Dept.

Doc # Page 1 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

DOCUMENT COVER SHEET

 Dept. Doc # Page 2 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

1. PURPOSE
To establish a safe working practice during tank gas freeing and cleaning operation.

2. SCOPE
The procedure describes all activities relating to the tank cleaning operation.

This procedure is written for competent Operators, Supervisors and Shift Leaders.

3. ABREVIATIONS
LEL - Lower Explosive Limit

SHE - Safety, Health and Environment

MSDS - Material Safety Data Sheet

PPE - Personal Protective Equipment

TWA - Time Weighted Average

4. REFERENCES

4.1 Material Safety Data Sheet (MSDS)

4.2 Terminal Operations Work Instructions Manual
CRL Work Instructions:

4.2.1 Use of PPE

4.2.2 PIG a Pipeline
4.2.3 Tank cleaning
4.2.4 Confined Space Work Procedure.
 Dept. Doc # Page 3 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

5 RESPONSIBLITIES

a) Supervisor and Shift Team Leader

The Supervisor and Shift Team Leader shall ensure compliance with this procedure
at all times.

b) Operations Manager

The Operations Manager is the Author of this procedure and shall ensure the
improvement and development of this Procedure.

c) Terminal Manager

The Terminal Manager is the Authoriser of this procedure.

This Procedure shall be reviewed every 2 years.

6.Health & Safety:

Operators or Contractors should always be aware of the product held in the tank
prior to un-boxing. They should refer Material Safety Data Sheets avaiable in the
Operation’s office. They should check if the product would require them to wear a
respirator mask or full chemical suit. A risk assessment must be carried out
before the tank is un-boxed, this will detail the work to be carried out and whether
the rescue equipment needs to be positioned at tankside. Empty tanks must
always be isolated according to procedure to prevent ingress of unauthorised
personnel or product. Tank entry should never be initiated until all procedures
and checks are in place. If required by the risk assessment the confined space
rescue team must be present with pagers before any tank entry commences.

Person should wear safety shoes, goggles, safety helmet and hand gloves during
Tank cleaning / Gas freeing activities.
 Dept. Doc # Page 4 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

7.Environmental Protection:

Product is bio degradable; Vopak regulation or local regulation (which so ever is

more stringent) to be followed.

8 PROCEDURES
This Operating Procedure shall be used for Gas freeing and Tank cleaning operations.

Before a tank is taken out of service, a number of preparatory activities must be taken in
close liaison with operations, SHE, maintenance.

8.1 Preparation before Tank Cleaning Operation

1 Identify the method & equipment to be used for tank cleaning after confirming the next
product to be stored in the tank. The Upcoming cargo can be confirmed from the
Commercial department.

2 The slope tank to be used for handling the waste water. Establishing the amount of
slope which might be generated and the ullage in the respective tank.

3 The requirement for degassing of vapour’s prior to cleaning operations.

4 The isolation, lock—out or tag-out requirement must be defined to assure that all
connections & sources of energy are covered.

5 PPEs required during the job must be selected based on PPE matrix.

6 Latest MSDS of the concerned product must be available.

7 Mark out the tank under cleaning and determine any potential hazards.
 Dept. Doc # Page 5 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

8 Review Terminal’s ERP and actions that need to be available in responding to a rescue
and or tank cleaning emergency.

9 Identify duration of job and establish starting and completion date for each phase of tank
cleaning activity

10 Applicable engineering drawing, tank site plot plan, p & ID electrical utilities should be

kept available during planning and operation phase on site near vicinity of the tank

11 Site survey of the tank surrounding must be made to plan normal excess route for
personnel movement, equipment and to establish possible emergency escape route.

12 The permit requirement shall be defined, establishing type of permit requirement, permit
authorization, permit issuance condition, cancellation etc

13 Before start of tank cleaning activity, tank must be emptied out to the maximum extend
by using normal operational piping system followed by lower drain operational piping
system.

8.2 Gas Freeing.

1 Carry out and ensure physical isolation of tank from any other tank, shared
pipelines, electrical system unless system has to be required for tank cleaning purpose.
2 Positive isolation has to be carried out by removing / dropping pipe section from
every line to the tank, including product connection, drain, air
3 In order to reduce thermal over pressurizing of pipeline, it has to be ensured that
no liquid filled lines are left in a blocked section
4 Any electrical supply connection to tank mounted equipment must be isolated, if
applicable
 Dept. Doc # Page 6 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

5 Whether it is mechanical or natural ventilation, gas freeing operation is a

potential health and fire hazard. It should be carried only when no activity is
being carried out in nearby surrounding. Vapour being heavier will tend to settle
at the bottom, so all the energy and spark sources nearby must be identified.

6 Gas freeing to be carried out in such a way that the vapours are released from
top of the tank (higher elevation).

Note:
 Vapour and gas freeing activity is one of mot hazardous activity. All personnel
involved must be aware of potential hazard (toxic, fire, explosion, physical hazard
etc) associated with this activity, its control measure and how to minimize hazard
etc
 Whenever presence of pyrophoric deposit is suspected, lower part of the tank
must be emptied very slowly during the decommissioning. During entire gas
freeing activity, water flooding/water spraying of the bottom sediment has to be
carried out in order to reduce risk of static spark build-up.
 Ensure not hot work at surrounding area while gas freeing activity is going on.
 Vehicle and other source of ignition is not allowed to enter nearby tank under gas
freeing.

8.3 Tank Cleaning Operation

In order to reduce the risk in the tank cleaning, it has to be ensured that product, residue, sludge
has to be removed as much as possible before start of tank cleaning activity

 Ensure that both top manholes and side manholes are kept open.
 In case of an electrical storm or high wind, the PTW for cleaning must be withdrawn
 The tank must be monitored for the presence of toxic or flammable gases periodically- 4
Hr.
 Dept. Doc # Page 7 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

 Adequate lighting if provided inside the tank must be approved for flammable
atmosphere.
 If the temperature inside the tank increases or if additional ventilation is required,
 In case respiratory protection is required while cleaning it must be provided.
 MSDS of the product concerned must be made available at all time both near tank side
and CCR.
 In case of caustic cleaning shift officer to ensure that if a gear pump is being used , hot
work permit to be raised (if the motor is not flame proof) with proper approved JSA and
joint site visit by HOD’s.Workers should wear proper PPE during jetting as per PPE
matrix. Eyes wash to be kept at site. Ensure that the tank has been marked with
signboards mentioning “Keep distance tank under caustic cleaning”.
 In case of jetting has to be carried out from inside especially in case of bigger tanks two
manhole watchers to be kept standby.
 Shift officer and fire man to be stand by near the tank at all time.
 In case the work is suspended, the manholes to be covered by no entry
plate.
 After the cleaning operation is complete, the slope water to be removed in the
slope tank decided. Discharge line of the tank to be pigged. (refer PIG a line work
instruction).
 Incase of requirement of liquid, sludge, solid waste removal, it can be removed by one or
a combination of the following methods:
 Manually
 Using vacuum equipment
 Pumping
 Using mechanical squeegees

 Activities involved in cleaning of the tank:

 Dept. Doc # Page 8 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

I) Desludging
II) Cleaning
III) Mopping
IV) Inspection

 After desludging of tank, remove the tank residue from inside and collect it in drums..
 Gauge the slope tank after the cleaning operation has been completed.
 Inspection of the tank has to be carried out by the respective surveyor and tank fitness
certificate has to be collected. Whether its a visual inspection or wall wash test,
inspection has to be carried out with all the necessary precautions for entering the
confined space. Refer Confined space work Procedure.
8.4.Special Precaution:
 Physically remove a suction of pipe work or remove valves so that the pipeline into the
tank cannot be used to transfer gas or liquid into the tank.
Or if this is not possible
 Fit a spade in the line to physically block the pipeline so it is not possible to transfer gas
or liquid into the tank. The spade must be capable of withstanding the maximum possible
pressure in the pipeline. These need to be clearly identified as solid blank/spades
without any confusion to them being assumed to be or mistaken as spectacle plates.
Or if this is not possible (this is considered the least safe option and must only be used if
all other options have been explored and discounted)
o Fit a blanking flange or cap to all points where gas or product can be put into the
pipelines, these need to be locked and tagged in place. ;and
o Close and lock all valves on the line system connected to the tank and prevent
connection of supply hoses (by padlock through flange bolt hole, locking blanking pieces
into service line connections, or prevention by some other secure means).
If none of these are possible, entry into tank (i.e. confined space) not permitted.
 Entry is not allowed unless all other options have been reviewed and ruled out.
 Field operators to maintain good housekeeping at tank farm and jetty and no jump and
run while carries out the task to prevent trip and fall.
 Dept. Doc # Page 9 of 09
Operations PRO-03-12

CRL TERMINALS , KANDLA

Owner Date Revision
Gas freeing & Tank Cleaning Manager Operations 30/08/2016 2

 Any waste generation from pigging, containment sump, and hoses cleaning shall be
properly contained and subsequently transferred to slops tank for disposal to SEPPL.
 Ensure that all leakage’s / spillage's are absorbed and cleaned to eliminate slipping and
fire hazard. All waste is within the containment are transferred to the slops tank for
disposal to SEPPL. Oily absorbed rags to be disposed into closed disposal bins and
disposed to SEPPL.

 Ensure that proper, correct and well-maintained tools are used. All contaminated tools
and equipment should be properly cleaned after use and kept in a proper tool box.
 No entry into tanks or confined spaces is allowed, unless the tank or confined spaces
has been gas freed and a tank entry permit (confined space permit) is issued.
 Operations to be stopped in case of any weather issues or lightning.
 All Operators involved with this procedure shall be familiar with the Product MSDS sheet
and be in possession of the necessary PPE, which must be worn during loading
operation.
 Even where tank is gas freed and well ventilated, ensure that safety observer is available
at the entrance access point when any one is working inside tank. The safety observer
will raise the alarm but not take active part in rescue operations.
 Ensure breathing apparatus and other rescue equipment has to be located upwind of the
tank.
 Monitor the air temp from inside of the tank. Provide additional ventilation or stop the
work increase tank temp increase to 40 deg c or more.
 Cleaning operation during dark hours must be avoided or minimize.
 First aid facilities has to be provided near the safety observer for easy access as
required.
 Steam cleaning tanks produces a charged mist and for tanks which might contain a
flammable atmosphere it is not acceptable (unless the tank size is below 100 m3).
 During tank cleaning, any potentially pyrophoric scale should be kept wet