GFA BULLETIN FALL 2016
FUEL MANAGEMENT SYSTEM INSTALLATION Franklin Fueling Systems trials a new Fuel Management System for Shell in Novorizhskaya, outside Moscow.
PRODUCT
INNOVATION
INSTALLATION
TRAINING
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IN THIS
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6 4 3” DIP CAP INSTALLATION The first Franklin 3” dip cap is installed at a Shell site.
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DEFENDER SERIES® OPV The Defender Series® Overfill Prevention Valve is included in the new GIDS.
5 FFS PRO: UNIVERSITY Franklin launches its new training, certification and resource tool.
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8 6 ELECTRICAL CONTAINMENT TRIAL Shell Huddersfield is the pilot installation for Franklin’s new electrical containment system.
7 FUEL MANAGEMENT MOSCOW Franklin trialls its fuel management system for Shell in Novorizhskaya, outside Moscow.
8 SHELL ON-BOARDING WORKSHOPS Franklin’s engineering and commercial teams attended Shell on-boarding workshops for new EPCMs.
GLOBAL SUPPLY AGREEMENT
UPDATE IPSWICH, ENGLAND A warm welcome to the Fall 2016 edition of the GFA Bulletin. This publication is produced by Franklin Fueling Systems, Shell’s global petroleum equipment manufacturing partner. Here we highlight recent stories of achievement resulting from this dynamic global partnership. The new year 2016 kicked off with a stunning industry headline “Franklin inks new 5-year deal with Shell”. Building on the achievements of the original 2012 global agreement, the partnership negotiated a new, deeper arrangement with a wider scope of commitments from Franklin. Based on targeting individual safety, we plan to drive lower total cost of ownership through improved fuel system designs. Building on core GIDS products such as FE PETRO® submersible turbine pumps and UPP® flexible pipework system – which have been in use on Shell branded sites for many years - the team has further developed both products and services that are now being deployed across global regions. Let’s have a look at what’s happened in summary over the last twelve months. Several new products have been developed and launched into network including: Defender Series® overfill prevention valves, Cable-Tight™ Wire Management System, UPP® 40mm retrofit pipe lining, 3 inch retrofit dip cap, retrofit positive shut off valve, TS-550 evo™ fuel management system. Hundreds of examples of our innovative Optimization service have been issued, in which Franklin experts assist fuel system designers in creating the optimum site layout for critical underground equipment. The cost and efficiency benefits of Franklin’s offer is now available to all 43,000 branded Shell sites globally. Just months into this new contract, the effect can already been seen in increased inventory movement. Excitingly, the partnership has opened up a new platform for promoting the Franklin global design standard of critical fueling equipment. Beyond the company operated network of some 13,000 sites, a major launch aimed at all Shell dealer and licensed sites worldwide offers bestin-class design and equipment packages to dealer and
STEPHEN DeWILD Shell Account Director
licensee managed sites as well. Franklin territory and training services management team members are now working with Shell’s network of project management companies (EPCMs), maintenance providers and consultant designers to bring about improvements in underground systems quality. This is profiled as ‘E2E Assurance’ and is a benefit now available to all Shell site operators. FFS PRO: University is launched. This new full-feature platform now serves as the industry’s premier training, certification, and resource tool for installation professionals. Through this comprehensive online and live training and accreditation service, Shell’s fuel system installers can become trained and certified in the safe installation and maintenance of all Franklin Fueling Systems’ products. FFS PRO: University has been designed with Franklin’s Total System Solutions™ approach and built on a platform that focuses on installer safety at every step. The new platform capitalizes on practical end-to-end installation by focusing on functional areas of the petroleum equipment system and installer competence. This provides the installer with a holistic view of how the individual components are designed to work in harmony as a complete GIDS system. As a prerequisite for all training, installers are required to take a Fueling System Safety certification course to educate them on potential site dangers and prepare them for work in hazardous environments. As our Executive Vice President, Jay Walsh, says “Franklin continues to introduce ways to deliver safety and protection of human health and the environment, while striving for the lowest total cost of ownership. This is another example of how we are leading the charge for safer installation practices that protect installers and reduce onsite exposure, which in turn provides station owners with reduced installation costs”. FFS PRO feeds into vital areas such as Permit To Work procedures, ensuring that every person involved with fuel system installation is checked off for accreditation before work begins.
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3” DIP CAP
INSTALLATION
NILAI MYANSHUR, MALAYSIA On Friday 15th January the first Franklin 3” dip cap was installed at Shell Nilai Myanshur in Malaysia. The installation was inspected by Shell on Monday 18th January (above). The 3” dip caps have since received final approval from Shell to be rolled out for other installations in Malaysia. The dip caps have now also begun trials in Pakistan, India and South Africa, and are on route to Thailand. Conventional dip caps are easily removed and replaced and often incorporate locking facilities, however when the dip cap is not replaced correctly during tank filling operations and an overfill occurs, the incorrectly fitted or missing dip cap can be the source of backflow of fuel up the dip cap riser leading to Loss of Primary Containment (LOPC). Franklin’s 3” dip cap solution incorporates a spring loaded valve which closes when the cap is removed and the dipstick is not in place. It also has a mounting facility in the sealing cap to allow the dipstick to be stored in the tank.
DEFENDER SERIES ®
OPV
The launch of the Defender Series® Overfill Prevention Valve (OPV) in 2015 has resulted in inclusion usion to the GIDS and a subsequent roll-out to sites across many markets. This 4” valve hits many buttons in terms of achieving key Shell goals. These include: lower total cost of ownership through reduced installation and maintenance ance time, with simpler and easier inspection. The valve is retro-fittable into conventional fill lines with minimum fuss,, no drilling needed and less chance of any unit damage as the valve remains in place at all times. We have taken out any need to flare, rivet or use epoxy. The Defender Series® OPV uses an error-proof roll crimp and thread installation to achieve a perfectly in-line installation. The magnetically-coupled actuator system allows for primary functionality testing without any need to remove the assembly from the riser, this speedy visual inspection can be conducted by a single L3 contractor. To date, eight markets in Asia have installed over multiple sites, with ensuing application in Africa, Europe and other locations planned during 2016. This product is available now from Franklin’s local stocking distribution network, more details of which can be provided by Franklin representatives or direct from website. PAGE 4
FFS PRO:
UNIVERSITY MADISON, USA Franklin Fueling Systems has announced the launch of FFS PRO: University; a new training, certification and resource tool for industry professionals. Through this exciting new online and live training system, fuel system installers and technicians get trained and certified in the installation and maintenance of all of Franklin’s Total System Solutions™ product lines. FFS PRO: University has been designed with Franklin’s Total System Solutions™ approach front and center. The new training platform focuses on the functional areas of the petroleum equipment system rather than individual products. This provides installers with a holistic view of how the individual components are designed to work in harmony as a complete system. After completing a free prerequisite Fueling System Safety module, installers can choose to train in three certification tracks: Forecourt Specialist, Controller Specialist or Site Startup Specialist. Once an individual has completed all the certification courses within a given track and passed an end of course examination for each they earn the “Specialist” accreditation for that track. “Safety has always been a number one concern for Franklin Fueling Systems.” said Jay Walsh, Franklin Fueling System Executive Vice President. “That’s why we included the compulsory Fueling System Safety module, to help make sure that all of the professionals we train make it home safely every night. Our certification courses provide the safest installation practices to follow while on site.” Franklin has also launched the FFS PRO: University Rewards Program, which provides companies with tools to help put their training into practise. Certified professionals are offered a 50% discount on Franklin’s installation tools, along with free branded promo gear and vehicle signage. Training is available online at university.ffspro.com, or face-to-face with Franklin’s live Total System Solutions™ end-to-end training workshop.
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ELECTRICAL
CONTAINMENT HUDDERSFIELD, UK Shell Huddersfield is a petrol filling station on Westbourne Road in Huddersfield, West Yorkshire, England. As part of ongoing network investment a complete refurbishment of this site was scheduled in 2015 including new underground fuel tanks and fuel system, canopy and shop. Shell’s UK project management company, Artelia ltd and Shell designated this site as a pilot installation for Franklin Fueling Systems new Electrical containment system. The installation was carried out by Williams Southern Ltd (main contractor), AJ Bayliss Ltd (fuel system contractor) and DRB UK Ltd (electrical contractor). It is vital that electrical and electronic cables routed underground at a petrol filling station are contained safely within a ducting system and that where these ducts penetrate into hazardous areas that the ducts are sealed effectively to prevent the tracking of flammable liquid or vapor. It is usual for these ducts to be brought back to an intermediate drawpit located outside of any hazardous zone where multiple duct runs from the various hazardous areas can be combined into a smaller number of ducts before passing back towards the forecourt shop and electrical cabinet. Historically there has not been a complete engineered solution for the electrical containment system and contractors have had to devise solutions from various products from multiple suppliers. Where high-quality cable sealing systems do exist they are expensive and time consuming to install. This has led to issues with poor duct sealing to sumps and chambers so it is common to see these containment spaces full of ground water which leads to large maintenance and operational costs. Other problems frequently seen on such installations are non-vapor tight sealing of the duct internals (which can be a real health and safety hazard) and in-efficient duct sizing and routing (which can lead to installation difficulties due to congestion of underground services and unnecessary costs). Where sites are poorly designed the number of drawpits utilized can also be very high which can also lead to considerable cost implications for the site owner/operator. Franklin’s Cable-Tight™ wire management system is an engineered ‘total system solution’ for electrical and data cable containment, underground on petrol station forecourts or in any fuel installation. All three different diameter UPP® conduits (32mm, 75mm and 110mm) were used on site to allow optimization of the system based on the quantity of cables being routed to each area of the site. The semi-rigid nature of the 32mm and 75mm duct (which is supplied in coils) means that it was easy to roll-out and install without the need for joints. The flexibility of the duct allows it to be bent around corners and the gentle achievable bend radius means that there were no sharp PAGE 6
bends in the pipe and therefore cable pulling is a lot easier than with the corrugated ducts used historically. Patented UPP® Electrofusion entry seals offer 100% liquid tight seal of the duct to the tank chambers, dispenser sumps and drawpits on site. Cable sealing was achieved using the simple and very effective new UPP® duct seal system which doesn’t require any threading of cables through sealing glands or the use of any sealing compounds or resins. The cable seal is achieved using rubber glands with multiple ‘split’ cable holes each with their own integrated internal sealing ring. Cables can be pulled into the holes and sealed by tightening a single threaded compression ring from the inside of the chamber in seconds. Blanking plugs seal unused gland holes and new cables can be added at a later date without the need for any new glands or sealants. Two new UPP® electrical drawpits were installed. One was designated for all the intrinsically safe data cables and the other for power and non-intrinsically safe data. These 660x760mm drawpits come complete with a pre-installed load-rated and water tight access cover for fast and simple installation.
SHELL
MOSCOW MOSCOW, RUSSIA A Shell site in Novorizhskaya, outside Moscow, required a new fuel management system. Seeking to replace thier pressurised leak detection sysem (PLLD), they selected Franklin Fueling Systems’ TS-550 evo™. Franklin’s TS-550 evo™ fuel management system with Electrical Line Leak Detection (ELLD) was selected, because of the comprehensive monitoring it provides. As a standard feature of ELLD, AutoLearn™ automatically learns the pressure characteristics of each pipeline for precision leak detection. By automatically learning the pressure characteristics, AutoLearn™ eliminates the need to enter pipe lengths and diameters, removing the potential for human error. The existing pumps were also replaced with FE Petro® Submersible Turbine Pumps (STPs). The STPs were installed with TS-LS500 transducer kits to enable ELLD. Additionally, new probes and sensors were installed in the existing tanks to provide density measurement and other upgraded features for the multiple product lines. The TS-550 evo™ LON module was selected to allow communication with the point of sale system on site, with all connections rewired in to the TS-550 evo™. Now the site owner can view shift reports, alarms, delivery reports, monitor product levels and much more. With a comprehensive fuel management system in place and more efficient, energy-saving STPs, the Novorizhskaya site benefits from increased efficiency and reduced total cost of ownership.
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SHELL ON-BOARDING
WORKSHOPS Franklin Fueling Systems engineering and commercial teams attended Shell on-boarding workshops for new EPCMs during the early part of 2016. Here we can see Paul Ridge at the Thailand event. Franklin’s contribution centred on the practical application of fuel system design best practice to GIDS specification, deep diving into design Optimisation and the twin drives toward both Goal Zero and TCO. Similar events were held in Poland and Indonesia.
THAILAND
JAKARTA
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POLAND
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