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
7
TH
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
7
TH
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 23C.
Petroleum
Class B
- Petroleum having a flash
point of 23C and above but
below 65C.
Petroleum
Class C
- Petroleum having a flash
point of 65C and above but
below 93C.
Excluded
Petroleum
- Petroleum which have a
flash point of 93C 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
its 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 manufacturers
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 MLeach
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 drivers 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 vehicles
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 vehicles 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 vehicles 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.