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Design and Handling of Chemical Tanks
Guidance
website
address
[email protected] FloorThe Exchange 262 Market StreetAberdeen AB11 5PJ
P • O • L • I • C • EGRAMPIAN
Chemical Tanks Cover 6/11/06 10:47 Page 1
22
• BS EN 12079: 1999 - Offshore Containers - Design,Construction, Testing, Inspection & Marking
• Control of Substances Hazardous to Health RegulationsSI 1999/437 (COSHH)
• DNV Certification Notes 2.7-1
• IMDG Code - International Maritime Dangerous GoodsCode
• International Maritime Organisation
• Lifting Operations and Lifting Equipment Regulations SI 1998 / 2307, (LOLER)
• Manual Handling Operations Regulations SI 1992 / 2793
• Merchant Shipping (Dangerous Goods and MarinePollutants) regulations SI 1998 / 2367
• PUWER - Provision and Use of Work EquipmentRegulations SI 1998 / 2306
• Regulation 9 of LOLER, Approved Code of Practice,(HSE Books L113)
• Step Change in Safety Fatality Report
• Step Change in Safety Lifting and Mechanical HandlingGuidance (re-issue 2004)
• Step Change in Safety Task Assessment Guidance (2ndedition 2003)
• The Carriage of Dangerous Goods by Road Regulations,SI 1996 / 209
• UKOOA / Chamber of Shipping Guidelines for the SafeManagement and Operation of Offshore Support Vessels(Issue 4th November 2002)
• UKOOA Guidance for the safe Packing and Handling ofCargo to and from Offshore Installations (latest edition)
• Working at Height Regulations SI 2005 / 735
Acknowledgments
Step Change would like to thank the followingorganisations for their contributions in developing thisguidance:
AMEC
Baker Petrolite
BP
Conserve Oilfield Services Ltd
Elected Safety Representatives Network
Ferguson Seacabs Ltd
Harran Ltd
Marathon
Marathon Oil
Nalco Ltd
Shell Exploration and Production UK
Suretank Ltd
Swire Oilfield Services Ltd
Talisman Energy
Transocean
• Step Change in Safety website: www.stepchangeinsafety.net
1 INTRODUCTION 1
2 SCOPE 2
3 SUMMARY / RECOMMENDATION 33.1 Design 3
3.2 Handling 3
3.3 Tank Access 4
3.4 Contents Measuring Gauge 4
3.5 Contents Management 4
3.6 Checklists 4
3.7 Risk Assessment 4
3.8 Document Pouches/Load Security Tagging 5
3.9 Responsibilities and Training 5
3.10 Documentation and Labelling of Tanks 6
3.11 Tank Life Cycle Flowchart 6
3.12 Backloading of Chemicals and Waste 6
4 LOAD SECURITY INSPECTION PROCEDURE 74.1 Introduction 7
4.2 Purpose 7
4.3 Scope 7
4.4 Definitions 7
4.4.1 Cargo 7
4.4.2 Transportation 7
4.4.3 Responsibilities 8
4.4.4 Procedure Description 8
4.4.5 Cargo Integrity Tagging 9
4.4.6 Vendor Premises 9
4.4.7 Quayside 9
5 SAFETY CONSIDERATIONS AND CHECKS 105.1 Good Practice Chemical Tank Inspection Illustrated Checklist 10
5.2 Recommended Checks - Prior to Tank Fill for Preparation for Dispatch Onshore/Offshore 11
5.3 Safety Considerations Associated with Tank Use and Risk Assessment 12
7.5 Bottom Outlet Valve Arrangement
Bottom outlet valve arrangement highlighting the main discharge valve, the sample point and the control handle for the secondary tank discharge valve.
7.6 Ancillaries on the Tank Top
View of the Manway Lid and and Pressure / Tank Vacuum Valve (grating removed for picture clarity).
Main Discharge Valve
Lever Operated Foot Valve
End CapEnd Cap
Pressure Vacuum Relief Valve (not to bemanually operated)
Air Inlet Valve
Manway Lid (Tank Top Lid / Man Lid)
Sampling Point Valve
21
6 TANK PRACTICES 136.1 Accessing the Tank 13
6.2 Tank and Contents Handling 13
6.2.1 Sampling 13
6.2.2 Discharging 14
6.2.3 PV valve/Relief valve operation 14
6.2.4 Tank Ancillaries Intervention 14
6.3 Hooking On/Off 15
6.4 Stacking 15
6.5 Labelling And Documentation 15
6.6 Receipt and Dispatch 16
6.7 Lifting Assemblies and Slinging 16
7 APPENDICES 177.1 Outbound/Inbound Tank Checklist 17
7.2 Load Security Inspection Procedures Flowchart 18
7.3 Pre - Fill Tank Checklist 19
7.4 Tank / Vessel Types and General Arrangements 20
7.5 Bottom Outlet Valve Arrangement 21
7.6 Ancillaries on the Tank Top 21
8 REFERENCES AND ACKNOWLEDGMENTS 22
Horizontal Chemical Tank. Supply Vessel Offloading. Vertical Chemical Tank.
This Guideline, Design and Handling of Chemical Tankshas been compiled as part of the Step Change In Safetyoverall objective of improving safety within the Oil & Gasindustry.
The Guideline was commissioned due to offshore industryconcerns over the design and safe use of cargo carryingunits and portable chemical tanks, and fatalities offshorerelating to the handling of these units (See Step Change inSafety Fatality Report).
The objective of this Guidance is to provide information toDesigner, Manufacturer, Owner and End User of IMOChemical Transport Tanks, which will lead to rationalisationof equipment and practices used within the industry thusreducing accidents or incidents during handlingoperations.
From a design perspective, the guidance looks at keyissues. It recommends that:
• valves requiring manual operation,
• the lifting accessories master link,
be accessible from deck or ground level. This will reducethe need to access the top of the tank in the offshoreenvironment.
From an operational aspect, key issues addressed includerecommendations to eliminate:
• access to the top of a tank,
• manual operation of the pressure/vacuum valve.
Further recommendations on :
• contents measurement,
• tank access
• back loading fluids from offshore facilities are alsoincluded.
The Guidance also outlines the risk assessment approachfor any operations out with the Guidance.
The Guidance provides assistance to meet theserecommendations by providing:
• a Tank Lifecycle Flowchart,
• Tank Inspection Checklists,
• an Outbound/Inbound Chemical Tanks Checklistoutlining competency levels for personnel.
120 Example of 500 gallon tank. Comparison of new and old tank design (600 imperial gallons).
INSPECTED BY:SIGNATURE:DATE:
7.4 Tank / Vessel Types and GeneralArrangements
Example of 600 gallon, (2900 litres), vertical tank.
Example of 1000 gallon, (4800 litres), horizontal tank.
19
7.3 Pre-Fill Tank Checklist
The following checklist is a generic checklist for use prior to tank filling.
PRE-FILLING TANK CHECKLIST
Tank ID: Date:
1 CHECK SERIAL NUMBERS, TARE & BLACK PATCH STICKER q
2 CONDITION OF TANK FRAME FOR DAMAGE ETC q
3 EXAMINE TANK VESSEL & CRADLES q
4 CHECK END CAPS ARE SUPPLIED AND SECURED q
5 CHECK CONDITION / OPERATION OF FOOT VALVE & OPERATING LEVER q
6 CHECK CONDITION OF DISCHARGE VALVE q
7 CHECK CONDITION OF SAMPLE / DRAIN VALVE q
8 CHECK DUST CAP & SECURING WIRE ON DISCHARGE / SAMPLE VALVES q
9 CHECK CONDITION OF EARTHING POINT q
10 CHECK CONDITION OF DOCUMENT TUBE HOLDER q
11 CHECK CONDITION OF DIP STICK HOLDER & DIP STICK WHERE FITTED q
12 CHECK LIFTING LUGS FOR DAMAGE q
13 CHECK LIFTING SLINGS, SHACKLES & SPLIT PINS q
14 CHECK TANK MANWAY LID q
15 CHECK CONDITION OF TANK MANWAY LID, SWING BOLTS & HINGE PIN q
16 CHECK CONDITION OF TANK-LID, INCLUDING LID SEAL q
17 CHECK TANK INTERIOR FOR CLEANLINESS INCLUDING FOOT VALVE & SAMPLE VALVE q
18 CHECK CONDITION OF PRESSURE VACUUM RELIEF VALVE & GAUZE q
19 CHECK CONDITION OF DIP VALVE, DUST COVER & RETAINING WIRE q
20 CHECK THAT TEST DATA PLATE IS FIXED & TANK MARKINGS / CHEVRONS ARE LEGIBLE q
21 COMPLETE CERTIFICATE OF CLEANLINESS & PASS TO RELEVANT PERSON FOR ACTION q
DETAILS OF DAMAGE OR DEFECTS FOUND:
The guidance identified within this publication is aimed atensuring personnel, whose duties involve the handling andtransportation of chemical tanks and their contents atoffshore installations, are aware of the hazards andprecautions which must be considered during tankoperations.
The objective of this guidance is to increase awareness ofkey factors relating to chemical tanks and contentshandling and to reinforce existing knowledge withadditional information.
To achieve maximum impact, supervision should follow upsafety presentations by talking to appropriate personnelabout tank handling techniques, and their understandingof the required safety standards. Subsequent monitoringof chemical tank operations should be undertaken toensure safety considerations have been raised to, andmaintained at, an acceptable level.
2Step Change in Safety Fatality Report
www.stepchangeinsafety.net
Positioning of Masterlink.Typical view of a fully grated tank. Typical access ladder.
The points made within this section apply to all new andexisting tanks, with an overall objective that all current tankstock can fall in line with this guidance by the end of 2005.
3.1 Design
All valves should be suitably placed to allow safe accessand be accessible from ground/deck level.
All tanks to have fully grated or flat plate tops to ensurecomplete closure
All tanks to have non-slip paint coated to access ladderswhere fitted.
All pipefittings will be to a recognised standard
All tanks to have a sling configuration that allow easyaccess to the master ring without accessing/climbing onthe tank in any way
All tanks will have a functional sealable document pouchfitted
Note: The Design of Chemical Tanks is primarily coveredby the IMDG code.
3.2 Handling
The practice of double stacking tanks offshore is notrecommended and should be avoided. Where deemednecessary it should be by exception only and a formal riskassessment is recommended followed by directsupervision of the activity.
When double stacking is being practiced then access tothe crane master link must be independent of the tank, bymeans of a suitable access platform or ladder.
There will be no crane movement other than attaching thecrane hook to the master link until all personnel havewithdrawn from the immediate vicinity of the tank and thebanksman/loadhandler has given the all clear to the craneoperator.
318
7.2 Load Security Inspection Procedures (LSIP)
The following flowchart depicts the procedure to be followed prior to any movements of chemical tanks.
Load Security Inspection Procedure
This procedure has been adapted from the Talisman Energy (UK) Ltd. process for ensuring the safety and security of cargo during transportation to andfrom offshore installations.
To this end, the term ‘Unit’ can be taken to be CCU’s (Cargo Carrying Units both closed and open top), Tubulars (slung or in frames), Waste Skips,Helifuel Tanks, Chemical Tanks, Specialist Loads (wire line units and other well service packages) Suppliers/Users of the above should nominate a Load
Checker within their organisation to ensure that the procedure is carried out and suitable verification methods implemented to provide an audit trail.
Start
End of Process
Onshore Load Checker
Prior to loading ofContainer/Tank, nominatedLoad Checker shall carryout a visual inspection ofthe unit to ensure that all
items are properly packed,container doors are
securely closed, and thatno loose items are left lying
on the unit in any place.
Onshore Load Checker
Arrangers for the person/sresponsible for
packing/securing the unitto carry out necessary
remedial action.
Onshore Load Checker
Informs the relevantperson that the unit hasbeen checked and theLoad Security Tag and
Label attached.
Onshore Load Checker
Affixes YELLOW LoadSecurity Tie and Label to
the unit.
Onshore Load Checker
Removes any loose itemsfrom unit prior to loading
operations.
Transporter/Shipper
Transports/Ships unit torelevant destination.
End-User of Cargo
Unloads/Empties unit and,where applicable, packs
the unit for return toBeach and informs
Offshore Load Checkerthat unit is ready for
shipping.
Offshore Load Checker
Attaches ORANGE LoadSecurity Tag and Labelinforms relevant personthat unit is ready to be
shipped back to beach.
Offshore Load Checker
Arranges for the personresponsible for
packing/securing the unitto carry out the necessary
remedial action.
Transporter/Shipper
Refuses to transport/shipunit until Load Security
Tag and Label is attached(thereby indicating that
the load has beensecurity checked).
Offshore Load Checker
Prior to loading, OffshoreLoad Checker carries outa visual inspection of the
unit to ensure that allitems are securely
packed, container doorsare closed, and that noloose items are left lyingon the load in any place.
Transporter/Shipper
Prior to loading(Vehicles/Vessel)
Transporter/Shipperchecks to ensure that
YELLOW Load SecurityTag and Label have been
attached to unit.
Is the unit packedproperly with no
loose items foundanywhere on unit?
Has Load SecurityTag and Label
been attached tounit?
Is the unit packedsecurely with no
loose items foundanywhere on unit?
Does the problemconcern loose
items left on unit?
Yes
Yes
Yes
Yes
No
No
No
No
7.1 Outbound/Inbound Chemical Tanks Checklist
The following checklist is a revision of the existing UKOOA tank checklist, which both updates and clarifies requirements andchecklist contents to further enhance the management and safety associated with the use of tanks.
A key point and change recommended is that for every tank there exists a single corresponding checklist, which follows thetank in its journey.
17
Tank ID: Product Name: Customer Details Offshore Location:
Does Test Plate have at least a full month remaining? Yes/No Tank Supplier:Last Test Date: Collection Address (if different from above): Ready for Collection:
Date:Time:
Item No Cargo Ref Cargo ID Product Total “Lift” IMDG Class / UN Customs StatusQuantity litres Weight (Kg) No
1
Check Tank / Cargo Checklist Chemical Shipper Offshore Back Shipper OnshoreNo Provider Outbound Receiver Load Inbound Receiver
OperativeConfirm that (a) Tank is clean (and dry depending on the product to be filled),or (b) Tank is “dedicated” and previously contained the SAME product.(Chemical Provider and Back Load Operative only, as appropriate)
1 Have all old labels been removed?2 Have copies of all relevant certificates, dangerous goods, MSDS’s and TREM
cards been dispatched with the tank?3 Are there any signs of leaking chemical?4 Are all valves closed, and caps refitted?5 Has the main valve been tagged and tie wrapped closed?6 Is manlid closed and fully secured and has security tag been fitted?7 Is special coupling attached (if applicable)? (Chemical Provider and Back
Loader only)8 Have you checked the gross weight against SWL?9 Does the lifting set details match those on the Data / Inspection plate?10 Where appropriate, has dangerous goods cargo been completed and relevant
authorities notified as per IMDG Code?11 Product Label is on each side?12 Hazard Label is on each side?13 Has Tank been visually checked for any obvious damage (frame, gratings,
slings, lifting points, fittings etc)?14 Have you checked for and removed any loose objects / debris on the unit or in
the forklift pockets and fitted / checked the Load Security Inspection Tag? 15 Have appropriate declarations been made for waste backload?
*Any “No” above will result in non-shipment Sign Off For All Of the Above Checks
Name of Yard Operative:
Signature of Yard Operative:
Date:
Name of Shipping Outbound Operative:
Signature of Shipping Outbound Operative:
Date:
Name of Back Load Operative:
Signature of Backload Operative:
Date:
Name of Shipper Inbound Operative:
Signature of Shipper Inbound Operative:
Date:
Name of Offshore Receiver:
Signature of Offshore Receiver:
Date:
Name of Onshore Receiver:
Signature of Onshore Receiver:
Date:
3.3 Tank Access
Working on the top of the tank should only be undertakenas a last resort AND IS NOT RECOMMENDED. Howevershould this be absolutely necessary then a riskassessment must be conducted and all appropriate safetyprecautions be implemented. Reference should be madeto the Working at Height Regulations.
Access to the top of the tank should be via the permanentaccess ladder (if fitted), portable ladder or a suitable workplatform and appropriate fall arrest equipment must beworn.
Access requirements to both valving and lifting assemblymust be considered when positioning or laying downtanks.
Opening of the tank manway lid is not permissible offshoreunless access is required for backloading, which wouldthen fall under special circumstances and should besubject of a risk assessment.
3.4 Contents Measuring IMDG Code
Any contents measuring device fitted to tank must conformto current IMDG Code requirements.
3.5 Contents Management
Clarity of tank contents being dispatched or returned mustexist through labelling and documentation.
Offshore procedures regarding the return of good or spentchemicals must be clear and supported by correctlabelling and accompanying documentation to ensurewaste legislation compliance and to facilitate handling/disposal on return.
All tanks should be fitted with a telltale, (tiewrap or similar),on the tank manway lid and main discharge valve to verifythe tank has not been opened.
3.6 Checklists
A checklist for tanks is included in the “UKOOA guidancefor Safe Packaging and Handling of Cargo to and fromOffshore Locations”, however this has been expandedupon with the Outbound/Inbound summary ticket(appendix 7.1)
3.7 Risk Assessment
It is recommended that risk assessments should be carriedout for the following established operations:
• Accessing the tops
• Sampling and Dipping
• Stacking
• Discharging & Filling
• Filling, Discharging and including Hose AssemblyManual Handling
• Crane lifts inbound/outbound
• Backloading of chemicals/waste
• Opening of manlid for loading of chemicals
• Access to the lifting assembly master link when tanksare stacked
• Chemical compatibility
Note: Such assessments should include worker exposurerisk, the Control Of Substances Hazardous To Health(COSHH), and reference the appropriate Material SafetyData Sheets (MSDS’s).
4 Step Change in Safety Task Risk Assessment Guidewww.stepchangeinsafety.net
6.6 Receipt and Despatch
Upon receipt of any tank always ensure:
• The lifting accessories and padeyes are in goodcondition and not damaged.
• The tank has not been damaged in transit.
• The product and hazard labels are visible and intact.
• A Health and Safety data sheet is available for thecontents.
• Retrieve all documents from document pouch.
Prior to dispatch from offshore always ensure:
• The tank and frame are undamaged.
• The tank manway lid is securely fastened.
• The discharge valve and sampling point end caps arefitted.
• The product and hazard labels are appropriate for thecontents and are visible or where the tank is empty alllabels have been removed.
• All relevant documentation has been inserted intodocument pouch.
The instructions identified above, are for general guidance.It is the ultimate responsibility of all users and handlers toensure that all operating and safety procedures are strictlyobserved.
Refer to Outbound/Inbound Tank Summary Checklist(Appendix 7.1).
6.7 Lifting Assemblies and Slinging
The lifting and slinging of tanks falls within regulationsbelow and as such will not be covered in this document.
For reference the key documents are:
• Lifting Operations and Lifting Equipment Regulations1998 SI2307, (LOLER).
• Regulation 9 of LOLER, Approved Code of Practice,(HSE Books L113).
• Step Change in Safety Lifting and MechanicalHandling Guidelines.
16
3.8 Document Pouches/Load Security Tagging
Marshalling of tanks utilising a tagging method, (Loadsecurity Inspection Procedure See section 4), carried outby the nominated responsible person for freight forwardingand return is a recommended practice.
Document pouches should be present and clearlyidentified on the tank. Where this is not the case, remedialaction to ensure the effective communication of the tankcontents details must be arranged.
There shall be a designated responsible person offshore toboth accept and dispatch chemical tanks.
Contents documentation shall be kept in the documentpouch and remain with the tank throughout it’s cycle andbe updated as and when appropriate (referenceflowchart).
3.9 Responsibilities and Training
Training of personnel with ‘hands on’ responsibility fortanks (including content) is considered essential.
It is recommended the information contained in thisguidance document be used only as a supplement tofurther training.
These guidelines are aimed at providing supervision withsufficient training material from which they can developtheir own specific training programme, for personnel whoare expected to work with chemical tanks or their contents.
It is recommended that there are nominated persons withassigned responsibilities for the management andhandling of all aspects of chemical tanks both onshore andoffshore. Ideally this person should also be responsible forbaskets, CCU’s (Cargo Carrying Units) etc. to ensure a fulloverview of the freight situation, risks and controls from anorganisational and management perspective.
Typical duties would include:
• Receipt and dispatch
• Lifting and discharging of contents
• Document control
• Participation in associated risk assessments
• Contents and tank monitoring & management
• Tank labelling compliance and update/changemanagement
• Integrity of the manway lid and discharge valve telltale
In conjunction with the above offshore personnel handlingor using tanks should receive appropriate training, whichincludes:
LIFTING AND MECHANICAL HANDLING OPERATIONS
MANUAL HANDLING
RISK ASSESSMENT
CHEMICAL HANDLING (COSHH)
ENVIRONMENTAL ISSUES
SAFETY OBSERVATION SYSTEMS
The Step Change in Safety Lifting and MechanicalHandling Guidance contains further information on trainingand competency.
5Example of Document Pouch. Inspection Security Tag.
15
6.3 Hooking On/Off
When in the stowed position, the tank lifting accessoriesshould be located hanging down the outside of the tankframe. This allows easy access to the master link, whenhooking on/off the crane hook. This also avoids thenecessity for climbing on top of the tank.
Particular care must be taken to ensure that the liftingaccessories and crane hook does not inadvertentlysnag on the tank framework or ancillaries causing thepossibility of premature movement of the tank.
View showing the correct position and height of the master linkand the tank slinging arrangement.
6.4 Stacking
Double stacking of chemical tanks offshore should beactively discouraged and only sanctioned where itbecomes absolutely essential and following an appropriaterisk assessment.
Personnel should never climb on to a double-stackedchemical tank. Where deemed required a thorough androbust risk assessment process with mitigating measuresand actions is required.
IDEALLY THE TANKS SHOULD BE UNSTACKED.
6.5 Labelling and Documentation
All cargos, including backloaded cargos of dangerousgoods shall be correctly declared, packaged and labelled,secured, placarded and documented, and segregated inaccordance with the regulations and MGN 282(M) andIMDG Code plus subsequent notices issued by theMaritime and Coastguard Authority.
To assist the Master of the Offshore Supply Vessel inplanning the cargo stowage to ensure that segregation ofdangerous goods is maintained, it is a requirement that:
• The Offshore Supply Vessel is advised by the quaysideservice provider of the quantity and nature of dangerousgoods prior to loading.
• The Offshore Supply Vessel is advised by the OIM(Offshore Installation Manager) / Duty Holder ornominated deputy, of the quantity and nature ofbackloaded dangerous goods prior to loading.
In the case of the backload, it is the responsibility of theconsignor/packer to ensure that the backloaded goods arebackloaded in accordance with the requirements of theIMDG code. That means correctly declared, packaged,labelled, secured, placarded and with the correctdocumentation. In addition consideration must also begiven to the order of backloading to ensure that thesegregation requirements can be complied with.
It is the responsibility of the consignee/receiver of anydangerous goods to remove any old placards affixed to thecontainer prior to its re-use.
3.10 Documentation and Labelling of Tanks
Tank contents labels are to be clear and visible on all sidesto facilitate deck loading and avoid incorrect decanting.
On completion of all checks, an Outbound/Inbound Tanksummary checklist should be completed for each loadbeing dispatched offshore or returned onshore. Thechecklist should then be placed in the document pouchalong with relevant shipping details.
3.11 Tank Life Cycle Flowchart
Attached for reference (front cover) is a flowchart whichrepresent the life cycle of a tank, it also identifies thepersons associated with each stage; their duties and keyinformation to ensure that operations and works associatedwith it are managed safely and effectively.
3.12 Backloading of Chemicals and Waste
Where backloading of chemicals or waste is required thenit is recommended dedicated tanks should be requested toavoid cross contamination.
Clear labelling and documentation are essential, howeverthere may be occasions when previously used tanks mustbe used. In all cases of backloading, a risk assessment isrequired which would consider all aspects in section 5.3 asa minimum and requires the authority of the offshore dutyholder.
Where waste or contaminated chemical is to bebackloaded, appropriate labelling MSDS should beobtained and fixed to the tank that correctly identifies thetank contents and hazards. All waste or contaminatedchemicals should be sent to your responsible WasteManagement Contractor for disposal. Only part used andnon contaminated chemicals should be returned to theoriginal Provider in the tank with original labels and MSDS.
6
Enclosed Tank Lid.
Storage Areas.
Offshore Unloading, demonstrating potential for snagging(open tanks not meeting guidelines).
(Diagram of flowchart can be found in appendix 7.2)
4.1 Introduction
This describes the procedures to be followed to ensurethe safety and security of cargo during transportation toand from sites.
4.2 Purpose
The purpose of the document is to ensure as far as isreasonably practicable that cargo, as defined in section4.4.1, is in a secure condition and free from any looseitems that could, if they fell, cause injury to people ordamage to plant, equipment, trucks, offshore supplyvessels and other road users.
4.3 Scope
The procedures shall apply at all sites both on andoffshore. It shall also apply at the premises of otherparties such as fabricators and vendors that areresponsible for packaging and preparing equipment fordelivery to sites that need to be lifted by crane or othermechanical means.
4.4 Definitions
4.4.1 Cargo
For the purposes of this guidance document cargo isany item that is to be lifted by crane or other mechanicalmeans. The range of such items is diverse therefore itis not practicable to attempt to list them all in thisdocument. However some examples are:
• CCU’s (Cargo Carrying Unit’s both closed and open top)
• Tubulars (Slung or in frames).
• Specialist Vendor packages (Wire line units and otherwell service packages).
• Waste skips.
• Helifuel tanks.
• Chemical tanks.
• Special loads (Fabrications).
4.4.2 Transportation
For the purposes of this guidance documenttransportation shall be any means of conveying theabove items e.g. a truck or offshore Supply Vessel.
7Load Inspection Security Tagging Procedure Flowchart.
6.2.2 Discharging
When discharging tanks containing flammable product,the tank should be bonded, (earthed by a competentperson) in order to prevent a build up of static electricityand subsequent danger of ignition/explosion.
• Remove drip cap from the main discharge outlet andconnect hose to the main discharge outlet valve.
• Remove end caps from air inlet valve, then open air inletvalve manually.
• Open the lever operated foot valve and main dischargevalve, (in that order), to allow the tank to discharge.
When discharging the tank, the following actions should beconsidered:
• Ambient temperature, viscosity and specific gravity, allmay inhibit free flow.
• Poor flow - on no account should pneumatic air be usedto assist with the process.
Note: Operators should be aware of the following hazard.The design of the manual air inlet valve is such that anybuild up of pressure will be vented clear of personnel whenthe valve is opened.
Upon completion of discharging the tank contents:
• Ensure all valves are closed, end caps are refitted andsecured accordingly.
Where tanks are fitted with manual Air Inlet Valves (AIV) asrecommended by these guidelines this valve will bemarked air inlet valve for venting purposes only.
6.2.3 Pressure Vacuum Valve/Relief Valve Operation
At no time during the tank life cycle shall the pressure /vacuum relief valve be manually operated (only exceptionbeing onshore tank maintenance routine).
Any interference with this valve will affect its operationalfunctionality and thereby compromise safety and tankintegrity.
Note: The design of Chemical Tanks is primarily coveredby IMDG Code.
6.2.4 Tank Ancillaries Intervention
Intervention on any tank ancillary equipment is notrecommended. Intervention may only be permittedfollowing consultation with the tank manager/owner andafter a suitable risk assessment.
14 Example of Air Inlet Valve.Example of vacuum/relief valve fitted with flame arresting gauze.
6.1 Accessing the Tank
Access/climbing on top of a chemical tank should only beundertaken as a last resort AND IS NOTRECOMMENDED.
However, should this become absolutely necessary,access should be gained by using the tank’s built in ladder,(if fitted), or by utilising a custom-made tank access ladder.
Note: All tanks should have a fully enclosed grated orplated top and where not in place then access to the top ofthe tank should be avoided and only carried out followinga risk assessment and if the activity is accompanied by awatchperson.
Suitable height safety arrangements in line with Working atHeights Regulation must be in place should access to thetop of a tank be necessary.
6.2 Tank and Contents Handling
Among the reasons given for climbing on top of tanks are,
• Accessing the dip tube.
• Opening the tank lid to determine level.
• To take samples.
• To operate the vacuum breaker or open the hatch toassist flow.
• To hook the crane on to the master link.
With the new design there is no actual reason to climb ontop of the tank. By the end of 2005, when the designcriteria and the application of the procedures within theseguidelines are implemented, the need to access the top ofthe tank will be eliminated.
6.2.1 Sampling
Sampling of the tank contents should be carried outthrough the 3/4” sample valve, an off-take from the maindischarge line at the base of the tank.
• Remove the cap, open the lever-operated foot valve.
• Place clean sample jar at sample valve discharge anddrain off sample carefully ensuring all potential fordrips/spillages/splashes are catered for in the riskassessment.
• Replace protective cap, close valves.
• Adhere to precautions identified on Health and SafetyData Sheets and the COSHH and Risk Assessments.
Note: No intervention on Air Inlet valve or Pressure/Vacuumbreaker valve is required for sampling.
13Example of fall protection equipment.
Example of grated tank top.
4.4.3 Responsibilities
Management shall ensure that a competent person isnominated to act as a Load Checker with theresponsibility to carry out a check of cargo prior to itbeing lifted onto a means of transport.
As far as reasonably practicable such checks shallensure, that the cargo has been properly packed. Thisdoes not absolve the person responsible for packing theconsignment from carrying out the task with allreasonable care.
The checker shall not be responsible for the correctpackaging of the cargo unless they have personallycarried out the task. In the event that the checker doessuspect a load has not been properly packed he shallbring this to the attention of the packer so that remedialaction can be taken.
4.4.4 Procedure Description
Before cargo is transferred to the supply vessel, thechecker shall carry out a visual inspection to ensure:
• There are no loose items on or beneath the loads,which may fall. Items which are required for theoperations offshore that are not an integral part of thetank should be shipped separately in closedcontainers.
Note: this does not absolve the equipment originatorfrom taking all reasonable precautions to ensure theload is fit for lifting in the first place.
• All securing mechanisms should be properlyengaged.
• The design of tanks is such that there should be noprotrusions out with the tank frame which wouldpresent a snagging hazard.
• That nothing has been added to the tank to present asnagging hazard.
Further information on carrying out safety checks iscontained in the UKOOA Guidance for the SafePacking and Handling of Cargo to and from OffshoreInstallations.
8
Tank Inspection prior to loadout
Details on purchasing inspection tags can be obtainedfrom www.stepchangeinsafety.net (company specific tagsmay differ)
5.3 Safety Considerations Associatedwith Tank Use and Risk Assessment
Prior to undertaking any work associated with chemicaltanks and their contents, personnel must consider allaspects of safety and ensure safe working practices areadhered to.
This can be effectively achieved by carrying out a RiskAssessment, which should consider as a minimum thefollowing safety questions:
• Is a formal Risk Assessment required?
• Is the tank located at the correct stowage point ordesignated area?
• Is it a danger to other operations?
• Is it too close to the edge of a facility, equipment or othercargo unit?
• Has the segregation of products been considered?
• When stowed are all the valves and fittings accessible?
• How can the contents be sampled and measured?
• Is it clear what the contents of the tank are?
• Are the contents labelling clear and visible?
• Is the lifting sling master link accessible without climbingon top of the tank frame?
• Is there a MSDS sheet available for the tank contents?
• Is there a danger of radiant heat from a flare or othersource?
• Has the tank been checked for loose items?
• Is double stacking unavoidable and if so are tanks andStacking posts compatible?
• Is there any visible mechanical damage?
• Is the tank load within the storage area weight limit?
• Has backload product compatibility been established toensure hazardous chemical by products have not beenformed?
• Is it possible for flammable vapours to escape toatmosphere?
• Has the tank been properly earthed by a competentperson?
4.4.5 Cargo Integrity Tagging
Once the load checker is satisfied the cargo is safe tobe lifted he will attach a coloured security tie and labelto a suitable and conspicuous point on the load. Thelabel must be initialled and dated by the checker.
The checker will not be responsible for ensuring thatloads have been prepared properly. That will be theresponsibility of the packer/filler. The purpose of thesecurity tie and label is to signify that the load is safe fortransportation. The packer/filler will confirm that he hasproperly packed the load on the manifest.
The packer/filler and checker may be the same personbut where they are not, the checker must be satisfied asfar as is reasonably practical that the packer hasprepared the load properly.
Copies of the pre shipment checklist must be retainedfor audit purposes.
4.4.6 Vendor Premises
Prior to cargo being collected from the vendor’spremises, the vendor shall ensure it is safe to be loadedon to the transporting vehicle. Once the vendor issatisfied that the cargo is secure, the person appointedas checker must attach a yellow security tie and label tothe load and initial and date same.
4.4.7 Quayside
Once the cargo has been loaded and is in transit, thereshould be no occasion that should cause its security orintegrity to be jeopardised. However the followingchecks that are good practice must be carried out atmid points in the delivery of the cargo although thefitting of additional security ties and labels is notrequired.
• Outbound cargo arriving at the quayside shall besubjected to a further inspection prior to it beingloaded onto the supply vessel.
• Inbound cargo destined for onward shipping to avendor shall be inspected prior to it being loaded ontothe transporting vehicle
A flowchart depicting the Load Security InspectionProcedure (LSIP) can be found in appendix 7.2 of thisguidance.
INBOUND TAG
OUTBOUND TAG
912
Tank condition and clear markings.
Onshore tank filling facility showing means of safe access.
11
5.1 Good Practice Chemical Tank Inspection Illustrated Checklist
Chemical Tank Illustrated Checklist
10
5.2 Recommended Checks - Prior toTank Fill for Preparation forDispatch Onshore/Offshore
The following checks when working with tanks and theircontents should be carried out as a minimum but notlimited to:
• Check the condition of the frame and ensure there are nosigns of excessive corrosion or deformation.
• Ensure that the tank is not overloaded, (volume of productin tank x product density = payload)
• Ensure there is no evidence or signs of leakage.
• Check that all certification is fully in date at the time of use,and has sufficient test period remaining so as to preventcertification expiring when offshore.
• Ensure that any old hazard and supply labelling has beenremoved
• Affix all relevant hazard and supply labelling (whererequired).
• Ensure all unit markings clear and legible
• Ensure there is no obvious damage to lifting pad-eyes,etc.
• Ensure there are no obvious structural defects ormechanical damage
• Check all valve assemblies for damage and ensure endcaps are in place. Plastic ties as indicators of valveclosure are recommended.
• Check the manlid is securely closed and in goodcondition, plastic indication ties are recommended.
• Check the lifting equipment for any signs of damage.
• Ensure the master link or fifth leg of the lifting assembly isstowed on the outside of the tank frame for ease ofconnection to the crane both onshore and offshore.Ensure this is secured to the tank prior to transportationonce onshore.
• Check the grating for any signs of damage or loosefittings.
• Check the top surfaces for any potential loose or potentialdropped objects.
• Check the forklift pockets for loose items such as tools,stones, timber, etc.
Note: Offshore tanks are being fitted with air inlet valves atthe same end as the main bottom discharge valve. This isto remove the need for personnel to climb on top of thetank to vent prior to discharge. This valve is sometimesdifficult to see through the frame of the tank and must bechecked for security.
Defects: - any defects noted within the above are to beformally reported. Thereafter the tank should be isolatedand remedial action taken in accordance with the dutyholders responsibilities. (Refer to Outbound/Inbound Tanksummary checklist appendix 7.1 and Pre-fill tank checklist7.3)
Pre-filling Tank Checklist.
11
5.1 Good Practice Chemical Tank Inspection Illustrated Checklist
Chemical Tank Illustrated Checklist
10
5.2 Recommended Checks - Prior toTank Fill for Preparation forDispatch Onshore/Offshore
The following checks when working with tanks and theircontents should be carried out as a minimum but notlimited to:
• Check the condition of the frame and ensure there are nosigns of excessive corrosion or deformation.
• Ensure that the tank is not overloaded, (volume of productin tank x product density = payload)
• Ensure there is no evidence or signs of leakage.
• Check that all certification is fully in date at the time of use,and has sufficient test period remaining so as to preventcertification expiring when offshore.
• Ensure that any old hazard and supply labelling has beenremoved
• Affix all relevant hazard and supply labelling (whererequired).
• Ensure all unit markings clear and legible
• Ensure there is no obvious damage to lifting pad-eyes,etc.
• Ensure there are no obvious structural defects ormechanical damage
• Check all valve assemblies for damage and ensure endcaps are in place. Plastic ties as indicators of valveclosure are recommended.
• Check the manlid is securely closed and in goodcondition, plastic indication ties are recommended.
• Check the lifting equipment for any signs of damage.
• Ensure the master link or fifth leg of the lifting assembly isstowed on the outside of the tank frame for ease ofconnection to the crane both onshore and offshore.Ensure this is secured to the tank prior to transportationonce onshore.
• Check the grating for any signs of damage or loosefittings.
• Check the top surfaces for any potential loose or potentialdropped objects.
• Check the forklift pockets for loose items such as tools,stones, timber, etc.
Note: Offshore tanks are being fitted with air inlet valves atthe same end as the main bottom discharge valve. This isto remove the need for personnel to climb on top of thetank to vent prior to discharge. This valve is sometimesdifficult to see through the frame of the tank and must bechecked for security.
Defects: - any defects noted within the above are to beformally reported. Thereafter the tank should be isolatedand remedial action taken in accordance with the dutyholders responsibilities. (Refer to Outbound/Inbound Tanksummary checklist appendix 7.1 and Pre-fill tank checklist7.3)
Pre-filling Tank Checklist.
Details on purchasing inspection tags can be obtainedfrom www.stepchangeinsafety.net (company specific tagsmay differ)
5.3 Safety Considerations Associatedwith Tank Use and Risk Assessment
Prior to undertaking any work associated with chemicaltanks and their contents, personnel must consider allaspects of safety and ensure safe working practices areadhered to.
This can be effectively achieved by carrying out a RiskAssessment, which should consider as a minimum thefollowing safety questions:
• Is a formal Risk Assessment required?
• Is the tank located at the correct stowage point ordesignated area?
• Is it a danger to other operations?
• Is it too close to the edge of a facility, equipment or othercargo unit?
• Has the segregation of products been considered?
• When stowed are all the valves and fittings accessible?
• How can the contents be sampled and measured?
• Is it clear what the contents of the tank are?
• Are the contents labelling clear and visible?
• Is the lifting sling master link accessible without climbingon top of the tank frame?
• Is there a MSDS sheet available for the tank contents?
• Is there a danger of radiant heat from a flare or othersource?
• Has the tank been checked for loose items?
• Is double stacking unavoidable and if so are tanks andStacking posts compatible?
• Is there any visible mechanical damage?
• Is the tank load within the storage area weight limit?
• Has backload product compatibility been established toensure hazardous chemical by products have not beenformed?
• Is it possible for flammable vapours to escape toatmosphere?
• Has the tank been properly earthed by a competentperson?
4.4.5 Cargo Integrity Tagging
Once the load checker is satisfied the cargo is safe tobe lifted he will attach a coloured security tie and labelto a suitable and conspicuous point on the load. Thelabel must be initialled and dated by the checker.
The checker will not be responsible for ensuring thatloads have been prepared properly. That will be theresponsibility of the packer/filler. The purpose of thesecurity tie and label is to signify that the load is safe fortransportation. The packer/filler will confirm that he hasproperly packed the load on the manifest.
The packer/filler and checker may be the same personbut where they are not, the checker must be satisfied asfar as is reasonably practical that the packer hasprepared the load properly.
Copies of the pre shipment checklist must be retainedfor audit purposes.
4.4.6 Vendor Premises
Prior to cargo being collected from the vendor’spremises, the vendor shall ensure it is safe to be loadedon to the transporting vehicle. Once the vendor issatisfied that the cargo is secure, the person appointedas checker must attach a yellow security tie and label tothe load and initial and date same.
4.4.7 Quayside
Once the cargo has been loaded and is in transit, thereshould be no occasion that should cause its security orintegrity to be jeopardised. However the followingchecks that are good practice must be carried out atmid points in the delivery of the cargo although thefitting of additional security ties and labels is notrequired.
• Outbound cargo arriving at the quayside shall besubjected to a further inspection prior to it beingloaded onto the supply vessel.
• Inbound cargo destined for onward shipping to avendor shall be inspected prior to it being loaded ontothe transporting vehicle
A flowchart depicting the Load Security InspectionProcedure (LSIP) can be found in appendix 7.2 of thisguidance.
INBOUND TAG
OUTBOUND TAG
912
Tank condition and clear markings.
Onshore tank filling facility showing means of safe access.
6.1 Accessing the Tank
Access/climbing on top of a chemical tank should only beundertaken as a last resort AND IS NOTRECOMMENDED.
However, should this become absolutely necessary,access should be gained by using the tank’s built in ladder,(if fitted), or by utilising a custom-made tank access ladder.
Note: All tanks should have a fully enclosed grated orplated top and where not in place then access to the top ofthe tank should be avoided and only carried out followinga risk assessment and if the activity is accompanied by awatchperson.
Suitable height safety arrangements in line with Working atHeights Regulation must be in place should access to thetop of a tank be necessary.
6.2 Tank and Contents Handling
Among the reasons given for climbing on top of tanks are,
• Accessing the dip tube.
• Opening the tank lid to determine level.
• To take samples.
• To operate the vacuum breaker or open the hatch toassist flow.
• To hook the crane on to the master link.
With the new design there is no actual reason to climb ontop of the tank. By the end of 2005, when the designcriteria and the application of the procedures within theseguidelines are implemented, the need to access the top ofthe tank will be eliminated.
6.2.1 Sampling
Sampling of the tank contents should be carried outthrough the 3/4” sample valve, an off-take from the maindischarge line at the base of the tank.
• Remove the cap, open the lever-operated foot valve.
• Place clean sample jar at sample valve discharge anddrain off sample carefully ensuring all potential fordrips/spillages/splashes are catered for in the riskassessment.
• Replace protective cap, close valves.
• Adhere to precautions identified on Health and SafetyData Sheets and the COSHH and Risk Assessments.
Note: No intervention on Air Inlet valve or Pressure/Vacuumbreaker valve is required for sampling.
13Example of fall protection equipment.
Example of grated tank top.
4.4.3 Responsibilities
Management shall ensure that a competent person isnominated to act as a Load Checker with theresponsibility to carry out a check of cargo prior to itbeing lifted onto a means of transport.
As far as reasonably practicable such checks shallensure, that the cargo has been properly packed. Thisdoes not absolve the person responsible for packing theconsignment from carrying out the task with allreasonable care.
The checker shall not be responsible for the correctpackaging of the cargo unless they have personallycarried out the task. In the event that the checker doessuspect a load has not been properly packed he shallbring this to the attention of the packer so that remedialaction can be taken.
4.4.4 Procedure Description
Before cargo is transferred to the supply vessel, thechecker shall carry out a visual inspection to ensure:
• There are no loose items on or beneath the loads,which may fall. Items which are required for theoperations offshore that are not an integral part of thetank should be shipped separately in closedcontainers.
Note: this does not absolve the equipment originatorfrom taking all reasonable precautions to ensure theload is fit for lifting in the first place.
• All securing mechanisms should be properlyengaged.
• The design of tanks is such that there should be noprotrusions out with the tank frame which wouldpresent a snagging hazard.
• That nothing has been added to the tank to present asnagging hazard.
Further information on carrying out safety checks iscontained in the UKOOA Guidance for the SafePacking and Handling of Cargo to and from OffshoreInstallations.
8
Tank Inspection prior to loadout
(Diagram of flowchart can be found in appendix 7.2)
4.1 Introduction
This describes the procedures to be followed to ensurethe safety and security of cargo during transportation toand from sites.
4.2 Purpose
The purpose of the document is to ensure as far as isreasonably practicable that cargo, as defined in section4.4.1, is in a secure condition and free from any looseitems that could, if they fell, cause injury to people ordamage to plant, equipment, trucks, offshore supplyvessels and other road users.
4.3 Scope
The procedures shall apply at all sites both on andoffshore. It shall also apply at the premises of otherparties such as fabricators and vendors that areresponsible for packaging and preparing equipment fordelivery to sites that need to be lifted by crane or othermechanical means.
4.4 Definitions
4.4.1 Cargo
For the purposes of this guidance document cargo isany item that is to be lifted by crane or other mechanicalmeans. The range of such items is diverse therefore itis not practicable to attempt to list them all in thisdocument. However some examples are:
• CCU’s (Cargo Carrying Unit’s both closed and open top)
• Tubulars (Slung or in frames).
• Specialist Vendor packages (Wire line units and otherwell service packages).
• Waste skips.
• Helifuel tanks.
• Chemical tanks.
• Special loads (Fabrications).
4.4.2 Transportation
For the purposes of this guidance documenttransportation shall be any means of conveying theabove items e.g. a truck or offshore Supply Vessel.
7Load Inspection Security Tagging Procedure Flowchart.
6.2.2 Discharging
When discharging tanks containing flammable product,the tank should be bonded, (earthed by a competentperson) in order to prevent a build up of static electricityand subsequent danger of ignition/explosion.
• Remove drip cap from the main discharge outlet andconnect hose to the main discharge outlet valve.
• Remove end caps from air inlet valve, then open air inletvalve manually.
• Open the lever operated foot valve and main dischargevalve, (in that order), to allow the tank to discharge.
When discharging the tank, the following actions should beconsidered:
• Ambient temperature, viscosity and specific gravity, allmay inhibit free flow.
• Poor flow - on no account should pneumatic air be usedto assist with the process.
Note: Operators should be aware of the following hazard.The design of the manual air inlet valve is such that anybuild up of pressure will be vented clear of personnel whenthe valve is opened.
Upon completion of discharging the tank contents:
• Ensure all valves are closed, end caps are refitted andsecured accordingly.
Where tanks are fitted with manual Air Inlet Valves (AIV) asrecommended by these guidelines this valve will bemarked air inlet valve for venting purposes only.
6.2.3 Pressure Vacuum Valve/Relief Valve Operation
At no time during the tank life cycle shall the pressure /vacuum relief valve be manually operated (only exceptionbeing onshore tank maintenance routine).
Any interference with this valve will affect its operationalfunctionality and thereby compromise safety and tankintegrity.
Note: The design of Chemical Tanks is primarily coveredby IMDG Code.
6.2.4 Tank Ancillaries Intervention
Intervention on any tank ancillary equipment is notrecommended. Intervention may only be permittedfollowing consultation with the tank manager/owner andafter a suitable risk assessment.
14 Example of Air Inlet Valve.Example of vacuum/relief valve fitted with flame arresting gauze.
15
6.3 Hooking On/Off
When in the stowed position, the tank lifting accessoriesshould be located hanging down the outside of the tankframe. This allows easy access to the master link, whenhooking on/off the crane hook. This also avoids thenecessity for climbing on top of the tank.
Particular care must be taken to ensure that the liftingaccessories and crane hook does not inadvertentlysnag on the tank framework or ancillaries causing thepossibility of premature movement of the tank.
View showing the correct position and height of the master linkand the tank slinging arrangement.
6.4 Stacking
Double stacking of chemical tanks offshore should beactively discouraged and only sanctioned where itbecomes absolutely essential and following an appropriaterisk assessment.
Personnel should never climb on to a double-stackedchemical tank. Where deemed required a thorough androbust risk assessment process with mitigating measuresand actions is required.
IDEALLY THE TANKS SHOULD BE UNSTACKED.
6.5 Labelling and Documentation
All cargos, including backloaded cargos of dangerousgoods shall be correctly declared, packaged and labelled,secured, placarded and documented, and segregated inaccordance with the regulations and MGN 282(M) andIMDG Code plus subsequent notices issued by theMaritime and Coastguard Authority.
To assist the Master of the Offshore Supply Vessel inplanning the cargo stowage to ensure that segregation ofdangerous goods is maintained, it is a requirement that:
• The Offshore Supply Vessel is advised by the quaysideservice provider of the quantity and nature of dangerousgoods prior to loading.
• The Offshore Supply Vessel is advised by the OIM(Offshore Installation Manager) / Duty Holder ornominated deputy, of the quantity and nature ofbackloaded dangerous goods prior to loading.
In the case of the backload, it is the responsibility of theconsignor/packer to ensure that the backloaded goods arebackloaded in accordance with the requirements of theIMDG code. That means correctly declared, packaged,labelled, secured, placarded and with the correctdocumentation. In addition consideration must also begiven to the order of backloading to ensure that thesegregation requirements can be complied with.
It is the responsibility of the consignee/receiver of anydangerous goods to remove any old placards affixed to thecontainer prior to its re-use.
3.10 Documentation and Labelling of Tanks
Tank contents labels are to be clear and visible on all sidesto facilitate deck loading and avoid incorrect decanting.
On completion of all checks, an Outbound/Inbound Tanksummary checklist should be completed for each loadbeing dispatched offshore or returned onshore. Thechecklist should then be placed in the document pouchalong with relevant shipping details.
3.11 Tank Life Cycle Flowchart
Attached for reference (front cover) is a flowchart whichrepresent the life cycle of a tank, it also identifies thepersons associated with each stage; their duties and keyinformation to ensure that operations and works associatedwith it are managed safely and effectively.
3.12 Backloading of Chemicals and Waste
Where backloading of chemicals or waste is required thenit is recommended dedicated tanks should be requested toavoid cross contamination.
Clear labelling and documentation are essential, howeverthere may be occasions when previously used tanks mustbe used. In all cases of backloading, a risk assessment isrequired which would consider all aspects in section 5.3 asa minimum and requires the authority of the offshore dutyholder.
Where waste or contaminated chemical is to bebackloaded, appropriate labelling MSDS should beobtained and fixed to the tank that correctly identifies thetank contents and hazards. All waste or contaminatedchemicals should be sent to your responsible WasteManagement Contractor for disposal. Only part used andnon contaminated chemicals should be returned to theoriginal Provider in the tank with original labels and MSDS.
6
Enclosed Tank Lid.
Storage Areas.
Offshore Unloading, demonstrating potential for snagging(open tanks not meeting guidelines).
6.6 Receipt and Despatch
Upon receipt of any tank always ensure:
• The lifting accessories and padeyes are in goodcondition and not damaged.
• The tank has not been damaged in transit.
• The product and hazard labels are visible and intact.
• A Health and Safety data sheet is available for thecontents.
• Retrieve all documents from document pouch.
Prior to dispatch from offshore always ensure:
• The tank and frame are undamaged.
• The tank manway lid is securely fastened.
• The discharge valve and sampling point end caps arefitted.
• The product and hazard labels are appropriate for thecontents and are visible or where the tank is empty alllabels have been removed.
• All relevant documentation has been inserted intodocument pouch.
The instructions identified above, are for general guidance.It is the ultimate responsibility of all users and handlers toensure that all operating and safety procedures are strictlyobserved.
Refer to Outbound/Inbound Tank Summary Checklist(Appendix 7.1).
6.7 Lifting Assemblies and Slinging
The lifting and slinging of tanks falls within regulationsbelow and as such will not be covered in this document.
For reference the key documents are:
• Lifting Operations and Lifting Equipment Regulations1998 SI2307, (LOLER).
• Regulation 9 of LOLER, Approved Code of Practice,(HSE Books L113).
• Step Change in Safety Lifting and MechanicalHandling Guidelines.
16
3.8 Document Pouches/Load Security Tagging
Marshalling of tanks utilising a tagging method, (Loadsecurity Inspection Procedure See section 4), carried outby the nominated responsible person for freight forwardingand return is a recommended practice.
Document pouches should be present and clearlyidentified on the tank. Where this is not the case, remedialaction to ensure the effective communication of the tankcontents details must be arranged.
There shall be a designated responsible person offshore toboth accept and dispatch chemical tanks.
Contents documentation shall be kept in the documentpouch and remain with the tank throughout it’s cycle andbe updated as and when appropriate (referenceflowchart).
3.9 Responsibilities and Training
Training of personnel with ‘hands on’ responsibility fortanks (including content) is considered essential.
It is recommended the information contained in thisguidance document be used only as a supplement tofurther training.
These guidelines are aimed at providing supervision withsufficient training material from which they can developtheir own specific training programme, for personnel whoare expected to work with chemical tanks or their contents.
It is recommended that there are nominated persons withassigned responsibilities for the management andhandling of all aspects of chemical tanks both onshore andoffshore. Ideally this person should also be responsible forbaskets, CCU’s (Cargo Carrying Units) etc. to ensure a fulloverview of the freight situation, risks and controls from anorganisational and management perspective.
Typical duties would include:
• Receipt and dispatch
• Lifting and discharging of contents
• Document control
• Participation in associated risk assessments
• Contents and tank monitoring & management
• Tank labelling compliance and update/changemanagement
• Integrity of the manway lid and discharge valve telltale
In conjunction with the above offshore personnel handlingor using tanks should receive appropriate training, whichincludes:
LIFTING AND MECHANICAL HANDLING OPERATIONS
MANUAL HANDLING
RISK ASSESSMENT
CHEMICAL HANDLING (COSHH)
ENVIRONMENTAL ISSUES
SAFETY OBSERVATION SYSTEMS
The Step Change in Safety Lifting and MechanicalHandling Guidance contains further information on trainingand competency.
5Example of Document Pouch. Inspection Security Tag.
7.1 Outbound/Inbound Chemical Tanks Checklist
The following checklist is a revision of the existing UKOOA tank checklist, which both updates and clarifies requirements andchecklist contents to further enhance the management and safety associated with the use of tanks.
A key point and change recommended is that for every tank there exists a single corresponding checklist, which follows thetank in its journey.
17
Tank ID: Product Name: Customer Details Offshore Location:
Does Test Plate have at least a full month remaining? Yes/No Tank Supplier:Last Test Date: Collection Address (if different from above): Ready for Collection:
Date:Time:
Item No Cargo Ref Cargo ID Product Total “Lift” IMDG Class / UN Customs StatusQuantity litres Weight (Kg) No
1
Check Tank / Cargo Checklist Chemical Shipper Offshore Back Shipper OnshoreNo Provider Outbound Receiver Load Inbound Receiver
OperativeConfirm that (a) Tank is clean (and dry depending on the product to be filled),or (b) Tank is “dedicated” and previously contained the SAME product.(Chemical Provider and Back Load Operative only, as appropriate)
1 Have all old labels been removed?2 Have copies of all relevant certificates, dangerous goods, MSDS’s and TREM
cards been dispatched with the tank?3 Are there any signs of leaking chemical?4 Are all valves closed, and caps refitted?5 Has the main valve been tagged and tie wrapped closed?6 Is manlid closed and fully secured and has security tag been fitted?7 Is special coupling attached (if applicable)? (Chemical Provider and Back
Loader only)8 Have you checked the gross weight against SWL?9 Does the lifting set details match those on the Data / Inspection plate?10 Where appropriate, has dangerous goods cargo been completed and relevant
authorities notified as per IMDG Code?11 Product Label is on each side?12 Hazard Label is on each side?13 Has Tank been visually checked for any obvious damage (frame, gratings,
slings, lifting points, fittings etc)?14 Have you checked for and removed any loose objects / debris on the unit or in
the forklift pockets and fitted / checked the Load Security Inspection Tag? 15 Have appropriate declarations been made for waste backload?
*Any “No” above will result in non-shipment Sign Off For All Of the Above Checks
Name of Yard Operative:
Signature of Yard Operative:
Date:
Name of Shipping Outbound Operative:
Signature of Shipping Outbound Operative:
Date:
Name of Back Load Operative:
Signature of Backload Operative:
Date:
Name of Shipper Inbound Operative:
Signature of Shipper Inbound Operative:
Date:
Name of Offshore Receiver:
Signature of Offshore Receiver:
Date:
Name of Onshore Receiver:
Signature of Onshore Receiver:
Date:
3.3 Tank Access
Working on the top of the tank should only be undertakenas a last resort AND IS NOT RECOMMENDED. Howevershould this be absolutely necessary then a riskassessment must be conducted and all appropriate safetyprecautions be implemented. Reference should be madeto the Working at Height Regulations.
Access to the top of the tank should be via the permanentaccess ladder (if fitted), portable ladder or a suitable workplatform and appropriate fall arrest equipment must beworn.
Access requirements to both valving and lifting assemblymust be considered when positioning or laying downtanks.
Opening of the tank manway lid is not permissible offshoreunless access is required for backloading, which wouldthen fall under special circumstances and should besubject of a risk assessment.
3.4 Contents Measuring IMDG Code
Any contents measuring device fitted to tank must conformto current IMDG Code requirements.
3.5 Contents Management
Clarity of tank contents being dispatched or returned mustexist through labelling and documentation.
Offshore procedures regarding the return of good or spentchemicals must be clear and supported by correctlabelling and accompanying documentation to ensurewaste legislation compliance and to facilitate handling/disposal on return.
All tanks should be fitted with a telltale, (tiewrap or similar),on the tank manway lid and main discharge valve to verifythe tank has not been opened.
3.6 Checklists
A checklist for tanks is included in the “UKOOA guidancefor Safe Packaging and Handling of Cargo to and fromOffshore Locations”, however this has been expandedupon with the Outbound/Inbound summary ticket(appendix 7.1)
3.7 Risk Assessment
It is recommended that risk assessments should be carriedout for the following established operations:
• Accessing the tops
• Sampling and Dipping
• Stacking
• Discharging & Filling
• Filling, Discharging and including Hose AssemblyManual Handling
• Crane lifts inbound/outbound
• Backloading of chemicals/waste
• Opening of manlid for loading of chemicals
• Access to the lifting assembly master link when tanksare stacked
• Chemical compatibility
Note: Such assessments should include worker exposurerisk, the Control Of Substances Hazardous To Health(COSHH), and reference the appropriate Material SafetyData Sheets (MSDS’s).
4 Step Change in Safety Task Risk Assessment Guidewww.stepchangeinsafety.net
Positioning of Masterlink.Typical view of a fully grated tank. Typical access ladder.
The points made within this section apply to all new andexisting tanks, with an overall objective that all current tankstock can fall in line with this guidance by the end of 2005.
3.1 Design
All valves should be suitably placed to allow safe accessand be accessible from ground/deck level.
All tanks to have fully grated or flat plate tops to ensurecomplete closure
All tanks to have non-slip paint coated to access ladderswhere fitted.
All pipefittings will be to a recognised standard
All tanks to have a sling configuration that allow easyaccess to the master ring without accessing/climbing onthe tank in any way
All tanks will have a functional sealable document pouchfitted
Note: The Design of Chemical Tanks is primarily coveredby the IMDG code.
3.2 Handling
The practice of double stacking tanks offshore is notrecommended and should be avoided. Where deemednecessary it should be by exception only and a formal riskassessment is recommended followed by directsupervision of the activity.
When double stacking is being practiced then access tothe crane master link must be independent of the tank, bymeans of a suitable access platform or ladder.
There will be no crane movement other than attaching thecrane hook to the master link until all personnel havewithdrawn from the immediate vicinity of the tank and thebanksman/loadhandler has given the all clear to the craneoperator.
318
7.2 Load Security Inspection Procedures (LSIP)
The following flowchart depicts the procedure to be followed prior to any movements of chemical tanks.
Load Security Inspection Procedure
This procedure has been adapted from the Talisman Energy (UK) Ltd. process for ensuring the safety and security of cargo during transportation to andfrom offshore installations.
To this end, the term ‘Unit’ can be taken to be CCU’s (Cargo Carrying Units both closed and open top), Tubulars (slung or in frames), Waste Skips,Helifuel Tanks, Chemical Tanks, Specialist Loads (wire line units and other well service packages) Suppliers/Users of the above should nominate a Load
Checker within their organisation to ensure that the procedure is carried out and suitable verification methods implemented to provide an audit trail.
Start
End of Process
Onshore Load Checker
Prior to loading ofContainer/Tank, nominatedLoad Checker shall carryout a visual inspection ofthe unit to ensure that all
items are properly packed,container doors are
securely closed, and thatno loose items are left lying
on the unit in any place.
Onshore Load Checker
Arrangers for the person/sresponsible for
packing/securing the unitto carry out necessary
remedial action.
Onshore Load Checker
Informs the relevantperson that the unit hasbeen checked and theLoad Security Tag and
Label attached.
Onshore Load Checker
Affixes YELLOW LoadSecurity Tie and Label to
the unit.
Onshore Load Checker
Removes any loose itemsfrom unit prior to loading
operations.
Transporter/Shipper
Transports/Ships unit torelevant destination.
End-User of Cargo
Unloads/Empties unit and,where applicable, packs
the unit for return toBeach and informs
Offshore Load Checkerthat unit is ready for
shipping.
Offshore Load Checker
Attaches ORANGE LoadSecurity Tag and Labelinforms relevant personthat unit is ready to be
shipped back to beach.
Offshore Load Checker
Arranges for the personresponsible for
packing/securing the unitto carry out the necessary
remedial action.
Transporter/Shipper
Refuses to transport/shipunit until Load Security
Tag and Label is attached(thereby indicating that
the load has beensecurity checked).
Offshore Load Checker
Prior to loading, OffshoreLoad Checker carries outa visual inspection of the
unit to ensure that allitems are securely
packed, container doorsare closed, and that noloose items are left lyingon the load in any place.
Transporter/Shipper
Prior to loading(Vehicles/Vessel)
Transporter/Shipperchecks to ensure that
YELLOW Load SecurityTag and Label have been
attached to unit.
Is the unit packedproperly with no
loose items foundanywhere on unit?
Has Load SecurityTag and Label
been attached tounit?
Is the unit packedsecurely with no
loose items foundanywhere on unit?
Does the problemconcern loose
items left on unit?
Yes
Yes
Yes
Yes
No
No
No
No
19
7.3 Pre-Fill Tank Checklist
The following checklist is a generic checklist for use prior to tank filling.
PRE-FILLING TANK CHECKLIST
Tank ID: Date:
1 CHECK SERIAL NUMBERS, TARE & BLACK PATCH STICKER ❑
2 CONDITION OF TANK FRAME FOR DAMAGE ETC ❑
3 EXAMINE TANK VESSEL & CRADLES ❑
4 CHECK END CAPS ARE SUPPLIED AND SECURED ❑
5 CHECK CONDITION / OPERATION OF FOOT VALVE & OPERATING LEVER ❑
6 CHECK CONDITION OF DISCHARGE VALVE ❑
7 CHECK CONDITION OF SAMPLE / DRAIN VALVE ❑
8 CHECK DUST CAP & SECURING WIRE ON DISCHARGE / SAMPLE VALVES ❑
9 CHECK CONDITION OF EARTHING POINT ❑
10 CHECK CONDITION OF DOCUMENT TUBE HOLDER ❑
11 CHECK CONDITION OF DIP STICK HOLDER & DIP STICK WHERE FITTED ❑
12 CHECK LIFTING LUGS FOR DAMAGE ❑
13 CHECK LIFTING SLINGS, SHACKLES & SPLIT PINS ❑
14 CHECK TANK MANWAY LID ❑
15 CHECK CONDITION OF TANK MANWAY LID, SWING BOLTS & HINGE PIN ❑
16 CHECK CONDITION OF TANK-LID, INCLUDING LID SEAL ❑
17 CHECK TANK INTERIOR FOR CLEANLINESS INCLUDING FOOT VALVE & SAMPLE VALVE ❑
18 CHECK CONDITION OF PRESSURE VACUUM RELIEF VALVE & GAUZE ❑
19 CHECK CONDITION OF DIP VALVE, DUST COVER & RETAINING WIRE ❑
20 CHECK THAT TEST DATA PLATE IS FIXED & TANK MARKINGS / CHEVRONS ARE LEGIBLE ❑
21 COMPLETE CERTIFICATE OF CLEANLINESS & PASS TO RELEVANT PERSON FOR ACTION ❑
DETAILS OF DAMAGE OR DEFECTS FOUND:
The guidance identified within this publication is aimed atensuring personnel, whose duties involve the handling andtransportation of chemical tanks and their contents atoffshore installations, are aware of the hazards andprecautions which must be considered during tankoperations.
The objective of this guidance is to increase awareness ofkey factors relating to chemical tanks and contentshandling and to reinforce existing knowledge withadditional information.
To achieve maximum impact, supervision should follow upsafety presentations by talking to appropriate personnelabout tank handling techniques, and their understandingof the required safety standards. Subsequent monitoringof chemical tank operations should be undertaken toensure safety considerations have been raised to, andmaintained at, an acceptable level.
2Step Change in Safety Fatality Report
www.stepchangeinsafety.net
Horizontal Chemical Tank. Supply Vessel Offloading. Vertical Chemical Tank.
This Guideline, Design and Handling of Chemical Tankshas been compiled as part of the Step Change In Safetyoverall objective of improving safety within the Oil & Gasindustry.
The Guideline was commissioned due to offshore industryconcerns over the design and safe use of cargo carryingunits and portable chemical tanks, and fatalities offshorerelating to the handling of these units (See Step Change inSafety Fatality Report).
The objective of this Guidance is to provide information toDesigner, Manufacturer, Owner and End User of IMOChemical Transport Tanks, which will lead to rationalisationof equipment and practices used within the industry thusreducing accidents or incidents during handlingoperations.
From a design perspective, the guidance looks at keyissues. It recommends that:
• valves requiring manual operation,
• the lifting accessories master link,
be accessible from deck or ground level. This will reducethe need to access the top of the tank in the offshoreenvironment.
From an operational aspect, key issues addressed includerecommendations to eliminate:
• access to the top of a tank,
• manual operation of the pressure/vacuum valve.
Further recommendations on :
• contents measurement,
• tank access
• back loading fluids from offshore facilities are alsoincluded.
The Guidance also outlines the risk assessment approachfor any operations out with the Guidance.
The Guidance provides assistance to meet theserecommendations by providing:
• a Tank Lifecycle Flowchart,
• Tank Inspection Checklists,
• an Outbound/Inbound Chemical Tanks Checklistoutlining competency levels for personnel.
120 Example of 500 gallon tank. Comparison of new and old tank design (600 imperial gallons).
INSPECTED BY:SIGNATURE:DATE:
7.4 Tank / Vessel Types and GeneralArrangements
Example of 600 gallon, (2900 litres), vertical tank.
Example of 1000 gallon, (4800 litres), horizontal tank.
7.5 Bottom Outlet Valve Arrangement
Bottom outlet valve arrangement highlighting the main discharge valve, the sample point and the control handle for the secondary tank discharge valve.
7.6 Ancillaries on the Tank Top
View of the Manway Lid and and Pressure / Tank Vacuum Valve (grating removed for picture clarity).
Main Discharge Valve
Lever Operated Foot Valve
End CapEnd Cap
Pressure Vacuum Relief Valve (not to bemanually operated)
Air Inlet Valve
Manway Lid (Tank Top Lid / Man Lid)
Sampling Point Valve
21
6 TANK PRACTICES 136.1 Accessing the Tank 13
6.2 Tank and Contents Handling 13
6.2.1 Sampling 13
6.2.2 Discharging 14
6.2.3 PV valve/Relief valve operation 14
6.2.4 Tank Ancillaries Intervention 14
6.3 Hooking On/Off 15
6.4 Stacking 15
6.5 Labelling And Documentation 15
6.6 Receipt and Dispatch 16
6.7 Lifting Assemblies and Slinging 16
7 APPENDICES 177.1 Outbound/Inbound Tank Checklist 17
7.2 Load Security Inspection Procedures Flowchart 18
7.3 Pre - Fill Tank Checklist 19
7.4 Tank / Vessel Types and General Arrangements 20
7.5 Bottom Outlet Valve Arrangement 21
7.6 Ancillaries on the Tank Top 21
8 REFERENCES AND ACKNOWLEDGMENTS 22
22
• BS EN 12079: 1999 - Offshore Containers - Design,Construction, Testing, Inspection & Marking
• Control of Substances Hazardous to Health RegulationsSI 1999/437 (COSHH)
• DNV Certification Notes 2.7-1
• IMDG Code - International Maritime Dangerous GoodsCode
• International Maritime Organisation
• Lifting Operations and Lifting Equipment Regulations SI 1998 / 2307, (LOLER)
• Manual Handling Operations Regulations SI 1992 / 2793
• Merchant Shipping (Dangerous Goods and MarinePollutants) regulations SI 1998 / 2367
• PUWER - Provision and Use of Work EquipmentRegulations SI 1998 / 2306
• Regulation 9 of LOLER, Approved Code of Practice,(HSE Books L113)
• Step Change in Safety Fatality Report
• Step Change in Safety Lifting and Mechanical HandlingGuidance (re-issue 2004)
• Step Change in Safety Task Assessment Guidance (2ndedition 2003)
• The Carriage of Dangerous Goods by Road Regulations,SI 1996 / 209
• UKOOA / Chamber of Shipping Guidelines for the SafeManagement and Operation of Offshore Support Vessels(Issue 4th November 2002)
• UKOOA Guidance for the safe Packing and Handling ofCargo to and from Offshore Installations (latest edition)
• Working at Height Regulations SI 2005 / 735
Acknowledgments
Step Change would like to thank the followingorganisations for their contributions in developing thisguidance:
AMEC
Baker Petrolite
BP
Conserve Oilfield Services Ltd
Elected Safety Representatives Network
Ferguson Seacabs Ltd
Harran Ltd
Marathon
Marathon Oil
Nalco Ltd
Shell Exploration and Production UK
Suretank Ltd
Swire Oilfield Services Ltd
Talisman Energy
Transocean
• Step Change in Safety website: www.stepchangeinsafety.net
1 INTRODUCTION 1
2 SCOPE 2
3 SUMMARY / RECOMMENDATION 33.1 Design 3
3.2 Handling 3
3.3 Tank Access 4
3.4 Contents Measuring Gauge 4
3.5 Contents Management 4
3.6 Checklists 4
3.7 Risk Assessment 4
3.8 Document Pouches/Load Security Tagging 5
3.9 Responsibilities and Training 5
3.10 Documentation and Labelling of Tanks 6
3.11 Tank Life Cycle Flowchart 6
3.12 Backloading of Chemicals and Waste 6
4 LOAD SECURITY INSPECTION PROCEDURE 74.1 Introduction 7
4.2 Purpose 7
4.3 Scope 7
4.4 Definitions 7
4.4.1 Cargo 7
4.4.2 Transportation 7
4.4.3 Responsibilities 8
4.4.4 Procedure Description 8
4.4.5 Cargo Integrity Tagging 9
4.4.6 Vendor Premises 9
4.4.7 Quayside 9
5 SAFETY CONSIDERATIONS AND CHECKS 105.1 Good Practice Chemical Tank Inspection Illustrated Checklist 10
5.2 Recommended Checks - Prior to Tank Fill for Preparation for Dispatch Onshore/Offshore 11
5.3 Safety Considerations Associated with Tank Use and Risk Assessment 12
Design and Handling of Chemical Tanks
Guidance
website
address
[email protected] FloorThe Exchange 262 Market StreetAberdeen AB11 5PJ
P • O • L • I • C • EGRAMPIAN
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