lifting device (1) in the reverser order

36
REMOVABLE ELBOWS & PACKING REPLACEMENT STYLE 40
Replacement of packing at Style 40
Lock the arm in vertical position of inboard arm
Use the personal protective equipment (refer to the instructions sheet "Use of the safety equipments"), to climb up to the Style 40. For the
arms without platforms or ladders, it is necessary to use a man basket (or aerial lift) or equivalent
Refer to the Style 50 paragraph for the next steps of the procedure
Install the new packing(s) and always replace the spiral wound gasket (5)

In each case, inspect the packing faces on the male piece and on the flange. They must be in perfect condition. Some
superficial corrosion may be eliminated by polishing. If more corrosion is present, it cannot be removed that way, it is
necessary to replace the swivel pieces (Contact the After Sales Department of FMC).

See instruction
i i sheet
h in Operating & Maintenance Manuall for
f Packing
k s replacement
l

37
REMOVABLE ELBOWS & PACKING REPLACEMENT STYLE 80

Secure the arm


Operate the arm in such a way that the Style 80 reaches the jetty or the dummy manifold 4
(where available)
Secure the arm with slings and wire rope (Tirfor winch) or chain blocks :
Fasten the outboard / inboard arm firmly to mooring points on the jetty or base riser gusset
(taking up on 3 points). See detailed procedure in the Operating and Maintenance Manual 5

Replacement of packing at Style 80


The swivel joints 4 & 6 are 2 pieces type SWJs without flanges. It is necessary to fully Style 80
dismantle the SWJs to be able to replace the packing.
For the SWJ 6, it can be easily dismantled by rotating the connecting flange. 6
For the SWJ 4, it will be necessary to disconnect all hydraulic flexible hoses, instrument
cables between outboard arm and ERS to ensure that the lower part of the style 80 is
secured on dummy manifold.
manifold The split
split flange
flange SWJ 5 will be disconnected from the
flange and the SWJ 4 will be dismantled by rotating the elbow.

The swivel joints 5 is "split flange" type (3 parts swivel joints), a complete disassembly of
the ball races to replace the packing is not required. The packing is accessible when the
flange is taken apart. Refer to the instructions sheet "Disassembly / Reassembly of swivel
joints
Note:
Before the disassembly of a Style 80 swivel joints, always ensure that the arm is
correctly secured to compensate unbalance. Contact the After Sales Department
of FMC for assistance
Spare parts must be always available prior to start the maintenance works
(Packings, SWJs components, electrical insulation components)

Arm in maintenance position


Style 80 on the dock

38
SWIVEL JOINTS PREVENTIVE MAINTENANCE

Preventive maintenance
Check for abnormal noise during operation( If the sea side pantograph cable is too tight, it would impose undue loads on the style
40 and balancing sheaves bearings; if required loose a sea side turnbuckle and check again the parallelism and/or pantograph
sheave bearing may need lubrication,ect...)
Periodical checking all fixing parts (Apply the corresponding torque on bolts, screws ,refer to the maintenance manual).
Periodical touch paint : Check for damage to the painted surfaces and a formation of rust. Where necessary use a suitable paint
repair procedure to restore protection.
The need for an major overhaul will normally confirmed by excessive corrosion ,wear of components.
Periodical lubrication manual or centralized greasing system ( bearings and all moving parts ,refer to the maintenance manual )
Grease : Molykote 44 light
Packing : AD / SS
Procedure
Proper lubrication consists in small amounts of grease, lightly and smoothly applied and evenly distributed through out the bearing
chamber. Even distribution can be best achieved by rotating the swivel through 30 to 40 degrees between successive small
applications of grease. Swivels should be checked for smooth rotation after lubrication.

Important :
The removal of any parts for maintenance, repair or inspection should only be undertaken by qualified and trained
personnel .

39
SWIVEL JOINTS PREVENTIVE MAINTENANCE \ PACKINGS

16 AD\SS Packing

16 AD\SS Packing Damaged sealing surface &


g p
Presence of foreign particles

40
CENTRALIZED GREASING SYSTEM & MOBILE LUBRICATION UNIT
Centralized greasing system
This system is installed to lubricate the swivel
joints at style 50, style 40, balancing sheave and
the axis of the return pulley of the inboard drive
(only 8 arms) without having to climb the arm to
perform this maintenance preventive
p p operation.
p
The style 80 swivel joints are manually greased.
The filling of the centralised greasing system is
effected from the dock by a manual pump.

Benefit:
Benefit

Provides for better protection against moisture,


corrosion, rust the environment

Limits and g
guards against
g the risk of internal
components corrosion

Allows for the lubrication of areas and joints of


the arm not easily accessible

Permit continuous functioning of arms and thus


saves important intervention time

Reduces the risk of pollution from the lubricant

Prolongs
g the life and good
g working
g condition of
the arm
Centralized greasing system
Drawing N 24027081297521A

Mobil manual lubrication pump

41
CENTRALIZED GREASING SYSTEM

Style 40
Measuring valves (4 points)

Centralized greasing system:


Inboard pulley
The greasing pump is connected on two lines dia 18. The
grease is pressurized with the pump and delivered inside the
li
lines. At each
h swivel
i l joint
j i t is
i installed
i t ll d a measuring
i valves
l which
hi h
deliver small quantity of grease and ensure that all swivel joints
are lubricated in same time.
While using the manual pump, the grease must be pressurized
at approx 120 bars before to be delivered in 1 line. One
greasing
i cycle l is
i achieved
hi d when
h the
th grease has
h been
b
pressurized two times and that the grease has been delivered Style 50
in the 2 lines. (to be able to be dispatched

Annual p
preventive maintenance:
Annually inspect the centralised greasing system: Measuring
valves, fittings, flexible hoses(If any)
Protect measuring valves with Densyl tape
Balancing
sheave

42
ELECTRIC INSULATION FLANGES \ PRINCIPLE & MAINTENANCE
Purpose :
To
T isolate
i l t and
d avoid
id sparks
k att the
th ship/loading
hi /l di arm flanges
fl connection
ti
The isolation flange is an electrical insulation barrier that prevents electrical current flow
between the loading arm and tanker during oil loading (stray currents and static electricity )
The isolation flanges are one of several systems used to minimize current flows between the
berth and the tanker

Electric insulation test : ( yearly )


The electric insulation shall be measured though the swivel joint which has no external
contact with ground or other metallic part
M
Measurementt shall
h ll be
b performed
f d with
ith the
th arm in
i empty
t condition
diti and
d fully
f ll dried
d i d att
ambient temperature
Measure with a Mega ohmmeter the electrical insulation resistance under 20 Volts dc
(direct current) . The resistance must be equal to or higher than 1000 ohms ( 1 K After
hydrostatic testing )
Material measurement Dielectrometre MC 5 Chauvin Arnoux or equivalent
(Equipment calibrated by an independent laboratory)

Electric insulation / Annual preventive


maintenance :
Th
The electric
l t i insulation
i l ti joint
j i t will
ill be
b
disassembled and inspected in case of
test failure. The defective elements will
be replaced and the insulation joint will
be reassembled and re-tested
Three factors are necessary
Check the external coating condition to initiate an explosion:
Check the hydraulic flexible hoses A. Oxygen
condition ( if any by pass, all flexible
B. Gas (from leakages)
hoses at the style 80 section must be
electrically insulated type ) C. Initiation of sparks
For value torque, refer to the OMM

43
ELECTRIC INSULATION FLANGES

Silicomet "joint blue" packing paste


Used for re-sealing the epoxy glass pipes &
washer . After fitting the bushes and washers
,fill the remaining cavities with packing paste
( Used as seal to prevent ingress of moisture).
moisture)

External coating / Two coats of "Carbo


mastic 14" product or equivalent ( Epoxy
resin )). The special
p black coating
g ensures a
non-conductive protection for rain

Sealing against external agent : Replaced


the protective compound if it's damaged or
cracked
1

Item 1 : Isolating washer 2


Item 2 : Isolating pipe

Item 3 : Isolating plate

Item 4 : Lattygraph seal (both side)


3
4
Electric insulation disassembly & re-assembly procedure

It is strongly misadvised to carry out the disassembling of the electric


insulation flanges without having as a preliminary the spare parts
necessary at the reassembly

44
ELECTRIC CONTINUITY ON THE ARM

Each arm and his line is fitted with an


electrical continuity, the bypass rotations
being effected by copper cables. The
base is equipped with a bracket to be
grounded.
Purpose :
To ensure the continuity of electric arm
to avoid possible damage rotations in
contact occasional ball / Snap in the case
of a potential difference important.

The electrostatic charging of an arm can


create a spark if the electrical continuity
is not assured. Considering that the
static loading arm can occur during
loading, due to the flow of product in the
pipeline, we must consider an electrical
continuity the arm to the grounding.

This independently of the joint electrical


insulation on the arm (between flange or
rotation ST80, which has the function of Style 40 section
preventing a spark to establish if the
vessel is not at the same potential as the
dock upon login / disconnect).
disconnect)

45
MECHANICAL JACK & ANTI-ROTATION SYSTEM ON STYLE 80
Jack has 3 main goals :
Single leg jack
The mechanical jack is
located at the style 80
(terminal) swivel joint of the
marine loading arm .The jack
partially transfers arm loads
to the tankers deck this
reducing manifold stresses.

To balance the style 80. If


jack is removed, style 80 will
be unbalanced, and angle
between coupler and
manifold flange will be
increased.

Prevent the rotation of ERS


after an emergency
disconnection sequence:

Indeed, hydraulic actuator is


shifted from flange axis. If
arm is designed with a
vapour return
t li
line, th
the
bending moment is still more
important. Friction swivel
torque is inferior to the
moment of hydraulic
actuator(s)
( )
Anti-rotation system is linked to the jack. If jack is removed after a disconnection sequence
the Style 80 can fall on vessel deck

Preventive maintenance:
Twin leg
g jjack
Regularly
R l l grease the
th jacks
j k screws and
d anti-rotating
ti t ti system
t (b
(bearing)
i )

46
NITROGEN PURGING LINE \ BASE RISER TO APEX
1 nipple
1
Style 40
(apex) swivel Non return valve
joint

Style 50
(riser) swivel
joint

Swivel
Flexible hose
joint

Style 80
(terminal)
swivel joint
Line supports

Line flange
1 Nitrogen purging line (for 12 arms)_ Drawing N 2402608129752

Nitrogen purging line 1" dia. from base riser to apex (Style 40) \ Purpose :

Drain the arm out with nitrogen injection at style. Product in inboard arm and base riser is pushed back to shore and outboard arm to the ship.
Nitrogen draining is used when the product shall not get in contact with open air or to accelerate the draining procedure time
Bypass of the style 50 (riser) swivel joint by a combination of flexible hose coupled to a swivel joint to increase the overall life expectancy
Installed on each arm, it allows filling nitrogen in the outboard arm from the Style 40 of the arm to drain the arm off. This 1" line is fitted with a
check-valve at its tops to avoid any ejection of product from the line.
The connection to the nitrogen circuit on the dock is achieved by the 1"1 ANSI 150 RF flange with a ball valve

47
PURGE SEQUENCE DESCRIPTION WITH NITROGEN LINE FROM
BASE RISER TO APEX OF THE ARM
Clapet Anti-retour
Check valve

Sequence description : Ligne de chasse azote


Nitrogen injection line Apex

After the end of loading (no pressure


in product line), with product line

a rm
valves V1 and V2 open :

rd
oa
Open valve V3 (to inject nitrogen at

nb

T ube
I
apex).

Exte
ern
The product located in the inboard

Int

rn
arm and in the base riser is pushed

be

eO
Tu
towards the land, when the outboard

utbo
arm and style 80 swivel joint is

ard a
drained (by gravity) towards the

rm
tanker.
When the arm is empty, close valves

Embase Base Riser


V3, V1 and V2.

Vers le navire
Vers le terminal
To ship tank
To the terminal

C t
Customer
V3 V2
Azote
Nitrogen
Produit
Produit Product
Product Customer
V1

Navire - Ship
Jete - Jetty

48
QUICKON 3 HYDRAULIC COUPLER \ DESCRIPTION
General

The Quikcon 3 is a hydraulically operated Quick Connect / Disconnect Coupler


(QCDC) based on the Chiksan manual Quikcon coupler. During operation, the
jaws of the clamps rotate simultaneously to the correct position as the clamps
open or close across the tankers manifold flange. One O-ring seal fitted in a
groove of the Quikcon 3 coupler flange insures a positive sealing.
sealing

Quikcon 3 offers faster mating of flanges than possible through manual flanging
operations, another FMC innovation for improved operator safety and lowering
tanker dock time.

Description

Quikcon 3 operates with three (6 and 10 ) or four clamps (12) assemblies to


secure to the ships manifold flange. Designed to work with new, as well as
existing, hydraulic pumping units, the coupler may be adjusted to function at
different operating pressures

Features :
Mechanically locked using irreversible screw and nut mechanism for
enhanced safety.
In case of electric power failure, can be opened either hydraulically or
manually using a spanner
Reduced turnaround time of vessels

Quikcon 3 hydraulic coupler / ANSI 300 _ OMM

49
QUIKCON III HYDRAULIC QCDC / 6, 10 & 12 ANSI - 300 FLANGE
Quick Connect/Disconnect Coupler

Important notice:

Never pressurise the loading arm with the blind


flange
g installed on the coupler
p except p for those
which have a safety pressure relief valve or a
hole

During a disconnection operation, do not hold the


coupler opening switch control until the jaw is full
stroke opened.
opened Once the jaw of each tightening
unit has opened and that the ship manifold flange
is free by coupler, the operator shall release the
joystick switch (or control panel switch). Do not
attempt to open the clamps full stroke at its
maximum position

Do not attempt to connect the arm on a ships


manifold flange having either a different pressure
rating or a different diameter than forecasted

Check for connecting manifold or spool


flange face condition : it must be clean and
free of any scratches. Surface roughness of
manifold flange must be of the same type and
quality than the one of the coupler

Never attempt to connect the


h coupler
l on flange
fl
which do not comply this surface roughness
requirements. Otherwise, the coupler may
probably leak

50
QUICKON 3 - HYDRAULIC COUPLER DESCRIPTION

QUICKON III closing - Video


QUICKON III opening - Video

Quikcon III is a hydraulically operated coupling, during operation the jaws of the clamps rotate simultaneously to the correct
position as the clamps open or close across the ships manifold flange. One O-ring seal fitted in a groove of the Quikcon III
coupling flange insures a positive sealing

51
QUICKON III \ HYDRAULIC COUPLER
PREVENTIVE MAINTENANCE \ PRIMARY SEAL REPLACEMENT
Primary seals replacement
During the replacement of the primary packing seal, unscrew the M6 screws which maintain the retaining seal brackets. Replace the packing
seal and screw the M6 screws.
Payy attention to the retaining
g seal bracket is located as far as possible
p from the sealing
g face,, to avoid that packing
p g comes into brackets during
ga
connection operation.
Check for connecting manifold or spool flange face condition : it must be clean and free of any scratches. Surface roughness of
manifold flange must be of the same type and quality than the one of the coupler.
Never attempt to connect the coupler on flange which do not comply this surface roughness requirements. Otherwise, the coupler may
probably leak
leak.

52
QUIKCON III HYDRAULIC QCDC \ HYDRAULIC SYSTEM PRINCIPLE
QCDC control block
Q
The aim of this manifold is to control the closing or the Hydraulic schematic
opening of the hydraulic coupler, by controlling the 4
hydraulic drives (1 for each clamp) in serial or parallel mode.
When closing from an open position :The serial mode
is automatically on.
on The clamps start to close with the
same oil flow, while the pressure is divided by three.

When one clamp is almost closed: the flow decreases.


Then the parallel mode is automatically on. on The clamps
continue to close with independent flows, but with the same
pressure (190 on each)

Quikcon III is a hydraulically operated coupling, during


operation the jaws of the clamps rotate simultaneously to
the correct position as the clamps open or close across the
ships manifold flange. One O-ring seal fitted in a groove of
the Quikcon III coupling flange insures a positive sealing
Hydraulic pressure is not required to maintain the clamping
The closing operation stops in parallel mode,
mode when the force. The non reversible drive screw system is designed so
operator estimates that the coupler is completely closed. that this clamping force is maintained automatically
The hydraulic block is composed of metering jets : the
hydraulic oil must be clean and without particle to avoid
hydraulic trouble shooting

53
QUICKON 3 - HYDRAULIC COUPLER \ PREVENTIVE MAINTENANCE

Yearly maintenance

Open the cover, inspect and


full grease QCDC driving
system

Before reassembling, clean


and degrease the
polyethylene cover (07) and
the plate (06). Spread a blue
silicon layer on the cover
surface
f and
d reassemble
bl it with
ith
the 4 screw (21).

Preventive maintenance / Greasing


Every three months, grease each tightening unit of the hydraulic
coupler
l with
ith FMC specified
ifi d grease. The
Th coupler
l mustt be
b greasing
i ini
open position trough items (17) in two places for each module. Insert
approximately 100 g of grease
In order to distribute the grease in the whole tightening unit, make a
few opening and closing cycles after greasing
If some squealing noises are audible since functioning, grease the
hydraulic Quikcon III coupler using the same procedure
Regularly check the seal cover condition to avoid increase water
inside the mechanism of the QCDC driving system (motorization) and
fullyy g
grease the gearing
g g system
y
Recommended grease: Kubler Isoflex Topas L32

54
QUICKON III \ HYDRAULIC COUPLER MAINTENANCE BOARD
Periodic servicing and routine inspections
Coupler requires little maintenance, but that which is required is essential and must be accomplished if ultimate service life is to be achieved
Each time that the hydraulic coupler is operated, it would be well to quickly check all hydraulic tubing, hoses and hydraulic block for leakage while
the clamps are being closing

55
QUICKON III - HYDRAULIC COUPLER \ MANUAL OPERATION
Manual operation of the hydraulic coupler is provided as a safety feature for times where hydraulic operation is not possible
Recommended procedure by manual operation of hydraulic block
Remove the protecting cover on the hydraulic block
If any (depends of hydraulic bloc generation) , remove the plastic cap fitted on the setting rod, unscrew the counter-nut then screw the rod on
the side of the hydraulic block, in order to push the internal distributor. The block is then in parallel position
Unscrew the screw (23) and the washer (22) located on the driving screw then remove the plug (9) with the V-seal
V seal ring (14).
(14)
Release each clamps independently, operating each driving screw (3) with a standard 21 mm wrench in the correct direction of rotation
The driving screw (3) has a left handed thread. Screw clockwise to open the clamp
After having unlocked each clamp, unscrew the rod of the hydraulic block in order to bring it back to its initial position. The hydraulic block is
returned in serial position
Operate the screw of one of the motorizations using the wrench. All clamps open simultaneously (the hydraulic flow drives all the motors
together). The shaft has to be fully turned approximately 25 times to get it from its closed position to the opened position
Reassemble the plug (9) with V-seal ring (14), the washer (22) and the screw (23)

56
QUICKON 3 - HYDRAULIC COUPLER \ MANUAL OPERATION

Manual operation in case of electric power failure or hydraulic failure


Drain the arm and check that it is empty
Remove the main screw gear plug (9) and parts (14), (21) and (23).
Remove the square key (25 & 24)
Use 21 mm socket wrench to actuate coupler manually (either opening or closing)
Hydraulic functioning recovering
Reassemble the square key (24), the gear plug (09) and the screw (21-22)

For more information, refer to:


Quikcon 3 / Operating & Maintenance manual

57
QUICKON III \ HYDRAULIC COUPLER MANUAL OPERATION

Manual operation in case of electric power failure or hydraulic failure


Remove the main screw gear plug
Remove the square key
Use 21 mm socket wrench to actuate coupler manually (either opening or
closing)
Hydraulic functioning recovering
Reassemble the square key the gear plug and the screw

58
EMERGENCY RELEASE SYSTEM (E.R.S.) \ PRINCIPLE
The
h Double-Disco
bl i Valves/Emergency
l / Release
l Coupler
l (DDV/ERC)
( / ) provides
id the
h
means to isolate the flow of product and disconnect the marine loading arm
from the tanker in the event of an emergency.
Upon disconnection, the loading arm side valve remains part of and isolates the marine
loading arm. The ship side valve remains attached to the tanker flange isolating the
tanker manifold. Spillage of product is therefore prevented from both the arm and tanker
manifold.
manifold
The DDV/ERC is activated by the FMC control system. The speed of the operation of the
DDV/ERC, opening/closure of disco valves and disconnection of ERC, is adjusted by
controlling the flow rate of hydraulic oil from the hydraulic power unit.

Two independent
p functions are integrated
g in the ERS actuator:
ERS Valves actuation
PERC release
Mechanical & hydraulic Interlocks between the 2 functions. When the ERS valves are
opened
p or not fullyy closed: Impossible
p to release the PERC without closing
g completely
p y
the double valves
The two disco valves are actuated simultaneously, through a parallelogram link system,
as used on hundreds of FMC ERS systems in service.
All the parts of this actuator are protected against corrosion, using the same materials
as on Chiksan Marine Loading Arm and hydraulic QC/DC.
QC/DC

FMC / 6 DDV / PERC_Drawing N 24KTV030630Y

FMC / 10
10 DDV / PERC Drawing N
N 24KTV031030Y

FMC / 12 DDV / PERC drawing N 24KTV1312200

FMC / DDV / PERC / Operating & Maintenance manual

59
ERS TANDEM DESCRIPTION \ DDV & PERC ASSEMBLY

60
ERS TANDEM DESCRIPTION \ DDV & PERC ASSEMBLY

61
ERS TANDEM - DDV \ PERC CLAMPS DESCRIPTION
The ERC consists
Th i off two clamps
l connected
d by
b
rods forming a collar around the ball valve
middle flanges (Face plates). The shape of the
clamps acting on the profile of the middle flanges
exerts a force holding them together.
Complete Assembly
A embl in stainless
t inle steel
teel
Spring Energized (Belleville washers) PERC to
ensure proper opening under 25mm ice coating
OCIMF 1999
Easier to reconnect after a disconnection: no
specific equipment required
Maintenance facilities:
Possible to simulate a disconnection without
releasing the PERC: removing of the PERC axis
Possible to release the PERC without separating
the double valves: use of maintenance clamps

Belleville spring washers:


Assembling of the 8 Belleville washer in
4 places

General assembly of the 2 clamps PERC assembled on the two valves

62
ERS TANDEM - DDV \ PERC CLAMPS DESCRIPTION

The PERC collar is energized by Belleville PERC in closed and opened position
washers located inside the two clamps in order
to break the ice layer and open properly the
PERC. A shear pin prevents PERC from
unexpected release.

Belleville spring washers:


Assembling of the 8 Belleville
washer in 4 places

Shear pin:
A shear pin is fitted in the
releasing fork for added security
by preventing accidental release
of the Perc ((Onlyy use FMC shear
pin).
Regularly check that the shear pin
is in position and undamaged.
The correct shear pin position
guarantee that the PERC clamps
and release fork is well positioned

Picture N2 Picture N1
PERC axis in Shear pin with
operating position safety pin

63
TANDEM HYDRAULIC CYLINDER / ESD1 SEQUENCE

Vido

Picture N3 / ERS Double ball valves Picture N


N4
4 / ERS Double ball valves closed /
opened / PERC closed PERC closed (ESD1)

ESD1 / Stop loading sequence description:


The first part of the tandem cylinder stroke is used for closing the valves (ESD1 sequence). For this, the yoke pushes the roller of the operating
lever and the upper valve is closed. Simultaneously, the lower valve is closed by the connecting rods linked to the second operating lever.

64
TANDEM HYDRAULIC CYLINDER / ESD2 SEQUENCE

ESD2 routine test \ Vido ESD2 Vido

Picture N5 / ERS Double ball valves closed / PERC released after emergency disconnection sequence (ESD2)

ESD2 / Emergency disconnection sequence description:


The second part of the tandem cylinder stroke is used to release the PERC by pushing the PERC axis via the pusher (ESD2 sequence). At this
stage,
t th
the upper valve
l iis free
f from
f th
the llower operating
ti lever.
l

65
ERS ACTUATOR \ TANDEM HYDRAULIC CYLINDER \ PRINCIPLE

Description: A B C D E
Very simple (few moving parts) and very light
Mechanical interlock:
Impossible to release the PERC without closing
completely
l l the h double
d bl valves.
l
Meet OCIMF and EN1474: disconnection in two
sequences:
1. Closing of the valves
2 Disconnection
2. Di ti
Use of a tandem cylinder which is composed of
two cylinders overlapped
Two hydraulic valves to control this actuator:
1 One for manoeuvring the double valves
1.
2. One for releasing the PERC
Design:
Composed of 2 oil chambers and 2 movable parts
Functioning steps:
A: valves in opened position
B: valves in closed position
C: PERC release
D: valves re-opening after disconnection
E: valves in opened position

66
TANDEM HYDRAULIC CYLINDER \ ESD2 SEQUENCE

Picture N6 / Valves closed Picture N7 / PERC releasing / Breaking shear pin

67
TANDEM HYDRAULIC CYLINDER \ ESD2 SEQUENCE

Picture N8 / PERC releasing / Opening the DBV clamps Picture N9 / The PERC collar is energized by
Belleville washers located inside the two clamps

68
ACTUATOR DESCRIPTION \ DDV IN OPEN POSITION
DDV hydraulic
cylinder

PERC clamps
Pusher

DDV
connecting
rods

PERC
Caaxis
s:

Installed: PERC can be PERC axis


activated removed

Removed: PERC
cannot
nnot be activated
ti ted

69
ACTUATOR DESCRIPTION \ DDV CLOSE & PERC OPEN

DBV
hydraulic
cylinder DBV in closing position &
PERC activated (PERC clamps
open)

PERC clamps

Pusher

PERC axis :

Installed: PERC activated

70
DDV & PERC ASSEMBLY \ PERC LOCKING VALVE
Hydraulic
y circuit for PERC control is equipped
q pp
with a manually operated locking valve, installed
directly at triple swivel assembly ( Style 80)
It has to be opened at time of connection and closed at
time of disconnection.
A control switch detects its position "opened
Position "closed or Perc valve not armed :
The manoeuvring of the arm is possible
Disconnection of the PERC during manoeuvring or rest
position of the arm is not possible
Position "opened"
opened or Perc
Perc valve armed
armed::
The manoeuvring of the arm is not possible (selection of
the arm is automatically disable by the FMC logic when
the Perc valve is armed)
The disconnection of the PERC is possible in case of
emergency after closing of ERS valves.
Important :
This PERC locking valve must be imperatively opened
for the PERC to be operational.
The PERC valve is manually operated after arm
connection to the ships
p manifold and stayy in opening
p g
position during all loading time. This PERC valve must
be closed before to disconnect the arm.
When the PERC valve is in open position ( PERC armed,
arm in Loading selection), the arm is automatically
unselected by the logic, its means the arm is in free
wheel and cannot be operated.
p
Preventive maintenance:
Regularly check the inductive proximity switch and
manual operation valve efficiency
Check manual operation valves efficiency and grease
the mechanism

71
INDUCTIVE PROXIMITY SWITCHES ON DDV & PERC ASSEMBLY
PERC collar detection One inductive proximity switch to Inductive proximity switch DBV
ensure that
th t th
the axis
i PERC is
i detection in opening position
placed. Removing this axis enables
to carry out ESD2 (Emergency
disconnection sequence)
simulation without releasing the
PERC ((Show without PERC axis))

One proximity switch to indicate if the


PERC clamps are full closed and
tightened (Show PERC collar in correct
closing position_ When Perc collar is Show on this picture PERC axis
fully open after ESD2 Open DDV installed \ PERC in operating Inductive proximity switch DBV detection
operation is disabled ) condition in closing position

72
INDUCTIVE PROXIMITY SWITCHES ON DDV & PERC ASSEMBLY
Picture N10 / PERC hydraulic valve not
armed (valve closed)

PERC disconnection not allowed

Control light on jetty control panel Arm ready


for loading is Off

Picture N11 / Switch two position / To


inform the FMC logic (green control light on
jetty control panel) and DCS (customer info)
that the QCDC is closed and arm in operating
condition (Operator action)
Picture N 12 / Inductive proximity switch PERC
axis detection / PERC axis removed PERC not in
operating condition

Picture N13 / Inductive proximity switch PERC


axis detection / PERC axis installed PERC in
operating condition

73
EMERGENCY RELEASE SYSTEM \ SAFETY & RE-ASSEMBLY RODS
The 4 safety/re-assembly rods must be installed :
For testing the closing of the DDV and activation of the ERC
During maintenance works on the DDV/ERC assembly
For the re-assembly of the DDV after emergency disconnection
At the end of the loading/unloading operations, after closing the PERC
valve and prior to disconnect the arm from the ship
These safety rods should be stored on the berth if possible

4 places

74
DDV/PERC EMERGENCY DISCONNECTION SEQUENCE

FMC factory yard test \ September 2009 ERS valves closed, PERC activated Loading arm hydraulically blocked in position

ESD2 sequence _ Closing of ERS valves and PERC activation video

75
SECURING THE LOADING ARMS FOLLOWING AN EMERGNECY
DISCONNECTION SEQUENCE (ESD2)
Manoeuvre the arm after emergency disconnection :
Warning / Major safety issue :
It is forbidden to reset an ESD2 emergency disconnection sequence before having stored and secured all the emergency
disconnected loading arms on parked position or connected again on the ship. This would put the disconnected arms out of all
control and could cause serious personal injury or death (the ESD reset switch key must be removed from the switch).
During all operations putting the personal in contact with the products, this personal should be equipped with the safety
clothes adapted to the product .
Select manually all emergency disconnected arms, from selector valve cabinet (imperatively), See Picture N23:
Following an emergency disconnection (DDV close & PERC collar opened), two different alternatives are possible, depending the situation on the
berth. The first one is to drain, store and secure the loading arm; the second one is to directly reconnect the loading arm on the ship
From the main control panel, select radio cordless mode for the loading arm operation

Picture N23/ Selector valve


manual command with locking
device ( show on this picture in
selected mode, Arm hydraulically
blocked)

76
DOUBLE VALVES / PERC RE-ASSEMBLY AFTER ESD2
PERC re-assembly procedure for one
emergency disconnected arm:
From selector valve assembly: Manually select
the emergency disconnected arm as indicated
in Slide 76
From remote control, re-select
re select the emergency
disconnected arm ( See instructions and procedure at
the next page)
If possible, operate the arm / Style 80 near the ship
deck or on the jetty and install a rope on the
outboard arm (to secure the arm) and close the
PERC hydraulic isolating valve
Move the inboard arm to the vertical position and
lock it with the mechanical locking device
Operate the outboard arm 10 above the horizontal
position (see the drawing)
The outboard arm will be also drained by gravity
inside the inboard arm product line
Open the 1 valve nitrogen purging line (located on
the base riser) and open drain valve (customer
process). The product inside the inboard arm and the
base riser product line will be drained on shore side
(slop tank)
After complete draining, bring back the outboard arm
to the park position and secure it with the temporary
rope and close the outboard valve (located on
selector valve assembly). Drain valve
As soon as all emergency disconnected arms are
drained and secured, it is possible to reset the ESD2
sequence.
The ESD2 sequence can be reset only when all
arms are drained and secure

77
RE-CONNECTING THE LOADING ARMS AFTER ESD2
Reconnection of the loading arm on the ship:
Thi
This secondd solution
l i allow
ll the
h reconnection
i off the
h Clapet Anti-retour
loading arm full of product directly on the ship when Check valve
possible to be able to start again the loading/unloading Ligne de chasse azote Style 40
sequences. Nitrogen injection line Style 40 - Apex

The steps are as follow:


The V1 valve is closed during the emergency Tube Interne
Inboard arm
disconnection sequence (ESD1)
Style 50 Tube Externe
Select the loading arm from the cordless remote control Style 50 Outboard Arm
or from the control panel
IImperatively
ti l manuallyll select
l t the
th disconnected
di t d loading
l di
arms for safety reasons (as indicated slide 71)
Ensure that the ship is positioned in the correct working
area. ERS (Vannes ouvertes)
PERC (ferm) ERS (Opened valves)
Bring back the loading arm on the ship
PERC (closed) Vers le navire
Vers le terminal
Close the PERC valve To ship tank
To the terminal Embase
Reconnect the PERC collar between the DDVs. (see the Base Riser
Customer
ERS reconnection procedure starting slide 74) Azote
V3
Nitrogen
Unselect the loading arm (electrically and manually) Produit
Produit Product
Proceed to the same operation for all disconnected Product Customer
V1
loading arms V2

Reset the ESD2 sequence.


Navire - Ship
Jete - Jetty
The key switch Reset
Reset ESD sequences
sequences can be
used only when all loading arms are stored and
secured.
Open the V1 valve
Restart the loading/unloading operations.

78
RECONNECTION OF THE DDV/ERC SYSTEM
Reconnection arm per arm TOP VIEW

This operation can be done on the ship (lower valve still connected on the ship) or
on the jetty (free of ship and lower valve connected on dummy manifold)
When the alarm sequence has been reset and if the hydraulic PERC
locking valve is still armed (unlocked), it is therefore impossible to select
the arm from the electric or radio remote control panels
4 places
It is then necessary to operate the loading arm from the directional
control valves (by using the manual command) after selected manually
the loading arm
Ensure that the ship is in the correct working area
Start the hydraulic pump
Select electrically the loading arm from the remote control
Select manually the loading arm from the selector valve for safety reasons (see
picture on slide 76) Re-assembly & safety rods
After an emergency disconnection, the loading arm is operated
unbalanced
Remove the safety sling from the outboard arm (if installed before)
Remove the stow locks and operate the loading arm and upper valve so that the
middle
iddl flanges
fl are approximately
i t l 300mm
300 apart.
t It may be
b necessary to
t attach
tt h a
rope to the upper valve so as to bring the middle flanges parallel
Ensure that the seal area between the PERC flanges is clean, dry and free from
foreign matter and that the seals are in a perfect condition and correctly installed.
The seals should be replaced if any damage or scratching even minor, is detected.
Th seall groove area should
The h ld also
l beb perfectly
f tl clean
l and
d free
f from
f any scratching
t hi

Install the re-assembly & safety threaded rods as shown on picture


Close the PERC valve (if not done before)
Chain blocks can also be used in addition on instead of the threaded rods

79
RECONNECTION OF THE DDV/ERC SYSTEM
Using the re-assembly threaded rods, or with the chain blocks line up the valves
and adjust
adj st the th
threaded
eaded rods
ods o
or hoists so that the middle flanges are
ae
approximately aligned and parallel, maintaining a distance of 300mm between
the flanges
Manually unselect the arm from selector valve assembly and from the remote
control, switch to 0 position). The arm will be in free wheeling mode and will
move with the ships motion
Replace the PERC gasket (between ERS flanges)
Bring the two disco valves together by adjusting the hoist and ensuring that:
The notch in the middle flange of the upper valve is oriented and aligned
with the notch in the middle flange of the lower valve (see Picture N19).
Check that the cross linkages
linkage s Y
Y shaped connections are engaging
correctly around the pins on the ship side lower valve lever (see Picture
N20)
The spigot in the middle flanges is correctly engaged( see Picture N18)
Position the PERC collar around the disco valves middle flanges ensuring that the
p
position is correct.

Picture N19 _ DDV notch alignment

Picture N18
DDV/ Flanges alignment Pi t
Picture N20 _ Reassembly
R bl DDV/ERC cross li
linkage
k

80
RECONNECTION OF THE DDV/ERC SYSTEM
Once both valves flanges are together, remove the PERC axe if not done before
Un tight
g the PERC collar of turn using
g the adjustable
j screw with nut welded
Position the PERC around the flanges PERC and engage the came (See Pictures N30)
Re-tight the screw, as recommended torque value
The tightening torque value is different for each double valve/Perc diameter. Refer
to the table on the following slide for the torque value of each loading arm
Reinstall a new shear pin in the releasing fork for added security by preventing accidental
release of the Perc (Only use FMC shear pin)
The correct shear pin position guarantee that the PERC clamps and release fork is well
positioned (See Picture N30)

PERC clamps
position

Adjustable screw

Came in
position

Shear pin installed


back

Picture 30: Perc collar re-assembly Picture 24: Tightening Perc collar

81
RECONNECTION OF THE DDV/ERC SYSTEM

Adjustable screw

Warning:
The tightening torque value is different for each double valve/Perc diameter.
Refer to the table on the following slide for the torque value of each loading arm

82
RECONNECTION OF THE DBV/ERC SYSTEM
Reconnect the QCDC coupler hydraulic lines via the snap connectors
(Pi
(Picture 27)
Unlock the DDV driving system by pulling the locking disk (see pictures
in slide 79 ) Shear pin

Start the hydraulic pump of the HPU and re open the ERS valves (DDV)
using the command on the control panel or on the cordless remote
control
As soon as all PERC / ERS valves are reassembled, carry out a
pneumatic pressure test as indicated in operating and maintenance
manual as indicated in section 4 ( DDV flange N leak test at 6 bar)
R
Repeat
t the
th above
b procedure
d for
f the
th remaining
i i loading
l di arms
Picture N25b \ Torque wrench
Option 1 After ERS\DDV reconnection \ Restart the transfer: for PERC re-assembly
As soon as all the conditions of loading are joined, all ERS\DDV
reconnected :
If it iis nott done,
d manually
ll deselect
d l t the
th arm ( ArmA in
i free
f wheel
h l
mode). Unselect this arm from the selector valve assembly (see Picture
27) by unscrewing the manual selection and from the remote or local
control panel
Remove the re-assembly & safety rods. Install the ERS in working
condition
diti (S(See Pi
Picture
t 25 : ERS ready
d for
f operation
ti (PERC axisi
installed)
Open the PERC isolating valve on all connected arms The loading
arms are now back in normal operation mode
Restart the p
product transfer (refer
( to the normal operating
p g procedure
p
\ OMM Operating instruction)

Quick coupling/ Picture 27

83
RECONNECTION OF THE DDV - MECHANICAL LOCKING SYSTEM
Unlock the DDV driving system by pulling the locking disk (disengage the locking pin from the housing)

Pull the
locking disk
to unlocked
DDV in opening position DDV in closing position the DDV
Mechanicallyy locked

84
RECONNECTION OF THE DDV/ERC SYSTEM
Option 2 Disconnect and bring back the arm in storage position:
If it is not done, manually deselect the arm ( Arm in free wheel mode). Unselect this arm from the selector valve assembly (see
Picture 27) by unscrewing the manual selection and from the remote or local control panel
Start the hydraulic pump, reselect the arm and open the hydraulic coupler (From radio cordless)
Disconnect the arm from the tanker manifold and open the hydraulic coupler, replace the coupler face plate cover
Operate the arm and manoeuvre it back to the stowed / parked position and lock this arm (Mechanical device for the inboard arm and manual
valve on the hydraulic line of the outboard arm)
Unselect the arm from jetty control panel or from the radio cordless unit
Repeat the above procedure for the remaining loading arms

Pusher connected to
the tandem cylinder

Perc axis

Shear pin
with safety
split pins

Picture 25: ERS Perc axis in position:


ready for operation ERS ready for
Picture 27: Arm manually deselected operation

85
DDV/PERC ASSEMBLY / INSPECTIONS AND TESTING
1. Routine inspection (Every three months)
Refer
R f tot th
the preventive
ti maintenance
i t b
board
d
2. Routine testing
ERS valves close/open tests (Operation from local control panel or from cordless remote control)
After the inspection & before the arrival of each tanker
ERS valves closure testing by ESD1 activation (Stop loading sequence)
After the inspection before the arrival of the first tanker, this test must be performed monthly or before each loading.
PERC hydraulic cylinder routine testing by ESD2 activation (Emergency disconnection sequence)
After the inspection before the arrival of the first tanker, this test must be performed monthly or before each loading
PERC hydraulic valve testing
After the inspection before the arrival of the first tanker, this test must be performed every year
PERC controlled release testing
After the inspection before the arrival of the first tanker, this test must be performed every year

Warning Very important / Actions to be carry out before any routing testing

The key switch maintenance override must be on position 1 and the yellow light
Maintenance Override Activated must be On (stop automatic retraction)
PERC axis removed
Prior to operating the unloading arm or opening the hydraulic coupler check that the loading ERS system ready for
arm is empty of product routine tests
The loading arm is equipped with an emergency release system (Double Disco Valves/PERC
assembly). Before maneuvering the loading arm check that the PERC locking valve located on
style 80 is closed to prevent any opening of the PERC . On Jetty control panels , all green light
Arm ready for loading must be Off on all arms
Ensure that the 4 safety and re-assembly rods are installed as indicated in Slide N74
During this test ensure that there are no personnel within a three meter radius of the style 80
With the radio control unit maneuver the loading arm so that the style 80 is accessible to
jetty
Manually select the arm to be tested as indicated in slide N76
Remove the PERC axis from the PERC collar as indicated here and on slide 73

86
FUNCTIONNING TEST \ ERS VALVES CLOSE
This test will be performed from the local control panel or from the cordless remote control:
Check
h k that
h conditions
d indicated
d d slide
lid 86 are achieved
h d
Start the hydraulic motor pump (if not running yet)
When the loading arms is in parked position or in manoeuvring mode, the ERS valves should be
opened and the corresponding green light ERS VALVES OPENED should be ON on the local control
panel
Close the ERS valves using the rotating switch on local control panel (direct command) or
using the switch button on the cordless remote control after corresponding loading arm has
been selected
The corresponding red light ERS VALVE CLOSED should lights On on the local control panel
Open the ERS valves using the rotating switch on local control panel (direct command) or
using the switch button on the cordless remote control after corresponding loading arm has
been selected
The corresponding red green ERS VALVE OPENED should lights On on the local control panel
When the
Wh h di
disco valves
l are iin iintermediate
di position,
i i both
b h lights
li h ERS VALVES OPENED and
d
ERS VALVES CLOSED are flashing

Radio cordless
transmitter
Open DDV

Close DDV Synoptic jetty control panel

87
ESD1 - STOP LOADING SEQUENCE ROUTING TEST PROCEDURE
Warning Very important / Actions to be carry out before The hydraulic pump is automatically started. The corresponding
any routing testing as indicated in slide 86 lamp "Pump running" lights up on the local control panel.
Check that the maintenance override key switch is on The solenoid valve SV10 in the HPU to release the pressure of the
position 1 and that the yellow light maintenance override accumulator is energized.
activated is On A time delay starts (corresponding to the time closing of the main
shut off valve and stopping
pp g of the pump).
p p) T1: 0 seconds. Can be
adjusted during pre-commissioning/commissioning.
These tests can be done from push buttons on the local control
panel and from equivalent customer device At the end of this time delay T1 (average timing: 5 seconds), a
Deselect the arm (Arm selector switch in position 0 on local and new time delay starts (corresponding to the closing time of the ERS
remote control panel). Arm will then be in free wheeling. The "Arm valves) and the solenoid valve DDV closing is energised
p lights
selected" lamp g Off ((Temporisation
p T2: 6 seconds);
); The first section of the piston
p rod
For safety reasons, the arms will be kept manually selected as extend to close the DDVs (The closing/opening time of the DDV is
indicated on slide 76 adjusted with the flow control valves installed on each selector
valve assembly).
The hydraulic pump is stopped
The local control panel is kept under power Once the DDV are closed (red control light ERS VALVE CLOSED
lights On, cancel the sequence: key operated switch "ESD reset"
Ensure that the PERC axis is removed from the PERC collar as
indicated in slide 73: ERS operation - Routine testing (Actuator with The red lamp "ESD1 / Stop loading", the external audible and visual
PERC axis removed from the PERC)) in order to prevent an alarms go Off
inadvertent release of the PERC
Re-open the ERS valve from the local control panel

ERS valves closure testing by "ESD1


ESD1 / Stop loading
loading
PERC hydraulic cylinder routine testing by ESD1/ Stop
Open the PERC locking valve located on style 80 The lamp on the loading
local control panel Arm ready for loading for the arm under test
lights up .
Press the push button "ESD1
ESD1 / Stop loading
loading" on the local control
panel
The red lamp "ESD1 / Stop loading" flashes on the local control
panel
The external audible and visual alarms give an intermittent signal

88
PERC HYDRAULIQUE VALVE TESTING
Warning Very important / Actions to be carry out before any PERC valve to be tested
routing testing as indicated in slide 86 (shown in closed position)
This test is done with the manual drives of the ERS and PERC valves
directional control valves on the selector valves assembly
This test is to control the efficiency of the hydraulic interlock on
the PERC valve
For safety reasons,
reasons the arms will be kept manually selected as indicated
on slide 76
Start the hydraulic pump
Ensure that the PERC valve is closed. The green light Arm ready for
loading must be Off
Ensure that the PERC axis is removed from the PERC collar as indicated in
slide 73: ERS operation - Routine testing (Actuator with PERC axis
removed from the PERC)) in order to prevent an inadvertent release of the
PERC.
Close the ERS valves from the local control panel or from the Perc axis removed
cordless remote control
Check that the corresponding red light ERS VALVE CLOSED is On Closing of the ERS valves Opening of the ERS valves
Remove the PERC manual drive safety pin on the selector valve assembly
(solenoid valve TAG # UNCOUPLE)
Fully press the manual drive of the PERC valve directional control
valve on the selector valve assembly
The second section of the tandem cylinders piston rod must not extend.
The piston rod must remain at same position
Re-open the ERS valve from local control panel or from the cordless
remote control
Install back the PERC manual drive safety pin on the selector valve
assembly
If the second section of the tandem cylinders piston rod extend,
the PERC valve at the style 80 must be immediately replaced Activation of the PERC

89
ESD2 - EMERGENCY DISCONNECTION SEQUENCE
ROUTINE TEST PROCEDURE
Warning Very important / Actions to be carry out before At the end of the time lag and if the ERS valves of the arm are
any routing testing as indicated in slide 86 closed, the second section of the piston rod of the double acting
Check that the maintenance override key switch is on hydraulic cylinder extends but not open the PERC collar (actuator
position 1 and that the yellow light maintenance override with PERC axis removed from the PERC) and a new delay starts
activated is On (corresponding to the opening of the PERC). Temporisation T3:
2seconds
These tests can be done from push buttons on the local control
panel and from equivalent customer device i The arm is automatically blocked by selection
PERC hydraulic cylinder routine testing by ESD2/ Emergency Since the maintenance override is activated, there is no
disconnection automatic retraction after ESD2
Open
p the PERC locking
g valve located on style
y 80 The lamp p on
Cancel the sequence: key operated switch "ESD reset
reset
the local control panel Arm ready for loading for the arm under
test lights up The red lamp "ESD1 / Stop loading and red lamp "ESD2/
Press the push button "ESD2/ Emergency disconnection" on the Emergency disconnection" , the external audible and visual alarms
local control panel goes Off
The red lamp "ESD1/ Stop loading" flashes on the local control Re-open
p the ERS valve from the local control p
panel or from the
panell cordless remote control
The red lamp "ESD2/ Emergency disconnection" lights up on the
local control panel Close the PERC locking valve. The lamp "Arm ready for loading" of
the tested arm goes off on the local control panel
The external audible and visual alarms give a continuous signal
The hydraulic pump starts. The corresponding lamp "Pump After these checks
running"
i " lights
li h up on the
h electric
l i controll panell Bring back the arm in parked position and lock it
The solenoid valve SV10 in the HPU to release the pressure of the
accumulator is energized If not, unselect the arm by unscrewing the manual handle on the
selector valve assembly
A time delay starts (corresponding to the time closing of the main
shut off valve and stopping of the pump). T1: 0 seconds start Stop the Hydraulic Power Unit
At the end of this time delay T1 (average timing: 5 seconds, a new Switch off the local control panel
time delay starts (corresponding to the closing time of the ERS
valves) and the solenoid valve DDV closing is energised
(Temporisation T2: 6 seconds); The first section of the piston rod
extends to close the DDVs (The closing/opening time of the DDV PERC hydraulic cylinder routine testing by ESD2/ Emergency
is adjusted with the flow control valves installed on each selector disconnection
al e assembly)
valve assembl )

90
EMERGENCY RELEASE SYSTEM
PERC CONTROLLED RELEASE TESTING
Warning Very important / Actions to be carry out before any
routing testing as indicated in slide 86
Check that the maintenance override key switch is on position 1
and that the yellow light maintenance override activated is
On
These tests can be done from push buttons on the local control panel and
from equivalent customer device i
After the inspection before the arrival of the first tanker, this
check will be made every one year or prior to seal change out or
other maintenance
D
During
i th operation
the ti off the
th disconnection,
di ti ensure no personnell
within a two meter radius
If needed, install the 4 hoists between upper and lower valves :
Used to separate PERC flange in case of DDV Seal replacement
For the reconnection, see the above paragraph Reassembly after
the emergency disconnection
disconnection
PERC controlled release testing by ESD2 / Emergency
disconnection
Temporary remove shear pin from PERC collar as indicated in slide 76
Put in place PERC axis on PERC collar as indicated in Picture N29
(PERC in operating condition)
Open the PERC locking valve located on style 80 The lamp on the local
control panel Arm ready for loading for the arm under test lights up
Press the push button "ESD2 / Emergency disconnection" on the local
control panel
The red lamp "ESD1
ESD1 / Stop loading
loading" flashes on the local control panel Picture N29_
N29 Temporary
The red lamp "ESD2/ Emergency disconnection" lights up on the local clamping device & PERC in
control panel operating condition
The external audible and visual alarms give a continuous signal
The hydraulic pump starts. The corresponding lamp "Pump running" lights
up on the electric control panel

91
EMERGENCY RELEASE SYSTEM
PERC CONTROLLED RELEASE TESTING
The solenoid valve SV10 in the HPU to release the pressure of the
accumulator is energized
A time delay starts (corresponding to the time closing of the main
shut off valve and stopping of the pump). T1: Average timing 5
seconds start
At the end of this time delay T1, a new time delay starts
(corresponding to the closing time of the ERS valves) and the
solenoid valve DDV closing is energised (Temporisation T2: 6
seconds); The first section of the piston rod extends to close the
DDVs (The closing/opening time of the DDV is adjusted with the flow
controll valves
l i
installed
ll d on each
h selector
l valve
l assembly)
bl )
At the end of the time lag and if the ERS valves of the arm are
closed, the second section of the piston rod of the double acting
hydraulic cylinder extends but not open the PERC collar (actuator
with PERC axis removed from the PERC) and a new delay starts
(corresponding to the opening of the PERC)
PERC). Temporisation T3: 2
seconds
The arm is automatically blocked by selection
Since the maintenance override is activated, there is no
automatic retraction after ESD2
The four temporary safety & re-assembly rods will prevent
the separation of the ERS valves when the emergency
release coupler is opened
To reset the system :
Stop the alarm : key button "ESD reset" on the Local Control Panel..
Allll the
h signals
l and
d the
h motor stops
Remove the PERC axis from PERC clamps

Picture N30_ DDV closed & PERC clamps open in


controlled release

92
EMERGENCY RELEASE SYSTEM
PERC CONTROLLED RELEASE TESTING
Un tighten PERC collar of 1/2 turn the screw with nut welded
welded. To move the screw
screw, a nut is welded on it (see Picture N31)
N 31)
Position the PERC around the flanges PERC and engage the came as indicated in slide 80
Re-tighten the screw, at the corresponding torque value
The tightening torque value is different for each double valve/Perc diameter. Refer to the table on the following slide for the
torque value of each loading arm(as indicated in table slide 82)
Reinstall a new shear pin in the releasing fork for added security by preventing accidental release of the Perc (Only use FMC shear pin)
The correct shear pin position guarantee that the PERC clamps and release fork is well positioned as indicated in slide 81
If installed, remove the hoists
Unlock the DDV driving system by pulling the locking disk (disengage the locking pin from the housing) as indicated in slide 84
Operate in opening position the ERS valve using the local control panel or cordless remote control
Bring back the arm in parked position and lock it and remove the manual selection from the selector valve

Picture N31_ PERC collar


Adjusting screw

93
DDV & PERC \ GOOD PRACTICE AND PREVENTIVE MAINTENANCE
After prolonged service, the DDV/ERC will need to be completely overhauled. The interval between such overhauls will vary
from between 5 and 7 years, dependent upon the operating conditions, standard of maintenance and the inspection reports.
The need for an overhaul will normally be confirmed by excessive corrosion, wear of components, or difficulty in operation .
Only minor repairs will be carried out on the coupler in jetty. Major maintenance task should be performed in repair shop in a
clean working area by qualified, trained and authorized FMC personnel.
The use of non-FMC OEM (Original Equipment Manufacturer) parts voids all design, type, case, test and quality approvals by
third-party certifying authorities and may void product warranty.
Major maintenance tasks should be carried out by suitably experienced personnel in a clean area, where the components can
be properly documented, repaired or replaced and tested before being reinstalled.

Good practice
Never test operate the ERC unit unless the ship side ball valve is fully supported or the temporary clamping device installed on PERC clamps
Always ensure that the personnel are at least two meters away from the unit prior to operating the ERC
For low temperature DBV/ERC systems it is important that the ball valves are never rotated when there is ice formation on the sphere. Water
wash must no be used to disperse the ice
Ensure maintenance and production personnel operating this equipment read and understand the FMC operating & maintenance manual

Preventive maintenance

Routine testing as per FMC operating & maintenance manual ( It is suggested that the routine test is carried out prior to every cargo transfer )
Check for oil leaks on hydraulic actuators , cylinders, sequence valve and hydraulic Perc valve
Ensure all hydraulic fittings and hoses are free from oil leaks and are undamaged
Check that all pins and washers are in position, secure and undamaged
Check that the Y shaped connections on the cross linkages are well greased and in correct position
Check that the shear pin is in position and undamaged
Check hydraulic sequence valve efficiency ( plunger sticky)
Yearlyy greasing
g g all DDV and PERC actuator moving
g parts
p (Rail
( guide,
g , guiding
g g rod,, pushing
p g rod,, mechanical interlocks ect..))

94
FMC EQUIPMENTS DDV & PERC \ GOOD PRACTICE
Important
p note:
The double valves are only designed for the events of Emergency Disconnection.
FMC does not recommend using the double valves as process valves
Storage of the arms with the double valves closed presents risks that an accidental disconnection occurs
FMC declines
d li all
ll responsibilities
ibiliti for
f using
i the
th double
d bl valves
l as process piping
i i valves
l
Warning / Major safety issue :
These double ball valves are supposed stay all time in opening position (When the arms are in storage position or in motion).
The ERS/DDV are Emergency valves and not process valves. When the ERS/DDV are in open position, the tandem cylinder
is fully retracted and do not allow operating the ERC when the ERS valves are opened. These entire safety devices are in
place to secure the operators against any miss operation. I remind you that the MLAs must be operated empty of product
and without pressure into the product line.
In case the terminal operating policy requires that the ERS valves of FMC loading arms are closed whilst the arms are in
stored position, FMC highlights the fact that this creates a potential risks to accidentally pressurize the loading arms. If for
any
y reason the jetty
j y ESD valves are leaking,g, havingg the ERS valves closed will not allow operation
p people
p p to detect this leak.
Proper terminal procedures shall be put in place to ensure it has been checked the arms are empty and out of any pressure
before the operators manoeuvre the arms and /or open the ERS valves. Non respect of this advice could lead to major
accident and FMC will not be responsible for the consequences of such unsafe operations.

Warning:
Any removal of any parts of the DDV/PERC for inspection, maintenance and repair, disassembly or reassembly of major arm
components should be only undertaken by qualified personnel and with great precaution and care as to avoid handling
accidents.
For better safety, these operations should be preferable performed under supervision of FMC personnel.
Never attempt any inspection or repair on a loading arm before having make sure:
That the arm is empty and without pressure
That the arm is locked
That the arm cannot be operated

95
MAINTENANCE BOARD FOR ARM / MECHANICAL PART

FMC Standard Maintenance Board


Option Visual checks Day Week Month 3 Mon 6 Mon Year Comments
Detailed check of the arm, look for leakages, corrosion, and control hydraulic flexible
General look *
hoses
Paint * Touch ups where needed
Anchor bolts * Check for anti corrosion protection
Check for anti corrosion protection and tension / Visually inspect the cable for damage
Pantograph / Inboard &
* / Check loosen turnbuckle lock nuts ( protect them with "Densyl tape") & check the
outboard wire ropes
tightening attachement
Check the tighteness of all fixing parts ( use the torque wrench / refer to FMC
Structure arm *
maintenance manual for torque values ) : structure bearing ,c/w beams, ect
Structure bearing & Swivel Grease every 6 months, depends of working frequency / Check for abnormal noise
*
joints during operation (Manual grease pump and/or centralized greasing system)
Check the screws tightening of product line flanges ( Refer to the maintenance manual
Product line *
for torque requirement / use a torque wrench )

Regulary check proximity switch condition and adjustment (If any)+ Regulary test
Parking locking system *
effeciency and grease mechanisum

Test and verify the resistance value( 1 Kohm/1000 Vdc) / Check the condition of the
insulated hydraulic flexible hoses/Inspect for wears tears and cracks.Check if
Electrical insulation flanges *
leakages / control the tightening bolts ( use torque wrench )& re-coating the flange
yearly

Check the parrallelisum of the outboard c/w beam and the outboard arm and arm
Parrallelisum & inboard /
* balancing .Select and extend the arm over the sea, control tendency to raise or faaling
outboard balancing
down or stabilize , re-adjust if necessary .
Counterweights ( primary &
* Check for corrosion and threaded rod tightness.(protect them with "Densyl tape")
secondary )
Ladders * Inspect for corrosion .Check the trolleys , check all fixing parts ( tighteness )
Plarforms * p
Inspect for corrosion , check all fixing
gpparts ( tighteness
g )
Mechanical jack * * Check before each loading & regulary greasing all moving parts
Check the good functionning of all measuring valves ( protect them with "Densyl tape")
Centralised greasing system *
& check the flexible hose condition (inspect for wears tears and cracks)
Balancing wheel / Style 50 * Lubricate the bearing (Manual grease pump and/or centalised greasing system )

96
MAINTENANCE BOARD FOR ALL ARMS / MECHANICAL PART
Option Visual checks Day Week Month 3 Mon 6 Mon Year Comments
Regulary check the hydraulic flexible hoses, pipework and hydraulic fittings condition.
Check the shafts condition (wearness, leaks and tears on the rods) .Check movement
Inboard hydraulic cylinder * and look out for weird noises.Checks the tightening of the hydraulic cylinders fixing
parts,pivots, couling sleeves,turnbuckles & lock nuts and grease .Check if any
misalignement & regulary grease the inboard wire ropes

Regulary check the hydraulic flexible hoses, pipework and hydraulic fittings condition
Check the shafts condition (wearness, leaks and tears on the rods)wearness, leaks
outboard hydraulic cylinder * and tears on the rods .Check movement and look out for weird noises.Checks the
tightening of the hydraulic cylinders fixing parts (Pivots) & lock nuts and grease
.Check if any misalignement

Regulary check the hydraulic flexible hoses, pipework and hydraulic fittings condition
Check the shafts condition (wearness, leaks and tears on the rods)wearness, leaks
slewing hydraulic cylinder * and tears on the rods .Check movement and look out for weird noises.Checks the
tightening of the hydraulic cylinders fixing parts (Pivots) & lock nuts and grease
.Check if any misalignement

Inboard movement * Check movement & speed and look out for weird noises, grease up if necessary.

Outboard movement * Check movement & speed and look out for weird noises, grease up if necessary.

Rotation movement * Check movement and & speed look out for weird noises, grease up if necessary.

Open/Close QUIKCON III Check functionning and look out for weird noises, grease up bearings and all moving
*
Hydraulic coupler parts. Check the functionning of the proximity switches

QUIKCON III Hydraulic coupler * At each loading ,check the seals condition on QCDC face

Inspect for corrosion / Greasing all moving parts / Check that all bearings and
bushings are in good condition and where is necessary are proprely greased /
QUIKCON III / Hydraulic coupler
* Deterioration and corrosion. Regulary check the hydraulic flexible hoses, pipework and
(QCDC)
hydraulic fittings condition ( refer to the FMC maintenance manual ) / Check the
alignment cone condition and fixing part

97
MAINTENANCE BOARD FOR ALL ARMS / MECHANICAL PART
Option Visual checks Day Week Month 3 Mon 6 Mon Year Comments

Product line swivel joints * Check for leakage on primary packing

Check at each loading the N inlet pressure & the outlet flow at the last swivel joint on
Nitrogen drying swivel joints
N/A * * style 80 ( N6) / Inspect the flexible hoses for wear tears and cracks ;Check if
(LNG arms)
leakages and check the condition of the N N lines , fittings and fixing parts .

Check the good functionning of all measuring valves ( protect them with "Densyl tape")
Centralized greasing system *
& check the flexible hose condition (inspect for wears tears and cracks)

Nitrogen
g p purging
g g line * Check all flexible hoses condition

Inspect for corrosion, Check all fixing parts ( tighteness ) / Regulary check the
Vacuum breaker * greasing condition of spring return valve & valve / Inspect and replace if necessary the
vacuum breaker wire rope / Anually full grease valve and spring return valve

Routing testing as per FMC manual ( test ESD1 & ESD2 sequences on dummy
DV & PERC / Routine testing * *
manifold or on the ship with safety bolts on DV & Perc in routine test position )

Test the ESD1 & ESD2 in automatic sequence ( from proximity switches ) and by
DV & PERC / ESD automatic
manual activation from the selector valve cabinet ( switch off the electric motors power
sequences and manual * *
supply , test has to be done with accumulators only / on dummy manifold only with
activativation / Routine testing
safety bolts on DV)

Open the PERC collar in control release and check DV flanges ( upper & lower ) if any
moisture or damage /Open the release fork spring box's cover and greasing the belville
DV & PERC system *
spring washers & re-sealing/ Check the shear pin condition / ERC maintenance to be
done on dummy manifold only with the ERC safety device installed

Inspect for corrosion , check all fixing parts ( tighteness) / Visually inspect DV &
DV & PERC system * PERC actuator conditions / Check and test the hydraulic ERS sequence valve /
Check the proximity switches condition and test effeciency.

98
MAINTENANCE BOARD FOR HYDRAULIC & ELECTRIC CONTROL SYSTEMS
Hydraulic
y system
y on the arm

Hydraulic tubings & fittings & fixing


* Inspect for corrosion, leakages and damages.Check all fixing parts
parts
Inspect for wears tears and cracks.Check if leakages / Checks the cable ties
Hydraulic flexible hoses *
condition, replace if necessary
Hydraulic cylinders
cylinders, motors
motors,
* Inspect for corrosion, leakages and damages.Check all fixing parts
actuators

Check the functionning and grease the piston plugger on the hydraulic control valve
Hydraulic sequence valve on DBV *
,look for hydraulic oil leakages

p g ((locared
Quick disconnect coupling
* Check the effeciency & look for hydraulic oil leakage
on style 80 / Used for QCDC)

Check the condition of the electric conduits and fixing parts , electric cables , cable
Electric system on the arm * glands, junction boxes ( check if any moisture and re-sealing ) check & test all
proximity switches .

Check the condition of the electric conduits and fixing parts , electric cables , cable
Proximity switches * glands, junction boxes ( check if any moisture and re-sealing ) check & test all
proximity switches .

Check the good functionning / Checks the proximity switch condition (if any moisture
PERC manual locking valve on
* inside) and resealing if necessary / Check the two positions valve condition and grease
style 80
mechanisum

Check functionning of the overeach alarm , operate the arm outsisde the working area
and test the first alarm and second alarm extention & slewing right/left .Verify the
Alarm system on arm *
setting of the extention & slewing alarm ( refer to the FMC drawing for the angles
calibration)

Check the functionning and grease the axis driving system and cahain (slewing
PMS / P
Potentiometric
t ti t i sensors *
sensors) / Check all fixing parts

Parking locking system / Inboard Check proximity switch adjustment / Regulary test proximity switch (Inspect if any
*
arm locking device (If any) moisture inside)

99
MAINTENANCE BOARD FOR HYDRAULIC CONTROL SYSTEMS
Option
p Visual checks Dayy Week Month 3 Mon 6 Mon Year Comments
HYDRAULIC POWER UNIT
General look * Check for corrosion
Paint * Touch ups
Tubings & fittings * Pressure test for leaks, check for crushed tubings
Electric cables * Check connections, avoid moisture
Main pressure * Check before each loading and adjust if necessary ( 190 bar )
Hydraulic oil level * Check before each loading and refill the tank if necessary
Before each loading check if any hydraulic oil leakage ( visit door , ect) / Yearly
,open and drain & clean oil hydraulic tank ( drain all accumulators first ) / Clean or
Hydraulic oil tank * *
replace strainer filters on two hydraulic pumps and pneumatic pump / Take hydraulic
oil sample
Oil temperature transmitter
N/A * * Check efficiency / Set point: Hight temperature alarm 60C
4-20 Ma
Hydraulic oil level transmitter Check efficiency / Set point: Low oil level alarm 15 mb ( Corresponding at more or
N/A *
4-20 Ma less 30% of total oil tank capacity)
Pressure & return line hydraulic Before each loading ,check the visual clogging indicator on both oil filters / Yearly
* *
oil cartridge filters replace by new both cartridge filters ( dont try to clean up !!!!)
Moisture filter / air dryier Inspect the dissecant cartridge ( when the dissecant change into rose color , the
*
system dissecant element must be replaced )

Manual emergency hand pump * Check effeciency and regulary grease the moving parts

Electric motors pump Check the good functionning / Grease bearing every 5 years
Pressure gauge / Main
* * Pressure = 190 bar / recalibrate every year
pressure
Hydraulic bloc & set of
* Check for corrosion , leaks or damages
hydraulic valves

Control directional valves and


solenoid valves for * Greasing the manual command and check if efficiency
"Accumulator release pressure"

Accumulators nitrogen pressure


* Check the N pressure every six months = P : 130 bar / Refill if necessary
into bladder

HPU accumulator / 20 litters * Check accumulator vessel condition (corrosion and/or damages) / Checks for leaks

100
MAINTENANCE BOARD FOR HYDRAULIC CONTROL SYSTEMS
Option Visual checks Day Week Month 3 Mon 6 Mon Year Comments
Hydraulic power unit
Pressure transmitter / Oil low
Check the good functionning : Alarm low oil pressure below 175 bar / recalibrate every
pressure accumulator for ERS * *
year
system

Pressure transmitter
Check the good functionning : start hydraulic pump at 178 bar & stop pump at 180 bar
accumulator hydraulic pressure * *
/ recalibrate every year
regulation for ERS system

Selector Valve Assy. * Check for leaks corrosion and damages

Control directional valves and


solenoid valves for ERS/DV, * Greasing the manual command and check if efficiency
Arm movements & selection

Throttle valves & flow regulators * Greasing the screws adjustment ( both sides )

Greasing the manual command and check if efficiency / Check the inductive proximity
Selector valve *
switch condition and check the effeciency
ERS manual command ( for
* Check the good functionning and grease regulary he mechanisum
ESD2 in case of power failure)
Pressure transmitter /
Check the good functionning : Alarm abnormal oil pressure alarm at 40 bar /
Abnormal pressure into ERS * *
recalibrate every year
lines

Pressure gauge / Check if any


abnormal oil pressure into ERS * * Pressure = 0 bar or less than 40 bar / recalibrate every year
line

Accumulator Pack (for ERS) * Check for leaks corrosion and damages

Pressure gauge / Check * * Pressure = 178 to 180 bar / recalibrate every year
Accumulators
Acc m lators nitrogen press
pressure
re
* Check the N pressure every six months = P : 135 bar / Refill if necessary
into bladder

ERS accumulator / 32 liters * Check accumulator vessel condition (corrosion and/or damages) / Checks for leaks

Hydraulic bloc & set of


* Check for corrosion , leaks or damages
hydraulic valves

101
MAINTENANCE BOARD FOR ELECTRIC CONTROL SYSTEMS
Option Visual checks Day Week Month 3 Mon 6 Mon Year Comments

N/A Remote Control Pendant

Check the good functionning / Every year, open transmitter box and check for humidity
Work test * * ,sealness of connections,if the presence of moisture inside the pendant ,dry it up with
hair dryer and clean the connection terminal ,and re-sealing .
* * Check the cable & connector's conditions
RADIO CORDLESS

Check the good functionning / Every year, open transmitter box and check for humidity
Work test * * ,sealness of connections,if the presence of moisture inside the pendant ,dry it up with
hair dryer and clean the connection terminal ,and re-sealing .

Before each use, recharge and install new battery / Check the battery condition
Battery *
Activate the "battery test" at each use (LED must "On" steady light)

Before to power "On" the radio transmitter, position all the switches in neutral or "0"
position.
pos t o Radio
ad o co
cordless
d ess po
portable
tab e ttransmitter
a s tte ccheck
ec tthee co
communication
u cat o status with t tthe
e
Communication
C i ti (t (transmitter
itt tot
* shore, if Radio base unit is ok , the lamp "radio cordless in operation" must be "On" on
base unit receiver)
the radio cordless cabinet and LED transmitter must "On" (steady light), If not refer to
the operating & maintenance manual

CONTROL PANEL
General look * Check labels, plates, and lamps
Paint * Touch ups
Electric cable * Avoid moisture
Check power * Check continuity and insulation
Lamp test * Before every unloading
N/A Pressurization system * Regulary verify the inlet pressure : 7 bar / Check efficiency
Working test * Check all functions
Power "On" electric control No alarm must be activated, if yes, checks the corresponding indicating alarm light
*
panel Report and ask the maintenance department to intervene

102
PREVENTIVE MAINTENANCE / MAJOR OVERHAUL
ITEM DESIGNATION LOCATION FREQUENCY REMARKS
Fo r mo re details, refer to the standard preventive maintenance bo ard and to
M arine lo ading arms &
Weekly / M o nthly the o pearting & maintenance manual supplied with the equipments
1 assio ciated co ntro l /
Yearly The need fo r an o verhaul will no rmally be co nfirmed by excessive co rro sio n,
systems
wear o f co mpo nents, o r difficulty in o peratio n .
A fter pro lo nged service, the DV/ERC will need to be co mpletely o verhauled.
Yearly / M ajo r The interval between such o verhauls will vary fro m between 2 and 5 years
Emergency release system M arine lo ading arms
2 o verhaul every five ,dependent upo n the o perating co nditio ns, standard o f maintenance and the
ERC & DV Style 80
years inspectio n repo rts.

A fter p
pro lo nged
g service, the QCDC will need to be co mpletely
p y o verhauled. The
Yearly / M ajo r
M arine lo ading arms interval between such o verhauls will vary fro m between 3 and 5 years
3 QCDC hydraulic co upler o verhaul every five
Style 80 ,dependent upo n the o perating co nditio ns, standard o f maintenance and the
years
inspectio n repo rts.

A fter pro lo nged service, the structure bearing will need to be co mpletely
Yearly / M ajo r
Strure bearings & Structure o verhauled.
verhauled The interval between such o verhauls will vary fro m between 20 and
4 M arine lo ading arms o verhaul every five
swivel jo ints 22 years ,dependent upo n the o perating co nditio ns, standard o f maintenance
years
and the inspectio n repo rts.

A fter pro lo nged service, the pro duct line swivel jo int will need to be co mpletely
Yearly / M ajo r
o verhauled. The interval between such o verhauls will vary fro m between 10 and
5 P ro duct line swivel jo int M arine lo ading arms o verhaul every five
15 years ,dependent upo n the o perating co nditio ns, standard o f maintenance
years
and the inspectio n repo rts.

103
PREVENTIVE MAINTENANCE / MAJOR OVERHAUL
ITEM DESIGNATION LOCATION FREQUENCY REMARKS
Co mplete draining accumulato rs and o il tank and cleaning all hydraulic pump
Hydraulic po wer unit strainer filters
+ selecto r valve Draining the hydraulic circuit (do ck lines and o n the lo ading arm lines).
Yearly / M ajo r
assemblies + Overhaul o f the hydraulic po wer unit and selecto r valve assembly , ERS cabinet
6 Hydraulic system o verhaul every five
accumulato r pack + and accumulato r pack Dismantling, cleaning all hydraulic internal
years
y
h d li sytem
hydraulic t on co mpo nents t andd replacing
l i gaskets
k t and d o rings.
i
M LA 's Overhaul o f all hydraulic cylinders and hydraulic actuato rs (ERS and hydraulic
co upler), Hydraulic blo cking valves and sequence valves Cleaning internal
chamber and replace all seals , o rings, ect...
Overhaul the hydraulic limit sto p (A pex limit angle, Inbo ard arm limit angle),
parking
p g lo ck valve,, P ERC & Hydraulic
y co upler
p interlo ck valves : Dismantling,
g,
cleaning all internal co mpo nents and replacing all gaskets and O rings, check
fo r co rrect adjustment and functio ning, check fo r co rro sio n, apply to uch paint
if necessary.
Replacement o f all hydraulic flexible ho ses o n lo ading arm.
A ccumulato r envelo pe : A n internal inspectio n must be carried o ut every five
Hydraulic cylinders + years and an external visual inspectio n every two years ( Fo r further
Yearly / M ajo r info rmatio n, refer to the P ressure vessels regulatio ns and Safety
Hydraulic o n M arine hydraulic mo to r &
7 o verhaul every five regulatio ns in acco rdance with the co ncerned co untry ).
lo ading arms actuato rs + hydraulic
years A ccumulato r bladders & pisto n seals replacement .
flexible ho ses
Refill the hydraulic o il tank with new o il
Flushing g and purging
g g the hydraulic
y circuit with new hydraulic
y o il.
Greasing the bearing o f the electric mo to r ( hydraulic pump HP U).
Recalibrate the pressure gauges and pressure and temperature switches.
Checks the visit do o r gasket
Check fo r damage to the painted surfaces and a fo rmatio n o f rust. Where
necessary use a suitable paint repair pro cedure to resto re pro tectio n ( On all
hydraulic equipments)
equipments).

104