OISD - RP - 157

FOR RESTRICTED
CIRCULATION ONLY

RECOMMENDED PRACTICES FOR TRANSPORTATION

OF
BULK PETROLEUM PRODUCTS

OISD-RP-157
First Edition, September 1996
 OISD - RP - 157

September, 1996

RECOMMENDED PRACTICES FOR TRANSPORTATION

OF
BULK PETROLEUM PRODUCTS

Prepared by :

COMMITTEE ON
TRANSPORTATION OF BULK PETROLEUM PRODUCTS
 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.
 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 - Petroleum contained in a tank irrespective of the quantity of
bulk 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 - Petroleum having a flash point below 23°C.
A
Petroleum Class - Petroleum having a flash point of 23°C and above but below
B 65°C.
Petroleum Class - Petroleum having a flash point of 65°C and above but below 93°C.
C
Excluded - Petroleum which have a flash point of 93°C and above.
Petroleum
Flash Point - The flash point of a petroleum is the minimum temperature at
which the liquid gives off vapour in sufficient concentration to
form an ignitable mixture with air and produces a momentary flash
on application of a small pilot flame under specified conditions of
test.

4.0 TRANSPORTATION BY ROAD

 Petroleum products are transported in small container (upto capacity of
200 litres) and in tanks drawn by animals, push carts and pedal carts, and
in bulk, tanks mounted on mechanically propelled vehicles.
Transportation of petroleum products by road is regulated by Department
of Explosives through The Petroleum Rules 1976 and The Motor Vehicle
Act 1988. Transportation of LPG in bulk is regulated through The Static
and Mobile Pressure Vessels (unfired) Rules, 1981 and The Motor
Vehicle Act, 1988.

4.1 DESIGN CRITERIA

Containers and tank trucks shall be fabricated in accordance with design

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

4.2.1 Containers for Petroleum Class A & B

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

4.2.2 Container for Petroleum Class C

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

4.2.3 Tank Trucks for Petroleum Class A & B

Minimum vapour space of 3% shall be kept in each compartment of the

truck. No single compartment of the tank truck shall exceed the capacity
of 5 kl and no truck carrying petroleum in bulk shall exceed 25 kl
capacity.

4.2.4 Tank Trucks for Petroleum Class C

Minimum vapour space of 2% shall be kept in each compartment of the

tank trucks. The total product in bulk shall not exceed 25 kl in any tank
truck.

4.2.5 Tank Trucks for LPG

 Minimum vapour space or the maximum quantity of LPG filled in any
vessel shall be limited to the filling density of LPG and shall be such that
the vessel should not become liquidfull due to expansion of the content
with the rise in temperature to 55 deg. centigrade. This requirement shall
be applicable irrespective of the ambient temperature of the product at the
time of filling.

4.2.6 Tank Trucks for Asphalt and Low Sulphur Heavy Stock

Sufficient vapour space shall be provided to prevent leakage or spillage

due to sudden braking of the truck while in transit and in no case it should
be less than 2%. Gross weight of tank truck not to exceed manufacturer’s
recommendations for the model/chassis.

4.3 DETAILS OF SAFETY APPURTENANCES AND OTHER

SAFETY RELATED FEATURES OF TANK TRUCK

4.3.1 Tank Trucks for Petroleum Class A & B

4.3.1.1 The cabin of the vehicle shall be of fully metal construction

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

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

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

4.3.1.4 The exhaust system shall be fitted with effective spark arrestor of a
design approved by the Chief Controller of Explosives and the same
should be labeled in the spark arrestor.

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

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

4.3.1.7 The voltage of the electric circuit shall not exceed 24 volts.

4.3.1.8 Electrical wiring shall be provided with suitable over current

protection in the form of automatic circuit breakers and installed so as to
be protected from physical damage and contact with possible product
spill either by location or by being encased in metal conduit or other
protective covering.
 The electrical system shall preferably use two wire systems (double pole
wiring) instead of earthing of negative terminal to the body of the vehicle.

4.3.1.9 The Generator, battery, switches and circuit breakers shall be

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

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

4.3.1.11 The vehicle should have a bonding lug and a bonding cable and the
tank/vessel shall be electrically continuous with the chassis.

4.3.1.12 A portable ISI marked 10 kg DCP extinguisher shall be provided in

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

4.3.1.13 Each compartment of tank truck shall have an emergency shut off
valve located inside the shell with control lever provided in an accessible
position and away from the fill openings of discharge faucets.
 The wire rope connecting the shut off valve and control lever shall be
provided with a approved type fusible section/link which will permit the
shut off valve to close automatically in the event of a fire.

4.3.1.14 Every compartment of a tank shall be provided with independent

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

4.3.1.15 In addition to the above PV vent an emergency venting facility of

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

4.3.1.16 The inner end of the top fill pipe shall be fitted with splash
deflector and shall extend to 25 mm from bottom of the tank. The top
end of the fill pipe should have an oil tight locker cap. The fill pipe shall
have perforations all along and covered with wire gauge of a mesh not
less than 11 to the linear centimetre and chamfered at the bottom.

4.3.1.17 All tank top fittings shall be provided with dome cover so as to
protect from damage in the event of the over turning of the vehicle on
which it is mounted. Height of tank not to exceed cabin height and a
height barrier guard to be provided to protect against accidental damage
of top fittings.
4.3.1.18 The rear of the vessel shall be protected by a robust steel bumper
and this bumber shall be:

i) Attached so that collision stresses will be transmitted to the frame

work of the vehicle or in the case of an articulated vehicle, to the
frame work carrying the wheels of the tank.
ii) Situated at least 15 cm to the rear of the rear most part of the tank.
iii) Extended on each side of the vessel to at least cover the maximum
width of the tank.

4.3.1.19 Every tank truck used for transportation of petroleum shall be

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

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

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

(ii) The filling pipe,discharge faucet and the vent pipe of one
compartment shall not be interconnected by manifolding or
otherwise with the filling pipe, discharge faucet or vent pipe of any
other compartment.
 (iii) A metal band not less than 2.5 cm wide, coloured red and bearing
embossed or printed words “MOTOR SPIRIT” shall be securely
attached to the fill pipe and discharge faucet of each compartment
carrying petroleum Class A. A similar metal band, coloured green,
blue or grey and bearing embossed or printed words describing the
class of petroleum shall be securely attached to the fill pipe and
discharge faucet of each compartment carrying such class of
petroleum.
(iv) Separate braided rubber hoses bearing ISI mark for each class of
petroleum shall at all times be carried in the licensed vehicle.

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

4.3.1.22 Checklists for POL tank trucks are given in Annexure-IX.

4.3.2 Tank Truks for Petroleum Class C

4.3.2.1 Exhaust pipe shall be fitted with an approved spark arrestor which
shall be checked from time to time for fitness.
4.3.2.2 Suitable fire extinguishers shall be provided as in 4.3.1.12.
4.3.2.3 Each compartment shall have an emergency shut off valve as in
4.3.1.13.
4.3.2.4 A suitable and effective vent shall be provided on each tank.
4.3.2.5 Rear of the vessel shall be protected by a steel bumper as in
4.3.1.18.
4.3.2.6 The vehicle shall have double pole wiring and nonsparking
electrical fittings.
4.3.3 Tank Trucks for LPG
4.3.3.1 All valves and accessories shall be safeguarded against accidental
damage or interference. For protection of fittings mounted on tank trucks
OISD Standard 160 may be refered.
4.3.3.2 Openings for liquid and vapour flow and pressure guage etc. in the
truck shall be protected by suitable excess flow check valves mounted in
the openings of the vessel. Openings of less than 1.5 mm need not have
such a valve.
4.3.3.3 Valves or accessories situated at the rear of a vehicle shall be
protected by the rear cross member of the frame of the vehicle against
damage.
4.3.3.4 All pipings, fittings, pumps and meters permanently mounted on
the vehicle shall be designed to withstand the most severe combined
stresses imposed by the following, namely:
(a) The maximum design pressure of the vessel.
(b) The superimposed pressure of the shock loading caused by road
movements.
4.3.3.5 All piping, fittings and equipment shall be adequately protected to
minimise accidental damage which may be caused by road accidents or
overturning. All trucks should be provided with suitable height barriers
on the drivers cabin if the height of the bullet exceeds the cabin height.
4.3.3.6 The engine and exhaust system together with all electrical
generators, motors, batteries, switch gears and circuit breakers shall be
efficiently screened from the vessel or the body of the vehicle by a fire-
resisting shield or by enclosure within an approved fire resisting
compartment.
4.3.3.7 When the equipment referred in 4.3.3.6 above is mounted forward
of the rear of the driving cabin the cabin can be considered to act as an
acceptable shield, provided the back, the roof and the floor of the cabin
are of fire resisting construction for the full width of the cabin, without
any openings in the back or roof, and that the back extends downwards to
the top of the chassis.
4.3.3.8 When the cabin construction does not conform to the requirements
mentioned above, a separate fire-resistant shield should be installed
extending upwards without any openings from the top of the chassis to
the top of the vessel.
4.3.3.9 In any case where windows are provided in the shield, they should
be fitted in fire-resistant framing with wired glass or other heat resistant
material and shall not be capable of being opened.
4.3.3.10 When the equipment referred in 4.3.3.6 above is mounted to the
rear of the cabin,it shall be contained wholly within an approved fire-
resistant compartment.
4.3.3.11 In any case where the fuel used to propel a vehicle gives off a
flamable vapour at a temperature less than 65 degree C, the fuel tank shall
not be behind the shield unless the following requirements are complied
with namely:
(i) the fuel tank is protected by stout steel guards or by the frames of
the vehicle.
(ii) the fill pipe of the fuel tank of the vehicle is provided with a cover
having locking arrangements.
 (iii) fuel feed apparatus placed in front of the fire-resisting shield is
used to lift the contents of the fuel tank.
4.3.3.12 The electrical systems shall have the same safety features as
detailed in 4.3.1.7 to 4.3.1.11.
4.3.3.13 Tyres shall be of the “anti-skid” type.
4.3.3.14 There shall be a clear space of at least 15 cm. between the rear of
the cabin and the front of the vessel.
4.3.3.15 The rear of the vessel shall be protected by a robust steel bumper
and this bumper shall be:
(i) Attached so that collision stresses will be transmitted to the frame
work of the vehicle or, in the case of an articulated vehicle to the
frame work carrying the wheels of the vessel.
(ii) Situated at least 7.5 cm to the rear of the rearmost part of the vessel
providing complete cover to the body.
(iii) Extended on each side of the vehicle to at least cover the maximum
width of the vessel.
(iv) The maximum weight of the liquefied gas for which the vehicle is
designed should not exceed the difference in weight between the
unladden weight of the vehicle and the maximum gross weight
permitted for that class of vehicle under the appropriate transport
regulations or CCOE licensed capacity whichever is less.
4.3.3.16 The vessel shall be conspicuously marked (Refer para 4.6) to show
the product which is being carried.
4.3.3.17 Two portable ISI marked 10 kg. DCP fire extinguishers shall be
provided on each vehicle, one on each side and should be accessible
from outside the cabin and another 1 kg CO2 /DCP/Halon or Halon
equivalent extinguisher should be kept in the driver’s cabin. All
extinguishers (minimum 3 nos) should have the marking indicating next
due date for pressure testing.
4.3.3.18 Pressure relief valves shall be tested every year by competent
person and certificates/records maintained. The functioning of excess
flow check valves should also be checked once a year.
4.3.3.19 All pressure gauges, level gauges & temperature gauges should be
calibrated once a year.
4.3.3.20 Tank/bullet mounted on the chassis shall be hydrostatically tested
every 5 years through competent person and Certificates/records
maintained. If the chassis is not suitable for taking the load the
tank/bullet should be removed & tested separately.
4.3.3.21 After maintenance / repair job the LPG tank trucks are to be
purged by water displacement by LPG/inert gas.
4.3.3.22 Driver of the vehicle should carry TREM card and route-map with
detail locations and contact agencies in case of an emergency.
4.3.3.23 Checklists for Bulk LPG tank trucks are given in Annexure -
X.
4.3.4 Tank Trucks for Asphalt
4.3.4.1 Exhaust pipe shall be fitted with an approved spark arrestor.
4.3.4.2 Each tank shall be provided with a goose-neck vent having an
effective opening at least equivalent to a nominal 50mm pipe.
4.3.4.3 Each tank shall be provided with a manhole having a free opening
of at least 381 mm in diameter designed to relieve internal pressure
between 9.095 and 0.143 KPa, or an equivalent relief device.
4.3.4.4 Overflow protection for asphalt tank vehicles shall be provided in
the form of reservoirs or flashing around fill and vent pipes. Overflow
and drain pipes shall have thickness heavier than the tank shell and shall
be designed so that hot asphalt will not spill onto tyres, brakes, burner
equipment or vehicle’s exhaust system.
4.3.4.5 Fuel tanks for the vehicle engine and fuel tanks or the burners on
asphalt trucks shall be located remotely from the burner or protected by a
noncombustible shield from the burner to prevent flash back.
4.3.4.6 Burner tubes shall be properly installed and maintained.
4.3.4.7 The bottom of internal burner tubes shall be located as low as
possible in the tank.
4.3.4.8 A legible red warning sign shall be permanently attached near the
burners on any tank vehicle equipped with burners and shall contain at
least the following information
iii.3 “WARNING”
iii.4 The burner equipment must not be operated while the vehicle is being
loaded or is in transit, or when the burner tubes are not completely
submerged.
4.3.4.9 The rear of the vessel shall be protected by a robust steel bumper as
detailed in 4.3.1.18.
4.3.4.10 Suitable fire extinguishers shall be provided as detailed in 4.3.1.12.
4.3.5 Tank Trucks for LSHS
4.3.5.1 Exhaust pipe shall be fitted with an approved spark arrestor.
4.3.5.2 A suitable and effective vent shall be provided on each tank.
4.3.5.3 Heater coils when provided, shall be so constructed that the
breaking-off of their external connections will not cause leakage of
contents. There should be no flange connections inside the tank.
4.3.5.4 Each compartment of the tank truck shall have emergency shut off
valves located inside the shell, with control lever provided in an
accessible position and away from the openings or discharge faucets.
4.3.5.5 The rear of the vessel shall be protected by a robust steel bumber as
detailed in 4.3.1.18.
4.3.5.6 Suitable fire extingishers shall be provided as detailed in 4.3.1.12.
4.4 SAFETY OF TANK TRUCKS IN TRANSIT
4.4.1 Except for driving crew and oil companies officials during
emergencies/leaks/accidents, no other person shall be carried on the tank
truck.
4.4.2 Vehicle shall be constantly attended by the driver or his assistant.
4.4.3 The vehicle shall be halted at a safe place.
4.4.4 The vehicle should be parked with the consent of the occupier in an open
yard or enclosed premises subject to the Factories Act.
4.4.5 The driver should take all reasonable precaution to ensure that the vehicle
is parked in safe environment.
4.4.6 The driver of a vehicle carrying petroleum product shall be trained in the
properties of the material carried, the handling method applicable to the
grades being carried, in the use of the fire extinguishing equipment
carried on the vehicle and in the emergency procedure to be followed.
The training to drivers should be in line with syllabus under rule 9 of The
Central Motor Vehicle Rules 1989 and OISD Standard 154 : Safety
Aspect in Functional Training or should be by any approved Govt.
agencies for this purpose.
4.4.7 All necessary steps shall be taken by the owner/loader of the vehicle to
ensure that the driver is fully aware of and understands all instructions.
4.4.8 As a precaution against any accident or emergency that may occur during
carriage, the driver shall be supplied with instructions in writing as
detailed in safety instruction booklet attached in annexure VI.
4.4.8.1 The nature of the danger presented by the dangerous substances
carried and the safety measures that must be taken to avert that danger.
4.4.8.2 The action to be taken and treatment to be given in the event of
persons coming in contact with the dangerous substances being carried or
with any substances which might escape therefrom.
4.4.8.3 The measures to be taken in case of fire and in particular the
extinguishing methods and/or agents or groups of extinguishing methods
and/or agents not to be used.
4.4.8.4 The measures to be taken in case of breakage or deterioration of
packaging or spillage of the dangerous substances, particularly on the
road.
4.4.8.5 These instructions should be in local language, Hindi and English.
4.4.9 The system of Transport Emergency Cards (TREM) meets the above
requirements. A specimen each of TREM cards for petroleum Class A, B
& C, LPG and heavy oils are given in the Annexure-III. Translation into
respective local language may be made by operating company as
required.
4.4.10The tank trucks carrying 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.

5.4.10Disposal of sludge from the LPG wagons should be transported away

from the siding in wet condition and disposed of in safe manner.
6.0 REFERENCES

i) Fire Protection Handbook - Fifteenth Edition 1981.

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

iii) NFPA - 58 Standard For the Storage and Handling of Liquefied

Petroleum Gases - 1983.
iv) Loss Prevention in the Process Industries - Vol. 2 by Lees.

v) The Petroleum Rules - 1976.

vi) The Gas Cylinder Rules - 1981.

vii) The Static and Mobile Pressure Vessels Rules - 1981.

viii) Maintenance Manual for 4 - Wheeled Liquefied Petroleum Gas Tank

Wagon Type TPGLR - 1983.

ix) Red Tariff No. 19 (Indian Railways Conference Associations).

x) Cefic Tremcards - Group Text Chemical Industries Association, U.K.

xi) Transport of Dangerous Goods (Recommendations of the Committee of

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

xii) The Central Motor Vehicle Rule - 1989.

 Annexure
IX

checklist for bulk pol tank trucks at loading location :

(Daily Checks)

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

available in the vehicle ?

2. Whether the vehicle has fire two extinguishers ?

3. Whether there are any sources of ignition like matches etc. in the
vehicle ?

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

5. Whether the driver has a valid driving licence with endorsement for
having undergone training for carrying hazardous goods as per Motor
vehicle act.

6. Whether approved quality flame arrester provided on the engine exhaust

and muffler/silencer is properly bolted without any leaks?

7. Whether each compartment of tank is fitted with independent vacuum and

pre-operated vents (PV Valve)?
8. Whether vehicle’s cabin is checked for presence of any
flammable/explosive substance being carried by the crew ?

Addl. half yearly checks

9. Whether the vehicle has a cut off switch for electrical system ?

10. Whether there is facility to shut off the drain valves from the cabin in
case of emergency?

11. Whether the vehicle has First Aid Box, Tool Box and Emergency
Lighting ?

12. Whether the driver has a copy of standing instructions and TERM card ?

13. Whether the exhaust is wholly in front of tank truck and has ample
clearance from fuel oil system and combustible material.

14. Whether all electric wiring is properly insulated ?

15. Whether all junction boxes are sealed properly ?

16. Whether electrical equipments like generator swithces, fuses and circuit
breakers are located inside the cabin or engine compartment?

17. Whether battery is in easily accessible position with a heavy duty switch
close by, to cut off the battery in emergency ?
18. Whether battery terminals have protective rubber covers ?

Annexure IX

checklist for bulk pol tank trucks at unloading location :

(terminals / depots)

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

available in the vehicle ?

2. Whether the vehicle has two fire extinguishers ?

3. Whether there are any sources of ignition like matches etc. in the
vehicle ?

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

5. Whether approved quality flame arrester provided on the engine exhaust

and muffler / silencer is properly bolted without any leaks ?

6. Whether vehicle’s cabine is checked for presence of any flammable /

explosive substance being carried by the crew ?

checklist for bulk pol tank trucks at unloading location :

 (Retail outlets/customer premises)

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

available in the vehicle ?

2. Whether the vehicle has two fire extinguishers ?

3. Whether there are any sources of ignition like matches etc. and
inflammable substances in the cabin of the vehicle ?

4. Whether the vehicle has at least a driver and a cleaner as its crew member
?
 Annexure – X

Checklist for unloading of bulk lpg tank trucks

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

inside licenced area

* Has suitable spark arrestor of make and design approved by CCE,

Nagpur, properly fixed to exhaust.

Carries 2 nos. 10 Kg. DCP extinguishers in easily accessible and

removable position with Truck No. date of checking and charging painted
on it.
1
Quick closing manifold valve with lever indicating close and open status.

l No visible dent on the bullet.

l Whether tyres fitted is in roadworthy condition.

l All junction boxes are properly sealed.

l Any loose electrical wiring/terminal.

l Electrical wiring is insulated and provided with suitable over current

protection.

l Truck is self starting.

l Readily accessible master switch for switching off the engine is provided
inside the cabin.

l Leakage from any fittings or joints.

Checks required to be carried out before issuing loading memo

(DUring the course of unloading operations)

l Height barrier provided as per specifications.

l Fuel tank is protected by means of stout guard and fuel tank cap is
locked.

l Paint of bullet is not peeling off.

l First aid kit is available.

checks required to be carried out on randon basis

- minimum one day, once in a month :

l Internals of fire extinguishers in good condition.

l Carries TREM CARD, instructions booklet detailing instructions on

handling emergencies enroute.
l Carries route map.
L Carries TERM card.

l Has valid CCE licence and authenticated copy of drawing.

l Carries RTO permits.

l RLW-ULW Licenced capacity.

l Hazchem sign, name of contractor with address and telephone No.

displayed prominently.

l Bullet has no sign of external corrosion.

l Excess flow check valves are functioning.

l Liquid/vapour lines are adequaltely anchored and are well protected by

means of stout steel guard.

l Liquid/vapour pipe lines are in single piece from excess flow check valve
to discharge valves

- Safety fitting viz. safety valve, roto-gauge, pressure gauge and

temperature gauge are adequatlely protected.
L
Operative fittings like roto gauge, pressure gauge and temperature gauge
are operational.

General :
Following are available in Tank Truck :

l Tools for all fittings.

l 4 Nos. caution sign board wit luminous paint for stopping traffic in case
of any emergency.
Based on the nature of defects either all the deficiencies should be got
corrected at the unloading location itself or the tanker should be allowed
to get the repairs done enroute and submit the details at loading location.
NOTE