Oisd 167

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OISD - RP- 167


First Edition
July, 1997

FOR RESTRICTED
CIRCULATION ONLY

NO. 

POL TANKLORRY DESIGN & SAFETY 

Prepared by:
FUNCTIONAL COMMITTEE ‘POL TANKLORRY DESIGN & SAFETY’

OIL INDUSTRY SAFETY DIRECTORATE


TH
7  FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD
NEW DELHI - 110 001.  
 

NOTE

OISD publications are prepared for use in the oil


and gas industry under Ministry of Petroleum and Natural
Gas. These are the property of Ministry of Petroleum and
Natural Gas and shall not be reproduced or copied or
loaned or exhibited to others without written consent from
OISD.

Though every effort has been made to assure the


accuracy and reliability of data contained in these
documents, OISD hereby expressly disclaims any liability
or responsibility for loss of damage resulting from their
use.

These documents are intended only to supplement


and not replace the prevailing statutory requirements.
 

FOREWARD

The Oil Industry in India is 100 years old. Due to various collaboration
agreements, a variety of international codes, standards and practices are in vogue.
Standardisation in design, philosophies and operating and maintenance at a national
level was hardly in existence. This coupled with feed back from some serious
accidents that occurred in the recent past in India and abroad, emphasised the need
for the industry to review the existing state of art in designing, operating and
maintaining oil and gas installations.

With this in view, the then Ministry of Petroleum and 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 Functional Committees of experts nominated from the industry to draw up
standards and guidelines on various subjects.

The present standard on :"POL Tanklorry Design & Safety" was prepared by
the Functional Committee. This document is based on the accumulated knowledge
and experience of industry members and the various national and international codes
and practices. This document is meant to be used as a supplement and not as
replacement for existing codes and practices. It is hoped that the provision of this
standard, if implemented objectively may go a long way to improve the safety and
reduce accidents in Oil and Gas Industry. Users are cautioned that no standard can
be a substitute for the judgment of a responsible and experienced engineer.

This document will be reviewed periodically for improvements based on the new experiences and better
understanding. Suggestions are invited from industry members may be addressed to The Coordinator, Committee
on POL Tanklorry Design & Safety,
OIL INDUSTRY SAFETY DIRECTORATE
TH
7  FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD
NEW DELHI - 110 001.  
 

FUNCTIONAL COMMITTEE
ON
POL TANKLORRY DESIGN & SAFETY

List of Members

----------------------------------------------------------------------------------------------------

Name Designation & Position


Organisation in Committee

----------------------------------------------------------------------------------------------------

1. Mr. S.K. Jain Executive Chairman Leader


PII.

2. Mr. R.H. Bhalekar Jt. Chief Controller Member


of Explosives, Nagpur.

3. Mr. Barath Balan Principal- NIGDI Member


HPCL (M).

4. Mr. P.R. Waghmare Sr. Manager (Ops.), Member


IOC (M).

5. Mr. A.I. Deshmukh Manager Ops. Member


BPCL (M).

6. Mr. K.S. Venkateswaran Dy. Manager Engg; Member


HPCL (M).

7. Mr. K.R. Soni Addl. Director (Engg.), Member-


OISD. Coordinator
----------------------------------------------------------------------------------------------------
 

 
OISD RP 167

POL TANKLORRY DESIGN & SAFETY

CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------
SECTION NO. CONTENTS
--------------------------------------------------------------------------------------------------------------------------------------

1. INTRODUCTION

2. SCOPE

3. SALIENT FEATURES

4. ENGINE

5. TANK MATERIAL SPECIFICATIONS

6. TANK DESIGN

7. TANK BOTTOM FITTINGS

8. TANK TOP FITTINGS

9. TANK MOUNTINGS

10. CATWALK

11. TANK OVERTURN PROTECTION

12. REAR END PROTECTION

13. ELECTRICAL SYSTEM

14. DRIVER'S CABIN

15. SPARK ARRESTOR

16. THIRD PARTY INSPECTION

17. COLOUR SCHEME

18. REFERENCES

 Annexure I TANKLORRY DESIGN SAMPLE


CALCULATIONS

 Annexure II DIAGRAM SHOWING DOME COVER


ON A TANK LORRY
 

-------------------------------------------------------------------------------------------------------------------------------
SECTION NO. CONTENTS
--------------------------------------------------------------------------------------------------------------------------------

 Annexure III PRESSURE VACCUM VALVE


(SPECIMEN)

 Annexure IV EMERGENCY VENT (SPECIMEN)

 Annexure V CATWALK DETAILS

 Annexure VI OVERALL VIEW

 Annexure VIA GENERAL ARRANGEMENT OF


MANHOLE COVER FITTINGS

 Annexure VII EXHAUST FLAME TRAP/


SPARK ARRESTER
 

SECTION No. 1
b) Roll over design is adopted giving
protection to top fittings vulnerable to
INTRODUCTION  damage during overturning of a tanklorry.

In the wake of NGL tanklorry overturning and c) Bottom loading provision has been
subsequent fire which occurred near included.
Mendhwan Village in Thane District in
November 1991 claiming a number of lives, a d) Colour scheme to identify tanklorries
technical committee comprising of senior carrying POL products.
executives from Oil Companies, Oil Industry
Safety Directorate and Chief Controller of e) Protection for tank body against lateral and
Explosives (CCOE) was constituted to longitudinal impact during overturning.
investigate into the cause of the incident and
recommend the measures for avoidance of
such incidents. The committee recommended
SECTION NO. 4
several measures based on the directly
attributable causes of the incident as well as
with regard to deficiencies in tanklorry design ENGINE
and inspection practices of the fabricators.
The recommendations include development of LOCATION
engineering standard covering all facets of
design, minimum inspection and tests for The engine shall be in front of the rear line of
soundness of the tank, protection of tank the cab or be otherwise protected so that any
against lateral & longitudinal impact during spillage or leakage of flammable liquid cannot
overturning of a tanklorry, colour scheme of impinge on the heated surfaces of the engine.
tanklorries carrying POL products, etc.
TYPE
This Standard has been prepared keeping in
view the above recommendations and to Engine shall be an internal combustion engine
standardise the tanklorries carrying POL (diesel driven). Engine power shall be
products in India. adequate for the intended terrain operation.

 AIR INDUCTION SYSTEM


SECTION NO. 2
The air induction system shall be located
and/or protected so as to minimise the
SCOPE possibility of induction of flammable vapour
from any spillage of flammable liquid or from
This Standard lays down minimum any release from a safety relief device on the
requirements of design, inspection and quality cargo tank. The air intake shall be fitted with
assurance for tank-lorry used for transportation an effective flame arrestor capable of
of POL products other than Excluded preventing emission of flame from the side of
Petroleum (such as LSHS, bitumen (asphalt), the engine in the event of backfiring.
wax, etc., as defined under Petroleum Act,
1934, and Petroleum Rules, 1976. The scope
EXHAUST SYSTEM
of this Standard includes tanklorries of
capacities up to 18 kl on rigid chassis.
The exhaust system shall be located in such a
way that any spillage or leakage of the
flammable tank contents cannot normally
SECTION NO. 3 impinge on the heated surfaces of the system.
The exhaust pipe shall be fitted with Spark
SALIENT FEATURES  Arrestor procured from CCOE approved
manufacturer. The muffler or silencer shall not
Salient features of a tanklorry constructed as be cut off from the exhaust system. The Spark
per this Standard vis-a-vis existing tanklorries  Arrestor shall be firmly attached to the exhaust
are as under : pipe by a proper bolting system.

a) Tank sheet material having higher tensile Fuel system


strength, yield strength and impact
resistance has been recommended.
 

The vehicle fuel tank shall be positioned so


that leaking or spilled fuel can drain directly to 3. Tanklorry shall comply with the Petroleum
the ground without impinging on the engine or  Act, 1934, and the rules framed
its exhaust system. Additionally, it shall be thereunder. The maximum net carrying
located on the side opposite to the tanklorry capacity of a tank shall be 97 percent of its
discharge faucets. gross carrying capacity in the case of
petroleum Class A and B and 98 percent in
The fuel tank shall be protected by stout steel the case of petroleum Class C. In case
guards, and shall have provision for locking. the tank is likely to be used for all Classes,
then the provision required for Class A
 Alteration/addition to the originally designed shall apply.
fuel tank (supplied by the vehicle
manufacturer) shall not be carried out. 4. Registered laden weight (RLW) of the
vehicle shall not exceed the authorised
SECTION NO. 5 registered weight of the vehicle by
concerned transport authority or
manufacturer, whichever is less. The
TANK MATERIAL SPECIFICATIONS  weight product filled plus the unladden
weight shall not exceed RLW or the
Tank shall be fabricated out of carbon steel licensed capacity as permitted by statutory
material meeting the following minimum authority.
requirements:
5. Each tank or compartment of the tank
Thickness : 3.15mm (10 BWG) shall be constructed with a manhole on the
top to provide access to enable the interior
Yield strength : 30kg/mm2(300 to be examined. The manhole shall be not
Mpa) less than 450 mm in diameter.

Ultimate tensile : 44-56 kg/mm2 6. Maximum width of the tank shall be less
strength (440-560 MPa) than the overall width of the cabin of the
vehicle on which it is mounted, and also
Minimum elongation : 21% less than the overall width of the outer
edges of the vehicle tyres.
Impact strength : 40 Joules at 0 deg.
(Charpy V-notch) C. 7. A tank having a net capacity exceeding
5000 litres shall be divided into
Bend test (Mandrel : 3 times thickness compartments by oil-tight partitions. No
Dia) compartment shall have net capacity
exceeding 5000 litres.

SAILMA 300 HI of Steel Authority of India 8. Tank ends and the partitions shall be
meets the above requirements. However, dished. The depth of dish excluding the
steel sheet from any other reputed flange shall not be less than 8% of the
manufacturer with equivalent or better minor axis of the tank cross-section
characteristics may also be used after testing. subject to a minimum of 100 mm.

SECTION No. 6 9. The distance between two partitions, and


any adjacent tank end and a partition, shall
not exceed 2500 mm.
TANK DESIGN
10. Baffles shall be continuously welded to the
1. Tanklorry shall be designed and shell.
constructed ensuring correct structural 11. All joints shall be welded conforming to IS
relationship between the cargo tank, the 814. This shall include attention to the
propulsion equipment and supporting following :
members, its ruggedness, safe road
performance and braking power. i. Weld joint preparation.
2. Tanklorry shall comply with the Motor ii. Welding procedure.
Vehicles Act, 1988, and the rules framed
thereunder. iii. Weld thickness.
 

  2. The Emergency Valve shall be of the type


iv. Acceptable limits of welding defects fitted with a suitable means for preventing
considering the fact that the welds are development of dangerous static charge
to be accepted without radiographic inside the tank during bottom loading.
test. This can be achieved either by the design
of the valve or by fitting a suitable deflector
v. Proper fabrication plan shall be plate.
prepared indicating the actual
positions of weld joints. It shall be 3. The operating mechanism (Termed
ensured that three plate joints do not Bottom Operator) for the Emergency
occur at intervals closer than 500 mm. Valves shall be provided with a secondary
control (Emergency Release) in an easily
vi. Welding electrodes shall be of reputed accessible position remote from all fill
make and conform to E - 6013 grade. openings and the discharge faucets.

 All weld inside and outside the tank shall 4. The Bottom Operator shall incorporate a
be ground smooth prior to painting. fusible link which will permit automatic
closing of all the Emergency Valves in the
event of fire. One end of the fusible link
12. Every compartment shall be tested by shall be anchored to the body of the
hydrostatic pressure of minimum 0.316 Bottom Operator and the other end
kg/sq.cm. g. gauged at the top of the attached to the Bottom Operator spring
compartment. This can be achieved by release mechanism in such a way that all
means of a 3160 mm high pipe fitted on open Emergency Valves are closed at the
top of the tank and filled up to the brim same time. The link shall be capable of
with water. The pressure shall be withstanding a minimum load of 35 kgs
maintained for a period of not less than and the two halves shall not separate
one hour. During testing, all the closures during normal handling of the valve but
shall be in place and the operating relief shall separate only when the fusible alloy
devices shall be clamped, plugged or melts at 93 degrees C. in the event of a
otherwise rendered inoperative. The fire. Fusible link shall be procured from
compartment under test shall not show CCOE approved manufacturer.
any leakage or drop of pressure during
the test. Two adjoining compartments 5. The Emergency Valve shall incorporate a
shall not be tested or filled with water shear section designed to break when
simultaneously. Tanks failing to pass this subjected to excessive strain. This shall
test shall be suitably repaired and the be located on the discharge side of the
above test shall be continued until no leak valve seat as close as possible to the
is detected. valve seal.

13. Center of gravity of fully loaded tanklorry 6. All tank valves, fittings, pipework and
shall not be higher than that ancillary fittings shall be so fitted and
recommended by the chassis protected as to minimise the risk of
manufacturer. Sample Design and damage and leakage of contents in the
Stability Calculations are given as event of the vehicle being involved in an
 Annexure I. accident.

SECTION NO. 7 7. Tank valves, sealing caps and other


fittings, including joint seals and sealants,
shall be manufactured from materials
TANK BOTTOM FITTINGS which are suitable for handling refined
petroleum products including presently
Bottom draw-off/loading systems shall conform known additives.
to the following requirements:
8. Provision shall be made to prevent
1. Tank shall be designed to ensure the damage to pipework due to vibration by
complete drainage of the contents of each the incorporation of Flexible Bellow
compartment via an internal stop valve connections within pipework runs.
(Emergency Valve) and an external
discharge faucet.
SECTION NO. 8
 

  geometrical center of the compartment. It


shall be extended to the bottom of the tank
TANK TOP FITTINGS
and shall be supported against vibration.
The bottom end of the pipe shall be
The manhole mentioned in Section No. 6 shall
sealed. The pipe shall be truly vertical
be closed off with a mild steel (minimum 5 mm
when the bottom of the tank is horizontal.
thick) base plate assembly fitted with a 24 bolt
airtight fixing all around and a 3 mm thick
2. Internally, the pipe shall be provided with
compressed nitrile cork gasket.
5mm dia holes throughout its length and
circumference, including at a level above
The Manhole shall be enclosed in a dome
the maximum level of the contents, the
cover having a hinge joint at one end and a
number of holes being minimum 5 nos. in
spring loaded sealing arrangement at the other
minimum 5 rows. The openings shall be
end. (Refer to Diagram in Annexure II). The
covered with 2 layers of wire gauze having
dome cover shall not restrict the emergency
not less than 11 meshes per centimeter.
venting capability of the vapour or liquid
emergency vent.
3. The Dip pipe shall be projected from the
manhole plate and it shall be at least 15
Following fittings shall be provided within each
mm below the tank shell in case of
manhole plate:
 Alternative I mentioned in Section 11.
FILL PIPE:
4. Top open end of dip pipe shall be
externally threaded and fitted with an oil-
1. Fill pipe shall be of Mild Steel of size 100
tight locker cap. The cap shall be fine
mm nominal bore and flange mounted to
finished from the inside and provided with
the manhole base plate. Internally the pipe
compressed nitrile cork gasket.
shall be extended till almost bottom of the
compartment leaving a clearance of 25
5. A datum plate of size 100 x 100 mm and
mm. The fill pipe should not be slotted,
thickness not exceeding 5 mm shall be
however, it should have an opening in the
provided exactly below the dip pipe.
wall not greater than 13mm in diameter
which should be above the maximum level
PRESSURE-VACUUM VALVE:
of the tank contents in order to provide a
pressure balance.
1 Pressure Vacuum valve procured from
CCOE approved manufacturer shall be
2. The inner end of the fill pipe shall be
mounted on the manhole cover base plate.
provided with a splash deflector
Specimen drawing is enclosed as
arrangement (45 degree angular cut).
 Annexure III.
3. Top open end of the fill pipe shall be
2 P/V valve shall be of the double spring
externally threaded and fitted with an oil-
type, one for pressure and one for vacuum
tight locker cap. The cap shall be fine
and shall incorporate an anti-roll over
finished from the inside and provided with
device which will not allow leakage of
a compressed nitrile cork gasket.
contents in the event of vehicle upset.
4. The top of the internal pipe is to have a
3 The settings of the P/V valve shall be :
gauzed opening of 140 Sq. mm minimum
located above the maximum level of the
Pressure : 210 cm of water gauge
contents to provide pressure balance. The
stainless steel gauze shall be
Vacuum : 5 cm of water gauge
manufactured from wire with a diameter
not less than 0.3 mm forming apertures of
4 P/V valve shall provide a minimum flow
not more than 0.5 mm x 0.5 mm.
venting area of 300 sq.mm., the opening
being covered with 2 layers of wire gauze
DIP PIPE :
having not less than 11 meshes per
centimeter.
1. Dip pipe of nominal bore of 75 mm shall be
of mild steel with a longitudinal opening
EMERGENCY VENT:
along its full internal length covered by
gauze. The Dip Pipe shall be flange-
1. An emergency vent procured from CCOE
mounted to the manhole base plate at the
approved manufacturer shall be mounted
 

on the manhole cover base plate. It shall be as per recommendation of


Specimen drawing is enclosed as chassis manufacturer.
 Annexure IV.
g) Packing shall be provided between saddle
2. The emergency vent shall be of fusible plate and the chassis as per
type to melt at 93 degrees Centigrade. recommendation of chassis manufacturer.

3. The vent shall provide a minimum opening h) U-bolts for securing the tank shall be
having a net area in sq. cms. equal to 8 tightened to the specified torque level, and
plus 4.3 times the gross capacity of the number of bolts shall not exceed the
compartment in kilolitres. number recommended by the chassis
manufacturer.

SECTION NO. 9
SECTION NO. 10
TANK MOUNTINGS 
CATWALK
Tank (including its supports and attachments)
shall be so fitted that if under the maximum a) Catwalks shall be minimum 600 mm wide
permissible load it is subjected to an and provided on both sides of the
acceleration of 2 g in the direction of travel, 1 g manholes throughout the length of the tank
at right angles to the direction of travel, 1 g and between the manholes. (Refer
vertically upwards or 2 g vertically downwards,  Annexure V).
the maximum stress in any part thereof shall
not exceed 75% of the yield proof stress of the b) Catwalk shall be made of chequered
material of construction. Where it is plates or gratings.
foreseeable that the tanker may be subjected
to higher loading conditions, e.g. where it may c) Catwalk supports shall not be welded
be used over rough terrain, appropriate loads directly to the tank shell but welded with a
shall be established. padding of 5mm thick plate of size 100x
100 mm.
The tank shall be securely attached to the
vehicle in accordance with the following d) In case of Alternative II mentioned in
conditions: Section No. 11, catwalk shall be above the
level of the fittings and capable of
a) Mounting structures shall be designed to withstanding the weight of the loaded
prevent excessive movement of the tank in tanklorry.
relation to the chassis. This would include
the use of flexible mountings as well. e) 1 No. ladder shall be provided at the rear
of the tank.
b) The design of mounting structures shall
take into account the loadings referred
above.

c) Where the mounting structures are


designed as an integral attachment to the
shell, each attachment shall be designed SECTION NO. 11
to meet the requirements of the maximum
stress referred above.
TANK OVERTURN PROTECTION
d) Anchors shall not allow any movement
between the tank and the vehicle during a) All top fittings shall be protected against
starting, stopping and turning. damage from roll over accidents. This can
be achieved by any of the two alternatives
e) All anchors shall be installed in a manner below:
so as to be easily accessible for inspection
and maintenance.
 Alternative I Manholes shall be
f) Special care shall be taken on the location recessed within the
of bolting of the tank to the chassis frame. contour of the tank shell
 

and all fittings each side of the tank to at least the maximum
protruding above the width of the vehicle.
manhole base plate
shall be at least 15 mm
below the top of the SECTION NO. 13
tank shell. (Refer
 Annexure VI.)
ELECTRICAL SYSTEM
 Alternative II Manholes shall be
flushed with the top of The electrical system shall be designed,
the tank shell and all installed and adequately protected so as to
fittings on the manhole minimise mechanical damage and the risk of
base plate shall project electrical fires. In particular, the system shall
above the shell only to conform to the following requirements:
the minimum extent
necessary. Catwalk a) The nominal circuit voltage on the vehicle
shall be as mentioned in shall not exceed 24 volts.
item 4 of Section No. 10.
b) Batteries shall be effectively protected
against contact with any spillage of
flammable liquid, and be fitted with an
insulator cover to protect against
b) All the fittings shall be provided within the
inadvertent contact by objects which could
manhole cover base plate.
cause a spark.
c) Manhole cover lids as specified in Section
c) All cables shall be secured on the vehicle
No. 8 shall be provided.
so that they are protected against
mechanical damage and heat.
d) The gross volume of the tank
compartment shall be calculated as the net
d) All control switches shall be in the feed
liquid load volume plus 2 to 3% of the
side of the circuit.
volume and the level shall be never less
than 75 mm below the top of the tank
e) All cables shall be armoured and protected
shell.
from mechanical/ chemical damages.
e) The center of gravity of the fully loaded
f) Except for cables to the starter motor, the
vehicle shall not be higher than that
current rating of any cable shall be chosen
recommended by the chassis
so that the conductor temperature will not
manufacturer.
exceed 70 deg. C when it is carrying full
load continuously.
f) Saddle plates shall be extended on both
the sides up to at least half the height of
g) Junction boxes, connectors and all
the tank, for bearing the impact in the
electrical equipment shall be adequately
event of vehicle overturn.
protected and shielded from the ingress of
moisture or flammable liquid.

h) Either an insulated return circuit shall be


used or every item of electrical apparatus
on the vehicle shall be individually bonded
SECTION NO. 12 by cable either to the chassis or structural
members attached to the chassis.
REAR-END PROTECTION
i) To enable electrical circuits to be isolated
The vehicle shall be provided with a rear (including any open circuit of alternator
robust steel bumper so that collision stresses field windings), a multipole master switch
will be transmitted to the frame of the vehicle shall be fitted as close to the battery as
and thus protect the tank and its fittings in the possible and shall comply with the
event of a rear-end collision. The bumper shall following provisions :
be so located that its inside face is never less
than 100 mm from the rear of the tank shell or
its fittings. The bumper shall be extended on
 

i. Master switch shall include double lead connector. The maximum electrical
pole switching to isolate outgoing resistance of all such connections shall not
circuits from both poles of the battery; exceed 10 ohms. All discharge hoses shall be
electrically conducting. The electrical
ii. Master switch control shall be readily resistance from the external earth lead
accessible to persons outside the connector of the vehicle to the ground through
vehicle and its location shall be the tyres shall not exceed 10 ohms.
indicated by a clearly visible, legible
and durable notice.
SECTION NO. 14
iii. Visual means shall be provided to
indicate clearly when the master
switch is in the "ON" or "OFF" position. DRIVER'S CABIN

iv. Means shall be provided for the driver a) The height of the vehicle cabin shall be
to put off the master switch without more than that of the tank.
leaving the driver's seat.
b) Cabin shall be fabricated out of steel plate
VEHICLE ELECTRICAL CIRCUIT material.
PROTECTION
c) Its rear window, if provided, shall be fully
The following steps shall be taken to ensure covered with toughened glass.
protection of the electrical circuits:
d) 1 kg ISI approved DCP/CO2 fire
a) All circuits, with the exception of the main extinguisher and a fully equipped first aid
battery supply and the starter and box shall be provided inside the cabin.
alternator circuits, shall be protected with
fuses or circuit breakers. e) A 10 kg. ISI approved DCP fire
extinguisher shall carried on the vehicle in
b) All circuit protective devices, with the an easily accessible position and away
exception of any barrier device for a from the discharge faucets.
tachograph or other intrinsically safe
device, shall be mounted forward of the
rear of the cab. SECTION NO. 15

c) Fuses or circuit breakers shall be fitted SPARK ARRESTOR 


within an enclosed unit. Fuse holders shall
be permanently marked with the maximum a) Spark Arrestor procured from CCOE
fuse rating. approved manufacturer shall be fitted at
outlet of exhaust pipe of the vehicle to
d) Number of circuits connected to any avoid emission of sparks. (Specimen
protective device shall not exceed four, drawing enclosed as Annexure VII).
and the rating of the device shall be
compatible with the smallest conductor in b) Its inlet end with swirling blade assembly
any of these circuits. shall be fitted with the outlet end of the
vehicle exhaust pipe by a proper bolting
e) Grouping of circuits shall be so arranged system.
that the failure of any minor circuit does
not render a major or obligatory circuit c) The carbon of engine exhaust comes out
inoperative. through swirling blade and is deposited in
the soot box of the spark arrestor
PROTECTION AGAINST STATIC assembly.
ELECTRICITY
d) The carbon deposits shall be cleared
The vehicle shall be provided with a connector regularly.
for connecting an external earthing lead during
loading/unloading. The tank, its associated
pipework and fittings, both internal and
SECTION NO. 16
external, and the metal structure of the
carrying vehicle shall all be in good electrical
contact with each other and the external earth THIRD PARTY INSPECTION 
 

  d) Approval of welding procedures, welding


Inspection at every stage of fabrication of a equipment and welder's qualification in
POL Tanklorry is necessary to ensure that accordance with relevant IS code.
right materials as per the specification are
used and fabrication is carried out exactly as 2nd stage:  
per the drawings and other technical details.
a) Ensuring that welding is being carried out
INSPECTION AGENCY  as per predetermined sequence and
procedures, by approved welders with
Inspection shall be carried out by a competent specified electrodes.
party approved by CCOE.
b) Inspection of weld joints :
ROLE OF INSPECTION AGENCY  
c) Dye penetration test of external weld joints
a) To check the design, drawings and not subjected to hydrotesting.
technical specifications.
d) Ensuring repairs of the defective welds, if
b) Inspection/verification/checking of all the any, before giving clearance for hydrostatic
materials to ensure that correct material is testing.
used.
e) Inspection during fabrication shall be
c) Inspection of MS plates/sheets for carried out as per the requirement of
thickness and any surface defects. applicable codes, specifications, approved
drawings etc.
d) Testing of welders for welder's qualification
as per relevant IS code. f) To ensure installation of all the fittings as
per drawing.
e) Welding procedures as per codes and as
per the fabrication drawings.

f) To ensure that welding is being done as 3rd stage:


per predetermined welding sequence
using approved electrodes. (Shall be carried out as pre-commissioning
checks after completion of the entire
g) Inspection of workmanship fabrication work).

h) Final pre-commissioning tests a) Check for physical dimensions (as per


(Hydrotesting, etc.) after completion of drawings).
fabrication work.
b) Visual inspection for workmanship and
i) Review and certification of records and quality of work.
test certificates pertaining to welding
material, MS plates, P.V. Vent, Master c) To ensure that quality of welding meets the
Valve etc. requirement of 2nd stage Inspection.

VARIOUS STAGES OF INSPECTION  d) Hydrotesting of the tank as specified in


tank design.
1st stage :
e) Check for installation and working of all the
a) Verification of all the Manufacturer's test safety and other fittings.
certificates ensuring material to be of the
correct specification. f) Tank capacity to be checked physically
using IS approved water meter.
b) Check for thickness and its uniformity:
Mechanical/ Ultrasonic test. g) To ensure proper surface preparation and
painting.
c) Visual inspection for any surface defects,
cracks or lamination. h) Check for external and internal painting.

i) Issue of Inspection certificate after the final


inspection.
 

 
4th stage: a) Petroleum Act, 1934 & Petroleum Rules,
1976.
(Shall be carried out every 5 years from the
date of commissioning). b) Motor Vehicles Act, 1988.

a) Check for physical dimensions as per c) Approved Code of Practice (1992 edition)
drawings). for Design And Construction of Vented,
Non-pressure Road Tankers Used For The
b) Visible signs of tank damage. Carriage Of Flammable Liquids, issued by
Health And Safety Commission, U.K.
c) Check for external painting.
d) Code No. API 650 for fabrication of tanks.
d) Condition of all fittings.
e) IS Code No. 814 - Covered Electrodes For
e) Hydrotesting of the tank as specified in Manual Metal Arc Welding Of Carbon
tank design. Steel And Carbon Manganese Steel.

f) Condition of fire extinguisher and first aid


box.

g) Issue of fitness certificate.

SECTION No. 17

COLOUR SCHEME 

a) POL tanklorries shall be painted as per


RTO and other applicable regulations.

b) Emblem of the oil company shall be


painted only on tanklorries owned by them.
Transport contractors shall not paint oil
companies' emblems on their tank lorries.

c) Every tanklorry shall have an Emergency


Information Panel painted on the three
sides of the tank and two hazard class
labels, one in front of the engine and one
on top of the cabin, as laid down in the
Motor Vehicles Act, 1988 and Motor
Vehicle Rules, 1989.

d) “ML” and "Highly Inflammable" shall be


indicated as laid down in Petroleum Rules,
1976.

SECTION No. 18

REFERENCES
 

 ANEXURE I 

TANK LORRY DESIGN SAMPLE CALCULATIONS

===========================================================================
MODEL : ALCO COMET 3/1 CAPACITY : 12 KL

TANK DIMENSIONS:

MAJOR AXIS (a) 230.00 cm

MINOR AXIS (b) 145.00 cm

SHELL LENGTH (l) 466.00 cm

DISHED END DEPTH (d) 13.00 cm

TOTAL TANK LENGTH 492.00 cm

TANK SUPPORT HEIGHT 22.00 cm

CHASSIS DIMENSIONS :

FRAME HEIGHT 1015.00 cm

WHEEL BASE 447.00 cm

FRONT OVERHANG 111.80 cm

REAR OVERHANG 167.80 cm

OVERALL LENGTH 726.40 cm

DESIGN CALCULATIONS :

CABIN LENGTH 180.00 cm

PLATE THICKNESS (t) 0.32 cm

SHELL VOLUME 1.06*3.14*a*b*l/4000000 12938.31 lts

DISH END VOLUME 4*3.14*a*b*d/12000 454.01 lts

TOTAL TANK VOLUME 13392.32 lts

FILLING RATIO (MAXM. PERMISSIBLE=0.97) 0.90

PRODUCT VOLUME 12000.00 lts

PRODUCT DENSITY 0.85 gm/cu/.cm

PRODUCT WEIGHT 10200.00 kg

STEEL DENSITY (G) 7.85 gm/cu.cm


TANK SHELL WEIGHT 22/7*SQRT(a*a+b*b/2)*l*G* t 707.03 kg
 

 
DISH END WEIGHT 1.4*22/7*a*b*2*g*t 184.23 kg

PARTITION NOS. 3.00

NO. OF PARTITION PLATES 2.00

WEIGHT OF EACH PARTITION PLATE 65.80 kg

TOTAL WEIGHT OF PARTITION PLATES 131.60 kg

TOTAL TANK WEIGHT 1022.85 kg

MOUNTING WEIGHT 350.00 kg

WEIGHT OF GUARD AT TOP 60.00 kg

TANK + MOUNTING WEIGHT 1432.85 kg

PRODUCT + TANK + MOUNTING WEIGHT 11632.85 kg

REACTION AT REAR AXLE = Rr

GAP BETWEEN CABIN AND TANK SHELL (e) 15.00 cm

GAP AT REAR END (f) 39.40 cm

TANK C.G. DISTANCE FROM FRONT AXLE 329.20 cm

Rr (FULL) 8567.19 kg

Rr (EMPTY) 3065.66 kg
 

TANKLORRY STABILITY CALCULATIONS (SAMPLE)

WEIGHT DISTRIBUTION
 _________________________________________________________________________________
DESCRIPTION FRONT AXLE REAR AXLE
(KG) (KG)

 AXLE+SUSPENSION WEIGHT 400.00 900.00

ENGINE+TRANSN+CHASSIS 1395.00 665.00

CABIN WEIGHT 400.00

CREW WEIGHT 130.00

PRODUCT+TANK+MOUNT WEIGHT 3065.66 8567.19

TOTAL 5390.66 10132.19

 AXLE RATING 5675.00 10200.00

 ________________________________________________________________________________

STABILITY CALCULATIONS

C.G TABLE
 _________________________________________________________________________________
ITEM  LOAD ON C.G. HEIGHT FROM
GROUND LEVEL
FRONT AXLE REAR AXLE TOTAL UNLADEN LADEN
KG. KG. KG.
CHASIS FRAME 300.00 500.00 800.00 1015.00 960.00

ENGINE & TRANS. 1095.00 165.00 1260.00 1315.00 1260.00

CREW WEIGHT 130.00 130.00 1860.00 1805.00

CABIN WEIGHT 400.00 400.00 1860.00 1805.00

F.A.+ SUSPENSION WT 400.00 400.00 450.00 435.00

R.A. + SUSPENSION 900.00 900.00 498.00 483.00


WT.

PRODUCT WEIGHT 2688.05 7511.95 10200.00 1835.00

TANK + MOUNTING WT 377.61 1055.25 1432.85 1905.00 1850.00

TOTAL WEIGHT 5390.66 10132.19 15522.85


 

STABILITY RATIO

UNLADEN WEIGHT WU 5322.85


LADEN WEIGHT WL 15522.85
DISTANCE BETWEEN REAR END TYRES X 2105.00
HEIGHT OF C.G. (UNLADDEN) YU 1279.86
STABILITY RATIO YU/X 0.61
HEIFGHT OF C.G. (LADEN) YL 1629.13
STABILITY RATIO YL/X 0.77
 

 
 

 
 

 
 

 
 

 
 

 
 

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