Oisd 167
Oisd 167
Oisd 167
FOR RESTRICTED
CIRCULATION ONLY
NO.
Prepared by:
FUNCTIONAL COMMITTEE ‘POL TANKLORRY DESIGN & SAFETY’
NOTE
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
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OISD RP 167
CONTENTS
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SECTION NO. CONTENTS
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1. INTRODUCTION
2. SCOPE
3. SALIENT FEATURES
4. ENGINE
6. TANK DESIGN
9. TANK MOUNTINGS
10. CATWALK
18. REFERENCES
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SECTION NO. CONTENTS
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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.
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.
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.
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.
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.
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
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.
SECTION No. 17
COLOUR SCHEME
SECTION No. 18
REFERENCES
ANEXURE I
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MODEL : ALCO COMET 3/1 CAPACITY : 12 KL
TANK DIMENSIONS:
CHASSIS DIMENSIONS :
DESIGN CALCULATIONS :
DISH END WEIGHT 1.4*22/7*a*b*2*g*t 184.23 kg
Rr (FULL) 8567.19 kg
Rr (EMPTY) 3065.66 kg
WEIGHT DISTRIBUTION
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DESCRIPTION FRONT AXLE REAR AXLE
(KG) (KG)
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STABILITY CALCULATIONS
C.G TABLE
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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
STABILITY RATIO