User manual for tata fuel tanker application on LPT 2516

Prepared by: RAMAN DHIMAN For any queries please contact: [email protected] FOR ACADEMIC PURPOSE ONLY. NOT FOR ANY COMMERCIAL USE

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18 KL Fuel Tanker on LPT 2516 / 48


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Contents

1) Introduction 5

2) Controls & Equipments 6 2.1) Emergency Shut off 2.2) Gate Valve 2.3) Dust Cap for Gate Valve 2.4) Gravity Discharge Hose 2.5) Manhole Assembly 2.6) Pressure Vacuum Valve 2.7) Emergency Vent 2.8) Fusible Link 2.9) Remote Control Emergency Shut off Valve 2.10) Grounding Plate 2.11) Abloy Locking system 2.12) Cutoff switch 2.13) Spark Arrestor

3) Features 13 3.1) Right Hand Side View 3.2) Left Hand Side View 3.2) Rear View

4) Procedure for Loading a Top Loading Tanker 16 5) Procedure for Unloading Top Loading Tanker 17


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6) Do’s & Don’ts / Precautions 18 7) Service Schedule for Tanker 20 8) Additional Information 21 8.1) Technical Specifications 8.2) Offer Drawing

8.3) General Tank / safety Requirements from different Oil companies:


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1) Introduction: We are pleased to inform you about the introduction of 18 KL Fuel Tanker on LPT 2516 / 48. LPT 2516 is suitable for long distance transportation with reliability. Salient features of chassis:

• CUMMINS 6BTAA 5.9,160 -20 • 6 speed gear box. • SQR 109, Bogie Axle. • Semi elliptical leaf spring at front and rear antiroll bar at front axle only • Cab Full Forward • Dual circuit full air S-cam brake • Anti-lock Braking System

The Fuel Tanker has been provided with the standardized aggregates complying with CCOE. To ensure the better accessibility and to provide quick and satisfying service while repairing and maintenance, proper service schedule and service cutouts where ever required have been provided. At the end, we say that this Fuel Tanker is meticulously designed to take care of vehicle transportation needs. Note:

• The pictures shown in this manual are for illustration purpose only.


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2) Controls & Equipments

2.1 Emergency Shut off Valve: It is fitted at the bottom of the sump at each compartment. These valves are being used for unloading. At the time of loading these are closed. This valve is operated manually through lever connected with wire rope.

2.2 Gate Valve: It is an outlet point to unload the product. It is connected with Emergency Shut off Valve through a pipe line. Gravity discharge hose is connected to the gate valve

Note: Gate valves need to be in closed position during loading.

Spring

Lever Link

Brass Spring Seat

MS Cover

Flange bolted underneath the Tank Flange Bolted to the Pipeline

CCOE approved supplier details

Hand Operated Wheel Gate Valves – Separate

for each compartment


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2.3 Dust cap for Gate valve: It acts as the protective Cover for the Gate valves. It is made up of aluminum, for the reason of non corrosion and easy handling.

2.4 Gravity Discharge Hose: Gravity discharge hose is designed according to the petroleum standards. 3”flexible hose with 3” gunmetal swivel nut on both ends.

Dust Cap – Having internal threads. Screwed onto external threads on Gate Valve

Flexible Gravity discharge hose

Gun Metal Swivel nut. One end is fitted to the Gate Valve and other to the receiver


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2.5 Manhole Assembly: All compartments of petroleum tank are equipped with manhole openings, large enough for a man to pass through. All these openings are covered by a lid. It consists of fill pipe, dip pipe, pressure vacuum valve & Emergency vent. It consists of fill pipe to fill the product, dip pipe to check the quantity level

Fuel pipe: This portion remains

inside the tank

Dip Pipe for inserting dip stick


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2.6 Pressure Vacuum Valve: For compartment breathing i.e. to prevent the development of pressure and Vacuum,

while the product is being drained off, inside the compartment. 2.7 Emergency Vent: The role of emergency vent is to release the smoke and fire (pressurized gas).the

emergency vent is designed in such a way to release pressurized gas and fire at time of emergency.

End Remain Outside the Tank. Fitted on Manhole cover

End goes inside the tank. Fitted on the Manhole cover

Assembly of Pressure Vacuum Valve

Lead

Outer Ring

Top Cover


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2.8 Fusible Link: It acts as a fuse, linking the emergency shut off valve and Remote Control Emergency Shut

off Valve Operation lever. At the time of fire accident the fuse link will be de-linked due to heat and the entire valves will be automatically closed.

2.9 Remote Control Emergency Shut off Valve Operation: It is mounted on the remote control emergency shut off valve operation box. Each compartment is fixed with a shut off valve and the same is connected with the Wire Rope to the lever

Remote Controlled Emergency Shut off valve lever Wire rope – connected to Emergency shut off valve via fusible link

Lead Insert

Ends fitted to the connecting wire

Fusible Link


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2.10 Grounding Plate: It is used to ground the track while loading and unloading. Crocodile clip is connected to the

grounding plate while loading \ unloading grounding plate is primarily services as ear thing.

2.11 Abloy Locking System: Abloy locking system designed in such away that all manhole domes at single operation and also its lock remote control emergency shut off valve operation box.

Anti Skid Cat Walk

Abloy Locking

Manhole cover


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2.12 Battery Cut off switch: To disconnect entire electrical circuit in the vehicle while loading and unloading the product this switch serves the purpose.

Caution: Cut off the battery while loading and unloading.

2.13 Spark Arrestor: It is fitted at the end of exhaust pipe in order to prevent the sparks if any to come out and pose a safety threat.

Spark Arrestor

Aluminum Fins inside the Spark Arrestor


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3) Features: 3.1 Left Hand Side View: 3.2 Right Hand Side View:

Spark Arrestor

FUPD

Valve Box – Stainless Steel

HPCL Logo

Hazardous Goods Instruction from HPCL in compliance to CCOE


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3.3 Rear View:

SS Mudguard

Z-Section Long Member

HPCL Sticker

10 Kg Fire Extinguisher

D-Shape Shell

U-Bolt Mounting

Display Board


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Rear Bumper

Lever Box – In order to operate emergency shut off valve

Rear Dished End

Ladder

SS Number Plate

HPCL Logo

Hazardous Goods instruction Sticker as per CCOE

RUPD


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4) Procedure for Loading the Top Loading Tanker: 1. Park Tank truck in the loading bay

2. Switch off the Engine.

3. Ground the truck.

4. All the compartment Gate Valves close condition

5. Close the Dust Caps from the Gate valve

6. Remote Control Emergency Shut Off Valve lever is close

condition

7. Insert and secure the top loading arm in the manhole of the

compartment to be loaded

8. Start the loading operation.

9. After the completion of loading operation, remove the loading

arm and close the manhole cover

10. Repeat steps 7to 9 for remaining compartment to be

loaded.

11. Remove the grounding. The Loading Operation is complete.

PRODUCT OUT

PRODUCT IN

VAPOUR OUT

TOP LOADINGTOP LOADING

Man hole plate

Delivery valve


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5) Procedure for Unloading the Top Loading Tanker 1. Park Tank truck in the unloading bay.

2. Switch the off Engine.

3. Ground the truck.

4. Open the lever box.

5. Remove the Dust Caps from the Gate valve.

6. Connect the Gravity Discharge hose to the Gate valve of the compartment to be unloaded.

7. Pull the Remote Control Emergency Shut Off Valve lever corresponding compartment to be unloaded.

8. Open the Gate valve

9. After completion of the unloading operation of the compartment, close the Gate valve.

10. Disconnect the Gravity Discharge hose from the gate valve.

11. Repeat the steps from 5 to10 for remaining compartments to be unloaded.

12. Replace the dust caps on the Gate valve.

13. Close the lever box.

14. Remove the grounding. The Unloading Operation is complete.


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6) DO’S & DON’T’S / Precautions:

Ø Loading and Unloading of Fluid: a) Do not unload the material in areas other than the place approved by the authorized agencies. b) The Engine of the vehicle should be switched OFF before loading and Unloading of the product. Battery

should be disconnected from the electrical system through Battery Cut off Switch. c) Do not park the vehicle carrying Petroleum product on a public road or in any congested area or at place 10

meters of any source of Fire. d) Do not drive the tank with Lube oil, if the Tank walls, Valves are leaking. Attend to the leakage before

loading the vehicle. e) During loading the tank, Filling pipe and the chassis of the tank vehicle should be efficiently grounded. f) Dip rod if lowered into the tank before loading of the tank should not be completely raised above the liquid

level during or within one minute of the completion of such loading.

Ø Prevention of Static Charge Generation: a) No tanker or compartment of the tank vehicle which has last carried petroleum class A product shall be filled

with petroleum of any other class if the interior has any floating non-conducting loose objects or water. b) No tanker should be Splash Loaded. c) No tank vehicle shell be loaded unless the vehicle’s wheels have been secured by efficient brakes. d) Tank compartment which carried petroleum class A should not be filled with petroleum of other class unless

the compartment has been completely drained of residual oil and its discharge faucet and emergency valve have been closed firmly.

Ø Maintenance, Periodic Inspection & Testing:

Adequate care should be taken to prevent any ignition source that May arise while maintenance / repair is being carried out on a Tanker. Caution: DON’T DO ANY WELDING ON TANKER UNLESS ANY PART OF THE TANKER IS FREE FLAMMABLE LIQUID OR VAPOUR. a) Every compartment and all piping Hoses should be emptied of liquid contents. b) All shut off valve should be closed and all outlet or inlet connections should be capped.


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c) Any residue in the compartment, Hose, Pipe should be removed d) No repair should be done unless

1. Tank is purged free of Dangerous goods. 2. Inspected and tested in such a manner sufficient to ensure that the tank is free from dangerous

goods.

e) Inspected and tested in such a manner sufficient to ensure that the tank is free from dangerous goods.


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7) Service Schedule for Tank

SI.NO Description Frequency Action

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Check for proper functioning of emergency shout off valve by operating the hand lever.

Daily

3 Check the tightness of the ‘U’ bolt. Every 3000Kms Tighten the ‘U’ bolt

4 Check rubber gaskets in the Manhole and in the Emergency shut off valve Daily

Replace the gaskets,

If damaged

5 Compartment Flushing

When required to carry different product

Use Soap/Caustic solution to

flush the compartment

6 Manhole Locking bolts Tightness.

Daily

Tighten the bolt, if it is loose


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8) Additional Information: 8.1 Technical Specification:

Parameter 18 Kl on LPT 2516Model LPT 2516 / 48Type 18 Kl on LPT 2516

Chassis DetailsEngine Cummins 6BT 5.9Clutch Single Plate Dry Friction Type, Clutch Lining Dia: 352mm, Transmission TATA G 600Electrical System 24 V DCCabin Sleeper tilt Cab

Wheel & Tyres 10 X 20, 16 PR - Rib 7.5 X20 Wheel Rim

Wheelbase,mm 4800Max. Width,mm 2440Track width front 1964Track width rear 1814Front Overhang,mm 1338.5

Tank Capacity 20000 L + 3% ullage

External Dimensions:Length 6400Width 2350Height 1750

Specification Sheet for 18 KL Fuel Tankers


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Shell:Shape : D ShapeMaterial: Fe 410Thickness:3.15 mmNo. of Compartments: 4No. of Manholes: 4Compartment Capacity:C1– 5000; C2 – 5000; C3 – 5000;C4 – 5000 .

Fitments:1) Fire Extinguisher: 10 kg DCP – One no.2) Battery box provision: Inside cabin (Below cabin incase of Tilt Cab)3) Hose Carrier: 150 mm Mild Steel Pipe – One no. per vehicle4) Hose pipe :One no. composite hose with end coupling 5) Rear Bumper: Steel Structure (Heavy Duty)6) Mud Guard:Stainless steel Sheet with M.S. Brackets

7) Ladder: On rear side of Tanker8) Catwalk: Steel structure9) Marking on the Body: As per CMVR Regulations10) Dip Rod: One no. per Vehicle. (Aluminium / Brass)11) Spark arrestor:As per Petroleum Rules 2002 Rule No 63 and 77 (ENESAR Make – CCOE Approved)12) Battery Cut off switch:Heavy duty with Double pole wiring.13) SUPD : As per CMVR Regulations14) Security Locking System: As per Petroleum Company Rules

Body


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Integration Type Mounted with Chassis main frame using Z shape runners with U Bolts

Safety Fittings CCOE Approved - NSR make

Painting Inside: No Coating/Epoxy Coating (Optional)Outside: Epoxy Primer Coating and two coats of Polyeurethin Paint


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8.2 Schematics:


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8.3) General Tank / safety Requirements from different Oil companies:

S.No Descriptions BPCL IOCL HPCL

1. Spark arrester as per Petroleum rules

Applicable Applicable Applicable

2. Battery cut off switch as per Petroleum rules


3. Battery provision as per Petroleum rules


4. Wiring through Conduit pipe Counseled


5. Double pole wiring as per Petroleum rules


6. Earth plate Applicable Applicable Applicable 7. Discharge hose electrically

continuous Applicable (Gun metal end fitting)

Applicable (Cam lock type Aluminum end fitting.)

Applicable (Gun metal end fitting)

8. Fire extinguisher on cabin & tank 2kg - C 10kg - T 2kg – C 10kg - T 10kg - C 10kg - T 9. Distance between tank & cabin

(min 150mm required) Applicable Applicable Applicable

10. Cabin use only M.S or Non flammable material


11. Fuel Tank Guard Applicable Applicable Applicable 12. Master valves as per Petroleum

rules Applicable Applicable Applicable

13. Fusible links as per Petroleum rules


14. Shear section on discharge pipe line



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15. Dome covers As per BPCL type dome cover.

As per IOCL type dome cover.

As per HPCL type dome cover.

16. Fill pipe to be covered with brass mesh

Applicable Applicable Not applicable

17. Dip Rod pipe to be covered with brass mesh


18. Dip Rod (Gauge) Applicable Applicable Applicable 19. Pressure vacuum valve as per

Petroleum rules Applicable Applicable Applicable

20. Emergency Vent as per Petroleum rules


21. Hydrostatic pressure of not less than 0.316 kg/cm2.


22. locking for dome Abloy locking Abloy locking Not Applicable 23. Advertisement Board Not applicable Not applicable Applicable 24. Valve sleeve assembly (For

locking Delivery Valve) Not Applicable Not Applicable Applicable

User manual for tata fuel tanker application on LPT 2516

Automotive

gate valve note

raman dhiman

commercial use

academic purpose onl

time of emergency

fuel tanker

loading tanker

tank dip pipe