INCIDENT OF HSD IV SAMPLE FAILURE IN TW RAKE LOADED FROM

OUR INSTALLATION
INCIDENCE

A rake of 4 BS III HSD and 46 BS IV HSD was loaded ex Our Installation on 11.01.2014 was
received at receiving locn 12.01.2014 at 0710 hrs. They started unloading of BS IV HSD wagons
into tank no. 101 on the basis of Lab report. Since it was a BS IV rake, as per practice, they
started unloading the rake, checked in random the samples of some tank wagons for Sulphur.
During the testing it was observed that some of the wagons were not passing the sulphur test.
They stopped unloading of TWs. By this time they had received 1137 KL of product in to their
tank 101, which was having a stock of 1210 KL. Only 20 out of the 46 TWs of BS IV HSD met the
requirement and the remaining tank wagons were having sulphur beyond the range of 50 ppm.

The stock in tank 101, after unloading part of the TW stock was found to be failing in lab test for
sulphur. The remaining stock of 755 KL BS IV in the 20 TWs which was passing in the lab test
was unloaded in to BS IV Tank number 719.The rake was detained for joint investigation.

Sample in one TW of BS III was checked and was found to be having a sulphur of 266 ppm
whereas the loading BS III tank at had reported a sulphur of 320 ppm.

LOADING LOCATION

1) Loading location have got separate receipt and issue lines to the tank and from the
tank. The pipelines for BSIII and 24” for BSIV coming separately from the individual
tanks are connected at the manifold at a 28” line and then enter to the TLFG/TWD pump
house area.
2) There are four bifurcations taken from the 28” dia. line to the four HSD pumps at TWD
pump house.
3) Inlet pipeline to the pump is of 14” dia. and outlet line from the pump is of 12” dia.
4) Dia of the HSD delivery line to the TW Gantry & Header in the TW Gantry are of 20” dia.
5) The capacity of the four pumps is of 513 KL/hour each.
6) The pipeline content quantity from Exchange pit to the last point in the TW gantry is to
the tune of 294 KL.
7) Flow meters are used to fill the tank wagons.
8) The pipeline from TW pump house to the siding is always kept in BS III HSD.
9) BS III and BS IV HSD from the manifold come into the pump house of TLFG and TWD
through a single pipeline of 28” Size.
 10) Since the loading to TLFG and TWD is through the same manifold line, they can only do
one at a time. Normally BS IV TWs are loaded the night after completing the loading of
the tank Lorries Else location has to stop BS III T/L loading during the BS IV TW loading.
11) Installation carries out TW loading & T/L Loading of BSIII simultaneously from the
common header line. The suction line to the TW pumps & Suction line to the T/L loading
pumps start from the same header. The TW pumps are provided with Bypass line
12) Installation has on occasions observed cavitations in the TWD loading line at the time of
commencing TW Loading.

BS IV HSD LOADING OPERATION FOLLOWED

1) Rake of 50 TWs is loaded with 4 BS III and 46 BS IV HSD as per the following loading
pattern

Batch 1. TW nos. 1 to 4 = Line content of BS III HSD is taken in to 4 TWs

by pumping HSD IV into the line.
Batch 2 TW nos. 9 to 29 = 21 TWs are loaded as Batch II i.e. BS IV HSD TWs
Batch 3 TW nos. 30 to 50 = 21 TWs are loaded as Batch III i.e. BS IV HSD TWs
Batch 4 TW nos. 5 to 8 = Left for loading in the last line pushing by BS III HSD to
Convert the pipeline back on BS III HSD – Batch IV loading.

2) Based on the sulfur content of the TWs (As per Lab report), it is calculated that
a) 4 TWs filled first with the BS III HSD (TWs 1 to 4) to displace the BS III stock in the
line was mixed up with 21 % of BS IV HSD
b) 20 TWs filled next with BS IV HSD (TWs 9 to 28) was mixed up with 3.6% of BS III.
c) 20 TWS filled next with BS IV (TWs 29 to 48) was found to be meeting the BS IV
requirements
d) 4 TWs filled next with the BS IV HSD (TWs 5 to 9) to displace the BS IV stock in the
line was mixed up with 11% of BS III HSD