PRESENTATION ON TANK FARM OPERATIONS

TANK FARM OPERATIONS

          TYPES OF TANKS ADVANTAGES & DISADVANTAGES OF DIFFERENT TYPES OF TANKS FITTINGS ON DIFFERENT TYPES OF TANKS SAFE OPERATING PRACTICES FOR FLOATING ROOF TANKS CRITICAL LEVEL OF FLOATING ROOF TANKS RECALIBRATION OF TANKS - EXCISE REQUIREMENTS SAFTEY CHECK-LIST FOR TANK FARM OPERATIONS QUALITY CONTROL ASPECTS DURING : A) PIPELINE RECEIPT B) STORAGE QUALITY MONITORING RESPONSIBILITY AREAS FOR MAINTAINING THE QUALITY OF PRODUCTS DURING : A. TRUNK PIPELINE TRANSFERS FROM REFINERY TO TAP OFF POINT OF MARKETING COMPANY B. LOCAL PIPELINE TRANSFER FROM REFINERY TO MARKETING COMPANY

TANK FARM OPERATIONS ( Contd. )

 PRECAUTIONARY MEASURES FOR TANK FARM OPERATIONS  PRESSURE VACCUM VALVE  OIL-WATER SEPARATOR  GAUGING & TANK QUANTITY CALCULATION  PIPELINE TRANSFERS  STOCK-LOSS : CAUSES & METHODS OF CONTROLLING STOCKLOSS

 CONTAMINATION & DETERIORATION OF PRODUCT

TANKS FOR PETROLEUM PRODUCTS

 TANKS FOR PETROLEUM PRODUCTS
   CYLINDRICAL IN SHAPE GENERALLY MADE OF MILD STEEL INSTALLED UNDERGROUND OR ABOVE GROUND

 UNDERGROUND TANKS
     CYLINDRICAL & HORIZONTAL GENERALLY RESTRICTED TO CAPACITY OF 200 KL INSTALLED IN EARTH OR MASONRY CONCRETE PIT HELD IN POSITION BY METAL RINGS STRAPPED AROUND THE BODY OF THE TANK. ONLY FITTINGS ARE VISIBLE.

 ADVANTAGES OF UNDERGROUND TANKS

 NEGLIGIBLE VARIATION IN PRODUCT TEMPERATURE  LESSER SAFETY DISTANCES REQUIRED  NO BUND ENCLOSURES REQUIRED  RECEIPT POSSIBLE WITHOUT USE OF PUMP

 DISADVANTAGES
 SLOWER DELIVERIES  SUCTION PROBLEM FACED DURING HOT WEATHER OR DEFECTIVE FOOT VALVE  EXCESSIVE CORROSION  POSSIBILITY OF FLOATING DURING HEAVY RAINS, IF EMPTY OR WITH LOW STOCKS  SMALL CAPACITY

FITTINGS ON UNDER GROUND TANKS

 GENERALLY TWO MANHOLES ON THE TOP CLOSE TO EITHER ENDS  AIR-TIGHT MANHOLE COVERS  VENT PIPE ABOUT 4 METERS HIGH  VENT OR PRESSURE VACCUM (PV) VALVE  DIP HATCH  PERFORATED FILL PIPE EXTENDING ALMOST UPTO BOTTOM OF THE TANK

ABOVE GROUND TANKS

 HORIZONTAL ABOVE GROUND TANKS
 INSTALLED ON PEDESTALS  SMALLER CAPACITY (UPTO 200 KL)

 VERTICAL ABOVE GROUND TANKS

 RESTED ON SAND / RCC FOUNDATION PADS  MADE OF MILD STEEL PLATES  WITH EITHER FIXED OR FLOATING ROOF  DESIGNED AS PER API 650 AND IS-803

FITTINGS ON FIXED ROOF TANKS

FITTINGS ON FIXED ROOF TANKS
                MANHOLES DIP HATCH DATUM PLATE TEMPERATURE / SAMPLE HATCH INLET / OUNET VENTS PV VALVE WATER DRAW OFF LINE SAFETY RAILINGS STAIRWAYAS EARTHIING CONNECTIONS EXPANSION LINE MANOMETER FIRE WATER SPRINKLER SYSTEM FOAM POURER AUTO LEVEL GAUGES

FIOATING ROOF TANKS

 ROOF FLOATING ON THE SURFACE OF THE LIQUID STORED  ROOF IN COMPLETE CONTACT WITH THE LIQUID SURFACE  AT LOW LEVELS THE ROOF RESTS ON ADJUSTABLE LEGS  THESE TANKS ARE GENERALLY USED FOR LIGHT HYDROCARBONS SUCH AS MS. NAPHTHA. HEXANE, ETC.

ADVANTAGES COMPARED TO FIXED ROOF TANKS

 ELIMINATES PRODUCT LOSS THROUGH EVAPORATION  SAFE, AS NO VAPOUR ACCUMULATED UNDER THE ROOF  INTER CHANGEABILITY EASY TO CLASS A SERVICE WITHOUT CHANGE IN FITTINGS  LESS AIR POLLUTION, AS PRACTICALLY NO VENTING.

DISADVANTAGES AS COMPARED TO FIXED ROOF TANKS

 HIGH COST OF CONSTRUCTION  HIGH COST OF MAINTENANCE  HIGH DEAD STOCK  NEEDS CLOSER SUPERVISION DURING OPERATION  POSSIBILITY OF ROOF SINKING /TILTING DUE TO LEAKS / HEAVY RAINS  AT LOWER LEVELS HEAVY ACCUMULATION OF VAPOURS ON THE ROOF .

FITTINGS ON FLOATING ROOF TANKS

                   ADJUSTABLE LEGS FOAM SEAL ROOF BLEEDER VENTS ROOF WATER DRAIN EMERGENCY DRAIN ROOF LADDER WIND GIRDER GAUGEWELL PIPE MANHOLES ON SHELL & ROOF GAUGE HATCH WITH COVER DATUM PLATE PRODUCT INLET / OUTLET NOZZLE TANK WATER DRAIN VALVE FOAM NETWORK SPRINKLER LANDING PLATFORM STAIRWAY EARTHING EXPANSION LINES

VIEW OF FLOATING ROOF TANK

SAFE OPN.OF FLOATING ROOF TANKS

1) OPERATION OF FLOATING ROOF TANKS NEEDS CLOSER SUPERVISION AND ADDITIONAL MEASURES. 2) ACCESS TO FLOATING ROOF SHALL BE RESTRICTED. 3) WHENEVER ANY PERSON IS ALLOWED ON THE ROOF, KEEP STAND BY PERSON ON LANDING PLATFORM. 4) CHECK FOR PETROLEUM VAPOUR ON THE ROOF. USE BREATHING APPARATUS WHENEVER NECESSARY. 5) NO ONE SHOULD BE ALLOWED ON THE FLOATING ROOF DURING PRODUCT RECEIPT OR WHEN ROOF IS AT LOWER LEVELS. 6) IF ABSOLUTELY NECESSARY TO GO ON THE ROOF, THE PERSON SHALL WEAR BREATHING APPARATUS AND STANDBY PERSONS ON LANDING PLATFORM.

SAFE OPN. OF FR TANKS (contd.)

7) KEEP GAUGE HATCHES OR OTHER OPENINGS CLOSED EXCEPT FOR ESSENTIAL OPERATIONS GAUGE HATCH SHALL NOT BE SLAMMED WHILE CLOSING. IT SHOULD NOT BE LEFT OPEN AFTER GAUGING . GAUGING SHOULD NOT BE CARRIED OUT DURING THUNDER STORM OR LIGHTN1NG. DEVELOP PROCEDURES TO PREVENT OVERFILLING. IF FITTED, CHECK HIGH LEVEL ALARMS MONTHLY FOR OPERABILITY. ROOF SHOULD ALWAYS REMAIN IN FLOATING CONDITION WHILE TANK IS BEING FILLED OR EMPTIED OUT. DO NOT KEEP THE TANK IN SEMI FLOAT CONDITION

8) 9) 10) 11)

SAFE OPN. OF FR TANKS (contd.)

8) KEEP THE ROOF AFLOAT DURING NORMAL OPERATION. LANDING OF ROOF CREATES VAPOUR SPACE SO THAT THE INHERENT SAFETY ADVANTAGES OF FLOATING ROOF TANKS ARE LOST. WITHDRAWAL OF PRODUCT FROM THE TANK SHALL BE AVOIDED WHEN THE ROOF IS EITHER RESTING ON ITS PIPE SUPPORTS OR IS IN SEMI FLOAT CONDITION, AS THIS RESULTS IN APPARENT PRODUCT LOSS.

9)

SAFE OPN. OF FR TANKS (contd.)

14) IF THE PRODUCT IS TO BE WITHDRAWN UP TO THE DEAD STOCK LEVEL, ENSURE THAT ALL PIPE SUPPORTS ARE IN RIGHT POSITION AND ROOF BLEEDER VENTS ARE IN OPERATING CONDITION 15) IF AT ANY TIME THE ROOF GETS STUCK OR LIKELY TO GET STUCK, TANK SHALL NOT BE OPERATED TILL IT IS INSPECTED BY ENGG PERSONNEL 16) REMOVE PROMPTLY ANY ACCUMULATION OF OIL ON A ROOF DECK. THE FIRE PROTECTION SYSTEM IS DESIGINED FOR RIM FIRE ONLY AND NOT FOR LARGE EXPOSED SURFACES OF OIL 17) KEEP THE SUMP FOR THE CHECK VALVE OF THE ROOF DRAIN SYSTEM FREE FROM SCALE OR DEBRIS, WHICH CAN PLUG THE CHEK VALVE AND ROOF DRAIN INLET. 18) IF OIL APPEARS AT THE ROOF DRAIN OUTLET, CHECK THE ROOF IMMEDIATELY TO ESTABLISH ITS SOURCE.

CRITICAL LEVEL OF FLOATTNG ROOF TANKS

DURING OPERATION AND GAUGING OF FLOATJNG ROOF TANKS:

 IT IS NECESSARY TO KNOW THE POSITION OF THE ROOF

i.e. WHETHER IT IS FULLY IMMERSED OR RESTING ON LEGS FLOATING, PARTIALLY

 WHEN ROOF IS FULLY FLOATING, IT DISPLACES ITS OWN

WEIGHT OF OIL AND THE TANK CAN BE GAUGED

 WHEN THE ROOF IS PARTIALLY IMMERSED, ITS ACTUAL

DISPLACEMENT IS UNCERTAIN. SO THE GAUGING OF THE TANK SHOULD NOT BE UNDERTAKEN, AS OIL QUANTITY CALCULATION WILL NOT BE ACURATE.

 WHEN ROOF IS RESTING ON LEGS, THE TANK IS LIKE

CONVENTIONAL CONE ROOF TANK AND THUS TANK CAN BE GAUGED CORRECTLY. HOWEVER THERE WILL BE LOT OF VAPOUR LOSS IN THIS CONDITION.

RECALIBRATION OF TANKS EXCISE REQUIREMENTS

GOVERNMENT OF INDIA HAS LAID DOWN THE FOLLOWING PROCEDURE FOR RECALIBRATION OF TANK : VALIDITY OF CALIBRATION CHART

 BESIDES CPWD, WEIGHTS, & MEASURES DEPT. OF THE

STATES / UNION TERRITORIES HAVE ALSO BEEN APPROVED FOR CALIBRATION OF STORAGE TANKS. SHOULD BE CARRIED OUT AFTER TEN YEARS

 FOR TANKS WITH WATER BOTTOM, RECALIBRATION  FOR TANKS WITH OIL BOTTOM, RECALIBRATION SHOULD
BE CARRIED OUT AFTER FIVE YEARS.

TANK FARM OPERATIONS

1) HISTORY SHEET OF THE TANKS SHALL BE AVAILABLE AT THE LOCATION. 2) FOLLOWING DETAILS SHALL BE INDICATED ON THE TANK SHELL NEAR STAIRCASE: 1) TANK NO., PRODUCT GRADE, CAPACITY IN LITRES, DATE LAST CLEANED AND DUE DATE OF NEXT CLEANING, DATE LAST CALIBRATED AND DATE OF LAST EARTH TEST. TANK NO. AND GRADE SHALL BE INDICATED BOLDLY ON THE UPPER STRAKE SO AS TO BE VISIBLE FROM A DISTANCE. 2) IN CASE OF UNDERGROUND TANKS, THE ABOVE DETAILS SHALL BE INDICATED ON A BOARD DISPLAYED ON/NEAR THE VENT PIPE. 3) TYPE OF VALVE, i.e. INLET, OUTLET, PRODUCT DRAIN, WATER DRAIN, SHALL BE INDICATED ON THE TANK SHELL BEHIND THE RESPECTIVE VALVES, WITH THE DIRECTION OF OPENING AND CLOSING MARKED WITH ARROWS.

TANK FARM OPERATIONS

1) TANK EARTH RESISTANCE SHALL BE CHECKED AT LEAST ONCE IN SIX MONTHS AND SHALL BE MAXIMUM 7 OHMS. VENTS OF THE TANK SHALL BE CHECKED ONCE A QUARTER TO ENSURE THAT THEY ARE FREE OF ANY CLOGGING. SETTINGS OF PV VALVES SHALL BE CHECKED EVERY 6 MONTHS. THE SETTINGS IN TERMS OF W.G. FOR PRESSURE AND VACUUM RESPECTIVELY SHALL BE 21. 5 AND 2.5 FOR ABOVEGROUND TANKS AND 10 AND 1 FOR UNDERGROUND TANKS. SAFE HEIGHT (CORRESPONDING TO 95% OF THE TANK CAPACITY) AND PROOF LEVEL SHALL BE INDICATED NEAR THE DIP HATCH.

2)

3)

4)

TANK FARM OPERATIONS (Contd.)

6) MANOMETER SHALL BE TOPPED UP IF REQUIRED AND ENSURE THAT IT IS ALWAYS FILLED WITH WATER, PREFERABLY COLOURED FOR BETTER CONTRAST. 7) DURING MONSOON OR IN ANTICIPATION OF HEAVY RAINS, UNDERGROUND TANK SHALL BE LEFT FULL WITH PRODUCT TO AT LEAST 25% OF THE TOTAL CAPACITY TO AVOID ITS FLOATING. 8) BUND ENCLOSURE DRAIN VALVE SHALL BE KEPT IN CLOSED POSITION EXCEPT WHEN DRAINING OUT RAIN WATER 9) BUND AREA SHALL BE CLEAR OF VEGETATION. 10) BUND WALL SHALL BE INTACT WITHOUT ANY GAPS.

TANK FARM OPERATIONS (Contd.)

6) TANKS SHALL BE CLEANED EVERY 5 YEARS (EVERY YEAR IN CASE OF ATF AND EVERY 2 YEARS IN CASE OF HEXANE) OR MORE FREQUENTLY, DEPENDING ON THE NEED, LIKE CHANGE IN PRODUCT, EXCESSIVE SLUDGE FORMATION, ETC. 7) AN ALL LEVEL SAMPLE AFTER RECEIPT OF FIRST PARCEL IN A NEWLY COMMISSIONED TANK / AFTER GRADE CHANGE OVER SHALL BE SUBJECTED TO BATCH FORMATION TEST.

TANK FARM OPERATIONS (Contd.)

13) QUANTITY OF SLUDGE REMOVED DURING TANK CLEANING SHALL BE CERTIFIED BY THE LOCATION-IN-CHARGE AND APPROVAL SOUGHT CONCURRENCE IN LINE WITH MANUAL OF AUTHORITIES. THEREAFTER, IT SHALL BE DISPOSED OFF AFTER CHECKING FOR ANY LOCAL REGULATION PROHIBITING BURIAL OF SLUDGE. SLOT-SLIT DIPPING DEVICE SHALL BE FITTED ON VOLATILE PRODUCT TANKS. IT IS A FITTING WITH AN OPENING JUST SUFFICIENT TO ACCOMMODATE THE WIDTH AND THICKNESS OF THE DIP TAPE AND THEREBY PREVENT LOSS OF VAPOUR DURING GAUGING. ONLY ONE TANK SHALL BE OPERATED AT A TIME FOR ONE PARTICULAR OPERATION, EXCEPT IN AN EMERGENCY SITUATION OR FOR VALID REASONS (NORMALLY LOCATION SPECIFIC).

14)

15)

TANK FARM OPERATIONS (Contd.)

13) INTERMEDIATE DIPS SHALL BE TAKEN AT THE END OF THE SHIFT OR IF A TANK IS USED FOR ANOTHER ACTIVITY DURING THE DAY TO ASSESS THE STOCK VARIATIONS DURING THE OPERATION. ALL TANKS SHALL BE GAUGED AT THE END OF THE DAY AND BOOK STOCKS UPDATED ACCORDINGLY. TANKWISE STOCK VARIATION SHOULD BE WORKED OUT FOR EACH PRODUCT AND ANY ABNORMAL VARIATION (MORE THAN THE SET TARGET) SHOULD BE INVESTIGATED. ZONE / RO SHOULD BE KEPT ADVISED OF THE ABNORMAL VARIATION AND CORRECTIVE ACTION TO BE TAKEN.

14)

15)

16)

TANK FARM OPERATIONS (Contd.)

18) ONCE A WEEK, ON A PARTICULAR DAY, ALL TANKS - DISTURBED AND UNDISTURBED SHALL BE GAUGED AND BOOK STOCKS UPDATED ACCORDINGLY. ANY WIDE VARIATION IN THE DIPS OF UNDISTURBED TANKS SHALL BE INVESTIGATED. GAUGING DETAILS SHALL BE RECORDED STRAIGHTWAY IN THE DIP BOOK IN INK BY AN OFFICER AND SIGNED BY HIM. ALTERATIONS / CORRECTIONS, IF ANY, IN THE DIP BOOK SHALL BE ATTESTED AND SHALL BE DONE IN SUCH A WAY SO THAT THE ORIGINAL ENTRY IS STILL LEGIBLE. PRIOR TO RECEIPT OPERATIONS, ENSURE THAT ENTIRE QUANTITY IN THE TANK i.e. OIL AND WATER, IS CONSIDERED SO AS TO CORRECTLY WORK OUT THE ULLAGE AVAILABLE AND ELIMINATE THE POSSIBILITY OF AN OVERFLOW. AT LOCATIONS WHERE WATER BOTTOM IN TANKS IS NOT MAINTAINED, FREE WATER IN THE TANK SHALL BE REMOVED AT THE EARLIEST OPPORTUNITY. UNDRAINABLE WATER QUANTITY IN THE TANK SHALL BE ACCOUNTED SEPARATELY AND NOT TREATED AS OIL.

19)

20)

21)

TANK FARM OPERATIONS (Contd.)

18) DISCHARGE OF A TANKWAGOAN OR A TANKLORRY INTO THE TANK SHALL BE PLANNED IN SUCH A WAY THAT ENTIRE QUANTITY IN A TANKWAGON OR ENTIRE QUANTITY IN A TANKLORRY COMPARTMENT CAN BE ACCOMMODATED INTO THE TANK. PRIOR TO DELIVERY OPERATIONS, ASCERTAIN THE LIQUID COLUMN IN THE TANK SO THAT AN ENTIRE TANKWAGON OR AN ENTIRE TANKLORRY COMPARTMENT CAN BE FILLED. THE ABOVE WILL FACILITATE MEANINGFUL PRODUCT LOSS / GAIN ANALYSIS. ALL DRAIN VALVES OF THE TANK SHALL BE FLANGED AND LOCKED WHEN NOT IN USE. BODY VALVES OF THE TANKS SHALL BE LOCKED OUTSIDE WORKING HOURS. ALL STIPULATIONS GIVEN IN THE INDUSTRY QUALITY CONTROL MANUAL SHALL BE ADHERED TO.

19)

20) 21) 22)

OIL WATER SEPARATOR

NEED AND CONSTRUCTION I. OIL WATER SEPARATOR (OWS), IS AN INTEGRAL PART OF TANK FARM OPERATIONS. IT IS A MANDATORY REQUIREMENT THAT DRAINS FROM LICENSED AREA SHALL PASS THROUGH AN INTERCEPTOR SO THAT OIL TRACES AND OIL SPILLAGES ARE TRAPPED BEFORE THE WATER IS LET OUT INTO THE OUTSIDE DRAINS.

II. AN OWS IS OF RCC / CC/ BM CONSTRUCTION WITH 3 OR MORE CHAMBERS. EVERY CHAMBER HAS AN INLET AT THE TOP AND AN OUTLET AT ITS BOTTOM. FLOW INTO AND OUT OF THE OWS IS CONTROLLED BY INLET AND OUTLET VALVES. WHEN OILWATER MIXTURE ENTERS THE OWS, OIL BEING LIGHTER, REMAINS TRAPPED AND FLOATING ON WATER, WHILE WATER FLOWS INTO THE NEXT CHAMBER. III. INLET AND OUTLET VALVES SHALL BE OF RISING STEM TYPE AND WITH PROPER LOCKING ARRANGEMENT.

OIL WATER SEPARATOR

OPERATION I. OIL CONTENTS IN THE EFFLUENT LEAVING THE OWS SHALL BE 10 PPM MAXIMUM. II. OUTLET VALVE SHALL BE ALWAYS KEPT IN CLOSED POSITION AND LOCKED EXCEPT WHEN DRAINING OUT THE CLEAR WATER. III. DRAINING OF WATER SHALL BE UNDER SUPERVISION. IV. OIL LEVEL AND WATER LEVEL IN THE OWS SHALL BE CHECKED ON A DAILY BASIS AND RECORD MAINTAINED. V. OIL ACCUMULATED IN THE OWS SHALL BE SALVAGED AND RECORD MAINTAINED. VI. WATER LEVEL IN THE OWS SHALL BE MAINTAINED ABOVE THE LEVEL OF THE OUTLET VALVE. VII.OWS SHALL BE CLEANED PRIOR TO THE ONSET OF MONSOON. VIII.FUNCTIONING OF THE INLET AND OUTLET VALVES SHALL BE CHECKED PERIODICALLY.

TANK FARM OPERATIONS

SAFETY CHECKLIST
 GENERAL:
 WHETHER THE LOCATION LAYOUTS, INTERSPACING IN THE TANK FARM MEET OISD STD-118/STATUTORY REQUIREMENS?  WHETHER DYKE/FIRE WALLS MEET OISD-I18/STATUTORY REQUIREMENS?  WHETHER THE ROADS ARE AVAILABLE AROUND THE TANK FARM FOR MOVEMENT OF FIRE TENDERS?  WHETHER PIPING IN THE DYKE FARM IS KEPT MINIMUM?  WHETHER HOUSE KEEPING IN THE AREA IS SATISFACTORY AND IT IS FREE OF ANY DRY VEGETATION  WHETHER ILLUMINATION IN THE AREA IS ADEQUATE.

SAFETY CHECKLIST ( Contd.)

SEWERS  WHETHER THE TANKFARM DRAINS ARE CLEAR?  WHETHER PROVISION EXISTS TO DIVERT TANK FARM DRAINAGE EITHER TO STORM WATER DRAIN OR TO OIL WATER SEPERATOR? TANKS  WHETHER TANKS PROPERLY PAINTED AND IMPORTANT SPECIFICATIONS ARE MARKED ON THE TANK ?  WHETHER ALL TANKS ARE CIRCUMFERENTIAL RAILINGS? PROVIDED WITH

 WHETHER THE ROOF DRAIN OF FLOATING ROOF TANKS IS PROVIDED WITH A CHECK VALVE  WHETHER ANY DEPRESSION DUE TO TANK SETTLEMENT OBSERVED ON THE TANK PAD ALONG THE CIRCUMFERENCE?

SAFETY CHECKLIST ( Contd.)

 WHETHER FIXED/SEMI-FIXED FOAM SYSTEM ARE PROVIDED ON ALL TANKS STORING A CLASS AND B CLASS PRODUCTS (18 M AND ABOVE DIA FOR FLOATING ROOFS) AND ALSO TANKS STORING C CLASS PRODUCTS OF MORE THAN 40 M DIA (FLOATING/FIXED ROOF TANKS)?  WHETHER SPRINKLER SYSTEMS ARE PROVIDED ON ALL FIXED ROOF TANKS AS PER OISD NORMS?  WHETHER THE TANKS ARE PROPERLY PAINTED AND NUMBERED?  WHETHER GOOSE NECK TYPE VENT CONNECTIONS ARE PROVIDED WITH SUTTABLE WIRE MESH TO AVOID BIRDS ENTRY / FORMATION OF NESTS?

SAFETY CHECKLIST ( Contd.)

PIPING :
 WHETHER PIPE ALLEYS PROPERLY GRADED TO ENSURE THAT NO OIL/WATER GETS ACCUMULATED BELOW?  WHETHER PIPE SUPPORTS, ANCHORS, GUIDES ARE IN ORDER?  WHETHER PROPER COLOUR CODINGS, IDENTIFICATION MARKS HAVE BEEN PROVIDED? PRODUCTS

 WHETHER THE FLOOR UNDER THE MAINFOLD ARE PAVED, HAVE CURB WALLS AND DRAINS CONNECTED TO OWS?  WHETHER ANY BOLT IS FOUND MISSING ON FLANGES OF HYDROCARBON LINES, PARTICULARLY OF MS, NAPTHA ETC.  WHETHER THE REDUNDANT LINES ARE KEPT POSITIVELY ISOLATED WITH ALL THE ENDS PLUGGED/BLINDED AND ACTIONS ARE TAKEN TO GET THEM REMOVED?

SAFETY CHECKLIST ( Contd.)

OPERATING PROCEDURES :
   WHETHER A COPY OF UPDATED OPERATING MANUAL WITH OPERATING INSTRUCTIONS IS AVAILABLE TO ALL CONCERNED. WHETHER THERE IS ANY POSSIBILITY OF PRODUCT CONTAMINATION DURING TANK LINE UP/CHANGE OVER WHETHER PERIODICAL CHECKS ARE MADE FOR LOCATING ANY LEAKAGE ON TANK, FLOATING ROOF TANK VALVES, PIPING ETC. AND RECORDED FOR RECTIFICATION. WHETHER THE ROOF DRAIN VALVES OF FLOATING ROOF TANKS ARE NORMALLY KEPT CLOSED. WHETHER PRE-MONSOON CHECKS ARE CARRIED OUT. WHETHER CROSS CHECKING OF AUTO LEVEL GAUGE IS DONE THROUGH MANUAL GAUGE, WHILE THE TANKS ARE UNDER OPERATION. WHETHER IT IS ENSURED DURING INITIAL FILLING A FLOW VELOCITY OF MAXIMUM 1 M/SEC IS MAINTAINED FOR PRODUCTS LIKE SKO, ATF? WHETHER USE OF NYLON ROPE FOR SAMPLING WAS OBSERVED?

    

SAFETY CHECKLIST ( Contd.)

INSPECTION & MAINTENANCE :
 WHAT ARE THE SCHEDULES OF INSPECTION OF TANKS (FLOATING/FIXED) AND WHETHER RECORDS MAINTAINED IN LINE WIIH OISD STD-129. WHAT IS THE FREQUENCY OF INSPECTION OF PV VENTS, RELIEF VALVES ? WHETHER RECORDS ARE MAINTAINED IN LINE WITH OISD STD-129 WHETHER ANY PROVISION EXISTS FOR STATIC ELECTRICITY DISCHARGE? WHAT IS THE FREQUENCY OF INSPECTION OF EARTHING CONNECTIONS AND WHETHER RECORDS MAINTAINED . WHETHER THE PONTOON GOOD CONDITION? COVERS ARE IN PLACE AND ARE IN

SAFETY CHECKLIST ( Contd.)

INSPECTION & MAINTENANCE :
  WHETHER FOAM/NEOPRENE SEALS ARE CHECKED REGULARLY FOR PERFECT SEALING AND RECORD MAINTAINED. WHETHER ANY DOCUMENIED PROCEDURE EXISTS FOR TANK CLEANING? WHAT IS THE METHODOLOGY TO ENSURE STRICT ADHERENCE? WHETHER THE LADDERS, STAIRWAYS ARE IN GOOD CONDITION WHETHER THE PIPELINE RELIEF VALVES ARE KEPT RELIEVING TO TANKS OR TO OUTSIDE? WHETHER ANY INSPECTIONS ARE CARRIED OUT ON REPAIRED TANKS BEFORE TAKING THEM INTO OPERATION? WHAT ARE THE SCHEDULES FOR PAINTING OF TANKS?

   

GAUGING
GAUGING IS THE PROCESS OF TAKING ALL THE NECESSARY MEASUREMENTS IN A TANK IN ORDER TO DETERMINE THE QUANTITY OF LIQUID CONTAINED IN IT. GAUGING INVOLVES : 1) TAKING OIL DIP IN THE TANK 2) TAKING WATER DIP IN THE TANK 3) OBSERVE TANK TEMPERATURE 4) OBSERVE DENSITY & TEMPERATURE OF THE TANK SAMPLE.

   

GAUGING EQUIPMENTS: 1) DIP TAPE 2) DIP BOB 3) WATER FINDING PASTE 4) OIL FINDING PASTE

5) 6) 7) 8)

THERMOMETER HYDROMETER SAMPLING EQUIPMENT SAMPLE CONTAINER

GAUGING
GAUGING IS THE PROCESS OF TAKING ALL THE NECESSARY MEASUREMENTS IN A TANK IN ORDER TO DETERMINE THE QUANTITY OF LIQUID CONTAINED IN IT.

        

GAUGING TERMS: 1) GROSS DIP 10) REFERENCE HEIGHT 2) WATER DIP 11) REFERENCE POINT 3) ULLAGE DIP 12) SAFE HEIGHT 4) DIP HATCH 5) DATUM PLATE 13) DEAD STOCK 6) TEMPERATURE / SAMPLE HATCH 14) GROSS CAPACITY 7) TANK TEMPERATURE 15) SAFE CAPACITY 8) SAMPLE TEMPERATURE 16) WATER BOTTOM 9) SAMPLE DENSITY

TANK QUANTITY CALCULATION

I. II. III. IV. V. VI. VII. VIII. IX. GROSS DIP OF THE TANK. WATER DIP OF THE TANK. TANK TEMPERATURE SAMPLE TEMPERATURE SAMPLE DENSITY DENSITY AT 15 DEG. C. CORRESPONDING TO IV AND V ABOVE, BASED ON ASTM TABLE 53 B. NET VOLUME CORRESPONDING TO DIFFERENCE IN QUANTITIES CORRESPONDING TO I AND II ABOVE VOLUME REDUCTION FACTOR (VRF) CORRESPONDING TO III AND VI ABOVE, BASED ON ASTM TABLE 54 B. VOLUME AT 15 DEG. C. = NET VOLUME * VRF.

PIPELINE TRANSFERS
SAFEST MODE OF PRODUCT TRANSFER FROM ONE LOCATION TO OTHER LOCATION. TERMS OF SETTLEMENT IN REGARD TO PRODUCT QUANTITY TYPES OF TRANSFER REFINERY TO MARKETING REFINERY TO REFINERY MARKETING TO MARKETING MARKETING TO REFINERY TERM OF SETTLEMENT RECEIVING COMPANY TANK DIPS DESPATCHING REFINERY TANK DIPS DESPATCHING COMPANY TANK DIPS MARKETING COMPANY TANK DIPS

PIPELINE TRANSFERS
SAFEST MODE OF PRODUCT TRANSFER FROM ONE LOCATION TO OTHER LOCATION. PRECAUTIONS DURING PIPELINE TRANSFER  ENSURE SUFFICIENT ULLAGE IN THE RECEIVING TANKS  RECORDING BEFORE RECEIPT GAUGE OF TANKS FOR OIL, WATER & TEMP  PROPER LINE UP BEFORE COMMENCING THE PLT  SAMPLING OF PRODUCT IN LINE WITH IQCM GUIDLINES.  HOURLY GAUGING/SAMPLING AND COMPARISON WITH PUMPED QUANTITY.  PROVISIONAL GAUGE AFTER CLOSING ALL VALVES SUBSEQUENT TO STOPPING OF PLT.  FINAL GAUGING OF TANKS FOR OIL, WATER AND TEMP TO ASSESS THE LOSS / GAIN DURING THE PLT AFTER GIVING SUFFICIENT SETTLING TIME  MARKETING TRANSACTIONS ARE SETTLED FOR QUANTITIES AT 15 DEGREE CELCIUS  ANY ABNORMAL LOSS TO BE IMMEDIATELY REPORTED & INVESTIGATED  SUFFICIENT PRECAUTION DURING SWITCHOVER OF TANKS

PIPELINE TRANSFER LOSS

1) 2) (QTY SHIPPED QTY RECEIVED) AT- 15 C IS LOSS DURING PIPELINE TRANSFER FACTORS CAUSING PIPELINE TRANSFER LOSSES A. B. PHYSICAL FACTORS : WHERE OIL IS ACTUALLY LOST e.g. A LEAK. LOSSES NOT ACTUALLY INCURRED e.g. WRONG GAUGING. MAJOR FACTORS CONTRIBUTING TO PLT LOSSES A. PHYSICAL FACTORS :i. LINE SLACK ii. LEAKS iii. FAULTY SEGREGATION iv. INADEQUATE FLUSHING ON WATER LINES v. DELAYED SWITCHOVER vi. OVER DRAINING OF TANKS vii. PARCEL SIZE

BOOK LOSS FACTORS : BUT BOOKED

PIPELINE TRANSFER LOSS

B. BOOK LOSS FACTORS :B. INCORRECT GAUGING C. INCORRECT CALIBRATION D. WRONG OUTTURN CALCULATIONS E. FLOATING ROOF POSITION

FACTORS WHICH INFLATE VOLUME AT 15 DEG. C.

    HIGHER OIL DIP LOWER WATER DIP LOWER TANK TEMPERATURE. HIGHER SAMPLE DENSITY (VRF REDUCES WITH INCREASE IN DENSITY, AND OBSERVED TEMPERATURES ARE GENERALLY MORE THAN 15 DEGREE CELCIUS. HIGHER SAMPLE TEMPERATURE (INCREASES THE DENSITY WHEN CONVERTED TO 15 DEGREE CELCIUS )

QUALITY CONTROL DURING TANK FARM OPERATIONS

DURING PIPELINE RECEIPT
SAMPLING OF TANKS NOMINATED FOR RECEIVING PRODUCT  BEFORE RECEIVING PRODUCT THROUGH MULTI-PRODUCT PIPELINE / WATER FLUSH PIPE LINE / OCEAN TANKERS, UML COMPOSITE SAMPLES FROM INDIVIDUAL TANKS NOMINATED FOR RECEIVING THE PRODUCT, SHALL BE TAKEN, LABELLED, SEALED AND RETAINED. IN CASE OF RECEIPT THROUGH CROSS COUNTRY / FEEDER PIPELINE, UML COMPOSITE SAMPLES SHALL BE TAKEN JOINTLY BY OFFICERS OF MARKETING / PIPELINE DIVISIONS FROM THE INDIVIDUAL NOMINATED TANKS.

QUALITY CONTROL DURING TANK FARM OPERATIONS

DURING PIPELINE RECEIPT
SAMPLING OF TANKS NOMINATED FOR RECEIVING PRODUCT  IF THE SAMPLE, AFTER RECEIPT, CONFORMS TO THE SPECIFICATION REQUIREMENTS IN RESPECT OF TESTS CARRIED OUT, SAMPLE TAKEN AS STATED ABOVE MAY BE DISCARDED. IN THE EVENT OF THE SAMPLE AFTER RECEIPT NOT CONFORMING TO SPECIFICATION, THEN THESE RETAINED SAMPLES SHALL NOT BE DESTROYED TILL THE INVESTIGATION IS OVER

QUALITY CONTROL DURING PIPELINE RECEIPT

 FOR THE FIRST HALF AN HOUR, OF EACH PRODUCT BEING PUMPED THROUGH A MULTI-PRODUCT PIPELINE, LINE SAMPLES SHALL BE DRAWN FROM THE PIPELINE MANIFOLD AT INTERVALS OF TEN MINUTES, AND THE TEST A DONE AND RECORDED. IN CASE, THE DENSITY VARIATION IS OUTSIDE THE PERMISSIBLE LIMITS, THEN THE PUMPING SHALL BE STOPPED. REASONS FOR THE VARIATION ESTABLISHED, CORRECTIVE ACTION TAKEN AND THEN RESUME PUMPING.

QUALITY CONTROL DURING PIPELINE RECEIPT

 WHENEVER PUMPING OF THE PRODUCT IS STOPPED AND THEN RESTARTED, THE PROCEDURE OF THE SAMPLING DURING THE FIRST HALF AN HOUR AND THEN HOURLY SAMPLING SHALL BE FOLLOWED. TWO LITRES RETENTION LINE SAMPLE EACH SHALL BE TAKEN BOTH AT DESPATCHING END AND RECEIVING END DURING COMMENCEMENT, MIDDLE AND END OF THE PIPELINE TRANSFER AND RETAINED UNTIL QUALITY OF THE PRODUCT AFTER RECEIPT IS ESTABLISHED.

QUALITY CONTROL DURING PIPELINE RECEIPT (Contd.)

 WHEN A TRANSFER TAKES PLACE FROM A REFINERY, JOINT SAMPLING SHALL BE DONE. A VALID TEST REPORT FOR THE TANK(S) FROM WHICH THE PRODUCT IS TRANSFERRED, SHALL BE MADE AVAILABLE.  FROM THOSE TAP-OFF POINT TANKS WHERE PRODUCT / PRODUCT ALONG WITH INTERFACE IS ACCOMMODATED, A SAMPLE SHALL BE DRAWN FROM TOP / MIDDLE / BOTTOM AFTER RECEIPT AND TESTED FOR DENSITY INDIVIDUALLY TO ENSURE HOMOGENEITY OF THE PRODUCT. IF THE DENSITY VARIATION IS MORE THAN 3 BETWEEN ANY TWO LEVELS, THIS IS TO BE INVESTIGATED AND REASONS FOR DENSITY VARIATION TO BE RECORDED.

QUALITY CONTROL DURING PIPELINE RECEIPT (Contd.)

 WHEN THE TRANSFER IS THROUGH A DEDICATED PIPELINE, A UML COMPOSITE SAMPLE SHALL BE TAKEN JOINTLY FROM THE NOMINATED SHIPPING TANKS AND RETAINED, TILL THE QUALITY OF THE PRODUCT HAS BEEN ESTABLISHED BY THE RECEIVING LOCATION.  DURING RECEIPT THROUGH DEDICATED PIPELINES SAMPLES FROM THE TOP AND BOTTOM OF THE PIPELINE NEAR THE MANIFOLD SHALL BE TAKEN AT INTERVALS OF ONE HOUR AT THE DESPATCHING AND RECEIVING END, TEST A DONE AND THE OBSERVATIONS RECORDED CHRONOLOGICALLY.

QUALITY CONTROL DURING PIPELINE RECEIPT (Contd.)

I. ON COMPLETION OF TRANSFER AND AFTER ALLOWING A MINIMUM SETTLING TIME OF ONE HOUR, A COMPOSITE OF TOP, MIDDLE AND BOTTOM SAMPLES FROM RECEIPT TANKS SHALL BE SENT TO LAB FOR BATCH FORMATION TEST & THE PRODUCT SHALL BE RELEASED ONLY AFTER LAB CLEARANCE. A COMPOSITE SAMPLE OF KEROSENE SHALL BE RETAINED FOR THREE MONTHS & RECORD MAINTAINED. II. AFTER RECEIPT THROUGH DEDICATED PIPELINES, SAMPLES FROM UPPER, MIDDLE AND LOWER LEVELS SHALL BE INDIVIDUALLY SUBJECTED TO TEST A AND THE OBSERVATIONS RECORDED. IF THE DENSITY VARIATION AT 15 DEG C IS WITHIN LIMITS, THE PRODUCT MAY BE RELEASED.

QUALITY CONTROL DURING PIPELINE RECEIPT (Contd.)

I. WHEN STOCK TRANSFER IS EFFECTED FROM OTHER OIL MARKETING COMPANY THROUGH LOCAL DEDICATED PIPELINES, SUCH TRANSFERS SHALL COMMENCE FROM VALID STOCK HAVING BATCH FORMATION TEST CERTIFICATE. JOINT SAMPLES SHALL BE TAKEN FROM THE NOMINATED TANKS. THE DENSITY VARIATION OF SUCH STOCK DURING TRANSFER SHALL NOT BE BEYOND +3 AT ANY TIME. SAMPLE SHALL BE DRAWN AND OBSERVATIONS RECORDED. IV. A BATCH NUMBER SHALL BE ASSIGNED FOR EACH RECEIPT OF PRODUCT THROUGH PIPELINE IN A LOCATION ON THE BASIS OF A BATCH FORMATION TEST REPORT.

QC DURING PIPELINE RECEIPT (Contd.)

THE INTERFACE OF PRODUCT TANK TO ACCOMMODATE INTERFACE MS SK HSD HF HSD HSD FO INTERFACE QUANTITY ACCEPTABLE 1% NO LIMIT 2% NO LIMIT NO LIMIT 5%

MS & SK SK & ATF SK & HSD / LSHF/HF HSD/ ELS HSD LSHF/HF HSD HSD & LSHF/HF HSD/ ELS HSD LDO & FO

THE ABOVE INTERFACE PERCENTAGE ABSORPTION ON GRADE WISE IS DIRECTIONAL. IT WILL BE THE RESPONSIBILITY OF OIL COMPANIES TO ENSURE THAT THE PRODUCT, AFTER RECEIPT IN MARKETING TANK (S), MEETS THE RELEVANT BIS SPECIFICATIONS AND GOVT . DIRECTIVES IN BATCH FORMATION TEST.

QUALITY CONTROL DURING STORAGE

 SAMPLING COCKS SHALL BE PROVIDED AT THE TOP AND BOTTOM OF THE RECEIVING LINE BEFORE THE RECEIPT TANK VALVE TO DRAW LINE SAMPLES.THE TOP AND BOTTOM SAMPLING COCK FACILITY SHALL BE AVAILABLE AT THE PIPELINE MANIFOLD, AT THE DELIVERY MANIFOLD AND / OR CUSTODY TRANSFER PONT AT REFINERY / PIPELINE TRANSFER / RECEIPT LOCATIONS. SPECTACLE FLANGES / LINERS, HAMMER BLINDS OR SPOOL PIECES SHALL BE PROVIDED IN THE LINE WHENEVER A COMMON MANIFOLD AND PIPELINE IS USED, FOR POSITIVE SEGREGATION.

QUALITY CONTROL DURING STORAGE

 STORAGE TANKS SHALL BE CLEANED ONCE IN EVERY FIVE YEARS OR MORE FREQUENTLY, DEPENDING ON THE NEED, LIKE CHANGE OF PRODUCT, SLUDGE FORMATION ETC. TANK CLEANING CERTIFICATE SHALL BE MAINTAINED. DATE OF TANK CLEANING AND THE DUE DATE OF NEXT CLEANING SHALL BE PAINTED ON THE MANHOLE COVERS. AN ALL-LEVEL SAMPLE AFTER RECEIPT OF FIRST PARCEL IN A NEWLY COMMISSIONED TANK/AFTER ANY GRADE CHANGE OVER SHALL BE SENT TO THE LABORATORY FOR BATCH FORMATION TEST.

Q C DURING STORAGE (Contd.)

 WHEN THERE IS NO FRESH RECEIPT INTO A KEROSENE TANK FOR 7 DAYS, A TOP SAMPLE SHALL BE TAKEN AND CHECKED FOR DENSITY AND FLASH POINT.  THIS CHECKING SHALL BE CONTINUED SUBSEQUENTLY ON EVERY 7 DAYS BASIS TILL FRESH RECEIPT.  FO / LDO SHALL BE CIRCULATED WITHIN THE TANKS EVERY 15 DAYS FOR AT LEAST TWO HOURS, WHEN THERE IS NO FRESH RECEIPT INTO THE TANKS DURING THIS PERIOD.

Q C DURING STORAGE (Contd.)

 IF WATER BOTTOM IS MAINTAINED IN THE TANK, TEST E SHALL BE CARRIED OUT ON THE WATER SAMPLE ON FORTNIGHTLY BASIS. IN CASE THE TEST INDICATES PRESENCE OF SULPHIDE, WATER SHALL BE REPLACED.  ALL BOX STRAINERS / LINE STRAINERS SHALL BE OPENED ONCE IN THREE MONTHS AND INTERNALLY CLEANED. THE DATE OF CLEANING TO BE DOCUMENTED.

QUALITY CONTROL DURING STORAGE (Contd.)

 PIPELINES SHALL BE COLOUR CODED TO INDICATE THE PRODUCT THAT IS BEING CARRIED.  COLOUR CODING FOR ALL PRODUCTS SHALL HAVE ONE BAND OF 100 MM (4) ON EACH SIDE WITH A GAP OF 300 MM (12) IN BETWEEN.  THE BAND SHALL BE PAINTED NEAR BOTH SIDES OF THE VALVES AND THEREAFTER EVERY 20 MTS. OF LENGTH OF PIPELINE.

QUALITY CONTROL DURING STORAGE (Contd.)

 A 45-50 MM THICK *300 MM LONG ARROW SHALL BE PAINTED AFTER EACH BAND ON THE PIPELINE WITH RESPECTIVE COLOUR CODE IN THE FLOW DIRECTION. THE RECOMMENDED COLOUR CODING FOR BANDS SHALL BE :

PRODUCT MS 93 OCTANE MS 87 OCTANE SK HSD, LSHF HSD, HF HSD, ELS HSD, LDO FO NAPHTHA (LAN & HAN)

COLOUR SIGNAL RED DARK ORANGE GOLDEN YELLOW OXFORD BLUE ALUMINIUM ALUMINIUM DARK BROWN

ISCODE 537 591 356 105 412

REFER INDIAN STANDARD COLOUR NO. OF IS-5-1994

QUALITY MONITORING
 A COMPOSITE SAMPLE FROM THE STOCK OF EACH PRODUCT
TANK OF THE DEPOT SHALL BE SUBJECTED TO MONTHLY MONITORING TESTS AT NEAREST LAB.

 COPPER STRIP CORROSION TEST SHALL BE CARRIED OUT

FORTNIGHTLY ON A BOTTOM SAMPLE FROM LSHF HSD TANKS.

 WHEN NO FRESH PRODUCT IS RECEIVED FOR THREE MONTHS

INTO A TANK, UPPER, MIDDLE & LOWER COMPOSITE SAMPLE FROM THE VERTICAL TANK / AN ALL-LEVEL SAMPLE FROM THE HORIZONTAL TANK SHALL BE SENT FOR BATCH FORMATION TESTS. INTER TANK TRANSFER TO AVOID THIS IS NOT PERMITTED.

PRODUCT FAILURES
 IN
CASE ANY STOCK FAILS TO MEET THE SPECIFICATION DURING MONITORING OR OTHERWISE, THE STOCKS SHALL BE FROZEN AND THE ZONAL O&D & QC DEPT. TO BE ADVISED IMMEDIATELY.

 CORRECTIVE ACTION TO SALVAGE THE PRODUCT

SHALL BE INITIATED ONLY AFTER SPECIFIC INSTRUCTIONS ARE RECEIVED FROM QC DEPT.

 UNDER NO CIRCUMSTANCES SHALL A LOCATION ON

THEIR OWN ATTEMPT TO CORRECT THE PRODUCT.

STOCK LOSS
BASIC CAUSES OF PETROLEUM LOSSES :      EVAPORATION INACCURATE MEASUREMENT LEAKAGE PILFERAGE TEMPERATURE VARIATIONS

EVAPORATION LOSS EVAPORATION LOSS IS THE NATURAL PROCESS WHEREBY LIQUIDS ARE CONVERTED TO VAPOUR AND LOST TO ATMOSPHERE.

STOCK LOSS CONTROL CHECKLIST

CHECK-LIST FOR POSSIBLE SOURCES OF PRODUCT LOSSES : 1. i. SOURCES OF ERRORS IN MEASURING EQUIPMENT FAULTY DIP RODS (WORN OUT, BENT, WRONGLY GRADUATED). FAULTY DIP TAPES (NON-STANDARDS, WRONGLY GRADUATED). DISTORTED,

ii.

iii.

FAULTY DIP BOBS (WORN OUT, INCORRECTLY ATTACHED TO THE TAPE, WRONGLY GRADUATED).

STOCK LOSS CONTROL CHECKLIST

CHECK-LIST FOR POSSIBLE SOURCES OF PRODUCT LOSSES :

i.

FAULTY THERMOMETERS (NON-STANDARD, CALIBRATED, WITH BROKEN MERCURY COLUMN). FAULTY HYDROMETERS CALIBRATED, DAMAGED). ((NON-STANDARD,

NOT

ii.

NOT

iii.

FAULTY FLOWMETERS (WRONG SIZE, INCONSISTENT FLOW RATES, INCORRECTLY INSTALLED, WRONGLY CALIBRATED).

STOCK LOSS CONTROL CHECKLIST

2. i. SOURCES OF ERRORS IN TAKING MEASUREMENTS INCORRECT OBSERVATIONS OF PRODUCT DIPS, WATER DIPS, TANK TEMPERATURES, SAMPLE DENSITY AND SAMPLE TEMPERATURE , METER READINGS. UNEVEN RAIL SIDING, TANKLORRY GANTRY BAY. SOURCES OF ERRORS IN CALIBRATION INCORRECT STORAGE TANK CALIBRATION TABLES DUE TO : ERRORS IN THE ORIGINAL MEASUREMENTS OR CALCULATIONS. UNEVEN SETTLEMENT. FLEXING OF BOTTOM PLATES. REPLACEMENT OF BOTTOM PLATES AND FRESH CALIBRATION NOT CARRIED OUT. DISTORTION OF SHELL PLATES DUE TO FIRE, FAILURE OF INTERNAL REINFORCEMENTS, FITTING OF NEW ROOF PLATES. CHANGE IN THE LEVEL OF DIP PROOF LEVEL. ALTERATIONS IN THE WEIGHT OF THE FLOATING ROOF.

ii. 3. i.

STOCK LOSS CONTROL CHECKLIST

ii. INCORRECT CALIBRATION OF TANKWAGONS OR TANK LORRIES DUE TO : MISTAKES IN ORIGINAL CALIBRATION. CHANGES IN PROOF LEVEL DUE TO NEW / ALTERED FITTING. DISTORTION OF SHELL OR INTERNAL PARTITIONS BY ACCIDENT, OVERLOADING. 4. i. ii. iii. iv. SOURCES OF ERRORS IN CALCULATIONS ERRORS IN RECORDING OF THE OBSERVATIONS. ERRORS IN COMPUTATIONS OF QUANTITIES. USE OF WRONG CALIBRATION CHARTS. USE OF WRONG / ERRORS IN READING PETROLEUM MEASUREMENT TABLES.

STOCK LOSS CONTROL CHECKLIST

5. i. SOURCES OF LOSS FROM TANKS LEAKAGE OF LIQUID DUE TO :
y RUPTURED TANK BOTTOMS (CHECK BY WATCHING THE LEVEL OF A TEMPORARY WATER BOTTOM). y RUPTURED SEAMS, RIVETS (CHECK VISUALLY). y FITTINGS LOOSELY CONNECTED. y DEFECTIVE FITTINGS.

STOCK LOSS CONTROL CHECKLIST

5. SOURCES OF LOSS FROM TANKS

ii.

LOSS OF VAPOUR DUE TO :

y DEFECTIVE SEAMS, FITTINGS (CHECK VISUALLY OR WITH SOAP WATER SOLUTION WHILE TANK IS UNDER PRESSURE). y

DEFECTIVE PACKING FOR MANHOLES, DIP HATCHES, AUTOMATIC GAUGING DEVICES (EXAMINE).

y INCORRECT CLOSING OF MANHOLES, DIP HATCHES (EXAMINE).

* DEFECTIVE SEALS, FOAM CONNECTIONS, ARTICULATED DRAINS ON FLOATING ROOF TANKS (EXAMINE).

STOCK LOSS CONTROL CHECKLIST

5. iii. SOURCES OF LOSS FROM TANKS EXCESSIVE BREATHING AND EVAPORATION DUE TO :
y FREE VENTS INSTEAD OF PRESSURE VACUUM VALVES ON TANKS FOR VOLATILE PRODUCTS. y INCORRECT SETTING OF PRESSURE VACUUM VALVES

(CHECK PRESSURE ON MANOMETER WHEN VALVES ARE OPERATING).

y DEFECTIVE PRESSURE VACUUM VALVES (CHECK REGULARLY). y EXCESSIVE TEMPERATURE VARIATION DETERIORATED PAINT OF STORAGE TANKS. y INCREASE IN RVP OF THE PRODUCT HANDLED.

DUE

TO

STOCK LOSS CONTROL CHECKLIST

6. i. SOURCES OF LOSSES IN OTHER EQUIPMENTS LEAKAGE THROUGH PIPELINE WALLS OR JOINTS (CHECK VISUALLY OR TEST UNDER PRESSURE. IF NECESSARY DIG UP THE PIPELINE). LEAKAGE THROUGH VALVE GLANDS (CHECK VISUALLY AND TIGHTEN OR REPACK LEAKY GLANDS; IF VALVE STILL LEAKS, RE-GRIND FACE AND SEAT). LEAKAGE THROUGH PUMP GLANDS (CHECK VISUALLY AND TIGHTEN, REPACK, FIT MECHANICAL SEALS).

ii.

iii.

STOCK LOSS CONTROL CHECKLIST

6. SOURCES OF LOSSES IN OTHER EQUIPMENTS :

iv.

LEAKAGE THROUGH DRAIN COCKS OF FILTERS, WATER SEPARATORS ETC. (CHECK VISUALLY AND REPAIR). LEAKAGE THROUGH WALLS OR JOINTS OF DEFECTIVE HOSES (EXAMINE AND REPLACE JOINTS, REPAIR, CONDEMN DAMAGED HOSE). LEAKAGE FROM FILLING MACHINES AND FILLING ARMS (EXAMINE AND REPAIR).

v.

vi.

STOCK LOSS CONTROL CHECKLIST

7. SOURCES OF LOSS IN BULK OPERATIONS LEAKAGE OF VAPOUR DURING DIPPING AND SAMPLING (AS FAR AS POSSIBLE GAUGE WHEN INTERNAL AND EXTERNAL PRESSURES ARE EQUAL). EXCESSIVE DISPLACEMENT LOSSES DUE TO HEAVY WITHDRAWALS (FLOATING ROOF / HIGH PRESSURE TANKS PREFERRED). EXCESSIVE DISPLACEMENT LOSSES DUE TO INTER-TANK TRANSFER (UNDERTAKE ONLY IN CASE OF DISTINCT ADVANTAGE). SPILLAGE OF PRODUCT IN HOSE HANDLING (PROVIDE ARRANGEMENTS FOR DRAINING HOSES).

i.

ii.

iii.

iv.

STOCK LOSS CONTROL CHECKLIST

8. i. SOURCES OF LOSS IN FILLING : EXCESSIVE EVAPORATION OR SPLASH DUE TO THE USE OF SHORT LOADING HOSE / ARM (USE HOSE / ARM EXTENDING TO THE BOTTOM OF THE CONTAINER). DISPLACEMENT LOSS DURING RECEIPT AND WITHDRAWAL. OVERFILLING DUE TO CARELESS (SUPERVISION AND EDUCATION). OPERATIONS

ii. iii.

STOCK LOSS CONTROL CHECKLIST

8. iv. SOURCES OF LOSS IN FILLING : OVERFILLING DUE TO INCORRECT SETTING OF PRESET FLOW METERS (SUPERVISION, CHECKING OF CALCULATIONS). SPILLAGE FROM FILLING HOSES (PROVIDE PROPER DRAINAGE ARRANGEMENTS, USE SELF-SEALING COUPLINGS). FILLING WRONG PRODUCT NECESSITATING DECANTATION (SUPERVISION AND TRAINING).

v.

vi.

STOCK LOSS CONTROL CHECKLIST

9. i. OTHER SOURCES OF LOSS IN OPERATIONS : INCOMPLETE DRAINAGE OF TANKWAGONS AND TANKLORRIES (SUPERVISE DISCHARGE OPERATIONS). LEAKAGE OF LIQUID FROM FILLED CONTAINERS (TEST BEFORE FILLING, INSPECT BEFORE STORAGE AND REPAIR LEAKS). OVER-ISSUES OF PACKED STOCKS (SUPERVISION AND CHECKING). CONTAMINATION (MAINTAIN POSITIVE SEGREGATION, KEEP TANKS, PIPELINES, CONTAINERS CLEAN, REGULAR CLEANING OF FILTERS, WATER SEPARATORS). DOWNGRADING (MINIMISE).

ii.

iii.

iv.

v.

STOCK LOSS CONTROL CHECKLIST

9. vi. OTHER SOURCES OF LOSS IN OPERATIONS : LOSSES BY FIRE OR FLOOD (IMPLEMENT SAFETY MEASURES). FAILURE TO ACCOUNT OWN USE PRODUCT (PROPER ACCOUNTING). THEFT OR MISAPPROPRIATION (SEAL ALL FILTERS, STRAINERS, TANK DRAINS, COCKS AND LOCK VALVES WHEN NOT IN USE, CHECK SEALS AND LOCKS AT REGULAR INTERVALS, CHECK ALL BULK AND PACKED DELIVERIES, SEAL LOADED TANKLORRIES AND TANKWAGONS, KEEP WAREHOUSE LOCKED WHEN NOT IN USE, KEEP PACKED STOCKS AWAY FROM FENCES, KEEP FENCES, GATES, VALVES IN GOOD CONDITION, ENSURE PROPER SECURITY, CHECK SEALS REGULARLY).

vii.

viii.

STOCK LOSS ( Contd. )

LEAKAGE INDICATION OF THE LOSS MAGNITUDE DUE TO LEAKAGES :2 DROPS PER SECOND 4728.5 LTRS. PER YEAR

DROPS BREAKING INTO A STEADY STREAM 30730 LTRS. PER YEAR 1/8 STREAM 3/16 STREAM 1/4 STREAM 332500 LTRS. PER YEAR 535850 LTRS. PER YEAR 1179500 LTRS. PER YEAR

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