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