PRESENTATION

ON

TANK FARM
OPERATIONS
 TANK FARM OPERATIONS

 TYPES OF TANKS
 ADVANTAGES & DISADVANTAGES OF DIFFERENT TYPES OF
TANKS
 FITTINGS ON DIFFERENT TYPES OF TANKS
 SAFE OPERATING PRACTICES FOR FLOATING ROOF TANKS
 CRITICAL LEVEL OF FLOATING ROOF TANKS
 RECALIBRATION OF TANKS - EXCISE REQUIREMENTS
 SAFTEY CHECK-LIST FOR TANK FARM OPERATIONS
 QUALITY CONTROL ASPECTS DURING :
A) PIPELINE RECEIPT B) STORAGE
 QUALITY MONITORING
 RESPONSIBILITY AREAS FOR MAINTAINING THE QUALITY OF
PRODUCTS DURING :
A. TRUNK PIPELINE TRANSFERS FROM REFINERY TO TAP
OFF POINT OF MARKETING COMPANY
B. LOCAL PIPELINE TRANSFER FROM REFINERY TO
MARKETING COMPANY
TANK FARM OPERATIONS ( Contd. )

 PRECAUTIONARY MEASURES FOR TANK FARM OPERATIONS

 PRESSURE VACCUM VALVE

 OIL-WATER SEPARATOR

 GAUGING & TANK QUANTITY CALCULATION

 PIPELINE TRANSFERS

 STOCK-LOSS : CAUSES & METHODS OF CONTROLLING STOCK-

LOSS

 CONTAMINATION & DETERIORATION OF PRODUCT

TANKS FOR PETROLEUM PRODUCTS
 TANKS FOR PETROLEUM PRODUCTS
 CYLINDRICAL IN SHAPE
 GENERALLY MADE OF MILD STEEL
 INSTALLED UNDERGROUND OR ABOVE GROUND

 UNDERGROUND TANKS
 CYLINDRICAL & HORIZONTAL
 GENERALLY RESTRICTED TO CAPACITY OF 200 KL
 INSTALLED IN EARTH OR MASONRY CONCRETE PIT
 HELD IN POSITION BY METAL RINGS STRAPPED
AROUND THE BODY OF THE TANK.
 ONLY FITTINGS ARE VISIBLE.
 ADVANTAGES OF UNDERGROUND TANKS
 NEGLIGIBLE VARIATION IN PRODUCT TEMPERATURE
 LESSER SAFETY DISTANCES REQUIRED
 NO BUND ENCLOSURES REQUIRED
 RECEIPT POSSIBLE WITHOUT USE OF PUMP

 DISADVANTAGES
 SLOWER DELIVERIES
 SUCTION PROBLEM FACED DURING HOT WEATHER OR
DEFECTIVE FOOT VALVE
 EXCESSIVE CORROSION
 POSSIBILITY OF FLOATING DURING HEAVY RAINS, IF
EMPTY OR WITH LOW STOCKS
 SMALL CAPACITY
FITTINGS ON UNDER GROUND TANKS

 GENERALLY TWO MANHOLES ON THE TOP CLOSE TO

EITHER ENDS

 AIR-TIGHT MANHOLE COVERS

 VENT PIPE ABOUT 4 METERS HIGH

 VENT OR PRESSURE VACCUM (PV) VALVE

 DIP HATCH

 PERFORATED FILL PIPE EXTENDING ALMOST UPTO

BOTTOM OF THE TANK
 ABOVE GROUND TANKS

 HORIZONTAL ABOVE GROUND TANKS

 INSTALLED ON PEDESTALS

 SMALLER CAPACITY (UPTO 200 KL)

 VERTICAL ABOVE GROUND TANKS

 RESTED ON SAND / RCC FOUNDATION PADS

 MADE OF MILD STEEL PLATES

 WITH EITHER FIXED OR FLOATING ROOF

 DESIGNED AS PER API 650 AND IS-803

FITTINGS ON FIXED ROOF TANKS
FITTINGS ON FIXED ROOF TANKS
 MANHOLES
 DIP HATCH
 DATUM PLATE
 TEMPERATURE / SAMPLE HATCH
 INLET / OUNET
 VENTS
 PV VALVE
 WATER DRAW OFF LINE
 SAFETY RAILINGS
 STAIRWAYAS
 EARTHIING CONNECTIONS
 EXPANSION LINE
 MANOMETER
 FIRE WATER SPRINKLER SYSTEM
 FOAM POURER
 AUTO LEVEL GAUGES
FIOATING ROOF TANKS
 ROOF FLOATING ON THE SURFACE OF THE LIQUID
STORED
 ROOF IN COMPLETE CONTACT WITH THE LIQUID
SURFACE
 AT LOW LEVELS THE ROOF RESTS ON ADJUSTABLE LEGS
 THESE TANKS ARE GENERALLY USED FOR LIGHT
HYDROCARBONS SUCH AS MS. NAPHTHA. HEXANE, ETC.

ADVANTAGES COMPARED TO FIXED ROOF TANKS

 ELIMINATES PRODUCT LOSS THROUGH EVAPORATION
 SAFE, AS NO VAPOUR ACCUMULATED UNDER THE ROOF
 INTER CHANGEABILITY EASY TO CLASS “A” SERVICE
WITHOUT CHANGE IN FITTINGS
 LESS AIR POLLUTION, AS PRACTICALLY NO VENTING.
DISADVANTAGES AS COMPARED TO FIXED ROOF
TANKS
 HIGH COST OF CONSTRUCTION
 HIGH COST OF MAINTENANCE
 HIGH DEAD STOCK
 NEEDS CLOSER SUPERVISION DURING OPERATION
 POSSIBILITY OF ROOF SINKING /TILTING DUE TO
LEAKS / HEAVY RAINS
 AT LOWER LEVELS HEAVY ACCUMULATION OF
VAPOURS ON THE ROOF .
FITTINGS ON FLOATING ROOF TANKS
 ADJUSTABLE LEGS
 FOAM SEAL
 ROOF BLEEDER VENTS
 ROOF WATER DRAIN
 EMERGENCY DRAIN
 ROOF LADDER
 WIND GIRDER
 GAUGEWELL PIPE
 MANHOLES ON SHELL & ROOF
 GAUGE HATCH WITH COVER
 DATUM PLATE
 PRODUCT INLET / OUTLET NOZZLE
 TANK WATER DRAIN VALVE
 FOAM NETWORK
 SPRINKLER
 LANDING PLATFORM
 STAIRWAY
 EARTHING
 EXPANSION LINES
VIEW OF FLOATING ROOF TANK
SAFE OPN.OF FLOATING ROOF TANKS
1) OPERATION OF FLOATING ROOF TANKS NEEDS CLOSER
SUPERVISION AND ADDITIONAL MEASURES.

2) ACCESS TO FLOATING ROOF SHALL BE RESTRICTED.

3) WHENEVER ANY PERSON IS ALLOWED ON THE ROOF, KEEP

STAND BY PERSON ON LANDING PLATFORM.

4) CHECK FOR PETROLEUM VAPOUR ON THE ROOF. USE

BREATHING APPARATUS WHENEVER NECESSARY.

5) NO ONE SHOULD BE ALLOWED ON THE FLOATING ROOF

DURING PRODUCT RECEIPT OR WHEN ROOF IS AT LOWER
LEVELS.

6) IF ABSOLUTELY NECESSARY TO GO ON THE ROOF, THE

PERSON SHALL WEAR BREATHING APPARATUS AND
STANDBY PERSONS ON LANDING PLATFORM.
 SAFE OPN. OF FR TANKS (contd.)
7) KEEP GAUGE HATCHES OR OTHER OPENINGS CLOSED EXCEPT
FOR ESSENTIAL OPERATIONS

8) GAUGE HATCH SHALL NOT BE SLAMMED WHILE CLOSING. IT

SHOULD NOT BE LEFT OPEN AFTER GAUGING .

9) GAUGING SHOULD NOT BE CARRIED OUT DURING THUNDER

STORM OR LIGHTN1NG.

10) DEVELOP PROCEDURES TO PREVENT OVERFILLING. IF FITTED,

CHECK HIGH LEVEL ALARMS MONTHLY FOR OPERABILITY.

11) ROOF SHOULD ALWAYS REMAIN IN FLOATING CONDITION

WHILE TANK IS BEING FILLED OR EMPTIED OUT. DO NOT KEEP
THE TANK IN SEMI FLOAT CONDITION
 SAFE OPN. OF FR TANKS (contd.)

8) KEEP THE ROOF AFLOAT DURING NORMAL OPERATION.

LANDING OF ROOF CREATES VAPOUR SPACE SO THAT THE
INHERENT SAFETY ADVANTAGES OF FLOATING ROOF TANKS
ARE LOST.

9) WITHDRAWAL OF PRODUCT FROM THE TANK SHALL BE

AVOIDED WHEN THE ROOF IS EITHER RESTING ON ITS PIPE
SUPPORTS OR IS IN SEMI FLOAT CONDITION, AS THIS RESULTS
IN APPARENT PRODUCT LOSS.
 SAFE OPN. OF FR TANKS (contd.)
14) IF THE PRODUCT IS TO BE WITHDRAWN UP TO THE DEAD
STOCK LEVEL, ENSURE THAT ALL PIPE SUPPORTS ARE IN
RIGHT POSITION AND ROOF BLEEDER VENTS ARE IN
OPERATING CONDITION

15) IF AT ANY TIME THE ROOF GETS STUCK OR LIKELY TO GET

STUCK, TANK SHALL NOT BE OPERATED TILL IT IS
INSPECTED BY ENGG PERSONNEL

16) REMOVE PROMPTLY ANY ACCUMULATION OF OIL ON A ROOF

DECK. THE FIRE PROTECTION SYSTEM IS DESIGINED FOR RIM
FIRE ONLY AND NOT FOR LARGE EXPOSED SURFACES OF OIL

17) KEEP THE SUMP FOR THE CHECK VALVE OF THE ROOF DRAIN
SYSTEM FREE FROM SCALE OR DEBRIS, WHICH CAN PLUG
THE CHEK VALVE AND ROOF DRAIN INLET.

18) IF OIL APPEARS AT THE ROOF DRAIN OUTLET, CHECK THE

ROOF IMMEDIATELY TO ESTABLISH ITS SOURCE.
CRITICAL LEVEL OF FLOATTNG
ROOF TANKS
DURING OPERATION AND GAUGING OF FLOATJNG ROOF
TANKS:

 IT IS NECESSARY TO KNOW THE POSITION OF THE ROOF

i.e. WHETHER IT IS FULLY FLOATING, PARTIALLY
IMMERSED OR RESTING ON LEGS

 WHEN ROOF IS FULLY FLOATING, IT DISPLACES ITS OWN

WEIGHT OF OIL AND THE TANK CAN BE GAUGED

 WHEN THE ROOF IS PARTIALLY IMMERSED, ITS ACTUAL

DISPLACEMENT IS UNCERTAIN. SO THE GAUGING OF THE
TANK SHOULD NOT BE UNDERTAKEN, AS OIL QUANTITY
CALCULATION WILL NOT BE ACURATE.

 WHEN ROOF IS RESTING ON LEGS, THE TANK IS LIKE

CONVENTIONAL CONE ROOF TANK AND THUS TANK CAN BE
GAUGED CORRECTLY. HOWEVER THERE WILL BE LOT OF
VAPOUR LOSS IN THIS CONDITION.
RECALIBRATION OF TANKS – EXCISE
REQUIREMENTS
GOVERNMENT OF INDIA HAS LAID DOWN THE FOLLOWING
PROCEDURE FOR RECALIBRATION OF TANK :
VALIDITY OF CALIBRATION CHART
 BESIDES CPWD, WEIGHTS, & MEASURES DEPT. OF THE
STATES / UNION TERRITORIES HAVE ALSO BEEN APPROVED
FOR CALIBRATION OF STORAGE TANKS.
 FOR TANKS WITH WATER BOTTOM, RECALIBRATION
SHOULD BE CARRIED OUT AFTER TEN YEARS
 FOR TANKS WITH OIL BOTTOM, RECALIBRATION SHOULD
BE CARRIED OUT AFTER FIVE YEARS.
 TANK FARM OPERATIONS
1) HISTORY SHEET OF THE TANKS SHALL BE AVAILABLE AT THE
LOCATION.
2) FOLLOWING DETAILS SHALL BE INDICATED ON THE TANK SHELL
NEAR STAIRCASE:
1) TANK NO., PRODUCT GRADE, CAPACITY IN LITRES, DATE LAST
CLEANED AND DUE DATE OF NEXT CLEANING, DATE LAST
CALIBRATED AND DATE OF LAST EARTH TEST. TANK NO. AND
GRADE SHALL BE INDICATED BOLDLY ON THE UPPER STRAKE
SO AS TO BE VISIBLE FROM A DISTANCE.
2) IN CASE OF UNDERGROUND TANKS, THE ABOVE DETAILS
SHALL BE INDICATED ON A BOARD DISPLAYED ON/NEAR THE
VENT PIPE.
3) TYPE OF VALVE, i.e. INLET, OUTLET, PRODUCT DRAIN, WATER
DRAIN, SHALL BE INDICATED ON THE TANK SHELL BEHIND
THE RESPECTIVE VALVES, WITH THE DIRECTION OF OPENING
AND CLOSING MARKED WITH ARROWS.
 TANK FARM OPERATIONS

1) TANK EARTH RESISTANCE SHALL BE CHECKED AT

LEAST ONCE IN SIX MONTHS AND SHALL BE MAXIMUM 7
OHMS.
2) VENTS OF THE TANK SHALL BE CHECKED ONCE A
QUARTER TO ENSURE THAT THEY ARE FREE OF ANY
CLOGGING.
3) SETTINGS OF PV VALVES SHALL BE CHECKED EVERY 6
MONTHS. THE SETTINGS IN TERMS OF W.G. FOR
PRESSURE AND VACUUM RESPECTIVELY SHALL BE 21. 5”
AND 2.5” FOR ABOVEGROUND TANKS AND 10” AND 1” FOR
UNDERGROUND TANKS.
4) SAFE HEIGHT (CORRESPONDING TO 95% OF THE TANK
CAPACITY) AND PROOF LEVEL SHALL BE INDICATED
NEAR THE DIP HATCH.
 TANK FARM OPERATIONS (Contd.)

6) MANOMETER SHALL BE TOPPED UP IF REQUIRED AND ENSURE THAT

IT IS ALWAYS FILLED WITH WATER, PREFERABLY COLOURED FOR
BETTER CONTRAST.

7) DURING MONSOON OR IN ANTICIPATION OF HEAVY RAINS,

UNDERGROUND TANK SHALL BE LEFT FULL WITH PRODUCT TO AT
LEAST 25% OF THE TOTAL CAPACITY TO AVOID ITS FLOATING.

8) BUND ENCLOSURE DRAIN VALVE SHALL BE KEPT IN CLOSED

POSITION EXCEPT WHEN DRAINING OUT RAIN WATER

9) BUND AREA SHALL BE CLEAR OF VEGETATION.

10) BUND WALL SHALL BE INTACT WITHOUT ANY GAPS.

 TANK FARM OPERATIONS (Contd.)

6) TANKS SHALL BE CLEANED EVERY 5 YEARS (EVERY YEAR IN CASE OF

ATF AND EVERY 2 YEARS IN CASE OF HEXANE) OR MORE
FREQUENTLY, DEPENDING ON THE NEED, LIKE CHANGE IN PRODUCT,
EXCESSIVE SLUDGE FORMATION, ETC.

7) AN ALL LEVEL SAMPLE AFTER RECEIPT OF FIRST PARCEL IN A

NEWLY COMMISSIONED TANK / AFTER GRADE CHANGE OVER SHALL
BE SUBJECTED TO BATCH FORMATION TEST.
 TANK FARM OPERATIONS (Contd.)
13) QUANTITY OF SLUDGE REMOVED DURING TANK CLEANING
SHALL BE CERTIFIED BY THE LOCATION-IN-CHARGE AND
APPROVAL SOUGHT CONCURRENCE IN LINE WITH MANUAL OF
AUTHORITIES. THEREAFTER, IT SHALL BE DISPOSED OFF
AFTER CHECKING FOR ANY LOCAL REGULATION
PROHIBITING BURIAL OF SLUDGE.

14) SLOT-SLIT DIPPING DEVICE SHALL BE FITTED ON VOLATILE

PRODUCT TANKS. IT IS A FITTING WITH AN OPENING JUST
SUFFICIENT TO ACCOMMODATE THE WIDTH AND THICKNESS
OF THE DIP TAPE AND THEREBY PREVENT LOSS OF VAPOUR
DURING GAUGING.

15) ONLY ONE TANK SHALL BE OPERATED AT A TIME FOR ONE

PARTICULAR OPERATION, EXCEPT IN AN EMERGENCY
SITUATION OR FOR VALID REASONS (NORMALLY LOCATION
SPECIFIC).
 TANK FARM OPERATIONS (Contd.)
13) INTERMEDIATE DIPS SHALL BE TAKEN AT THE END OF THE
SHIFT OR IF A TANK IS USED FOR ANOTHER ACTIVITY DURING
THE DAY TO ASSESS THE STOCK VARIATIONS DURING THE
OPERATION.

14) ALL TANKS SHALL BE GAUGED AT THE END OF THE DAY AND
BOOK STOCKS UPDATED ACCORDINGLY.

15) TANKWISE STOCK VARIATION SHOULD BE WORKED OUT FOR

EACH PRODUCT AND ANY ABNORMAL VARIATION (MORE
THAN THE SET TARGET) SHOULD BE INVESTIGATED.

16) ZONE / RO SHOULD BE KEPT ADVISED OF THE ABNORMAL

VARIATION AND CORRECTIVE ACTION TO BE TAKEN.
 TANK FARM OPERATIONS (Contd.)
18) ONCE A WEEK, ON A PARTICULAR DAY, ALL TANKS - DISTURBED
AND UNDISTURBED SHALL BE GAUGED AND BOOK STOCKS
UPDATED ACCORDINGLY. ANY WIDE VARIATION IN THE DIPS OF
UNDISTURBED TANKS SHALL BE INVESTIGATED.
19) GAUGING DETAILS SHALL BE RECORDED STRAIGHTWAY IN THE
DIP BOOK IN INK BY AN OFFICER AND SIGNED BY HIM.
ALTERATIONS / CORRECTIONS, IF ANY, IN THE DIP BOOK SHALL BE
ATTESTED AND SHALL BE DONE IN SUCH A WAY SO THAT THE
ORIGINAL ENTRY IS STILL LEGIBLE.
20) PRIOR TO RECEIPT OPERATIONS, ENSURE THAT ENTIRE QUANTITY
IN THE TANK i.e. OIL AND WATER, IS CONSIDERED SO AS TO
CORRECTLY WORK OUT THE ULLAGE AVAILABLE AND ELIMINATE
THE POSSIBILITY OF AN OVERFLOW.
21) AT LOCATIONS WHERE WATER BOTTOM IN TANKS IS NOT
MAINTAINED, FREE WATER IN THE TANK SHALL BE REMOVED AT
THE EARLIEST OPPORTUNITY. UNDRAINABLE WATER QUANTITY
IN THE TANK SHALL BE ACCOUNTED SEPARATELY AND NOT
TREATED AS OIL.
 TANK FARM OPERATIONS (Contd.)
18) DISCHARGE OF A TANKWAGOAN OR A TANKLORRY INTO THE
TANK SHALL BE PLANNED IN SUCH A WAY THAT ENTIRE
QUANTITY IN A TANKWAGON OR ENTIRE QUANTITY IN A
TANKLORRY COMPARTMENT CAN BE ACCOMMODATED INTO THE
TANK.
19) PRIOR TO DELIVERY OPERATIONS, ASCERTAIN THE LIQUID
COLUMN IN THE TANK SO THAT AN ENTIRE TANKWAGON OR AN
ENTIRE TANKLORRY COMPARTMENT CAN BE FILLED. THE ABOVE
WILL FACILITATE MEANINGFUL PRODUCT LOSS / GAIN ANALYSIS.
20) ALL DRAIN VALVES OF THE TANK SHALL BE FLANGED AND
LOCKED WHEN NOT IN USE.
21) BODY VALVES OF THE TANKS SHALL BE LOCKED OUTSIDE
WORKING HOURS.
22) ALL STIPULATIONS GIVEN IN THE INDUSTRY QUALITY CONTROL
MANUAL SHALL BE ADHERED TO.
 OIL WATER SEPARATOR
NEED AND CONSTRUCTION

I. OIL WATER SEPARATOR (OWS), IS AN INTEGRAL PART OF TANK

FARM OPERATIONS. IT IS A MANDATORY REQUIREMENT THAT
DRAINS FROM LICENSED AREA SHALL PASS THROUGH AN
INTERCEPTOR SO THAT OIL TRACES AND OIL SPILLAGES ARE
TRAPPED BEFORE THE WATER IS LET OUT INTO THE OUTSIDE
DRAINS.
II. AN OWS IS OF RCC / CC/ BM CONSTRUCTION WITH 3 OR MORE
CHAMBERS. EVERY CHAMBER HAS AN INLET AT THE TOP AND
AN OUTLET AT ITS BOTTOM. FLOW INTO AND OUT OF THE OWS
IS CONTROLLED BY INLET AND OUTLET VALVES. WHEN OIL-
WATER MIXTURE ENTERS THE OWS, OIL BEING LIGHTER,
REMAINS TRAPPED AND FLOATING ON WATER, WHILE WATER
FLOWS INTO THE NEXT CHAMBER.
III. INLET AND OUTLET VALVES SHALL BE OF RISING STEM TYPE
AND WITH PROPER LOCKING ARRANGEMENT.
 OIL WATER SEPARATOR
OPERATION
I. OIL CONTENTS IN THE EFFLUENT LEAVING THE OWS SHALL
BE 10 PPM MAXIMUM.
II. OUTLET VALVE SHALL BE ALWAYS KEPT IN CLOSED
POSITION AND LOCKED EXCEPT WHEN DRAINING OUT THE
CLEAR WATER.
III. DRAINING OF WATER SHALL BE UNDER SUPERVISION.
IV. OIL LEVEL AND WATER LEVEL IN THE OWS SHALL BE
CHECKED ON A DAILY BASIS AND RECORD MAINTAINED.
V. OIL ACCUMULATED IN THE OWS SHALL BE SALVAGED AND
RECORD MAINTAINED.
VI. WATER LEVEL IN THE OWS SHALL BE MAINTAINED ABOVE
THE LEVEL OF THE OUTLET VALVE.
VII.OWS SHALL BE CLEANED PRIOR TO THE ONSET OF
MONSOON.
VIII.FUNCTIONING OF THE INLET AND OUTLET VALVES SHALL
BE CHECKED PERIODICALLY.
 TANK FARM OPERATIONS
SAFETY CHECKLIST
 GENERAL:

 WHETHER THE LOCATION LAYOUTS, INTERSPACING IN

THE TANK FARM MEET OISD STD-118/STATUTORY
REQUIREMENS?

 WHETHER DYKE/FIRE WALLS MEET OISD-I18/STATUTORY

REQUIREMENS?

 WHETHER THE ROADS ARE AVAILABLE AROUND THE

TANK FARM FOR MOVEMENT OF FIRE TENDERS?

 WHETHER PIPING IN THE DYKE FARM IS KEPT MINIMUM?

 WHETHER HOUSE KEEPING IN THE AREA IS

SATISFACTORY AND IT IS FREE OF ANY DRY VEGETATION

 WHETHER ILLUMINATION IN THE AREA IS ADEQUATE.

 SAFETY CHECKLIST ( Contd.)

SEWERS
 WHETHER THE TANKFARM DRAINS ARE CLEAR?

 WHETHER PROVISION EXISTS TO DIVERT TANK FARM

DRAINAGE EITHER TO STORM WATER DRAIN OR TO OIL
WATER SEPERATOR?

TANKS
 WHETHER TANKS PROPERLY PAINTED AND IMPORTANT
SPECIFICATIONS ARE MARKED ON THE TANK ?

 WHETHER ALL TANKS ARE PROVIDED WITH

CIRCUMFERENTIAL RAILINGS?

 WHETHER THE ROOF DRAIN OF FLOATING ROOF TANKS IS

PROVIDED WITH A CHECK VALVE

 WHETHER ANY DEPRESSION DUE TO TANK SETTLEMENT

OBSERVED ON THE TANK PAD ALONG THE
CIRCUMFERENCE?
 SAFETY CHECKLIST ( Contd.)

 WHETHER FIXED/SEMI-FIXED FOAM SYSTEM ARE

PROVIDED ON ALL TANKS STORING A CLASS AND B CLASS
PRODUCTS (18 M AND ABOVE DIA FOR FLOATING ROOFS)
AND ALSO TANKS STORING “C” CLASS PRODUCTS OF MORE
THAN 40 M DIA (FLOATING/FIXED ROOF TANKS)?

 WHETHER SPRINKLER SYSTEMS ARE PROVIDED ON ALL

FIXED ROOF TANKS AS PER OISD NORMS?

 WHETHER THE TANKS ARE PROPERLY PAINTED AND

NUMBERED?

 WHETHER GOOSE NECK TYPE VENT CONNECTIONS ARE

PROVIDED WITH SUTTABLE WIRE MESH TO AVOID BIRDS
ENTRY / FORMATION OF NESTS?
 SAFETY CHECKLIST ( Contd.)
PIPING :

 WHETHER PIPE ALLEYS PROPERLY GRADED TO ENSURE THAT

NO OIL/WATER GETS ACCUMULATED BELOW?

 WHETHER PIPE SUPPORTS, ANCHORS, GUIDES ARE IN ORDER?

 WHETHER PROPER COLOUR CODINGS, PRODUCTS

IDENTIFICATION MARKS HAVE BEEN PROVIDED?

 WHETHER THE FLOOR UNDER THE MAINFOLD ARE PAVED,

HAVE CURB WALLS AND DRAINS CONNECTED TO OWS?

 WHETHER ANY BOLT IS FOUND MISSING ON FLANGES OF

HYDROCARBON LINES, PARTICULARLY OF MS, NAPTHA ETC.

 WHETHER THE REDUNDANT LINES ARE KEPT POSITIVELY

ISOLATED WITH ALL THE ENDS PLUGGED/BLINDED AND
ACTIONS ARE TAKEN TO GET THEM REMOVED?
 SAFETY CHECKLIST ( Contd.)
OPERATING PROCEDURES :
 WHETHER A COPY OF UPDATED OPERATING MANUAL WITH OPERATING
INSTRUCTIONS IS AVAILABLE TO ALL CONCERNED.
 WHETHER THERE IS ANY POSSIBILITY OF PRODUCT CONTAMINATION
DURING TANK LINE UP/CHANGE OVER
 WHETHER PERIODICAL CHECKS ARE MADE FOR LOCATING ANY
LEAKAGE ON TANK, FLOATING ROOF TANK VALVES, PIPING ETC. AND
RECORDED FOR RECTIFICATION.
 WHETHER THE ROOF DRAIN VALVES OF FLOATING ROOF TANKS ARE
NORMALLY KEPT CLOSED.
 WHETHER PRE-MONSOON CHECKS ARE CARRIED OUT.
 WHETHER CROSS CHECKING OF AUTO LEVEL GAUGE IS DONE THROUGH
MANUAL GAUGE, WHILE THE TANKS ARE UNDER OPERATION.
 WHETHER IT IS ENSURED DURING INITIAL FILLING A FLOW VELOCITY OF
MAXIMUM 1 M/SEC IS MAINTAINED FOR PRODUCTS LIKE SKO, ATF?
 WHETHER USE OF NYLON ROPE FOR SAMPLING WAS OBSERVED?
 SAFETY CHECKLIST ( Contd.)

INSPECTION & MAINTENANCE :

 WHAT ARE THE SCHEDULES OF INSPECTION OF TANKS
(FLOATING/FIXED) AND WHETHER RECORDS MAINTAINED IN LINE
WIIH OISD STD-129.
 WHAT IS THE FREQUENCY OF INSPECTION OF PV VENTS, RELIEF
VALVES ? WHETHER RECORDS ARE MAINTAINED IN LINE WITH
OISD STD-129
 WHETHER ANY PROVISION EXISTS FOR STATIC ELECTRICITY
DISCHARGE? WHAT IS THE FREQUENCY OF INSPECTION OF
EARTHING CONNECTIONS AND WHETHER RECORDS MAINTAINED .
 WHETHER THE PONTOON COVERS ARE IN PLACE AND ARE IN
GOOD CONDITION?
 SAFETY CHECKLIST ( Contd.)

INSPECTION & MAINTENANCE :

 WHETHER FOAM/NEOPRENE SEALS ARE CHECKED REGULARLY

FOR PERFECT SEALING AND RECORD MAINTAINED.
 WHETHER ANY DOCUMENIED PROCEDURE EXISTS FOR TANK
CLEANING? WHAT IS THE METHODOLOGY TO ENSURE STRICT
ADHERENCE?
 WHETHER THE LADDERS, STAIRWAYS ARE IN GOOD CONDITION
 WHETHER THE PIPELINE RELIEF VALVES ARE KEPT RELIEVING
TO TANKS OR TO OUTSIDE?
 WHETHER ANY INSPECTIONS ARE CARRIED OUT ON REPAIRED
TANKS BEFORE TAKING THEM INTO OPERATION?
 WHAT ARE THE SCHEDULES FOR PAINTING OF TANKS?
 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.

GAUGING INVOLVES :
1) TAKING OIL DIP IN THE TANK
2) TAKING WATER DIP IN THE TANK
3) OBSERVE TANK TEMPERATURE
4) OBSERVE DENSITY & TEMPERATURE OF THE TANK SAMPLE.

GAUGING EQUIPMENTS:
 1) DIP TAPE 5) THERMOMETER
 2) DIP BOB 6) HYDROMETER
 3) WATER FINDING PASTE 7) SAMPLING EQUIPMENT
 4) OIL FINDING PASTE 8) SAMPLE CONTAINER
 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.

GAUGING TERMS:
 1) GROSS DIP
 2) WATER DIP
 3) ULLAGE DIP
 4) DIP HATCH
 5) DATUM PLATE
 6) TEMPERATURE / SAMPLE HATCH
 7) TANK TEMPERATURE
 8) SAMPLE TEMPERATURE
 9) SAMPLE DENSITY
10) REFERENCE HEIGHT
11) REFERENCE POINT
12) SAFE HEIGHT
13) DEAD STOCK
14) GROSS CAPACITY
15) SAFE CAPACITY
16) WATER BOTTOM
 TANK QUANTITY CALCULATION

I. GROSS DIP OF THE TANK.

II. WATER DIP OF THE TANK.

III. TANK TEMPERATURE

IV. SAMPLE TEMPERATURE

V. SAMPLE DENSITY

VI. DENSITY AT 15 DEG. C. CORRESPONDING TO IV AND V

ABOVE, BASED ON ASTM TABLE 53 B.

VII. NET VOLUME CORRESPONDING TO DIFFERENCE IN

QUANTITIES CORRESPONDING TO I AND II ABOVE

VIII. VOLUME REDUCTION FACTOR (VRF) CORRESPONDING TO

III AND VI ABOVE, BASED ON ASTM TABLE 54 B.

IX. VOLUME AT 15 DEG. C. = NET VOLUME * VRF.

 PIPELINE TRANSFERS
SAFEST MODE OF PRODUCT TRANSFER FROM ONE LOCATION TO
OTHER LOCATION.
TERMS OF SETTLEMENT IN REGARD TO PRODUCT QUANTITY

TYPES OF TRANSFER TERM OF SETTLEMENT

REFINERY TO MARKETING RECEIVING COMPANY TANK DIPS

REFINERY TO REFINERY DESPATCHING REFINERY TANK
DIPS
MARKETING TO MARKETING DESPATCHING COMPANY TANK
DIPS
MARKETING TO REFINERY MARKETING COMPANY TANK DIPS
 PIPELINE TRANSFERS
SAFEST MODE OF PRODUCT TRANSFER FROM ONE LOCATION TO
OTHER LOCATION.
PRECAUTIONS DURING PIPELINE TRANSFER
 ENSURE SUFFICIENT ULLAGE IN THE RECEIVING TANKS
 RECORDING BEFORE RECEIPT GAUGE OF TANKS FOR OIL, WATER &
TEMP
 PROPER LINE UP BEFORE COMMENCING THE PLT
 SAMPLING OF PRODUCT IN LINE WITH IQCM GUIDLINES.
 HOURLY GAUGING/SAMPLING AND COMPARISON WITH PUMPED
QUANTITY.
 PROVISIONAL GAUGE AFTER CLOSING ALL VALVES SUBSEQUENT TO
STOPPING OF PLT.
 FINAL GAUGING OF TANKS FOR OIL, WATER AND TEMP TO ASSESS THE
LOSS / GAIN DURING THE PLT AFTER GIVING SUFFICIENT SETTLING
TIME
 MARKETING TRANSACTIONS ARE SETTLED FOR QUANTITIES AT 15
DEGREE CELCIUS
 ANY ABNORMAL LOSS TO BE IMMEDIATELY REPORTED &
INVESTIGATED
 SUFFICIENT PRECAUTION DURING SWITCHOVER OF TANKS
 PIPELINE TRANSFER LOSS
1) (QTY SHIPPED – QTY RECEIVED) AT- 15º C IS LOSS DURING PIPELINE
TRANSFER
2) FACTORS CAUSING PIPELINE TRANSFER LOSSES
A. PHYSICAL FACTORS : WHERE OIL IS ACTUALLY LOST e.g.
A LEAK.
B. BOOK LOSS FACTORS : LOSSES NOT ACTUALLY INCURRED
BUT BOOKED
e.g. WRONG GAUGING.

MAJOR FACTORS CONTRIBUTING TO PLT LOSSES

A. PHYSICAL FACTORS :-
i. LINE SLACK
ii. LEAKS
iii. FAULTY SEGREGATION
iv. INADEQUATE FLUSHING ON WATER LINES
v. DELAYED SWITCHOVER
vi. OVER DRAINING OF TANKS
vii. PARCEL SIZE
 PIPELINE TRANSFER LOSS

B. BOOK LOSS FACTORS :-

B. INCORRECT GAUGING
C. INCORRECT CALIBRATION
D. WRONG OUTTURN CALCULATIONS
E. FLOATING ROOF POSITION
FACTORS WHICH INFLATE VOLUME
AT 15 DEG. C.
 HIGHER OIL DIP

 LOWER WATER DIP

 LOWER TANK TEMPERATURE.

 HIGHER SAMPLE DENSITY (VRF REDUCES WITH INCREASE IN

DENSITY, AND OBSERVED TEMPERATURES ARE GENERALLY
MORE THAN 15 DEGREE CELCIUS.

 HIGHER SAMPLE TEMPERATURE (INCREASES THE DENSITY

WHEN CONVERTED TO 15 DEGREE CELCIUS )
 QUALITY CONTROL DURING TANK
FARM OPERATIONS
DURING PIPELINE RECEIPT
SAMPLING OF TANKS NOMINATED FOR RECEIVING PRODUCT

 BEFORE RECEIVING PRODUCT THROUGH MULTI-PRODUCT

PIPELINE / WATER FLUSH PIPE LINE / OCEAN TANKERS, UML
COMPOSITE SAMPLES FROM INDIVIDUAL TANKS NOMINATED
FOR RECEIVING THE PRODUCT, SHALL BE TAKEN, LABELLED,
SEALED AND RETAINED.

IN CASE OF RECEIPT THROUGH CROSS COUNTRY / FEEDER

PIPELINE, UML COMPOSITE SAMPLES SHALL BE TAKEN JOINTLY
BY OFFICERS OF MARKETING / PIPELINE DIVISIONS FROM THE
INDIVIDUAL NOMINATED TANKS.
 QUALITY CONTROL DURING TANK
FARM OPERATIONS
DURING PIPELINE RECEIPT
SAMPLING OF TANKS NOMINATED FOR RECEIVING PRODUCT

 IF THE SAMPLE, AFTER RECEIPT, CONFORMS TO THE

SPECIFICATION REQUIREMENTS IN RESPECT OF TESTS CARRIED
OUT, SAMPLE TAKEN AS STATED ABOVE MAY BE DISCARDED.

 IN THE EVENT OF THE SAMPLE AFTER RECEIPT NOT

CONFORMING TO SPECIFICATION, THEN THESE RETAINED
SAMPLES SHALL NOT BE DESTROYED TILL THE INVESTIGATION
IS OVER
QUALITY CONTROL DURING PIPELINE
RECEIPT

 FOR THE FIRST HALF AN HOUR, OF EACH PRODUCT BEING PUMPED

THROUGH A MULTI-PRODUCT PIPELINE, LINE SAMPLES SHALL BE
DRAWN FROM THE PIPELINE MANIFOLD AT INTERVALS OF TEN
MINUTES, AND THE TEST ‘A’ DONE AND RECORDED.

 IN CASE, THE DENSITY VARIATION IS OUTSIDE THE PERMISSIBLE

LIMITS, THEN THE PUMPING SHALL BE STOPPED. REASONS FOR THE
VARIATION ESTABLISHED, CORRECTIVE ACTION TAKEN AND THEN
RESUME PUMPING.
QUALITY CONTROL DURING PIPELINE
RECEIPT

 WHENEVER PUMPING OF THE PRODUCT IS STOPPED AND THEN

RESTARTED, THE PROCEDURE OF THE SAMPLING DURING THE
FIRST HALF AN HOUR AND THEN HOURLY SAMPLING SHALL BE
FOLLOWED.

 TWO LITRES RETENTION LINE SAMPLE EACH SHALL BE TAKEN

BOTH AT DESPATCHING END AND RECEIVING END DURING
COMMENCEMENT, MIDDLE AND END OF THE PIPELINE TRANSFER
AND RETAINED UNTIL QUALITY OF THE PRODUCT AFTER RECEIPT
IS ESTABLISHED.
QUALITY CONTROL DURING PIPELINE
RECEIPT (Contd.)
 WHEN A TRANSFER TAKES PLACE FROM A REFINERY, JOINT
SAMPLING SHALL BE DONE. A VALID TEST REPORT FOR THE
TANK(S) FROM WHICH THE PRODUCT IS TRANSFERRED,
SHALL BE MADE AVAILABLE.

 FROM THOSE TAP-OFF POINT TANKS WHERE PRODUCT /

PRODUCT ALONG WITH INTERFACE IS ACCOMMODATED, A
SAMPLE SHALL BE DRAWN FROM TOP / MIDDLE / BOTTOM
AFTER RECEIPT AND TESTED FOR DENSITY INDIVIDUALLY TO
ENSURE HOMOGENEITY OF THE PRODUCT. IF THE DENSITY
VARIATION IS MORE THAN ± 3 BETWEEN ANY TWO LEVELS,
THIS IS TO BE INVESTIGATED AND REASONS FOR DENSITY
VARIATION TO BE RECORDED.
QUALITY CONTROL DURING PIPELINE
RECEIPT (Contd.)
 WHEN THE TRANSFER IS THROUGH A DEDICATED PIPELINE, A
UML COMPOSITE SAMPLE SHALL BE TAKEN JOINTLY FROM
THE NOMINATED SHIPPING TANKS AND RETAINED, TILL THE
QUALITY OF THE PRODUCT HAS BEEN ESTABLISHED BY THE
RECEIVING LOCATION.

 DURING RECEIPT THROUGH DEDICATED PIPELINES SAMPLES

FROM THE TOP AND BOTTOM OF THE PIPELINE NEAR THE
MANIFOLD SHALL BE TAKEN AT INTERVALS OF ONE HOUR AT
THE DESPATCHING AND RECEIVING END, TEST “A” DONE AND
THE OBSERVATIONS RECORDED CHRONOLOGICALLY.
QUALITY CONTROL DURING PIPELINE
RECEIPT (Contd.)
I. ON COMPLETION OF TRANSFER AND AFTER ALLOWING A
MINIMUM SETTLING TIME OF ONE HOUR, A COMPOSITE OF
TOP, MIDDLE AND BOTTOM SAMPLES FROM RECEIPT TANKS
SHALL BE SENT TO LAB FOR BATCH FORMATION TEST & THE
PRODUCT SHALL BE RELEASED ONLY AFTER LAB
CLEARANCE. A COMPOSITE SAMPLE OF KEROSENE SHALL BE
RETAINED FOR THREE MONTHS & RECORD MAINTAINED.

II. AFTER RECEIPT THROUGH DEDICATED PIPELINES, SAMPLES

FROM UPPER, MIDDLE AND LOWER LEVELS SHALL BE
INDIVIDUALLY SUBJECTED TO TEST “A” AND THE
OBSERVATIONS RECORDED. IF THE DENSITY VARIATION AT 15
DEG C IS WITHIN LIMITS, THE PRODUCT MAY BE RELEASED.
QUALITY CONTROL DURING PIPELINE
RECEIPT (Contd.)
I. WHEN STOCK TRANSFER IS EFFECTED FROM OTHER OIL
MARKETING COMPANY THROUGH LOCAL DEDICATED
PIPELINES, SUCH TRANSFERS SHALL COMMENCE FROM VALID
STOCK HAVING BATCH FORMATION TEST CERTIFICATE.
JOINT SAMPLES SHALL BE TAKEN FROM THE NOMINATED
TANKS.

THE DENSITY VARIATION OF SUCH STOCK DURING TRANSFER

SHALL NOT BE BEYOND +3 AT ANY TIME. SAMPLE SHALL BE
DRAWN AND OBSERVATIONS RECORDED.

IV. A BATCH NUMBER SHALL BE ASSIGNED FOR EACH RECEIPT OF

PRODUCT THROUGH PIPELINE IN A LOCATION ON THE BASIS
OF A BATCH FORMATION TEST REPORT.
QC DURING PIPELINE RECEIPT (Contd.)
THE INTERFACE OF PRODUCT TANK TO INTERFACE QUANTITY
ACCOMMODATE ACCEPTABLE
INTERFACE

MS & SK MS 1%
SK & ATF SK NO LIMIT
SK & HSD / LSHF/HF HSD/ HSD 2%
ELS HSD
LSHF/HF HSD HF HSD NO LIMIT
HSD & LSHF/HF HSD/ HSD NO LIMIT
ELS HSD
LDO & FO FO 5%
THE ABOVE INTERFACE PERCENTAGE ABSORPTION ON GRADE WISE IS
DIRECTIONAL. IT WILL BE THE RESPONSIBILITY OF OIL COMPANIES TO
ENSURE THAT THE PRODUCT, AFTER RECEIPT IN MARKETING TANK (S),
MEETS THE RELEVANT BIS SPECIFICATIONS AND GOVT . DIRECTIVES IN
BATCH FORMATION TEST.
QUALITY CONTROL DURING STORAGE

 SAMPLING COCKS SHALL BE PROVIDED AT THE TOP AND

BOTTOM OF THE RECEIVING LINE BEFORE THE RECEIPT
TANK VALVE TO DRAW LINE SAMPLES.THE TOP AND BOTTOM
SAMPLING COCK FACILITY SHALL BE AVAILABLE AT THE
PIPELINE MANIFOLD, AT THE DELIVERY MANIFOLD AND / OR
CUSTODY TRANSFER PONT AT REFINERY / PIPELINE
TRANSFER / RECEIPT LOCATIONS.

 SPECTACLE FLANGES / LINERS, HAMMER BLINDS OR SPOOL

PIECES SHALL BE PROVIDED IN THE LINE WHENEVER A
COMMON MANIFOLD AND PIPELINE IS USED, FOR POSITIVE
SEGREGATION.
QUALITY CONTROL DURING STORAGE

 STORAGE TANKS SHALL BE CLEANED ONCE IN EVERY FIVE

YEARS OR MORE FREQUENTLY, DEPENDING ON THE NEED,
LIKE CHANGE OF PRODUCT, SLUDGE FORMATION ETC. TANK
CLEANING CERTIFICATE SHALL BE MAINTAINED. DATE OF
TANK CLEANING AND THE DUE DATE OF NEXT CLEANING
SHALL BE PAINTED ON THE MANHOLE COVERS.

 AN ALL-LEVEL SAMPLE AFTER RECEIPT OF FIRST PARCEL IN

A NEWLY COMMISSIONED TANK/AFTER ANY GRADE CHANGE
OVER SHALL BE SENT TO THE LABORATORY FOR BATCH
FORMATION TEST.
 Q C DURING STORAGE (Contd.)
 WHEN THERE IS NO FRESH RECEIPT INTO A KEROSENE TANK FOR 7
DAYS, A TOP SAMPLE SHALL BE TAKEN AND CHECKED FOR DENSITY
AND FLASH POINT.

 THIS CHECKING SHALL BE CONTINUED SUBSEQUENTLY ON EVERY 7

DAYS’ BASIS TILL FRESH RECEIPT.

 FO / LDO SHALL BE CIRCULATED WITHIN THE TANKS EVERY 15 DAYS

FOR AT LEAST TWO HOURS, WHEN THERE IS NO FRESH RECEIPT INTO
THE TANKS DURING THIS PERIOD.
 Q C DURING STORAGE (Contd.)

 IF WATER BOTTOM IS MAINTAINED IN THE TANK, TEST “E” SHALL BE

CARRIED OUT ON THE WATER SAMPLE ON FORTNIGHTLY BASIS. IN
CASE THE TEST INDICATES PRESENCE OF SULPHIDE, WATER SHALL BE
REPLACED.

 ALL BOX STRAINERS / LINE STRAINERS SHALL BE OPENED ONCE IN

THREE MONTHS AND INTERNALLY CLEANED. THE DATE OF CLEANING
TO BE DOCUMENTED.
QUALITY CONTROL DURING STORAGE
(Contd.)
 PIPELINES SHALL BE COLOUR CODED TO
INDICATE THE PRODUCT THAT IS BEING
CARRIED.

 COLOUR CODING FOR ALL PRODUCTS

SHALL HAVE ONE BAND OF 100 MM (4”) ON
EACH SIDE WITH A GAP OF 300 MM (12”) IN
BETWEEN.

 THE BAND SHALL BE PAINTED NEAR BOTH

SIDES OF THE VALVES AND THEREAFTER
EVERY 20 MTS. OF LENGTH OF PIPELINE.
QUALITY CONTROL DURING STORAGE
(Contd.)
 A 45-50 MM THICK *300 MM LONG ARROW SHALL BE PAINTED AFTER EACH
BAND ON THE PIPELINE WITH RESPECTIVE COLOUR CODE IN THE FLOW
DIRECTION.
THE RECOMMENDED COLOUR CODING FOR BANDS SHALL BE :

PRODUCT COLOUR ISCODE

MS 93 OCTANE SIGNAL RED 537
MS 87 OCTANE DARK ORANGE 591
SK GOLDEN YELLOW 356
HSD, LSHF HSD, OXFORD BLUE 105
HF HSD, ELS HSD, LDO ALUMINIUM -
FO ALUMINIUM -

NAPHTHA (LAN & HAN) DARK BROWN 412

“REFER – INDIAN STANDARD COLOUR NO. OF IS-5-1994”

 QUALITY MONITORING

 A COMPOSITE SAMPLE FROM THE STOCK OF EACH PRODUCT

TANK OF THE DEPOT SHALL BE SUBJECTED TO MONTHLY
MONITORING TESTS AT NEAREST LAB.

 COPPER STRIP CORROSION TEST SHALL BE CARRIED OUT

FORTNIGHTLY ON A BOTTOM SAMPLE FROM LSHF HSD TANKS.

 WHEN NO FRESH PRODUCT IS RECEIVED FOR THREE MONTHS

INTO A TANK, UPPER, MIDDLE & LOWER COMPOSITE SAMPLE
FROM THE VERTICAL TANK / AN ALL-LEVEL SAMPLE FROM THE
HORIZONTAL TANK SHALL BE SENT FOR BATCH FORMATION
TESTS. INTER TANK TRANSFER TO AVOID THIS IS NOT
PERMITTED.
 PRODUCT FAILURES

 IN CASE ANY STOCK FAILS TO MEET THE

SPECIFICATION DURING MONITORING OR OTHERWISE,
THE STOCKS SHALL BE FROZEN AND THE ZONAL O&D &
QC DEPT. TO BE ADVISED IMMEDIATELY.

 CORRECTIVE ACTION TO SALVAGE THE PRODUCT

SHALL BE INITIATED ONLY AFTER SPECIFIC
INSTRUCTIONS ARE RECEIVED FROM QC DEPT.

 UNDER NO CIRCUMSTANCES SHALL A LOCATION ON

THEIR OWN ATTEMPT TO CORRECT THE PRODUCT.
 STOCK LOSS
BASIC CAUSES OF PETROLEUM LOSSES :
 EVAPORATION
 INACCURATE MEASUREMENT
 LEAKAGE
 PILFERAGE
 TEMPERATURE VARIATIONS
EVAPORATION LOSS
EVAPORATION LOSS IS THE NATURAL PROCESS WHEREBY
LIQUIDS ARE CONVERTED TO
VAPOUR AND LOST TO ATMOSPHERE.
STOCK LOSS CONTROL CHECKLIST
CHECK-LIST FOR POSSIBLE SOURCES OF PRODUCT LOSSES :

1. SOURCES OF ERRORS IN MEASURING EQUIPMENT

i. FAULTY DIP RODS (WORN OUT, BENT, WRONGLY

GRADUATED).

ii. FAULTY DIP TAPES (NON-STANDARDS, DISTORTED,

WRONGLY GRADUATED).

iii. FAULTY DIP BOBS (WORN OUT, INCORRECTLY ATTACHED

TO THE TAPE, WRONGLY GRADUATED).
STOCK LOSS CONTROL CHECKLIST
CHECK-LIST FOR POSSIBLE SOURCES OF PRODUCT LOSSES :

i. FAULTY THERMOMETERS (NON-STANDARD, NOT

CALIBRATED, WITH BROKEN MERCURY COLUMN).

ii. FAULTY HYDROMETERS ((NON-STANDARD, NOT

CALIBRATED, DAMAGED).

iii. FAULTY FLOWMETERS (WRONG SIZE, INCONSISTENT FLOW

RATES, INCORRECTLY INSTALLED, WRONGLY
CALIBRATED).
STOCK LOSS CONTROL CHECKLIST
2. SOURCES OF ERRORS IN TAKING MEASUREMENTS
i. INCORRECT OBSERVATIONS OF PRODUCT DIPS, WATER DIPS, TANK
TEMPERATURES, SAMPLE DENSITY AND SAMPLE TEMPERATURE ,
METER READINGS.
ii. UNEVEN RAIL SIDING, TANKLORRY GANTRY BAY.

3. SOURCES OF ERRORS IN CALIBRATION

i. INCORRECT STORAGE TANK CALIBRATION TABLES DUE TO :
ERRORS IN THE ORIGINAL MEASUREMENTS OR CALCULATIONS.
UNEVEN SETTLEMENT.
FLEXING OF BOTTOM PLATES.
REPLACEMENT OF BOTTOM PLATES AND FRESH CALIBRATION NOT
CARRIED OUT.
DISTORTION OF SHELL PLATES DUE TO FIRE, FAILURE OF
INTERNAL REINFORCEMENTS, FITTING OF NEW ROOF PLATES.
CHANGE IN THE LEVEL OF DIP PROOF LEVEL.
ALTERATIONS IN THE WEIGHT OF THE FLOATING ROOF.
STOCK LOSS CONTROL CHECKLIST
ii. INCORRECT CALIBRATION OF TANKWAGONS OR TANK LORRIES
DUE TO :
MISTAKES IN ORIGINAL CALIBRATION.
CHANGES IN PROOF LEVEL DUE TO NEW / ALTERED FITTING.
DISTORTION OF SHELL OR INTERNAL PARTITIONS BY ACCIDENT,
OVERLOADING.

4. SOURCES OF ERRORS IN CALCULATIONS

i. ERRORS IN RECORDING OF THE OBSERVATIONS.

ii. ERRORS IN COMPUTATIONS OF QUANTITIES.

iii. USE OF WRONG CALIBRATION CHARTS.

iv. USE OF WRONG / ERRORS IN READING PETROLEUM MEASUREMENT

TABLES.
STOCK LOSS CONTROL CHECKLIST
5. SOURCES OF LOSS FROM TANKS

i. LEAKAGE OF LIQUID DUE TO :

 RUPTURED TANK BOTTOMS (CHECK BY WATCHING THE
LEVEL OF A TEMPORARY WATER BOTTOM).
 RUPTURED SEAMS, RIVETS (CHECK VISUALLY).
 FITTINGS LOOSELY CONNECTED.
 DEFECTIVE FITTINGS.
STOCK LOSS CONTROL CHECKLIST
5. SOURCES OF LOSS FROM TANKS

ii. LOSS OF VAPOUR DUE TO :

 DEFECTIVE SEAMS, FITTINGS (CHECK VISUALLY OR
WITH SOAP WATER SOLUTION WHILE TANK IS UNDER
PRESSURE).
 DEFECTIVE PACKING FOR MANHOLES, DIP HATCHES,
AUTOMATIC GAUGING DEVICES (EXAMINE).
 INCORRECT CLOSING OF MANHOLES, DIP HATCHES
(EXAMINE).
* DEFECTIVE SEALS, FOAM CONNECTIONS, ARTICULATED
DRAINS ON FLOATING ROOF TANKS (EXAMINE).
STOCK LOSS CONTROL CHECKLIST
5. SOURCES OF LOSS FROM TANKS

iii. EXCESSIVE BREATHING AND EVAPORATION DUE TO :

 FREE VENTS INSTEAD OF PRESSURE VACUUM VALVES ON

TANKS FOR VOLATILE PRODUCTS.
 INCORRECT SETTING OF PRESSURE VACUUM VALVES
(CHECK PRESSURE ON MANOMETER WHEN VALVES ARE
OPERATING).
 DEFECTIVE PRESSURE VACUUM VALVES (CHECK
REGULARLY).
 EXCESSIVE TEMPERATURE VARIATION DUE TO
DETERIORATED PAINT OF STORAGE TANKS.
 INCREASE IN RVP OF THE PRODUCT HANDLED.
STOCK LOSS CONTROL CHECKLIST
6. SOURCES OF LOSSES IN OTHER EQUIPMENTS

i. LEAKAGE THROUGH PIPELINE WALLS OR JOINTS (CHECK

VISUALLY OR TEST UNDER PRESSURE. IF NECESSARY DIG
UP THE PIPELINE).

ii. LEAKAGE THROUGH VALVE GLANDS (CHECK VISUALLY

AND TIGHTEN OR REPACK LEAKY GLANDS; IF VALVE STILL
LEAKS, RE-GRIND FACE AND SEAT).

iii. LEAKAGE THROUGH PUMP GLANDS (CHECK VISUALLY AND

TIGHTEN, REPACK, FIT MECHANICAL SEALS).
STOCK LOSS CONTROL CHECKLIST
6. SOURCES OF LOSSES IN OTHER EQUIPMENTS :

iv. LEAKAGE THROUGH DRAIN COCKS OF FILTERS, WATER

SEPARATORS ETC. (CHECK VISUALLY AND REPAIR).

v. LEAKAGE THROUGH WALLS OR JOINTS OF DEFECTIVE

HOSES (EXAMINE AND REPLACE JOINTS, REPAIR, CONDEMN
DAMAGED HOSE).

vi. LEAKAGE FROM FILLING MACHINES AND FILLING ARMS

(EXAMINE AND REPAIR).
STOCK LOSS CONTROL CHECKLIST
7. SOURCES OF LOSS IN BULK OPERATIONS

i. LEAKAGE OF VAPOUR DURING DIPPING AND SAMPLING (AS

FAR AS POSSIBLE GAUGE WHEN INTERNAL AND EXTERNAL
PRESSURES ARE EQUAL).

ii. EXCESSIVE DISPLACEMENT LOSSES DUE TO HEAVY

WITHDRAWALS (FLOATING ROOF / HIGH PRESSURE TANKS
PREFERRED).

iii. EXCESSIVE DISPLACEMENT LOSSES DUE TO INTER-TANK

TRANSFER (UNDERTAKE ONLY IN CASE OF DISTINCT
ADVANTAGE).

iv. SPILLAGE OF PRODUCT IN HOSE HANDLING (PROVIDE

ARRANGEMENTS FOR DRAINING HOSES).
STOCK LOSS CONTROL CHECKLIST
8. SOURCES OF LOSS IN FILLING :

i. EXCESSIVE EVAPORATION OR SPLASH DUE TO THE USE OF

SHORT LOADING HOSE / ARM (USE HOSE / ARM
EXTENDING TO THE BOTTOM OF THE CONTAINER).

ii. DISPLACEMENT LOSS DURING RECEIPT AND WITHDRAWAL.

iii. OVERFILLING DUE TO CARELESS OPERATIONS

(SUPERVISION AND EDUCATION).
STOCK LOSS CONTROL CHECKLIST
8. SOURCES OF LOSS IN FILLING :

iv. OVERFILLING DUE TO INCORRECT SETTING OF PRESET

FLOW METERS (SUPERVISION, CHECKING OF
CALCULATIONS).

v. SPILLAGE FROM FILLING HOSES (PROVIDE PROPER

DRAINAGE ARRANGEMENTS, USE SELF-SEALING
COUPLINGS).

vi. FILLING WRONG PRODUCT NECESSITATING DECANTATION

(SUPERVISION AND TRAINING).
STOCK LOSS CONTROL CHECKLIST
9. OTHER SOURCES OF LOSS IN OPERATIONS :

i. INCOMPLETE DRAINAGE OF TANKWAGONS AND

TANKLORRIES (SUPERVISE DISCHARGE OPERATIONS).

ii. LEAKAGE OF LIQUID FROM FILLED CONTAINERS (TEST

BEFORE FILLING, INSPECT BEFORE STORAGE AND REPAIR
LEAKS).

iii. OVER-ISSUES OF PACKED STOCKS (SUPERVISION AND

CHECKING).

iv. CONTAMINATION (MAINTAIN POSITIVE SEGREGATION,

KEEP TANKS, PIPELINES, CONTAINERS CLEAN, REGULAR
CLEANING OF FILTERS, WATER SEPARATORS).

v. DOWNGRADING (MINIMISE).
STOCK LOSS CONTROL CHECKLIST
9. OTHER SOURCES OF LOSS IN OPERATIONS :

vi. LOSSES BY FIRE OR FLOOD (IMPLEMENT SAFETY

MEASURES).

vii. FAILURE TO ACCOUNT OWN USE PRODUCT (PROPER

ACCOUNTING).

viii. THEFT OR MISAPPROPRIATION (SEAL ALL FILTERS,

STRAINERS, TANK DRAINS, COCKS AND LOCK VALVES
WHEN NOT IN USE, CHECK SEALS AND LOCKS AT REGULAR
INTERVALS, CHECK ALL BULK AND PACKED DELIVERIES,
SEAL LOADED TANKLORRIES AND TANKWAGONS, KEEP
WAREHOUSE LOCKED WHEN NOT IN USE, KEEP PACKED
STOCKS AWAY FROM FENCES, KEEP FENCES, GATES,
VALVES IN GOOD CONDITION, ENSURE PROPER SECURITY,
CHECK SEALS REGULARLY).
 STOCK LOSS ( Contd. )
LEAKAGE

INDICATION OF THE LOSS MAGNITUDE DUE TO LEAKAGES :-

2 DROPS PER SECOND 4728.5 LTRS. PER YEAR

DROPS BREAKING INTO A STEADY STREAM 30730 LTRS. PER YEAR

1/8” STREAM 332500 LTRS. PER YEAR

3/16” STREAM 535850 LTRS. PER YEAR

1/4” STREAM 1179500 LTRS. PER YEAR

THANK YOU