RP-157

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OISD - RP - 157 September, 1996 FOR RESTRICTED CIRCULATION ONLY

RECOMMENDED PRACTICES FOR TRANSPORTATION OF

BULK PETROLEUM PRODUCTS

Prepared by :

COMMITTEE ON TRANSPORTATION OF BULK PETROLEUM PRODUCTS

OIL INDUSTRY SAFETY DIRECTORATE 7TH FLOOR, NEW DELHI HOUSE

27, BARAKHAMBA ROAD NEW DELHI - 110 001.

NOTE

OISD publications are prepared for use in the oil and gas industry under Ministry of Petroleum & Natural Gas. These are the property of Ministry of Petroleum & Natural Gas and shall not be reproduced or copied and loaned or exhibited to others without written consent from OISD.

Though every effort has been made to assure the

accuracy and reliability of the data contained in these documents, OISD hereby expressly disclaims any liability or responsibility for loss or damage resulting from their use.

These documents are intended to supplement rather

than replace the prevailing statutory requirements.

FOREWORD

The Oil Industry in India is more than 100 years old. Because of various collaboration agreements, a number of international codes, standards and practices have been in vogue. Standardisation in design philosophies and operating and maintenance practices at a national level was hardly in existence. This, coupled with feed back from some serious accidents that occured in the recent past in India and abroad, emphasised the need for the industry to review the existing state of the art in designing, operating and maintaining oil and gas installations.

With this in view, the Ministry of Petroleum & Natural Gas in 1986

constituted a Safety Council assisted by Oil Industry Safety Directorate (OISD) staffed from within the industry in formulating and implementing a series of self regulatory measures aimed at removing obsolescence, standardising and upgrading the existing standards to ensure safer operations. Accordingly, OISD constituted a number of technical committees of experts nominated from the industry to draw up standards and guidelines on various subjects.

The present document on “Recommended Practices for

Transportation of Bulk Petroleum Products” was prepared by the Committee on Transportation of Petroleum Products. This document is based on the accumulated knowledge and experience of industry members and various national & international codes and practices. It is hoped that the provision of this document, if implemented objectively, may go a long way to improve the safety and reduce accidents in the oil and gas industry. Suggestions for amendments to this document should be addressed to:

The Coordinator,

Committee on Transportation of Petroleum Products

OIL INDUSTRY SAFETY DIRECTORATE 7TH FLOOR, NEW DELHI HOUSE

27, BARAKHAMBA ROAD NEW DELHI - 110 001.

COMMITTEE ON TRANSPORTATION OF PETROLEUM PRODUCTS

Revision - I _______________________________________________________________________________

NAME ORGANISATION __________________________________________________________________

LEADER Shri Barath Balan Hindustan Petroleum Corpn. Ltd. Mumbai MEMBERS

Shri E. Nandakumar Cochin Refineries Ltd. Cochin Shri B. K. Dutta Bharat Petroleum Corporation Ltd. Mumbai Shri D. K. Kantak Lubrizol India Ltd. Mumbai MEMBER COORDINATOR Shri A. Ghatak Oil Industry Safety Directorate, New Delhi

______________________________________________________________________________ In addition to the above, several other experts from the industry contributed in the preparation, review & finalisation of this document.

RECOMMENDED PRACTICES FOR TRANSPORTATION OF BULK PETROLEUM PRODUCTS

CONTENTS

________________________________________________________________________________ SECTION DESCRIPTION ________________________________________________________________________________ 1.0 INTRODUCTION

2.0 SCOPE

3.0 DEFINITIONS

4.0 TRANSPORTATION BY ROAD

4.1 Design Criteria

4.2 Maximum Filling Volume

4.3 Details of Safety Appurtenances and other Safety Related Features of Tank Trucks 4.4 Safety of Tank Trucks in Transit

4.5 Safety Recommendations at Unloading Point

4.6 Labelling of Containers, Vehicles carrying Hazardous Material 5.0 TRANSPORTATION BY RAIL

5.1 Design Criteria

5.2 Filling Considerations

5.3 Details of Safety Appurtenances and other Safety related Features of Tank Trucks 5.4 Procedure for Degassing of LPG Tank Wagons 6.0 REFERENCES ANNEXURES

I Typical Petroleum Tank Truck (item 4.3)

II General arrangement of LPG Tank Truck (item 4.3.3)

III TREM Cards (item 4.4.9)

IV Labelling of containers/vehicles (item 4.6.2)

V HAZCHEM Codes (item 4.6.4.2)

VI Instructions in writing (item 4.4.8)

VII Typical LPG Wagon (item 5.3.3.3)

VIII Typical BTPN LPG Wagon (item 5.3.3.3)

IX Checklists For Bulk POL Tank Trucks (item 4.3.1.21)

X Checklists For Bulk LPG Tank Trucks (item 4.3.3.24)

RECOMMENDED PRACTICES FOR TRANSPORTATION OF BULK PETROLEUM PRODUCTS

1.0 INTRODUCTION In recent times the rapid increase in demand of petroleum has brought about a significant increase in transportation of petroleum products. Location of any petroleum processing plant or installation depends to a large extent on economics of transport of crude oil and finished products from refineries and other storage terminals and depots etc. The type of transport used also greatly determines the storage requirements. In India, petroleum products are transported by tankers, barges, rail, road and pipelines. The inherent characteristics of petroleum products pose a hazard while transporting them and may affect the transporter, the crew or the public and the oil companies under The Public Liability Act. The events, which give rise to hazards, include, particularly, container failure, accident impact and mishaps during loading and unloading operations. The purpose of this document is to recognize these potential hazards and recommend guidelines on design, safety procedures and practices to be followed in various modes of transportation of petroleum products. 2.0 SCOPE This document covers the guidelines on design, safety procedures and practices in transportation of petroleum products and unloading operations for road and rail transportation. Statutory requirements covered under The Petroleum Rules 1976, The Static and Mobile Pressure Vessels (Unfired) Rules 1981, The Factory Act 1948, The Motor Vehicle Act 1988, The Central Motor Vehicle Rules 1989 & the amendments thereof and other relevant agencies shall be adhered to in addition to the recommended practices covered in this document. In case of any difference in interpretation, the Statutory Acts shall apply. Emergency response system, transportation by cross-country pipelines & tanker/barges are not covered in this document. The Marchant Shipping Act 1958 and relevant rules shall be referred for safety requirements of transportation by water. 3.0 DEFINITIONS Container - A receptacle for petroleum

not exceeding 1000 litres in capacity

Petroleum in bulk

- Petroleum contained in a tank irrespective of the quantity of petroleum contained therein.

Tank Trailer

- A vehicle with a tank mounted thereon or built as integral part thereof and constructed in such a manner that it has at least two axles and all its load rests on its own wheels

Tank - a receptacle for petroleum exceeding 1000 litres in capacity

Tank Truck

- a single self-propelled vehicle with a tank mounted thereon.

Tank Wagon

- a railway carriage with a tank mounted thereon.

Petroleum Class A

- Petroleum having a flash point below 23°C.

Petroleum Class B

- Petroleum having a flash point of 23°C and above but below 65°C.

Petroleum Class C

- Petroleum having a flash point of 65°C and above but below 93°C.

Excluded Petroleum

- Petroleum which have a flash point of 93°C and above.

Flash Point

- The flash point of a petroleum is the minimum temperature at which the liquid gives off vapour in sufficient concentration to form an ignitable mixture with air and produces a momentary flash on application of a small pilot flame under specified conditions of test.

4.0 TRANSPORTATION BY ROAD

Petroleum products are transported in small container (upto capacity of 200 litres) and in tanks drawn by animals, push carts and pedal carts, and in bulk, tanks mounted on mechanically propelled vehicles. Transportation of petroleum products by road is

regulated by Department of Explosives through The Petroleum Rules 1976 and The Motor Vehicle Act 1988. Transportation of LPG in bulk is regulated through The Static and Mobile Pressure Vessels (unfired) Rules, 1981 and The Motor Vehicle Act, 1988.

4.1 DESIGN CRITERIA

Containers and tank trucks shall be fabricated in accordance with design parameters specified in The Petroleum Rules 1976. Pressure vessels used for transportation of LPG shall be designed and fabricated in accordance with The Static and Mobile Pressure Vessels (Unfired) Rules 1981, IS: 2825 and OISD Standard 160 - Protection to fittings mounted on existing LPG Tank Trucks.

4.2 MAXIMUM FILLING VOLUME 4.2.1 Containers for Petroleum Class A &

B

Vapour space of not less than 5% of its capacity shall be kept in each container.

4.2.2 Container for Petroleum Class C

Vapour space of not less than 3% of it’s capacity shall be kept in each container for petroleum Class C.

4.2.3 Tank Trucks for Petroleum Class A

& B

Minimum vapour space of 3% shall be kept in each compartment of the truck. No single compartment of the tank truck shall exceed the capacity of 5 kl and no truck carrying petroleum in bulk shall exceed 25 kl capacity.

4.2.4 Tank Trucks for Petroleum Class C

Minimum vapour space of 2% shall be kept in each compartment of the tank trucks. The total product in bulk shall not exceed 25 kl in any tank truck.

4.2.5 Tank Trucks for LPG

Minimum vapour space or the maximum quantity of LPG filled in any vessel shall be limited to the filling

density of LPG and shall be such that the vessel should not become liquidfull due to expansion of the content with the rise in temperature to 55 deg. centigrade. This requirement shall be applicable irrespective of the ambient temperature of the product at the time of filling.

4.2.6 Tank Trucks for Asphalt and Low

Sulphur Heavy Stock

Sufficient vapour space shall be provided to prevent leakage or spillage due to sudden braking of the truck while in transit and in no case it should be less than 2%. Gross weight of tank truck not to exceed manufacturer’s recommendations for the model/chassis.

4.3 DETAILS OF SAFETY

APPURTENANCES AND OTHER SAFETY RELATED FEATURES OF TANK TRUCK

4.3.1 Tank Trucks for Petroleum Class A

& B 4.3.1.1 The cabin of the vehicle shall be of

fully metal construction and its rear window, if provided, shall be covered with wire reinforced glass. Alternatively, the cabin and engine shall be separated from the tank or the load, as the case may be, by a fire resisting shield or screen which shall fully cover the tank or the load. There shall be a clear space of at least 15 cm. between the back of the cabin and the tank.

4.3.1.2 The exhaust shall be located wholly in

front of the tank or the load, as the case may be,and shall have ample clearance from fuel system and combustible materials and shall not be exposed to leakage or spillage of the fuel or product or accumulation of grease or oil.

4.3.1.3 The exhaust line and the muffler shall

be free from leaks and shall have adequate clearance from the fuel system and combustible materials so that it shall not be exposed to leakage or spillage of fuel or product carried or accumulation of grease and oil. The

exhaust line and the muffler should be rigidly fixed.

4.3.1.4 The exhaust system shall be fitted with

effective spark arrestor of a design approved by the Chief Controller of Explosives and the same should be labeled in the spark arrestor.

4.3.1.5 Fuel tank of the vehicle, if installed

behind the cabin of the vehicle, shall be protected against blows by stout steel guards and provided with a lock on the fuel tank cap.

4.3.1.6 The engine air intake shall be

equipped with an air cleaner having effective flame arresting characteristics to prevent emmission of flame from the intake side of the engine in the event of back firing.

4.3.1.7 The voltage of the electric circuit shall

not exceed 24 volts. 4.3.1.8 Electrical wiring shall be provided with

suitable over current protection in the form of automatic circuit breakers and installed so as to be protected from physical damage and contact with possible product spill either by location or by being encased in metal conduit or other protective covering.

The electrical system shall preferably use two wire systems (double pole wiring) instead of earthing of negative terminal to the body of the vehicle.

4.3.1.9 The Generator, battery, switches and

circuit breakers shall be located in the cabin of the vehicle or in the engine compartment and the battery shall be in an easily accessible position with an approved type heavy duty master switch/cut off switch of not less than 300 amps rating close by to cut-off the battery.

4.3.1.10 Generator, motors and switches

thereof which are not installed within the engine compartment shall be of the approved flame proof type. Provided that where such generators or motors or switches thereof are installed in enclosed space,adequate provision shall be made for air circulation to prevent overheating and possible accumulation of inflamable vapours.

4.3.1.11 The vehicle should have a bonding lug

and a bonding cable and the tank/vessel shall be electrically continuous with the chassis.

4.3.1.12 A portable ISI marked 10 kg DCP

extinguisher shall be provided in an easily accessible position away from the discharge faucets on every vehicle. One portable 1 kg CO2 /DCP/Halon/Approved equivalent fire extinguisher shall be kept in the cabin of the vehicle. All extinguishers must have marking indicating the next due date for pressure testing.

4.3.1.13 Each compartment of tank truck shall

have an emergency shut off valve located inside the shell with control lever provided in an accessible position and away from the fill openings of discharge faucets.

The wire rope connecting the shut off valve and control lever shall be provided with a approved type fusible section/link which will permit the shut off valve to close automatically in the event of a fire.

4.3.1.14 Every compartment of a tank shall be

provided with independent PV vent so as to limit the pressure within the compartment to 0.21 kg/sq.cm g and the vacuum to 5 cm water gauge. The vent shall be so designed as to prevent loss of liquid through the vent in the event vehicle is overturned.

4.3.1.15 In addition to the above PV vent an

emergency venting facility of fusible type shall be provided so as to provide minimum fire venting opening having a net area in sq. cms equal to 8 plus 4.3 times the gross capacity of the compartment in kls. The fusible vent shall be actuated at a temperature not exceeding 93 degree C. The emergency vent shall be so designed to prevent loss of liquid through the vent in case of vehicle upset except in case of pressure rise when in overturned position.

4.3.1.16 The inner end of the top fill pipe shall

be fitted with splash deflector and shall extend to 25 mm from bottom of the tank. The top end of the fill pipe should have an oil tight locker cap. The fill pipe shall have perforations all

along and covered with wire gauge of a mesh not less than 11 to the linear centimetre and chamfered at the bottom.

4.3.1.17 All tank top fittings shall be provided

with dome cover so as to protect from damage in the event of the over turning of the vehicle on which it is mounted. Height of tank not to exceed cabin height and a height barrier guard to be provided to protect against accidental damage of top fittings.

4.3.1.18 The rear of the vessel shall be

protected by a robust steel bumper and this bumber shall be:

i) Attached so that collision stresses will be transmitted to the frame work of the vehicle or in the case of an articulated vehicle, to the frame work carrying the wheels of the tank.

ii) Situated at least 15 cm to the rear of the rear most part of the tank.

iii) Extended on each side of the

vessel to at least cover the maximum width of the tank.

4.3.1.19 Every tank truck used for

transportation of petroleum shall be conspicuously marked in a contrasting colour with the word “FLAMMABLE’ and the common name of the flammable liquid being transported.

4.3.1.20 Whenever petroleum class A

is carried along with any other class of petroleum in the same vehicle following additional requirements shall be adhered to:

(i) Two capital letters ‘ML’each not less than 10 cm. square shall be printed in a conspicuous colour on each side and the rear of the vessel.

(ii) The filling pipe,discharge faucet and the vent pipe of one compartment shall not be interconnected by manifolding or otherwise with the filling pipe, discharge faucet or vent pipe of any other compartment.

(iii) A metal band not less than 2.5 cm wide, coloured red and bearing embossed or printed words “MOTOR SPIRIT” shall be securely attached to the fill pipe and discharge faucet of each compartment carrying petroleum Class A. A similar metal band, coloured green, blue or grey and bearing embossed or printed words describing the class of petroleum shall be securely attached to the fill pipe and discharge faucet of each compartment carrying such class of petroleum.

(iv) Separate braided rubber

hoses bearing ISI mark for each class of petroleum shall at all times be carried in the licensed vehicle.

4.3.1.21 The tank trucks used for fuelling an aircraft do not fulfill the requirements of those used for petroleum class B in respect of restriction on capacity of individual tank and power take off unit provided for pumping fuel into aircraft. The requirement of such tank trucks called refuellers are not regulated through The Petroleum Rules 1976. Industry Quality Control Manual & Indian Aircraft Manual may be referred for safety guidelines in this regard.

4.3.1.22 Checklists for POL tank trucks

are given in Annexure-IX. 4.3.2 Tank Truks for

Petroleum Class C

4.3.2.1 Exhaust pipe shall be fitted with an approved spark arrestor which shall be checked from time to time for fitness.

4.3.2.2 Suitable fire extinguishers shall be

provided as in 4.3.1.12. 4.3.2.3 Each compartment shall have an

emergency shut off valve as in 4.3.1.13.

4.3.2.4 A suitable and effective vent shall be provided on each tank.

4.3.2.5 Rear of the vessel shall be protected by a steel bumper as in 4.3.1.18.

4.3.2.6 The vehicle shall have double pole wiring and nonsparking electrical fittings.

4.3.3 Tank Trucks for LPG 4.3.3.1 All valves and accessories shall be

safeguarded against accidental damage or interference. For protection of fittings mounted on tank trucks OISD Standard 160 may be refered.

4.3.3.2 Openings for liquid and vapour flow and pressure guage etc. in the truck shall be protected by suitable excess flow check valves mounted in the openings of the vessel. Openings of less than 1.5 mm need not have such a valve.

4.3.3.3 Valves or accessories situated at the rear of a vehicle shall be protected by the rear cross member of the frame of the vehicle against damage.

4.3.3.4 All pipings, fittings, pumps and meters permanently mounted on the vehicle shall be designed to withstand the most severe combined stresses imposed by the following, namely: (a) The maximum design

pressure of the vessel. (b) The superimposed pressure of

the shock loading caused by road movements.

4.3.3.5 All piping, fittings and equipment shall be adequately protected to minimise accidental damage which may be caused by road accidents or overturning. All trucks should be provided with suitable height barriers on the drivers cabin if the height of the bullet exceeds the cabin height.

4.3.3.6 The engine and exhaust system together with all electrical generators, motors, batteries, switch gears and circuit breakers shall be efficiently screened from the vessel or the body of the vehicle by a fire-resisting shield or by enclosure within an approved fire resisting compartment.

4.3.3.7 When the equipment referred in 4.3.3.6 above is mounted forward of

the rear of the driving cabin the cabin can be considered to act as an acceptable shield, provided the back, the roof and the floor of the cabin are of fire resisting construction for the full width of the cabin, without any openings in the back or roof, and that the back extends downwards to the top of the chassis.

4.3.3.8 When the cabin construction does not conform to the requirements mentioned above, a separate fire-resistant shield should be installed extending upwards without any openings from the top of the chassis to the top of the vessel.

4.3.3.9 In any case where windows are provided in the shield, they should be fitted in fire-resistant framing with wired glass or other heat resistant material and shall not be capable of being opened.

4.3.3.10 When the equipment referred in 4.3.3.6 above is mounted to the rear of the cabin,it shall be contained wholly within an approved fire-resistant compartment.

4.3.3.11 In any case where the fuel used to propel a vehicle gives off a flamable vapour at a temperature less than 65 degree C, the fuel tank shall not be behind the shield unless the following requirements are complied with namely: (i) the fuel tank is protected by

stout steel guards or by the frames of the vehicle.

(ii) the fill pipe of the fuel tank of the vehicle is provided with a cover having locking arrangements.

(iii) fuel feed apparatus placed in front of the fire-resisting shield is used to lift the contents of the fuel tank.

4.3.3.12 The electrical systems shall have the same safety features as detailed in 4.3.1.7 to 4.3.1.11.

4.3.3.13 Tyres shall be of the “anti-skid” type. 4.3.3.14 There shall be a clear space of at least

15 cm. between the rear of the cabin and the front of the vessel.

4.3.3.15 The rear of the vessel shall be protected by a robust steel bumper and this bumper shall be:

(i) Attached so that collision stresses will be transmitted to the frame work of the vehicle or, in the case of an articulated vehicle to the frame

work carrying the wheels of the vessel.

(ii) Situated at least 7.5 cm to the rear of the rearmost part of the vessel providing complete cover to the body.

(iii) Extended on each side of the vehicle to at least cover the maximum width of the vessel.

(iv) The maximum weight of the liquefied gas for which the vehicle is designed should not exceed the difference in weight between the unladden weight of the vehicle and the maximum gross weight permitted for that class of vehicle under the appropriate transport regulations or CCOE licensed capacity whichever is less.

4.3.3.16 The vessel shall be conspicuously marked (Refer para 4.6) to show the product which is being carried.

4.3.3.17 Two portable ISI marked 10 kg. DCP fire extinguishers shall be provided on each vehicle, one on each side and should be accessible from outside the cabin and another 1 kg CO2 /DCP/Halon or Halon equivalent extinguisher should be kept in the driver’s cabin. All extinguishers (minimum 3 nos) should have the marking indicating next due date for pressure testing.

4.3.3.18 Pressure relief valves shall be tested every year by competent person and certificates/records maintained. The functioning of excess flow check valves should also be checked once a year.

4.3.3.19 All pressure gauges, level gauges & temperature gauges should be calibrated once a year.

4.3.3.20 Tank/bullet mounted on the chassis shall be hydrostatically tested every 5 years through competent person and Certificates/records maintained. If the chassis is not suitable for taking the load the tank/bullet should be removed & tested separately.

4.3.3.21 After maintenance / repair job the LPG tank trucks are to be purged by water displacement by LPG/inert gas.

4.3.3.22 Driver of the vehicle should carry TREM card and route-map with detail locations and contact agencies in case of an emergency.

4.3.3.23 Checklists for Bulk LPG tank trucks are given in Annexure - X.

4.3.4 Tank Trucks for Asphalt 4.3.4.1 Exhaust pipe shall be fitted with an

approved spark arrestor. 4.3.4.2 Each tank shall be provided with a

goose-neck vent having an effective opening at least equivalent to a nominal 50mm pipe.

4.3.4.3 Each tank shall be provided with a manhole having a free opening of at least 381 mm in diameter designed to relieve internal pressure between 9.095 and 0.143 KPa, or an equivalent relief device.

4.3.4.4 Overflow protection for asphalt tank vehicles shall be provided in the form of reservoirs or flashing around fill and vent pipes. Overflow and drain pipes shall have thickness heavier than the tank shell and shall be designed so that hot asphalt will not spill onto tyres, brakes, burner equipment or vehicle’s exhaust system.

4.3.4.5 Fuel tanks for the vehicle engine and fuel tanks or the burners on asphalt trucks shall be located remotely from the burner or protected by a noncombustible shield from the burner to prevent flash back.

4.3.4.6 Burner tubes shall be properly installed and maintained.

4.3.4.7 The bottom of internal burner tubes shall be located as low as possible in the tank.

4.3.4.8 A legible red warning sign shall be permanently attached near the burners on any tank vehicle equipped with burners and shall contain at least the following information

iii.3 “WARNING” iii.4 The burner equipment must not be

operated while the vehicle is being loaded or is in transit, or when the burner tubes are not completely submerged.

4.3.4.9 The rear of the vessel shall be protected by a robust steel bumper as detailed in 4.3.1.18.

4.3.4.10 Suitable fire extinguishers shall be provided as detailed in 4.3.1.12.

4.3.5 Tank Trucks for LSHS 4.3.5.1 Exhaust pipe shall be fitted with an

approved spark arrestor. 4.3.5.2 A suitable and effective vent shall be

provided on each tank. 4.3.5.3 Heater coils when provided, shall be

so constructed that the breaking-off of their external connections will not cause leakage of contents. There should be no flange connections inside the tank.

4.3.5.4 Each compartment of the tank truck shall have emergency shut off valves located inside the shell, with control lever provided in an accessible position and away from the openings or discharge faucets.

4.3.5.5 The rear of the vessel shall be protected by a robust steel bumber as detailed in 4.3.1.18.

4.3.5.6 Suitable fire extingishers shall be provided as detailed in 4.3.1.12.

4.4 SAFETY OF TANK TRUCKS IN TRANSIT

4.4.1 Except for driving crew and oil companies officials during emergencies/leaks/accidents, no other person shall be carried on the tank truck.

4.4.2 Vehicle shall be constantly attended by the driver or his assistant.

4.4.3 The vehicle shall be halted at a safe place.

4.4.4 The vehicle should be parked with the consent of the occupier in an open yard or enclosed premises subject to the Factories Act.

4.4.5 The driver should take all reasonable precaution to ensure that the vehicle is parked in safe environment.

4.4.6 The driver of a vehicle carrying petroleum product shall be trained in the properties of the material carried, the handling method applicable to the grades being carried, in the use of the fire extinguishing equipment carried on the vehicle and in the emergency procedure to be followed. The training to drivers should be in line with syllabus under rule 9 of The Central Motor Vehicle Rules 1989 and OISD Standard 154 : Safety Aspect in Functional Training or should be by any approved Govt. agencies for this purpose.

4.4.7 All necessary steps shall be taken by the owner/loader of the vehicle to ensure that the driver is fully aware of and understands all instructions.

4.4.8 As a precaution against any accident or emergency that may occur during carriage, the driver shall be supplied with instructions in writing as detailed in safety instruction booklet attached in annexure VI.

4.4.8.1 The nature of the danger presented by the dangerous substances carried and the safety measures that must be taken to avert that danger.

4.4.8.2 The action to be taken and treatment to be given in the event of persons coming in contact with the dangerous

substances being carried or with any substances which might escape therefrom.

4.4.8.3 The measures to be taken in case of fire and in particular the extinguishing methods and/or agents or groups of extinguishing methods and/or agents not to be used.

4.4.8.4 The measures to be taken in case of breakage or deterioration of packaging or spillage of the dangerous substances, particularly on the road.

4.4.8.5 These instructions should be in local language, Hindi and English.

4.4.9 The system of Transport Emergency Cards (TREM) meets the above requirements. A specimen each of TREM cards for petroleum Class A, B & C, LPG and heavy oils are given in the Annexure-III. Translation into respective local language may be made by operating company as required.

4.4.10 The tank trucks carry ing petroleum products/LPG should preferably have anti skid tyres.

4.5 SAFETY RECOMMENDATIONS AT UNLOADING POINT

4.5.1 In order to prevent accidental movement, the handbrake and wheel chocks shall be firmly on and the engine shall be stopped.

4.5.2 When discharge is in progress, the driver shall remain at his vehicle in such a position as to be able to stop the discharge immediately in an emergency.

4.5.3 A visual check shall be made of the surroundings, the tank and connections for unusual or dangerous situations.

4.5.4 Warning notices shall be displayed and suitable fire appliances shall be available for instant use.

4.5.5 Bonding leads shall be connected before making the hose connections and shall remain connected till the hoses have been removed. Perfect bonding contact should be ensured.

4.5.6 When operations are commenced, a further examination for leakage at connections shall be carried out.

4.5.7 No person shall smoke while on or attending such a vehicle.

4.5.8 No article or substance capable of causing fire or explosion shall be carried on such a vehicle.

4.6 LABELLING OF CONTAINERS, VEHICLES CARRYING HAZARDOUS MATERIAL

4.6.1 All dangerous substances are divided into 8 main classifications. LPG falls under Class 2 and other petroleum products are grouped under Class 3. It is recommended that containers or vehicles carrying hazardous chemicals which include petroleum products, shall be provided with a distinct mark of the class labels on vehicles showing the specified emblems pictorially representing particular dangers. (For details, refer The Central Motor Vehicle Rules-1989 & Amendments thereof).

4.6.2 To ensure that any package or truck carrying dangerous goods is recognised from a iv) distance, the

recommendations include a labelling system. The recommended labels are diamond shaped i.e. they are in the form of square ( 25 cm x 25 cm) set at an angle of 45 degrees. The upper half of the label is reserved for the pictorial symbol representing the nature of the risk, different symbols being provided for each of the Classes.The number of the class or division should be shown in block in the bottom corner of the label unless the substance in question presents more than one risk. Any other text inserted optionally in the lower half of the label should be printed in black and should be confined to particulars indicating the nature of the risk and precautions to be taken in handling. The labelling system for trucks is shown in Annexure-IV.

4.6.3 Every goods carriage carrying any dangerous or hazardous goods shall display the class label both in front and in the rear in a conspicuous manner.

4.6.4 Every goods carriage used for transporting any dangerous or hazardous goods shall be legibly and conspicuously marked with an emergency information panels as indicated in Annexure-IV.

4.6.4.1 The display on vehicles of the descriptive names or prescribed “correct technical names” of the chemicals/petroleum products in letters not less than 50 mm high.

4.6.4.2 The display on vehicle of special signs or plates denoting that dangerous goods are being conveyed or plates bearing special code numbers (HAZCHEM) which may identify the substances or reveal its hazardous property or indicate what action should be taken in emergencies as shown in Annexure-V.

4.6.4.3 The name and telephone numbers of the emergency services to be contacted in the event of any fire or any other accident in letters and numerals that are not less than 50 mm high and the name and telephone number of the consignor of the dangerous or hazardous goods or of some other person from whom expert information and advice can be obtained concerning the measures that should be taken in the event of an emergency involving such goods.

4.6.4.4 Every class label and emergency information panel shall be marked on the goods, carriage as stipulated in the Motor Vehicle Rules 1989 and shall be kept free and clean from instructions at all the times.

5.0 TRANSPORTATION BY RAIL In India, Railway Administration, acting as a carrier of Petroleum Products, is exempted from taking any licence for transporting it under Petroleum Rules 1976. Railway Administration have elaborate rules for the carriage of petroleum by rail as provided in Indian Railways Act and Red Tariff No.19 of Indian Railways Conference Association. 5.1 DESIGN CRITERIA

All tank wagons used for the conveyance of petroleum products and LPG shall be of a design approved by RDSO. Design parameters for tank wagons used for transportation by rail are issued by the Wagon Directorate, Research, Design, and Standards Organisation of Indian Railways.

5.2 FILLING CONSIDERATIONS

5.2.1 Tank Wagons for Petroleum Class A

Vapour space of not less than 4% of the capacity of tank wagon shall be kept. Since tank wagons are loaded in accordance with the load carrying capacity by weight in relation to axle design, the above vapour space is allowed. In addition the tank wagons are filled as per

the calibration tables provided by railways and which specifies the maximum dip to be loaded for various products.

5.2.2 Tank wagons for Petroleum Class B & Class C Vapour space shall be a minimum of 2.5%. Provision of fill pipe or a contraption in lieu of fill pipe to avoid splash loading if unloading arm/hose is not extending fully.

5.2.3 Tank Wagons for LPG The maximum quantity of LPG filled in any tank wagon shall be limited to the filling density of the LPG and shall be such that the tank wagon shall not be liquidful due to expansion of the contents with rise of the temperature to 55 degree C. or limited to specified gross weight on the wagon whichever is less.

5.2.4 Tank Wagons for Asphalt and LSHS Minimum of 2.5% air space shall be left and also loading limited to specified gross weight on the wagon.

5.3 DETAILS OF SAFETY APPURTENANCES AND OTHER SAFETY RELATED FEATURES OF TANK WAGONS

5.3.1 Tank wagons for petroleum class A These wagons are marked as “TP” as per Railway Code, except Hexane which is loaded in TH tank wagon.

5.3.1.1 Each tank wagon is provided with an effective pressure valve as per approved design.

5.3.1.2 All openings of fill pipe and dip pipe

are provided with air tight caps. 5.3.1.3 A master valve set at the bottom inside

the body with control from the top of tank wagon.

5.3.1.4 A block valve at bottom of the wagon

to which unloading hose is connected. 5.3.1.5 The top fittings are protected by a

dome cover. 5.3.2 Tank wagons for petroleum class B &

C (Railway code ATF TK & TL) 5.3.2.1 Each tank wagon is provided with an

effective vent as per approved design. 5.3.2.2 The master valve control is from top of

the tank. 5.3.2.3 The top fittings are protected by a

dome cover. 5.3.3 Tank wagons for LPG (Railway code

TG) (4-wheeler/8-wheeler)

5.3.3.1 Tank wagons designed by RDSO are provided with safety valve with Discharge Capacity : 10.3 cum/sec.

5.3.3.2 All other fittings such as liquid valves,

vapour valves, magnetic gauging device, thermowell, sample valve and safety valves, pressure gauges are provided on top of the pressure vessel in a protective housing known as ‘dome’ with a cover.

5.3.3.3 After repair or maintenance tank

wagons are required to be purged with LPG/inert gases.

Typical drawings of LPG tank wagons are shown in annexure VII & VIII.

5.3.4 Tank wagon for asphalt (TBT) or

LSHS (TOH) There are no specific safety fittings required for these wagons except that these are provided with a dome on top with full opening to facilitate filling. These wagons are also provided with steam coils. Only precaution necessary is that no tank wagon for Asphalt or LSHS be loaded if any water is found present inside the tank to avoid boil over condition during loading.

5.4 PROCEDURE FOR DEGASSING OF

LPG Tank WAGONS The following sequence shall be followed: 5.4.1 During degassing operation, all

loading/unloading operations on that spur shall be stopped. Earthing to be ensured even on the degassing bay before commencing the degassing.

5.4.2 Sampling valve should be opened and

vapours allowed to escape fully. 5.4.3 The plugs of liquid and vapour

eduction valves should be unscrewed and then valve be opened.

5.4.4 The method adopted to make the

barrel free from LPG is to fill the barrel completely with water and allow to overflow for an hour. Pump out the water after 24 hours.

5.4.5 Remove the manhole cover. In no

case the heating of studs/bolts shall be adopted to open them. If required, rust remover solution shall be used.

5.4.6 Check thoroughly for presence of LPG

vapours inside by explosimeter. Repeat the procedure under 5.6.3 if explosimeter shows presence of vapour inside.

5.4.7 Ensure that the barrel is completely

dry in case water filling or steam purging method of degasing is adopted.

5.4.8 A safety instruction checklist should be

exhibited at the degassing station containing all relevant points in the degassing procedure.

5.4.9 Degassing operation should be

discontinued at the approach of thunder storm and all valves manhole covers and hoses disconnected to make the wagon ready for removal.

5.4.10 Disposal of sludge from the LPG

wagons should be transported away from the siding in wet condition and disposed of in safe manner.

6.0 REFERENCES i) Fire Protection Handbook - Fifteenth

Edition 1981.

ii) NFPA 385 - Standard for Tank Vehicles for Flammable and Combustible Liquids - 1985.

iii) NFPA - 58 Standard For the Storage

and Handling of Liquefied Petroleum Gases - 1983.

iv) Loss Prevention in the Process Industries - Vol. 2 by Lees.

v) The Petroleum Rules - 1976. vi) The Gas Cylinder Rules - 1981. vii) The Static and Mobile Pressure

Vessels Rules - 1981. viii) Maintenance Manual for 4 - Wheeled

Liquefied Petroleum Gas Tank Wagon Type TPGLR - 1983.

ix) Red Tariff No. 19 (Indian Railways

Conference Associations). x) Cefic Tremcards - Group Text

Chemical Industries Association, U.K. xi) Transport of Dangerous Goods

(Recommendations of the Committee of Experts on the Trasport of Dangerous Goods), Third revised edition.

xii) The Central Motor Vehicle Rule -

1989.

Annexure IX

checklist for bulk pol tank trucks at loading location : (Daily Checks)

1. Whether valid licence, Fitness, Calibration and explosives certificates are available in the

vehicle ? 2. Whether the vehicle has fire two extinguishers ? 3. Whether there are any sources of ignition like matches etc. in the vehicle ? 4. Whether the vehicle has at least a driver and a cleaner as its crew member ? 5. Whether the driver has a valid driving licence with endorsement for having undergone training

for carrying hazardous goods as per Motor vehicle act. 6. Whether approved quality flame arrester provided on the engine exhaust and muffler/silencer

is properly bolted without any leaks? 7. Whether each compartment of tank is fitted with independent vacuum and pre-operated vents

(PV Valve)? 8. Whether vehicle’s cabin is checked for presence of any flammable/explosive substance being

carried by the crew ?

Addl. half yearly checks 9. Whether the vehicle has a cut off switch for electrical system ? 10. Whether there is facility to shut off the drain valves from the cabin in case of emergency? 11. Whether the vehicle has First Aid Box, Tool Box and Emergency Lighting ? 12. Whether the driver has a copy of standing instructions and TERM card ? 13. Whether the exhaust is wholly in front of tank truck and has ample clearance from fuel oil

system and combustible material. 14. Whether all electric wiring is properly insulated ? 15. Whether all junction boxes are sealed properly ? 16. Whether electrical equipments like generator swithces, fuses and circuit breakers are located

inside the cabin or engine compartment? 17. Whether battery is in easily accessible position with a heavy duty switch close by, to cut off the

battery in emergency ? 18. Whether battery terminals have protective rubber covers ?

Annexure IX

checklist for bulk pol tank trucks at unloading location : (terminals / depots)

1. Whether valid licence, Fitness, Calibration and explosives certificates are available in the

vehicle ? 2. Whether the vehicle has two fire extinguishers ? 3. Whether there are any sources of ignition like matches etc. in the vehicle ? 4. Whether the vehicle has at least a driver and a cleaner as its crew member ? 5. Whether approved quality flame arrester provided on the engine exhaust and muffler / silencer

is properly bolted without any leaks ? 6. Whether vehicle’s cabine is checked for presence of any flammable / explosive substance

being carried by the crew ?

checklist for bulk pol tank trucks at unloading location : (Retail outlets/customer premises)

1. Whether valid licence, Fitness, Calibration and explosives certificates are available in the

vehicle ? 2. Whether the vehicle has two fire extinguishers ? 3. Whether there are any sources of ignition like matches etc. and inflammable substances in

the cabin of the vehicle ? 4. Whether the vehicle has at least a driver and a cleaner as its crew member ?

Annexure – X

Checklist for unloading of bulk lpg tank trucks

checks required to be carried out before allowing entry of tank trucks inside licenced area

* Has suitable spark arrestor of make and design approved by CCE, Nagpur, properly fixed to

exhaust.

Carries 2 nos. 10 Kg. DCP extinguishers in easily accessible and removable position with Truck No. date of checking and charging painted on it.

1 Quick closing manifold valve with lever indicating close and open status. l No visible dent on the bullet. l Whether tyres fitted is in roadworthy condition. l All junction boxes are properly sealed. l Any loose electrical wiring/terminal. l Electrical wiring is insulated and provided with suitable over current protection. l Truck is self starting. l Readily accessible master switch for switching off the engine is provided inside the cabin. l Leakage from any fittings or joints.

Checks required to be carried out before issuing loading memo (DUring the course of unloading operations)

l Height barrier provided as per specifications. l Fuel tank is protected by means of stout guard and fuel tank cap is locked. l Paint of bullet is not peeling off. l First aid kit is available.

checks required to be carried out on randon basis

- minimum one day, once in a month : l Internals of fire extinguishers in good condition. l Carries TREM CARD, instructions booklet detailing instructions on handling emergencies

enroute. l Carries route map.

L Carries TERM card. l Has valid CCE licence and authenticated copy of drawing. l Carries RTO permits. l RLW-ULW Licenced capacity. l Hazchem sign, name of contractor with address and telephone No. displayed prominently. l Bullet has no sign of external corrosion. l Excess flow check valves are functioning. l Liquid/vapour lines are adequaltely anchored and are well protected by means of stout steel

guard. l Liquid/vapour pipe lines are in single piece from excess flow check valve to discharge valves - Safety fitting viz. safety valve, roto-gauge, pressure gauge and temperature gauge are

adequatlely protected. L Operative fittings like roto gauge, pressure gauge and temperature gauge are operational. General : Following are available in Tank Truck : l Tools for all fittings. l 4 Nos. caution sign board wit luminous paint for stopping traffic in case of any emergency.

Based on the nature of defects either all the deficiencies should be got corrected at the unloading location itself or the tanker should be allowed to get the repairs done enroute and submit the details at loading location.

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