PROJECT : MUSANDAM GAS PLANT PROJECT LOCATION : MUSANDAM, SULTANATE OF OMAN COMPANY : OMAN OIL COMPANY EXPLORATION &

PRODUCTION LLC PO NUMBER : MGP-GEN-ICS-POR-HEC-000-00007-00 ITEM : LEVEL GAUGE

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

DOC # MGP-GEN-ICS-MAN-SAI-000-00010-00-U-01
DOCUMENT STATUS

1 2 3 4

: Approved : Approved with Comments : Not Approved : Information Only

NOTE: Permission to proceed does not constitute acceptance of approval of design details, calculations, analysis, test methods or materials developed/selected by the Supplier and does not relieve the Supplier from full compliance with contractual obligations. REVIEW DATE: . 27th . Mar.. 2013 LEAD ENGINEER

ENGINEER

Y.R.JEONG

C.W.BAK

U-01 K-00 REV.

15-Mar-13 09-Dec-12 DATE

ISSUED FOR CONSTRUCTION ISSUED FOR INFORMATION DESCRIPTION

L.Y.B L.Y.B PREPARED

S.S.K S.S.K CHECKED

H.G.H H.G.H APPROVED

SAMIL INDUSTRY CO.,LTD

MGP-GEN-ICS-MAN-SAI-000-00010-00-U-01

Page 1 of 16 SAMIL INDUSTRY CO.,LTD.

MGP-GEN-ICS-POR-HEC-000-00007-00

Musandam Gas Plant Project

Installation, Operation And Maintenance Manual

REVISION LOG
REV. NO. K-00 U-01 REV. DATE 09-Dec-12 15-Mar-13 REVISED PAGE REVISION DESCRIPTION Issued for Information Issued for Construction

MGP-GEN-ICS-MAN-SAI-000-00010-00-U-01

Page 2 of 16 SAMIL INDUSTRY CO.,LTD.

MGP-GEN-ICS-POR-HEC-000-00007-00

Musandam Gas Plant Project

Installation, Operation And Maintenance Manual

TABLE OF CONTENTS
1. INSTALLATION, OPERATION AND MAINTENANCE MANUAL.4

MGP-GEN-ICS-MAN-SAI-000-00010-00-U-01

Page 3 of 16 SAMIL INDUSTRY CO.,LTD.

MGP-GEN-ICS-POR-HEC-000-00007-00

Installation operation
SAM IL INDUSTRY CO.,LTD

No. : SICS-03-02

and maintenance manual

PAGE : 1 OF 5

MAGNETIC FLOAT TYPE LEVEL GAUGE

[MODEL : SMF-50A,65A, 50AN, 50AJ, 50ALD, 50AU]

0 Rev. No.

04.01.2004 M . D . YEAR

First Issue Rev. Description

M.Y CHOI Prepared By

E.M JEONG Reviewed By

K.T CHOI Approved By

FORM NO. : SICS-03-02 REV.0

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Installation operation
SAM IL INDUSTRY CO.,LTD

No. : SICS-03-02

and maintenance manual

PAGE : 2 OF 5

Table of Contents

1. Things to Check before Installation------------------------------------- 3

2. Test Operation Procedure------------------------------------------------ 3

3. Cause for malfunctioning FLOAT ---------------------------------------- 4

4. LEVEL GAUGE Maintenance/Repair----------------------------------------- 4 Disassemble and assemble.

5. Precautions ------------------------------------------------------------ 5

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Installation operation
SAM IL INDUSTRY CO.,LTD

No. : SICS-03-02

and maintenance manual

PAGE : 3 OF 5

1. Things to Check before Installation

1) Check to see if there are any damages done during the transportation. 2) Check to make sure there are no foreign objects like dirt or rocks within the pipes of Tank(Vessel), and connection part of the flange (It is to insure the proper operation of the float) 3). In order to prevent the malfunction of the float caused by leakage in Level Gauge or torsion of the column, the section drawing of the flange face, aligned bolt hole of the flange, distance in between C to C, and the height of the Flange face must be checked. 4) Please remove the spring that was installed within the chamber to prevent the movement of the float [Refer to the picture in PAGE 4 OF 5]. 2. Test operation procedure The most important part of the Magnetic Float Type Level Gauge is the float. Therefore, it is important not to harm the Float part during the test operation, The fluid used in the Float is designed to the pressure and the temperature used in the normal operating condition. Therefore, it is important to set the environment to the standards of normal operating condition before performing the test operation. The high temperature (100 C) liquid must be dealt with special care. The float is not designed to be operated in the worst condition. Please careful not to damage the float part. Sudden change in the pressure or temperature could damage the float In the case of pressure is inflow suddenly inside the chamber, the float can crush or deform by striking into an upper blind of the chamber. In order to prevent the above, be sure to follow the below order without fail. 1). Open the upper valve very slowly, so that the pressure and fluid increases very slowly inside the float chamber. repeat 4 ~ 5 time that opening and closing the upper valve very slowly. 2). If the temperature of the Level Gauge Body(Column) reaches the operation temperature, fully open the upper & lower block valve to fill in the level gauge with the liquid. 3). If there are no problems with the Float, the level gauge indicator will mark the liquid level of the tank as it is. (10 cm difference could occur due to the temperature difference in between the tank and the level gauge)

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Installation operation
SAM IL INDUSTRY CO.,LTD

No. : SICS-03-02

and maintenance manual

PAGE : 4 OF 5

3. Cause of malfunctioning FLOAT. 1). Distortion or damage to the Float 2). Ration difference in between the Float and the operating liquid. 3). Foreign object within the interior of the Level Gauge Body(Column) and blocking the movement of the Float. 4). Due to the disclosure or malfunction of the Drain Valve, liquid is not filled up fully into the Level Gauge Body(Column) 5). During the installation of the level gauge, the spring to prevent the movement of the body during the shipment was not removed 4. LEVEL GAUGE Maintenance and Repair If there are no damages done to the float, the operation and maintenance of the Magnetic Float Type Level Gauge is not difficult at all. If the color of the Indicator is changed, it must be exchanged in a periodical basis. Assemble and Disassemble. Due to simple structure of the Magnetic Float Type Level Gauge (Picture-1), it can be easily disassembled and assembled. If the exchange of the float and the cleaning of the Level Gauge Body (Column) is needed, the following procedure could be followed. Close the upper and lower block valve. Open the Drain Valve to relieve the inner pressure and liquid. (If it is a hot liquid, the Level Gauge will also be very hot. Be careful for the burn) Loose the bolt & nut of the Bottom Blind Flange Bolt & Nut and disassemble the blind flange. Then, take out the float. Be careful not to drop the float. Check to see if the Float is in good condition. If the Float is in good condition, it could be reused. The assemble of the equipment could be done by following the disassemble procedure backward. Do not put the Float into the Level Gauge. Set the Bottom Blind Flange, and tighten it with the Bolt & Nut. The Gasket must be exchanged with a new product. The test operation procedure is the same with the test operation procedure in article 2

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Installation operation
SAM IL INDUSTRY CO.,LTD

No. : SICS-03-02

and maintenance manual

PAGE : 5 OF 5

5. Precautions During the final test of the Tank(Vessel), there may be cases where the Magnetic Float Type Level gauge must be installed and operated in the same time. In this case, the maximum operation pressure is set as 1.5 times greater than the designed pressure. In this case, please remove the float before the test operation. (If the float is operated under an irregular condition, it may be damaged.)
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SAM IL INDUSTRY CO.,LTD

INSTALLATIONOPERATION AND MAINTENACE PROCEDURE

NO. : SICS-03-02 PAGE : 1 OF 8

TUBULAR, REFLEX, TRANSPARENT TYPE LEVEL GAUGE

[MODEL : SBG-1,2,3 & SRG-1,2,3,4 & STG-1,2,3,4]

0 Rev. No.

04.01.2004 M . D . YEAR

First Issue Rev. Description

M.Y CHOI Prepared By

E.M JEONG Reviewed By

K.T CHOI Approved By

FORM NO. : SICS-03-02 REV.0

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SAM IL INDUSTRY CO.,LTD

INSTALLATIONOPERATION AND MAINTENACE PROCEDURE

NO. : SICS-03-02 PAGE : 2 OF 8

TABLE OF CONTENTS

1. THINGS TO CHECK BEFORE INSTALLATION ----------------------------------- 3

2. CAUTIONS FOR VENT AND DRAIN PIPING ------------------------------------ 3

3. THE ORDER OF MAKING A TRIAL RUN AND CAUTIONS -------------------------- 3 1) CONFIRMATIONS BEFORE A TRIAL OPERATION 2) THE ORDER OF A TRIAL OPERATION 4. TROUBLESHOOTING FOR THE MALFUNCTIONS OR TROUBLES ---------------------- 4 5. DISASSEMBLING AND ASSEMBLING ------------------------------------------ 4 [1] TUBULAR TYPE LEVEL GAUGE ------------------------------------------- 4 1) THE ORDER OF DISASSEMBLING 2) THE ORDER OF ASSEMBLING A) GLASS TUBE B) HOSE(PFA) [2] REFLEX, TRANSPARENT TYPE LEVEL GAUGE ------------------------------ 6 1) THE ORDER OF DISASSEMBLING 2) THE ORDER OF ASSEMBLING 3) HYDROSATIC OR PNEUMATIC TEST AFTER ASSEMBLING

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SAM IL INDUSTRY CO.,LTD

INSTALLATIONOPERATION AND MAINTENACE PROCEDURE

NO. : SICS-03-02 PAGE : 3 OF 8

1. THINGS TO CHECK BEFORE INSTALLATION

1). Make sure that a leak on the connected parts of the level gauge or the distance from center to center in order to prevent fracture or damage of the glass, a parallel level of flange face, the P.C.D of bolt holes of the level gauge flange and counter-part. also, whether the height of flange face is equivalent or not. 2) Make sure of no mud, welding slag, dust, etc inside of tank (vessel) pipe and the flange. 3) In case of check ball type, confirm if the check ball is set properly to the gauge valve. 4) Confirm if the gasket of the flange to be connected is suitable for the operating condition. (like as fluid state, temperature , pressure and type). 5) Make sure of the Tag no., required material and etc. 2. CAUTIONS FOR VENT AND DRAIN PIPING 1) The vent and drain piping are required for operators safety when fluid is drained or vented. 2) SAM ILs standards of vent and drain are 1/2 NPT and 15A PT. as customers requirement, other size [3/4, 1] can be supplied. 3. THE ORDER OF MAKING A TRIAL RUN AND CAUTIONS 1) Confirmations prior to a trial operation No damage or breakage of glass. Make sure that the vent, drain valves or plug shall be closed totally. 2) The order of a trial operation (Refer to Fig.-1) Fully close the upper(A), lower valves (B) and drain valve(C) Open the drain valve (C) Gradually open the upper valve(A) and eliminate air in the level gauge. Fully close the drain valve (C) to give pressure same as the vessel(tank) to the level gauge. if the temperature of fluid is high or low, preheating or pre-cooling have to be applied to prevent thermal shock. If the fluid is high temperature, leakage can occur from gasket due to thermal expansion of the bolt. Make sure to wait until the level gauge turn into stabilized to the operating temperature.
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SAM IL INDUSTRY CO.,LTD

INSTALLATIONOPERATION AND MAINTENACE PROCEDURE

NO. : SICS-03-02 PAGE : 4 OF 8

Gradually open lower valve(B) to in-flow the fluid to the level gauge from the vessel. Finally, open the upper and lower valves fully. With improper opening, the ball check cant give its function fully.(Refer to Fig.-2)

BALL CHECK OPERATED

BALL CHECK NOT OPERATED

BALL CHECK
Fig.-1 Fig.-2

4. TROUBLESHOOTING FOR THE MALFUNCTION OR TROUBLES. 1) When leakage occurs on the Level gauge body, close the upper and lower valves and open drain valve to depressurize interior of the level gauge (in accordance with No.5). 2) When leakage occurs on the connection between gauge body and gauge valve, depressurize interior of the level gauge like No.1 and loose connection nut and replace the gasket. 3) When liquid level is not indicated in the level gauge. In case of ball checks trouble, fully close the upper and lower valves and then gradually open them slightly. In case that upper and lower valves are choked with something wrong, close the block valve and dismantle the level gauge and clean it up. In case Drain Valve is set closed or leaked, confirm if the drain valve is closed or leaked. (If leakage occurs on the valve, replace it.)

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SAM IL INDUSTRY CO.,LTD

INSTALLATIONOPERATION AND MAINTENACE PROCEDURE

NO. : SICS-03-02 PAGE : 5 OF 8

5. DISASSEMBLING AND ASSEMBLING (=MAINTENANCE). [1] disassembling and assembling procedure for tubular type level gauge . 1) disassembling (Refer to Fig.-3) Close the gauge valve (lower, upper) and open the drain valve to eliminate the fluid and pressure. Loose hose band[1] and union nut[3] and separate the glass(or hose) and protector from valve. Remove them carefully for preventing damages. 2) Reassembling (Refer to Fig.-3) A) In case of glass tube. Loose the union Nut[3] of gauge valve and set it to glass tube[6]. Set gland[4] to glass tube with union nut and then set packing[5:Gasket] to it. After following & , set the glass tube to gauge valve. Push gland to gauge valve and fix gland and packing into the gauge valve. For no leakage, fasten union nut properly so far as glass cant be breakable. With control of C to C, fix the protector[2] to gland of gauge valve. Fasten the protector firmly with hose band[1].

NO. 1 2 3 4 5 6

NAME OF PARTS Hose Band Protector Union Nut Gland Packing / Hose Nipple Glass / PFA Hose

TUBULAR TYPE LEVEL GAUGE Fig.-3

B) In case of hose (PFA). Loose the union nut[3] of gauge valve and set it to hose[6]. Set gland[4] to hose with union nut.
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SAM IL INDUSTRY CO.,LTD

INSTALLATIONOPERATION AND MAINTENACE PROCEDURE

NO. : SICS-03-02 PAGE : 6 OF 8

After heating the end of hose (until it becomes smooth), insert it into hose nipple[5]. Fix hose nipple with hose to gauge valve. Push gland to gauge valve and fix the union nut. Fasten the union nut firmly for no leakage. With control of C to C, fix the protector[2] to gland of gauge valve. Fasten the protector firmly with hose band[1]. [2] Disassembling and Assembling procedure for Reflex, Transparent type Level Gauge 1) disassembling (Refer to fig.-4) Close the gauge valve (lower, upper) and open the drain valve to eliminate the fluid and pressure. Remove the accessories (Illuminator, non-frost, etc) Unfastening nut[7], separate the cover from body and then detach the glass. Remove the gasket[2] and cushion gasket[4] carefully for no scratch or any damage on it because gasket adhere to Body firmly for long time. at this point of the above, make sure that there is no scratch or any damage on its surface (leakage may occur). 2) Reassembling (Refer to Fig.-4) Clean a contacted face with gasket of Level gauge. If not, leakage may occur. In case of Reflex type level gauge, put in order the Gasket[2], Glass[3] Cushion Gasket[4] on a contacted face with gasket of Level gauge. In case of Transparent type Level gauge at high temperature or corrosive fluid, put in order the Gasket[2], Mica[9], Glass[3], Cushion Gasket[4] on a contacted face with gasket of Level gauge. Additionally put in the Mica[9] for protecting the glass. Put bolts into the holes of the cover and fasten them with washer[6] and nut[7] smoothly. For re-using bolts, make sure conditions for corrosion of bolts and thread of screw. Confirm if Gasket, Glass and etc are set correctly in their places and fasten the bolts with 50~100kgf-cm Torque for first time bolting. Make sure for the above again and then re-bolt them with maximum value of torque. If torque value is high for high-pressure, bolt them into 3~5 times. At the point of the above, make sure to follow the procedure in accordance of fig-5. If its not, leakage may occur. Also be careful that glass can be broken when excessive pressure apply. ( apply the uniformed torque among all cover).

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SAM IL INDUSTRY CO.,LTD

INSTALLATIONOPERATION AND MAINTENACE PROCEDURE

NO. : SICS-03-02 PAGE : 7 OF 8

Fig.-4
NO 1 2 3 4 5 6 7 8
9

NAME OF PART Gauge Body Gasket Glass Cushion Gasket Gauge Cover Washer Nut Bolt
Shield(MICA)

NO MODEL PRESSURE
1 2 3 4 1 2 3 4 STG-1 STG-2 STG-3 STG-4 SRG-1 SRG-2 SRG-3 SRG-4 30kgf/cm2 50kgf/cm2 80kgf/cm2 180kgf/cm2 30kgf/cm2 50kgf/cm2 100kgf/cm2 200kgf/cm2 250kgf/cm2

1ST
100 100 100 100 100 100 100 100 200

2ND 3RD 4TH

200 200 200 200 200 200 200 200 500 350 400 400 400 400 400 400 400 800 600 600 1000 500 500

5TH

6TH

600

700 800 1200 1400

FASTENING TORQUE [kgf-cm ]

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SAM IL INDUSTRY CO.,LTD

INSTALLATIONOPERATION AND MAINTENACE PROCEDURE

NO. : SICS-03-02 PAGE : 8 OF 8

The above table is torque values for using the non-asbestos gasket and for using 320 mm of the glass length. the torque values may be changed a bit according to gasket material and glass length.

TRANSPARENT & REFLEX TYPE LEVEL GAUGE Fig.-5

At the point of the above, make sure to follow the procedure in accordance with Fig.-5. If does not, leakage may occur. Also be careful that glass can be broken when excessive pressure apply. ( apply the uniformed torque among all covers). Replace the gasket, cushion gasket and etc with new one surely. If re-use them, leakage may occur.

3) Hydrostatic (or Pneumatic) test after assembling. First of all, operate the pressure test with it greater than operating pressure. - Hydrostatic test : Operating pressure x 1.5 for 5 minutes (SAMILs standard) - Pneumatic test : Operating pressure x 1.1 for 5 minutes (SAMILs standard) 4) After setting up, warming up in accordance with clause 3.

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