OISD - RP - 157

FOR RESTRICTED
CIRCULATION ONLY

No.

RECOMMENDED PRACTICES FOR TRANSPORTATION

OF
BULK PETROLEUM PRODUCTS

OISD-RP-157
First Edition, September 1996

Oil Industry Safety Directorate

Government of India
Ministry of Petroleum & Natural Gas
 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

2nd Floor, ‘Kailash’
26, Kasturba Gandhi Marg,
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
2nd Floor, ‘Kailash’
26, Kasturba Gandhi Marg,
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 not exceeding 1000 litres in

capacity
In recent times the rapid increase in Petroleum - Petroleum contained in a
demand of petroleum has brought about a in bulk tank irrespective of the
significant increase in transportation of quantity of petroleum
petroleum products. Location of any petroleum contained therein.
processing plant or installation depends to a Tank - A vehicle with a tank
large extent on economics of transport of Trailer mounted thereon or built as
crude oil and finished products from refineries integral part thereof and
and other storage terminals and depots etc. constructed in such a
The type of transport used also greatly manner that it has at least
determines the storage requirements. In two axles and all its load
India, petroleum products are transported by rests on its own wheels
tankers, barges, rail, road and pipelines. The Tank - a receptacle for petroleum
inherent characteristics of petroleum products exceeding 1000 litres in
pose a hazard while transporting them and capacity
may affect the transporter, the crew or the Tank Truck - a single self-propelled
public and the oil companies under The Public vehicle with a tank mounted
Liability Act. The events, which give rise to thereon.
hazards, include, particularly, container failure, Tank - a railway carriage with a
accident impact and mishaps during loading Wagon tank mounted thereon.
and unloading operations. The purpose of this Petroleum - Petroleum having a flash
document is to recognize these potential Class A point below 23°C.
hazards and recommend guidelines on design, Petroleum - Petroleum having a flash
safety procedures and practices to be followed Class B point of 23°C and above but
in various modes of transportation of below 65°C.
petroleum products. Petroleum - Petroleum having a flash
Class C point of 65°C and above but
below 93°C.
2.0 SCOPE Excluded - Petroleum which have a
Petroleum flash point of 93°C and
This document covers the guidelines above.
on design, safety procedures and practices in Flash - The flash point of a
transportation of petroleum products and Point petroleum is the minimum
unloading operations for road and rail temperature at which the
transportation. Statutory requirements covered liquid gives off vapour in
under The Petroleum Rules 1976, The Static sufficient concentration to
and Mobile Pressure Vessels (Unfired) Rules form an ignitable mixture
1981, The Factory Act 1948, The Motor with air and produces a
Vehicle Act 1988, The Central Motor Vehicle momentary flash on
Rules 1989 & the amendments thereof and application of a small pilot
other relevant agencies shall be adhered to in flame under specified
addition to the recommended practices conditions of test.
covered in this document. In case of any
difference in interpretation, the Statutory Acts
shall apply. Emergency response system, 4.0 TRANSPORTATION BY ROAD
transportation by cross-country pipelines &
tanker/barges are not covered in this Petroleum products are transported in
document. The Marchant Shipping Act 1958 small container (upto capacity of 200
and relevant rules shall be referred for safety litres) and in tanks drawn by animals,
requirements of transportation by water. push carts and pedal carts, and in
bulk, tanks mounted on mechanically
3.0 DEFINITIONS propelled vehicles. Transportation of
petroleum products by road is
Container - A receptacle for petroleum
 regulated by Department of the vessel should not become
Explosives through The Petroleum liquidfull due to expansion of the
Rules 1976 and The Motor Vehicle Act content with the rise in temperature to
1988. Transportation of LPG in bulk is 55 deg. centigrade. This requirement
regulated through The Static and shall be applicable irrespective of the
Mobile Pressure Vessels (unfired) ambient temperature of the product at
Rules, 1981 and The Motor Vehicle the time of filling.
Act, 1988.
4.2.6 Tank Trucks for Asphalt and Low
4.1 DESIGN CRITERIA Sulphur Heavy Stock

Containers and tank trucks shall be Sufficient vapour space shall be

fabricated in accordance with design provided to prevent leakage or
parameters specified in The spillage due to sudden braking of the
Petroleum Rules 1976. Pressure truck while in transit and in no case it
vessels used for transportation of LPG should be less than 2%. Gross weight
shall be designed and fabricated in of tank truck not to exceed
accordance with The Static and manufacturer’s recommendations for
Mobile Pressure Vessels (Unfired) the model/chassis.
Rules 1981, IS: 2825 and OISD
Standard 160 - Protection to fittings 4.3 DETAILS OF SAFETY
mounted on existing LPG Tank Trucks. APPURTENANCES AND OTHER
SAFETY RELATED FEATURES OF
4.2 MAXIMUM FILLING VOLUME TANK TRUCK

4.2.1 Containers for Petroleum Class A &

B 4.3.1 Tank Trucks for Petroleum Class A
&B
Vapour space of not less than 5% of
its capacity shall be kept in each 4.3.1.1 The cabin of the vehicle shall be
container. of fully metal construction and its rear
window, if provided, shall be covered
4.2.2 Container for Petroleum Class C with wire reinforced glass.
Alternatively, the cabin and engine
Vapour space of not less than 3% of shall be separated from the tank or
it’s capacity shall be kept in each the load, as the case may be, by a fire
container for petroleum Class C. resisting shield or screen which shall
fully cover the tank or the load. There
4.2.3 Tank Trucks for Petroleum Class A shall be a clear space of at least 15
&B cm. between the back of the cabin
and the tank.
Minimum vapour space of 3% shall be
kept in each compartment of the 4.3.1.2 The exhaust shall be located wholly in
truck. No single compartment of the front of the tank or the load, as the
tank truck shall exceed the capacity of case may be,and shall have ample
5 kl and no truck carrying petroleum in clearance from fuel system and
bulk shall exceed 25 kl capacity. combustible materials and shall not be
exposed to leakage or spillage of the
4.2.4 Tank Trucks for Petroleum Class C fuel or product or accumulation of
grease or oil.
Minimum vapour space of 2% shall be
kept in each compartment of the tank 4.3.1.3 The exhaust line and the muffler shall
trucks. The total product in bulk shall be free from leaks and shall have
not exceed 25 kl in any tank truck. adequate clearance from the fuel
system and combustible materials so
4.2.5 Tank Trucks for LPG that it shall not be exposed to leakage
or spillage of fuel or product carried or
Minimum vapour space or the accumulation of grease and oil. The
maximum quantity of LPG filled in any exhaust line and the muffler should be
vessel shall be limited to the filling rigidly fixed.
density of LPG and shall be such that
4.3.1.4 The exhaust system shall be fitted 4.3.1.11The vehicle should have a bonding
with effective spark arrestor of a lug and a bonding cable and the
design approved by the Chief tank/vessel shall be electrically
Controller of Explosives and the same continuous with the chassis.
should be labeled in the spark
arrestor. 4.3.1.12 A portable ISI marked 10 kg
DCP extinguisher shall be provided in
4.3.1.5 Fuel tank of the vehicle, if installed an easily accessible position away
behind the cabin of the vehicle, shall from the discharge faucets on every
be protected against blows by stout vehicle. One portable 1 kg CO2
steel guards and provided with a lock /DCP/Halon/Approved equivalent fire
on the fuel tank cap. extinguisher shall be kept in the cabin
of the vehicle. All extinguishers must
4.3.1.6 The engine air intake shall be have marking indicating the next due
equipped with an air cleaner having date for pressure testing.
effective flame arresting
characteristics to prevent emmission 4.3.1.13 Each compartment of tank
of flame from the intake side of the truck shall have an emergency shut
engine in the event of back firing. off valve located inside the shell with
control lever provided in an accessible
4.3.1.7 The voltage of the electric circuit shall position and away from the fill
not exceed 24 volts. openings of discharge faucets.

4.3.1.8 Electrical wiring shall be provided with The wire rope connecting the shut
suitable over current protection in the off valve and control lever shall be
form of automatic circuit breakers and provided with a approved type fusible
installed so as to be protected from section/link which will permit the shut
physical damage and contact with off valve to close automatically in the
possible product spill either by event of a fire.
location or by being encased in metal
conduit or other protective covering. 4.3.1.14 Every compartment of a tank
shall be provided with independent PV
vent so as to limit the pressure within
The electrical system shall preferably the compartment to 0.21 kg/sq.cm g
use two wire systems (double pole and the vacuum to 5 cm water gauge.
wiring) instead of earthing of negative The vent shall be so designed as to
terminal to the body of the vehicle. prevent loss of liquid through the vent
in the event vehicle is overturned.
4.3.1.9 The Generator, battery, switches and
circuit breakers shall be located in the 4.3.1.15 In addition to the above PV
cabin of the vehicle or in the engine vent an emergency venting facility of
compartment and the battery shall be fusible type shall be provided so as to
in an easily accessible position with an provide minimum fire venting opening
approved type heavy duty master having a net area in sq. cms equal to
switch/cut off switch of not less than 8 plus 4.3 times the gross capacity of
300 amps rating close by to cut-off the the compartment in kls. The fusible
battery. vent shall be actuated at a
temperature not exceeding 93 degree
4.3.1.10 Generator, motors and C. The emergency vent shall be so
switches thereof which are not designed to prevent loss of liquid
installed within the engine through the vent in case of vehicle
compartment shall be of the approved upset except in case of pressure rise
flame proof type. Provided that where when in overturned position.
such generators or motors or switches
thereof are installed in enclosed 4.3.1.16 The inner end of the top fill
space,adequate provision shall be pipe shall be fitted with splash
made for air circulation to prevent deflector and shall extend to 25 mm
overheating and possible from bottom of the tank. The top end
accumulation of inflamable vapours. 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 (ii) The filling pipe,discharge
than 11 to the linear centimetre and faucet and the vent pipe of
chamfered at the bottom. one compartment shall not be
interconnected by manifolding
4.3.1.17 All tank top fittings shall be or otherwise with the filling
provided with dome cover so as to pipe, discharge faucet or vent
protect from damage in the event of pipe of any other
the over turning of the vehicle on compartment.
which it is mounted. Height of tank not (iii) A metal band not less than 2.5
to exceed cabin height and a height cm wide, coloured red and
barrier guard to be provided to protect bearing embossed or printed
against accidental damage of top words “MOTOR SPIRIT” shall
fittings. be securely attached to the fill
pipe and discharge faucet of
4.3.1.18 The rear of the vessel shall be each compartment carrying
protected by a robust steel bumper petroleum Class A. A similar
and this bumber shall be: metal band, coloured green,
blue or grey and bearing
embossed or printed words
i) Attached so that collision describing the class of
stresses will be transmitted to petroleum shall be securely
the frame work of the vehicle attached to the fill pipe and
or in the case of an articulated discharge faucet of each
vehicle, to the frame work compartment carrying such
carrying the wheels of the class of petroleum.
tank.
(iv) Separate braided rubber
ii) Situated at least 15 cm to the hoses bearing ISI mark for
rear of the rear most part of each class of petroleum shall
the tank. at all times be carried in the
licensed vehicle.

iii) Extended on each side of the

vessel to at least cover the 4.3.1.21 The tank trucks used for
maximum width of the tank. fuelling an aircraft do not fulfill
the requirements of those
4.3.1.19 Every tank truck used for used for petroleum class B in
transportation of petroleum respect of restriction on
shall be conspicuously capacity of individual tank and
marked in a contrasting colour power take off unit provided
with the word “FLAMMABLE’ for pumping fuel into aircraft.
and the common name of the The requirement of such tank
flammable liquid being trucks called refuellers are not
transported. regulated through The
Petroleum Rules 1976.
4.3.1.20 Whenever petroleum class A Industry Quality Control
is carried along with any other Manual & Indian Aircraft
class of petroleum in the Manual may be referred for
same vehicle following safety guidelines in this
additional requirements shall regard.
be adhered to:
4.3.1.22 Checklists for POL tank trucks
are given in Annexure-IX.
(i) Two capital letters ‘ML’each
not less than 10 cm. square
shall be printed in a 4.3.2 Tank Truks for
conspicuous colour on each Petroleum Class C
side and the rear of the
vessel.
4.3.2.1 Exhaust pipe shall be fitted with an
approved spark arrestor which shall
 be checked from time to time for the rear of the driving cabin the cabin
fitness. can be considered to act as an
acceptable shield, provided the back,
4.3.2.2 Suitable fire extinguishers shall be the roof and the floor of the cabin are
provided as in 4.3.1.12. of fire resisting construction for the full
4.3.2.3 Each compartment shall have an width of the cabin, without any
emergency shut off valve as in openings in the back or roof, and that
4.3.1.13. the back extends downwards to the
4.3.2.4 A suitable and effective vent shall be top of the chassis.
provided on each tank. 4.3.3.8 When the cabin construction does not
4.3.2.5 Rear of the vessel shall be protected conform to the requirements
by a steel bumper as in 4.3.1.18. mentioned above, a separate fire-
4.3.2.6 The vehicle shall have double pole resistant shield should be installed
wiring and nonsparking electrical extending upwards without any
fittings. openings from the top of the chassis
4.3.3 Tank Trucks for LPG to the top of the vessel.
4.3.3.1 All valves and accessories shall be 4.3.3.9 In any case where windows are
safeguarded against accidental provided in the shield, they should be
damage or interference. For fitted in fire-resistant framing with
protection of fittings mounted on tank wired glass or other heat resistant
trucks OISD Standard 160 may be material and shall not be capable of
refered. being opened.
4.3.3.2 Openings for liquid and vapour flow 4.3.3.10 When the equipment referred
and pressure guage etc. in the truck in 4.3.3.6 above is mounted to the
shall be protected by suitable excess rear of the cabin,it shall be contained
flow check valves mounted in the wholly within an approved fire-
openings of the vessel. Openings of resistant compartment.
less than 1.5 mm need not have such 4.3.3.11In any case where the fuel used to
a valve. propel a vehicle gives off a flamable
4.3.3.3 Valves or accessories situated at the vapour at a temperature less than 65
rear of a vehicle shall be protected by degree C, the fuel tank shall not be
the rear cross member of the frame of behind the shield unless the following
the vehicle against damage. requirements are complied with
4.3.3.4 All pipings, fittings, pumps and meters namely:
permanently mounted on the vehicle (i) the fuel tank is protected by
shall be designed to withstand the stout steel guards or by the
most severe combined stresses frames of the vehicle.
imposed by the following, namely: (ii) the fill pipe of the fuel tank of
(a) The maximum design the vehicle is provided with a
pressure of the vessel. cover having locking
(b) The superimposed pressure of arrangements.
the shock loading caused by (iii) fuel feed apparatus placed in
road movements. front of the fire-resisting shield
4.3.3.5 All piping, fittings and equipment is used to lift the contents of
shall be adequately protected to the fuel tank.
minimise accidental damage which 4.3.3.12 The electrical systems shall have
may be caused by road accidents or the same safety features as detailed
overturning. All trucks should be in 4.3.1.7 to 4.3.1.11.
provided with suitable height barriers 4.3.3.13 Tyres shall be of the “anti-skid” type.
on the drivers cabin if the height of the 4.3.3.14 There shall be a clear space of at
bullet exceeds the cabin height. least 15 cm. between the rear of the
4.3.3.6 The engine and exhaust system cabin and the front of the vessel.
together with all electrical generators, 4.3.3.15 The rear of the vessel shall be
motors, batteries, switch gears and protected by a robust steel bumper
circuit breakers shall be efficiently and this bumper shall be:
screened from the vessel or the body (i) Attached so that collision
of the vehicle by a fire-resisting shield stresses will be transmitted to
or by enclosure within an approved the frame work of the vehicle
fire resisting compartment. or, in the case of an
4.3.3.7 When the equipment referred in articulated vehicle to the
4.3.3.6 above is mounted forward of
 frame work carrying the 4.3.3.23 Checklists for Bulk LPG tank
wheels of the vessel. trucks are given in Annexure - X.
(ii) Situated at least 7.5 cm to the 4.3.4 Tank Trucks for Asphalt
rear of the rearmost part of 4.3.4.1 Exhaust pipe shall be fitted with an
the vessel providing complete approved spark arrestor.
cover to the body. 4.3.4.2 Each tank shall be provided with a
(iii) Extended on each side of the goose-neck vent having an effective
vehicle to at least cover the opening at least equivalent to a
maximum width of the vessel. nominal 50mm pipe.
(iv) The maximum weight of the 4.3.4.3 Each tank shall be provided with a
liquefied gas for which the manhole having a free opening of at
vehicle is designed should not least 381 mm in diameter designed to
exceed the difference in relieve internal pressure between
weight between the unladden 9.095 and 0.143 KPa, or an equivalent
weight of the vehicle and the relief device.
maximum gross weight 4.3.4.4 Overflow protection for asphalt tank
permitted for that class of vehicles shall be provided in the form
vehicle under the appropriate of reservoirs or flashing around fill and
transport regulations or CCOE vent pipes. Overflow and drain pipes
licensed capacity whichever is shall have thickness heavier than the
less. tank shell and shall be designed so
4.3.3.16 The vessel shall be conspicuously that hot asphalt will not spill onto
marked (Refer para 4.6) to show tyres, brakes, burner equipment or
the product which is being carried. vehicle’s exhaust system.
4.3.3.17 Two portable ISI marked 10 kg. 4.3.4.5 Fuel tanks for the vehicle engine and
DCP fire extinguishers shall be fuel tanks or the burners on asphalt
provided on each vehicle, one on trucks shall be located remotely from
each side and should be accessible the burner or protected by a
from outside the cabin and another noncombustible shield from the
1 kg CO2 /DCP/Halon or Halon burner to prevent flash back.
equivalent extinguisher should be 4.3.4.6 Burner tubes shall be properly
kept in the driver’s cabin. All installed and maintained.
extinguishers (minimum 3 nos) 4.3.4.7 The bottom of internal burner tubes
should have the marking indicating shall be located as low as possible in
next due date for pressure testing. the tank.
4.3.3.18 Pressure relief valves shall be 4.3.4.8 A legible red warning sign shall be
tested every year by competent permanently attached near the
person and certificates/records burners on any tank vehicle equipped
maintained. The functioning of with burners and shall contain at least
excess flow check valves should the following information
also be checked once a year. iii.3 “WARNING”
4.3.3.19 All pressure gauges, level gauges & iii.4 The burner equipment must not be
temperature gauges should be operated while the vehicle is being
calibrated once a year. loaded or is in transit, or when the
4.3.3.20 Tank/bullet mounted on the chassis burner tubes are not completely
shall be hydrostatically tested every submerged.
5 years through competent person 4.3.4.9 The rear of the vessel shall be
and Certificates/records maintained. protected by a robust steel bumper as
If the chassis is not suitable for detailed in 4.3.1.18.
taking the load the tank/bullet 4.3.4.10 Suitable fire extinguishers shall be
should be removed & tested provided as detailed in 4.3.1.12.
separately. 4.3.5 Tank Trucks for LSHS
4.3.3.21 After maintenance / repair job the 4.3.5.1 Exhaust pipe shall be fitted with an
LPG tank trucks are to be purged approved spark arrestor.
by water displacement by LPG/inert 4.3.5.2 A suitable and effective vent shall be
gas. provided on each tank.
4.3.3.22 Driver of the vehicle should carry 4.3.5.3 Heater coils when provided, shall be
TREM card and route-map with so constructed that the breaking-off of
detail locations and contact their external connections will not
agencies in case of an emergency. cause leakage of contents. There
 should be no flange connections 4.4.8.2 The action to be taken and treatment
inside the tank. to be given in the event of persons
4.3.5.4 Each compartment of the tank truck coming in contact with the dangerous
shall have emergency shut off valves substances being carried or with any
located inside the shell, with control substances which might escape
lever provided in an accessible therefrom.
position and away from the openings 4.4.8.3 The measures to be taken in case of
or discharge faucets. fire and in particular the extinguishing
4.3.5.5 The rear of the vessel shall be methods and/or agents or groups of
protected by a robust steel bumber as extinguishing methods and/or agents
detailed in 4.3.1.18. not to be used.
4.3.5.6 Suitable fire extingishers shall be 4.4.8.4 The measures to be taken in case of
provided as detailed in 4.3.1.12. breakage or deterioration of
4.4 SAFETY OF TANK TRUCKS IN packaging or spillage of the
TRANSIT dangerous substances, particularly on
4.4.1 Except for driving crew and oil the road.
companies officials during 4.4.8.5 These instructions should be in local
emergencies/leaks/accidents, no other language, Hindi and English.
person shall be carried on the tank 4.4.9 The system of Transport Emergency
truck. Cards (TREM) meets the above
4.4.2 Vehicle shall be constantly attended requirements. A specimen each of
by the driver or his assistant. TREM cards for petroleum Class A, B
4.4.3 The vehicle shall be halted at a safe & C, LPG and heavy oils are given in
place. the Annexure-III. Translation into
4.4.4 The vehicle should be parked with the respective local language may be
consent of the occupier in an open made by operating company as
yard or enclosed premises subject to required.
the Factories Act. 4.4.10 The tank trucks carry ing petroleum
4.4.5 The driver should take all reasonable products/LPG should preferably have
precaution to ensure that the vehicle anti skid tyres.
is parked in safe environment. 4.5 SAFETY RECOMMENDATIONS AT
4.4.6 The driver of a vehicle carrying UNLOADING POINT
petroleum product shall be trained in 4.5.1 In order to prevent accidental
the properties of the material carried, movement, the handbrake and wheel
the handling method applicable to the chocks shall be firmly on and the
grades being carried, in the use of the engine shall be stopped.
fire extinguishing equipment carried 4.5.2 When discharge is in progress, the
on the vehicle and in the emergency driver shall remain at his vehicle in
procedure to be followed. The training such a position as to be able to stop
to drivers should be in line with the discharge immediately in an
syllabus under rule 9 of The Central emergency.
Motor Vehicle Rules 1989 and OISD 4.5.3 A visual check shall be made of the
Standard 154 : Safety Aspect in surroundings, the tank and
Functional Training or should be by connections for unusual or dangerous
any approved Govt. agencies for this situations.
purpose. 4.5.4 Warning notices shall be displayed
4.4.7 All necessary steps shall be taken by and suitable fire appliances shall be
the owner/loader of the vehicle to available for instant use.
ensure that the driver is fully aware of 4.5.5 Bonding leads shall be connected
and understands all instructions. before making the hose connections
4.4.8 As a precaution against any accident and shall remain connected till the
or emergency that may occur during hoses have been removed. Perfect
carriage, the driver shall be supplied bonding contact should be ensured.
with instructions in writing as detailed 4.5.6 When operations are commenced, a
in safety instruction booklet attached further examination for leakage at
in annexure VI. connections shall be carried out.
4.4.8.1 The nature of the danger presented by 4.5.7 No person shall smoke while on or
the dangerous substances carried and attending such a vehicle.
the safety measures that must be 4.5.8 No article or substance capable of
taken to avert that danger. causing fire or explosion shall be
carried on such a vehicle.
4.6 LABELLING OF CONTAINERS, “correct technical names” of the
VEHICLES CARRYING HAZARDOUS chemicals/petroleum products in
MATERIAL letters not less than 50 mm high.
4.6.1 All dangerous substances are divided 4.6.4.2 The display on vehicle of special signs
into 8 main classifications. LPG falls or plates denoting that dangerous
under Class 2 and other petroleum goods are being conveyed or plates
products are grouped under Class 3. It bearing special code numbers
is recommended that containers or (HAZCHEM) which may identify the
vehicles carrying hazardous substances or reveal its hazardous
chemicals which include petroleum property or indicate what action should
products, shall be provided with a be taken in emergencies as shown in
distinct mark of the class labels on Annexure-V.
vehicles showing the specified 4.6.4.3 The name and telephone numbers of
emblems pictorially representing the emergency services to be
particular dangers. (For details, refer contacted in the event of any fire or
The Central Motor Vehicle Rules-1989 any other accident in letters and
& Amendments thereof). numerals that are not less than 50 mm
4.6.2 To ensure that any package or truck high and the name and telephone
carrying dangerous goods is number of the consignor of the
recognised from a dangerous or hazardous goods or of
iv) distance, the some other person from whom expert
recommendations include a information and advice can be
labelling system. The obtained concerning the measures
recommended labels are that should be taken in the event of an
diamond shaped i.e. they are emergency involving such goods.
in the form of square ( 25 cm 4.6.4.4 Every class label and emergency
x 25 cm) set at an angle of 45 information panel shall be marked on
degrees. The upper half of the the goods, carriage as stipulated in
label is reserved for the the Motor Vehicle Rules 1989 and
pictorial symbol representing shall be kept free and clean from
the nature of the risk, different instructions at all the times.
symbols being provided for
each of the Classes.The 5.0 TRANSPORTATION BY RAIL
number of the class or In India, Railway Administration, acting as a
division should be shown in carrier of Petroleum Products, is exempted
block in the bottom corner of from taking any licence for transporting it
the label unless the substance under Petroleum Rules 1976. Railway
in question presents more Administration have elaborate rules for the
than one risk. Any other text carriage of petroleum by rail as provided in
inserted optionally in the lower Indian Railways Act and Red Tariff No.19 of
half of the label should be Indian Railways Conference Association.
printed in black and should be
confined to particulars 5.1 DESIGN CRITERIA
indicating the nature of the
risk and precautions to be All tank wagons used for the
taken in handling. The conveyance of petroleum products
labelling system for trucks is and LPG shall be of a design
shown in Annexure-IV. approved by RDSO. Design
4.6.3 Every goods carriage carrying any parameters for tank wagons used for
dangerous or hazardous goods shall transportation by rail are issued by
display the class label both in front the Wagon Directorate, Research,
and in the rear in a conspicuous Design, and Standards Organisation
manner. of Indian Railways.
4.6.4 Every goods carriage used for
transporting any dangerous or 5.2 FILLING CONSIDERATIONS
hazardous goods shall be legibly and
conspicuously marked with an 5.2.1 Tank Wagons for Petroleum Class A
emergency information panels as Vapour space of not less than 4% of the
indicated in Annexure-IV. capacity of tank wagon shall be kept.
4.6.4.1 The display on vehicles of the Since tank wagons are loaded in
descriptive names or prescribed accordance with the load carrying
 capacity by weight in relation to axle 5.3.2.3 The top fittings are protected by a
design, the above vapour space is allowed. dome cover.
In addition the tank wagons are filled as
per the calibration tables provided by 5.3.3 Tank wagons for LPG (Railway code
railways and which specifies the TG) (4-wheeler/8-wheeler)
maximum dip to be loaded for various
products. 5.3.3.1 Tank wagons designed by RDSO are
provided with safety valve with
5.2.2 Tank wagons for Discharge Capacity : 10.3 cum/sec.
Petroleum Class B & Class C
Vapour space shall be a minimum of 5.3.3.2 All other fittings such as liquid valves,
2.5%. Provision of fill pipe or a vapour valves, magnetic gauging
contraption in lieu of fill pipe to avoid device, thermowell, sample valve and
splash loading if unloading arm/hose safety valves, pressure gauges are
is not extending fully. provided on top of the pressure vessel
5.2.3 Tank Wagons for LPG in a protective housing known as
The maximum quantity of LPG filled ‘dome’ with a cover.
in any tank wagon shall be limited to
the filling density of the LPG and shall 5.3.3.3 After repair or maintenance tank
be such that the tank wagon shall not wagons are required to be purged with
be liquidful due to expansion of the LPG/inert gases.
contents with rise of the temperature
to 55 degree C. or limited to specified Typical drawings of LPG tank wagons
gross weight on the wagon whichever are shown in annexure VII & VIII.
is less.
5.2.4 Tank Wagons for Asphalt and LSHS 5.3.4 Tank wagon for asphalt (TBT) or
Minimum of 2.5% air space shall be LSHS (TOH)
left and also loading limited to There are no specific safety fittings
specified gross weight on the wagon. required for these wagons except that
5.3 DETAILS OF SAFETY these are provided with a dome on top
APPURTENANCES AND OTHER with full opening to facilitate filling.
SAFETY RELATED FEATURES OF These wagons are also provided with
TANK WAGONS steam coils. Only precaution
5.3.1 Tank wagons for petroleum class A necessary is that no tank wagon for
These wagons are marked as “TP” Asphalt or LSHS be loaded if any
as per Railway Code, except Hexane water is found present inside the tank
which is loaded in TH tank wagon. to avoid boil over condition during
5.3.1.1 Each tank wagon is provided with an loading.
effective pressure valve as per
approved design. 5.4 PROCEDURE FOR DEGASSING OF
LPG Tank WAGONS
5.3.1.2 All openings of fill pipe and dip pipe
are provided with air tight caps. The following sequence shall be followed:
5.3.1.3 A master
valve set at the bottom inside the 5.4.1 During degassing operation, all
body with control from the top of tank loading/unloading operations on that
wagon. spur shall be stopped. Earthing to be
ensured even on the degassing bay
5.3.1.4 A block valve before commencing the degassing.
at bottom of the wagon to which
unloading hose is connected. 5.4.2 Sampling valve should be opened and
vapours allowed to escape fully.
5.3.1.5 The top fittings are protected by a
dome cover. 5.4.3 The plugs of liquid and vapour
5.3.2 Tank wagons for petroleum class B & eduction valves should be unscrewed
C (Railway code ATF TK & TL) and then valve be opened.
5.3.2.1 Each tank wagon is provided with an
effective vent as per approved design. 5.4.4 The method adopted to make the
5.3.2.2 The master valve control is from top barrel free from LPG is to fill the
of the tank. barrel completely with water and
 allow to overflow for an hour. Pump i) Fire Protection Handbook - Fifteenth
out the water after 24 hours. Edition 1981.

5.4.5 Remove the manhole cover. In no ii) NFPA 385 - Standard for Tank
case the heating of studs/bolts shall Vehicles for Flammable and
be adopted to open them. If required, Combustible Liquids - 1985.
rust remover solution shall be used.
iii) NFPA - 58 Standard For the Storage
5.4.6 Check thoroughly for presence of LPG and Handling of Liquefied Petroleum
vapours inside by explosimeter. Gases - 1983.
Repeat the procedure under 5.6.3 if iv) Loss Prevention in the Process
explosimeter shows presence of Industries - Vol. 2 by Lees.
vapour inside.
v) The Petroleum Rules - 1976.
5.4.7 Ensure that the barrel is completely
dry in case water filling or steam vi) The Gas Cylinder Rules - 1981.
purging method of degasing is
adopted. vii) The Static and Mobile Pressure
Vessels Rules - 1981.
5.4.8 A safety instruction checklist should
be exhibited at the degassing station viii) Maintenance Manual for 4 - Wheeled
containing all relevant points in the Liquefied Petroleum Gas Tank Wagon
degassing procedure. Type TPGLR - 1983.

5.4.9 Degassing operation should be ix) Red Tariff No. 19 (Indian Railways
discontinued at the approach of Conference Associations).
thunder storm and all valves manhole
covers and hoses disconnected to x) Cefic Tremcards - Group Text
make the wagon ready for removal. Chemical Industries Association, U.K.

xi) Transport of Dangerous Goods

5.4.10 Disposal of sludge from the LPG (Recommendations of the Committee
wagons should be transported away of Experts on the Trasport of
from the siding in wet condition and Dangerous Goods), Third revised
disposed of in safe manner. edition.

6.0 REFERENCES 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.
NOTE