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NOTE
OISD publications are prepared for use in the oil and gas industry
under Ministry of Petroleum and Natural Gas. These are the property of
Ministry of Petroleum and Natural Gas and shall not be reproduced or copied
or 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.
The Oil Industry in India is over 100 years old. As such, various
practices have been in vogue because of collaboration/association with
different foreign companies and governments. Standardisation in design
philosophies and operating and maintenance practices at a national level was
hardly in existence. This, coupled with feedback from some serious accidents
that occurred 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 is view, the Ministry of Petroleum and Natural Gas in 1986
constituted a Safety Council assisted by the Oil Industry Safety Directorate
(OISD), staffed from within the industry, for 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 functional committees comprising of
experts nominated from the industry to draw up standards and guidelines on
various subjects.
The Coordinator
Committee on "Oil Storage and Handling"
OIL INDUSTRY SAFETY DIRECTORATE
7th Floor, New Delhi House
27, Barakhamba Road
New Delhi 110 001
COMMITTEE
ON
LEADER ORGANISATION
------------- ------------- ------------
MEMBERS
----------------
MEMBER CO-ORDINATOR
----------------------------------------
Shri S.N.Mathur, Oil Industry Safety Directorate,
New Delhi
(In addition to the above, several other experts from industry contributed in the
preparation, review and finalisation of this document.)
RECOMMENDED PRACTICES
ON
1.0 INTRODUCTION
2.0 SCOPE
3.0 DEFINITIONS
3.1 Terminals
3.2 Slop
3.3 Gantry
3.4 Tanks
3.5 Sick Wagon
3.6 Classification of Petroleum
10.0 REFERENCES
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RECOMMENDED PRACTICES
ON
Nominal capacity shall mean the Floating roof may be single deck
geometric volume of the tank from bottom pontoon roof, double deck or pan roof. Pan
upto curb angle in case of fixed roof tanks roof shall not be used as these are unsafe.
and the underside of roof deck upto the For designing these tanks, API 650
maximum floating position of floating roof in guidelines may be followed.
case of floating roof tanks.
Fixed Roof
3.4.2 Gross Capacity of a Tank
Fixed roof may be of cone type or
Gross capacity (stored volume) is the dome shaped. The tank may be
capacity of the tank upto the maximum pressurised (to a few inches of water) type
safe filling height of the tank. with breather valves. Alternatively, tanks
may be provided with fuel gas or inert gas
3.4.3 Net Capacity blanketing to prevent oxygen/moisture
ingress. Fixed roof tanks for light products
Net capacity is the net pumpable (e.g. Motor Spirit) breathing into a
capacity of the tank during operation after neoprene balloon is not acceptable. For
subtracting the volume of tank bottom designing atmospheric/low pressure tanks,
contents up to the top of normal pumpout API 650 or API 620 may be followed
nozzle from safe filling capacity of the tank. based on the type of the tank.
Sick wagons are those which are These tanks have a fixed roof over a
declared defective because of leaky bottom floating roof.They are used for products
valve, missing safety valve, leaking body or having very stringent water content
any other mechanical failure. specifications like Aviation Turbine Fuel
and products sensitive to oxygen like light
3.6 CLASSIFICATION OF PETROLEUM intermediate feed tanks. Where oxygen
ingress is to be avoided, it is preferable to
Petroleum products are divided into provide Nitrogen blanketing.
three classes based on their flash points as
follows: 4.1.1 Selection of Roof
Size (in mm) of Inlet Pipe Max.Flow (i) Pumps shall be located in an
(cu.m./hr) exclusive paved area with drainage
-------------------------- ------------------- facilities. To avoid wide variation
300 246 in pressure, leading to a 'kick' or
250 168 'hammering' in header and hoses,
200 109 it is necessary to choose pumps
150 59 with flat characteristic curves.
100 27 (ii) Loading pumps shall also be
80 25.5 provided with additional explosion
proof switches located at the
(iv) Conductive footwear e.g. leather soles gantry to switch off the pump in
or electrically conducting rubber soles, case of emergency.
should be worn while gauging, (iii) It is preferred to have a dedicated
sampling or taking tempertures. Nylon pump for each product. Common
rope shall not be used for lowering standy pump may be used for
sample bottles in the tank. MS/Naptha or Kero/HSD or
LDO/FO etc. However, positive
(v) One of the most common sources of blinding facility shall be available.
leaks and spills is mobile storage Common standby pump shall not
tanks,such as diesel fuel tanks used for be used between Class 'A' and
construction machinery. It is desirable
Class B/C or Class 'B' and Class (xi) For tank truck, loading should
'C' products. preferably be done with set flow
(iv) It is desirable to have separate indicators rather than manual.
pumps for truck loading and not (xii) It is desirable to consider fire proof
combined with wagon loading as remote operated shut off valves for
the latter are normally of much loading headers so that gantry
higher capacity. headers can be isolated in case of
(v) Receiving lines as well as emergency.
discharge lines shall be provided
with thermal safety relief valves to 8.2 WAGON & TRUCK LOADING
relieve pressure due to ambient GANTRIES
temperature rise. Whenever
isolation valves are used to isolate (i) Loading points shall have quick
TSV, isolation valve with lock open shut-off valves viz. Plug or Ball
provision should be considered. Valves.
(vi) Safety relief valves may vent into a (ii) Vacuum release valves shall be
tank or may be piped to a collector provided with chain lever
drum having level indicator/alarm arrangement for release in case of
or to OWS located in safe area. stuck up vacuum release valves.
When connected to tank, it should (iii) As there would be variations in
be provided with isolation valve number of trucks/wagons being
on either side and break loaded at a time, the flow rate
flange/union on tank side. through each point would also
Also,location shall be close to drain vary. Hence, restriction orifices or
sump. SRV discharge for flow control valves must be
congealing service should not be provided to restrict velocity upto 6
routed to OWS but to a paved m/sec, particularly for motor spirit,
area. kerosene, ATF and diesel.
(vii) No cast iron valve shall be used (iv) Kero and diesel can form a
in oil service. Only cast steel valves multipoint. Similarly, LDO and FO
shall be considered. may be combined. Two types of
(viii) Provision shall exist for emptying Naphtha viz. HAN & LAN can be
out the loading headers back to put together. However, ATF or MS
tank by means of loading pumps or shall be exclusive.
through a drain vessel. Use of (v) All flanged points, in loading
loading pump is feasible by header and loading points shall be
connecting discharge pipe to pump provided with jumper wires.
suction, downstream of suction (vi) Earthing of loading gantry shall be
valve and giving a similar provided at structure pillars.
connection from upstream of Railway gantry should be grounded
discharge valve to upstream of at every 25m. Loading header in
suction valve. This ensures safe the loading gantry shall be bonded
maintenance. to the Railway track at every 25m.
(ix) In case of large capacity wagon Earthing of truck tankers to be
loading gantries where loading ensured before commencing
could vary from a rake to few loading / unloading operation.
wagons, it is desirable to provide a (vii) In case of loading hoses, only
minimum flow controller on neoprene impregnated hoses,
discharge line to take care of supplemented with external wire
pressure fluctuations. When more connecting loading nozzle to pipe
than one loading pump is required should be used.
to be run to meet higher loading (viii) All tank wagons and tank trucks
rates, minimum continuous flow should have a fill pipe leading to
requirement of each pump shall be the bottom. In the absence of the
considered. same, portable fill pipe shall be
(x) Where flow indicators/totalisers are used. However, splash filling is
provided for gantries, vapour permissible for asphalt loading in
eliminators shall be incorporated. tank truck or tank wagons.
(ix) Where bottom loading is done, gratings so as not to endanger
deflector plates in the trucks / movement of personnel.
wagons to be ensured. (xxi) All trucks entering truck loading
(x) Bottom flameproof lighting should gantry shall be provided with flame
be provided for night time checking arrestors at the exhaust.
of wagon bottom leaks and also for (xxii) Oil and water collected from
proper sealing and inspection loading areas should be routed to
wherever loading/unloading during central waste water treatment
night is required to be done. facilities. Where such central
(xi) Loading gantry platform should facility does not exist, as in the
have atleast one explosion-proof case of terminals/bulk plant/depots,
telephone for communication with local oil water collection and
pump house as well as in separation system should be
emergencies. provided. Depending on size, this
(xii) Gantries shall be protected with could be a catch basin or trap, API
well designed fire fighting system. separator or similar facility. A slop
For details refer OISD-STD-116 tank may be earmarked for storing
and 117. separated oil.
(xiii) Tank wagon and truck loading 8.3 HANDLING OF SICK WAGON/TRUCK
gantries shall be suitable for all
weather conditions. When a wagon is found leaking during
(xiv) Loading platforms (swing type) loading, provision should be kept for
shall be light in construction and unloading the content safely. A drain
bottom rest shall be neoprene header should be provided to drain out the
packed to avoid spark generation content to a underground tank/sump from
due to impact. where it can be pumped out to storage tank
(xv) Proper handrail arrangement shall or to the loading header. Alternatively, in
be provided on opposite side of case, mobile pump is used for unloading
loading point for safe movement of sick wagon, explosion proof motor and
personnel over truck/wagon. power connection should be provided.
(xvi) Well maintained earthing clamps Similar facility should be provided for
should be available for earthing of unloading sick truck tanker also.
trucks.
(xvii) Protection against pressure surge 9.0 HANDLING OF SLOP
in the loading header due to
sudden change in loading rate 9.1 COLLECTION
need to be considered. Provision of
shock absorber as one of the surge 9.1.1 Underground Drainage
protection method at suitable
locationons on rail/road loading A network of undeground drainage system
header may be considered. should be provided to collect oil drains from
(xviii) Wagon/truck loading gantries shall various equipments, gantry areas, pump
be on concrete supports. houses etc. They should also collect
Alternatively, fire-proofing shall be surface drains from places where oil
done upto the platform if made of spillages are likely to occur. The
steel structure. underground drainage should lead to
(xix) Entire loading gantry, including central waste water treatment plant/oil
areas below railway lines/truck catcher as the case may be.
bays,shall be paved for smooth
draining and collection of spillages 9.1.2 Receiving Sump
into drains. Also, underground
drain shall be provided with riser The receiving sump of the central
and funnel for each loading point oily water treatment facilities shall have
so that the hose after loading can inverted weir arrangement to skim off upper
be inserted into the same to avoid layer of accumulated oil. Skimmed oil shall
spillages. be pumped directly to wet slop tanks. Left
over oil water mixture shall be routed to
(xx) Open drains along the railway waste water treatment.
line/gantry shall be covered with
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