Hazira Depot

OVERVIEW

BPCL Hazira POL Depot was commissioned and started its commision in 1996.
But the actual operations takes place in 2002. The POL Depot receives products
from Manmad and Manglia Depot of BPCL and from Jamnagar (Reliance/Essar).
Apart from that product is also received through bridging i.e. through tank Lorries
from Sewree specially for HFHSD product. After receiving and storing products it
dispatches it to retail outlets (RO) for sale to customers.

It is going to be equipped with latest automation facilities for its operations but
right now it is working manually. The POL is maintained well and all safety
majors are installed. The POL was also audited from Oil Industry Safety
Directorate for its safety standards.

The POL is situated in outskates of Surat means it is 15 kms before the Hazira. The
POL Depot is along with HPC and IOC terminals.

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TANK FARMS
All products handled are in bulk and are stored in tanks. Tanks are cylindrical in
shape, of mild steel material, of various sizes, and installed either underground or
aboveground.

Tanks are the major storage facility at the Kota Depot. There are two types of tanks
used at Kota Depot.

1. Underground tank
2. Above ground tank (Fixed roof)
3. Above ground tank (Floating roof)

Underground tank

It has six underground tanks and these tanks are cylindrical and horizontal,
generally restricted to capacity of 200 kilos, installed in earth or masonry concrete
pits, held in position by metal rings strapped around the body and covered with
earth so that only the fittings are visible.

The advantages in having such tanks are - negligible variation in product

temperature, lesser safety distances required to be maintained, no bund enclosure
required and receipt at a faster rate, even without use of pumps.

The disadvantages are - slower deliveries, suction problem faced during extreme
hot weather or due to defective foot valve, excessive corrosion, possibility of
floating during heavy rains if empty or with low stocks, small capacity, prolonged
period of ventilation required for gas-freeing, higher cost per kl, etc.

They are provided generally with two manholes, on the top, close to either ends,
air-tight manhole covers; vent pipe about 4 meters high and fitted with a vent or
Pressure Vacuum (PV) valve, dip hatch, perforated fill pipe extending almost to
the bottom of the tank.

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Aboveground Tanks

It has 12 aboveground tanks and these are only vertical shape but these tanks have
following classifications.

Horizontal Aboveground Tanks

These tanks are same as underground tanks except that they are laid on masonry
pedestals above ground level.

Vertical Aboveground Tanks

These tanks are rested on sand / RCC foundation pads, made of M.S. plates stack-
welded one above the other, and with either a fixed or a floating roof.

Fixed Roof Tanks

Fixed roof tanks are of two types, Pressure and Non Pressure tanks used on volatile
and non-volatile products respectively.

Special Features in Pressure Tanks

Tanks are designed to operate at high pressures in their vapor spaces, the
internal pressure exceeding the atmospheric pressure.
Regulated ventilation by means of PV valves as compared with free venting in
non-pressure tanks
Anchored firmly on a ring beam as compared with non-pressure tanks which
merely rest on foundation
Vertical non-High Pressure tanks are also bolted to the foundation if the height
is more than 1.5 times diameter and where strong winds or cyclonic storms are
common.

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Floating Roof Tanks
Floating Roof Tank has the roof floating on the surface of the liquid contents in an
open tank and to be in complete contact with that surface, except at low levels
when the weight of the roof is taken on the supports on the tank bottom.

Advantages as Compared to Fixed Roof Tanks

Interchangeability
The tanks can be switched over to Class `A' service from other Classes,
without any change in the fittings.
Safety
Tanks do not have vapor accumulated under the roof and as such a
hazardous vapor space above the product is almost eliminated.
Reduce corrosion
The corrosion of the tank is considerably reduced as the inside of shell plates
areas exposed to air/vapors is limited.
Reduce air pollution
Environmental pollution is greatly reduced as there is practically no venting
of the tank.
Eliminate product loss
As product vapor is conserved within the tank, product loss is ruled out due
to breathing of the tank during storage and displacement of vapor during
receipt.

Disadvantages as Compared to Fixed Roof Tanks

High cost of construction.
High cost of maintenance.
Relatively hazardous operation requiring constant supervision.
Possibility of sinking of the roof on developing leak or by the weight of rain
water collected on the roof which cannot be drained in the event of failure of
the articulated draining system.
Exposure of the under-side of the floating roof at lower liquid levels, leading to
heavy accumulation of the toxic petroleum vapor on the roof.

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Floating roof tanks can be either internal floating roof (IFR) or external floating
roof (FR). In internal FR tanks, the deck floats on products within a cone roof tank.
The external FR tank is open tank and the deck floats on the product. Internal FR
tanks are used where there can be snow fall or heavy rain fall and also for products
which are sensitive to water like Benzene.

Existing cone roof tanks can also be converted to IFR, wherever required to get the
benefits of floating roof tanks.
Floating Roof tanks are generally used for light hydrocarbons such as MS,
Aviation Gas, Naphtha, Hexane, SBP, Benzene and Toluene.

Fittings in Fixed Roof Tanks

1. Manholes
2. Dip Hatch
3. Datum Plate
4. Temperature / Sample Hatch
5. Inlet / Outlet
6. General Facilities
7. Vents
8. Pressure Vacuum (PV) Valve
9. Centre Sump
10.Water Draw-off Line
11.Product Drain Line
12.Safety Railings
13.Stairways
14.Grounding Connections
15.Expansion Line
16.Manometer
17.Fire Water Sprinkler System
18.Foam Pourer
19.Auto Level Gauges
20.Jet nozzles
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Fittings in Floating Roof Tanks
1. Primary Seal
2. Secondary Seal
3. Adjustable Legs
4. Roof Auto Bleeder Vents
5. Roof Water Drain
6. Emergency Drain
7. Roof Ladder
8. Wind Girder
9. Anti-rotation Device
10.Manhole on Shell and Roof
11.Gauge Hatch with Cover
12.Datum Plate
13.Product Inlet/Outlet Nozzles
14.Drain Nozzle
15.Foam Network
16.Sprinkler
17.Gauging Platform
18.Stairway
19.Earthing
20.Expansion Line

Marking on Tanks
1. Tank No.,
2. Product Grade,
3. Capacity in liters,
4. Date last cleaned
5. Due date of next cleaning,
6. Date last calibrated
7. Date of last earth test.

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The various tank farms in Hazira Depot are:

TANK FARM 01
S.No. TYPE OF TANK PRODUCT CAPACITY
HANDLING
8. Above ground (floating) MS 3 2155
Under Maintenance
9. Above ground (floating) MS 4 2155

TANK FARM 02
S.No. TYPE OF TANK PRODUCT CAPACITY
HANDLING
10. Above ground (fixed) MS 4 1362
Under Maintenance
11. Above ground (fixed) SKO 1362
Under Maintenance

TANK FARM 03
S.No. TYPE OF TANK PRODUCT CAPACITY
HANDLING
5. Above ground (fixed) HSD 3 3417
6. Above ground (fixed) HSD 3 3417

TANK FARM 04
S.No. TYPE OF TANK PRODUCT CAPACITY
HANDLING
7. Above ground (fixed) HSD 4 3417

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 TANK FARM 05
S.No. TYPE OF TANK PRODUCT CAPACITY
HANDLING
14. Above ground (fixed) FO 2301
15. Above ground (fixed) FO 578
17. Above ground (fixed) FO 2301

TANK FARM 06
S.No. TYPE OF TANK PRODUCT CAPACITY
HANDLING
1. Underground ground Ethanol 200
2. Underground ground MS 3 200
Under Maintenance
3. Underground ground Speed 200
4. Underground ground HSD 3 200
16. Underground ground HFHSD 200
19. Underground ground HSD 4 200

Tanks are marked with different color-coding of products as follows.

Product Color Code

MS Deep Orange
HSD Oxford Blue
SKO Golden Yellow
Water Green

All the tanks are situated in tank farm. Tank farms are licensed areas. These tanks
farms are fully protected with dike walls and other safety majors. Tanks have one
inlet and one outlet pipe. Both inlet and outlet should not be opened together.

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TLF PUMP HOUSE
Tank filling pumps shade has eight pumping sets. Two for HSD, Two for MS and
Two for SKO and Two FO pumps. There is also one doping unit for Speed.

1. 2 MS pumps ( 22KW 120KL/HR and 37KW 249 KL/HR )

2. 2 HSD pumps ( 45KW 300KL/HR and 45KW 350 KL/HR )
3. 2 SKO pumps
4. 2 FO pumps
5. 1 Doping point for making additives of SPEED

Generally one pump is on for filling at TLF Gantry. If the required flow rate is
more, then second pump is switched on.

TLF GANTRY
Tank Lorry feeling gantry is used for filling products in tank Lorries. The Gantry is
fully equipped with automation. There are total eight bays and eighteen loading
arms. Flow rate of arms is 600 to 700 liters per minute. It is maintained properly.

Each bay has one or two filling hands and the details are as follows:

Gantry has eight bays:

(NW) : Not Working condition

BAY DETAILS
BAY NUMBER ARM On Left ARMs On Right
Bay 01 HSD 4 and MS 4 Ethanol (NW) and
Speed
Bay 02 MS 4 and HSD 4 Ethanol (NW) and
HSHSD 4 (NW)
Bay 03 HSD 4 and MS 4 MS 4 and HSHSD 4 (NW)
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Bay 04 HSD 3 and MS 4 Speed
Bay 05 HSD 3 HFHSD and SKO (NW)
Bay 06 HSD 3 and FO HFHSD and SKO (NW)
Bay 07 HSD 3 and FO SKO (NW)
Bay 08 HSD 3 and FO SKO (NW)

WATER TANKS
Presently there are two water tanks at BPCL Hazira Depot. The details for two
tanks are as follows.

WATER CAPACITY
TANK NUMBER CAPACITY
Tank 12 1200
Tank 13 1200

Water tanks are for fighting against any fire at theDepot. Certain checks which are
always done for water tanks are as follows
Tanks should be always full.
Tank body is provided with grounding.
The pips carrying water are pained in red.

Sprinklers are installed on tanks and connected to water tanks through pipes.
Sprinklers are used to cool tanks. The mounted setup for holding sprinklers is
known as Sprinkler line.

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FIRE ENGINES PUMP
Three are with 273m3/hr. capacity and one among them is there for additional
safety purpose.
These pumps are generally on switch off mode. Small pumps called jockey pumps
are installed. The required pressure of water is 7.5 to 8 kg per cm3. The Jockey
pipes keep pressure of 4 to 4.5 kg per cm3. The pumps can operate on automation
and manually too. Jockey pumps are the pump sets which are supposed to be
running 24 by 7. The fire engines pump run there for 2 to 3 hrs.

Power supply
Power supply is received through High-voltage Overhead Transmission Lines of
11000 volts. Transformer of 400 KVA is installed at the POL site. For
uninterrupted supply of electricity two generators are installed. In case of power
failure manual switch over is done from main supply to generators. Power can be
supplied through only one generator at a time.

DEPARTMENTS AT HAZIRA DEPOT

There are mainly two departments at BPCL Hazira Depot.

Supply and Despatch

The S&D team looks after following:

Administration
Planning
Operations
Maintenance
Store Room
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 E&P
HSSE
Security

Planning is the group which looks after the sales of different products. Planning
uses different software for its operation like SAP and STM.

Territory office
Territory office looks after promoting sales in the area which is from Bharuch to
Daman and it covers all the area of it. The office also has Lubes Department with
him as Lubes has major percentage of market in Surat Territory area.

OPERATIONS
All the operations at the TOP can be divided into three sections:

1. Receiving
2. Storage facilities
3. Dispatch

Receiving
Main Mode of receive at BPCL Hazira Depot is train wagon means rake. The
following are major stations from which the product is being received.

1. Manmad through TW
2. Manglia through TW
3. Reliance through TW
4. Essar through TW

Bridging is process of receiving product through TTs. As HFHSD cycle is of

seven days at BPCL Hazira Depot, bridging is mainly performed for HFHSD.

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Storage
The products are received in tanks. There are different above ground tanks and
underground tanks which are used for storage.

Despatching

Mode of dispatch to different retail outlets is Tank Trucks (T.T.)/Tank Lories.

Gantry is the main dispatching unit at the Depot. All the planning of dispatch is
done by S&D department.
Tanks are generally of 12 Kilo liters (KL), 20KL, 18KL and 24 KL. Tanks on
Tank trucks (T.T.) are generally divided in 3 or 4 compartments.

STEPS IN COMPLETING AN ORDER/PDP

1. Receive an order from customer:
PDP is synonym to an order. PDP are received via mail or over the phone.
Drivers also come with the details of PDP. It is a check for the correctness of
order. After receiving the PDP, the details are fed in SAP by a planning
officer.

2. Receive the payment:

Payment is received trough RTGS. UTR number is also used for issuing the
product.

3. Reporting of Tank Trucks(T.T.)

Tank trucks are reported to security by drivers.

4. Allocation of T.T.s
Allocations of tank trucks are done against a PDP.

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5. Creation of document
Invoice (Pro forma Invoice) It contains details about billing and parties
involved in the process. It is created through SAP.
The document is created by allocating the vehicle through manually and it is
being announced by security team. The anoouncing statement has TLs
number and TLs are being reported.
The prepared documents are passed to security for further process. These
documents are being prepared by Clerk person of company.

6. Allocation of Vehicle

7. Handover of documents to drivers:

The allocated tank trucks are called by use of microphones and speakers.
The drivers receive the documents and take their trucks inside the Depot.
Before entering into Depot area security and safety test is performed by the
security guards.

8. Entry of T.Ts into the gantry area

The TLS enteres into the licence are through licence gate and the gate has
security person over check for safety purpose.

9. Filling of the tank trucks

Filling is done with the help of loading arms at any bay of gantry. After the
filling Q and Q checks are done.

10. Securing the valves of the tank trucks by locks

11. Dispatch of tank trucks from T.O.P.
12. Delivery at petrol stations/ Retail Outlets.

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SIDING SECTION
As products are mainly received through Tank Wagons and rake is the one of the
most important section. The unit is segregated from the main unit and function on
its own.

Products are received by TW from the particular dispatch location. The process of
receiving product is called TWD (Tank Wagon Decantation). The rake has 50 nos
of BTPN as BTPN means Bogie Tank with Pneumatic Brakes. Each rake has
capacity of 3250 to 3500 KL. The rake has generally mixed products like HSD and
MS. After receiving of products testing of Samples are done. When samples are
passed through QC department then the products in the tanks are ready for
dispatches.

DEPARTMENTS
The Pump House is the main department at the siding of DEPOT. It is 3 kms away
from the Depot and it is inside the IOCL Terminal. The siding comprises three
companies BPC, IOC and HPC. The siding has IOC and BPC P/H while HPC has
their P/H in its Depot.

OPERATIONS AT SIDING SECTION

Placement time is the time of completion of the placement in the siding. While
placement is going on, it should be ensured that no material like hoses, buckets are
left on the tracks and the wagons are placed correctly to facilitate hose connections
to the risers. The tank wagons are placed at the siding by Railways. Hence quick
action shall be taken to unload the tank wagons to avoid any demurrage.

Collect card labels from tank wagon pockets, the copy of loading memo from
loading location placed in the manhole covers and mark with chalk on every tank
wagon the product grade, date of placement and company's name (if siding is
shared with OMCs).

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Check if top & bottom seals are intact.

For Tank wagons carrying Aviation products, the procedure outlined in Aviation
Quality Control and Assurance Manual shall be followed (i.e. checking of QCRC,
checking of bottom sample for density and comparing the same with dispatch
density etc.)

For SKO receipts, it shall be ensured that the relevant flash point and Density @ 15
oC information is available before commencement of discharge. The density of the
top sample of the individual tank wagon shall be checked and compared with the
dispatch density @ 15 oC and recorded. If not satisfactory, the tank wagon/s shall
be segregated and concerned department informed.

TANK TRUCK CHECK LIST

1. Explosive license and drawing

2. Calibration Certificate
3. Fitness Certificate
4. Insurance and its validity
5. TREM card
6. Identity card of Driver and helper
7. Driving license
8. Availability of DCPs (10 Kg and 1 Kg)
9. Availability of earthing wire along with crocodile clamp on it
10. Hose Pipe with coupling and electrical continuity
11. To find out for leakage in discharge valve, master valve
12. To find out any gap in Discharge Box
13. To look for the Hinge pin welding in the Discharge box

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14. Gap/Looseness in Dome covers
15. Dome Cover Hinge pin welding
16. To look whether manhole cover is sealed
17. To check for any signs of fresh welding, Hot work
18. Flange Nut welding with a strip on the discharge pipes
19. Spark arrestor
20. Fusible link
21. To check the master switch (300 amp with 4 terminals)
22. To check for the PV valve and fusible cap on Man Hole
23. To check the length of dip Pipe with calibration chart
24. To check for the geometric centre of compartment and subsequent dip
hole.
25. To check for the information on the Emergency panel
26. To check for Lock on Diesel service tank
27. To check for proper conduit of the wiring system
28. Tank Lorry locking system as per Company recommended design
29. Painting as per the standard scheme.
30. To check whether T/L no. Painted on the body
31. Tyre Size and pressure (to be tallied with calibration chart)
32. To check whether Battery is kept in wooden enclosures
33. To check the earthing strip on Tank Body
34. To check the safety belt of Driver and cleaner in tank Truck cabin
35. To check the PPEs of PCVO crew
36. To check the shear section
37. To check for the brazing of wheels on Discharge valve.
38. To check the leaf springs in front and rear.

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MEASURING THE INVENTORY

Measuring of inventories in tanks is done through gauging.

Gauging
Gauging is the process of taking all the necessary measurements in a tank in order
to determine the quantity of liquid contained in it.

It involves dipping for oil and water levels in the tank, observing density and
temperature of product sample drawn from the tank, and observing the tank
temperature. All these operations are to be carried out within a short span of time
to avoid any discrepancy due to temperature variation, if any.

Gauging Equipment
Dip Tape
Dip Bob
Water Finding Scale
Dip Rod for Tank wagon
Dip Rod for Tank lorry
Oil Finding Paste
Water Finding Paste

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MANUAL OPERATION
Introduction

BPCL Hazira Depot is manually operated.

On an average 70 to 90 Tank Trucks are loaded through 8 bays working in one

shift with 18 loading arms every day. The demand for fuel is constant and Sundays
being a holiday for the Depot, the demand is higher on Saturdays as we have 91
ROs for the supply. The tank truck loading operation is carried in one shift.

Tank truck turnaround time

Tank truck turnaround time refers to the sum total of the time spent by a tank truck
inside the Depot starting from entering the gate to exit from the Depot.

The turnaround time is significant because there is a huge demand of the product
from consumers and retail outlets. Any failure to meet the demand would mean
loss of customers to BPCL.

The demand is higher during Saturdays and on the evening of any other holiday.
This would mean more tank trucks would need to be accommodated in a single
day.

More the time spent by a tank truck inside the Depot, the higher the risk that the
driver would over speed to meet the commitment of delivering the product on time.

The various steps a tank truck needs to follow once inside the Depot is as shown
below.

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Document Creation:
Document is created at first and before making the document, the announcement
for the particular TLs takes place.

SAP invoice:
Before all filling operations are started the documentation report is created at S&D.
SAP is responsible for printing the invoice after PDP is received.

Entry of truck:
The trucks first enter into parking area and get their entry time registered. Based on
the same, the trucks are being called. First Come First Serve Queue System is
followed. However, exceptions are made for critical customers. Such trucks that
give prior intimation of the load and owned by ROs are given priority and hence
are allowed to break the queue at entry.

Filling Time:
Driver and cleaner bring TT at the gate. The truck personnel are checked for safety
equipment like helmets, safety shoes and fire extinguisher and if satisfactory, the
truck is allowed inside the Depot.

Once a tank truck enters the Depot, it moves to the respective bay at Gantry for
loading. In case the bay is occupied; the tank truck would wait until the loading is
complete and the bay is empty.

The time required by the tank trucks to fill varies with capacity. For a 20KL truck
the filling time is about 24 to 26 minutes, for a 12KL truck 20.

Tank level checking, locking and signing of documents:

This is the time required to exit from Depot after being loaded and post filling
checking, locking, and signing of documents. After checking, the compartments
are locked to prevent pilferage and theft.

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Post filling, drivers of respective tanker trucks check the level of each
compartment to ensure desired quantity of fuel.

The time to exit would include all these activities.

Exit Gate: After collecting the post loading documentation the driver proceeds to
security gate and presents its security card to automated exit gate.

SUGGESTIONS

1. Skills of Cleaners should be improved

At times cleaners are not through with all the required activities to be carried
out at the Gantry. In such cases, drivers have to work double. These work
include, placing the loading arm, removing them, operating the automatic
filling system and checking dips of compartments. This increases both post
and pre filling time.

Total Time saved = 2 to 3 minutes in pre filling time and 5 to 7 minutes in

post filling time. So total time saved will be 7 to 10 minutes on one bay

2. After the filling is done, levels of tankers are measured to confirm whether
desired quantity is filled. The accuracy of filling is doubted still newer
mechanisms are in use. Officers usually inspect the dip level for each
compartment, which takes 2 to 3 minutes for each tank truck.

Time saved = Thus Depot can save around 2-3 minutes behind each 12/ 20/
25 KL tanker.

3. Checking at Security: if Dip rod is at place

In the check list of security at main gate, check of dip rod place should be
included.

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4. Lock opening process can be done before entering the gantry area

Lock operations done at the Gantry can be shifted near security gate or in
parking area. Sometimes the Officer/Staff who provide key is unavailable
which restricts the opening of the locks and results in late start of filling
process. Shifting the opening process at gate will insure that only those TTs
which are ready to be filled will enter into the Gantry area.

This will increase frequency of TTs to enter the bay.

Suggestions

1. Notification to Drivers through SMS

This will help them to utilize their time when there is delay in allocation. It will
also reduce the number of queries at the S&D window.

2. Reporting of TTs through SMS

3. Reporting of PDP trough SMS
4. Installation of safety

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 HAZIRA DEPOT

INTRODUCTION

The Hazira Depot is situated in Hazira mainly in the outskates of Suart. It is one of
the fifty two depots of BPCL in India and one of the eighty in western region of
India.

It was commissioned in year 1996 and is being operated since 2003. It mainly
serves following districts of Gujarat:

Surat
Tapi
Narmada
Bharuch
Valsad
Navsari
Daman
Vapi

RAILWAY SIDING

It is a railway owned area tank wagons are parked and decantation is done. A
700m long track is being there in the IOC Terminal.

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PROCESSES AT HAZIRA DEPOT

Planning
Planning is done by Supply and Dispatch section. Planning is mainly based on
following:

1. Ullage The total holding capacity left in the inventory(Tanks)

2. Actual and average selling(Demand )
3. In transit lead time Lead time of receiving products from different
locations.

Receipt and Decantation

3 kilometer long pipelines are installed from railway siding to the Depot. It is a job
with high risk.
Total time allocated to decantation is eight hours.

Railway demurrage
If decantation is not done inside the time limits then the railways charges
demurrage for it. Demurrage charges per hour increases with time.

DESPATCH
Dispatch is done through tank Lorries. Tanks Lorries are filled at TLF gantry with
help of TLF pumps.

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SAFETY

Fire Fighting
Firefighting is the most important aspect in setup of any infrastructure related to oil
and gas industry. In setup of any terminal, firefighting provisions are installed first.
Firefighting facilities are audited and get clearance then only any further
development in the project can take place.

Monthly firefighting drill is conducted to train staff and officials on a regular basis.

The safety of BPCL follows the triangle principle.

Fire Engine Area

There are three fire engines in the fire engine section each of 273 Kiloliter per
hour.

Water Tanks
There are two water tanks installed at the BPCL Hazira Depot.

WATER TANK DETAILS

TANK NUMBER HOLDING CAPACITY
12 1200
13 1200

Water pipes
These are the pipes which circulate water in every corner of the Depot. These are
also installed on the periphery of all tanks.

Water pipes are painted in red while Pipes which can carry both water and foam
are painted yellow.

Foam generator
These are the installations used to generate foam mixture by mixing water air and
foam from foam barrel. These are very helpful in firefighting.

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 Fig: Basic structure of a foam generator

MEFGs
Medium Expansion foam generator

There are two types of foam generator.

1. Portable
2. Installed

Foam Barrel Section

It contains foam barrel for firefighting. Total required liters for BPCL Hazira
Depot is 5.3KL

The type of foam is AFFF (Aqueous Film Forming Foam). AFFF (Aqueous Film
Forming Foam), used on A and B fires and for vapor suppression. It is the most
common type in foams. Foam barrels are used on first in First out (FIFO) basis for
consumption. Foam in the barrels is generally stirred from time to time by rotating
the barrel.

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Hosepipe boxes
These boxes contain hosepipe and nozzles. These hosepipes are connected to water
pipelines for use. There are different types of nozzles for different requirements.

Fire extinguisher
These are handheld cylinders that are used to extinguish fire. Based on requirement
there are different types of fire extinguisher.

DCP 10 kg 75 kg powder

CO2 2, 4.5 and 9 kg

OTHER SAFETY INSTALLATION AND EQUIPMENT

Hydrocarbon detectors
Total number of HSD is four. Out of which three are open and one is point type.

Panel for all the detectors are common type. All the sensors are calibrated with
propane.

Earth pits
These are to be used for discharge of static electricity present at any equipment of
area.

Label and signs

Labels and signs are used for many purposes. Such as instructions of handling
certain products, security signs, prohibited area etc.

PPEs (Personal Protective Equipment)

Personal protective equipment consists of equipment designed to protect the
wearer's body from injury. PPEs may include protective clothing, helmets, goggles,
or other garments or.

27
Major PPEs are as follows:

1. Gloves

Cotton

Rubber

2. Safety belt (Retractable type)

Firefighting PPEs
Emergency escape set
It will help to escape from a danger to life and health atmosphere.

SCABA set (Self-contained air breathing apparatus)

SCABA is a device worn by rescue workers, firefighters, or any other person to
provide breathable air in danger to life and health atmosphere. The breathing set is
not dependent on a remote supply thats why it is called "self-contained".

OTHER IMPORTANT EQUIPMENTS

Valves

PV valves spring and dead weight types

Gate Valves

Plug Valves

Non-Return Valves

Relief Valve

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Plug Valve

Pressure Balanced Plug Valve

MOV valve

Diaphragm valve

Ball valve

Remote Operated Shut off valve

Tank wagons
Product receipt is done through Tank wagons at Kota Depot. Bogie Tank wagons
with Pneumatic Brakes (BTPN) are generally used.

Tank Lorries
These are used for dispatch of product to different ROs (Retail Outlets).

GAUGING
Gauging is the process of taking all the necessary measurements in a tank in order
to determine the quantity of liquid contained in it.

It involves dipping for oil and water levels in the tank, observing density and
temperature of product sample drawn from the tank, and observing the tank
temperature. All these operations are to be carried out within a short span of time
to avoid any discrepancy due to temperature variation, if any.

29
GAUGING TERMS
Gross Dip
It is the height of liquid column inside the tank, i.e. height of oil column plus
height of water column, if any at the bottom. It is the distance from the datum
plate/tank bottom up to the oil surface level.

Water Dip
It is the height of water column inside the tank. Presence of water may be due to
flushing of pipelines during tanker receipts, receipt of product containing water, or
water accumulated due to condensation.

Ullage Dip
Also called as Outage, it is useful where accurate dipping is not possible. E.g. in
tankers' tanks where there is a network of pipeline causing obstruction, in case of
heavy formation of sludge on the datum plate of the tank, or due to change of proof
level due to flexing of bottom plates. Ullage is the distance from the oil surface to a
fixed reference point at the dip hatch. For example, if a tanker's tank has a total
height of 42 feet to the top of the dip hatch, Ullage of 4 feet would correspond to a
depth of 38 feet of oil in the tank.

Dip Hatch
Provided for dipping, it is an opening on the roof above the datum plate, and within
2 feet of the tank shell to avoid effect of flexing of roof plates which will alter the
proof level. Sampling is also carried out through the dip hatch if temperature hatch
is not provided.

Datum Plate
It is a 6 mm. thick plate, welded to the tank bottom directly under the dip hatch.
The purpose is to provide a flat surface for accurate dipping and to prevent pitting
of the bottom plate caused by frequent striking of the dip bob. The datum plate
represents the "zero level" in the tank calibration chart.

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Temperature / Sample Hatch
It is a central opening on the roof for observing temperature of product in the tank
or that of product sample drawn from the tank without the influence of the tank
shell temperature. If not provided, dip hatch is used for the purpose.

Reference Point
It is a point marked on the dip hatch when the tank is calibrated; for accuracy, dips
are to be taken by holding the dip tape at this point.

Proof Level
It is the distance from the reference point to the datum plate. Proof level is likely to
change in case of sludge formation in the tank, flexing of roof plates or flexing of
tank bottom plate with the change in the height of liquid column, etc. For accuracy
in dipping, it is essential that same proof level is maintained. For ready reference
during dipping, proof level shall be indicated near the dip hatch.

Dip Point
It is the point on the datum plate touched by the dip bob when dipped at the
reference point.

Safe Height
It is the distance from the datum plate to the point corresponding to volume of the
liquid equivalent to safe capacity of the tank. This is indicated near the dip hatch
for ready reference and particularly useful during topping up of the tank.

Drip Level
It is a level where the product just touches the entire circumference of the tank
shell. It is not advisable to operate the tank below this level as the calibration chart
will not be quite accurate. In cases where water bottom is maintained in tanks, the
water level shall be maintained above the drip level; in case this is not possible, the
water dip shall be maintained strictly at a constant level to avoid any distortion in
receipt/ withdrawal figures.

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Dead Stock
It is the quantity of product that remains in the tank at a point where suction fails
generally 40 cm above the tank bottom.

Stop Dip
This is a predetermined dip at which operation of receipt/delivery of product is to
be stopped. Stop dip is worked out based on quantity to be received/delivered.

Gross Capacity
It is the volume of product up to the top curb angle.

Safe Capacity
It is the gross capacity of the tank less 5%.

Water Bottom
It is a layer of water at the bottom of a tank, of such depth as to completely cover
the bottom. It is maintained only for white oil tanks where the receipts are through
water flushing lines. Quality sensitive products such as ATF and Black Oil tanks
shall never have water bottoms.

GAUGING EQUIPMENTS
Dip Tape
A steel tape used for measuring the depth of oil or water in a container. It is
graduated on one face in metric units and marked in meters, centimeters and
millimeters. The depth of etching of the markings is between 0.01-0.03 mm, with
major scale marks etched into a raised bright tablet and minor marks raised and
bright.

The tape is 13 mm. wide and 0.25 mm. thick, with length ranging from 10 to 20
meters depending upon the height of the tank to be dipped.

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Dip Bob
Attached to the dip tape, it is a cylindrical brass body of the torpedo pattern,
tapering at each end for easy penetration through the sludge, if any, and for
sensitivity of "touch". It is of sufficient weight to keep the tape taut.

It is designed to be used in conjunction with the dip-tape, to which it is

complementary in its graduation, i.e. zero marking of the tape starts from the
bottom end of the bob. It is graduated in metric units of length which corresponds
with the graduations of the dip-tape which is to be used, and marked in cm. and
mm. on a flat face about 12 mm wide along its length. It is about 15 cm in length
and 3 cm in diameter.

Water Finding Scale

It is of brass and 30 cm long and is used in place of the bob if either the water or
the oil level cut is between the bob and the tape.

Dip Rod for Tank wagon

Quadrilateral dip rod made usually of aluminium is used for measuring the height
of liquid column in a tank wagon. It is 3 meters in length and about 12 mm2 thick,
and graduated in cm. and mm with smallest division of 2 mm. A 5 cm long brass
piece is fitted at the lower end for protection against wear and tear.

Dip Rod for Tank lorry

Quadrilateral dip rod for tank lorry is of brass or aluminium and is stamped by
Weights and Measures Department. It bears markings of proof level, dip level &
the code for the quarter in which the tank lorry is calibrated. Each compartment of
the tank lorry has different levels and as such separate dip rods are used for each
compartment. In some States, there is a practice to use a single dip rod for all the
compartments, with markings for each compartment on each of the four sides of
the dip rod.

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Oil Finding Paste
A prominent oil level cut in the form of a thin film is obtained by applying a thin
layer of oil finding paste, a chemical substance, on the dip tape. This helps in
getting an accurate oil dip.

Water Finding Paste

A paste containing a chemical which changes colour in contact with water, without
affecting the product. It is used for indicating the level of free water in the tank.

TANK WAGONS
Product receipt is done through Tank wagons at Kota Depot. Bogie Tank wagons
with Pneumatic Brakes (BTPN) are generally used.

Fittings in Conventional Broad Gauge (BG) Tank wagons

Body
Tank wagon is a horizontal cylindrical steel tank mounted on a standard railway
wagon chassis and supported on cradles specially provided for the purpose.

Manhole
It is at the center on the top of the tank wagon and facilitates loading of product
into the tank wagon. During transit, it is closed with the manhole cover, which
works on a hinge joint and has the provision of as many as eight nut-bolts for
firmly bolting it down. On the underside of the cover is a groove in which is
embedded a packing material like asbestos rope/neoprene to provide gas-tight
condition and thereby prevent escape of product vapor during transit.

Manhole Cover Assembly

Manhole cover assembly is provided in some of the tank wagons. Fittings such as
Fill Pipe, Dip Pipe, Air Vent and Master Valve Spindle are part of the manhole

34
cover assembly. It is bolted down to the neck of the tank wagon. During
inspection/repairs, the entire assembly can be removed to facilitate inspection as
well as entry into the tank wagon.

Fill Pipe
One of the fittings of the manhole cover assembly, the fill pipe extends right down
to within 10 centimeters of the bottom of the tank wagon. The loading hose/arm is
inserted into the fill pipe, which being extended almost to the bottom of the tank
wagon, eliminates the possibility of splashing during top loading and thereby
prevents excessive generation of static charges. Fill pipe is closed with a threaded
cap to prevent overflow of product during transit.

Some of the tank wagons are open type, i.e. without the manhole cover assembly
and thus without the fill pipe. In such tank wagons, a detachable fill pipe is used
during filling.

Master Valve
Master valve is seated internally at the bottom of the tank wagon, just above the
bottom discharge valve, and operated through a spindle extending up to the
manhole. It provides an additional safety measure - in the event of any damage to
the bottom discharge valve, the contents of the tank wagon do not leak out.

Dip Hole
Dip hole is provided on the manhole cover assembly through which a dip rod is
inserted into the tank wagon for measuring the product height. It is closed with a
threaded plug to prevent overflow of product during transit. In tank wagon without
the manhole cover assembly, the dip rod is introduced directly into the open
manhole.

Air Vent
A part of the manhole covers assembly, it is basically provided to facilitate the
connection of the tank wagon with the vapor return line during loading/ unloading.
However, as the vapor return line is an outdated feature, It is generally used for
ventilation during loading and controlled by a lever.

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Safety Valve
A safety valve of co-axial type, set at 5 psi, is provided on the top at the side of the
manhole in some of the tank wagons. Class `A' products can be loaded only in such
tank wagons.

Baffle Plates
Baffle plates with suitable apertures at the bottom, top and centre are provided
internally to break the surge of the product while in motion and thus minimise
static charge generation.

Bottom Discharge Valve

Fitted externally at the bottom of the tank wagon, it is a simple gate valve provided
with a standard 80 mm. diameter flange to facilitate the connection of the tank
wagon to the unloading point by means of a standard 80 mm. dia. hose.

Hand Brake
Every tank wagon is provided with a manually operated hand brake. It is useful to
arrest movement of the tank wagon due to vibrations during loading/unloading
operations and thus prevent snapping of the loading/unloading hose.

Leaf Springs
Leaf springs of the tank wagon bend when the tank wagon is empty, and become
flat when the tank wagon is fully loaded. Thus leaf springs provide an additional
indication as to whether the tank wagon is empty or loaded.

Ladder
Every tank wagon is provided with a ladder. It is bolted to the chassis and to the
top of the tank wagon, and facilitates operating personnel to climb the tank wagon.

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Fittings in Meter Gauge (MG) Tank wagons
Fittings in MG tank wagons are similar to that in conventional BG tank wagons

Fittings in Bogie Tank wagons with Pneumatic Brakes (BTPN)

BTPN tank wagons have two manholes and two bottom valves. As there is little
space below the tank wagon, each bottom valve is extended by means of a pipe
vertically downwards and then branching off horizontally to either side, for ease of
connection. All other features remain the same as that of BG tank wagons. All
BTPN tank wagons are fitted with the Safety Valve. Fish Belly type BTPN tank
wagons have an extended bottom, resembling like belly of a fish, thus increasing
their capacities.

TANK WAGON UNLOADING PROCEDURES

On Placement
Placement time is the time of completion of the placement in the siding. While
placement is going on, it should be ensured that no material like hoses, buckets are
left on the tracks and the wagons are placed correctly to facilitate hose connections
to the risers. The tank wagons are placed at the siding by Railways. Hence quick
action shall be taken to unload the tank wagons to avoid any demurrage.

Collect card labels from tank wagon pockets, the copy of loading memo from
loading location placed in the manhole covers and mark with chalk on every tank
wagon the product grade, date of placement and company's name (if siding is
shared with OMCs).

Check if top & bottom seals are intact.

For Tank wagons carrying Aviation products, the procedure outlined in Aviation
Quality Control and Assurance Manual shall be followed (i.e. checking of QCRC,

37
checking of bottom sample for density and comparing the same with dispatch
density etc.)

For SKO receipts, it shall be ensured that the relevant flash point and Density @ 15
oC information is available before commencement of discharge. The density of the
top sample of the individual tank wagon shall be checked and compared with the
dispatch density @ 15 oC and recorded. If not satisfactory, the tank wagon/s shall
be segregated and concerned department informed.

Position safety boards - "No Shunting : Tank wagons under Discharge", "No
Smoking", "No Matches", "No Naked Fire" - on the tracks in front of the first tank
wagon, on each spur.

Position fire extinguishers and sand buckets - Portable extinguishers shall be

located at convenient locations and shall be at all times readily accessible and
clearly visible. The maximum running distance to locate an extinguisher shall not
exceed 15 meters. The top of extinguisher shall not be more than 1.5 meters above
floor level. 1 No extinguisher shall be located for every 50 meters length and 1 No
75 kg DCP mobile unit in each siding. Sand buckets should be located with covers
to prevent entry of water and sand should always be dry.

Depending upon the no. of tank wagons, unloading hoses shall be carried from the
stores along with equipment such as tee-connections, trays, spanners, etc.

Tank wagons shall be secured by operating the hand brakes.

Tank wagons shall be bonded with the decantation pipeline by means of an

electrically continuous earthling wire (at least one in six wagons should be
bonded).

Check and ensure that all valves along the entire length of the decantation pipelines
are in closed position.

Use ladder of the tank wagons for going up and down. Jumping from one tank
wagon to another is not allowed (not applicable in case of BTPN tank wagons).

38
Connection

Wait until the tank wagon Nos. as mentioned in card labels and loading memo
copy are matched with the despatch advice.

Do not slam the manhole covers while opening.

While opening the bottom flanges, position tray/ buckets below for collection of
spillage, if any.

While one end of the hoses can be connected to the flanges of the tank wagon
bottom discharge valves one after the other, the other end of the hose shall be
connected to the decantation point immediately after observing the dip and sample
of the product in the tank wagon; this will rule out the possibility of the tank
wagon being connected to the wrong decantation point, resulting in contamination.
This is the most vital aspect in the entire tank wagon unloading operations. Only
white oils hoses should be connected to white oil wagons and aviation hoses to
aviation wagons. Black oil hoses should not be used for white oil. Hoses used for
Aviation product shall be color coded and kept blanked after use.

Hose shall be connected at the either ends by minimum four nut-bolts and a sound
cardboard packing (preferable to use CAF packing).

Gauging

Particulars of tank wagon oil dip, water dip, product sample for observing color for
grade identification, temperature, density, placement and release time (after
completion of discharge), shall be entered in ink directly in the appropriate
columns of Tank wagon Receipt Book.

Water, if any, be shall drained out from the bottom discharge valve. However, in
case of abnormally high quantity of water, matter shall be taken up with
controlling office for advice.

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Discharge

Discharge is commenced by operating the master valve and the bottom valve of the
tank wagon as well as the valve on the decantation point, re-ensuring that the hose
is connected to the correct decantation point.

Closing

On completion of discharge of the product in a tank wagon, promptly close valve

on the decantation point; this will prevent any return flow of the product into the
tank wagon due to backpressure.

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REFERENCES

1. Manuals
a. Product manual
b. HSSE manual
c. OISD
d. Operations manual

2. Information from BPCL officers:

Mr Shiv Ramkrishna (OPS I/C)

Mr. Rahul Kachare (Asst Mgr OPS)

Mr. Ashok Meena (Asst Mgr HSSE)

Mr. Ganesh Salvi (Ex. OPS)

Mr. Dattatraya Sahane (Asst Mgr E & P)

3. Audit reports
4. Batch reports
5. Quality assesment reports from the lab

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