BS-402 - Part 2

DESIGN, CONSTRUCTION AND OPERATION
OF PETROLEUM DISTRIBUTION INSTALLATIONS
Model Code of Safe Practice in the Petroleum Industry

Part 2
Licenced to: Miss Ljson Mecoli. Single user licence only.

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Licenced to: Miss Lison Mecoli. Single user licence only.

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L.
DESIGN, CONSTRUCTION AND OPERATION
OF PETROLEUM DISTRIBUTION INSTALLATIONS
Model Code of Safe Practice in the Petroleum Industry

Part 2
September 2005
d
3
edition
Published by
ENERGY INSTITUTE, LONDON
The Energy Institute is a professional membership body incorporated by Royal Charter 2003
Registered charity number 1097899

IMPORTANT: This file is subiect to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions, It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44 (0)207 467 7100
The Energy Institute gratefully acknowledges the financial contributions towards the scientific and
technical programme from the following companies:
BG Group Kerr-McGee North Sea (UK) Ltd

BHP Billiton Limited Kuwait Petroleum International Ltd
BP Exploration Operating Co Ltd Murco Petroleum Ltd
BP Oil UK Ltd Shell UK Oil Products Limited
Chevron Shell U.K. Exploration and Production Ltd
ConocoPhillips Ltd Statoil (U.K.) Limited
Nexen Talisman Energy (UK) Ltd
EN! Total E&P UK plc
ExxonMobil International Ltd Total UK Limited
Copyright © 2005 by the Energy Institute, London:

The Energy Institute is a professional membership body incorporated by Royal Charter 2003.
Registered charity number 1097899, England
All rights reserved
No part of this book may be reproduced by any means, or transmitted or translated into a machine language without
the written permission of the publisher.
The information contained in this publication is provided as guidance only and while every reasonable care has been
taken to ensure the accuracy of its contents, the Energy Institute cannot accept any responsibility for any action taken,
or not taken, on the basis of this information. The Energy Institute shall not be liable to any person for any loss or
damage which may arise from the use of any of the information contained in any of its publications.
The above disclaimer is not intended to restrict or exclude liability for death or personal injury caused by own
negligence.
ISBN 0 85293 383 5

Published by the Energy Institute
Further copies can be obtained from Portland Customer Services, Commerce Way,
Whitehall Industrial Estate, Colchester CO2 8HP, UK. Tel: +44 (0) 1206 796 351
email: sales@portland-services.com

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CONTENTS
Page
Foreword ix
Acknowledgements x
Scope
1.1 Object
1.2 Inclusions
1.3 Exclusions 1
2 Planning of installations 3
2.1 General 3
2.2 Boundaries and security 4
2.3 Tankage layout and safety distances 4
2.4 Tank compounds and compound walls 5
2.5 Loading and unloading facilities 6
2.6 Roadways, parking areas and access 6
2.7 Buildings 7
2.8 Storage of packed products in the open 7
2.9 Drainage 8
3 Design and construction of plant, equipment and buildings 9

3.1 General 9
3.2 Electrical 9
3.3 Tanks 10
3.4 Piping, valves and fittings 15
3.5 Pumps 18
3.6 Compressors 19
3.7 Bulk road and rail loading and unloading facilities 19
3.8 Marine loading and unloading facilities 26
3.9 Vapour recovery and emission control 28
3.10 Additive injection 31
3.11 Blending 32
3.12 Package filling and package storage buildings 32
3.13 Package storage areas outside buildings 33
3.14 Drainage 33
3.15 Safety and directional signage 34

Contents Cont... Page
3.16 Final project documentation 34

3.17 Electrical and mechanical equipment and protective systems intended for use in
potentially explosive atmospheres 34
3.18 Safety-related control systems 35
4 Operations 37
r
4.1 General 37
4.2 Loading and unloading of road tank tankers 38
4.3 Loading and unloading of rail cars 39
4.4 Transferring petroleum products to and from ships 41
4.5 Storage tank operation 42
4.6 Vapour collection and recovery systems 44
4.7 Pumps 44
4.8 Pipelines 45
4.9 Packages 46
4.10 General facilities 48
4.11 Emergency procedures 49
5 Fire protection 51
5.1 General 51
6 Maintenance and modifications 53

6.1 General 53
6.2 Safety of work on site 54
6.3 Repairs, alterations, tests 55
6.4 Personnel 57
6.5 Equipment 57
7 Tank cleaning 59
7.1 General 59
7.2 Personnel 59
7.3 Planning 59
7.4 Equipment 59
8 Closure, decommissioning and demolition

8.1 General
61
61
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8.2 Closure 61
8.3 Decommissioning 61 fl
8.4 Demolition 62
9 Health, welfare and protection of personnel 65

9.1 General responsibilities 65
9.2 Specific responsibilities 66
9.3 Guidance 68
9.4 Visitors to site 68
10 Training and competence 69

10.1 Training requirements 69
10.2 Training subjects 69
10.3 Training records 70
vi

Contents Cont... Page
Annex A- Glossary of terms 71

Annex B Recommended minimum separation distances for installations handling Class I, 11(2) and
-
111(2) petroleum 75
Annex C Recommended list of records to be maintained at distribution installations
- 79
Annex D Classes and characteristics of petroleum products
- 81
Annex E Personal protective equipment requirements
- 83
Annex F Publications
- 87
vii

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FOREWORD
This publication is Part 2 of the IP Model Code of Safe Practice in the Petroleum Industry. It replaces the second
edition published in 1998. Its purpose is to provide a general guide to safe practice in the layout, design, construction
and operation of distribution installations and their equipment.
The Code provides recommendations for safe practice rather than a set of rigid rules. It is stressed that design and
construction of plant and equipment should be carried out by experienced people and that, in making provisions for
safety, due consideration should be given to the effect of any unusual circumstances, on which it is impossible to
generalise. It is not intended that the requirements of the Code should be applied rigidly to existing premises, where
for a variety of reasons it may not be practicable to comply with them.
Attention is drawn to the fact that in many countries there exist statutory requirements, both local and national,
pertaining to the petroleum industry, and this Code should be regarded as being complementary to such
requirements.
The information contained in this publication is provided for information only and while every reasonable care has
been taken to ensure the accuracy of its contents, the El cannot accept any responsibility for any action taken, or not
taken, on the basis of this information. The El shall not be liable to any person for any loss or damage which may
arise from the use of the information contained in any of its publications.
The above disclaimer is not intended to restrict or exclude liability for death or personal injury caused by own
negligence.
Suggested revisions are invited and should be submitted to the Technical Department, Energy Institute, 61 New
Cavendish Street, LONDON, WIG 7AR.
ix

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ACKNOWLEDGEMENTS
This edition of this publication was prepared by Mr Douglas Burns (Trident Engineering Consultants’) on behalf
ofthe El Distribution and Marketing Committee. It was subsequently reviewed by representatives of the following:
BP Oil UK
ChevronTexaco
ConocoPhiltips Ltd
Esso Petroleum Company Ltd
Federation of Petroleum Suppliers
Shell U.K. Oil Products Ltd
Total UK
Tank Storage Association
UKPIA
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‘Gatehouse Offices, Babcock Park, Porterfield Road, Renfrew PA4 8DJ, Scotland. Tel: +44 (0)14 1 561 2202,
Fax: +44 (0)14 1 561 2259, www.trident-engineering-consultants.co.uk

1
SCOPE
1.1 OBJECT Executive’s publications HS(G)51 The storage of

flammable liquids in containers, HS(G) 176 The storage
The object ofthis Code is to recommend basic standards offlammable liquids in tanks and HS(G)I 86 The bulk
and practice for the design, construction, operation, transfer of dangerous liquids and gases between ship
maintenance and decommissioning of facilities at and shore, or their local equivalent in other countries.
petroleum distribution installations.
It is not intended to preclude the use of alternative
designs, materials and methods where these provide 1.3 EXCLUSIONS
equivalent standards of safe operation.
This Code does not cover retail sites, facilities for the
storage of liquefied petroleum gas (LPG) and bitumen,
1.2 INCLUSIONS systems for the piped distribution and associated storage
of heating oil and certain aspects of fidel storage at
This Code covers the receipt, storage and handling of airports. These are covered by other IP publications (see
petroleum products at all locations and should be read Annex F).
in conjunction with the UK Health and Safety

DESIGN, CONSTRUCTION AND OPERATION OF PETROLEUM DISTRIBUTION INSTALLATIONS
Licenced to; Miss Lison Mecoli. Single user licence only.

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2
PLANNING OF INSTALLATIONS
2.1 GENERAL Installations which handle only Class 11(1) or Class

111(1) petroleum may present less risk, but in these cases
2.1.1 Legislative requirements safety distances from boundaries for storage and
handling facilities should have regard for the location
Statutory requirements, both national and local, and surroundings of the installation. Reference should
including any petroleum licensing conditions, planning, be made to Annex D (classes and characteristics of
building regulations and local bye-laws should be petroleum products).
considered. Early discussions should be held with all
authorities, including the fire officer, who are 2.1.3 Hazardous area classification
responsible for these and any other requirements.
Formal approvals should be obtained on conclusion of The storage, transferring, loading and unloading of
such discussions before starting construction. petroleum products, particularly those of Class I, create
Within the European Union, compliance with hazardous areas where a flammable atmosphere may be
national legislation implementing EC Council Directive present or may arise. The planning, layout and design of
96/82/EC and Directive 20031105!EC Control ofmajor the installation and equipment should take account of
accident hazards involving dangerous substances (so this, particularly in the selection ofelectrical equipment.
called SEVESO It Directive) is mandatory dependent
on the nature and quantity of dangerous substances 2.1.4 Prevention of leakage and containment
stored on site.
Leakage of product should be prevented, or otherwise
2.1.2 Layout and design safely contained, in order to avoid the creation of
hazardous situations or damage to third party property,
The recommendations given in this Code are intended drainage systems, waterways, local groundwater and
for guidance on sites in the low-to-medium risk water sources.
category, capable of straightforward development such Consideration should be given to providing
as a site on reasonably level ground in an urban, but not secondary containment systems for handling fire-
heavily built-up area. Sites in high risk areas may fighting water. In the United Kingdom reference should
require more stringent conditions. be made to Environment Agency Publication PPGI8
The layout and general design should take account Control of spillages and fire fighting run-off and to
of relevant IP publications with respect to health, safety, Guidance Note, EH7O: The control offirewater run-off
operational efficiency and environmental from CJMAH sites to prevent environmental damage,
considerations. published by the Health and Safety Executive.

2.1.5 Risk assessment tanks should take account of how emergency incidents
would be handled.
During the planning phase of the installation a risk Even where tanks containing volatile products are
assessment should be carried out to ascertain the likely fitted with external or internal floating roofs, it is not
risks to the health and safety of employees and anyone possible to prevent the escape of some petroleum
who may be affected by the work activity. Reference vapour during refilling.
should be made to HSE publications HS(G)176,
HS(G) 186 and INDG 163 Five steps to risk assessment. 2.3.1.2 In respect of Class I product stored in fixed
roof tanks, consideration should be given to the
installation of internal floating roofs or to linking the
2.2 BOUNDARIES AND SECURITY tanks to a vapour recovery system in order to minimise
the emission ofvapour to atmosphere, to reduce product
2.2.1 Boundary security losses, and to conform to any statutory controls.
Installations should be surrounded by a suitable security 2.3.1.3 Tanks should be placed so that any vapour
fence or wall of a minimum height of 2 m. The form of emissions will have diffused in the atmosphere to a
construction may be chain link fencing, weld mesh, concentration below the lower flammable limit before
steel paling, brick, mass concrete or post and slab reaching a non-hazardous area. IP Model Code of Safe
concrete construction. It will often be found that more Practice Part 15 Area class(fIcation code for
than one type of enclosure can usefully be employed at installations handling flammable fluids, (IP 15) gives
the same installation, such as chain link or other open guidance on determining the extent of hazardous areas.
style fencing for tank compounds, and brick or concrete
walling for busy operational areas, particularly where 2.3.2 Method of determining minimum
these adjoin a public thoroughfare. separation distances
Where installations are situated within a fenced or
controlled area, such as dock or harbour premises, the Recommended minimum separation distances are given
requirements for fencing may be relaxed by agreement in Annex B and refer to the horizontal distances in plan
with the local controlling authority. However, between the nearest points of the specified features, e.g.
consideration may also need to be given to the storage tanks, filling points, openings in buildings,
requirements of the TMO/ILO Code of practice on boundaries etc.
security in ports MESS HP/2003114. Special consideration should be given to sites on
sloping ground.
2.2.2 Additional security measures
2.3.3 Installations for Classes I, 11(2) and 111(2)
In conjunction with any applicable legislation or petroleum
associated guidance, a risk assessment should be carried
out to determine what further level of security is 2.3.3.1 A group of small tanks of diameter 10 m or
required. This might include closed-circuit television less and height of 14 m or less may be regarded as one
(CCTV) incorporating a recording/playback feature, an tank. Such small tanks may be placed together in
automatic alarm system on unmanned sites and remote groups, no group having an aggregate capacity of more
site surveillance by means of telecommunications to a than 8 000 m. The distances between individual tanks
3
main control room or independent security company. in the group need be governed only by constructional
and operating convenience.
The distances given in Annex B are the normal
2.3 TANKAGE LAYOUT AND minimum recommended for Class I petroleum stored in
SAFETY DISTANCES conventional above-ground fixed roof tanks, including
single small tanks, and external floating roof tanks.
2.3.1 General The distances shown in the tables should be used in
conjunction with the appropriate level of fire protection
2.3.].] Storage tanks should be laid out in such a way as recommended in IP Model Code of Safe Practice,
as to minimise the impact of their operation on Part 19 Fire precautions at petroleum refineries and
neighbouring properties and to enable effective bulk storage installations. They may be varied provided
containment of fire or spilt product. The disposition of the level of fire protection is adjusted accordingly.

2.33.2 For the purpose of spacing, fixed roof tanks 2.4.1 Compound walls - product containment
fitted with internal floating roofs should be regarded as
fixed roof tanks. Any compound for petroleum products should be
arranged to take into account 2.4.1.1 2.4.1.6. -
2.3.3.3 The location and spacing of buried, semi-

buried or mounded tanks need be governed by 2.4.1.1 The compound should be capable of holding
constructional and operational convenience only, 110% of the capacity of the largest tank standing in the
provided a risk assessment can justify the proposal. compound. Historically a reduction to 75 % of the
Special consideration should be given to the location of capacity was considered adequate in exceptional
vents. circumstances where there was minimal risk of
pollution or hazard to the public.
2.3.4 Installations for Class 11(1) petroleum
2.4.1.2 The total capacity oftanks in a bund should not
Installations intended for the storage and handling of exceed 60 000 m3 (120 000 m 3 for floating-roof tanks).
only Class 11(1) and Class 111(1) petroleum present a Early discussions with the appropriate local safety and
lower level of risk than those handling Class I, Class environmental regulatory agencies may further
11(2) arid Class 111(2). However, safe separation influence compound capacity calculations. Reference
distances of storage and handling facilities from should be made to HSE Guidance Note EH7O and
boundaries should still be observed. Environment Agency publication PPG 18.
It is unnecessary to space tanks for the storage of
Class 11(1) petroleum at distances greater than required 2.4.1.3 Allowance should be made for the safe
for constructional and operating convenience. It is disposal of storm water and predicted volumes of fire-
recommended however, that tanks for storage of Class fighting water and foam.
11(1) petroleum should be spaced from tanks for storage
of Class I petroleum at distances recommended in 2.4.1.4 If the site topography permits, spillage or
Annex B, and at a distance of not less than 10 m from major leaks from an’ tank may be directed quickly and
the boundary of the installation. Consideration should safely by gravity drainage and diversion walls, if
be given at the planning stage to the possibility of Class required, to a depression or impounding basin located at
11(1) petroleum tanks being required in the future for a convenient point within the boundary of the
storage of Class I petroleum. Where such a possibility installation. Consideration should be given to the
exists it is recommended that Class 11(1) petroleum prevention of fire spreading to the impounding basin.
storage should be planned to Class I petroleum
recommendations. 2.4.1.5 Tank compounds should be made impervious
to safeguard groundwater resources against pollution
2.3.5 Installation for Class 111(1) petroleum and from spillage or leakage. Guidance is given in CIRIA
unclassified liquids Report No. 164 Design of containment systems for the
prevention ofwater pollution from industrial incidents.
The spacing of tanks for Class 111(1) petroleum needs to
be governed by constructional and operational 2.4.1.6 Bund overtopping events are extremely rare.
convenience only. Each site should assess the level of risk associated with
such an event and determine what practical measures
2.3.6 Storage of non-hydrocarbons can be provided to reduce the risk to a tolerable level.
The most practicable way ofavoiding bund overtopping
Non-hydrocarbon products may be stored in the same events is to ensure good compliance with the original
compound as petroleum products providing a risk construction standard, implementation of planned
assessment reveals no likelihood of increased risk to inspection and maintenance by competent personnel and
health, safety or the environment. by ensuring any tank modifications following
construction are implemented in accordance with an
established standard.
2.4 TANK COMPOUNDS AND
COMPOUND WALLS 2.4.2 Compound walls fire protection
-
When planning new tank compounds and compound Where compound walls are also required for fire
walls the provisions in 2.4.1 and 2.4.2 should be made. protection, 2.4.2.1 to 2.4.2.3 should be taken into
account.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London. UK. All rights reserved. It may only be used in accordance with
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2.4.2.1 The height of walls or any purposely-raised protection and operational efficiency. Consultation
sections, as measured from the outside ground level, should be made at an early stage with the Port Authority
should be sufficient to afford protection for personnel and adjacent landowners. Reference should be made to
when engaged in fire-fighting, but it is recommended the HSE publication HS(G) 186, or its local equivalent
that they should not exceed a height which would in other countries.
interfere with fire-fighting. They should be located so The proximity of risks from outside sources should
that a reasonably close approach can be made to a tank be taken into account; for example ship berths should be
fire and adequate means of escape should be provided properly spaced in relation to one another, neighbouring
over the walls. jetties or wharves and the navigable channel.
Adequate space and depth of water should be
2.4.2.2 Intermediate walls of up to half the height of provided for manoeuvring vessels and for tugs where
the main walls, but normally not more than 0,5 m in these are necessary. This may entail initial and
height, may be provided to act as fire breaks by subsequent dredging and may well influence the siting
controlling spillages and to divide the tankage into of the jetty or wharf face.
groups of a convenient size.
2.4.2.3 Where the provision is for spillage or leakage 2.6 ROADWAYS, PARKING AREAS
to be directed to a depression or impounding basin, and AND ACCESS
a continuous wall is not provided, sections of wall at
specific locations may be necessary to form screens for 2.6.1 Layout
the protection of fire fighters.
2.6.1.1 In the planning of an installation, the provision
of roads should be dictated by operational requirements
2.5 LOADING AND UNLOADING and ease of access for fire-fighting purposes. In large
FACILITIES installations it is normally necessary to provide a
subsidiary road around the perimeter; this road may be
2.5.1 Road sited within the safety distance specified for the spacing
of tanks from the boundary.
Road loading and unloading facilities for Class I or 11(2)
petroleum should be located at least 15 m from any 2.6.1.2 Main roads should be suitably surfaced and
outer boundary of the installation, any designated non- drained. Those carrying traffic in two directions should
hazardous area, or any fixed source of ignition. not be less than 6 m wide and those carrying single line
Guidance on the extent of hazardous areas is given in traffic should not be less than 4 m wide. Subsidiary
IP 15. roads may be of single track width adequately surfaced
and with passing bays at suitable intervals.
2.5.2 Rail
2.6.1.3 Road junctions and curves should be
Rail sidings should be provided with an emergency constructed with sufficiently large radii to cater for
access route for fire-fighting purposes in addition to an emergency vehicles, and to ensure easy vehicle
access for normal operations. Where the sidings pass manoeuvring; it may be necessary to provide turning
through the security fence, lockable gates should be areas.
provided.
Facilities at which Class I or 11(2) petroleum 2.6.1.4 Where possible, provision should be made for
railcars are loaded or unloaded should be located at least alternative emergency access to the site; this should
15 m from any outer boundary of the installation, any normally remain locked, but with keys available to the
designated non-hazardous area, or any fixed source of emergency services.
ignition. Guidance on the extent of hazardous areas is
given in IP 15. 2.6.2 Vehicular access
2.5.3 Jetties and wharves Access areas should normally be large enough to allow
road tankers to drive on to and off loading areas in
The facilities for handling ships and barges will be safety and with the minimum of manoeuvring. A one-
determined by topographical conditions, but should be way traffic flow system should be considered.
planned with regard to health, safety, environmental At installations with few vehicle movements it may

IMPORTANT: This file is subject to s licence agreement issued by the Energy Institute, London, UK. All rights reserved. It msy only be used in accordance with
be acceptable to enter and leave loading gantries from operational buildings and any buildings in which hot
one end only; in this instance the layout should not work is carried out or which contain any source of
require laden tankers to manoeuvre or reverse, and there ignition.
should be sufficient space for vehicles to turn round In the case of a building where Class 11(1)
within the yard (see section 3.7.3.1). petroleum is handled or stored, the distance from the
boundary to openings in the side walls can be reduced
2.6.3 Parking to 6 m. No restriction need be placed on siting of an
operational building in which only Class 111(1)
2.6.3.1 Parking on access roads and in loading areas petroleum or unclassified liquids are handled or stored.
should be prohibited. Where possible, vehicle parking
areas should be located so that in the event of an 2.7.3 Service buildings
emergency, vehicles may be driven out of the
installation without obstruction and with minimum Service buildings which may constitute a fire risk due to
diversions. the nature of the work carried out or equipment used in
them should be situated in non-hazardous areas.
2.6.3.2 A dedicated parking area should be provided
for road tankers; for tankers that are loaded with 2.7.4 Boiler house, power plant and fire pump
petroleum spirit or have recently carried it, there should houses
be a specially marked area at least 3 m from any
boundary. Boiler houses, power plant and fire pump houses should
be located in non-hazardous areas, and where the
2.6.3.3 Parking for private cars should be remote from equipment can continue to be safely operated in the
operational areas; preferably it should be located outside event of fire or spillage elsewhere in the installation.
the main security fence of the installation.
2.7.5 Road tanker workshops
2.6.4 Pedestrian access
Road tanker workshops should preferably be located
A separate, safe and well-lit access with security outside the main security fence of the installation; in
protection should be provided for authorised pedestrians any case they should be located in a non-hazardous
and consideration should be given to the provision of area.
pedestrian crossings. There should be adequate vehicle standing and
access areas, and consideration should be given to the
turning circles of the largest vehicles likely to use the
2.7 BUILDINGS workshop, especially when reversing out. Reference
should be made to IP Road tanker workshop code when
2.7.1 Administrative buildings planning new workshops and extensions.
Consideration should be given to access for vehicle
Administrative buildings (including the control room) maintenance contractors’ vehicles, such as parts
should be located in a non-hazardous area preferably delivery vans.
near the main gates. Visitors should have access to the
administrative building without having to enter the
operational area. 2.8 STORAGE OF PACKED PRODUCTS
IN THE OPEN
2.7.2 Operational buildings
2.8.1 Layout
Any operational building in which Class I or 11(2)
product is handled or stored should not be less than Recommended minimum separation distances are given
15 m from the boundary; the construction of any wall in Annex B. Further guidance is available in HSE
without openings located on the boundary may justify publication HS(G)5 1.
a reduction in this distance to not less than 10 m.
Where the wall of the operational building closest 2.8.2 Storage
to the boundary has no openings and there are no
openings in the side walls of the building within 10 m of Consideration should be given in planning and
the boundary, these distances may be disregarded. constructing package storage areas (whether outside or
Similar distances should be observed between these within buildings) to the safe height to which packages

of various sizes can be stacked, the method of stacking petroleum distribution installations.
(whether with or without pallets or racking) and to any Where product can mix with rainwater in
type of mechanical handling equipment to be used. If containment areas, sumps with valved outlets should be
forklift trucks are used, the area should be sufficient to provided to enable controlled run-off through the site
allow adequate aisle width for safe manoeuvring. oil/water separators.
Road, rail and drum filling areas should be paved
2.8.3 Spillage containment with concrete or other material impervious to product,
so that all surface water can be directed to the main site
Stacks containing packed petroleum products should be oil/water separators.
placed in one or several bunded compounds if the total Discharges requiring special treatment (e.g. run-off
volume of packed products exceeds 200 000 litres, to from wash bays and other areas where detergent is used)
ensure containment in the event of leaking packages or should either be passed to an on-site treatment plant
fire. designed for the specific duty or to a foul water sewer
For stacks between 5 000 and 200 000 litres, small for treatment elsewhere.
walls within compounds are recommended to prevent
operational spillages or fire from spreading. 2.9.3 Areas where surface water cannot be
contaminated with oil
2.8.4 Containment volume
In these areas drainage should be provided for
Compounds for stacked petroleum products should be rainwater, domestic waste water and sewage without
capable of retaining 30 % of the volume of the stored special precautions. Every advantage should be taken of
packed products. The capacity of a compound should be natural seepage for disposal of uncontaminated surface
calculated by its geometrical dimension, disregarding water. Existing drains, sewers and watercourses may be
the space taken up by the packed products stacked in the used in agreement with the regulatory authority.
compound.
2.9.4 Oil/water separators (including
interceptors)
2.9 DRAINAGE
Oil/water separators should be sited in accordance with
2.9.1 General the general guidance in IP 15, away from boundaries
and, where possible. away from other hazardous areas
Drainage should be planned in accordance with national and with easy access for inspection, cleaning and
practice and with the approval of the authorities maintenance. The separator should be designed to give
concerned. an oil separation performance adequate to ensure that
Guidance on minimising pollution of site effluents the quality of effluent water discharged from the site
is given in IP Environmental guidelines for petroleum meets the consent levels imposed by regulatory
distribution installations. authorities.
All areas in the installation should be classified as
follows: 2.9.5 Fire water
Areas where surface water may be contaminated Allowances should be made in the design of drainage
with oil, e.g. within the tank compound or a filling and separator systems to accommodate increased flows
area. during fire-fighting operations. Most fire-fighting foams
— Areas where surface water cannot normally be inhibit gravity separation ofoil. Consideration should be
contaminated with oil, e.g. offices, roofs and car given to providing holding capability to permit
parks. subsequent disposal other than to surface waters.
2.9.2 Areas where surface water may be 2.9.6 Foul sewage

contaminated with oil
Where local foul sewerage exists adjacent to the
For areas where surface water may be contaminated installation, foul sewer outlets should be connected to
with oil, e.g. tank bunds, loading areas and pump rafts, them. Where this is impracticable, septic tanks or other
methods should be considered for controlling and suitable foul sewage disposal means should be
recovering both planned and unplanned releases of provided.
product as described in IP Environmental guidelinesfor

3
DESIGN AND CONSTRUCTION OF

PLANT, EQUIPMENT AND BUILDINGS
[Note: CEN/TR 15120 (Tanks for the transport of dangerous goods Guidance and recommendations for loading,
-
transport and unloading) provides additional recommendations concerning the design and operation of a loading
gantry to meet the requirements of the VOC Directive.]
3.1 GENERAL influence the project’s management. It is recommended

that the fire officer, safety and environment agencies be
The planning, design and construction of an installation involved in all studies.
should be entrusted to appropriately qualified and
experienced engineers. The design process should be
carried out in a methodical way, starting with a design 3.2 ELECTRICAL
brief which identifies the operational objectives and
ending with the provision of as-built documentation. 3.2.1 General
The design brief should be sufficiently detailed to
enable the level of automation and in-built safety Electrical apparatus, electrical installations, electrical
systems to be determined. earthing and bonding, cathodic protection, tele
A plan should be produced early in the project to communications and instrumentation should comply
identify the flow, review and approval steps which each with the recommendations of IP Model Code of Safe
generic type of project document will undergo, Practice Part 1 Electrical safely code, B SEN 60079 and
including production of as-built drawings and retention BS 7671 (the Institute of Electrical Engineers’ (lEE)
of records. Regulations (latest edition)) and, in the UK, the
A Hazard and Operability study (HAZOP) of the Electricity at Work Regulations 1989 (SI 635).
installation should be considered during the design stage
to ensure that all operational conditions, both normal 3.2.2 Power distribution
and abnormal, are identified and taken into account.
Other more general safety reviews may be appropriate At the design stage and during any subsequent
to ensure that the plant can be constructed, operated, modification, it should be ensured that electric cables —
maintained and decommissioned safely. both overhead and underground are not taken across
-
An Initial Risk Assessment should be carried out any areas where they could interfere with the petroleum
during the planning phase of the project and should be storage or handling operations, either in the immediate
reviewed during the design stage and revised where or long term future.
necessary.
Consideration should be given to all statutory 3.2.3 Data transmission cables
requirements, local environmental conditions and to
gaining any necessary consents for construction and IP HM 23 Fidelity and security of measurement data
operation of the installation. Local regulations such as transmission systems. Section 1: Electric and/or
the UK’s Construction (Design and Management) electronic pulsed data cabled transmission for fluid
Regulations 1994 (CDM) and Control of Major metering systems gives advice on data cable
Accident Hazards Regulations 1999 (COMAH) may transmission for fluid metering systems.

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All ights reserved, It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk 1: +44 (0)2074677100
DESIGN, CONSTRUCTION AND OPERATION OF PETROI.,EUM DISTRIBUTION INSTALLATIONS
3.2.4 Area classification 3.3 TANKS
IP 15 gives recommendations for the classification of 3.3.1 Standards

areas in which a hazardous atmosphere, which could be
ignited by an ignition source, may be present. 3.3.1.1 Above-ground tanks should be designed,
The hazardous areas detailed include the following fabricated and erected in accordance with a recognised
Zone Classifications, which are dependent on the tank standard, e.g. BS EN 14015, API Standard 620 or
probability of a hazardous atmosphere being present, API Standard 650. Smaller shop-fabricated horizontal
i.e. an atmosphere containing a flammable gas or tanks should be designed and fabricated in accordance
vapour in a concentration that is capable of ignition: with recognised standards, e.g. BS 2594. Tanks for
operation at higher pressures than covered by these
Zone 0 That part of a hazardous area in which a standards are not considered in this Code but should be
flammable atmosphere is continuously present designed and fabricated in accordance with a recognised
or present for long periods. pressure vessel code, e.g. PD 5500, or ASME Section
Zone I That part of a hazardous area in which a VIII.
flammable atmosphere is likely to occur in
normal operation. 3.3.1.2 Attention should be given to roof loading, tank
Zone 2 That part of a hazardous area in which a stability and rate of corrosion in areas where climatic
flammable atmosphere is not likely to occur in conditions are severe.
normal operation and, if it occurs, will exist
only for a short period. 3.3.1.3 Special consideration is required if a tank is to
contain liquids at temperatures below -18 °C, and
The areas outside these zones are defined as non- reference should be made to the low temperature
hazardous. requirements of the standards referred to above.
3.2.5 Electrical equipment 3.3.1.4 The standards referred to in 3.3.1.1 cover tanks
made of carbon steel; tanks made from other materials
3.2.5.1 All electrical equipment should be certified as should be designed to an appropriate standard and in
suitable for the zone applicable to its intended location accordance with good engineering practice.
of operation. In particular, if the use of glass-reinforced plastic
(GRP) tanks above ground is proposed, reference to BS
3.2.5.2 Equipment should be maintained in accordance 4994 or an equivalent standard is essential. For GRP
with manufacturers’ recommendations to ensure tanks below ground, reference should be made to BS
continued operability and compliance with the EN 976-1 Underground tanks of glass-reinforced
hazardous area certification. Maintenance records plastics (GRP). Horizontal cylindrical tanksfor the non-
should be retained for the lifetime of equipment. pressure storage of liquidpetroleum basedfuels Part 1
Requirements and test methods for single wall tanks.
3.2.6 Circuits in hazardous areas Particular attention should be paid to ensuring correct
design and installation, recognising the possible effects
3.2.6.1 Independent of their location, isolating of chemical attack, physical damage during transport
switches controlling circuits in Zone I or Zone 2 areas and installation and the importance of regular and
should isolate all live and neutral conductors to ensure adequate examination.
complete isolation before electrical equipment in Operating procedures should take account of the
hazardous areas is opened. likelihood of the generation of static electricity, and its
safe dissipation.
3.2.6.2 All isolating switches should be lockable in the If the use of a second-hand tank is proposed, or the
open position. change of use of an existing GRP tank, the new user
should be aware of the purpose for which the tank was
3.2.6.3 There should be no connection between neutral initially designed, what materials have been stored in it,
and earth conductors of a.c. circuits after isolating whether repairs have taken place (and their adequacy)
switches. and what examinations have been carried out.
10

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: a: pubs@energyinst.org.uk t: +44 (0)207 467 7100
DESIGN AND CONSTRUCTION OF PLANT, EQUIPMENT AND BUILDINGS
3.3.2 Design pressure should be fitted to minimise surface disturbance. A

maximum flow velocity of 7 m/s is recommended.
3.3.2.1 The maximum design pressure to which tanks
may be built is specified in the selected tank standard. 3.3.5 Normal venting for fixed roof tanks
The design pressure should take into account current
and possible future product densities. Where the 3.3.5.1 Tanks should be adequately vented to prevent
required design pressure exceeds those allowed within the development of pressure or vacuum exceeding the
the tank standards, a suitable pressure vessel code design limits of the tank. Venting should allow for
should be applied. changes in pressure due to filling or withdrawal of
product and due to tank breathing caused by changes in
3.3.2.2 Where there is a change in use of a tank, the atmospheric conditions.
design pressure should be checked to ensure it is
sufficient for the density and vapour pressure of the new 3.3.5.2 Vents for normal venting of atmospheric and
product. low pressure tanks should be sized in accordance with
a recognised venting guide, e.g. API Standard 2000.
3.3.2.3 Where tanks are used in conjunction with
vapour recovery units (VRUs), design standards should 3.3.5.3 Tanks for Classes I, 11(2) and 111(2) petroleum
be reviewed to ensure pressures required in the vapour should normally be fitted with internal floating roofs to
collection systems do not exceed those permitted in the comply with local environmental legislation. Where
tanks. tanks are fitted with pressure vacuum valves they
should be sized in accordance with API Standard 650 or
3.3.3 Tank fittings an equivalent standard. Tanks for Class 11(1) or Class
111(1) may be fitted with open vents.
3.3.3.1 Tanks should be provided with appropriate
fittings for filling, emptying, drawing off water and 3.3.5.4 Pressure and vacuum valves and open vents
draining, sampling, temperature monitoring, venting, should not be fitted with gauze of less than 6 mm mesh
inspection and fire-fighting. Additionally each tank to reduce the risk of clogging with dust, dirt or ice
should be fitted with a tank gauging system and which would impair the venting capacity. Additional
consideration should be given to installing an measures should be taken to avoid the possibility of
independent high level alarm which can be manually tank collapse caused by clogged mesh in a vent, e.g. the
tested. mesh may be designed to collapse, such as by using
non-corroding metal wire ofapproximately 400 microns
3.3.3.2 Tank fittings below the highest liquid level diameter.
should be liquid and vapour tight and fittings above the
highest liquid level should, in the case of Class I or 11(2) 3.3.6 Emergency venting
petroleum tanks, be vapour tight when closed.
3.3.6.1 Every above-ground tank should have some
3.3.4 Tank connections form ofemergency venting which will relieve excessive
internal pressure. For vertical fixed roof tanks
3.3.4.1 Connections to tanks should be designed in emergency venting may be provided by a weak roof-to-
accordance with the selected tank standard. Connections shell seam, which will fail preferentially to any other
to steel tank shells or bottoms should be steel seam or plate of the tank shell or bottom.
throughout. Connections to tanks other than steel should Note: emergency venting is an inherent feature of
take account ofthe guidance outlined in the appropriate floating roof tanks.
standard. Each tank connection through which liquid
can normally flow should be fitted with a cast steel 3.3.6.2 Where emergency venting is provided by
valve immediately adjacent to the shell or bottom ofthe means of pressure-relieving vents, the venting capacity
tank. of normal and emergency vents together should be
designed to be sufficient to prevent failure of the shell
3.3.4.2 Inlet pipes of tanks should terminate internally or floor of vertical tanks, or of the shell or ends of
near the bottom of the tank; this helps ensure smooth horizontal tanks.
and efficient flow, the minimisation of the generation of
static electricity through turbulence, and the avoidance 3.3.6.3 The emergency venting capacity provided
of disturbance of bottom sediment. Where internal should be in accordance with a recognised venting
floating roofs are installed in fixed roof tanks, a diffuser guide, e.g. API Standard 2000.
11

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. II may only be used in accordance with
3.3.6.4 Consideration should be given to preventing tanks and facilitate gas-freeing and tank cleaning
liquid overfills by the use of gauge mounted HI-level’ operations. They should be large enough, typically
and independent ‘Hi-Hi-level’ alarms. The latter may 600 mm inside diameter, to permit entry when full
provide a signal to initiate an automatic shutdown. personal protective equipment is worn, including
breathing apparatus.
3.3.7 Emissions control
3.3.9.2 For vertical tanks above ground, at least one
Where local legislation requires control of hydrocarbon manhole should be provided in the lowest shell strake
emissions it may be necessary to install secondary seals and one in the tank roof. Wherever possible, two
on floating rooftanks and internal floating roofs in fixed manholes installed as far apart as possible should be
—
-
rooftanks. Guidance on appropriate control measures is provided in each of these areas to provide adequate
given in IP Guidelines for the design and operation of means of emergency escape and to facilitate tank
gasoline vapour emission controls. ventilation for access and cleaning purposes.
It may also be necessary to ensure that the tank
external paint is selected to reflect solar radiation 3.3.10 Stairways, gangways and ladders
adequately, (see also 3.3.18).
In the UK reference should be made to the 3.3.10.1 Means of operational access to, and escape
Secretary of State’s Guidance PG1/13 Processes for- from tank roofs should be provided for personnel in the
the storage, loading and unloading of petrol at form ofpermanent stairways or ladders leading directly
terminals. from ground to individual tank roofs, or to bridges
between tanks. Where possible more than one means of
3.3.8 Capacity and high level alarms escape should be provided.
3.3.8.1 The rated capacity of a tank should provide 3.3.10.2 If access to the roofs of adjacent tanks is
sufficient ullage to permit expansion of product due to provided by means of bridges or gangways between
a rise in temperature during storage. Capacity levels tanks, there should be more than one stairway giving
should allow for operational limitations of any internal access to the group. The connections of bridges or
or external floating roof gangways to the tanks should take account of
differential settlement and expansion of the tanks.
3.3.8.2 Where tank filling operations are complex,
such as with tanks fed by cross-country pipelines, 3.3.10.3 For tanks not more than 4,5 m high, vertical
consideration should be given to the fitting of high level ladders terminating in a landing platform may be
alarms and devices for automatically cutting off the provided for access to roofs. Such ladders or any other
supply. Ideally automatic cut-off devices should be of fixed vertical ladders exceeding 2,3 m in height should
high integrity and independent of any normal measuring be provided with safety cages. Provision of fall arrest
or alarm system. equipment may also be considered.
As the operation of an automatic shut-off valve
could be sudden, care should be taken to alleviate or 3.3.10.4 Safe walking surfaces should be provided at all
relieve shock loading or general over-pressurisation. points where operational attendance or regular
Surges can often be avoided by increasing the valve maintenance is required, e.g. dipping and sampling
closure time. points and vents. All means of access should have non-
slip surfaces and be of adequate width to provide free
3.3.8.3 Where internal floating roofs are fitted within and safe movement of personnel.
tanks of fixed roof design, care should be taken to set
alarms and automatic cut-offs at such a level as to 3.3.10.5 Stairways, gangways, bridges, ladders,
prevent physical contact between the floating roof and platforms, landings and points on tank roofs to which
the tank roof support structure, instrumentation or foam access is required, should be provided with handrails in
pourers. accordance with the selected tank standard and should
take into account relevant regulations governing
3.3.9 Manholes working at height.
3.3.9.1 Manholes (in accordance with the selected tank 3.3.10.6 It is preferable that all stair treads and
standard) should be provided to permit entry to the platforms be of the galvanised open mesh type.
12

DESIGN AND CONSTRUCTION OF PLANT, EQUIPMENT AND GUILDINGS
3.3.11 Gauging, sampling and temperature 3.3.12 External floating roof tanks
measurement
3.3.12.1 The total pontoon volumes of external floating
3.3.11.1 Gauging, sampling and temperature roofs should give sufficient buoyancy to meet all
measurement are key factors in maintaining effective operating conditions, including abnormal loading
loss control systems at installations. Means should be conditions such as heavy rain or snow covering, with an
provided to ensure that stock and delivery adequate factor of safety. Pressure reliefvents should be
measurements are taken accurately and routinely installed to avoid pressure rising under the rim seal and
through the provision of: to release vapour from under the roof during initial
filling. Vacuum breakers should also be provided.
facilities for sampling and for level and
temperature gauging; 3.3.12.2 Provision should be made to drain rainwater
accurate tank calibration; from the roof with means of closing the outlet. Where
gantry meter systems for road and rail loading; the drain passes through the stored product the closure
metering systems for marine loading (otherwise use should be at the bottom end of the pipe and should be
gauging of shore tanks); kept closed except when water is being drained under
— weighbridge for weighed deliveries/receipts; controlled conditions. Product-sensing automatic
computerised petroleum measurement tables and shutoff valves may also be considered.
stock control systems;
— simple laboratory equipment to support, where 3.3.12.3 Ifpermanent access to the roof is required, one
necessary, gauging measurements e.g. density or more stairways should be provided that are hinged to
measuring equipment. the top curb angle ofthe shell and equipped with rollers
at the lower extremity, handrails and self-levelling flat
3.3.11.2 Guidance on the selection and use of such treads.
facilities and equipment and on stock control procedures
is provided in the IP Hydrocarbon Management series. 3.3.12.4 Roofs should be provided with adjustable
The complexity and range of measurement support legs which can be set for sufficient roof height
equipment installed at a particular installation will, to permit maintenance and tank cleaning work to be
firstly, be governed by regulatory requirements for carried out. They should be designed to be set also for
measurement and reporting, and, secondly, based on a a lower roof height, in order to ensure that the roof
cost-benefit approach. floats on the product under all normal operational
In general it will tend to be a function of the conditions. These supports should be provided with
throughput, with larger installations meriting better drain holes so that they can be cleared of product when
equipment. In the case of gauging equipment, both the tank is gas-freed for repairs. It is recommended that
manual and automatic systems are available; the wear plates are fitted to the tank floor at each roof
additional capital and maintenance costs of automatic support leg and the roof vent leg.
measuring equipment should be compared with the
operating costs of manual methods. 3.3.12.5 In order to provide adequate means of escape
in an emergency, roofs should be provided with two
3.3.11.3 Hatches for gauging, sampling and temperature manways diametrically opposed.
measurement should be such that they can be closed to
exclude moisture. In the case of tanks for Class I, Class 3.3.13 Internal floating roofs
11(2) and Class 111(2) petroleum, they should be vapour-
tight when closed, Installation of a strike plate on the 3.3.13.1 Guidance on the design, construction,
tank bottom is recommended where dipping manually. operation and maintenance of internal floating roofs is
given in API Standard 650 and API Standard 653.
3.3.11.4 Automatic level and temperature gauging
equipment may be fitted to reduce the risk to personnel 3.3.13.2 The roof at its lowest level should not obstruct
when carrying out gauging operations. All level and flow through the shell or bottom connections nor entry
gauging equipment should be installed in accordance through shell manholes. At its highest level the roof
with BS ISO 4266 or equivalent standard. For all tanks should not come into contact with members of the roof
in petroleum service, the equipment should be structure, nor at any point with items of gauging
adequately bonded to the tank structure, in accordance equipment, automatic level limits or foam pourers.
with IP Model Code of Safe Practice Part 1 Electrical
safety code.
13

IMPORTANT: This file is subiect to a licence agreement issued by the Energy Institute, London, UK. All rights reserved, It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44 (0)2074677100
3.3.13.3 In order to provide adequate means of escape conditions likely to be encountered.

in an emergency, roofs should be provided with two A thorough knowledge of the ground conditions
manways diametrically opposed. should be obtained with particular reference to
establishing the allowable bearing pressure, total and
3.3.14 Earthing and bonding differential settlement expected, risk of flotation and
possible deterioration oforiginal conditions. Settlement,
Electrical earthing of tanks and electrical bonding of in particular differential settlement, should be limited to
internal and external floating roofs for the reduction of prevent excessive stresses in the tank structure and
electrostatic charges and protection against lightning connected pipework. Areas having weak subsoil
discharge should be in accordance with IP Model Code conditions require special consideration.
of Safe Practice Part 1 Electrical safety code. Where the tank site may be subject to flooding,
protection should be given to the foundation to avoid
3.3.15 Buried and mounded tanks erosion and the tanks may have to be anchored.
3.3.15.1 Unless special considerations dictate otherwise 3.3.16.2 The design of foundations and supporting
the use of buried tanks should be avoided, because of structures for tanks designed and constructed to pressure
the lack of access for external inspection. Where buried vessel codes need special consideration.
tanks cannot be avoided consideration should be given
to the prevention and detection of leaks, e.g. double 3.3.16.3 Saddles for horizontal tanks should be shaped
skinned with interstitial monitoring. to conform with the tank shell. The minimum number of
supports should be provided, preferably two, located to
3.3.15.2 The design standards for vertical tanks cover give minimum bending moments and deflections. They
above-ground tanks only. A vertical steel tank for should be designed to prevent any accumulation of
installation as a buried or mounded tank may be water.
designed and constructed in accordance with these Where there is likely to be severe corrosion
standards, but special consideration will have to be between the tank shell and supports, steel sacrificial
given to surrounding the steel tank with concrete or corrosion plates should be welded to the shell or, as an
other means of protection against earth or water alternative, waterproof resilient pads should be used.
pressure, and to the design of the tank to cater for The tank should be securely anchored or weighted
superimposed loading. against hazards from high winds or if there is risk of
flotation due to flood water.
3.3.15.3 Horizontal tanks may be installed a.s buried or
mounded tanks, but precautions should be taken against 3.3.16.4 Supports for elevated tanks should be given
the possibility of flotation. fire protection to meet local regulatory requirements
unless the risk of collapse during a fire is considered
3.3.15.4 The filling point of a buried or mounded tank unlikely.
should be located at, or carried down internally to a
point near the bottom of the tank. 3.3.17 Inspection and testing
3.3.15.5 Shafts or tunnels should be incorporated to 3.3.17.1 Shop and site inspection of tanks should be
allow compliance with venting and access requirements. carried out in accordance with the selected tank
standard.
3.3.16 Foundations and Sllpports
3.3.17.2 Vertical tanks should be tested on site in
3.3.16.1 The design standards for vertical tanks give accordance with the selected tank standard. This may
recommendations for the construction offoundations for include testing of the tank floor for leaks by vacuum
tanks built to those standards. The foundation design box or other suitable method, testing of the tank shell
will depend generally on site conditions and for tightness and security by filling with water followed
consideration should be given to incorporating an by visual inspection, and testing for vapour tightness of
impermeable barrier such that continuity of the tank the roof and roof fittings. Controlled water loading of
compound containment system is achieved. The design new tanks during testing may be necessary to avoid
should provide drainage, prevent external corrosion of over-stressing the supporting ground. The total and the
the tank bottom, and give stability to the tank under test differential settlement should be carefully measured and
and under all service, wind and other climatic recorded throughout testing.
14

3.3.17.3 Buried or mounded tanks should be tested 3.3.20 Change in use

before backfilling or mounding.
Design of tankage and associated systems should be
3.3.18 Corrosion protection reviewed whenever change in use or modifications are
planned such as product composition, temperature or
3.3.18.1 Tanks, tank fittings and supports should be flow rate. In particular, design pressure and venting
adequately coated externally to prevent corrosion. The should be checked together with any change in height
reflectivity of the coating system may need to be between connected tanks or equipment to prevent
selected to comply with national environmental gravity transfer causing overflow.
legislation to minimise VOC emissions (see 3.3.7). The
need for internal coating is largely dependent on the 3.3.21 Geodesic domes
product to be stored.
Consideration is sometimes given to the conversion of
3.3.18.2 Buried and mounded tanks should be given an a floating roof tank to a fixed roof tank for a variety of
external protective coating system adequate to resist reasons, such as:
expected corrosion conditions arising from contact with
the soil and groundwater. climate conditions;
— water ingress around peripheral seals; or
3.3.18.3 Cathodic protection should be considered reduction of fumes from odorous products.
where severe corrosion by aggressive sub soils may be
expected. Where applied, cathodic protection should be Geodesic domes usually consist of a self-supporting
in accordance with BS 7361-1 Cathodic protection, lightweight tubular construction carrying a thin metal
Code ofpracticefor land and marine applications, with cover. Justification for their use is largely dependent on
due regard being paid to BS EN 14161 Petroleum and economics.
natural gas industries. Pipeline transportation systems
and IP Model Code of Safe Practice Part 1 Electrical
safety code. 3.4 PIPING, VALVES AND FITTINGS
3.3.19 Tank compounds 3.4.1 General
3.3.19.1 Compound walls should be fire-resistant and Following identification of the product flow
substantially impervious. requirements, hydraulic studies should be carried out to
establish the required line sizes. The hydraulic study
3.3.19.2 Every main compound wall should be should consider, and in some cases determine, required
substantially impervious to liquid and of sufficient flow rates, the available pressure drop and possible
strength to withstand the pressure to which it would be pressure variations.
subjected if the space within the tank compound were Once the line sizing and routing have been
filled with water. Consideration may also be given to established, the piping systems should be reviewed with
the forces that may be generated by a sudden release of the requirements of the selected piping code to ensure
tank contents. All expansion and construction joints that excessive pipe stresses are not induced by thermal
should be similarly impervious and be fire-resistant. expansion, settlement, or other means.
In the European Union reference should be made to
3.3.19.3 Compound floors should be substantially 97/23/EC The approximation oflaws ofMember States
impervious to the liquid to be stored and where concerning pressure equipment when determining the
necessary should be sloped to prevent rainwater full requirements of the piping system installation.
remaining around any tanks and to enable effective
recovery of any minor spillage of product. Existing 3.4.2 Piping code
facilities may be constructed from non-impervious
materials. In this case a risk assessment should be The design, including the selection of materials,
undertaken to determine whether upgrading is justified fabrication, assembly, inspection and testing of piping
taking into account the possible risks of retrofitting systems, should be suitable for the working pressures,
impervious flooring in operating areas. temperatures and stresses to which the system will be
subjected in service. It should conform with the
appropriate sections of a recognised piping code.
15
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3.4.3 Materials damage in the event of an emergency.
3.4.3.1 All materials, including non-metallic parts for 3.4.6.2 Valves should comply with the selected piping
valves, seals, gaskets and diaphragms, should be code, be of steel construction, of the correct design
resistant to the action of petroleum products (including rating, to a fire safe design and include adequate
additives) under the service conditions to which they are electrical continuity.
subjected.
3.4.6.3 Glands should be designed to permit repacking
3.4.3.2 Cast iron should not be used for valves or without removing the valve from service.
piping containing petroleum products; where it is used
for items such as flow meters, nodular cast iron should 3.4.6.4 Indication ofthe actual valve position (open or
be used; grey cast iron is not considered suitable. closed) should be clear, i.e. rising spindle gate or ball
valves. It should be physically impossible to assemble
3.4.3.3 Copper, brass, aluminium or non-metallic pipe a valve (for example after stripping for maintenance)
or tubing should not be used for main piping systems. such that indications of its position are reversed.
3.4.3.4 Steel pipe should conform to API Standard 5L 3.4.6.5 All open-ended valves should have blind
or equivalent. flanges or screwed plugs fitted.
3.4.4 Pipe thickness 3.4.6.6 Adequate access stairways or ladders and

operating platforms should be provided to enable the
Pipe thickness should be calculated in accordance with safe and convenient operation of valves.
the selected piping code. However, it will generally be
necessary to use pipe of a greater thickness than 3.4.7 Flanges and fittings
calculated to give rigidity and to provide a corrosion
allowance. Guidance should be taken from the relevant 3.4.7.1 Steel flanges and flanged fittings should be to
piping code. BS 1560, ANSI 816.5 or equivalent standard.
3.4.5 Pipe joints 3.4.7.2 Steel butt weld fittings should be to BS 1640,
ANSI B 16.9 or equivalent standard.
3.4.5.1 Joints on piping, particularly below ground
(see 3.4.8.4), should preferably be welded. Welding 3.4.7.3 Steel socket welding and screwed fittings
should be carried out in accordance with the selected should be to BS 3799, ANSI 816.11 or equivalent
piping code. Where practical considerations require a standard.
joint to be disconnected, such as at equipment or for
maintenance, flanged joints should be used. If below 3.4.7.4 Bolting should be to BS 4882 or equivalent
ground flanged joints cannot be avoided they should be standard.
installed in an impervious chamber.
3.4.7.5 The required integrity ofthe piping system will
3.4.5.2 Screwed joints should preferably not be used. determine the most suitable gasket for the service
Where their use is unavoidable they should only be conditions. Non-asbestos gaskets should be used with
applied to piping 50 mm nominal size and smaller and dimensions to ASME/ANSI B16.2l.
should be made in accordance with API Spec. 5B or
ASME/ANSI B 1.20.1. 3.4.8 Installation and flexibility
3.4.5.3 Flexible-typejoints incorporating non-metallic 3.4.8.1 Piping systems should have adequate
sealing rings are not recommended. flexibility to accommodate any settlement of tanks or
other equipment, thermal expansion and contraction and
3.4.6 Valves other stresses which may occur in the piping system.
Reference should be made to the sections on design and
3.4.6.1 Piping systems should contain a sufficient installation in the selected piping code for detailed
number of suitable valves to enable the system to be considerations to be taken into account to ensure the
operated efficiently, to protect the installation and to satisfactory installation and flexibility of piping
enable the system to be shut down quickly without systems.
16

the licence terms and conditions, It must not be forwarded to. or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44 (0)207 467 7100
3.4.8.2 Flexibility should preferably be provided by 3.4.9 Thermal pressure relief

changes indirection ofpiping, through the use ofbends,
loops or offsets. Where lack of space prohibits the use 3.4.9.] Any section of a piping system in which liquid
of these methods, suitable expansion joints of the may be trapped, e.g. between shut-off valves, should be
stainless steel bellows type may be used provided the protected against excessive pressure caused by thermal
pipework either side is properly anchored or guided. expansion of the contents. The discharge of any relief
Bellows joints should be protected from torsional valve provided for this purpose should preferably be
loads and should be designed in accordance with directed to a storage tank. This however is often not
guidance from the manufacturers. Bellows and practicable and therefore thermal pressure reliefs may
associated restraints should be routinely inspected have to be arranged in series along a line containing
against agreed retirement criteria following installation. several valves with only one final relief into tankage. In
Bellows should not be used to overcome misalignment designing such systems it should be recognised that the
at the installation stage. pressures at which relief occurs are cumulative at each
subsequent isolation point progressing away from the
3.4.8.3 Pipe supports should be adequately designed tank.
and spaced to suit the pipework configuration and to
withstand anchorage and guide friction forces or forces 3.4.9.2 Relief valves should preferably be of the
arising from pigging operations. Direct contact between enclosed bonnet type.
the supports and the pipe wall should be avoided by
utilising slip feet or friction pads. 3.4.9.3 Where isolating valves are installed either side
Pipe bridges or other support structures may be of a relief valve, a locking system should be provided to
required in certain circumstances. prevent inadvertent closure.
3.4.8.4 Piping systems should preferably be above- 3.4.10 Inspection and testing
ground. Those which are placed below ground should
be protected against corrosion (see 3.4.14.2), and 3.4.10.1 Reference should be made to the appropriate
against uneven ground settlement, particularly when sections in the selected piping code for
passing under railways, roads or other points where recommendations on inspection and testing.
severe local loading may be experienced.
Accurate as-built drawings should be maintained 3.4.10.2 Before they are commissioned, and in the case
for quick reference and lines should be marked at ofburied pipework before closing the trenches in which
ground level shortly after entry to ground and at all the lines are laid, completed piping systems should be
changes of direction. tested hydrostatically to one and a half times their
maximum operating pressure.
3.4.8.5 Open trenches and ducting in which pipes are In cases where it is not desirable to test
run are not recommended as they can allow flammable hydrostatically, it is recommended that a test for leaks
vapour to collect, but where they are unavoidable they with air be carried out at a pressure not exceeding I bar,
should have fire stops at suitable intervals. Short lengths followed by a pressure test with product to one and a
of duct without fire stops are acceptable for road half times the maximum operating pressure; in such
crossings. cases consideration should be given to increasing the
level of inspection.
3.4.8.6 Water lines, or lines in which water may
accumulate, should either have provision for complete 3.4.10.3 Facilities should be incorporated to assist
evacuation as a frost precaution or be protected, with an routine inspection and testing of underground pipelines
adequate safety margin, against the lowest anticipated and pipelines running above or near water courses.
ambient temperature.
3.4.11 Piping systems above or below ambient
3.4.8.7 Sufficient drain and vent points for testing, temperatures
commissioning, future alterations and maintenance
operations should be considered. These should be 3.4.11.1 Protection should be provided to prevent
blanked or plugged when not in use. personnel coming into contact with heated surfaces over
50 °C.
17

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk I: +44 (0)2074677100
3.4.11.2 Energy conservation Should be considered in 3.4.16 Segregation

all situations where pipework is designed to carry
liquids at temperatures significantly above or below Where isolating flanges, blanks and spades are used to
ambient. segregate sections of a piping system, they should be of
adequate strength and embody a means of clearly
3.4.11.3 Pipe insulation should be in accordance with indicating their setting. At the design stage, provision
the selected piping code. Consideration should be given should be made to permit safely clearing the lines and
to the prevention of corrosion under insulation. relieving line pressure before removing segregating
flanges, blanks or spades.
3.4.12 Hoses Gravitational flow between tanks may be
minimised by incorporation of non-return valves at
Hoses should be in accordance with a recognised suitable points but consideration should be given to
standard applicable to the duty they are to perform: more positive separation, e.g. double valve separation.
BS 1435 for hoses for ship discharge and loading. 3.4.17 Identification
BS 3492 for hoses for road tank vehicle and rail
tank car loading and unloading. Means of identification and direction of flow should be
applied to pipework to show the product or service.
3.4.13 Articulated pipe connections Where there is an approved and standardised colour
code in use (e.g. IP Code of practice for a product
The design, materials and construction of articulated identification systemfor petroleum products), it should
pipe connections should be suitable for the product be incorporated in the identification scheme.
which they are to handle. They should be capable of
withstanding a test pressure of one and a half times the
maximum pressure they will carry in service. 3.5 PUMPS
3.4.14 Corrosion protection 3.5.1 Location
3.4.14.1 Above-ground piping systems should be 3.5.1.1 Pumps should preferably be situated in open
adequately coated externally to prevent corrosion. air, unless severe climate conditions may be
experienced. They should preferably not be installed
3.4.14.2 Buried piping should be protected externally below ground level. Pumps and pump manifolds should
by suitable corrosion-preventing materials. Prior to not be located within tank compounds.
backfilling, the pipe coating should be tested for
integrity, i.e. holiday detection. Care should be taken 3.5.1.2 Pumps may be grouped together in one area or
not to damage such protection during backfilling, which individually sited to suit operational and constructional
should be carried out using fine granular material convenience.
immediately adjacent to the pipe.
3.5.2 Pump type and seal design
3.4.14.3 Cathodic protection should be considered
where severe corrosion by aggressive sub-soil could be 3.5.2.1 The type of pump to be used will be
expected or where piping crosses, or is adjacent to, determined by product characteristics and pumping
other services, e.g. electrical cables and metallic water duties, in particular the suction conditions. Pressure-
mains. Where applied, cathodic protection should be in retaining parts of pumps in hydrocarbon service should
accordance with BS 7361-1 and with reference to IP not be made of grey cast iron; cast steel is preferred but
Model Code of Safe Practice Part I Electrical safety nodular cast iron may be used where pumps can be
code. readily isolated in the event of fire.
3.4.15 Surge suppression 3.5.2.2 The service conditions for the pump will
determine the most suitable seal arrangement. It should
The design of piping systems should avoid pressure be noted that some standard type mechanical seals may
surges, but where this is not practicable accumulators of not offer the necessary integrity when they fail.
adequate strength and capacity may be fitted when Reference should be made to IP 15 and European
service conditions give rise to high surge pressures. Council Directive 94/9/EC The approximation of the
18

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44(0)2074677100
laws of Member States concerning equipment and local stop and a means of isolating and locking off the
protective systems intended for use in potentially power supply from the driving unit.
explosive atmospheres when selecting the most
appropriate seal type.
3.6 COMPRESSORS
3.5.3 Pump installation
3.6.1 Location
3.5.3.1 Ideally pumps and manifolds should be
dedicated to single products. 3.6.1.1 Compressors should, where possible, be
located in non-hazardous areas in thoroughly ventilated
3.5.3.2 Pumps should be protected by a coarse strainer buildings. They should preferably not be installed below
on the inlet side of the pump. ground level or inside road tanker workshops.
3.5.3.3 Pumps should be fitted with non-return valves: 3.6.1.2 The type of compressor to be used will largely
on the discharge side: be determined by the system characteristics and its
where two or more pumps operate in parallel, and location, particularly in relation to noise. In the UK, The
where gravity flow back from the discharge line Control ofNoise at Work Regulations 2005 give further
through the pump could take place when it is not guidance on monitoring noise levels in conjunction with
operating. rotating machinery and manufacturers should provide
noise data on their equipment
3.5.3.4 Positive displacement pumps should have an
integral bypass valve or other suitable protection against 3.6.1.3 In the UK. the Pressure Systems Safety
over-pressure or overloading if the pump is operated Regulations 2000 require that a written scheme of
against a closed discharge. examination should be prepared. Further guidance is
given in HSE INDG 178 (rev 1) Written sche,’nes of
3.5.3.5 Pumps should be fitted with non-sparking examination.
guards for moving parts.
3.5.3.6 Connections for pressure gauges to aid pump 3.7 BULK ROAD AND RAIL LOADING AND
commissioning should be fitted on both the suction and UNLOADING FACILITIES
discharge sides of each pump.
3.7.1 Constrllction materials
3.5.4 Driving units for pumps
Materials used in the construction of loading or
3.5.4.1 The driving units of pumps should be sized for unloading structures should be non-combustible.
continuous duty at maximum load in the prevailing
climatic conditions. They should be suitable for 3.7.2 Loading arrangements
operation in the hazardous area in which they are
located. Consideration should also be given to the likely 3.7.2.1 Road tankers and railcars may either be top or
number and frequency of pump starts. bottom loaded.
Bottom loading may be mandatory where
3.5.4.2 Gasoline engine driven pumps should not be legislation requires vapour collection and recovery
operated in hazardous areas. Diesel engine driven facilities for Class I product. In the UK reference should
pumps, when operated in an area in which there is risk be made to Secretary of State’s Guidance PG 1/14 when
of flammable vapour being present, should conform to determining the type of acceptable installation.
BSEN 1834-1:2000. Bottom loading, in conjunction with a secondary
fail-safe overfill prevention system, has other
3.5.4.3 Diesel engines should be installed above advantages (including for the loading of Class II and III
ground level and, if enclosed. should be well ventilated. products), being:
3.5.4.4 Driving units should be fitted with non- The safety of personnel (not being required to
sparking guards for moving parts. access the top of the road tanker or railcar).
Less risk of overfilling and consequential spillage.
3.5.4.5 There should be a means for rapid shut-down Higher flow rates.
of the driving unit in an emergency; as a minimum a — Multi-compartment simultaneous loading (where
applicable).
19

DESIGN. CONSTRUCTION AND OPERATION OF PETRO1.EUM DISTRIBUTION INSTALLATIONS
At high throughput terminals, the higher loading rates loading equipment and the loading vehicle (see Annex
may result in a need for fewer loading gantries; this may D). In order to limit drips from fuel oil loading arms it
be particularly relevant for periods of peak demand - is normal to use short drop pipes. A facility should be
e.g. start of driver shifts. provided to restrain the loading arm to prevent its
Top loading facilities should meet local Statutory movement out of the compartment during loading.
requirements, particularly with respect to the protection
of personnel working at height. 3.7.2.7 Slow start controls are available for loading
systems such that the fill pipe shoe or tee is covered
3.7.2.2 Where switch loading is undertaken, special before full flow starts. Slow flow start up control should
consideration should be given to minimising the risk of also be considered for bottom loading subject to
vapour ignition due to discharge of static electricity. In compliance with IP Model Code of Safe Practice Part
addition to the bonding requirements specified 21 Guidelines for the control of hazards arising from
elsewhere in this Code, the product loading rate and static electricity.
piping configuration should be carefully considered to
minimise the risk of a static discharge within the tanker 3.7.2.8 The design of the loading facility should
compartment. It may be appropriate to increase product permit proving of the product meters. This is generally
conductivity by addition of a static dissipative additive. effected by using a mobile reference meter in series
See IP Model Code of Safe Practice Part 1 Electrical with the gantry meter, with the product used during
safety code, BS 5958-1, BS 5958-2 and IP Model Code proving either passing into a road tanker, or returned
of Safe Practice Part 21 Guidelines for the control of direct to storage.
hazards arising from static electricity, for further Where Class I or Class II products are handled, the
guidance. safety implications of the operation should be carefully
considered. Installation of meter proving return lines is
3.7.2.3 To prevent overfilling, tankers should be recommended. Reference should be made to IP
loaded using a flow meter incorporating a preset trip to Guidelines for identUication and control of hazards
close a flow control valve when the preset quantity has during the proving ofroad loading gantry meters.
been delivered. A separate quick action shut-off facility
incorporating a pump stop control should be provided at 3.7.3 Layout of road tanker loading and
the loading point to enable immediate cessation of unloading facilities
loading in an emergency; this should preferably operate
on an independent valve. A secondary overfill 3.7.3.1 The layout of road loading and unloading
prevention system, including a static earth bond, linked facilities should permit ease of tanker entry and exit,
to the flow control valve should be used for bottom preferably on a one-way system without need for
loading, and is recommended for top loading. reversing (see section 2.6.2).
3. 7.2.4 When top loading railcars and road tankers, the 3.7.3.2 Tanker loading points should be grouped on
loading arm is lowered through an open manhole or fill islands, placed parallel to one another; for top loading,
hole on top of the railcar or road tanker (respectively); they may be spaced to permit the use of both sides of
it should have a weak point at high level to ensure the islands simultaneously. The spacing between islands
controlled failure in the event that a railcar or tanker is should allow sufficient clearance for the largest tankers
driven away without removal of the arm. Where top in use, and for the size of those anticipated.
loading is practised with a vapour collection system, it
should be based on sealing the open hole with modified 3.7.3.3 The loading equipment on the islands should
loading arms. be provided with protection from the access of tankers;
the use of kerbs in the area of connections on bottom
3.7.2.5 All arrangements for loading Class I or Class loading tankers should be avoided, to prevent a trip
II petroleum should be designed to avoid splash loading hazard. The positioning of the loading arms determines
and free fall of product in the tank or compartment. For the parking position of the tanker; once parked, the
normal top loading the drop pipe of the loading arm tanker should not require to be moved to allow
should be of sufficient length to reach the bottom of the completion of the loading operation. The work areas
deepest tank or compartment and terminate in a tee. and equipment should be arranged to allow free access
to the loading couplers or top loading arms.
3.7.2.6 When top loading fuel oils there is no
requirement to provide electrical continuity between the 3.7.3.4 The loading area between islands should
20

provide a substantially level standing for road tankers 3.7.4.2 The section of track serving railcar loading or
being loaded and should be constructed in concrete with unloading facilities should, wherever possible, be
adequate drainage falls. Consideration should be given reserved for these purposes only. The rail access to the
to providing appropriate road marking in the loading siding should be controlled by lockable gates.
gantry area to assist the correct parking of the tanker
relative to the loading island. The working area should 3.7.4.3 Rail sidings should be constructed with the
be free from trip hazards and have a non-slip surface, appropriate loading gauge clearances on a level
e.g. textured concrete. formation.
3.7.3.5 Each loading arm should be capable of being 3.7.4.4 Wherever possible, entry to rail sidings should
connected to the loading adaptor or inserted in the fill be laid on a falling gradient from the main line. The
hole of any compartment of a tanker and operated, gradient should not exceed 1 in 400.
without moving other loading arms or clashing with
them, whether they be stowed or connected. The 3.7.4.5 Ground frames or levers controlling points
loading arms should be stowed in a parked position to should be placed parallel to adjacent rail tracks in safe
prevent them swinging into the path of an approaching positions for the operators using them. Consideration
tanker during windy conditions. should be given to providing high level illumination of
rail tracks, safety handrails over railcars and water
3. 7.3.6 Loading equipment whether stowed or cooling spray facilities for use in the event of a fire.
connected should not restrict egress from the loading These may be incorporated into one longitudinal bridge.
area.
3.7.4.6 Gates across railway lines should be provided
3.7.3.7 The product allocation of each arm on each with catches to hold them open when required.
island is key to servicing the market efficiently. The
number and allocation of arms on loading terminals 3.7.4.7 Suitable barriers, stop signs, clamps, locks, or
requires careful business planning and is outwith the other means of control should be employed to prevent
scope of this Code. Each arm should be clearly unauthorised train movement. Whilst railcars are still
identified in accordance with the recommendations of connected to the loading or unloading facilities, access
IP Code ofpractice for a product ident.flcation system by locomotives to within the safe distance denoted by a
for petroleum products. locomotive stop sign should be prevented.
Wherever possible kerosene and gasoline arms
should not be located on the same loading island unless 3.7.5 Railcar loading and unloading areas
additional safeguards prevent the loading of both grades
onto the same tanker, or the incorrect grade onto the 3.7.5.1 Loading and unloading areas should be
tanker. surfaced in substantially impervious materials resistant
to damage by fire and product spillage.
3.7.3.8 It is preferable to locate tanker offloading
points remote from the road loading facilities. 3.7.5.2 Surfacesofloadingandunloadingareas should
Offloading points should be equipped with an be graded so that any product spillage will not flow
appropriate connection to permit bonding of the tanker. under the railcars, and its spread will be limited. This
In addition, offloading hoses, drainage and stripper may be achieved by installing an impermeable
pumps may be provided. membrane below the track ballast, and longitudinal
drains for rail loading and unloading areas.
3.7.4 Layout of railcar loading and unloading
facilities 3.7.6 Loading and unloading equipment for
railcars and road tankers
3.7.4.1 Loading and unloading of railcars may be
carried out on a siding provided with a number of 3.7.6.1 Loading / unloading equipment may be located
connection points spaced to suit railcar dimensions. As at ground level, or for top loading on a platform at a
- -
an alternative to this multi-point system, a single-point height to suit the road tanker or railcar fleet.
system may be used, in which the product handling
facilities are grouped in one position and the train of 3.7.6.2 Flexible connections between the fixed
railcars is moved so that each railcar is brought into facilities and the road tankers or railcars may be hoses
place successively. or articulated arms. These should be designed and
21

DESIGN. CONSTRUCTION AND OPERATION OF PETROLEUM DISTRIBUTION INSTALLATIONS
installed so that they can easily reach correctly Bottom loading arms should be designed such that
positioned tankers or railcars without undue strain. Drop the coupler rests centrally within the tanker’s loading
pipes used in top loading should reach the bottom of the adaptor envelope as detailed in IP Petroleum road
railcars or tankers without difficulty. tanker design and construction. The loading arm should
return the coupler to its vertical rest position following
3.7.6.3 Unloading points for road tankers and railcars any loading operation. The effort required to raise or
should be provided with non-return valves if there is the lower the coupler from its rest position should be the
possibility of gravity flow back from the receiving minimum practicable to reduce the loading between the
tanks. Consideration should be given to fitting sight tanker adaptor and loading arm coupler when
glasses or flow indicators to show when discharge is connected.
completed, and breakaway couplings which minimise Any counterbalance provided should include a
product escape in the event of a train being moved balancing facility that allows adjustment when the
whilst hoses are connected. loading arm is installed and filled with product. Where
the counterbalance includes a spring-loaded device the
3.7.6.4 IP Petroleum road tanker design and device should be enclosed and fitted with restraints to
construction gives the requirements for the position of avoid sudden release should a pre-stressed component
liquid and vapour return connections on bottom loading fail. The counterbalance should be adjustable with the
tankers. The design of each loading arm should permit use of hand tools only.
its coupler to be connected to each tanker adaptor; the
loading arm coupler is normally suspended off its 3.7.6.7 BS EN 13083 provides the dimensional
loading arm by a drop hose that provides additional tolerances for tanker loading adaptors with which gantry
flexibility. To provide additional protection, the drop loading couplers require to mate. Care should be taken
hose may be fitted with a flexible sleeve, which can when selecting couplers as they are subject to high
usefully be marked with product identification details to levels of wear even when maintained correctly, which
assist the driver when selecting the appropriate arm for affects their longevity.
loading. Both the vapour and liquid couplers should be kept
free from debris to ensure maximum durability and
3.7.6.5 The required operation of the loading arms minimum wear. Further detailed guidance is provided in
normally requires the use of swivels. All swivels should IP Research Report Investigation offactors causing
be electrically continuous such that the maximum leakage at road tanker loading gantly coupler/tanker
resistance to earth for the loading arm assembly is adaptor inteiface. Consideration should be given to
10 Ohms. Where electrical continuity cannot be providing ‘acceptance gauges’ for loading couplers to
achieved through the swivel, a carefully designed earth determine the extent of coupler wear.
shunt may bridge the swivel. Any shunt should not
adversely restrict the normal operation of the swivel. 3.7.6.8 The pressure rating of the loading arm
The use of electrically conductive greases has assembly should be ascertained from the manufacturer.
proven successful in achieving electrical continuity It is normal for the loading couplers to be the
through loading arm swivels. Great care should be components that have the lowest rated design pressure
exercised when applying grease to swivels on product on a loading gantry. It should be recognised that the
systems. The compatibility of the applied grease should maximum allowable operating pressure quoted by
be checked against the liquid being transferred through manufacturers is generally higher than the maximum
the swivel. pressure at which the coupler can be opened and closed.
All swivels, and particularly those subject to high High locked-in pressures during the
bending stresses, should be sufficiently robust to avoid disconnectlconnect operation can lead to operator injury
leakage when pressurised. Where swivels are positioned and it is therefore recommended to limit the maximum
at a high level consideration should be given to coupler locked-in pressures to the lowest practicable.
providing fixed grease lines from low level for ease of The maximum locked-in pressure at the coupler should
maintenance. be determined and appropriately limited to ensure the
couplers can be operated safely.
3.7.6.6 The loading arm design should minimise
operational effort within the guidelines for manual 3.7.6.9 Filters should be installed on all product
handling published in the UK by the HSE and, for loading point supply lines to ensure protection of
bottom loading, to minimise the connection forces downstream in-line equipment, and to allow product
between the tanker adaptor and the loading arm coupler. delivered onto road tankers to meet the appropriate level
22

the licence terms and conditions, It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: a: pubs@energyinst.org.uk 1: +44 (0)207 467 7100
of cleanliness. It should be noted that filters in clean detailed in IP Code ofpractice for drivers’ emergency
liquid systems are a cause of static generation, and actions on road loading racks.
suitable precautions should be taken. Filters should be
positioned as close to loading points as possible and 3.7.6.15 The driver may normally control the loading of
upstream of the flow meter subject to the requirements the tanker; this will involve him working in the open
of IP Model Code of Safe Practice Part 21 Guidelines around the tanker prior to loading, and following its
for the control ofhazards arisingfrom static electricity. completion. Immediately prior to loading commencing
During the start up of new systems, a significant he will be required to input loading information into a
amount of water and debris may be present in the batch preset device, which generally involves handling
system. Careful control during commissioning is paperwork. This process should therefore be carried out
required to avoid both damage to equipment and under cover in a position that affords some degree of
dangers associated with high levels of accumulated protection.
charge within the liquid.
3.7.7 Vapour collection system
3.7.6.10 The degree of filtration required on loading
island pipework is controlled by fuel quality 3.7.7.1 During bottom loading of a road tanker’s
requirements and the need to protect adequately in-line compartments, the displaced vapours are expelled via
gantry equipment. the tanker’s vapour collection manifold through the
tanker’s vapour adaptor and into the terminal’s
3.7.6.11 Loading should not be capable of proceeding collection system. Where the vapour within the tanker
unless all safety interlocks are in a healthy condition for is not fully saturated an element of vapour growth will
the loading of product; as a minimum this should occur up to the point when the vapour becomes fully
include the connection of: saturated.
— a satisfactory static earth bond (see 3.7.2.3); Note: Where road tankers are fitted with venting
the overfill prevention system (which gives a devices that vent directly to atmosphere when loading,
permissive signal), and vapour will be vented to atmosphere if the combined
the vapour collection hose. maximum filling rate is greater than that which can be
practically managed by the tanker’s venting/vapour
3.7.6.12 It is normal to meter liquid transfer into collection system within the pressure setting of its
tankers. A wide range of meter types has been venting devices. EU legislation limits the maximum
successfully utilised for this purpose including positive operational pressure at the tanker side of the vapour
displacement and turbine type. The type of meter return adaptor to 55 mbarg when loading at a maximum
selected will significantly influence the layout of liquid fill rate to any compartment is 2 500 1/mm. The
equipment and associated structures on the loading tanker should have a plate stating the maximum number
island. All flow meters have varying performance over of loading arms that can be connected at any one time
a range of flows. (for which the tanker’s maximum vapour back-pressure
A meter requires to be ‘proved to demonstrate its will not be exceeded).
accuracy; different companies apply different meter
proving regimes, all of which should satisfy regulatory 3.7.7.2 Loading should not be permitted unless the
requirements associated with liquid measurement vapour collection hose has been connected to the tanker
legislation. Reference should be made to IP HM 39. It and there is a free passage for the displaced vapours to
is normal to check the accuracy of each flow meter at flow into the terminal vapour collection system.
high and low flow rates during the proving.
3.7.7.3 The material of construction of the vapour
3.7.6.13 All tanker loading should be controlled using collection systems should resist internal corrosion
a batch control device, of which a wide variety of caused by the moisture and oxygen content present in
equipment is available. It should be capable of the system.
automatically loading a preset volume of liquid into the
tanker. A ticket detailing the quantity of product(s) 3.7.7.4 The vapour return coupler should offer a low-
loaded contents into each tanker should be produced. pressure drop characteristic and comply with the
There should be a provision to interrupt the load as may requirements ofBS EN 13081. The coupler should be
be required for safety reasons. protected against mechanical damage when in both the
stowed and engaged positions. The coupler may be
3.7.6.14 The requirements for emergency escape are fitted with a toughened sight glass to allow the operator
23

to determine if the coupler is empty prior to the inlet to the VRU).

disengaging. The coupler should be self-closing when
disengaged to ensure the vapour collection system 3.7. 7.10 The system should have provision to be tested
remains sealed. to demonstrate it is leak-tight. Further information on
vapour collection systems is provided in IP Guidance
3. 7.7.5 To prevent blockage by liquid of the vapour for the design and operation of gasoline vapour
pipework, consideration should be given to installing a emission controls.
liquid knockout pot with a drain facility in the vapour
collection system at each loading island. 3.7.7.11 At duty suspended facilities, vapour sampling
points should be installed to allow the determination of
3.7.7.6 Consideration should be given to the the duty reclaim from recovered vapour. Further
installation of a non-return valve, with a low pressure information on the location of these points is available
drop, in the vapour collection system at each island to in IP Procedures for the reclaim of duty on recovered
prevent reverse vapour flow and offer increased vapour at duty suspended installations.
integrity against system leakage.
3.7.8 Control for unloading operations
3. 7.7. 7 Where there is more than one loading island,
and there is a requirement for the vapour emitted from Readily accessible means should be provided at
each road tanker to be connected to a VRU, unloading facilities to enable the operator to shut offthe
consideration should be given to installing flame flow (including gravity flow) of product in an
arresters in the vapour collection pipework. A risk emergency.
assessment should review the probability that vapour in
the collection system is within its flammable range and 3.7.9 Platforms for top loading
the likelihood of ignitions occurring within the system,
including the tanker being loaded. 3.7.9.1 Platforms, which may be provided to give
Where installed, both the type and location offlame access to loading equipment above ground level, or
arresters should be reviewed to ensure that any ignition between loading equipment and the top of tankers,
in or around the vapour collection and recovery system should be designed so that they are the optimum height
does not escalate within the vapour pipework to any and length for the operations involved.
tankers connected. Flame arresters can be designed to
stop either slow moving flame fronts (deflagrations) or 3.7.9.2 Non-slip materials or design details should be
detonations. As deflagration arresters only stop flames used for the walking surfaces of platforms and the
close to the point of ignition, they should only be treads of access stairways, e.g. galvanised open mesh.
specified following a full design review to determine The platforms should be of adequate width to give free
their suitability as a safety related device in this passage around any loading equipment above the
application. Where a flame arrester is installed in the surface level of the platform. Handrails or other means
vapour collection system, consideration should be given to prevent falling should be provided. Reference should
to installing a pressure switch in the system upstream of be made EEMUA Publication No. 105.
the arrester. This should alarm when a high pressure Grab rails should be provided on loading gantries
condition occurs, possibly indicating fouling of the for personnel using tanker walkways during top loading
elements. A high pressure would indicate the potential operations and rail tank car walkways during unloading
for vapour release from the tankers being loaded. operations. A review of the length and depth of loading
bay guard/grab rails against the range of tanker sizes
3.7.7.8 Each island should be fitted with appropriate using the installation should be carried out to ensure
equipment (e.g. a manual block valve in the vapour line) adequate protection at all times.
to allow maintenance of the vapour collection Where adequate protection cannot be guaranteed
equipment whilst other loading islands remain for all different tanker sizes the use of fall arrest
operational. systems should be considered.
3.7.7.9 The vapour collection piping system should be 3.7.9.3 Adequate means of access to the platforms by
designed to be self-draining (e.g. the vapour line at each means of stairways with handrails, meeting accepted
loading island should drain towards the knockout pot at safety standards, should be provided. There should be
the island and the common vapour header from the an emergency exit at the opposite end of the platform
loading islands should slope towards a knockout pot at from the stairway either in the form of a second
24

stairway or a ladder. If it is a ladder it should have a valves (e.g. pressure surge) should be determined and
means of preventing a person falling off that end of the appropriate controls applied.
platform. The capability of the valve to close as prescribed
should be regularly checked by operating the meter pre
3.7.9.4 If access is required between fixed platforms set stop mechanism and recording the subsequent over
and the tops of tankers, hinged gangways or self run.
levelling steps will be necessary to prevent falls and
bridge the gaps or any difference in heights. 3.7.11.4 The site should have a reliable power supply
capable ofmaintaining essential supplies during an ESD
3.7.10 Stray currents, earthing and bonding event.
3.7.10.] Loading and unloading facilities should be 3.7.11.5 Manual intervention to stop product movement
electrically continuous and earthed, with means of for an ESD is not considered a satisfactory control
bonding tankers to the fixed facility, in accordance with measure. The control system should be designed to
the recommendations of IP Model Code of Safe Practice identify readily where the event occurred thus allowing
Part 1 Electrical safety code. The installation of earth any mitigating control measures to be implemented
interlock systems is recommended to prevent product efficiently. As the operation of loading a road tanker is
movements unless proper earthing connections have attended both locally and remotely, a facility for manual
been made. intervention to initiate ESD is required at both points.
3.7.10.2 Rail sidings for loading and unloading of rail 3.7.11.6 The activation of a fire alarm point should
cars should be provided with insulating joints to isolate initiate a site-wide ESD. The provision of a zoned fire
the track of the siding from the main line and to prevent alarm system may be considered. On islands loading
stray currents from electrified lines or railway signalling flammable liquids, two fire alarm break points should
track circuits. The siding track should also be be provided on the emergency egress routes. Dependent
independently earthed. on each individual site fire risk assessment it may be
appropriate to provide permanent fixed active fire
3.7.11 Loading island emergency systems protection in lieu of portable equipment.
3. 7.11.1 An emergency shut down (ESD) system should 3.7.11.7 Road tanker overfill prevention equipment
be provided at loading gantries in accordance with IP requirements are specified in IP Petroleum road tanker
Code ofpracticefor drivers ‘emergency actions on road design and construction. The tanker should be
loading racks. connected to the control unit on the gantry via a 10-pin
industry standard electrical connector. The male
3.7.11.2 The ESD system should be designed to: connector should be mounted on the tanker and the
stop all product movement on the affected loading female connector should be attached to a flying lead
gantry; connected to the island-mounted control unit.
stop flow of product to the affected loading island; Loading should not be permitted unless the
stop any pump supplying the loading island; combined earth!overfill control unit provides a
remove non-essential power from equipment permissive signal. In the event of an overfill condition,
controlling the flow of product to the loading or a loss of tanker earth, the control unit on the gantry
island, or group of loading islands. should close the gantry control valves. The tanker
should be bonded to the gantry via the common return
Where a series of loading islands are grouped together wire of the overfill sensors. In the UK this should be
or supplied with product from a common source, the connected to pin 10 on the male connector via the
grouping should shut down on ESD. tanker chassis; pin lOon the female connector should be
connected to the control-unit enclosure that should be
3.7.11.3 Equipment should be designed to ensure that connected to the gantry earth. The monitoring
when the non-essential supply is removed, it fails to a equipment should be positioned to avoid mechanical
safe condition, e.g. the loading island control valve damage whilst being clearly visible from the normal
should close. In a fault or stop condition the loading operational areas of the loading island.
island flow control valves should close sufficiently
quickly to ensure that no more than 150 litres ofproduct 3.7.11.8 The loading area should be provided with a
pass through the valve. The effect of rapid closure of permanent lighting system providing both area and task
25

specific lighting. Consideration should be given to 3.8.2.2 Connections between shore pipelines and
facilitating electrical isolation of each loading island vessels may consist of hoses, or of metal retractable
individually whilst retaining general area lighting. The swing arms, or a combination of both. Where hoses are
lighting circuits for task and area lighting should of a size which cannot be safely handled manually,
preferably be fed from different supplies. derricks or other mechanical hoists should be provided,
On larger sites the lighting supplies should be care being taken that hose slinging and securing gear do
further divided to allow maintenance of discrete areas not cause excessive curvature of the hose. Adequate
whilst normal operations continue in other areas. The access stairways or ladders and operating platforms
selection and positioning of light fittings should avoid, should be provided to facilitate the handling of flexible
where possible, lighting pollution. Lighting in the connections between ship and shore.
loading island area may be photocell controlled and be
provided with a remote override facility such that the 3.8.2.3 Piping, valves and fittings, including adaptors
lighting can be switched off during the hours of or extension pieces for ship to shore connections should
darkness when no loading operations are being carried be of steel or equally suitable material. Consideration
out. should be given to the use of quick release couplings in
the event that the ship’s mooring lines fail or need to be
3.7.11.9 Occasionally a driver may require assistance cut free. Shore pipelines should terminate at their
during the loading operation, generally of an offshore ends in steel valves, which should be located in
instructional basis. In addition it is desirable for the site a readily accessible position for operation in an
control room to be able to make verbal contact with the emergency.
driver when on the loading island to issue instructions Non-return valves should be fitted on the jetty or
and make safety announcements. A voice wharf pipelines as close as practicable to the ship
communication system should be provided between the connection to limit spillage in the event of a failure of
loading island and the control room where the nature of the ship to shore flexible connection. In the case of
the site dictates such a system to be beneficial. pipelines on a jetty, the incorporation of valves at or
near the inshore end of the jetty can be a means of
preventing loss of product in the event of damage to the
3.8 MARINE LOADING AND jetty or jetty approach.
UNLOADING FACILITIES
3.8.2.4 If it is not already a requirement of local
3.8.1 General regulations, consideration should be given to the need
for incorporating a heat shield for personnel on thejetty
Marine loading and unloading facilities should be to retire behind in event of a flash fire. This could be a
designed to meet the requirements of the International high pressure water curtain driven by dedicated pumps
safety guidefor oil tankers and terminals (ISGOTT) and and activated by conveniently placed and conspicuously
HSE publication HS(G)186. They should cater for the labelled emergency buttons. Consideration should be
full range of operating conditions including: given to locating additional remote monitors and
proximity and nature of local ship movements; variable sprays to give protection to isolating valves that
range of ship size; may need closing and to personnel access.
— manoeuvring room off the jetty;
sea conditions including tidal ranges and tide rates; 3.8.2.5 Pressure gauges should be installed, or
water depths and maximum swell during storms; connections should be available for their installation, on
change in draught of vessel during all shore pipelines as near as practicable to the ship, so
loading/unloading; that they are clearly visible to the operator in charge of
— wind direction and speed; and the flexible ship to shore connections and other
local methods of ship handling. discharge equipment. Since pressure gauges
permanently installed in exposed situations are liable to
3.8.2 Equipment at jetties and wharves deterioration if adequate protection from the weather is
not provided, it may be preferable to hold them in store
3.8.2.1 A resilient fendering system may be provided to be fitted only when product handling operations are
to minimise the effect of impact loads and distribute in progress.
them over a wide area of the ship and the jetty or wharf
structure.
26

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubsenergyinst.org.uk 1: +44 (0)207 467 7100
3.8.2.6 At major installations flow recorders, 3.8.4.3 All metal parts of the shore facilities should be
automated devices, remote control switches and power earthed; the ship will be earthed through the water. It is
operated valves may be considered. Automated and recommended that the earthing of the shore facilities
powered operated equipment should however be should incorporate a lamp or other device indicating the
designed to fail safe, and be suitable for manual state of the system in event of unsound earthing.
operation in an emergency.
3.8.4.4 Cargo hoses may be of conductive or non-
3.8.2.7 Ship to shore telephone or radio-telephone conductive construction, but when used to load or
communication is desirable particularly at major discharge petroleum, all metal connections on cargo
installations. The communication equipment should be hoses should be electrically connected to either the ship
of a design suitable for the classified area into which it or to the shore pipe work, but not both. To achieve this
could be taken. it is recommended either that one hose be of non-
conductive type, the others being conductive, or that all
3.8.3 Submarine petroleum pipelines hoses be the conductive type and an insulating flanged
joint be installed at the shore pipeline connection.
3.8.3.1 Submarine pipelines should be designed and
installed to comply with the requirements of BS EN 3.8.4.5 When petroleum is loaded or discharged using
14161. all-metal loading or discharging arms, an insulating
flanged joint should be installed in the loading
3.8.3.2 Submarine pipelines, which extend shore assembly. Care is necessary to ensure that the insulating
pipelines to open sea berths, should be constructed of joint is not short-circuited by bracing wires or other
heavyweight pipe, suitably anchored and protected conductors. Where a metal arm is used together with a
against corrosion and mechanical damage. length of flexible hose, an insulating flanged joint
should be installed where the hose connects to the metal
3.8.3.3 Valves on submarine pipelines should be arm.
constructed of steel. Where fitted under water they
should be power-operated and remote-controlled, or 3.8.4.6 Where insulating flanged joints are used,
self-closing and capable of manual operation in protecting covers should be provided to avoid the risk of
emergency. Non-return valves should be fitted at the causing a spark by accidental connection across the two
shore end. flanges.
3.8.3.4 Connections to the ship may be made through 3.8.4.7 In the case of submarine pipelines, the same
special buoy facilities or flexible hoses. In the latter situation can exist, and when conductive hoses are used
case, the hose should terminate in a self-sealing at a conventional buoy mooring, a length of non-
coupling or should be blanked off after use and marked conductive hose should be fitted into each hose string.
by means of a buoy to permit easy recovery. Insulating flanged joints are not suitable for submarine
use. Submarine hoses connecting the submarine pipeline
3.8.4 Protection against static electricity, to a single buoy mooring should all be of the non-
lightning and electric currents conductive type, so as to insulate the buoy from any
cathodic protection on the pipeline.
3.8.4.] International safety guide for oil tankers and Hoses used on the surface between a single buoy
terminals (ISGOTT) and IP Model Code of Safe mooring and the ship should be of the conductive type.
Practice Part 1 Electrical safely code, provide guidance Where a buoy has cathodic protection, precautions
on safety facilities and safe operating practices. The should be taken to prevent the flow of cathodic
following sub-clauses serve to emphasise certain protection currents to the ship by the use of either a non-
important features. conductive hose or other means. In all cases where a
submarine pipeline is cathodically protected, an
3.8.4.2 If an electrically conducting path is present insulating flanged joint should be fitted at a convenient
between ship and shore facilities, electric currents point where the pipeline comes ashore.
arising from cathodic protection or stray sources could
flow from ship to shore or vice versa, and any such 3.8.4.8 All product movement operations should be
currents could cause a spark if the conductive path is stopped during periods of lightning or electrical storms.
disconnected. For this reason it is recommended that no
ship to shore bonding cable is provided.
27

3.8.5 Vapour collection systems A storage tank vapour balancing system where
vapour displaced from loading road tankers and
3.8.5.1 Guidance on the design, construction and railcars is piped back to storage. In this
operation ofvapour collection and control systems, with arrangement the VRU can be sized according to the
emphasis on the reductions in risk from ignition maximum vapour flow from the tanks when they
propagation and pressurisation, is provided in the are being filled plus tank breathing and any vapour
International Maritime Organisation publication imbalance due to the loading of products from
MSC/Circ. 585 Standards for vapour emission control tanks not connected into the balancing system.
systems.
3.9.1.3 In some locations it may be possible to burn
3.8.5.2 The control of vapour emissions from marine the recovered vapours for power generation purposes.
gasoline loading, particularly of seagoing tankers, At small or remote locations vapour destruction by
introduces more risks than equivalent systems for road flaring may be appropriate.
tanker loading. This is because the vapour concentration
remains in the flammable range for considerably longer 3.9.1.4 The safety implications of all the above
than for road loading. To reduce the risks from ignition systems should be carefully reviewed e.g. by I-IAZOP,
propagation, flame arresters should be installed in the possibly in conjunction with a quantitative risk
vapour lines, with one on the jetty close to the ship assessment (QRA) study. This review should cover the
connection. system as a whole and not just the VRU, which may be
connected to a number of different parts of the
3.8.5.3 Depending upon the type of emission control installation. The review may identify that flame
system used, the lines may need to have inert or arresters are required to prevent an ignition propagating
enrichment gases added to ensure that vapour is always through the vapour pipework. Manufacturers’ guidance
outside of the flammable range. on the type of arrester required, its installation and
operation should be obtained.
3.8.5.4 Vapour lines may be of considerable length if
the loading jetties are some distance from the shore. 3.9.2 Design considerations
Blowers may be required to overcome the resultant
higher pressure drops in these lines, resulting in There are a number of technologies for vapour recovery
increased risks from over- and under-pressurisation of systems available:
the vessel cargo tanks. absorption;
adsorption;
membrane separation;
3.9 VAPOUR RECOVERY AND condensation.
EMISSION CONTROL
In general, the pressure available to transfer vapour
3.9.1 General through the recovery systems is limited. It will therefore
be necessary to consider the pressure drops throughout
3.9.1.] Where local legislation requires control of the system in detail to ensure that adequate flow rates
emissions, such requirements will need to be taken into can be achieved. Pressure drop calculations should take
account as part of the design process. Guidance for account of the density of the hydrocarbon vapour being
appropriate practical control measures is given in IP transferred at the maximum design hydrocarbon
Guidelines for the design and operation of gasoline concentration. In the case ofroad loading systems in the
vapour emission controls. EU, a maximum pressure of 55 mbarg is available on
the tanker side of the vapour adaptor fitted to the road
3.9.1.2 A complete vapour recovery installation tanker.
comprises:
3.9.3 Vapour holding tanks (VHTs)
— A vapour recovery unit (VRU), to recover
hydrocarbons from vent streams. 3.9.3.1 Vapour holding tanks may be used to eliminate
— A vapour holding tank, incorporating an peaks in vapour flows from loading gantries andlor to
impervious internal diaphragm, to smooth out store the vapours produced by storage tank breathing. In
peaks in vapour flow thus enabling a smaller VRU this way they may permit the installation of a smaller
to be installed. VRU, and the possibility ofreduced power tariffs (if not
28

used at periods of peak power demand). conductor in accordance with the recommendations of
IP Model Code of Safe Practice Part 1 Electrical safely
3,9.3.2 VHTs are normally above-ground vertical code.
tanks; they should be constructed in accordance with
BS EN 14015 or equivalent and should incorporate a 3.9.3.10 A pressure/vacuum valve should be installed,
weak roof to shell seam. connected to the vapour space beneath the diaphragm.
Spherical or horizontal tanks may be used for The valve should be located to permit ease of
vapour holding duty. maintenance.
The relief pressure should be well within the tank
3.9.3.3 When considering safety distances to other design rating. The pressure valve venting capacity
tanks, a VHT should be treated as a normal gasoline should be at least equal to the maximum design vapour
storage tank. As it does not contain any liquid it is not flow rate in the vapour header.
necessary for it to be located within a bund.
3.9.4 Vapour lines
3.9.3.4 Tanks for VHT duties should preferably be
symmetrical and the di aphragm joined to the shell at the 3.9.4.1 The vapour lines in to and out of the VHT
mid-height of the tank. After construction of the tank should be separated by at least 90 degrees to ensure
(and before the diaphragm is fitted) it is important that good mixing of the vapours within the VHT.
all internal welds are ground down to remove any
abrasive points, and consideration may be given to 3.9.4.2 A VHT by-pass line should be installed to
having the internal tank shell plates blast-cleaned to allow vapour to be fed directly to the VRU from the
remove mill scale, and painted to reduce abrasion of the loading gantry without having to shut down loading if
diaphragm due to rust. the VHT is out of service. The by-pass line should be
fitted with a flow rate controller and emergency vent
3.9.3.5 Perimeter vents should be fitted around the facility. The valves on this line should be locked shut
tank shell just above where the diaphragm is joined to when not in use.
the shell to allow ventilation of the space above the Note: When a VRU is used in conjunction with a
diaphragm. One vent should be installed within reach of VHT, the VRU can be sized to process the vapour in the
the tank stairway to permit manual detection of vapour. VHT at a steady continuous rate over many hours.
All vents should incorporate bird screens. However if the VHT is not in service and vapour is fed
directly to the VRU, loading restrictions may need to be
3.9.3.6 The diaphragm material should be able to introduced to prevent overloading of the VRU.
dissipate electrostatic charge or should be anti-static; it
should have an appropriate fatigue resistance and be 3.9.4.3 Vapour lines may be constructed in any
resistant to oxygenates in the gasoline vapour. material suitable for the duty, but they should be
electrically conductive throughout their length.
3.9.3.7 A roofvent should be provided that is suitably-
sized having a minimum open area of 300 cm 2 (46,5 sq 3.9.4.4 Apart from connections in and out of vessels,
inches). tanks and/or equipment, vapour lines should be run
A roof access manway should be provided to above ground level and should be designed without low
permit inspection and maintenance. If a simple points where liquid may accumulate.
mechanical level gauge is used in the VHT, it is
recommended that the manway be positioned adjacent 3.9.5 Vapour blower
to the gauge tape entry point on the roof to permit ease
of maintenance of the gauge. 3.9.5.1 A vapour blower may be required with a low
pressure VHT, i.e. a VHT that operates at a lower
3.9.3.8 Failure of the diaphragm will result in vapour pressure than the pressure drop through the VRU at
emissions from vents of the VHT. It is recommended design flow rate. This blower should have:
that a portable hydrocarbon detector is used at regular sparkiess blades;
intervals to measure for any hydrocarbons at the vent leak-tight mechanical seals;
located near the stairway. a fault alarm that activates a common VHT alarm
in the control room; and
3.9.3.9 All electrical conducting materials within the an explosion-proof motor housing.
VHT should be securely bonded to earth with a
29

the licence terms and conditions, It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk 1: +44 (0)207 467 7100
3.9.5.2 Consideration should be given to installing a tanks in systems with vapour balanced storage tanks, an
flow meter in the inlet line to the VRU, after the by-pass accurate estimation of fixed roof storage tank breathing
line to ensure that the blower is operating satisfactorily rates (caused by temperature changes within the tank
and/or to control flow to the VRU via the by-pass line ullage spaces between night and day) is required.
if the VHT is out of service. A fine mesh filter should Breathing rates are dependent primarily on ullage,
be installed upstream of the meter. volume, type oftank roof and colour. It is recommended
Consideration should also be given to the need for that the worst case condition for tank ullage volumes
a flame arrester. (all tanks at minimum working volumes) be used in
calculating breathing rates.
3.9.6 VRU controls
3.9.7.4 To prevent significant vapour losses, manual
Where a VRU operates in conjunction with a VHT, the dipping, sampling or ullaging through conventional roof
operation of the VRU may be stopped and started by dip hatches should not be undertaken. Tanks should be
preset low and high level switches fitted to the VHT and fitted with:
operated by the diaphragm as it rises and falls. The tankside sampling systems or partially closed tank
same level switches can be used to activate the vapour roof sampling systems; and
blower. tank gauges for level measurement.
A high level alarm should also be fitted. This
should activate an alarm (common VHT alarm) in the 3.9.7.5 The branch vapour line from the tank should
control room and an ESD to prevent more vapour being slope towards the main vapour header to prevent a
fed to the VHT, but not the VRU emergency stop device build-up of condensate. If a low point is unavoidable,
(ESD). condensate detection and drainage or pump-over
facilities are necessary.
3.9.7 Storage tank balancing systems The vapour line to each tank should be fitted with
a shut-off valve to permit isolation of the tank and
3.9.7.] Vapour displaced from road tankers being vapour line. This valve should be locked open in normal
loaded with product is piped back to storage tanks. The operation.
VRU required needs only to be sized to cope with the Connection points for pressure gauges should be
vapour flow from the storage tanks when they are being installed at appropriate points in the vapour collection
filled plus tank breathing and any vapour imbalance due system to permit the detection of a blockage if one
to loading of product (such as diesel fuel) from tanks occurs.
not connected into the balancing system.
To prevent product contamination, due to 3.9.7.6 The VRU (and vapour blower where installed)
absorption or condensation of vapour, only gasoline should be switched on and off when the pressure in the
tanks should be connected into the balancing system. vapour balancing system reaches certain set points.
The pressure sensor/switch should be installed in
3.9.7.2 When tanks are connected into a balancing one of the tank ullage spaces. The sensor should not be
system, the vapour spaces will all be at the same located in the vapour line as the pressure there can vary
pressure and this can be up to the maximum design rapidly.
pressure drop through the vapour collection piping and Consideration should be given to fitting pressure
VRU. sensors in at least two tanks to permit tank maintenance
Tanks connected to the vapour balancing systems without shutting the system down.
should have design pressures in excess ofthis maximum
pressure drop. If the design pressure ratings are too low 3.9.7. 7 Where a vapour blower is installed, it should
then: meet the requirements specified in 3.9.5. It may be
the tanks should be strengthened to be suitable for mounted either at the inlet or the vent of the VRU.
the operating pressure of the system; or The blower should have a fault alarm that activates
a vapour blower should be incorporated in the a common VRU alarm in the control room.
vapour collection system or on the VRU vent. A flow meter should be installed in the inlet line to
the VRU to ensure that the blower is operating
The tanks should be vapour-tight, e.g. all openings in satisfactorily and to permit the vapour flow to the VRU
the tank roofs should be sealed during normal operation. to be controlled within the design limits. A fine mesh
filter should be installed upstream of the meter.
3.9.7.3 To size correctly VRUs and vapour holding
30

3.9.7.8 The tanks should be protected from over- and pneumatically.

under-pressure with pressure/vacuum valves in case of b) Hand-dosing typically from the top of tank truck
blockage of the vapour line or inadvertent closure of the compartments.
line valve. c) Metering pumps.
These valves should be sized to cope with the d) Piston-based injectors, pressurised system.
maximum vapour vent flow due to the combination of e) Electronic-controlled injectors, pressurised system.
tank filling and tank breathing. Emergency venting
capacity should be in accordance with API Standard 3.10.1.2 Product additives are a complex mixture of
2000. amines and solvent components. Precautions should be
exercised in handling and when working on additive
3.9.8 VRU reclaimed product systems.
Certain cetane improvers, commonly used in diesel
3.9.8.] Product recovered from gasoline loading in a fuel additives, decompose exothermically at elevated
VRU is essentially a mix of butane and propane and temperatures. It is therefore necessary to assure all
hence will be considerably more volatile than gasoline. equipment is suitable for use and that the safety
Care needs to be taken, therefore, when returning it to integrity level ofthe system is adequate. The design and
main storage. The design of the return line should location of adjacent equipment where an exothermic
ensure that the recovered product is well mixed into the additive could leak or spray should also be considered.
receiving gasoline tank to prevent the recovered product
from flashing off in storage. 3.10.2 Point of injection
3.9.8.2 The return line in the tank should be in the 3.10.2.1 There are many factors that influence the point
form of a sparge pipe extending to the centre of the at which additive is added to the base product, including
tank. Where the VRU uses gasoline as an absorbent, the type of facilities available, whether these are shared
consideration should be given to separating the outlet or owned by third parties, and the extent of product
and return absorbent lines in the tank by at least 90 exchange agreements. Before it is decided to inject at
degrees. the loading gantry, the advantages and disadvantages of
other locations should be considered.
3.9.8.3 It is preferable to have connections into at least
two tanks to enable maintenance to take place without 3.10.2.2 Where product is required both with and
shutting down the system. without additive, or where third parties require different
additives, the additive will normally be injected at the
3.9.8.4 As the recovered product will increase the gantry, just upstream of the product flow meter. For
volatility of the receiving gasoline, the volume and injecting additives when loading tankers, various
turnover of the gasoline in the receiving tank should be systems are available.
sufficient to ensure that the upper volatility limit The most suitable type of equipment for any
specification of the gasoline is not exceeded. particular application will depend on the physical
properties of the additive to be injected and on the
3.9.8.5 Pipe runs should be constructed of seamless injection rate.
pipe API Standard 5L or similar. All valves and fittings
should be of cast steel. 3.10.2.3 For injection of additives while loading, pulse
signals taken from the product flow meters can be used
to control the injection operation. Provision for such
3.10 ADDITIVE INJECTION control should be incorporated in the electronic control
equipment (if available) or the installation of an
3.10.1 General electrical pulse transmitter to the loading meter.
3.10.1.1 Additives may be added for several reasons 3.10.2.4 To avoid cross-contamination between loads,
such as safety, quality improvement, tax law (to the injection system should be designed to stop injecting
distinguish products to deter their illicit use) and most additive prior to the end of the load thus leaving the
commonly, product differentiation. Additive injection at loading meter stream and loading arm purged of all
terminals has evolved as follows: additivated product. This normally requires the use of
an electronic control system that recognises the load
a) Injectors actuated by meters mechanically or size prior to the start of the load and that subsequently
31

initiates additive injection at rates slightly above 3.12 PACKAGE FILLING AND PACKAGE
proportionality to compensate for the fact that the last STORAGE BUILDINGS
part of the load should receive no additive.
3.12.1 General construction
3.10.2.5 The injection of additive requires the additive
system to operate above the product line pressure. The 3.12.1.1 Materials used for the construction of package
interaction of two pressure systems (product and filling and storage buildings should be fire-resistant and
additive) creates a number of significant challenges, materials for the construction of equipment should be
principally the need to prevent the migration of non-combustible.
product/additive to and from each system.
Experience has shown that the additive system 3.12.1.2 Floors may be tiled, paved or concrete, but
should be designed robustly such that the forward/back where drums are filled and loaded, steel or other oil-
flow of product is prevented, both during operation and and wear-resistant impervious flooring is recommended,
during periods when the additive system is not and consideration should be given to the containing and
operational; monitoring equipment and control cleaning of spills.
interlocks for such events are recommended.
3.12.2 Heating
3.10.2.6 Additive systems should be kept completely
segregated with separate product line connections. Buildings in which petroleum is stored or handled
Thermal relief arrangements should be given careful should preferably be unheated, but where heating is
consideration in the design of systems. required it should be provided by means not constituting
a source of ignition.
3.11 BLENDING 3.12.3 Ventilation
3.11.1 Additive injection is not considered a part of 3.12.3.1 Buildings should be adequately ventilated
the blending process but a separate function; blending either by natural or mechanical means. Those for
systems generally consist ofcombining greater volumes storage and handling of Class I or 11(2) petroleum
of components. Blending is generally required to form should have, as a minimum, natural openings in
an intermediate grade, and can offer both cost and opposite sides near to the floor and the roof, or they
product availability advantages by reducing the number may be constructed with open sides, in which case entry
of product storage tanks required. of unauthorised persons may be prevented by means of
metallic open mesh material.
3.11.2 The design of the system should recognise
restrictions imposed by the point at which duty is paid 3.12.3.2 Class I or 11(2) petroleum should not be stored
for the blended product and the components thereof. or handled in any part of a building below ground level
Sequential blending allows tailoring of the loading unless that part of the building is provided with
metering (where each blend component is loaded one at ventilation sufficient to prevent the accumulation of
a time and product mixing occurs in the tanker flammable or toxic vapour. Consideration may need to
compartment). This process is not suitable for heavy be given to the installation of a gas monitoring system.
products since sufficient mixing is unlikely to occur.
3.12.4 Service doors, windows and skylights
3.11.3 In-line blending is the process where all
components used in the blend are individually metered Doors should be placed and constructed so as to provide
and controlled simultaneously to precise ratios, and in a ready means of escape in the event of fire; they should
which mixing occurs in the blend discharge pipe be not less than 900 mm wide and should open
resulting in blended product being loaded into the tanker outwards.
compartment from start to finish. Wired glass should be used in the glazing of
windows and skylights.
3.11.4 Thermal relief arrangements should be given Escape routes should be in accordance with the
careful consideration in the design of blending systems. local fire precaution regulations but it is recommended
that at least two protected means of escape are provided.
32

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unsuthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44(0)207 467 7100
3.12.5 Packaging machinery 3.13.2 Spillage
3.12.5.1 Packaging systems should be designed to Leakage of products from storage can create a
minimise manual handling by providing suitable hazardous situation and cause pollution, so provision
conveyers and trolleys as appropriate. should be made to prevent uncontrolled outflow of
products from the storage area by the use of, for
3.12.5.2 All exposed gears, chains and similar example, low containment walls and impervious
dangerous moving parts should be provided with safety flooring.
guards to prevent accidental injury; the guards may be
fixed or automatic.
3.14 DRAINAGE
3.12.5.3 Adequate spacing should be provided around
machines to allow safe operation and maintenance. 3.14.1 General
3.12.5.4 Where required, exhaust extraction suctions Surface water drainage systems should be sized and
should be located close to the filling points. designed taking into account the known rainfall
Fumes/vapour should be discharged into an external conditions in the area and the levels ofuncontrolled run
safe area at points where recirculation or collection in a off. It is uneconomic to design for the heaviest rainfall
confined space is avoided. that could occur so it is accepted that under certain
exceptional conditions parts of the installation could be
3.12.5.5 To prevent overfilling, containers should flooded for short periods. In these instances precautions
preferably be filled using a preset batch meter or similar should be taken to ensure there is proper containment
arrangement. and no spread of contamination. As guidance, it should
be assumed that flooding from maximum expected rates
3.12.5.6 Due to the possibility of generating of rainfall and storm duration should not disrupt
electrostatic discharges during the filling of plastic operations for more than one hour.
containers, the filling of containers greater than 5 litres Further guidance on site drainage systems is given
capacity should be avoided where possible, particularly in IP Environmental guidelines for petroleum
where particles, water or vapour may be entrained. distribution installations.
When larger containers are filled, the flow rate
should be limited and a bonded metal fill pipe extending 3.14.2 Oil/water separators
to the bottom of the container should be used to
minimise the generation of electrostatic charges. 3.14.2.1 An oil/water separator designed to handle the
maximum discharges from the surface water drainage
3.12.5.7 Fine filtration can increase the generation of system would be a very large facility. It is suggested
electrostatic charges; where they cannot be avoided in that a facility capable of handling a proportion of this
the filling system, alternative controls for flow rate and run-off is provided in conjunction with a storm by-pass
relaxation time to minimise eletrostatic charge arrangement to handle excess. The percentage of
generation should be considered. These restrictions do maximum flow to be treated should be agreed with the
not apply where containers are used only for relevant regulatory authority.
unclassified products.
3.14.2.2 Where insufficient fall is available to permit
gravity discharge from the site it will be necessary to
3.13 PACKAGE STORAGE AREAS use lift pumps. These should preferably be placed on the
OUTSIDE BUILDINGS outlet side of the separator. Careful choice of pumps
(e.g. use of low shear pumps) placed on the inlet side
3.13.1 Construction will be required to prevent the emulsification of any oil
and hence a reduction in separator efficiency.
The area selected for storage should be secure from
flood water and provided with adequate drainage. The 3.14.2.3 Site topographical conditions will determine
base may be constructed in any suitable material which the number ofseparators required. Consideration should
will give adequate support for the loads to be carried, be given to segregating those areas used for storage and
including any mechanical handling equipment general operations from those used for cleaning road
employed. tankers where detergents and release agents may be
33

used. Discharges requiring special treatment should be 3.14.3.3 Provision should also be made to permit the
passed to an on-site treatment plant designed for the sampling of tank water bottoms to facilitate checking
specific duty or to the local foul water sewer. for the presence of microbial contamination.
3.14.2.4 Choice of separator design ranges from the 3.14.4 Loading island drainage
simple gravity separation chambers to more
sophisticated methods involving monitoring and control. 3.14.4.1 Surface drainage from loading islands should
The choice of system will be influenced by permissible be designed to cope with accidental product
limits of contamination of the final effluent and spillage/release. The loading area surface water
operating costs and the destination of the effluent. drainage system should be connected into an oily water
collection system capable ofreceiving and retaining the
3.14.2.5 The retention time within a separator relying largest reasonably foreseeable spillage in the loading
on gravity separation should be sufficient to permit oil bay.
to rise to the surface. It has been found in practice, that
for a distribution installation, an average flow velocity 3.14.4.2 The type of drainage collection system should
of I m/min and a rising velocity of 0,1 rn/mm are be determined on a site-specific basis. Where it is
satisfactory. necessary to minimise the extent of the hazardous area
the drainage system should be designed to retain any
3.14.2.6 Separators should be provided with isolating accidental release within the confines of the loading bay
valves on the inlet and outlet. To facilitate cleaning it area. This drainage design creates a high point around
may be desirable to divide the separator into two the loading bay with accidental release directed to either
parallel channels with isolating valves on each. The drainage channels or a series of gullies within the
loading bay area.
adoption of sludge traps prior to the separator should be
considered. Consideration should be given to the
3.14.4.3 It is preferable to avoid positioning
installation ofautomatic oil detection which could alarm
drainage/drainage channels under the area intended for
and/or operate the inlet/outlet valves.
tankers to park whilst being loaded. Drainage gullies
and channels should not be positioned under the
3.14.2.7 Covered oil separators should be adequately
tanker’s engine or exhaust.
ventilated.
3.14.4.4 In order to minimise maintenance of the road
3.14.2.8 Separators should be readily accessible for
pavement it is preferable where possible to avoid tanker
inspection and cleaning. wheel paths traversing gullies and associated manholes.
3.14.3 Tank water bottoms 3.14.4.5 Tanker loading areas should be constructed in
reinforced concrete with all joints sealed with oil-
3.14.3.1 Where water is to be drained from storage resistant sealants.
tanks, consideration should be given to selecting the
most appropriate means of disposal. The drained water 3.14.4.6 A secondary containment membrane should be
should generally be piped to an oil/water separator as considered under the road pavement in new loading
described above. However, where the water is likely to gantry areas. The continuity of the site earthing system
contain material which will not readily separate from should be reviewed when considering installation of
water, consideration should be given to providing a membranes.
collection system which enables the contaminated water
to be collected and sampled, for disposal off site if 3.14.4.7 Drainage systems should be checked for
necessary. For example, such a collection system may leakage following construction.
be necessary where products contain Methyl Tetra Butyl
Ether (MTBE) because of the low concentrations at
which it can be tasted in water. 3.15 SAFETY AND DIRECTIONAL SIGNAGE
3.14.3.2 In order to minimise the amount of oil passing Adequate safety and directional signage should be
to the separator from draining of water bottoms, erected before the installation accepts product.
consideration may be given to installing an intermediate Reference should be made to HSE publications SI 859
separation tank enabling recovery of the oil and return and 1471, BS 5378 and BS 5499. In addition specialised
to storage. instructional signs may also be required and erected.
34

3.16 FINAL PROJECT DOCUMENTATION can create a fire risk. Other examples include substances
which decompose or react exothermically when heated
On completion ofconstruction ofthe installation, or any (e.g. certain cetane improvers).
new facilities on it, adequate documentation should be For further details see IP Model Code of Safe
passed to the operator to allow the installation to be Practice Part I Electrical safely code and IP Model
safely and efficiently operated and maintained. As a Code of Safe Practice Part 15 Area class (fication code
minimum this should include, as appropriate, the for installations handlingflammable fluids.
documentation described in Annex C.
3.18 SAFETY-RELATED CONTROL

3.17 ELECTRICAL AND MECHANICAL SYSTEMS
EQUIPMENT AND PROTECTIVE SYSTEMS
INTENDED FOR USE IN POTENTIALLY 3.18.1 General
EXPLOSIVE ATMOSPHERES
The current relevant safety standard for safety-related
3.17.1 General control systems is IEC 61508/61511 Functional safely
ofelectrical/electronic/programmable electronic safety-
3.17,1.1 European legislation applies to electrical and related systems; it is the benchmark for tank high level,
mechanical equipment and protective systems intended tanker earth and overfill protection and other safety
for use in potentially explosive atmospheres. These related control systems.
include: When a system is being used to carry out a risk
reduction measure, the safety and reliability of the
Equipment and protective systems for use within system should be ensured throughout its lifecycle,
potentially explosive atmospheres. including design, construction, commissioning,
Devices for use outside potentially explosive operation, maintenance and testing, modifications and
atmospheres, but which are required for, or de-commissioning. This information should be
contribute to the safe functioning of equipment and documented to ensure traceability.
protective systems located inside such
atmospheres. 3.18.2 Design
Components relating to the above.
There should be a clear description of:
3.17.1.2 The EC Directive 94/9IEC has been
implemented in Great Britain by The Equipment and Each ofthe safety-related systems and its functions.
Protective Systems Intended for Use in Potentially The standards to which each of the systems are
Explosive Atmospheres Regulations 1996, as amended designed.
in 2001; the amendment principally covers the concept The process by which the risk reduction/safety
of’putting into service’. integrity for the function required is identified.
The process by which the site operator ensures that
3.17.2 Determination ofthe presence of dangerous the relevant safety integrity is achieved.
substances
3.18.3 Construction/commissioning
3.17.2.1 It should be determined for all products being
handled whether they have been classified as explosive, Safety-related control systems should be installed to a
oxidising, extremely flammable, highly flammable or satisfactory industry standard and should be properly
flammable; the products used and stored may extend calibrated to reflect the safety requirements
beyond the principal fuels and include products such as specification of the system.
fuel additives.
3.18.4 Operation
3.17.3 A risk analysis should be performed, based on
an assessment of the physical and chemical properties All process conditions should be considered in the
ofthe substances and the circumstances of the handling operation of the safety system; these should include
of those substances, to consider if a safety risk to abnormal conditions such as may be experienced during
persons could be created from a fire or explosion. start-up and shutdown. Under all these conditions the
For example diesel (or other high flash point safety integrity of the systems should not be
product), ifreleased in a high-pressure mist in a process, compromised.
35

DESIGN, CONSTRUCTION AND OPERATION OF PETROLEUM DISTRIBUTION [NSTALLATIONS
3.18.5 Maintenance competent personnel.
Items of the safety-related system should be identified 3.18.6 Modifications

for planned maintenance and testing; procedures should
be put in place that: Strict procedures should be put in place to ensure that
determine what maintenance and testing is carried instrument protection and control systems are assessed
out; as an integral part of any plant modifications. Any
lay down how the work is to be carried out: alterations made to the hardware or software of the
establish time schedules in line with manufacturers systems should be under strict control to ensure that the
recommendations or relevant historical data; integrity of the system is not compromised.
— ensure that the work is only carried out by
36

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44(0)207 467 7100
4
OPERATIONS
[Note: IP HM 31 Guide to hydrocarbon management in petroleum refinery operations provides complementary
guidance on the handling of products within a terminal, and should be read in conjunction with the relevant parts
of this Section.1
4.1 GENERAL 4.1.2 Security
4.1.1 Compliance Security of installations should be consistent with

safeguarding the general public, operating personnel,
The operation of a petroleum storage installation should products handled and plant and equipment. Access gates
take account of all relevant legislation, and in particular should be monitored continuously while the installation
health, safety and environmental considerations. Where is open and it is recommended that inspections be made
there is no applicable legislation, recommended industry of the perimeter fence at least once during every shift.
practices should be adopted. For marine facilities the recommendations of the
To demonstrate compliance, it is recommended IMO/ILO Code ofpractice on security in ports MESS
that: HP/2003/14 should be applied in accordance with the
installations approved Security Plan.
Approved written procedures are provided for all
activities including maintenance. 4.1.3 Staff
Detailed procedures are available for effective
response to emergency incidents. To ensure that the operation of the installation is
Records are kept identifiing everything that conducted in a proper manner, protecting both safety
happens within the installation and anything and product quality, only appropriately qualified and
outside that affects the operation of the installation experienced staff should be employed. Effective
(see Annex C). training is required and personnel should not be allowed
Note: These should be retained for a sufficient to use equipment or plant for which they have not
period to comply with local legislation or internal received comprehensive instruction. All operating
organisational standards. personnel should be familiar with the general layout of
All operational procedures, as well as being the installation.
checked for compliance with industry practices, A location plan, product flow diagram and an
should be the subject of a risk assessment: earlier emergency facilities plan should be readily available to
risk assessments carried out in conjunction with the staff for reference in an emergency.
planning and design of the installation may form
the basis ofthese assessments. Reference should be
made to HSE publications HS(G)176, HS(G)186
and INDG 163.
37

IMPORTANT: This file is sublect to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
4.1.4 Facilities 4.2 LOADING AND UNLOADING

OF ROAD TANK TANKERS
4.1.4.1 All areas should be maintained in a clean and
tidy state with regular inspections carried out. Any 4.2.1 General
equipment found not to be functioning as intended, orto
be defective, should be reported in writing and, where 4.2.1.1 If a loading bay is occupied, a tanker
appropriate, isolated. approaching that bay should not come closer than 6 m
from the loading position and the engine should be
4.1.4.2 Where there is an approved and standard stopped. This distance may be controlled by a warning
colour code in use (e.g. TP Code of practice for a line on the ground. Loaded tankers should be parked
product identfication system for petroleum products), greater than 6 m clear of the loading gantry.
this should be incorporated in the identification scheme
related to the product flow diagram. 4.2.1.2 While loading or unloading is in progress,
tankers should not be left unattended and the parking
4.1.4.3 Pipelines should be adequately identified brake should be applied.
throughout their length. Where manifold or branch
connections exist they should be appropriately marked. 4.2.1.3 While loading Class I or Class II petroleum,
the engine of the tanker being loaded and the battery
4.1.4.4 Particular attention should be given to pipeline master switch should be switched off. The engine
termination points by marking the pipe immediately should not be restarted until all caps, valves or covers
adjacent to all valves at loading/off-loading facilities, on the tanker have been closed and securely fastened,
pumps and tank connections. and the loading arms placed in the parked position.
4.1.4.5 For equipment such as valves, fittings etc. an 4.2.1.4 Electrical continuity (bonding) and earthing is
alternative method of identification may be required, always necessary when handling Class I and Class II
e.g. embossed tags or stencilled numbers related to the petroleum and particularly when switch loading.
product flow diagram on display at the installation. Bonding connections should be made in accordance
with recommendations of IP Model Code of Safe
4.1.4.6 Each tank should be clearly marked with the Practice Part 1 Electrical safely code, and before any
tank number, preferably near the inlet valve and dip other connection is made or loading operation
hatch. Consideration should be given to marking the commenced.
grade of product stored. Note: the bonding connection is normally an
intrinsic part of an overfill prevention system.
4.1.5 Supervisory controls
4.2.1.5 Wherevapourrecovery ispractised,thevapour
4.1.5.1 All activities on the installation should be recovery hose should be connected to the tanker before
subject to the control of a duty supervisor. No work any liquid loading hose.
involving maintenance or alterations and additions to
the existing facilities should start until the duty 4.2.1.6 When tankers are top loaded with Class I or
supervisor has given approval. Where appropriate, work Class II petroleum, or when switch loading occurs, the
permits should be issued and rigidly enforced. It is drop pipe of the loading arm should be lowered to the
recommended that a display and record system be bottom of the tank compartment before loading
established and spot audits be carried out to check the commences to avoid splash loading.
effectiveness of the permit system and the results
recorded. Further guidance is available in the HSE 4.2.1.7 Any tanker dip rods for measuring tank
Guidance on permit-to-work systems. contents should be securely stowed after use.
4.1.5.2 There should be an approved procedure for 4.2.1.8 Managers of installations should satisf’
hand over between supervisors; this should include themselves, for example by arranging spot
signed acceptance of a status report at the end of shift examinations, that tankers using the loading facilities,
by both supervisors. whether their company’s own or operated by third
parties, comply with minimum safety standards and,
where bottom loading is operated:
38

OPERATIONS
Are leakproof to avoid loss of vapour. 4.2.2.5 On completion of loading, arms should be
Have overfill prevention sensors that are regularly removed or hoses disconnected and stowed clear of the
checked to ensure that the ullage setting remains as tanker; all tank openings should be closed and fastened.
designed. Any movable steps or platforms on the loading rack
The operation of all pressure/vacuum valves is should be returned to the stowed position. Bonding
checked on a regular basis in accordance with any cables should remain connected until all other
local regulations. connections have been removed.
4.2.1.9 Only authorised and trained drivers should be 4.2.2.6 Open containers, e.g. a mobile slops trolley
allowed to load their tankers. All other drivers should containing Class I or Class 11(2) petroleum, should not
load under direct supervision. be permitted to remain in the loading or unloading area.
4.2.2 Procedures 4.2.2.7 All liquid hoses (100 mm nominal bore and
above) should be given a reference number or code;
4.2.2.1 When switch loading tankers, vapour in the they should be tested six-monthly for elongation and
tank may remain for a significant period within the electrical continuity, and inspected for wall
explosive range. In order to minimise the risk of deformation. All test results should be recorded in a
ignition, loading should start at a reduced rate until the hose register.
outlets of the fill pipe are submerged, see IP Model
Code of Safe Practice Part 21 Guidelinesfor the control 4.2.2.8 Loading arms or hoses should be properly
ofhazards arisingfrom static electricity. This assists in stowed after use and before movement of the road
minimising the build-up of electrostatic charge within tanker.
the tank. Thereafter loading rates may be increased.
Under such conditions it is emphasised that top loading 4.2.3 Emergency action
fill pipes should reach the bottom of the tank and should
be in a vertical position. IP Code ofpractice for drivers’ emergency actions on
road loading racks gives advice concerning the
4.2.2.2 When loading road tankers designed only for precautions and action to be taken in the event of a fire
top loading, the foot valves should be closed before or spillage of product.
loading commences. When top or bottom loading road
tankers designed for bottom loading the foot valves
should be open and only closed after completion of 4.3 LOADING AND UNLOADING OF
loading. When top loading, the only fillcovers RAIL CARS
Cmanlids’) open should be those of the tank
compartments which are in the process of being filled. 4.3.1 General
4.2.2.3 Before loading a tanker, effective measures 4.3.1.1 The entrance and exit of railcars should be
should be taken so that the correct product is being supervised by a competent person. Some positive
loaded into each compartment. Particular attention precautions such as a barrier, or locking points in the off
should be paid to ensuring that the tank compartment is position, should be taken to avoid locomotives or other
not overfilled. It is important to check before loading trains from entering any track where loading or
that the compartment is either empty, or that the unloading is taking place.
quantity and type of product which it already contains
are taken into account. 4.3.1.2 Locomotives and other railway vehicles
carrying a source of ignition should stop at least 15 m
4.2.2.4 Should a tank compartment be accidentally from any point where Class I or 11(2) petroleum is being
overfilled, consideration should be given to any handled.
requirement to remove the excess product, taking into
account operational and commercial factors. In any case 4.3.1.3 When loading or unloading operations are
it should be ensured that there remains sufficient ullage proceeding during hours of daylight, red warning flags
(typically 3 % 4% ofthe compartment capacity) in the
- or other devices should be conspicuously displayed on
affected tanker compartments(s). Any product that is both ends of the train, except at a buffer stop. In
removed should be transferred either to a slops system addition a sign conspicuously worded, e.g. TANK -
or directly back to tank storage. CARS CONNECTED should be displayed at any entry
-
39

IMPORTANT: This file is subject to a licence agreement issued by Ihe Energy Institute, London, UK. All rights reserved, It may only be used in accordance with
to the loading area. Where red warning flags are used 4.3.3 Discharge procedures
during daylight, red lights certified safe to use in a
hazardous area should be used at night or during fog. 4.3.3.1 Before unloading, ullages, temperatures and
water dips should be taken and entered on a rail
4.3.1.4 Before loading or unloading operations discharge record form. Samples may be taken as
commence: appropriate. Receiving tanks should be checked for
The positioning of railcars should be completed. grade of product and to confirm that sufficient ullage
The locomotive removed. exists to receive the load.
The railcars prevented from accidental movement.
4.3.3.2 Railcars carrying grades which require sealing
4.3.1.5 When railcars are top loaded with Class I or II should be inspected to see that the seals are intact and
petroleum or when switch loading, the drop pipe should show no signs of interference. The rail authority and the
be lowered to the bottom of the tank to avoid splash dispatch point should be notified immediately of any
loading. Vapour recovery legislation may require the seal found broken or railcar found to be leaking.
fitting of depressurisation couplings to railcars which
are top loaded. 4.3.3.3 Prior to opening any valves and before
connecting hoses, personnel should walk the full length
4.3.2 Loading procedures of the discharge header to ensure that all discharge
connection valves are closed.
4.3.2.1 Railcars to be top loaded should be inspected
for internal cleanliness and security of closures on the 4.3.3.4 To prevent spillage, all railcars should be
outlets; where procedures require, the product/grade connected before pumping commences. During
carried previously should be identified. In the event that pumping, operations personnel appointed to supervise
any product has been left on board, the grade and the discharge should be in attendance at all times and
quantity ofthis product should be determined so that the make periodic inspections ofhoses and headers to check
volume to be loaded may be adjusted accordingly. for leakage.
4.3.2.2 When railcars are required to be loaded with a 4.3.3.5 Railcars discharge at different rates: as each
change of grade from that previously carried, they one empties, the associated discharge header valve
should be drained of the previous product. When should be closed to prevent the ingress of large
loading products which may create a flammable quantities of air/vapour. Railcar valves should be left
atmosphere in the tank ullage space, including switch open until all the railcars in the train have been
loading, the loading should be at a reduced rate until the discharged and pump(s) stopped; they should then be
foot of the fill pipe is covered; thereafter the loading closed and the hoses finally drained, disconnected and
rate may be increased. stowed.
4.3.2.3 When top loading, the fill pipe should be in a 4.3.3.6 When railcars containing heated fuel oil have
vertical position and reach the bottom of the tank. been discharged, care should be taken to ensure that
final drainings do not solidify in the outlet pipes by
4.3.2.4 When railcars are top-loaded, both the closing the railcar foot valve. No attempt should be
discharge and foot valves should be closed before made to remove further fuel oil from the railcar.
loading is commenced. When railcars are bottom-loaded
(through the same connection as that used for 4.3.3.7 Before the train is removed from the siding, a
unloading), if required by local regulations, after certificate of readiness signed by the supervisor at the
loading the foot valve should be closed, the external line installation and railway operator representatives should
between the foot valve and discharge valve drained, and be completed. This certificate confirms that all valves
the discharge valve closed. are closed, hoses disconnected, man lids secured and the
railcars are in a safe condition to be removed.
4.3.2.5 Before dispatch:
Ullages should be checked to ensure that the 4.3.4 Safety precautions
railcars are not overloaded.
The manhole covers and all outlets should then be 4.3.4.1 Railcars containing Class I or 11(2) petroleum
properly secured. should be discharged with the man lids closed.
The railcars should be suitably labelled. Containers holding Class I or 11(2) petroleum should not
40

OPERATIONS
be permitted to remain open in the loading or unloading railway lines. A separate flexible bond is not necessary.
area. Reference should be made to IP Model Code of
Safe Practice Part 21 Guidelines for the control of
4.3.4.2 Only non-sparking mallets (e.g. wooden or hazards arisingfrom static electricity for further advice.
rubber-headed) should be used for opening or fastening
man lid covers. Covers should be handled carefully in 4.3.6 Personnel safety
case the railcars have become pressurised and care
should be taken not to allow them to fall heavily. 4.3.6.1 Personnel should not be permitted to:
Ride on the outside of a locomotive or railcar in
4.3.4.3 During pumping operations, personnel motion.
appointed to supervise the discharge should make — Cross a line of railcars by crawling or passing
periodic inspections of hoses and headers to check for through or underneath them.
leakage. — Climb up on top of a railcar which is standing on
an electrified line with overhead conductors.
4.3.4.4 In the event of a spillage or leakage, all loading
or unloading operations should be stopped immediately 4.3.6.2 A recognised code of signals should be used
and all foot valves should be closed. Operations should during movements of rail traffic. These should be
not be resumed until the area has been declared safe and distinctive in character and understood by installation
authority for resumption has been given by the staff and employees of the railway operator.
supervisor in charge.
4.3.4.5 No major repair work to railcars should be 4.4 TRANSFERRING PETROLEUM

permitted while they are in the loading or unloading PRODUCTS TO AND FROM SHIPS
sidings.
4.4.1 General
4.3.4.6 The burners of flame heated railcars should not
be ignited or used within any area where Class I or 11(2) The recommendations of HS(G)l86 and ISGOTT
petroleum is being loaded or unloaded. Before should be followed for transferring petroleum products
discharging flame heated railcars, the flame should be to and from ships. They cover:
extinguished.
Precautions for mooring.
4.3.4.7 Loading and unloading arms, hoses and Regulations of port and fire authorities.
connections should be clearly identified, by either Communications.
colour-coding to a standard such as IP Code ofpractice Procedures for receiving or delivering bulk cargoes.
for a product ident.flcation system for petroleum Flexible ship to shore connections.
products, or by nameplates, to indicate the grade of — Protection against static electricity, lightning and
product for which they are applicable. electrical currents.
Pipelines at discharging and loading berths.
4.3.4.8 Loading or unloading arms or hoses should be Prevention of spillage into waterways.
properly stowed after use, before the movement of any Ballasting, gas-freeing and cleaning ofships’ cargo
railcars is permitted. tanks.
Buoy berths and submarine pipelines.
4.3.4.9 In the event of a fire during loading or Receiving and delivering of packaged cargoes.
unloading, all operations should be stopped
immediately. Personnel should leave the loading gantry 4.4.2 Testing of safety systems
or sidings and the supply of products to the loading
facilities should be cut off. Local installation procedure 4.4.2.1 Hydrocarbon or oxygen analysers, where
for dealing with fires should be put into operation fitted, should be checked prior to the start of loading.
immediately. Calibration should be undertaken regularly. the
frequency depending upon the utilisation of the vapour
4.3.5 Electrical earthing and electrical bonding emission control system.
Electrical earthing of railcars is usually achieved by 4.4.2.2 All alarms and automatic shut-down systems
contact between the wheels of the railcar and the should be tested frequently.
41

4.4.2.3 High and low vapour line pressure alarms road. The procedures will include:
should be checked to ensure that they are set correctly
for the rating of the vessel’s tanks prior to the start of Quantities and grades of product to be delivered.
loading. The rate of delivery, the numbers and capacities of
the tanks to which deliveries are to be made.
4.4.3 Testing of pipework The method of controlling the operation ofthe inlet
valves to the tanks.
4.4.3.1 Vapour hose connections should be made
before loading commences. 4.5.2.2 Procedures should be clearly set out and
followed:
4.4.3.2 Insulating flanges or hoses should be visually — To avoid tank overfilling.
checked before loading to ensure that they are not short- For the changeover of tank and product grade, to
circuited. ensure segregation of grades and to avoid risk of
contamination.
4.5 STORAGE TANK OPERATION 4.5.2.3 There should be an efficient system of

communication established between all personnel
4.5.1 General concerned in the operations, in order that the procedures
referred to above are properly carried out and immediate
4.5. 1.1 Class I petroleum is normally stored in floating action can be taken in an emergency.
roof tanks, or fixed roof tanks fitted with pressure and
vacuum vents, or in tanks with internal floating covers. 4.5.3 Tank gauging and sampling
These alternatives may also be desirable for the Storage
of Class 11(2) petroleum under conditions of high 4.5.3.] The reference height used for manual gauging
ambient temperature. Class 11(1) and Class III petroleum should be clearly marked near dip hatches.
are normally stored in tanks with open vents. The
heavier grades of Class III petroleum may be stored in 4.5.3.2 Dip hatches for manual gauging of tanks
tanks with heating facilities, either within the tank or storing Class I or Class 11(2) petroleum should remain
external to it. fully closed unless gauging is being carried out.
4.5.1.2 Personnel engaged in operation of storage 4.5.3.3 If a tank is fitted with more than one dip hatch,
tanks should be thoroughly conversant with the type of only one should be open at a time.
tanks for which they are responsible, their gauging, safe
operating capacities, their fittings, connections and high 4.5.3.4 To avoid the possibility of electrostatic
and low level alarm settings. discharge, no manual gauging or sampling should take
place while tank filling operations are proceeding, or for
4.5.1.3 All valves from which product may be drawn 30 mm. afterwards. For further guidance reference
and all inlet valves should be closed when not in use. should be made to IP Model Code of Safe Practice Part
For additional security, locking ofall valves from which 21 Guidelines for the control of hazards arising from
product may be drawn and inlet valves in the closed static electricity.
position may be considered desirable when the
installation is closed, or when any tank is only operated 4.5.3.5 Movement of product(s) and manual gauging
infrequently. All valves should be operated as should not be carried out when atmospheric conditions
frequently as necessary to ensure ease of operation are liable to cause a static or other hazard to personnel
when needed. engaged in operations, e.g. an electric storm or flying
sand.
4.5.1.4 No person should go on to a tank roof during
an electrical storm. 4.5.3.6 Gauging and sampling should be carried out in
accordance with the procedure recommended in IP HM
4.5.2 Procedures 31. If any object is dropped accidentally into a tank, it
should be reported immediately.
4.5.2.1 Clear procedures should be established for
receipt ofproduct into the installation’s tanks; these will 4.5.3.7 Automatic level and temperature gauging
vary in accordance with the method of receipt to be equipment should be checked against manual methods
employed, i.e. cross country pipelines, marine, rail or at regular intervals. For further information see
42

OPERATIONS
IP HM39 and BS Iso 4266-1. the product under the roof has been drained; the
operation of these vents should be regularly checked.
4.5.4 Drainage of water from tanks
4.5.5.8 The floating roof should not be taken up to a
4.5.4.1 Water bottoms should not be retained in height at which any part of it rises above the top of the
storage tanks, since water can cause internal corrosion tank shell.
of tank bottoms and lower shell plates, and encourage
microbial growth. The only exception may be in the 4.5.5.9 No personnel should be allowed access onto a
event that a tank bottom is leaking, or suspected of floating roof when a tank is in operation without a work
leaking, in which case water may be temporarily permit. When the roof is more than 2 m below the top of
introduced to prevent loss of product; special the shell, the work permit should specif’ the use of
procedures should be established for operation of the breathing apparatus and supervision from the top of the
tank. access stairway.
4.5.4.2 In the event that water is introduced into tanks 4.5.6 Internal floating covers
from a ship, or if pipelines are cleaned by a water plug,
it should be drained as soon as separation from the The peripheral seal should be periodically inspected to
product has occurred. ensure that it remains effective. Lowering of a cover
onto its supports should be avoided, but if it become
4.5.5 Floating roof tanks necessary all the precautions set out in 4.5.5 should be
observed.
4.5.5.1 Floating roofs of floating roof tanks should be Where closed-cell composite aluminium
examined frequently to see that they are floating evenly polyurethane foam covers have been installed, care
and not sticking. This is particularly necessary during should be taken iii their removal, dismantling and
periods of heavy rain or in freezing weather. disposal due to their product absorption properties.
Similar precautions should be taken with peripheral
4.5.5.2 Water should be drained as necessary from seals.
floating roofs. Valves on the bottom outlets of roof
drains should be closed when the operation is completed 4.5.7 Precautions to avoid static charges
to prevent loss of product in the event of failure of the
internal drain line. To avoid the build-up of static charges when filling a
tank with Class I and Class II, or Class III products
4.5.5.3 Legs are provided to support the roof when the under conditions which may create a flammable
tank is empty for the purpose of carrying out cleaning, atmosphere in the tank ullage space by vaporisation or
maintenance or repair. During normal operation these formation of mist, the inlet velocity should not exceed
supports should be in the raised position and the roof I m/s until the inlet of the tank is completely
should not be grounded. Legs should only be adjusted submerged, and until the feed pipeline is free of any
and maintained whilst the tank is full. water or air. Subsequent inlet velocities should ensure
smooth flow into the tank without causing turbulence,
4.5.5.4 Lowering of the roof onto its legs should be breaking of the surface of the product or disturbing
avoided, but should this become operationally necessary bottom sediment. A maximum velocity of 7 m/s is
the outflow rate should be reduced to ensure the legs recommended.
land slowly.
4.5.8 Drainage of tank compounds
4.5.5.5 If a roof is to be re-floated, filling should start
at a reduced rate to avoid turbulence until the legs are 4.5.8.1 Water which accumulates in the tank
clear of the floor and it is certain that the roof is rising compound may be drained by normal gravity drainage.
evenly. In this case the compound should be isolated from any
outside drainage system by an externally sited valve,
4.5.5.6 The peripheral seal should be periodically kept closed, and preferably locked except when the area
inspected to ensure that it remains effective and that the is being drained of water under the control of the duty
supporting legs are free to be adjusted. supervisor.
Alternatively, the compound may be drained by
4.5.5.7 Vents are provided in the roof to permit the means of a manually controlled pump, or by a siphon
escape of air and vapour when refilling the tank after drain, which passes over the top of the wall of the
43

the licence terms and conditions, It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: a: pubs@energyinst.org uk t: +44 (0)207 467 7100
compound and which has to be primed by means of a process unit operational again. It is recommended that
small manually controlled pump. this is not implemented remotely, but involves
attendance at the unit to check the status of all the
4.5.8.2 Personnel should remain in attendance process equipment and utility supplies in order to ensure
throughout all compound draining operations. a safe restart.
A record of all operational activities and alarm
4.5.8.3 Water from tank compounds should be passed conditions should be kept to facilitate problem solving
through an oil/water separator before being discharged by maintenance personnel.
to any outside drainage system or surface waters.
4.6.2.2 VRU performance monitoring can be
4.5.9 Precautions to be taken with tanks undertaken by measuring the hydrocarbons in the
connected to vapour balancing systems vapour flowing to the unit and the vapour emitted from
the VRU vent. The vent emission data should be treated
4.5.9.1 Tanks connected to a vapour balanced system as qualitative rather than quantitative. However, they
can be operated normally with the exception that should give an indication of whether the unit is
sampling and dipping operations require revised maintaining a regular level of performance, or whether
procedures as the tank may be pressurised. Suitable there is a need to investigate for faults or to take
equipment and tank fittings are identified in BS ISO remedial measures.
4512 and Chapter 17, Section 2A of the API Manual of Guidance on the use of vent emission monitors is
Petroleum Measurement Standards. available in IP Research Report An investigation into
suitable instruments for the measurement of total
4.5.9.2 Pressure/vacuum valves should be checked and organic carbon (TOC) in emissions from petroleum
set carefully to avoid unnecessary vapour loss. distribution terminal vapour recovery units.
4.5.9.3 Care should be taken during repair and 4.6.2.3 There is a potential hazard from the
maintenance to ensure that means of isolation are in development of localised high temperatures (hot spots)
place to minimise emissions to atmosphere. in VRU carbon beds based on carbon adsorption
technology. Guidance on minimising this hazard is
provided in IP Vapour recovery units Guidance on -
4.6 VAPOUR COLLECTION AND preventing and controlling temperature excursions in

RECOVERY SYSTEMS carbon beds.
4.6.1 Vapour collection system checks 4.6.3 VRU maintenance
Vapour collection systems should be visually checked 4.6.3. 1 VRUs are process plants and therefore require
periodically for signs of damage: regular and thorough maintenance. Daily and weekly
checks and inspections should be undertaken and they
Knock-out pots should be drained regularly. should be logged together with the alarms and actions
Flame arresters should be checked regularly as part taken.
of an inspection system to ensure that there is no
mechanical damage and that they are not becoming 4.6.3.2 More extensive preventive maintenance will be
blocked. required on a periodic basis to ensure the smooth
Isolation, non-return and relief valves, if fitted, running of the unit. This may involve stripping down
should be checked for correct operation. and cleaning equipment, and in the case of pressure
vessels regular statutory inspections. A formal
4.6.2 Vapour recovery units maintenance schedule should be established specifying
the timing and content of activities and any comments
4.6.2.1 A VRU should be controlled by existing on the outcome should be recorded.
emergency shut down systems on the terminal. In
addition the unit should have its own separate 4.6.3.3 VRUs are complex pieces of equipment
emergency shut down facility which does not impact on incorporating extensive instrumentation and alarms. It
the remainder of the terminal. should be recognised that when an equipment or system
A procedure is needed for resetting after an failure occurs it may need a technician with a detailed
emergency shut down or fire alarm in order to make the understanding of the system to correct the fault.
44

the licence terms and conditions, It must not be forwarded to, or stored or accessed by, any unauthorised user, Enquiries: e: pubs@energyinst.org.uk 1: +44 (0)207 467 7100
OPEItATIONS
4.7 PUMPS operated in accordance with the recommendations ofl3S

EN 14161.
4.7.1 Inspection and testing
4.8.2 Multi-product pipelines
4. 7.1.1 Before initial commissioning, the connecting
flanges of a pump to suction and delivery pipework Multi-product pipelines may be operated by one of the
should be unbolted to check that the pipework, without following methods:
assistance from the pump, is adequately supported and
not transmitting unnecessary loads to the pump casing. (a) One product follows another directly: a planned
sequence for pumping operations is required, based
4.7.1.2 During initial commissioning and after major on product properties and a laid down procedure
repair, a pump should not be brought into operation for handling product interfaces. Interface volumes
until its alignment and direction of rotation have been may be limited by maintaining an adequately high
checked and, if electrically driven, the motor and pressure at all times within the pipeline. Where
control gear tested for continuity, earthing and possible interface material should be absorbed
insulation resistance. Thereafter it should be inspected wholly into the receiving tank of either the
regularly for noisy running, signs of overheating, gland preceding or following batch so that slopping is
leakage and general condition. avoided.
The means for emergency shut-down of the pump
should be tested at regular intervals. (b) Products are separated by pigs or spheres: a
planned sequence for pumping operations and
4.7.1.3 Pumps should not be operated without being procedures for handling pigs and spheres is
filled with product. required.
4.7.2 Pump operations (c) Pipeline cleared between products: water plugs are
inserted between batches.
4.7.2.1 Pumps should not be left to run for long Note: this practice is not recommended.
periods against a closed delivery valve or delivery from
an empty tank. This may cause overheating of pump 4.8.3 Line clearing
and product and may lead to cavitation.
Line clearing is not recommended for normal
4.7.2.2 Centrifugal pumps may be started against a operations, and it is therefore preferable to maintain a
closed delivery valve to reduce the starting load on the pipeline completely filled with product when it is not in
motor. use between operations. When line clearing is
necessary, four methods are suggested:
4.7.2.3 Positive displacement pumps should not be
started against a closed valve. (a) Drawing back
A ship’s pump or other transfer pump is used to clear
4.7.3 Pump glands and seals the line if a steady and sufficient fall to the pump exists.
Lines to be cleared by these means will have to be laid
Regular checks should be made for leaking glands and accordingly, and be vented at the high point.
seals. If this occurs pumps should be taken out of
service for rectification. (b) Water washing
The water inlet connection should be protected by a
4.7.4 Suction conditions check valve. Tanks into which pipeline contents are
washed should be left to settle and the water drawn off
Minimum suction conditions for a pump should be with the least possible delay. Water in tanks and
maintained to avoid cavitation and premature failure of pipelines introduces a considerable corrosion risk. Salt
mechanical seals. or brackish water should be avoided for cleaning
pipelines and consideration should be given to using a
slops tank for water removal. Water washing increases
4.8 PIPELINES the risk of pollution of drainage systems outside the
installation.
4.8.1 General A further risk is the build-up of static electricity,
due to the presence of water droplets in the product.
All pipelines feeding from outside the installation, Pipeline velocities should be limited to not more
whether cross-country or from a jetty, should be
45

than 1 m/s when pumping product after water washing any package until it has been cleaned and certified gas-
until it is certain that no water and product mixture is free; closures should first be removed. Such repairs
being pumped. should be carried out within an area designated as non-
Lines which have been cleared with water, hazardous.
particularly any small bore lines, should be protected Containers which have held a heavy oil can appear
against frost. If a pipeline which is to be left empty for gas-free when tested, but when heat is applied, traces of
a period is to be water washed, corrosion prevention product remaining in the container can vaporise to form
inhibitor should be added. a flammable atmosphere. No hot work should therefore
be permitted on any container, including those which
(c) Air or nitrogen clearing have held a heavy product, unless all traces of product
Air or nitrogen from a receiver used for clearing a line have been removed, the container certified gas-free, and
should be at the minimum practicable pressure for the procedures are in place to verify that this condition is
operation. It should not be allowed to enter a storage maintained.
tank containing Class I or Class II petroleum, but should
be vented safely to atmosphere. Careful consideration 4.9.3 Filling
should be given before using air to avoid the possibility
of generating a flammable atmosphere. 4.9.3.1 The filling of packages with Class I or Class
11(2) petroleum should only be carried out in a building
(d) Pigs and spheres designed for that purpose. Arrangements should be
A pipeline which is designed to take a pipeline pig or made for the packages and the filling installation to be
sphere may be cleared more effectively by interposing maintained at the same electrical potential, and the
a pig or sphere between product and the propellant used filling installation should be electrically bonded and
for clearing it. This system will require provision of pig earthed.
launchers and receivers. This is a potentially hazardous Adequate ventilation of the filling area should be
operation requiring specific attention to the design and maintained throughout filling operations.
adherence to appropriate operational procedures.
4.9.3.2 The filling of packages with Class 11(1) or
4.8.4 Valves Class III petroleum may be carried out in any building
except where a source of ignition could endanger the
4.8.4.] Valves should be kept free and easy to operate. operations.
In particular plug valves ofthe lubricated type should be
lubricated frequently. 4.9.3.3 Any spillage which occurs during filling
should be isolated, kept from spreading and cleaned up
4.8.4.2 Hand wheels or levers of valves, if removed without delay. If the spillage is of Class I or Class 11(2)
for an operational reason, should be readily available so petroleum all operations in the immediate vicinity
that the valve may be closed or opened, as necessary, in should be suspended. Filling should not be resumed
an emergency. Chaining and padlocking of valves is until the area has been declared safe and authority is
preferable. given by the supervisor in charge.
4.9.3.4 After filling, all packages should be marked or

4.9 PACKAGES labelled as required by legislation to indicate the
contents and related hazards.
4.9.1 Cleaning and gas-freeing
4.9.4 Storage
Cleaning of packages should be carried out in a well-
ventilated building or in the open air. The appropriate 4.9.4.1 Packages should be stored only in the buildings
safety precautions should be observed, e.g. no smoking or other space specifically allocated for the purpose.
or sources of ignition. Steam is the normal medium for Reference should be made to HSE publication HS(G)5 1.
cleaning and gas-freeing packages Floors of buildings should be of level construction, and
all access ways to outdoor storage should be free of
4.9.2 Repairs holes or other tripping hazards. Walkways should be
kept clear and should preferably be marked with white
All work should be controlled by a permit-to-work lines.
system. No hot work repairs should be carried out on
46

OPERATIONS
4.9.4.2 From the time packages are received, whether 4.9.4.9 Empty packages which are to be disposed of
empty or full, from a source outside the installation, a should be cleaned and made gas-free unless they are to
regular cycle of operations should be arranged to be delivered to a competent person who has been
eliminate any unnecessary handling. notified of their condition and of any precautions to be
taken prior to subsequent use.
4.9.4.3 When full packages are stacked, they should be
so arranged that leakage from any package can be 4.9.5 Handling
readily detected. They should be regularly inspected,
and the contents of any package found to be leaking 4.9.5.1 Care is necessary in handling packages in and
should be immediately transferred to a sound container. out of stacks to avoid injury both to those engaged in
the work and other persons in the vicinity.
4.9.4.4 Barrels and large drums, of 205 litres nominal
capacity or greater, stored horizontally, should be 4.9.5.2 When packages are handled in a hazardous
provided with adequate and safe means of restraining area, adequate precautions should be taken to avoid the
movement at both ends ofthe stack. Scrap metal, stones risk of sparks from the movement of packages or from
or other makeshift materials are not suitable for use as ancillary handling equipment.
chocks. Full barrels stored horizontally should not be
stacked higher than the loading on the bottom of the 4.9.6 Mechanical handling equipment
row will permit. This will normally be four high, but
will depend on the wall thickness and construction of 4.9.6.1 All mechanical handling appliances, whether
the barrels. Consideration should be given to providing hand- or power-operated, including lifting appliances,
weather protection. fork lift trucks, conveyors, palletisers, place packers and
other similar mechanical handling devices, should have
4.9.4.5 Barrels stored vertically should be arranged so a safe permissible working load clearly marked on them
that the stacks are stable and safe. This may be done by and this load should not be exceeded.
using pallets or similar devices between the tiers to All such appliances and any lifting gear, chains or
prevent tipping or by cross bonding the stacks by slings used with them, should be in good working order
placing each successive tier haIfa barrel to the left and and should be regularly examined and tested in
right alternately. Stacks of full barrels should not be accordance with local regulations. Records should be
higher than loading on the bottom tier permits; again kept of the examinations and tests. In the UK, reference
consideration should be given to providing weather should be made to the Lifting Operations and Lifting
protection. Equipment Regulations 1998.
4.9.4.6 Other packages should be stacked in a neat and 4.9.6.2 Mechanical handling appliances should only be
stable manner. Cartons of smaller packages which have used by properly trained and qualified personnel.
insufficient mechanical strength in themselves should
not be stacked without racking. 4.9.6.3 Lifting tackle should not be used for purposes
other than a vertical lift, e.g. it should not be used to
4.9.4.7 All stacks of packages should be confined to drag loads across the floor or to freejammed machinery.
properly marked areas. Adequate width of aisles should
be provided between stacks for normal movement, 4.9.6.4 All loads should be properly and adequately
including the use of mechanical handling equipment, secured.
fork lift trucks and power trolleys, and to provide breaks
in the event of fire. There should be clearance between 4.9.6.5 No person should stand under a suspended
the stacks and building or boundary walls so that in no load.
circumstances will stacks lean or exert pressure on
walls. 4.9.6.6 No person should be lifted or carried on any
lifting gear unless designed for the purpose.
4.9.4.8 Empty packages of any size may be stored to
suit operational requirements and package design 4.9.6.7 Only those chains, ropes, slings and other
limitations. Packages which have held petroleum should ancillary lifting equipment, which are provided
be treated as a potential fire hazard and the appropriate specifically for the purpose, should be used. Makeshift
safety precautions observed. materials should not be used. Chains should not be
joined by bolts, wire or knots. Ropes should be properly
47

spliced, where necessary, and not knotted together. second person should be available as a guide and to
keep other persons clear. Rear view mirrors are useful
4.9.7 Fork lift trucks, power trolleys aids to safe reversing. Manoeuvring and reversing
operations should be carried out smoothly withoutjerks
4.9.7.1 Vehicles such as fork lift trucks and power which might dislodge the load.
trolleys, if they are to operate inside buildings, should
preferably be powered by electrical batteries. If 4.9.7.10 All persons should be instructed to keep well
however adequate ventilation is maintained, diesel or clear of moving parts of vehicles.
LPG engine driven vehicles may be used, but the risk of
toxic exhaust fumes is less using LPG fuel. The fuel 4.9.7.11 Battery charging of electrically-operated
containers of LPG operated vehicles should be properly vehicles and refuelling and starting up of internal
protected against damage and spare containers stored in combustion engine operated vehicles should not be
a designated area. All fork lift trucks should be fitted carried out within hazardous areas.
with driver safety guards, carriage backrest, hooter and
flashing amber light.
4.10 GENERAL FACILITIES
4.9.7.2 No powered vehicle should be used in a
hazardous area or an area which, as the result of 4.10.1 Boilers
accidental damage to packages or other containers,
might become a hazardous area, unless it is suitably 4.10.1. 1 In the operation of boilers, whether of the
protected to prevent ignition of flammable vapour. automatic or manually operated type, established safe
Reference should be made to HS(G)1 13 and BS EN operating practices should be clearly understood and
1834-1. followed. These will vary in details according to the
type of equipment installed but the basic safety features
4.9.7.3 Vehicles should only be driven by properly should be the same. Reference should be made to
trained and authorised personnel. New drivers should be Health and Safety Guidance Notes, PM 5 and PM 60.
under the direct supervision of a competent person.
4.10.1.2 Water gauges should be tested and blown
4.9.7.4 A safe speed limit should be strictly enforced. down at least twice per shift to ensure that they are
working correctly. Low and high level alarms and flame
4.9.7.5 Vehicles should be carefully maintained, with failure protection should be tested weekly.
particular attention paid to hydraulic systems, elevating
gear, brakes, steering, flame and spark arresters. Vehicle 4.10.1.3 Unless a continuous blow down system is
operators should report defects immediately. installed, frequency of blowing down of the boiler
should be in accordance with the prescribed boiler water
4.9.7.6 Loads should never exceed the safe working control procedure.
load of the vehicle. They should be properly secured,
and in the case of a fork lift truck should be transported 4.10.1.4 A daily boiler log, recording operating
with forks as near to the ground as possible. This is readings, blow downs and tests of water gauges, boiler
particularly important when negotiating slopes or ramps alarms, flame failure protection devices and flue gas
to prevent the vehicle overturning. temperature should be maintained.
4.9.7.7 No person should walk under the forks of a 4.10.1.5 Water quality is an important factor in the
fork lift truck when it is carrying a load. When not in operation of steam raising boilers. Regular testing of
use the forks should be kept as close to the ground as feed/make-up water is essential to ensure that quality is
possible to prevent persons being injured by them. maintained within the boiler manufacturer’s
specifications. All test results should be recorded to
4.9.7.8 Fork lift trucks should not be used for towing determine trends in water quality that may require
other vehicles unless they are designed for this duty and different treatment.
they should not be used for any other purpose for which
they are not designed. 4.10.1.6 Where condensate is returned for reuse the
system should incorporate an oil/water separator. It is
4.9.7.9 Great care should be exercised when important that no oil contamination enters the boiler as
manoeuvring or reversing vehicles. If necessary a tube blistering and rupture can occur. A rise in flue gas
48

OPERATIONS
temperature of 10 °C generally indicates a need for maintained and there are no leaks. Reference should be
shutdown and tube cleaning. made to IP HM 17.
4.10.1. 7 All steam distribution systems, including 4.10.5.2 Additives can be hazardous and extreme care
pressure reducing stations, valves, filters, steam traps should be taken when handling them. Manufacturers’
etc, should the subject of a Written Scheme of procedures and health and safety data sheets should be
Examination review record. For further details see strictly adhered to.
INDG 178.
4.10.5.3 Where more than one additive is being injected
4.10.2 Hot oil heaters or more than one operating company is involved, care
should be taken to avoid cross-contamination of
4.10.2.1 Hot oil heaters are sometimes used as an additives.
alternative to steam raising boilers. The various safety
features such as thermostats, and flame failure cut-outs
should be tested regularly, and results recorded. 4.11 EMERGENCY PROCEDURES
4.10.2.2 Great care should be taken to prevent leaks of 4.11.1 General

hot oi as spontaneous combustion may occur if it
contaminates lagging material. 4.11.1.1 In the event of an emergency situation the shift
supervisor or other nominated person should be
4.10.3 Compressed air responsible for initiating emergency procedures.
A Written Scheme of Examination review record 4.11.1.2 All personnel, including drivers and office
prepared in accordance with the Pressure Systems and personnel, should have regular instruction in what
Transportable Gas Containers Regulations 1989, should actions they are expected to take in an emergency.
be maintained for all compressed air systems.
Water which accumulates in air receivers may 4.11.2 Fire
cause serious corrosion and should therefore be
manually drained off daily. Where automatic drain 4.11.2.1 Appropriate personnel should be trained in the
valves are fitted they should be checked regularly for action to be taken in the event of fire and in the use of
effective operation. first-aid and fire-fighting equipment. They should be
familiar with all types of fire extinguishers likely to be
4.10.4 Oil/water separators encountered in the course of operations. This aspect of
their training should include the theory and in particular
4.10.4.1 Oil/water separators should be inspected practice in extinguishing all types of fires.
regularly, preferably daily, and any free oil removed
from the surface of the main chambers. The surfaces of 4.11.2.2 Training should include the correct use and
these chambers should be cleaned as required to ensure response to fire alarms, practical experience in
efficient operation of the separator. A log should be summoning the fire and rescue service and other
kept of all inspections and cleaning operations. Where emergency services, and alerting neighbours.
water is removed during cleaning operations it needs to
be replaced by clean water prior to the separator 4.11.3 Accidents involving road tankers
continuing in use.
Drivers should receive regular instruction in handling
4.10.4.2 Samples of the effluent should be drawn and emergency situations involving road tankers within
tested regularly to monitor compliance with discharge petroleum installations.
consents. Reference should be made to IP
Environmental guidelines for petroleum distribution 4.11.4 Spillages
installations.
4.11.4.1 All installation personnel should be given
4.10.5 Additive injection equipment instructions on the sound operating practices to avoid
the risk of spillage and of subsequent fire. If however
4.10.5.1 Additive injection facilities should be checked any spillage or leakage occurs, the methods of
regularly to verify that correct injection rates are preventing ignition, of preventing product entering
49
Licenceci to: Miss Lison Mecoli. Single user licence only.

IMPORTANT: This file is sublect to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
drains, sewers or water courses, and of cleaning up the in the event of an accident involving personal injury and
spillage should be clearly understood. action to be taken to obtain first-aid, medical attention
or ambulance service.
4.11.4.2 A list of emergency clean-up contractors and
plant suppliers together with contact telephone and fax 4.11.6.2 Where deemed necessary by a risk assessment,
numbers, who can be called in at short notice in case the the appropriate number of qualified first-aiders should
spillage or leakage is too large for the installation be available to each shift.
personnel to handle on their own, should be held at the
installation. 4.11.7 Emergency exercises
4.11.5 Contamination Emergency exercises based on simulated incidents,

carried out with the participation of terminal customers,
Instructions should be given on the strict precautions the public services and, if possible, jointly with any
necessary to avoid hazards due to contamination of one neighbouring distribution installation operators, will
grade of product with another by crossover of pipeline familiarise all concerned with the equipment and
or tank connections, passing valves or other Operating techniques required to deal with emergency conditions.
error and, in the event that contamination occurs, the Installations subject to COMAH should have
steps necessary to prevent the mixture being delivered, formal on-site and off-site emergency plans.
sold or used.
4.11.6 Personal injury
4.11.6.1 Training should include measures to be taken
50

IMPORTANT: This file is subject to a licence agreement issued by Ihe Energy Institute, London, UK. All nghls reserved, It may only be used in accordance with
the licence terms and conditions. It must not be forwarded to, or stored or accessed by. any unauthonsed user. Enquiries: e: pubs@energyinst.org.uk 1: +44 (0)207 467 7100
5
FIRE PROTECTION
5.1 GENERAL and advice is given on fire protection and detection, on

extinguishing systems and on application rates for fire
The protection of installations from the hazard of fire extinguishing media. Preparation of a comprehensive
should be achieved primarily by the use of sound Fire Plan for a petroleum site is also considered. This
design, construction and operational methods. These covers the selection of equipment, the provision of
should ensure that the possibility of an outbreak of fire water and foam, development of emergency procedures
is remote and therefore permit the provision of fire- and training of staff.
fighting equipment to be limited to the means for rapid Where there is no statutory obligation for the local
extinguishing of any fire in its initial stages. fire authority to provide fire-fighting capability within
Guidance on fire protection at installations is given an acceptably short period of time, it is recommended
in IP Model Code of Safe Practice Part 19 Fire that provision of facilities is made in accordance with
precautions at petroleum refineries and bulk storage the guidance in IP Model Code of Safe Practice Part 19
installations, HS(G) 186 and HS(G) 176. The Fire precautions at petroleum refineries and bulk
flammable nature of petroleum products is discussed storage installations.
51

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK. All nghts reserved. It may only be used in accordance with
fl
52

6
MAINTENANCE AND MODIFICATIONS
6.1 GENERAL loading equipment;

lifting and mechanical handling equipment.
6.1.1 Introduction
6.1.3 Management of changes
This section provides guidance on planning and
execution of routine and non-routine maintenance of 6.1.3.1 A system should be in place which ensures that
plant and equipment on the installation. It also covers changes to the plant, process equipment, process control
modifications and construction works. software, mechanical integrity and procedures are
authorised before implementation. All changes should
6.1.2 Maintenance, planning and control be properly reviewed by adequately qualified person(s)
to ensure that operational integrity is not jeopardised.
6.1.2.1 The appropriate level ofmaintenance should be
established for all plant and equipment, taking into 6.1.3.2 A step by step method statement should be
account operating experience and statutory obligations. prepared to ensure there is no misunderstanding
This should be incorporated into a maintenance between management authorising the changes and
management system and will range from planned personnel or contractors undertaking the works.
routine tests and inspections to unplanned breakdown
repair. In each case the maintenance management 6.1.3.3 Drawings, documentation and procedures
system should ensure that work is carried out as should be updated to incorporate any changes.
required and adequate records kept to demonstrate
adherence to the plan. It also should provide sufficient 6.1.4 Safe systems of work
information for periodic review to ascertain the
appropriate level of maintenance. 6.1.4.1 The safe system of work established by
management of an installation should include all
6.1.2.2 In addition to routine operational checks, construction, maintenance, repair, modification and
planned routine maintenance should, as a minimum, demolition works. Control of all work should be by
include the periodic inspection and testing of: standing instructions, maintenance procedures,
safety systems and alarms; appropriate complementary method statements or a
electrical equipment and cables; work permit system.
— earthing and bonding;
storage tanks and pressure vessels; 6.1.4.2 All tasks and the location of the work should
boilers; be clearly defined, and the precautions explained and
— pumps and pipework; understood by all concerned. Particular attention should
relief valves; be given to work which will continue beyond shift
53

IMPORTANT: This file is subiect to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
changes. around construction works, plant and equipment to

prevent unauthorised access and to protect
6.1.4.3 The procedure for the use of work permits personnel working within the area.
should be rigorously enforced and records kept. Work — Display of warning notices in advance of the work
permits should be regularly monitored during the course and on the temporary fencing or barriers, such as
of the work. speed limits, no smoking, wearing ofPPE, services
and cable marking.
6.1.4.4 Reference should be made to the appropriate Depressurising, emptying, disconnecting and
sections of HSE Guidance on permit-to-work systems blanking off tanks, vessels, equipment and
HS(G) 250. pipelines.
Safe collection and disposal of all product
collected.
6.2 SAFETY OF WORK ON SITE Isolation from mechanical power.
Isolation from electrical power.
6.2.1 Assessment of extent of hazard — Isolation from sources of flammable, hot or
dangerous liquids, gases or pressurised systems.
When it is necessary to carry out work of maintenance, Isolation may be disconnection and blanking of
repair or plant modification in an operating installation pipelines or by insertion of spades etc; no reliance
a careful assessment of the extent of any likely hazard should be placed on closed valves.
and the risk it presents should be made considering: Isolation from radiation sources.
Ensure freedom from toxic hazards.
The effect of the work itself and the extent of any — Gas-freeing of equipment after emptying.
source of ignition under normal and possible Checks for gas-free conditions appropriate to the
abnormal or accident conditions. class of work to be carried out.
The petroleum handling operations being carried — Transfer of equipment which has been in service to
out and the possibility of an accident unrelated to workshops or outside the installation.
the work resulting in movement of product or Provision of an adequate supply of oxygen.
product vapour into the area of the work. — Wearing of protective clothing and breathing
The weather, humidity, direction of the wind, apparatus and specifying type to be used.
topographical features ofthe site and availability of Cleaning away of combustible materials, removal
assistance in the event of an emergency. or wetting down of wooden floors, decks,
platforms, scaffolds etc.
Further guidance on hazard assessment can be found in Safe disposition of welding or other equipment to
HS(G) 176 and HS(G)186. be used in carrying out the work.
The safety conditions to be included on the permit Earthing/bonding of electrical or welding
should reflect the conclusions of the risk assessment. equipment and steam, air and water lines and
nozzles to be used in the work.
6.2.2 Safety precautions Location of overhead or buried electric power lines
or product lines, particularly if digging or using
6.2.2.1 The safety precautions to be included on a cranes and other mechanical equipment.
work permit will depend on the extent of hot work, Provision of fire-fighting facilities and standby fire
sources of ignition or other potentially hazardous work, guards if necessary.
possible release of flammable liquid or vapour,
proximity to hazardous areas and operations being 6.2.3 Safety distances
carried out in the installation. Consideration should be
given to all conditions that might prevail during any It is not possible to lay down exact safety distances,
period of the works. since these will depend on the assessment of the extent
of the hazard and the availability of means to deal with
6.2.2.2 The following typical precautions cannot cover any emergency.
all conditions that may arise and circumstances may
require further actions to be considered and entered on 6.2.4 Hot work in or near hazardous areas
the permit:
When it is necessary to carry out hot work in or near
Erection of temporary fencing or movable barriers hazardous areas and petroleum handling facilities, the
54

following special checks and precautions may be Ensuring that there is coverage by another trained
necessary in addition to those in 6.3. fire watcher or stopping the work when he has to
leave his post.
6.2.4.1 No hot work should be permitted in a
hazardous area until the likelihood of a hazardous 6.2.5.3 Where necessary, liquid-retaining walls, fire
atmosphere occurring has been removed. This may be walls or screens may be erected to reduce the risk of
achieved by temporarily suspending the movement of flammable liquids or vapour approaching the area where
products by stopping operations, or sealing off or work is being carried out. Where hot work is to take
diverting possible sources of flammable liquids and place above other equipment or plant this should be
vapour. The action taken should be appropriate to the adequately protected by means of fireproof blankets or
particular situation in each case considered. equivalent.
6.2.4.2 When hot work is being carried out within a 6.2.5.4 Any sewers, drains, ducts or other surface
hazardous area there is always the possibility of a entries within 15 m of the work should be checked and
serious accident occurring on plant or equipment in use sealed off.
nearby which may give rise to a flammable atmosphere
or hazardous situation in the work area. A risk 6.2.5.5 Before the work takes place brief but explicit
assessment should be made to evaluate the likelihood instructions on how the alarm is raised, sound of the
and consequences of this occurring and a contingency alarm and the action to be taken in the event of a fire or
plan should be put in place appropriate to the level of the alarm sounding should be given to all personnel
risk. The contingency plan should be explained to all engaged on work covered by the work permit. Where
personnel concerned and their understanding checked. available such briefings should be complemented by a
short safety video presentation outlining the
6.2.5 Fire precautions installation’s fire and emergency procedures together
with safety aspects whilst working in a hazardous area.
6.2.5.1 Whenever non-routine or hot work is to be
carried out in a hazardous area, special precautions for 6.2.5.6 More guidance and advice can be obtained
fire protection should be taken. These will be specified from IP Model Code of Safe Practice Part 19 Fire
on the special or hot work permit and could include the precautions at petroleum refineries and bulk storage
provision of: installations.
A wind-sock erected on top of an adjacent tank or 6.2.6 Confined space entry

building.
Continuous gas monitoring equipment. In the UK requirements for entry into confined spaces
Additional fire-fighting equipment. are given in the The Confined Spaces Regulations 1997
— Cooling for adjacent tanks. (SI 1713). The use ofa permit-to-work system will be
Clearance or wetting down of combustible required.
materials.
A fire watcher to monitor the area where hot work
is to take place. 6.3 REPAIRS, ALTERATIONS, TESTS
6.2.5.2 The fire watcher should be trained in basic fire- 6.3.1 Detailed instructions
fighting and his duties should include:
When repairs or alterations necessitate the dismantling
Ensuring that adequate fire-fighting equipment is on site of important items of equipment, such as valves,
available in the area. pumps or pipelines, or entry into tanks or vessels,
Ensuring compliance with all the conditions specific notice should be conveyed to all concerned and
specified on the work permit. acknowledgement of receipt confirmed.
— Noting any changes in surrounding conditions
which will affect the work permit. 6.3.2 Tanks and vessels
Stopping the work if he suspects the presence of
any un-contained flammable liquid or vapour in the 6.3.2.1 Special precautions are required when gas-
vicinity. freeing and cleaning tanks which have held hydrocarbon
Bringing first aid fire-fighting equipment into products. Reference should be made to IP Model Code
immediate use in the event of a fire. of Safe Practice Part 16 Tank cleaning safety code and
55

HSE’s Approved Code of Practice Safe work in 6.3.2.7 If welding is to be done, there should be
confined spaces. adequate ventilation so that welding fumes are collected
and carried away from the breathing zone of the welder.
6.3.2.2 Tanks which previously contained leaded If this cannot be provided a face mask supplied with
product should be tested by qualified personnel for the fresh air should be used.
presence of lead and a certificate issued stating the
vessel is safe for entry of personnel. 6.3.2.8 Special attention should be given to providing
safe entry and egress through the manholes.
6.3.2.3 Tanks and vessels which have not previously
been gas-freed and tested for sufficiency of oxygen 6.3.3 Pipelines, pumps, valves
should not normally be entered even when wearing
breathing apparatus. 6.3.3.1 Prior to breaking connections, systems should
When entry under such conditions has to be made be adequately isolated, depressurised, drained as far as
for exceptional reasons, special management practicable and facilities put in place to collect any
authorisation should be obtained. An observer should be residual product.
stationed at the manhole throughout the operation to
take immediate action or summon assistance in case of 6.3.3.2 Where hot work is to be undertaken, gas-
collapse of or danger to any person or persons inside the freeing and thorough cleaning of the unit or units to be
tank or vessel. Observers and rescue personnel should repaired or altered should be carried out.
also be suitably equipped so that they do not become
casualties during rescue operations. 6.3.3.3 All openings or equipment left in place should
be closed by blank flanges or equivalent; reliance
6.3.2.4 Hot work or other hazardous work should not should not be placed on closed valves. Any product
commence on or inside a tank or vessel which has drainings should be captured in suitable containers and
stored petroleum until it has been emptied, isolated, disposed of safely and not be allowed to soak into the
cleaned and gas-freed. Before the application of heat, ground or enter drainage systems.
written certification should be obtained stating tests
carried out have revealed no product vapour to be 6.3.4 Electrical
present.
If repair work involving hot work from the inside 6.3.4.1 A competent person should satisfy himselfthat
of the tank is necessary on welded seams or plates of the equipment is isolated from live electrical circuits
buried or mounded tanks, or on the bottom plates of and should issue an electrical isolation certificate before
above-ground vertical tanks, holes should be carefully any work on tests, adjustments, maintenance or
drilled under cold work conditions; gas tests should be extensions is commenced.
carried out to ensure that product or gas is not trapped Where possible. main switches or circuit breakers
between the tank plates and the tank foundations and should be mechanically locked in the open position
surrounds. while work is in progress, but ifthere is no provision for
Reference should also be made to IP Model Code locking the switchgear, fuses should be withdrawn and
of Safe Practice Part 16 Tank cleaning safety code, locked away.
which contains precautions for work on tanks that have A warning notice that work is in progress should be
previously contained leaded gasoline before hot work is attached to the switchgear or fuseboard to prevent
allowed to proceed. accidental operation of the switchgear or replacement of
the fuses.
6.3.2.5 When tanks contain hard deposits which have
to be removed by chipping, the work permit should 6.3.4.2 After the work has been completed, a
specify that the surface should be kept thoroughly competent person should certify that the apparatus is
wetted during the operation. mechanically and electrically in order before it is
brought back into use.
6.3.2.6 Cylinders of oxygen or flammable gas should
not be taken into a tank. Blowpipes and hoses should be 6.3.4.3 There should be compliance with any relevant
removed from a tank when not in use, since a small leak local code or legislation such as IP Model Code of Safe
of oxygen or flammable gas over a period can make the Practice Part I Electrical safety code and, in the UK, the
atmosphere in a confined space hazardous. Electricity at Work Regulations 1989.
56

IMPORTANT: This file is subject to a licence agreement issued by the Energy Institute, London, UK, All rights reserved, It may only be used in accordance with
6.3.5 Records attach instructions to it indicating the service that it was

in and further precautions necessary to ensure that no
6.3.5.1 Records should be maintained of all items of flammable or toxic hazards will arise when hot work is
plant and equipment which are required by law to be carried out.
regularly inspected or tested. Such records should be The workshop or other premises receiving the
kept for the life of the equipment. equipment should not accept it without such
instructions, which should bear the signature of the
6.3.5.2 Records should be maintained of all other dispatching supervisor and the date of dispatch.
items of plant and equipment including the name of the
manufacturer, design conditions and any other relevant
information, details of any cleaning, inspections, 6.4 PERSONNEL
repairs, maintenance and modifications. Each piece of
plant and equipment should have a unique identifier (or 6.4.1 Planning and supervision
tag number).
6.4.1.1 Inspection, maintenance or new works should
6.3.5.3 As-built drawings and documentation as listed be planned and progressed by experienced and
in Annex C should be readily available to the responsible staff; they should ensure that those engaged
installation giving details of pipework, equipment and in the work observe all relevant precautions.
services.
6.4. 1.2 Management of installations should ensure that
6.3.6 Work on equipment in operation persons carrying out maintenance or construction have
received appropriate training (including appropriate
6.3.6.1 Repairs or modifications to plant and safety induction) and are fully acquainted with all
equipment in operation should not be permitted except relevant safety legislation and site procedures.
as given in 6.3.6.2.
6.4.2 Temporary personnel
6.3.6.2 Where unavoidable, the following work may
be carried out on equipment in operation; in both cases 6.4.2.1 Temporary personnel are frequently used for
the work should be carried out under rigorously maintenance and plant modifications. They may not be
controlled conditions: familiar with the normal precautions adopted in
premises storing petroleum, and should be given:
Non-hazardous cold work.
(Note: repairs or alterations to floating suction, A safety induction course when first reporting for
pressure and vacuum vents, float gauges, etc. work, such as in the form of a video.
should not be undertaken when tanks or vessels are Safety instruction, both general and specific, before
being filled or emptied.) starting work.
Hot tap connections may be permitted if no Adequate supervision to ensure that relevant
alternative is practicable. These should be carried precautions are observed.
out in accordance with local regulatory
requirements. The approval of the local safety A register of all training of personnel, including safety
inspector should be obtained. induction, should be held on site.
6.3.7 Removal of equipment to workshops or 6.4.2.2 As visitors to site (see section 9.4), all
outside the installation temporary personnel should be required to sign the
visitors register including times of entry and exit so that
If equipment has to be removed to a workshop, management have a detailed record of visitors and
contractors’ premises or other location outside the personnel on site at all times.
installation, a work permit should specify the cleaning
or gas-freeing to be done before transport, storage or
starting work so that no hazard will arise in subsequent 6.5 EQUIPMENT
handling.
When equipment is so removed, the supervisor Contractors’ equipment should only be brought into use
responsible for the moving or dispatching should ensure with written authority of the installation manager or his
that it is cleaned and gas-freed in accordance with the authorised representative. The equipment should be
work permit and is safe to handle in transit. He should inspected by a competent person before this authority is
57

IMPORTANT: This tile is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved, It may only be used in accordance with
given to ensure safety features are fitted and working, Mobile equipment located in a hazardous area
and to confirm an adequate state of maintenance. should be constructed and maintained so that it is not a
Vehicles or equipment fitted with petrol or spark- source of ignition. In general such equipment should be
ignition engines should not be allowed into the diesel-powered, fitted with a spark arrester on the
installation, exhaust system and with an over-speed cut-out in the
Use ofvehicles or equipment should be defined and induction system. BS EN 1834-1, 2000 gives guidance.
controlled, particularly in hazardous areas. Routes to or
from the place of work for pedestrians and vehicles
should be clearly indicated.
58

7
TANK CLEANING
7.1 GENERAL method statement should be prepared and agreed with

the installation management detailing the hazards to be
The cleaning of storage tanks that have held petroleum encountered, the tests to be carried out, the methods and
products can be a dirty and unpleasant operation. This equipment to be used and the precautions to be taken.
adds to the inherent hazards that are associated with the Any changes to the agreed method statement should be
flammable materials that the tanks may have stored. IP properly authorised before they take place.
Model Code of Safe Practice Part 16 Tank cleaning Some gasoline products will have contained
safely code contains guidance on preparatory work organic lead compounds which may be concentrated in
including medical aspects, taking tanks out of service, the sludge or scale found in the tank. Such materials
gas-freeing, entry into confined spaces, cleaning should only be removed by contractors equipped with
procedures, precautions specific to product groups and full breathing apparatus with external source of air
recommissioning. supply and protective suits. Strict precautions apply to
Further guidance and advice can be found in Health the disposal of these materials which should not be
and Safety Executive’s publication CS 15. removed from the site without the necessary approvals
having been obtained.
7.2 PERSONNEL
7.4 EQUIPMENT
Personnel should be fully conversant with the dangers
of tank cleaning and competent in the techniques Because of the danger associated with tank cleaning
required and fully trained in the operation of the operations, equipment selection is ofspecial importance
equipment to be used during tank cleaning. in order to minimise the risks. Maintenance is of
Personnel should be in possession of a current paramount importance to ensure that safety features
medical certificate stating they are medically fit to carry remain effective. Equipment should not be substituted
out tank cleaning. unless it is equivalent to that originally supplied.
7.3 PLANNING
Careful planning is essential to the success of the tank

cleaning operation. Before the work takes place a
59

DESIGN, CONSTRUCTION AND OPERATION OF PETROLEUM DISTRIBUTION JNSTALLATIONS
60

8
CLOSURE, DECOMMISSIONING
AND DEMOLITION
8.1 GENERAL Railway Authority.
The closure and subsequent decommissioning and Other matters to be considered are:
demolition of installations should be treated with the
same care and attention as given to operations and The setting up of continuing security.
maintenance. Disposal or sale ofredundant equipment or transfer
Particular consideration should be given to the of equipment to other installations.
degree of clean-up that may be necessary and possible Cancellation of maintenance and other contracts.
soil and groundwater remediation. Transfer of records which are required to be
retained.
Safety of the closed site.
8.2 CLOSURE Maintenance of electrical services and drainage
systems left operational.
Procedures will vary for different countries and will be Ongoing monitoring of any environmental liability.
site-specific for individual installations within each
country but the following items should cover most of
the statutory and other necessary actions. 8.3 DECOMMISSIONING
Authorities to be advised of installation closure
should, in the UK, include where appropriate: 8.3.1 General
HM Customs and Excise. It will not be possible for the operations staff at an
Utility companies i.e. gas, water, electricity, installation to remove all product from tankage and
telephone, refuse collection, drainage and sewage pipelines so consideration should be given at an early
disposal. stage to employing a specialist cleaning contractor. Any
— Fire Authority. recovered petroleum products should be transferred to
— Petroleum Officer (for surrender of Petroleum another installation or, if necessary, disposed of at a
Licence). licensed incineration plant or waste disposal facility
Pipeline Authority. together with all contaminated cleaning materials.
Local Authority (local government taxes). Disposal of hydrocarbon products in vehicle service
Environment Agency (discharges to atmosphere buildings and laboratories should not be overlooked.
and controlled waters). Water used for flushing systems should be allowed
— Health and Safety Executive (for COMAH sites). to flow to the site oil/water separator under controlled
— Landlord (for leasehold installations). conditions to ensure continued compliance with
Port Authority. discharge consents.
61

IMPORTANT: This tile is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved, It may only be used in accordance with
8.3.2 Risk assessment 8.3.7 Utilities
Tanks, pipework and other associated equipment which Surface water drains should be flushed clean with water
are to be taken out of service need to be made safe. and the run-off passed through the separator. On
Previous use, product handled, location and whether completion of all draining and flushing the last action
plant is to be taken out of service permanently or should be cleaning of the separator. This should be
temporarily will influence the method used. A risk carried out using high pressure water washing and the
assessment should be carried out at the planning stage separator refilled with clean water on completion.
to identify any additional hazards that decommissioning
may introduce. Reference should be made to HSE 8.3.8 Soil and groundwater
publications HS(G)176, HS(G)l86 and INDG 163.
If not previously carried out, surveys of the soil and
8.3.3 Tankage groundwater should be undertaken on cessation of
operations. It is probable that both will be contaminated
Storage tanks should be emptied and cleaned in to a degree depending on the age of the installation,
accordance with IP Model Code of Safe Practice Part 16 nature of the soil and the number and nature of
Tank cleaning safely code and any recommendations hydrocarbon spills. The level of clean-up should be
from the risk assessment. Floating roofs, iffitted, should agreed with the regulatory authorities and will depend
be left resting on their legs. Following cleaning the on the intended future use of the site. In order to avoid
manhole covers should be replaced on four bolts or unnecessary work, consideration should be given to
strong wire mesh bolted to the manhole flanges to obtaining guidance from experts experienced in these
prevent access by personnel or animals. activities.
TP Code of practice for the investigation and
8.3.4 Pipelines and pipework mitigation of possible petroleum-based land
contamination gives further guidance on such surveys.
Pipelines and pipework should be pumped free of all
petroleum products and flushed through with water.
Consideration should be given to passing the effluent to 8.4 DEMOLITION
a holding tank for primary separation of oil before
pumping for disposal through the site oil/water 8.4.1 General
separator. Where emulsification is caused greater
separation time will be needed. Pipework should be 8.4.1.1 Depending on the future use of the site, partial
physically disconnected from all tanks. or total demolition may be necessary. As demolition is
potentially a dangerous activity great care should be
8.3.5 Additive systems taken in its planning and execution. Further guidance is
given in BS 6187. In the UK the HSE should be
Undiluted additive should be recovered from tankage, informed well in advance of such work to comply with
pumps and piping systems and transferred to another the Construction (Design and Management) Regulations
operational installation, returned to the supplier or 1994 (reprinted May 2005).
disposed of according to the manufacturer’s
instructions. The system should be flushed with water. 8.4.1.2 An asbestos survey should be carried out prior
Any contaminated water may have to be treated as a to demolition and any asbestos removed from site by an
trade waste with special disposal arrangements. approved specialist contractor. Asbestos cement
products such as roof sheeting, gutters etc. may be
8.3.6 Electrical removed by the demolition contractor but care should be
taken when breaking, cutting and handling such
Electrical supplies to lighting, heating and some material.
equipment may be necessary for security staff or
contractors but all other electrical equipment should be 8.4.1.3 The electricity, gas and water supply
isolated, fuses removed, locked off where possible and companies should be asked to locate and disconnect all
suitable labels affixed. incoming services at appropriate times during
demolition.
62

CLOSURE, DECOMMISSIONING AND DEMOLITION
8.4.1.4 Even after thorough decommissioning and 8.4.4 Demolition contracts

cleaning there will remain a possibility that free product
could be trapped in pipelines or underneath tankage and 8.4.4.1 Demolition contractors should be selected with
other fixed facilities. Precautions should be taken to care and only those contractors with proven
prevent fire, explosion or escape of pollutants, performance in this field should be employed. Detailed
particularly to any watercourse. proposals for carrying out the work should be obtained
from contractors and reviewed with them before any
8.4.2 Site safety supervision decisions are taken on placing of contracts, to ensure
that adequate safety and environmental precautions will
8.4.2.1 Full time site safety supervisors should be be adopted.
appointed, appropriately qualified and experienced in
demolition procedures in the oil and chemical industry. 8.4.4.2 It is preferable that all underground equipment
The supervisors Should be responsible for the issue of such as pipelines and electrical cables, and concrete
work permits, adherence to method statements and paving and foundations are broken out and removed
given full authority to give instructions to contractors from site but this may depend on the planned reuse of
including halting work in the event of non-compliance. the site.
8,4.2.2 During demolition operations, sites should be 8.4.4.3 Particular care should be taken with the
isolated by fences or barriers to prevent inadvertent demolition, handling and disposal of steel which has
access by unauthorised persons. been in contact with leaded products; this should be
either flame-treated or disposed off-site for smelting.
8.4.3 Method statement
8.4.4.4 BS 6187 Code ofPracticefor Demolition gives
Before any demolition is carried out, full and detailed general guidance and includes a section on above-
safety method statements should be prepared by ground storage tanks. The use of tractor-mounted
contractors, discussed in detail and agreed with site hydraulic shears can be a safe and economic method of
management and local safety and environmental tank and pipework demolition.
regulators.
63

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64

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubsenergyinst.org.uk t: +44(0)207 467 7100
9
HEALTH, WELFARE AND

PROTECTION OF PERSONNEL
9.1 GENERAL RESPONSIBILITIES 9.1.1.6 Employers should provide employees and
other people at the workplace who might be at risk with
The main hazards associated with storage and handling suitable information, instruction and training on
of petroleum products are fire, explosion and risk to precautions and actions they need to take to safeguard
health through exposure to the products or contact with themselves and others, including:
them.
Management and employees have individual and — Names of the substances in use and risks they
joint responsibilities for the safeguarding of health and present.
safety at work, which may be embodied in national — Access to any relevant safety data sheets.
legislation. Details of legislation that applies to the hazardous
properties of those substances.
9.1.1 Management responsibilities The significant findings of the risk assessment.
9. 1.1.1 It is the responsibility ofmanagement to ensure Employers should also make information available to
that all reasonable precautions are taken for the safety employee representatives.
and welfare of personnel employed at the installation. Information, instruction and training may only need
to be provided to non-employees where it is required to
9.1.1.2 Management has a duty to ensure that risks at ensure their safety; where it is provided, it should be in
the workplace are minimised as far as is reasonably proportion to the level and type of risk.
practicable. This includes the setting up of safe working
procedures and adoption of customary industry practices 9.1.2 Employees’ responsibilities
to minimise the risks associated with the storage and
handling of petroleum products. 9.1.2.1 Employees have a duty to take all reasonable
steps to observe correct working practices in order to
9.1.1.3 Management should supply employees with ensure that neither they nor their colleagues, nor anyone
PPE, as specified in Annex E (see 9.2.3.2). who may be affected by their work, are exposed to
hazard.
9.1.1.4 All employees should be instructed and trained
in their duties and in regard to foreseeable emergencies. 9.1.2.2 Employees should wearthe personal protective
equipment issued to them, as required, noting the
9.1.1.5 A written statement setting out general safety precautions in use given in Annex E.
procedures and the employees’ duties and
responsibilities should be prepared, communicated to all 9.1.2.3 It is the employees’ responsibility to report any
staff and displayed in a prominent position. incident, activity or procedure which may have
65

DESIGN, CONSTRUCTION AND OPERATION OF PETROLEUM DISTRIBUTION TNSTALLATIONS
contributed to an infringement of regulations. daily exposure over a working lifetime. In the UK, HSE
Occupational exposure limits, published annually,
contains up to date regulatory limits.
9.2 SPECIFIC RESPONSIBILITIES
9.2.4 Protection of workers from the risk of
9.2.1 Health and safety policy statement explosive atmospheres
Employers should produce a health and safety policy 9.2.4.] General

statement which should be made available to all The European Council Directive 1999/92/EC (AlEX
personnel and displayed at all installations. In the UK 137, ‘The Workplace Directive’), which is also known as
this is required under the Health and Safety at Work etc. the ‘ATEX Use’ Directive, is implemented in the UK by
Act 1974 the Dangerous Substances and Explosive Atmospheres
Regulations 2002 (DSEAR)
. It came into force on 1st
2
9.2.2 Protection of employees and others July 2003 to coincide with the end of transition of the
ATEX ‘Equipment’ Directive (94/9/EC).
Management should carry out an assessment ofthe risks Employers are required to protect workers from the
to health and safety of employees and of anyone who risk of explosive atmospheres. An explosive
may be affected by the work activity. HSE publications atmosphere is defined as a mixture with air, under
HS(G)176, HS(G)l86 and INDG163, give further atmospheric conditions, of dangerous substances in the
guidance. In the UK, this is a requirement under the form of gases, vapours, mist or dust in which after
Management of Health and Safety at Work Regulations ignition has occurred, combustion spreads to the entire
1999. unburned mixture.
The end user should risk assess their workplace and
9.2.3 Control of Substances Hazardous to Health zone and mark hazardous areas according to their level
(COSHH) of risk for gases and dusts.
9.23.] A risk assessment of activities involving the 9.2.4.2 Responsibilities

handling and use of hazardous substances such as Employers and the self-employed should:
petroleum products and additives should be carried out
to determine the specific issues relating to their intended Carry out a risk assessment of any work activities
use and relevant to the work environment. In the UK. involving dangerous substances.
this is required by the Control of Substances Hazardous Provide technical and organisational measures to
to Health Regulations. eliminate or reduce as far as is reasonably
practicable the identified risks (including PPE, see
9.2.3.2 The risk assessment should guide the Annex E).
identification of adequate control programmes in order Provide equipment and procedures to deal with
to minimise: accident and emergencies.
Provide information and training to employees.
Potential exposure of workers to hazardous ClassifS’ places where explosive atmospheres may
substances. occur into zones, and mark the zones where
The identification of any personal protective necessary.
equipment (PPE) that should be worn (see Annex
E). 9.2.4.3 Scope
The development of training programmes to avoid Other than for certain maritime activities, DSEAR apply
or help mitigate exposure. whenever the following conditions have been satisfied:
9.2.3.3 Exposure of workers to hazardous substances There is work being carried out by an employer or
is controlled by national occupational exposure limits self-employed person.
(OELs). These limits are set at a level which would not A dangerous substance is present or is liable to be
be expected to cause adverse health effects on repeated, present at the workplace.
1n the UK DSEAR also implements the safety requirements of the Chemical Agents Directive (CAD) and complements the
2
Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres Regulations 1996 (that implement
the ATEX 95 Directive).
66

HEALTH, WELFARE AND PROTECTION OF PERSONNEL
The dangerous substance presents a risk to the 9.2.4.7 Safety measures

safety of persons (as opposed to a risk to health). Employers should ensure that the safety risks from
dangerous substances are either eliminated or reduced
9.2.4.4 Persons protected to as far as is reasonably practicable.
In addition to employees at the workplace, any other Where it is not reasonably practicable to eliminate
person whether at work or not who may be put at risk risks, employers should take, so far as is reasonably
by dangerous substances should be considered; this practicable, measures to control risks and measures to
includes employees working for other employers, mitigate the detrimental effects of a fire or explosion or
visitors to the site, members of the public, etc. PPE similar event.
required to protect such people is included in Annex E.
However, when considering arrangements to deal 9.2.4.8 Control measures
with accidents, incidents and emergencies and the The following control measures should be applied in the
provision of information, instruction and training, following priority order consistent with the risk
employers only have duties to persons who are at their assessment and appropriate to the nature of the activity
workplace. or operation:
9.2.4.5 Risk assessment i) Reduce the quantity of dangerous substances to a

Employers (or self-employed persons) should: minimum.
(a) Carry out a risk assessment before commencing ii) Avoid or minimise releases.
any new work activity involving dangerous iii) Control releases at source.
substances. iv) Prevent the formation of an explosive atmosphere.
(b) In the case of an employer with five or more v) Collect, contain and remove any releases to a safe
employees, record the significant findings of the place (e.g. by ventilation).
assessment as soon as is practicable after the vi) Avoid ignition sources.
assessment is made, including: vii) Avoid adverse conditions (e.g. exceeding the limits
The measures (technical and organisational) of temperature or control settings) that could lead
taken to eliminate andlor reduce risk. to danger.
—. Sufficient information to show that the viii) Keep incompatible substances apart.
workplace and work equipment will be safe
during operation and maintenance including 9.2.4.9 Mitigation
details of any hazardous zones and any special Mitigation measures should be applied that are
measures to ensure co-ordination of safety consistent with the risk assessment, and appropriate to
measures and procedures, when employers the nature of the activity or operation including:
share a workplace.
Arrangements to deal with accidents, incidents Reducing the numbers of employees exposed.
and emergencies. Providing plant which is explosion-resistant.
— Measures taken to inform, instruct and train — Providing explosion-suppression or explosion-relief
employees. equipment.
Taking measures to control or minimise the spread
9.2.4.6 Scope of the risk assessment of fires or explosions.
The risk assessment should be an identification and — Providing suitable personal protective equipment
careful examination ofthe dangerous substances present (PPE).
in the workplace, the work activities involving those
substances and how they might fail dangerously so as to 9.2.4.10 Elimination and reduction
give rise to fire, explosion and similar events with the The measures taken to achieve the elimination or the
potential to harm employees and the public. Its purpose reduction of risk should include:
is to enable employers to decide what they need to do to
eliminate, or reduce to as far as is reasonably Design, construction and maintenance of the
practicable, the safety risks from dangerous substances. workplace (e.g. fire-resistance, explosion relief).
The risk assessment should be carried out before Design, assembly, construction, installation,
commencing any new work activity, and the measures provision, use and maintenance of suitable work
identified as necessary by the risk assessment should be processes, including all relevant plant, equipment,
implemented before the work commences. control and protection systems.
67

The application of appropriate systems of work — Suitable warning (including visual and audible
including written instructions, permits-to-work and alarms) and communication systems.
other procedural systems of organising work, — Escape facilities if required by the risk
-
assessment.
9.2.4.11 Identification of contents Emergency procedures to be followed in the event
The hazardous contents of containers and pipes should of an emergency.
be identified. ‘Identification’ may include training, Equipment and clothing for essential persoimel
information or verbal instruction, but some may require dealing with the incident.
labelling, marking or warning signs. Practice drills.
Making information on the emergency procedures
9.2.4.12 Places where flammable atmospheres can available to employees.
occur Contacting the emergency services to advise them
In workplaces where flammable atmospheres may that information on emergency procedures is
occur, it should be ensured that: available (and providing them with any information
they consider necessary).
— The areas where flammable atmospheres may occur The scale and nature of the emergency
are classified into zones based on their likelihood arrangements should be proportionate to the risks.
and persistence. These requirements clarify what already needs to
The areas classified into zones are protected from be done in relation to the safety management of
sources of ignition by selecting equipment and dangerous substances and will not require any
protective systems. In the UK, they should meet the duties in addition to those already present in
requirements of the Equipment and Protective existing legislation.
Systems Intended for Use in Potentially Explosive
Atmospheres Regulations 1996, although
equipment already in use before 1 July 2003 can 9.3 GUIDANCE
continue to be used indefinitely provided the risk
assessment shows it is safe to do so; where Guidance on health, welfare and prOtection of personnel
necessary, areas classified into zones are marked can be obtained from the following publications.
with a specified ‘Ex’ sign at their points of entry.
Where employees work in hazardous areas they are — Health and Safety at Work etc. Act 1974.
provided with appropriate clothing that does not HS(G)65.
create a risk of an electrostatic discharge igniting — IP Code of practice for occupational hygiene
the flammable atmosphere. audits.
— Before coming into operation for the first time, the IP Guidelines for health surveillance and
areas where flammable atmospheres may be biological monitoringfor occupational exposure to
present are confirmed as being safe (verified) by a benzene.
person (or organisation) competent in the field of
explosion protection. The person carrying out the The above publications cover good current practice in
verification should be competent to consider the safeguarding the health of employees, based on
particular risks at the workplace and the adequacy legislation in the UK. In countries where there are
of control and other measures put in place. existing statutory requirements pertaining to the
petroleum industry, these should be considered as being
9.2.5 Arrangements to deal with accidents, complementary to such requirements.
incidents and emergencies
Employers should make arrangements to protect 9.4 VISITORS TO SITE

employees (and others who are at the workplace) in the
event of accidents. In the UK, the provisions should All visitors to site should be required to sign into a
build on existing requirements in Regulation 8 of the visitors’ register together with time of entry and whom
Management of Health and Safety at Work Regulations they are visiting. On leaving all visitors should enter
1999 and require employers to make arrangements time of leaving the site to enable management to have
including: a detailed record of personnel on site at all times.
68

10
TRAINING AND COMPETENCE
10.1 TRAINING REQUIREMENTS 10.2 TRAINING SUBJECTS
Good training for all personnel including supervisory Operations personnel should be thoroughly trained in all
staff, installation operators, road tanker drivers and all aspects oftheir duties including all the products handled
contractors is essential if work is to be carried out at the installation concerned. During the course of this
efficiently and safely. On-the-job training alone, in most training, as well as theoretical content, a period of
cases, is not sufficient and should be supplemented by practical work under supervision is recommended.
a properly co-ordinated programme of formal training. To achieve maximum benefit it is desirable that
While all newcomers should be properly trained, personnel be given an understanding of the reasons
the necessity for periodic refresher training of existing behind the various procedures. In order to ensure the
staff should not be neglected. effectiveness of the training, some form of competence
It is recommended that a senior member ofthe staff assessment should be performed at the end of the
should have direct responsibility for putting training training. The results of this assessment should be
programmes into effect and for keeping full records. recorded.
Training should be based upon the procedures set Safe practices in relation to specific operations are
out in the operating manual for the installation. It is covered in detail in other sections of this Code.
recommended that the following are provided: As appropriate the following specific points -
provided as a guide and not exhaustive should be -
— A concise instructional guide on basic information included in training programmes:

common to all installations operated by the owner.
Operating manuals for particular items ofplant and The properties of the products handled including
equipment specific to each installation, both fixed their flammability and toxicity (Appendix D gives
and mobile, that possess any degree of complexity. details of classes and characteristics of products.)
Static electricity and switch loading, and how these
If road vehicle drivers employed by agents, distributors hazards can be avoided or minimised.
or transport contractors load or unload their vehicles at Legislation, so far as it relates to and affects the
the installation, it is important that they should have individuals’ duties and responsibilities.
undergone a similar training programme to ensure that Statutory and other regulations relating to the
they are also competent and that they understand the storage and handling of petroleum products at the
proper use of the installation’s facilities. Full records of installation.
their training should be kept. The berthing and handling of ships, and the
Consideration should be given to providing basic techniques for loading I discharging them.
training for visitors supplying services to the — The positioning and handling of railcars within the
installation; this should cover, as a minimum, installation, the relevant procedures of the railway
emergency evacuation procedures. operator and the techniques for loading!
discharging them.
69

The techniques ofloadingldischarging road tankers. Emergency exercises based on simulated incidents,
— The precautions to be adopted when dipping, carried out with the participation of the public services,
gauging or sampling tanks and when filling and will familiarise all concerned with the equipment and
emptying them. techniques required to deal with emergency conditions.
The techniques of gas-freeing and cleaning, even
when this work is performed by specialist
contractors. 10.3 TRAINING RECORDS
The value of personal protective equipment,
including clothing, safety helmets, gloves, goggles, Records oftraining should be maintained showing dates
safety footwear, high visibility clothing and the use when personnel are adjudged proficient in their various
of barrier creams, hand cleansers and skin tasks, when certification expires and when retraining is
conditioning products. required. The records should show training in new
Instruction in the correct methods of lifting and techniques and in the operation of new equipment when
handling heavy and irregular objects; guidance is introduced,
given in the Manual Handling Operations The following forms of records are useful:
Regulations 1992.
Regular instruction in handling emergency — A record in the individual file of each person.
situations and using the emergency procedures in An overall chart showing training of all personnel
force at the installation; the training should include employed at the installation.
dealing with fires, accidents to road tankers, Records of rotational training of staff to ensure
spillages, product contamination, personal injury flexibility.
and security incidents. Records of refresher training.
Competence assessment records.
70

the licence terms and conditions, It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: a: pubs@energyinst.org.uk t: +44 (0)207 467 7100
ANNEX A
GLOSSARY OF TERMS
above-ground tank: tank which is not covered or conductor between sections of plant, equipment or
partially covered with earth, sand or similar material. structures. See IP Model Code of Safe Practice Part I
Electrical safety code.
additive: small quantity of chemical or dye intended to
enhance performance or to provide identification for tax breathing apparatus: device which ensures that the
purposes. wearer has a continuously available supply of
uncontaminated air through a face mask, helmet or
adequate ventilation: natural, artificial or a com mouth piece.
bination of both, sufficient to avoid persistence of
flammable atmospheres within sheltered or enclosed bund wall: wall of appropriate height and size,
areas but insufficient to avoid their initial formation and constructed of suitable materials and designed to
spread throughout the area. This will normally be confine a spillage from tanks etc. (see alsojire wall).
achieved by a uniform ventilation rate of a minimum of
12 air changes per hour with no stagnant areas. bunded area: area in which oil spillage is contained by
means of a bund wall.
anti-static additive: see static dissipative additive
(SDA). buried tank: tank buried in the ground so that no
portion of the tank shell or roof, except for fittings on
area classification: notional division of the space the tank roof, protrudes above ground.
surrounding a facility into hazardous and non-hazardous
areas and the sub-division of hazardous areas into zones class of petroleum: classification of petroleum liquids
reflecting degree of hazard. including crude oil and its products according to
Annex D.
bay: (1) each side of a Top Loading Gantry at
which road tankers can be filled. closed-circuit television (CCTV): surveillance system
(2) alongside the island of a Bottom Loading to monitor operations or improve security.
Facility.
cold work: carrying out of any task, using tools or
blending: process of combining components into a equipment which will not produce a source of ignition
finished product. Typically the components are not (see also hot work). It includes the use of tools for
blended in small quantities (normally greater than 2- erection, dismantling and cleaning, which are not liable
3%). to produce incendive sparks, and operations such as
drilling, tapping and cutting carried out in such a way as
bonding: provision of a low-resistance electrical to limit the heat produced and keep the temperature of
71

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DESIGN, CONSTRUCTION AND 0PERATIOP4IOfBR0LEUM DISTRIDUTION INSTALLATIONS
the tools and work below 100 °C. including 55 C. See Annex D].
combustible: capable of self-sustained burning in air, flammable atmosphere: mixture of flammable gas or
once ignited (see Jiammable). vapour with air in such proportion that, without any
further admixture, it will burn when ignited.
competent person: person who has the necessary
ability in the particular process, trade, plant or flammable limits: limits of combustibility of
equipment involved to render that person capable of the flammable gases or vapours when mixed with air (see
work involved, and who has been duly authorised to upperflammable limit andlowerfiammable limit). Note
undertake the work. these terms are synonymous with limits or range.
compound (tank): area containing one or more storage flash point: lowest temperature of material, corrected to
tanks. a barometric pressure of 101,3 kPa, at which application
of an ignition source causes vapour from the material to
detonation arrester: device that arrests the passage of ignite.
flames travelling at sonic velocity, i.e. detonations (see
flame arrester). foot valve: valve fitted at the outlet of a road tanker
compartment.
earthing: the provision of a safe path for electrical
currents to ground in order to protect structures, plant fuel oil: Class III petroleum comprising heavy
and equipment from the effects of stray electrical distillates, residues or blends of these, used as fuel for
currents and electrostatic discharges. production of heat or power.
gantry: structure associated with a product supply

enclosed area: area in a building, room or enclosed
system and provided with all equipment necessary for
space within which, in absence or failure of artificial
(top) loading and safe access to road tankers.
ventilation, the ventilation does not meet the
requirements for adequate ventilation. See IP 15.
gas-free: vessel, container or area in which the
concentration of flammable gases and/or vapours is less
fire-proofing: treatment applied to materials and
than a prescribed limit. (Note: the term gas-free does not
facilities to reduce their vulnerability to fire and heat.
imply absence of toxic gases or sufficiency of oxygen
for vessel entry.)
fire-resistant: resistance to fire as defined by a
specified standard (e.g. BS 5476). gas-freed: state of a tank, vessel, container or area
which has been made gas-free.
fire stop: a barrier across a pipeline trench to prevent
the spread of fire. gas-freeing: operation of removing flammable or toxic
gases from a tank, vessel, container or area to less than
fire wall: a wall of appropriate height, constructed of a prescribed limit.
earth, concrete, steel, masonry, brickwork or other
suitable material, designed to confine spillage, to gas oil: Class III petroleum distillate, having a viscosity
prevent the spread of fire, and to afford protection to and distillation range intermediate between those of
personnel engaged in fire fighting. kerosene and fuel oil, used as a fuel for high speed
diesel engines, and burner fuel in heating installations.
flame arrester: device to prevent the back-propagation
of flame. It may take the form of perforated plates, fine gasoline: Class I refined petroleum distillate intended
slots in metal blocks, wire mesh gauzes, crimped metal for use as a fuel in spark ignition engines. Other terms
or bunched small diameter metal tubes. in use are petrol, motor spirit and gasoline.
flammable: easily ignited in air. [It is synonymous with hazard: physical situation with significant potential for
inflammable but the term flammable is much preferred. human injury, damage to property or damage to the
The term non-flammable refers to substances which are environment (see also risk).
not easily ignited but does not necessarily indicate that
they are non-combustible. A petroleum liquid is hazardous area: area in which a flammable
classified as flammable if it has a flash point up to and atmosphere exists or may exist in such frequency as to
72

IMPORTANT: This tile is subject to a licence agreement issued by the Energy Institute, London, UK. All rights reserved. It may only be used in accordance with
the licence terms and conditions, It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44(0)2074677100
ANNEX A
require special precautions for the construction and use ignition of the prescribed flammable gas or vapour.
of electrical or other apparatus.
island: structure associated with product supply system
hazardous atmosphere: atmosphere in which there is and provided with all equipment necessary for (bottom)
hazard from flammable gases or other causes such as loading of road tankers.
toxicity, asphyxiation and radioactivity, see fla,nmable
atmosphere. kerosene: Class II refined petroleum distillate,
intermediate in volatility between gasoline and gas oil.
hazardous substance: substance having characteristics Its main use is as a flel for aviation turbine engines
such as flammability, toxicity, carcinogenicity, when it is known as Avtur. It also has use for heating
radioactivity, corrosivity etc. In the UK, substances and, in a more limited way, for lighting and for certain
hazardous to health are defined by COSHH. types of internal combustion engines. Known also as
paraffin or paraffin oil, particularly when used in
HAZOP: Hazard and operability study; a systematic domestic applications.
method utilising a multi-discipline team, usually
addressing a prescribed set of questions, to identify loading area: collective area embracing all filling
potential deviation from the design intent in operation islands and bays but excluding waiting areas.
and to assess the consequences of these deviations.
loading arm: system of pipe/hoses and swivels that are
hot work: work including welding or the use of any balanced for easy movement, and through which
flame or electric arc or use of any equipment likely to product is transferred into a tanker.
cause heat, flame or spark. It also includes caulking,
chipping, drilling, riveting and any other heat-producing lower flammable limit (LFL): lowest concentration of
operation, unless it is carried out in such a way as to a flammable gas or vapour in air at atmospheric
keep the temperature of the tools and work below pressure capable of being ignited. The figure is
100 C (see also cold work). expressed as percentage by volume.
ignition source: accessible source of heat or energy, meter pre-set control: device or system that controls
electrical or non-electrical, capable of igniting the quantity of incoming product loaded into a
flammable atmospheres. compartment of a road tanker.
incendive spark: spark of sufficient temperature and mobile equipment: equipment mounted on its own
energy to ignite flammable gas. wheels or tracks, or having some other facility for
mobility.
inerting: use of an inert gas to render the atmosphere of
a tank or container substantially oxygen-free or to mounded tank: tank above, or partly in the ground,
reduce the oxygen content to a point at which completely covered by earth, sand or other suitable
combustion cannot take place. material.
injector: device for proportioning the amount of non-hazardous area: area in which flammable
additive into a fuel stream. atmospheres are not expected to be present so that
special precautions for the construction and use of
installation (marketing): premises for the storage and electrical or other apparatus are not required.
secondary distribution of petroleum products to retail
outlets, commercial users and small distribution centres. oil/water separator: facility for removing
Supplies are normally received direct from refinery by contaminants from water effluents. At distribution
ship, barge, rail or pipeline. installations separators are used for removing oil before
water is discharged to surface waters or sewers.
interceptor: see oil/water separator.
overfill prevention: system which is designed to stop
intrinsically safe: electrical circuit, system or apparatus flow if the product rises above a predetermined level in
in which any sparking that may occur, under the the compartment of the tanker tank being filled.
conditions specified by the certifying authority and with
the prescribed components, is incapable of causing petroleum class: categorisation of a petroleum product
73

according to its properties, see Annex D. petroleum fuels to increase the conductivity and thereby
prevent accumulation of a hazardous level of
pig (pipeline): device used for Separating successive electrostatic charge during handling operations. Also
grades of product in a multi-product pipeline, or used, known as anti-static additive.
propelled by water, air or gas, for clearing a pipeline of
liquid (see sphere). static electricity: electrical difference of potential or
charge generated through friction between surfaces of
piping system: system of pipes, fittings, valves and dissimilar materials or substances.
ancillary equipment for conveyance of petroleum
products or service fluids. switch loading: operation of loading a low vapour
pressure product such as kerosene, gas oil, or fuel oil
relief valve: pressure-relieving device actuated by the into a tank, or tanker compartment, which has
static pressure in the pipe or vessel in which the valve previously contained a high vapour pressure product
is mounted. The valve opens in proportion to the such as gasoline.
increase in pressure over the opening pressure.
thermal reliefvalve: valve fitted to relieve the pressure
risk: likelihood of human injury, damage to property or increase due to temperature rise in a closed liquid-filled
damage to the environment from a specified hazard. system (see relief valve).
risk assessment: process of identifying the hazards toxicity: capacity of a material to produce injury if it
present in any undertaking (whether arising from work reaches an environmentally susceptible site or sites on,
activities or other factors) and those people likely to be or within, the body. A substance is said to be acutely
affected by them, and of evaluating the extent of the toxic if it produces effects within a short period of time
risks, bearing in mind the precautions that are already following exposure, and chronically toxic if effects
being taken. result only after prolonged or repeated exposures
measured in days, weeks, months or even longer.
ships: ocean-going, coastal, estuarial, river and canal
vessels including barges for carrying petroleum in bulk upper flammable limit (UFL): concentration of
or in packages. flammable gas or vapour in air at atmospheric pressure
above which combustion will not occur. The figure is
source of ignition: naked flames, certain electrical expressed as a percentage by volume.
equipment, hot surfaces above ignition temperature or
a spark or flame produced by any other means. ventilation: process of air movement and replacement
by fresh air. Natural ventilation refers to ventilation
spark arrester: device fitted to exhausts of internal caused by wind or convection effects. Artificial or
combustion engines which prevents the emission of hot forced ventilation refers to ventilation caused by air
carbonaceous particles. purges or mechanical means such as fans.
sphere (pipeline): sphere of flexible material used for work permit: document issued by authorised person or
separating successive grades of product in a multi- persons permitting precisely identified work to be
product pipeline (see pig (pipeline)). carried out in a defined area and in a defined manner so
as to avoid endangering safety on the installation.
spontaneous ignition temperature (SIT): temperature
at which a material will begin to burn without working platform: area of the gantry structure from
application of any source of ignition. which the person loading the tanker from the top
operates the meters, loading arms etc., and from which
static dissipative additive (SDA): chemical added to access is gained to the top of the tanker.
74

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44(0)207 467 7100
ANNEX B
RECOMMENDED MINIMUM
SEPARATION DISTANCES
FOR INSTALLATIONS HANDLING
CLASS I, 11(2) AND 111(2) PETROLEUM
75

Table B.! Location and spacing for above-ground tanks for product storage, Classes I, 11(2) and 111(2)
Note: These spacings should be used in conjunction with the appropriate level of fire protection given in IP Model
Code of Safe Practice Part 19 Fire precautions at petroleum refineries and bulk storage installations. The 2nd
edition of that code will include a risk assessment methodology for the determination ofseparation distances, which
may be followed rather than following the distances included below.
Tank Type Factor Recommended Minimum Distances

Fixed roof, 1. Between tanks within a group of small tanks. Determined solely by construction, maintenance
above-ground, and operational convenience.
including
those with
internal
floating roofs;
horizontal
cylindrical
tanks.
2. Between groups of small tanks as defined in 15 m.
2.3.3.1.
3. Between a group of small tanks and any tank Not less than 10 m; need not exceed 15 m.
outside the group.
4. Between tanks not being part of a group of Half the diameter of the larger tank or the diameter
small tanks. of the smaller tank, whichever is less, but in no case
less than 10 m; need not exceed 15 m.
5. Between a tank and any filling point, filling 15 m. But in agreement with licensing authority and
shed or building not containing a fixed source where tanks are small, this may be reduced to not
of ignition. less than 6 m.
6. Between a tank and outer boundary of 15 m.
installation, any designated non-hazardous
area, or any fixed source of ignition at ground
level.
Note 1: For tanks greater than 18 m in height it may be necessary to consider whether the distances
above should be increased to take account of the height of the tank.
External 1. Within a group of small tanks. As above for fixed roof tanks.
floating roof
2. Between two floating roof tanks. 10 m for tanks up to and including 45 m diameter.
15 m for tanks over 45 m diameter. The size of the
larger tank should govern the spacing.
3. Between a floating roof tank and a fixed roof Half the diameter of the larger tank or the diameter
tank. ofthe smaller tank, whichever is less, but in no case
less than 10 m; need not exceed 15 m.
4. Between a floating roof tank and any filling 10 m.
point, filling shed or a building not
containing a possible source of ignition.
5. Between a floating roof tank and outer 15 m.
boundary ofinstallation, any designated non-
hazardous area or any fixed source of ignition
at ground level.
Note 2: For tanks greater than 18 m in height, see Note 1 above.
Note 3: Floating roof tanks fitted with external metal domed roofs extending over the entire roof area
may be considered as fixed roof tanks for the purpose of tank location and spacing.
76

ANNEX 8
Table B.2 Minimum recommended separation distances for single ‘small’ tanks from site boundaries,
buildings, process areas and fixed sources of ignition
Tank capacity (m
)
3 Separation Distance (m)
Less than or equal to 1 1*
Greater than 1 and less than or equal to 5 4
Greater than 250 15

*But at least 2 m from doors, plain-glazed windows, or other openings or means of escape. Also not below any opening
(including building eaves and means of escape) from an upper floor, regardless of vertical distance.
Table B.3 Minimum separation distances for outdoor storage of packages containing Classes 1, 11(2) and
111(2) petroleum at all installations
Distance from occupied building, boundary, process unit,

Quantity stored in packages (litres)
flammable liquid tank or fixed ignition source (m)
Up to 1 000 2
1 000 to 100 000 4
Above 100 000 7,5
Notes:
1. The maximum stack size should be 300 000 litres, with at least 4 m between stacks.
2. Containers should not be stored within the bund of a fixed tank storing flammable liquids or within 1 m of a bund wall.
3. The distances are based on what is considered to be good practice and have been widely accepted by industry. Although
these distances may not provide complete protection to people or structures from a fire in the flammable liquid storage
area, they should allow time during a developing fire for people to evacuate to a place of safety.
77

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any uriauthorised user. Enquiries: e: pubs@energyinst.org.uk t: +44 (0)207 467 7100
78

ANNEX C
RECOMMENDED LIST OF RECORDS TO BE

MAINTAINED AT DISTRIBUTION
INSTALLATIONS
C.1 STATUTORY NOTIFICATION Earthing and elec. continuity test records.

Fire main routing and isolation diagram.
(This list is based on regulatory requirements in the UK. Fire alarm test records.
Similar requirements will apply elsewhere.)
— Planning approval(s). C.3 OPERATIONAL RECORDS

Building regulations approval(s).
Competent Authority approval(s) COMAH. - Written procedures.
Petroleum licence. Hazard and operability (HAZOP) studies.
HM Customs and Excise approval (where COSHH records.
necessary). Tank calibration tables.
Fire certificate (special premises). — Bund capacity calculations.
Consent(s) to discharge aqueous liquids to — High level alarm test register.
controlled waters. Pipeline capacities.
Consent(s) for airborne discharges. Meter proving certificates.
Notification of installations handling hazardous Electrical inspection certificate.
substances. Pressure relief valve test register (tanks and
Pipeline capacities. pipework).
— Boiler house weekly/daily log sheet.
Fire extinguisher inspection/test register.
C.2 CONSTRUCTION RECORDS — Lifting equipment inspection test certificate(s).
Pressure vessel inspection test certificate(s) for
— Storage tank test reports. boilers and compressor receivers.
Storage tank calibration certificates. — Pressure systems written review record.
-
— Piping pressure test certificates and inspection Oil/water separator cleaning register.
records. Product filter cleaning register.
Instrument calibration certificates. Rail tank car discharge record.
Pressure vessel test certificates. Rail tank car certificate of readiness.
— Site general arrangement drawing. Fire occurrence register.
— Product flow diagram. Accident register.
Layout of underground services. Product hose testing register.
Electrical test/inspection records. Oil/water separator sampling register.
79

Fire alarm test register. Record of work permits issued.

— Tank water bottom draining register. Personnel training and competence assessment
Tank maintenance record(s). records.
— Visitors’ register. Induction course register.
80
Licenced to: Miss Lison Mecolt. Single user licence only.

ANNEX D
CLASSES AND CHARACTERISTICS OF

PETROLEUM PRODUCTS
Table D.1 Petroleum Classes
Class 0 Liquefied petroleum gases (LPG)

Class I Liquids that have flash points below 21°C
Liquids that have flash points from 21°C upto and including 55°C, handled below flash
Class IJ1
“
‘ point
Liquids that have flash points from 21°C up to and including 55°C, handled at or above
Class II’2
flash point
Liquids that have flash points above 55°C up to and including 100°C, handled below flash
Class 111(1)
point
Liquids that have flash points above 55°C up to and including 100° C, handled at or above
Class III’2
“
‘ flash point
Unclassified Liquids that have flash points above 100° C
Classification of petroleum by the Energy Institute, Section 2 of the Area class(fication code for
based (except for liquefied petroleum gases, LPG) on petroleum installations.
closed cup flash points. Unclassified petroleum liquids (flash points>
100°C) should be considered as Class 111(2) when
Notes: handled at or above their flash points, but when
1. The definition of flash point is given in the these are or contain residual fractions, as in the
Glossary (Annex A). The distinction between the case of bitumen or residual fuels held in confined
flash point and the ignition temperature is fully tankage, reference again should be made to Section
explained in Section 8 of IP Area classfication 2 of the IP Area classification code for petroleum
codeforpetroleum installations. Some typical flash installations.
points of commonly handled petroleum materials
are given in Table D.2. 3. The IP Classes of Petroleum conform to the most
frequently used flash point divisions in European,
2. It will be noted that Class II and III petroleum may EU and UK regulations and directives. The above
be subdivided in accordance with the temperature subdivisions of Classes II and III have been
at which they are handled, dependent upon whether standardised by the Institute in its various codes of
this is above or below the flash point (see notes 3 practice to govern the handling of petroleum
and 4 below). Further reference can be found in materials throughout the sectors of bulk storage,
81

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk t: ‘-44 (0)207 467 7100
loading, conveyance, discharge and distribution. IP Model Code of Safe Practice Part 15, Area
It should, however, be recognised that there is classflcation codefor installations handlingflammable
an upper temperature limit, though unlikely to be fluids, 3rd edition 2005.
encountered, in the bulk storage, loading, Reference should also be made to the Area
conveyance, discharge and distribution sectors classification code for relationships between Class of
associated with installations for which further Petroleum, fluid category and Class I, 11(2) and 111(2)
details can be found in the relevant sections of temperature limits by fluid category.
Table D.2 Typical commonly encountered petroleum materials
Class of Petroleum Typical examples Typical flash point Typical boiling range
Flash point closed cup (°C) (°C)
Class 0 LPG, ethylene, propylene - Propane -42
n-butane —
Isobutane —12
Class I Gasoline (petrol) -45 ca. 20 to 205
<21°C Stabilised crude oil - ca. —1 to 380±
Avtag wide cut jet fuel —25 ca. 0 to 220
(JP4; Jet B)
Benzene —11 80
Toluene 4 110
Naphtha —2to 10 3Oto 177
Methanol 11 65
Class II Avtur/Jet A Turbofuel 38 150 to 240
21 55°C
- Kerosene
(a) premium grade 43 160 to 280
(b) regular 38 160 to 280
Class III Gas oil/distillate
>55- 100°C heatingoil 55± 250to360
Automotive diesel fuel 55 ± 180 to 360
Unclassified Atmospheric residues >100 >350
>100°C (fuel oils)
82

ANNEX E
PERSONAL PROTECTIVE EQUIPMENT

REQUIREMENTS
E.1 INTRODUCTION E.3 APPLICATION
Outsourcing ofpetroleum product distribution and inter The listings should be used by operators of distribution
company loading mean that greater numbers of people installations as a means of communicating PPE
can access and work at distribution installations. This requirements to those who access them or work there.
has resulted in some variation in personal protective The requirements may, for example, be included when
equipment (PPE) used by them and uncertainties over drawing up contracts with distribution contractors. They
whether it is fit for purpose. To help resolve these should therefore encourage consistency across the
difficulties, listings of PPE requirements have been sector.
developed. The listings should be used as part of a task risk
assessment process, which should also consider:
E.2 SCOPE The necessary level of protection offered by

different pieces of PPE where more than one
The listings comprise Minimum PPE Requirements for possibility is specified.
People Accessing Distribution Installation Operational Possible incompatibilities between components of
Areas (Table E.1), and Additional PPE Requirements a portfolio of PPE (e.g. for eye protection).
for Workers at Distribution Installation Operational The possibility of PPE increasing risks to other
Areas (Table E.2). The former listing is intended for hazards (e.g. using hearing protection that provides
visitors, road tanker drivers, inspectors, supervisors, excessive attenuation which reduces the likelihood
operations staff, maintenance contractors, etc. who of hearing vehicles, such as road tankers).
access distribution installation operational areas, and
covers specifications and precautions in use for foot, Whilst included in this Code, the current version of the
head, eye, and body protection, and high visibility PPE. PPE listings should be sought from the Internet page
Table E.2 is intended for road tanker drivers, operations http://www.energyinst.org.uk/dmsc/ppe.
staff, maintenance contractors, etc. who work at
distribution installation operational areas, and covers
specifications and precautions in use for additional PPE,
such as fall, hearing, respiratory, hand, eye and body
protection. These should supplement, or where
appropriate replace, PPE given in Table E. I.
83

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubs@energyinst.org.uk 1: +44 (0)207 467 7100
0
g -
CD —0
CD _ Table E.1 Minimum PPE Requirements for People Accessing Distribution Installation Operational Areas (Notes 1-3)
CD
CD 0 PPE Foot protection Head protection Eye protection Body protection High visibility
Safety shoes/boots Safety helmets Glasses Clothing High visibility work
BS EN ISO 20345, BS EN 397. BS EN 166 (type F). Used for Unspecified (Note 4). wear
antistatic, chemical general work affording basic BS EN 471 and
Coo—.
CD . resistant, hygienic. protection. antistatic.
CD CD Specification
5- Visors 0
C
DC CM
CD (0
BS EN 166 (type 1B93). Used for 0
general work affording basic z
CD— 3 c
.-.CDCD
CD. CD CD protection. 0
CD C)
CD.
i Ci CM
00
Safety shoes/boots should Safety helmets containing an integral visor None. Clothing should cover the High visibility work
be replaced when they no that covers the wearer’s nose should provide torso and lower limbs, wear should not be
longer provide adequate sufficient eye protection. unfastened or 0
- CD Ifl
CD cauti0 protection, such as when the Safety helmets have a maximum 5-year life- removed in
DCS
tread is insufficient to give span from date of manufacture (as per current hazardous areas. 0
o (0 0
adequate grip or when steel industry recommendations) and should be ‘0
gCD CO
toe caps are exposed. withdrawn from service thereafter.
a CD.
-
Notes 0
00 z
0) T 1. Minimum PPE requirements are intended for people accessing distribution installation operational areas, such as visitors, road tanker drivers, inspectors, supervisors, operations
CDO 0
CD CO
a staff, maintenance contractors, etc. ‘0
to
DC? 2. Other than visitors, inspectors and supervisors, those working at distribution installation operational areas may require additional PPE, as set out in Table 2.
CO
3. Requirements for PPE and the necessary level of protection where more than one possibility is specified should be determined by a task risk assessment. 0
C
Dl
CD — C
4. Requirements for clothing are not specified; in particular, there is no specific requirement for it to have antistatic properties.
a CD.
5. PPE should fit the user correctly. 0
CD — CM
6. When purchased, PPE should be CE marked. -
m CO
CD
.0 to
C C
CD
0
CD3
0)
CO
C
CD 0
CDCD
(011 0
a CM
CD
CD
a
0)
i zzzi z j j ,j .j I I I I
I [ EZ [Z3 [ EE z r-’: rzz rz r’ r-’ cz rz [Z1 r. rz.;
CD C)
c,C) 0=
C)
=CC CD
—z—
CD —IC
Table E.2 Additional PPE Reauirements for Workers in Distribution Installation Onerational Areas (Notes 1-2
DC DC Ci) Body protection
Ci) PPE Fall protection Hearing protection Respiratory protection Hand protection Eye protection
8 DC
0
- Full safety harness Ear muffs Orinasal masks PVC gloves Goggles Flameproof
D BS EN 361. BS EN 352-2 and BS EN 149 (type BS EN 374. Used for liquids and less BS EN 166. Used coveralls/overalls
BS EN 352-3. Used FF P1S). Used for hazardous chemicals, for general BS EN 531 and
DC
for hearing protection respiratory protection Nitrile gloves protection. BS EN 469.
between 85 dB(A) and against nuisance levels BS EN 374 to BS EN 388. Used where BS EN 175. Used Chemical suit
CC
C)) 100 dB(A). of non-toxic dusts. PVC gloves do not afford adequate for certain types of Unspecified as
C),
Ear plugs BS EN 149 (type chemical protection. welding and depends on the
BS EN 352-2. Used FF P2S). Used for Leather gauntlets welding assistance. identity of the specific
for hearing protection respiratory protection BS EN 420 to BS EN 388. Used for general hazardous substance.
Specification
0. 0 C) between 85 dB(A) and against fine toxic and work to prevent cuts. Guidance should be
CDC)
0. 100 dB(A). hardwood dusts. BS EN 388. Used for mechanical sought from a
C
CD BS EN 149 (type protection. specialist PPE
q
—
FF P3SD). Used for BS EN 407. Used for thermal hazard supplier.
0
- respiratory protection protection.
aCD
m
= against fumes, highly BS EN 348 (type 375). Used for molten
DC toxic metals and metal thermal hazard protection.
C) CD
go biohazards. BS EN 60903 for live or dead high voltage

CD electrical work.
0. —
0 —
Co Where there is no Ear plugs or muffs Specified PPE excludes For further guidance, refer to specialist PPE Eye protection Flameproof >
DC F LIC 2
C) C means of safe meeting specification use of respirators or supplier, should fit coveralls/overalls
‘< C) 2
ri
access and the should be worn where breathing apparatus sets adequately with should be worn by all 2
worker is exposed noise exceeds for respiratory protection other PPE. distribution
to falls (such as 85 dB(A) (Note 3). against greater hazards. installation operations
CD — from a height of 2 m However, where noise Guidance should be staff and maintenance
0. CD.
Co
more), a full exceeds 100 dB(A), sought from a specialist contractors. For work
CD recautions or
safety harness exposure should be PPE supplier, with particularly
C) CD should be worn; this reduced as far as is hazardous chemicals,
.0
9. CD should be connected reasonably practicable oils or biological
to a robust anchor, by means other than agents, a chemical suit
C
DC An emergency plan using hearing should be worn.
should be in place protection.
(gZ to recover suspen
CD D
CD
ded personnel.
Cog
Notes
II 1. Additional worker PPE requirements set Out in Table E.2 are intended for those working at distribution installation operational areas, such as road tanker drivers, operations staff and
maintenance contractors, etc. These should supplement, or where appropriate replace, PPE given in Table 1.
0. 2. Requirements for additional PPE set Out in Table E.2 and the necessary level of protection where more than one possibility is specified should be determined by a task risk assessment.
—DC
0
+ 0 3. The first action level is expected to be lowered from 85 dB(A) to 80 dB(A) in early 2006 when Directive 2003/10/EC on the minimum health and safety requirements regarding
• CD
exposure of workers to the risks arising from physical agents (noise) (referred to as the Physical Agents (Noise) Directive) is implemented with new regulations; this may affect
the specification for hearing protection.
4. PPE should fit the user correctly; this is a particular requirement for respiratory protection.
5. When purchased, PPE should be CE marked.
F
86
the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: e: pubsenergyinst.org.uk t: +44 (0j207 467 7100
ANNEX F
PUBLICATIONS
The following publications are relevant to the guidance API Std 653: Tank Inspection, Repair, Alteration and
given in this code: Reconstruction, 3rd edition, 2001.
API Std 2000: Venting Atmospheric and Low-
pressure Storage Tanks Non-
refrigerated and Refrigerated, 5th
F.l EUROPEAN COMMUNITIES COUNCIL edition, 1998.
EC Council Directive 94/9/EC The approximation ofthe

laws of Member States concerning equipment and F.3 AMERICAN SOCIETY OF
protective systems intended for use in potentially MECHANICAL ENGINEERS
explosive atmospheres.
EC Council Directive 96/82/EC and 2003/105/EC ASME: Boiler and pressure vessel code, Section VIII
Control ofma]or accident hazards involving dangerous Pressure Vessels.
substances (so called SEVESO II Directive). ASME/ANSI B 1.20.1: Screwed threads for pipe ends
EC Council Directive 97/23/EC The approximation of and general purpose, 1983.
laws ofMember States concerningpressure equipment. ASME/ANSI B16.5: Steel pipe flanges and flange
EC Council Directive 99/92/EC (ATEX 137, The fittings: 1988 and supplements (1992).
Workplace Directive’). ASME/ANSI B 16.9: Factory made wrought steel butt
welding fittings, 1993.
ASME/ANSI B 16.11: Forged steel fittings, socket-
F.2 AMERICAN PETROLEUM INSTITUTE welding and threaded, 1991.
ASME/ANSI B 16.21: Non-metallic flat gaskets for pipe
API Manual of Petroleum Measurement Standards. flanges, 1992.
API Spec 5B: Threading, gauging and tread

inspection of casing tubing, and line F.4 BRITISH STANDARDS INSTITUTION
pipe threads, 14th edition.
API Spec 5L: Specification for line pipe, 43rd edition. BS 1435: Rubber hose assemblies, for oil suction
API Std 5B: Steel pipe for the petroleum industry, and discharge services, Part 2: Recommen
13th edition, 1987. dations for storage testing and use, 2005.
API Std 620: Design and construction of large, (Part 1 replaced by BS EN 1765, 2004)
welded, low-pressure storage tanks, BS 1560: Part 3: Section 3.1: Specification for steel
10th edition, 2002. flanges, 1989.
API Std 650: Welded steel tanks for oil storage, 10th BS 1640: Specification for steel butt-welded fittings
edition, 1998. for the petroleum industry, Part 1: Wrought
87

carbon and ferritic alloy steel fittings, penetration, 2003. Part 3:

1962. Determination of resistance to
BS 2594: Specification for carbon steel welded permeation by chemicals, 2003.
horizontal cylindrical storage tanks, 1975. BS EN 388: Protective gloves against mechanical
BS 3492: Specification for road and rail tanker hoses risks, 2003.
and hose assemblies for petroleum BS EN 397: Specification for industrial safety
products, including aviation fuels, 1987. helmets, 1995.
13S 3799: Specification for steel pipe fittings, BS EN 407: Protective gloves against thermal risks
screwed and socket-welding for the (heat and/or fire), 2004.
petroleum industry, 1974. BS EN 420: Protective gloves. General requirements
BS 4882: Specification for bolting for flanges and and test methods, 2003.
pressure containing purposes, 1990. BS EN 469: Protective clothing for firefighters.
BS 4994: Specification for design and construction Requirements and test methods for
of vessels and tanks in reinforced plastics, protective clothing for firefighting,
1987. 1995.
BS 5378: Part 2: Specification for colorimetric and BS EN 471: High-visibility warning clothing for
photometric properties of materials, 1980. professional use. Test methods and
BS 5499: Fire safety signs, notices and graphic requirements, 2003.
symbols, Part 1: Specification for fire BS EN 531: Protective clothing for workers exposed
safety signs, 1990. Part 2: Specification for to heat, 1995.
self-luminous fire safety signs, 1986. Part BS EN 976-1 Underground tanks of glass-reinforced
5: Graphical symbols and signs. Safety plastics (GRP). Horizontal cylindrical
signs, including fire safety signs. Signs tanks for the non-pressure storage of
with specific safety meaning, 2002. liquid petroleum based fuels Part 1:
PD 5500: Specification for unfired fusion welded Requirements and test methods for
pressure vessels, 2000. single wall tanks, 1997.
BS 6187: Code of practice for demolition, 1982. BS EN 1765: Rubber hose assemblies for oil suction
BS 7361: Cathodic protection. Code of practice for and discharge service. Specification for
land and marine applications, Part 1: 1991. assemblies, 2004.
BS 7671: Requirements for electrical installations. BS EN 1834-1:Reciprocating internal combustion
tEE Wiring Regulations 16 th
edition. engines. Safety requirements for design
BS EN 149: Respiratory protective devices. and construction of engines for use in
Filtering half masks to protect against potentially explosive atmospheres.
particles. Requirements, testing, Group II engines for use in flammable
marking, 2001. gas and vapour atmospheres, 2000.
BSEN 166: Personal eye protection. Specifications, BS EN 10216-1: Seamless steel tubes for pressure
2002. purposes. Technical delivery
BS EN 175: Personal protection. Equipment for eye conditions. Non-alloy steel tubes with
and face protection during welding and specified room temperature properties,
allied processes, 1997. 2002.
BS EN 348: Protective clothing. Determination of BSEN 13081: Tanks for transport of dangerous goods.
behaviour of materials on impact of Service equipment for tanks. Vapour
small splashes of molten metal, 1992. collection adapter and coupler, 2001.
BS EN 352-2: Hearing protectors. Safety requirements BSEN 13083: Tanks for transport of dangerous goods.
and testing. Ear-plugs, 2002. Service equipment for tanks. Adapter
BSEN352-3: Hearingprotectors. Safety requirements for bottom loading and unloading,
and testing. Ear-muffs attached to an 2001.
industrial safety helmet, 2002. BS EN 14015: Specification for the design and
BS EN 361: Personal protective equipment against manufacture of site built, vertical,
falls from a height. Full body harnesses, cylindrical, flat-bottomed, above
2002. ground, welded steel tanks for the
BSEN374: Protective gloves against chemicals and storage of liquids at ambient
micro-organisms, Part 1: Terminology temperature and above, 2004.
and performance requirements, 2003. BS EN 14161: Petroleum and natural gas industries.
Part 2: Determination of resistance to Pipeline transportation systems, 2003.
88

the licence terms and conditions, It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: a: pubs@energyinst.org.uk t: +44 (0)207 467 7100
ANNEX F
BS EN 60079: Electrical apparatus for explosive gas F.9 (IP) ENERGY INSTITUTE
atmospheres series, 2004.
BS EN 60903: Live working. Gloves of insulating Model Code of Safe Practice in the Petroleum Industry:
material, 2003. Part 1: Electrical safety code.
BS EN 150 20345: Personal protective equipment. Part 15: Area classification code for installations
Safety footwear, 2004. handling flammable fluids, 3rd edition, 2005.
BS Iso 4266: Petroleum and liquid petroleum Part 16: Tank cleaning safety code, 2nd edition, 1996.
products Measurement of level and
-
Part 19: Fire precautions at petroleum refineries and
temperature in storage tartks by bulk storage installations, 1st edition, 1993.
automatic methods, 2002. Part 21: Guidelines for the control of hazards arising
BS ISO 4512: Petroleum and liquid petroleum from static electricity, 1st edition, 1998.
products. Equipment for measurement
of liquid levels in storage tanks. Manual
methods, 2000. IP Code of practice for drivers’ emergency actions on
CEN/TR 15120 Tanks for the transport of dangerous rod loading racks, 1st edition, 1999.
goods Guidance and recommend
-
IP Code of practice for the investigation and mitigation
ations for loading, transport and of possible petroleum-based land contamination, 1st
unloading. edition, 1993.
IP Code of practice for a product identification system
for petroleum products, 5th edition, 2004.
F.5 CONSTRUCTION INDUSTRY RESEARCH IP Code of practice for occupational hygiene audits, I’
AND INFORMATION ASSOCIATION (CIRIA) edition 1993.
IP Environmental guidelines for petroleum distribution
CIRIA Report No. 164: Design of containment systems installations, 1996.
for the prevention of water pollution from industrial IP Guidelines for health surveillance and biological
incidents. monitoring for occupational exposure to benzene.
IP Guidelines for the design and operation of gasoline
vapour emission controls, 2nd edition, 2000.
F.6 ENGINEERING EQUIPMENT AND
IP Guidelines for the identification and control of
MATERIALS USERS ASSOCIATION (EEMUA)
hazards during the proving of road loading gantry
meters, 1995.
EEMUA Publication 105:2002 factory stairways,
IP Petroleum road tanker design and construction, 2nd
ladders and handrails (including access platforms and edition, June 2003.
ramps). IP Petroleum distribution installation personal
protective equipment requirements:
http://www.energyinst.org.uk/dmsc/ppe
F.7 ENVIRONMENT AGENCY
IP Procedures for the reclaim of duty on recovered
vapour at duty suspended installations, 1st edition 1999.
Pollution Prevention Guidance:
IP Research Report An investigation into suitable
PPGI8: Control of spillages and fire fighting run-off
instruments for the measurement oftotal organic carbon
(TOC) in emissions from petroleum distribution
Secretary of States’ Guidance: PG1/13/14 Processes
terminal vapour recovery units, 2004.
-
for the storage, loading and unloading of petrol at

IP Research Report Investigation of factors causing
terminals.
leakage at road tanker loading gantry coupler/tanker
adaptor interface 1st edition, 2003.
IP Road tank vehicle workshop code, 1998.
F.8 INTERNATIONAL MARITIME
IP Vapour recovery units Guidance on preventing and
-
ORGANISATION (IMO)
controlling temperature excursions in carbon beds 1st
edition, 2001.
IMO/ILO Code of Practice on security in ports MESS
HP/2003/14.
Hydrocarbon Management:
HM 17 Meter proving. Section 8: Calibration of
IMO publication MSC/Circ.585 Standards for vapour
additive injection systems for road loading
emission control systems, April 1992.
gantries.
89

the licence terms and conditions. It must not be forwarded to, or stored or accessed by, any unauthorised user. Enquiries: a: pubs@energyinst.org.uk t: +44 (0)2074677100
HM 23 Fidelity and security of measurement data HS(G)65: Successful health and safety management,
transmission systems. Section 1: Electric 1992.
and/or electronic pulsed data cabled HS(G)113: Lift trucks in potentially flammable
transmission for fluid metering systems. atmospheres.
HM 31 Guide to hydrocarbon management in HS(G)176: The storage of flammable liquids in tanks,
petroleum refinery operations. 1998.
HM 39 Guide to recommended measurement practice HS(G)186: The bulk transfer of dangerous liquids and
for compliance with requirements of HM C&E gases between ship and shore, 1998.
Notice 179. HS(G)250: Guidance on permit-to work systems: A
guide for the petroleum, chemical and
allied industries, 2005.
F.lO INTERNATIONAL CHAMBER OF
SHIPPING/OIL COMPANIES LNDG 163: Five steps to risk assessment.
INTERNATIONAL MARINE FORUM] INDG 178 (Revi): Written schemes of examination.
INTERNATIONAL ASSOCIATION OF PORTS
AND HARBOURS PM 5: Automatically controlled steam and hot
water boilers.
International safety guide for oil tankers and terminals PM 60: Steam boiler blow down systems.
(ISGOTT).
F.13 UK LEGISLATION
F.1 I INTERNATIONAL
ELECTROTECHN\ICAL COMMISSION SI 128: The Pressure System Safety Regulations,
2000.
IEC 61508/61511 Functional safety of electrical/ SI 635: Electricity at Work Regulations, 1989.
electronic/programmable electronic safety-related SI 743 Control of Major Accident Hazards
systems. Regulations 1999 (COMAH)
SI 859: The traffic sign regulations and general
directions, 1981.
F.12 UNITED KINGDOM HEALTH AND SI 1471: Safety Sign Regulations, 1980.
SAFETY EXECUTIVE SI 1643: The Control ofNoise at Work Regulations,
2005.
HSE Occupational exposure limits SI 1713: The Confined Spaces Regulations, 1997.
SI 2307: The Lifting Operations and Lifting
CS 15: Cleaning and gas freeing of tanks containing Equipment Regulations, 1998.
flammable residues, 1985. SI 2793: Manual Handling Operations Regulations,
1992.
Guidance Notes: SI 2966: Personal Protective Equipment at Work
EH7O: The control of firewater run-off from Regulations, 1992.
CIMAH sites to prevent environmental S13140: The Construction (Design and
damage. Management) Regulations 1994, 2005.
GS4: Safey in pressure testing, revised 1998. SI 3242: Control of Substances Hazardous to Health
GS 5: Entry into confined spaces, 1995. Regulations, 1994.
HS(G)51: The storage of flammable liquids in
containers, 1998.
90


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DESIGN, CONSTRUCTION AND OPERATION

OF PETROLEUM DISTRIBUTION INSTALLATIONS

Model Code of Safe Practice in the Petroleum Industry

Licenced to: Miss Ljson Mecoli. Single user licence only.

Licenced to: Miss Lison Mecoli. Single user licence only.

Model Code of Safe Practice in the Petroleum Industry

Licenced to: Miss Lison Mecoli. Single user licence only.

BG Group Kerr-McGee North Sea (UK) Ltd

Copyright © 2005 by the Energy Institute, London:

ISBN 0 85293 383 5

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3 Design and construction of plant, equipment and buildings 9

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3.16 Final project documentation 34

6 Maintenance and modifications 53

8 Closure, decommissioning and demolition

9 Health, welfare and protection of personnel 65

10 Training and competence 69

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Annex A- Glossary of terms 71

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1.1 OBJECT Executive’s publications HS(G)51 The storage of

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2.1 GENERAL Installations which handle only Class 11(1) or Class

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2.3.3.3 The location and spacing of buried, semi-

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2.9.2 Areas where surface water may be 2.9.6 Foul sewage

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DESIGN AND CONSTRUCTION OF

3.1 GENERAL influence the project’s management. It is recommended

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3.2.4 Area classification 3.3 TANKS

IP 15 gives recommendations for the classification of 3.3.1 Standards

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3.3.2 Design pressure should be fitted to minimise surface disturbance. A

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3.3.13.3 In order to provide adequate means of escape conditions likely to be encountered.

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3.3.17.3 Buried or mounded tanks should be tested 3.3.20 Change in use

3.3.19 Tank compounds 3.4.1 General

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3.4.3 Materials damage in the event of an emergency.

3.4.4 Pipe thickness 3.4.6.6 Adequate access stairways or ladders and

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3.4.8.2 Flexibility should preferably be provided by 3.4.9 Thermal pressure relief

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3.4.11.2 Energy conservation Should be considered in 3.4.16 Segregation

3.4.14 Corrosion protection 3.5.1 Location

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