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Design and Handling of Chemical Tanks
Guidance
Acknowledgments
1 INTRODUCTION
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• Control of Substances Hazardous to Health Regulations SI 1999/437 (COSHH)
Step Change would like to thank the following organisations for their contributions in developing this guidance:
2 SCOPE
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• DNV Certification Notes 2.7-1
AMEC
3 SUMMARY / RECOMMENDATION
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• IMDG Code - International Maritime Dangerous Goods Code
Baker Petrolite
• BS EN 12079: 1999 - Offshore Containers - Design, Construction, Testing, Inspection & Marking
BP • International Maritime Organisation Conserve Oilfield Services Ltd
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3.2 Handling
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3.3 Tank Access
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3.4 Contents Measuring Gauge
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3.5 Contents Management
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3.6 Checklists
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3.7 Risk Assessment
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• Lifting Operations and Lifting Equipment Regulations SI 1998 / 2307, (LOLER)
Elected Safety Representatives Network
• Manual Handling Operations Regulations SI 1992 / 2793
Ferguson Seacabs Ltd
• Merchant Shipping (Dangerous Goods and Marine Pollutants) regulations SI 1998 / 2367
Harran Ltd
3.8 Document Pouches/Load Security Tagging
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Marathon
3.9 Responsibilities and Training
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3.10 Documentation and Labelling of Tanks
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3.11 Tank Life Cycle Flowchart
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3.12 Backloading of Chemicals and Waste
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• PUWER - Provision and Use of Work Equipment Regulations SI 1998 / 2306 • Regulation 9 of LOLER, Approved Code of Practice, (HSE Books L113)
Marathon Oil Nalco Ltd Shell Exploration and Production UK
4 LOAD SECURITY INSPECTION PROCEDURE
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• Step Change in Safety Fatality Report
Suretank Ltd 4.1 Introduction
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• Step Change in Safety Lifting and Mechanical Handling Guidance (re-issue 2004)
Swire Oilfield Services Ltd
4.2 Purpose
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Talisman Energy
4.3 Scope
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4.4 Definitions
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• Step Change in Safety Task Assessment Guidance (2nd edition 2003)
Transocean
4.4.1 Cargo
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• The Carriage of Dangerous Goods by Road Regulations, SI 1996 / 209
4.4.2 Transportation
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4.4.3 Responsibilities
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• UKOOA / Chamber of Shipping Guidelines for the Safe Management and Operation of Offshore Support Vessels (Issue 4th November 2002)
4.4.4 Procedure Description
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4.4.5 Cargo Integrity Tagging
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4.4.6 Vendor Premises
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• UKOOA Guidance for the safe Packing and Handling of Cargo to and from Offshore Installations (latest edition)
4.4.7 Quayside
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• Working at Height Regulations SI 2005 / 735
• Step Change in Safety website: www.stepchangeinsafety.net 22
3.1 Design
5 SAFETY CONSIDERATIONS AND CHECKS
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5.1 Good Practice Chemical Tank Inspection Illustrated Checklist
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5.2 Recommended Checks - Prior to Tank Fill for Preparation for Dispatch Onshore/Offshore
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5.3 Safety Considerations Associated with Tank Use and Risk Assessment
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6 TANK PRACTICES
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6.1 Accessing the Tank
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6.2 Tank and Contents Handling
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6.2.1 Sampling
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6.2.2 Discharging
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6.2.3 PV valve/Relief valve operation
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6.2.4 Tank Ancillaries Intervention
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6.3 Hooking On/Off
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6.4 Stacking
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6.5 Labelling And Documentation
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6.6 Receipt and Dispatch
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6.7 Lifting Assemblies and Slinging
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7.5 Bottom Outlet Valve Arrangement
Main Discharge Valve
Lever Operated Foot Valve Sampling Point Valve
7 APPENDICES
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7.1 Outbound/Inbound Tank Checklist
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7.2 Load Security Inspection Procedures Flowchart
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7.3 Pre - Fill Tank Checklist
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7.4 Tank / Vessel Types and General Arrangements
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7.5 Bottom Outlet Valve Arrangement
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7.6 Ancillaries on the Tank Top
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8 REFERENCES AND ACKNOWLEDGMENTS
End Cap
End Cap
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
22 Manway Lid (Tank Top Lid / Man Lid)
Air Inlet Valve Pressure Vacuum Relief Valve (not to be manually operated)
View of the Manway Lid and and Pressure / Tank Vacuum Valve (grating removed for picture clarity).
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7.4 Tank / Vessel Types and General Arrangements INSPECTED BY: SIGNATURE: DATE:
This Guideline, Design and Handling of Chemical Tanks has been compiled as part of the Step Change In Safety overall objective of improving safety within the Oil & Gas industry.
From an operational aspect, key issues addressed include recommendations to eliminate: • access to the top of a tank, • manual operation of the pressure/vacuum valve.
The Guideline was commissioned due to offshore industry concerns over the design and safe use of cargo carrying units and portable chemical tanks, and fatalities offshore relating to the handling of these units (See Step Change in Safety Fatality Report). The objective of this Guidance is to provide information to Designer, Manufacturer, Owner and End User of IMO Chemical Transport Tanks, which will lead to rationalisation of equipment and practices used within the industry thus reducing accidents or incidents during handling operations. Example of 600 gallon, (2900 litres), vertical tank.
From a design perspective, the guidance looks at key issues. It recommends that:
Further recommendations on : • contents measurement, • tank access • back loading fluids from offshore facilities are also included. The Guidance also outlines the risk assessment approach for any operations out with the Guidance. The Guidance provides assistance to meet these recommendations by providing: • a Tank Lifecycle Flowchart, • Tank Inspection Checklists,
• valves requiring manual operation, • the lifting accessories master link,
• an Outbound/Inbound Chemical Tanks Checklist outlining competency levels for personnel.
be accessible from deck or ground level. This will reduce the need to access the top of the tank in the offshore environment.
Example of 1000 gallon, (4800 litres), horizontal tank.
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Example of 500 gallon tank.
Comparison of new and old tank design (600 imperial gallons).
Horizontal Chemical Tank.
Supply Vessel Offloading.
Vertical Chemical Tank.
1
The guidance identified within this publication is aimed at ensuring personnel, whose duties involve the handling and transportation of chemical tanks and their contents at offshore installations, are aware of the hazards and precautions which must be considered during tank operations. The objective of this guidance is to increase awareness of key factors relating to chemical tanks and contents handling and to reinforce existing knowledge with additional information. To achieve maximum impact, supervision should follow up safety presentations by talking to appropriate personnel about tank handling techniques, and their understanding of the required safety standards. Subsequent monitoring of chemical tank operations should be undertaken to ensure safety considerations have been raised to, and maintained at, an acceptable level.
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:
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CHECK SERIAL NUMBERS, TARE & BLACK PATCH STICKER
q
2
CONDITION OF TANK FRAME FOR DAMAGE ETC
q
3
EXAMINE TANK VESSEL & CRADLES
q
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CHECK END CAPS ARE SUPPLIED AND SECURED
q
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CHECK CONDITION / OPERATION OF FOOT VALVE & OPERATING LEVER
q
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CHECK CONDITION OF DISCHARGE VALVE
q
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CHECK CONDITION OF SAMPLE / DRAIN VALVE
q
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CHECK DUST CAP & SECURING WIRE ON DISCHARGE / SAMPLE VALVES
q
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CHECK CONDITION OF EARTHING POINT
q
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CHECK CONDITION OF DOCUMENT TUBE HOLDER
q
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CHECK CONDITION OF DIP STICK HOLDER & DIP STICK WHERE FITTED
q
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CHECK LIFTING LUGS FOR DAMAGE
q
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CHECK LIFTING SLINGS, SHACKLES & SPLIT PINS
q
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CHECK TANK MANWAY LID
q
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CHECK CONDITION OF TANK MANWAY LID, SWING BOLTS & HINGE PIN
q
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CHECK CONDITION OF TANK-LID, INCLUDING LID SEAL
q
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CHECK TANK INTERIOR FOR CLEANLINESS INCLUDING FOOT VALVE & SAMPLE VALVE
q
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CHECK CONDITION OF PRESSURE VACUUM RELIEF VALVE & GAUZE
q
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CHECK CONDITION OF DIP VALVE, DUST COVER & RETAINING WIRE
q
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CHECK THAT TEST DATA PLATE IS FIXED & TANK MARKINGS / CHEVRONS ARE LEGIBLE
q
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COMPLETE CERTIFICATE OF CLEANLINESS & PASS TO RELEVANT PERSON FOR ACTION
q
DETAILS OF DAMAGE OR DEFECTS FOUND:
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Step Change in Safety Fatality Report www.stepchangeinsafety.net
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7.2 Load Security Inspection Procedures (LSIP)
The points made within this section apply to all new and existing tanks, with an overall objective that all current tank stock can fall in line with this guidance by the end of 2005.
The following flowchart depicts the procedure to be followed prior to any movements of chemical tanks.
Load Security Inspection Procedure
3.1 Design
This procedure has been adapted from the Talisman Energy (UK) Ltd. process for ensuring the safety and security of cargo during transportation to and from 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
Onshore Load Checker Is the unit packed properly with no loose items found anywhere on unit?
No
Yes
Does the problem concern loose items left on unit?
No
Arrangers for the person/s responsible for packing/securing the unit to carry out necessary remedial action.
Onshore Load Checker
Onshore Load Checker
Affixes YELLOW Load Security Tie and Label to the unit.
Removes any loose items from unit prior to loading operations.
End-User of Cargo
Prior to loading (Vehicles/Vessel) Transporter/Shipper checks to ensure that YELLOW Load Security Tag and Label have been attached to unit.
Unloads/Empties unit and, where applicable, packs the unit for return to Beach and informs Offshore Load Checker that unit is ready for shipping.
Transporter/Shipper Yes
Transports/Ships unit to relevant destination.
When double stacking is being practiced then access to the crane master link must be independent of the tank, by means of a suitable access platform or ladder. There will be no crane movement other than attaching the crane hook to the master link until all personnel have withdrawn from the immediate vicinity of the tank and the banksman/loadhandler has given the all clear to the crane operator.
All tanks to have a sling configuration that allow easy access to the master ring without accessing/climbing on the tank in any way
Note: The Design of Chemical Tanks is primarily covered by the IMDG code.
Transporter/Shipper Has Load Security Tag and Label been attached to unit?
All pipefittings will be to a recognised standard
The practice of double stacking tanks offshore is not recommended and should be avoided. Where deemed necessary it should be by exception only and a formal risk assessment is recommended followed by direct supervision of the activity.
All tanks will have a functional sealable document pouch fitted
Yes
Onshore Load Checker Informs the relevant person that the unit has been checked and the Load Security Tag and Label attached.
All tanks to have fully grated or flat plate tops to ensure complete closure All tanks to have non-slip paint coated to access ladders where fitted.
Onshore Load Checker Prior to loading of Container/Tank, nominated Load Checker shall carry out a visual inspection of the unit to ensure that all items are properly packed, container doors are securely closed, and that no loose items are left lying on the unit in any place.
All valves should be suitably placed to allow safe access and be accessible from ground/deck level.
3.2 Handling
No Offshore Load Checker Transporter/Shipper Refuses to transport/ship unit until Load Security Tag and Label is attached (thereby indicating that the load has been security checked).
Is the unit packed securely with no loose items found anywhere on unit? Yes
Prior to loading, Offshore Load Checker carries out a visual inspection of the unit to ensure that all items are securely packed, container doors are closed, and that no loose items are left lying on the load in any place.
No
End of Process 18
Offshore Load Checker
Offshore Load Checker
Attaches ORANGE Load Security Tag and Label informs relevant person that unit is ready to be shipped back to beach.
Arranges for the person responsible for packing/securing the unit to carry out the necessary remedial action.
Typical view of a fully grated tank.
Typical access ladder.
Positioning of Masterlink.
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3.3 Tank Access
3.7 Risk Assessment
7.1 Outbound/Inbound Chemical Tanks Checklist
Working on the top of the tank should only be undertaken as a last resort AND IS NOT RECOMMENDED. However should this be absolutely necessary then a risk assessment must be conducted and all appropriate safety precautions be implemented. Reference should be made to the Working at Height Regulations.
It is recommended that risk assessments should be carried out for the following established operations:
The following checklist is a revision of the existing UKOOA tank checklist, which both updates and clarifies requirements and checklist contents to further enhance the management and safety associated with the use of tanks.
• Accessing the tops • Sampling and Dipping • Stacking
Access to the top of the tank should be via the permanent access ladder (if fitted), portable ladder or a suitable work platform and appropriate fall arrest equipment must be worn.
• Discharging & Filling
Access requirements to both valving and lifting assembly must be considered when positioning or laying down tanks.
• Backloading of chemicals/waste
Opening of the tank manway lid is not permissible offshore unless access is required for backloading, which would then fall under special circumstances and should be subject of a risk assessment.
3.4 Contents Measuring IMDG Code
• Filling, Discharging and including Hose Assembly Manual Handling • Crane lifts inbound/outbound
Product Name: Offshore Location:
Does Test Plate have at least a full month remaining? Yes/No Last Test Date: Collection Address (if different from above):
Tank Supplier:
• Access to the lifting assembly master link when tanks are stacked • Chemical compatibility Note: Such assessments should include worker exposure risk, the Control Of Substances Hazardous To Health (COSHH), and reference the appropriate Material Safety Data Sheets (MSDS’s).
Item No
Ready for Collection: Date: Time:
Check No
1 2
8 9 10
Clarity of tank contents being dispatched or returned must exist through labelling and documentation.
11 12 13
Offshore procedures regarding the return of good or spent chemicals must be clear and supported by correct labelling and accompanying documentation to ensure waste legislation compliance and to facilitate handling/ disposal on return.
Cargo Ref
Cargo ID
Product Quantity litres
Total “Lift” Weight (Kg)
IMDG Class / UN No
Customs Status
1
3 4 5 6 7
3.5 Contents Management
14 15
Tank / Cargo Checklist
Chemical Shipper Offshore Provider Outbound Receiver
Back Shipper Onshore Load Inbound Receiver Operative
Confirm 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) Have all old labels been removed? Have copies of all relevant certificates, dangerous goods, MSDS’s and TREM cards been dispatched with the tank? Are there any signs of leaking chemical? Are all valves closed, and caps refitted? Has the main valve been tagged and tie wrapped closed? Is manlid closed and fully secured and has security tag been fitted? Is special coupling attached (if applicable)? (Chemical Provider and Back Loader only) Have you checked the gross weight against SWL? Does the lifting set details match those on the Data / Inspection plate? Where appropriate, has dangerous goods cargo been completed and relevant authorities notified as per IMDG Code? Product Label is on each side? Hazard Label is on each side? Has Tank been visually checked for any obvious damage (frame, gratings, slings, lifting points, fittings etc)? 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? Have appropriate declarations been made for waste backload?
*Any “No” above will result in non-shipment Sign Off For All Of the Above Checks
All tanks should be fitted with a telltale, (tiewrap or similar), on the tank manway lid and main discharge valve to verify the tank has not been opened.
3.6 Checklists
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Tank ID: Customer Details
• Opening of manlid for loading of chemicals
Any contents measuring device fitted to tank must conform to current IMDG Code requirements.
A checklist for tanks is included in the “UKOOA guidance for Safe Packaging and Handling of Cargo to and from Offshore Locations”, however this has been expanded upon with the Outbound/Inbound summary ticket (appendix 7.1)
A key point and change recommended is that for every tank there exists a single corresponding checklist, which follows the tank in its journey.
Step Change in Safety Task Risk Assessment Guide www.stepchangeinsafety.net
Name of Yard Operative:
Name of Shipper Inbound Operative:
Signature of Yard Operative:
Signature of Shipper Inbound Operative:
Date:
Date:
Name of Shipping Outbound Operative:
Name of Offshore Receiver:
Signature of Shipping Outbound Operative:
Signature of Offshore Receiver:
Date:
Date:
Name of Back Load Operative:
Name of Onshore Receiver:
Signature of Backload Operative:
Signature of Onshore Receiver:
Date:
Date:
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6.6 Receipt and Despatch
6.7 Lifting Assemblies and Slinging
Upon receipt of any tank always ensure:
The lifting and slinging of tanks falls within regulations below and as such will not be covered in this document.
• The lifting accessories and padeyes are in good condition 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 the contents. • 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 are fitted.
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For reference the key documents are: • Lifting Operations and Lifting Equipment Regulations 1998 SI2307, (LOLER). • Regulation 9 of LOLER, Approved Code of Practice, (HSE Books L113). • Step Change in Safety Lifting and Mechanical Handling Guidelines.
3.8 Document Pouches/Load Security Tagging Marshalling of tanks utilising a tagging method, (Load security Inspection Procedure See section 4), carried out by the nominated responsible person for freight forwarding and return is a recommended practice. Document pouches should be present and clearly identified on the tank. Where this is not the case, remedial action to ensure the effective communication of the tank contents details must be arranged. There shall be a designated responsible person offshore to both accept and dispatch chemical tanks.
It is recommended that there are nominated persons with assigned responsibilities for the management and handling of all aspects of chemical tanks both onshore and offshore. Ideally this person should also be responsible for baskets, CCU’s (Cargo Carrying Units) etc. to ensure a full overview of the freight situation, risks and controls from an organisational 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
Contents documentation shall be kept in the document pouch and remain with the tank throughout it’s cycle and be updated as and when appropriate (reference flowchart).
• Tank labelling compliance and update/change management • Integrity of the manway lid and discharge valve telltale
• The product and hazard labels are appropriate for the contents and are visible or where the tank is empty all labels have been removed.
3.9 Responsibilities and Training
In conjunction with the above offshore personnel handling or using tanks should receive appropriate training, which includes:
• All relevant documentation has been inserted into document pouch.
Training of personnel with ‘hands on’ responsibility for tanks (including content) is considered essential.
LIFTING AND MECHANICAL HANDLING OPERATIONS
The instructions identified above, are for general guidance. It is the ultimate responsibility of all users and handlers to ensure that all operating and safety procedures are strictly observed.
It is recommended the information contained in this guidance document be used only as a supplement to further training.
Refer to Outbound/Inbound Tank Summary Checklist (Appendix 7.1).
These guidelines are aimed at providing supervision with sufficient training material from which they can develop their own specific training programme, for personnel who are expected to work with chemical tanks or their contents.
MANUAL HANDLING
Example of Document Pouch.
RISK ASSESSMENT CHEMICAL HANDLING (COSHH) ENVIRONMENTAL ISSUES SAFETY OBSERVATION SYSTEMS The Step Change in Safety Lifting and Mechanical Handling Guidance contains further information on training and competency.
Inspection Security Tag.
5
3.10 Documentation and Labelling of Tanks Tank contents labels are to be clear and visible on all sides to facilitate deck loading and avoid incorrect decanting. On completion of all checks, an Outbound/Inbound Tank summary checklist should be completed for each load being dispatched offshore or returned onshore. The checklist should then be placed in the document pouch along with relevant shipping details.
6.3 Hooking On/Off
6.5 Labelling and Documentation
When in the stowed position, the tank lifting accessories should be located hanging down the outside of the tank frame. This allows easy access to the master link, when hooking on/off the crane hook. This also avoids the necessity for climbing on top of the tank.
All cargos, including backloaded cargos of dangerous goods shall be correctly declared, packaged and labelled, secured, placarded and documented, and segregated in accordance with the regulations and MGN 282(M) and IMDG Code plus subsequent notices issued by the Maritime and Coastguard Authority.
Particular care must be taken to ensure that the lifting accessories and crane hook does not inadvertently snag on the tank framework or ancillaries causing the possibility of premature movement of the tank.
• The Offshore Supply Vessel is advised by the quayside service provider of the quantity and nature of dangerous goods prior to loading.
3.11 Tank Life Cycle Flowchart Attached for reference (front cover) is a flowchart which represent the life cycle of a tank, it also identifies the persons associated with each stage; their duties and key information to ensure that operations and works associated with it are managed safely and effectively.
Enclosed Tank Lid.
• The Offshore Supply Vessel is advised by the OIM (Offshore Installation Manager) / Duty Holder or nominated deputy, of the quantity and nature of backloaded dangerous goods prior to loading.
3.12 Backloading of Chemicals and Waste Where backloading of chemicals or waste is required then it is recommended dedicated tanks should be requested to avoid cross contamination. Clear labelling and documentation are essential, however there may be occasions when previously used tanks must be used. In all cases of backloading, a risk assessment is required which would consider all aspects in section 5.3 as a minimum and requires the authority of the offshore duty holder.
To assist the Master of the Offshore Supply Vessel in planning the cargo stowage to ensure that segregation of dangerous goods is maintained, it is a requirement that:
View showing the correct position and height of the master link and the tank slinging arrangement.
In the case of the backload, it is the responsibility of the consignor/packer to ensure that the backloaded goods are backloaded in accordance with the requirements of the IMDG code. That means correctly declared, packaged, labelled, secured, placarded and with the correct documentation. In addition consideration must also be given to the order of backloading to ensure that the segregation requirements can be complied with.
Storage Areas.
6.4 Stacking Double stacking of chemical tanks offshore should be actively discouraged and only sanctioned where it becomes absolutely essential and following an appropriate risk assessment.
Where waste or contaminated chemical is to be backloaded, appropriate labelling MSDS should be obtained and fixed to the tank that correctly identifies the tank contents and hazards. All waste or contaminated chemicals should be sent to your responsible Waste Management Contractor for disposal. Only part used and non contaminated chemicals should be returned to the original Provider in the tank with original labels and MSDS.
It is the responsibility of the consignee/receiver of any dangerous goods to remove any old placards affixed to the container prior to its re-use.
Personnel should never climb on to a double-stacked chemical tank. Where deemed required a thorough and robust risk assessment process with mitigating measures and actions is required. IDEALLY THE TANKS SHOULD BE UNSTACKED.
Offshore Unloading, demonstrating potential for snagging (open tanks not meeting guidelines).
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6.2.2 Discharging When discharging tanks containing flammable product, the tank should be bonded, (earthed by a competent person) in order to prevent a build up of static electricity and subsequent danger of ignition/explosion. • Remove drip cap from the main discharge outlet and connect hose to the main discharge outlet valve. • Remove end caps from air inlet valve, then open air inlet valve manually. • Open the lever operated foot valve and main discharge valve, (in that order), to allow the tank to discharge. When discharging the tank, the following actions should be considered: • Ambient temperature, viscosity and specific gravity, all may inhibit free flow. • Poor flow - on no account should pneumatic air be used to assist with the process.
Where tanks are fitted with manual Air Inlet Valves (AIV) as recommended by these guidelines this valve will be marked 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 exception being onshore tank maintenance routine). Any interference with this valve will affect its operational functionality and thereby compromise safety and tank integrity. Note: The design of Chemical Tanks is primarily covered by IMDG Code.
(Diagram of flowchart can be found in appendix 7.2)
4.4 Definitions 4.4.1 Cargo
4.1 Introduction This describes the procedures to be followed to ensure the safety and security of cargo during transportation to and from sites.
4.2 Purpose The purpose of the document is to ensure as far as is reasonably practicable that cargo, as defined in section 4.4.1, is in a secure condition and free from any loose items that could, if they fell, cause injury to people or damage to plant, equipment, trucks, offshore supply vessels and other road users.
6.2.4 Tank Ancillaries Intervention
For the purposes of this guidance document cargo is any item that is to be lifted by crane or other mechanical means. The range of such items is diverse therefore it is not practicable to attempt to list them all in this document. 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 other well service packages). • Waste skips. • Helifuel tanks. • Chemical tanks.
Intervention on any tank ancillary equipment is not recommended. Intervention may only be permitted following consultation with the tank manager/owner and after a suitable risk assessment.
Note: Operators should be aware of the following hazard. The design of the manual air inlet valve is such that any build up of pressure will be vented clear of personnel when the valve is opened.
4.3 Scope
• Special loads (Fabrications).
The procedures shall apply at all sites both on and offshore. It shall also apply at the premises of other parties such as fabricators and vendors that are responsible for packaging and preparing equipment for delivery to sites that need to be lifted by crane or other mechanical means.
4.4.2 Transportation For the purposes of this guidance document transportation shall be any means of conveying the above items e.g. a truck or offshore Supply Vessel.
Upon completion of discharging the tank contents: • Ensure all valves are closed, end caps are refitted and secured accordingly.
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Example of vacuum/relief valve fitted with flame arresting gauze.
Example of Air Inlet Valve.
Load Inspection Security Tagging Procedure Flowchart.
7
4.4.3 Responsibilities Management shall ensure that a competent person is nominated to act as a Load Checker with the responsibility to carry out a check of cargo prior to it being lifted onto a means of transport. As far as reasonably practicable such checks shall ensure, that the cargo has been properly packed. This does not absolve the person responsible for packing the consignment from carrying out the task with all reasonable care. The checker shall not be responsible for the correct packaging of the cargo unless they have personally carried out the task. In the event that the checker does suspect a load has not been properly packed he shall bring this to the attention of the packer so that remedial action can be taken.
4.4.4 Procedure Description Before cargo is transferred to the supply vessel, the checker 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 the operations offshore that are not an integral part of the tank should be shipped separately in closed containers. Note: this does not absolve the equipment originator from taking all reasonable precautions to ensure the load is fit for lifting in the first place. • All securing mechanisms should be properly engaged. • The design of tanks is such that there should be no protrusions out with the tank frame which would present a snagging hazard.
6.1 Accessing the Tank
6.2 Tank and Contents Handling
Access/climbing on top of a chemical tank should only be undertaken as a last resort AND IS NOT RECOMMENDED.
Among the reasons given for climbing on top of tanks are,
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.
• Opening the tank lid to determine level.
Note: All tanks should have a fully enclosed grated or plated top and where not in place then access to the top of the tank should be avoided and only carried out following a risk assessment and if the activity is accompanied by a watchperson. Suitable height safety arrangements in line with Working at Heights Regulation must be in place should access to the top of a tank be necessary.
• Accessing the dip tube.
• To take samples. • To operate the vacuum breaker or open the hatch to assist flow. • To hook the crane on to the master link. With the new design there is no actual reason to climb on top of the tank. By the end of 2005, when the design criteria and the application of the procedures within these guidelines are implemented, the need to access the top of the tank will be eliminated.
6.2.1 Sampling
• That nothing has been added to the tank to present a snagging hazard.
Sampling of the tank contents should be carried out through the 3/4” sample valve, an off-take from the main discharge line at the base of the tank.
Further information on carrying out safety checks is contained in the UKOOA Guidance for the Safe Packing and Handling of Cargo to and from Offshore Installations.
• Remove the cap, open the lever-operated foot valve. • Place clean sample jar at sample valve discharge and drain off sample carefully ensuring all potential for drips/spillages/splashes are catered for in the risk assessment. • Replace protective cap, close valves.
Tank Inspection prior to loadout
Example of grated tank top.
• Adhere to precautions identified on Health and Safety Data Sheets and the COSHH and Risk Assessments. Note: No intervention on Air Inlet valve or Pressure/Vacuum breaker valve is required for sampling.
8
Example of fall protection equipment.
13
5.3 Safety Considerations Associated with Tank Use and Risk Assessment
4.4.5 Cargo Integrity Tagging Once the load checker is satisfied the cargo is safe to be lifted he will attach a coloured security tie and label to a suitable and conspicuous point on the load. The label must be initialled and dated by the checker.
Prior to undertaking any work associated with chemical tanks and their contents, personnel must consider all aspects of safety and ensure safe working practices are adhered to. This can be effectively achieved by carrying out a Risk Assessment, which should consider as a minimum the following safety questions: • Is a formal Risk Assessment required?
Tank condition and clear markings.
• Is it a danger to other operations? • Is it too close to the edge of a facility, equipment or other cargo unit?
Copies of the pre shipment checklist must be retained for audit purposes.
• Has the segregation of products been considered?
4.4.6 Vendor Premises
• 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 there a MSDS sheet available for the tank contents? • Is there a danger of radiant heat from a flare or other source? • Has the tank been checked for loose items? • Is double stacking unavoidable and if so are tanks and Stacking posts compatible? • Is there any visible mechanical damage? • Is the tank load within the storage area weight limit? • Has backload product compatibility been established to ensure hazardous chemical by products have not been formed? • Is it possible for flammable vapours to escape to atmosphere? • Has the tank been properly earthed by a competent person?
12
The checker will not be responsible for ensuring that loads have been prepared properly. That will be the responsibility of the packer/filler. The purpose of the security tie and label is to signify that the load is safe for transportation. The packer/filler will confirm that he has properly packed the load on the manifest. The packer/filler and checker may be the same person but where they are not, the checker must be satisfied as far as is reasonably practical that the packer has prepared the load properly.
• Is the tank located at the correct stowage point or designated area?
• Is the lifting sling master link accessible without climbing on top of the tank frame?
INBOUND TAG
Onshore tank filling facility showing means of safe access.
Prior to cargo being collected from the vendor’s premises, the vendor shall ensure it is safe to be loaded on to the transporting vehicle. Once the vendor is satisfied that the cargo is secure, the person appointed as checker must attach a yellow security tie and label to the load and initial and date same.
4.4.7 Quayside Once the cargo has been loaded and is in transit, there should be no occasion that should cause its security or integrity to be jeopardised. However the following checks that are good practice must be carried out at mid points in the delivery of the cargo although the fitting of additional security ties and labels is not required. • Outbound cargo arriving at the quayside shall be subjected to a further inspection prior to it being loaded onto the supply vessel. • Inbound cargo destined for onward shipping to a vendor shall be inspected prior to it being loaded onto the transporting vehicle A flowchart depicting the Load Security Inspection Procedure (LSIP) can be found in appendix 7.2 of this guidance.
OUTBOUND TAG
Details on purchasing inspection tags can be obtained from www.stepchangeinsafety.net (company specific tags may differ)
9
5.1 Good Practice Chemical Tank Inspection Illustrated Checklist
5.2 Recommended Checks - Prior to Tank Fill for Preparation for Dispatch Onshore/Offshore The following checks when working with tanks and their contents should be carried out as a minimum but not limited to: • Check the condition of the frame and ensure there are no signs of excessive corrosion or deformation. • Ensure that the tank is not overloaded, (volume of product in 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 prevent certification expiring when offshore. • Ensure that any old hazard and supply labelling has been removed • Affix all relevant hazard and supply labelling (where required). • 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 or mechanical damage • Check all valve assemblies for damage and ensure end caps are in place. Plastic ties as indicators of valve closure are recommended.
• Check the manlid is securely closed and in good condition, 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 is stowed on the outside of the tank frame for ease of connection to the crane both onshore and offshore. Ensure this is secured to the tank prior to transportation once onshore. • Check the grating for any signs of damage or loose fittings. • Check the top surfaces for any potential loose or potential dropped objects. • Check the forklift pockets for loose items such as tools, stones, timber, etc. Note: Offshore tanks are being fitted with air inlet valves at the same end as the main bottom discharge valve. This is to remove the need for personnel to climb on top of the tank to vent prior to discharge. This valve is sometimes difficult to see through the frame of the tank and must be checked for security. Defects: - any defects noted within the above are to be formally reported. Thereafter the tank should be isolated and remedial action taken in accordance with the duty holders responsibilities. (Refer to Outbound/Inbound Tank summary checklist appendix 7.1 and Pre-fill tank checklist 7.3)
Chemical Tank Illustrated Checklist
10
11
Pre-filling Tank Checklist.
5.1 Good Practice Chemical Tank Inspection Illustrated Checklist
5.2 Recommended Checks - Prior to Tank Fill for Preparation for Dispatch Onshore/Offshore The following checks when working with tanks and their contents should be carried out as a minimum but not limited to: • Check the condition of the frame and ensure there are no signs of excessive corrosion or deformation. • Ensure that the tank is not overloaded, (volume of product in 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 prevent certification expiring when offshore. • Ensure that any old hazard and supply labelling has been removed • Affix all relevant hazard and supply labelling (where required). • 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 or mechanical damage • Check all valve assemblies for damage and ensure end caps are in place. Plastic ties as indicators of valve closure are recommended.
• Check the manlid is securely closed and in good condition, 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 is stowed on the outside of the tank frame for ease of connection to the crane both onshore and offshore. Ensure this is secured to the tank prior to transportation once onshore. • Check the grating for any signs of damage or loose fittings. • Check the top surfaces for any potential loose or potential dropped objects. • Check the forklift pockets for loose items such as tools, stones, timber, etc. Note: Offshore tanks are being fitted with air inlet valves at the same end as the main bottom discharge valve. This is to remove the need for personnel to climb on top of the tank to vent prior to discharge. This valve is sometimes difficult to see through the frame of the tank and must be checked for security. Defects: - any defects noted within the above are to be formally reported. Thereafter the tank should be isolated and remedial action taken in accordance with the duty holders responsibilities. (Refer to Outbound/Inbound Tank summary checklist appendix 7.1 and Pre-fill tank checklist 7.3)
Chemical Tank Illustrated Checklist
10
11
Pre-filling Tank Checklist.
5.3 Safety Considerations Associated with Tank Use and Risk Assessment
4.4.5 Cargo Integrity Tagging Once the load checker is satisfied the cargo is safe to be lifted he will attach a coloured security tie and label to a suitable and conspicuous point on the load. The label must be initialled and dated by the checker.
Prior to undertaking any work associated with chemical tanks and their contents, personnel must consider all aspects of safety and ensure safe working practices are adhered to. This can be effectively achieved by carrying out a Risk Assessment, which should consider as a minimum the following safety questions: • Is a formal Risk Assessment required?
Tank condition and clear markings.
• Is it a danger to other operations? • Is it too close to the edge of a facility, equipment or other cargo unit?
Copies of the pre shipment checklist must be retained for audit purposes.
• Has the segregation of products been considered?
4.4.6 Vendor Premises
• 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 there a MSDS sheet available for the tank contents? • Is there a danger of radiant heat from a flare or other source? • Has the tank been checked for loose items? • Is double stacking unavoidable and if so are tanks and Stacking posts compatible? • Is there any visible mechanical damage? • Is the tank load within the storage area weight limit? • Has backload product compatibility been established to ensure hazardous chemical by products have not been formed? • Is it possible for flammable vapours to escape to atmosphere? • Has the tank been properly earthed by a competent person?
12
The checker will not be responsible for ensuring that loads have been prepared properly. That will be the responsibility of the packer/filler. The purpose of the security tie and label is to signify that the load is safe for transportation. The packer/filler will confirm that he has properly packed the load on the manifest. The packer/filler and checker may be the same person but where they are not, the checker must be satisfied as far as is reasonably practical that the packer has prepared the load properly.
• Is the tank located at the correct stowage point or designated area?
• Is the lifting sling master link accessible without climbing on top of the tank frame?
INBOUND TAG
Onshore tank filling facility showing means of safe access.
Prior to cargo being collected from the vendor’s premises, the vendor shall ensure it is safe to be loaded on to the transporting vehicle. Once the vendor is satisfied that the cargo is secure, the person appointed as checker must attach a yellow security tie and label to the load and initial and date same.
4.4.7 Quayside Once the cargo has been loaded and is in transit, there should be no occasion that should cause its security or integrity to be jeopardised. However the following checks that are good practice must be carried out at mid points in the delivery of the cargo although the fitting of additional security ties and labels is not required. • Outbound cargo arriving at the quayside shall be subjected to a further inspection prior to it being loaded onto the supply vessel. • Inbound cargo destined for onward shipping to a vendor shall be inspected prior to it being loaded onto the transporting vehicle A flowchart depicting the Load Security Inspection Procedure (LSIP) can be found in appendix 7.2 of this guidance.
OUTBOUND TAG
Details on purchasing inspection tags can be obtained from www.stepchangeinsafety.net (company specific tags may differ)
9
4.4.3 Responsibilities Management shall ensure that a competent person is nominated to act as a Load Checker with the responsibility to carry out a check of cargo prior to it being lifted onto a means of transport. As far as reasonably practicable such checks shall ensure, that the cargo has been properly packed. This does not absolve the person responsible for packing the consignment from carrying out the task with all reasonable care. The checker shall not be responsible for the correct packaging of the cargo unless they have personally carried out the task. In the event that the checker does suspect a load has not been properly packed he shall bring this to the attention of the packer so that remedial action can be taken.
4.4.4 Procedure Description Before cargo is transferred to the supply vessel, the checker 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 the operations offshore that are not an integral part of the tank should be shipped separately in closed containers. Note: this does not absolve the equipment originator from taking all reasonable precautions to ensure the load is fit for lifting in the first place. • All securing mechanisms should be properly engaged. • The design of tanks is such that there should be no protrusions out with the tank frame which would present a snagging hazard.
6.1 Accessing the Tank
6.2 Tank and Contents Handling
Access/climbing on top of a chemical tank should only be undertaken as a last resort AND IS NOT RECOMMENDED.
Among the reasons given for climbing on top of tanks are,
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.
• Opening the tank lid to determine level.
Note: All tanks should have a fully enclosed grated or plated top and where not in place then access to the top of the tank should be avoided and only carried out following a risk assessment and if the activity is accompanied by a watchperson. Suitable height safety arrangements in line with Working at Heights Regulation must be in place should access to the top of a tank be necessary.
• Accessing the dip tube.
• To take samples. • To operate the vacuum breaker or open the hatch to assist flow. • To hook the crane on to the master link. With the new design there is no actual reason to climb on top of the tank. By the end of 2005, when the design criteria and the application of the procedures within these guidelines are implemented, the need to access the top of the tank will be eliminated.
6.2.1 Sampling
• That nothing has been added to the tank to present a snagging hazard.
Sampling of the tank contents should be carried out through the 3/4” sample valve, an off-take from the main discharge line at the base of the tank.
Further information on carrying out safety checks is contained in the UKOOA Guidance for the Safe Packing and Handling of Cargo to and from Offshore Installations.
• Remove the cap, open the lever-operated foot valve. • Place clean sample jar at sample valve discharge and drain off sample carefully ensuring all potential for drips/spillages/splashes are catered for in the risk assessment. • Replace protective cap, close valves.
Tank Inspection prior to loadout
Example of grated tank top.
• Adhere to precautions identified on Health and Safety Data Sheets and the COSHH and Risk Assessments. Note: No intervention on Air Inlet valve or Pressure/Vacuum breaker valve is required for sampling.
8
Example of fall protection equipment.
13
6.2.2 Discharging When discharging tanks containing flammable product, the tank should be bonded, (earthed by a competent person) in order to prevent a build up of static electricity and subsequent danger of ignition/explosion. • Remove drip cap from the main discharge outlet and connect hose to the main discharge outlet valve. • Remove end caps from air inlet valve, then open air inlet valve manually. • Open the lever operated foot valve and main discharge valve, (in that order), to allow the tank to discharge. When discharging the tank, the following actions should be considered: • Ambient temperature, viscosity and specific gravity, all may inhibit free flow. • Poor flow - on no account should pneumatic air be used to assist with the process.
Where tanks are fitted with manual Air Inlet Valves (AIV) as recommended by these guidelines this valve will be marked 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 exception being onshore tank maintenance routine). Any interference with this valve will affect its operational functionality and thereby compromise safety and tank integrity. Note: The design of Chemical Tanks is primarily covered by IMDG Code.
(Diagram of flowchart can be found in appendix 7.2)
4.4 Definitions 4.4.1 Cargo
4.1 Introduction This describes the procedures to be followed to ensure the safety and security of cargo during transportation to and from sites.
4.2 Purpose The purpose of the document is to ensure as far as is reasonably practicable that cargo, as defined in section 4.4.1, is in a secure condition and free from any loose items that could, if they fell, cause injury to people or damage to plant, equipment, trucks, offshore supply vessels and other road users.
6.2.4 Tank Ancillaries Intervention
For the purposes of this guidance document cargo is any item that is to be lifted by crane or other mechanical means. The range of such items is diverse therefore it is not practicable to attempt to list them all in this document. 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 other well service packages). • Waste skips. • Helifuel tanks. • Chemical tanks.
Intervention on any tank ancillary equipment is not recommended. Intervention may only be permitted following consultation with the tank manager/owner and after a suitable risk assessment.
Note: Operators should be aware of the following hazard. The design of the manual air inlet valve is such that any build up of pressure will be vented clear of personnel when the valve is opened.
4.3 Scope
• Special loads (Fabrications).
The procedures shall apply at all sites both on and offshore. It shall also apply at the premises of other parties such as fabricators and vendors that are responsible for packaging and preparing equipment for delivery to sites that need to be lifted by crane or other mechanical means.
4.4.2 Transportation For the purposes of this guidance document transportation shall be any means of conveying the above items e.g. a truck or offshore Supply Vessel.
Upon completion of discharging the tank contents: • Ensure all valves are closed, end caps are refitted and secured accordingly.
14
Example of vacuum/relief valve fitted with flame arresting gauze.
Example of Air Inlet Valve.
Load Inspection Security Tagging Procedure Flowchart.
7
3.10 Documentation and Labelling of Tanks Tank contents labels are to be clear and visible on all sides to facilitate deck loading and avoid incorrect decanting. On completion of all checks, an Outbound/Inbound Tank summary checklist should be completed for each load being dispatched offshore or returned onshore. The checklist should then be placed in the document pouch along with relevant shipping details.
6.3 Hooking On/Off
6.5 Labelling and Documentation
When in the stowed position, the tank lifting accessories should be located hanging down the outside of the tank frame. This allows easy access to the master link, when hooking on/off the crane hook. This also avoids the necessity for climbing on top of the tank.
All cargos, including backloaded cargos of dangerous goods shall be correctly declared, packaged and labelled, secured, placarded and documented, and segregated in accordance with the regulations and MGN 282(M) and IMDG Code plus subsequent notices issued by the Maritime and Coastguard Authority.
Particular care must be taken to ensure that the lifting accessories and crane hook does not inadvertently snag on the tank framework or ancillaries causing the possibility of premature movement of the tank.
• The Offshore Supply Vessel is advised by the quayside service provider of the quantity and nature of dangerous goods prior to loading.
3.11 Tank Life Cycle Flowchart Attached for reference (front cover) is a flowchart which represent the life cycle of a tank, it also identifies the persons associated with each stage; their duties and key information to ensure that operations and works associated with it are managed safely and effectively.
Enclosed Tank Lid.
• The Offshore Supply Vessel is advised by the OIM (Offshore Installation Manager) / Duty Holder or nominated deputy, of the quantity and nature of backloaded dangerous goods prior to loading.
3.12 Backloading of Chemicals and Waste Where backloading of chemicals or waste is required then it is recommended dedicated tanks should be requested to avoid cross contamination. Clear labelling and documentation are essential, however there may be occasions when previously used tanks must be used. In all cases of backloading, a risk assessment is required which would consider all aspects in section 5.3 as a minimum and requires the authority of the offshore duty holder.
To assist the Master of the Offshore Supply Vessel in planning the cargo stowage to ensure that segregation of dangerous goods is maintained, it is a requirement that:
View showing the correct position and height of the master link and the tank slinging arrangement.
In the case of the backload, it is the responsibility of the consignor/packer to ensure that the backloaded goods are backloaded in accordance with the requirements of the IMDG code. That means correctly declared, packaged, labelled, secured, placarded and with the correct documentation. In addition consideration must also be given to the order of backloading to ensure that the segregation requirements can be complied with.
Storage Areas.
6.4 Stacking Double stacking of chemical tanks offshore should be actively discouraged and only sanctioned where it becomes absolutely essential and following an appropriate risk assessment.
Where waste or contaminated chemical is to be backloaded, appropriate labelling MSDS should be obtained and fixed to the tank that correctly identifies the tank contents and hazards. All waste or contaminated chemicals should be sent to your responsible Waste Management Contractor for disposal. Only part used and non contaminated chemicals should be returned to the original Provider in the tank with original labels and MSDS.
It is the responsibility of the consignee/receiver of any dangerous goods to remove any old placards affixed to the container prior to its re-use.
Personnel should never climb on to a double-stacked chemical tank. Where deemed required a thorough and robust risk assessment process with mitigating measures and actions is required. IDEALLY THE TANKS SHOULD BE UNSTACKED.
Offshore Unloading, demonstrating potential for snagging (open tanks not meeting guidelines).
6
15
6.6 Receipt and Despatch
6.7 Lifting Assemblies and Slinging
Upon receipt of any tank always ensure:
The lifting and slinging of tanks falls within regulations below and as such will not be covered in this document.
• The lifting accessories and padeyes are in good condition 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 the contents. • 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 are fitted.
16
For reference the key documents are: • Lifting Operations and Lifting Equipment Regulations 1998 SI2307, (LOLER). • Regulation 9 of LOLER, Approved Code of Practice, (HSE Books L113). • Step Change in Safety Lifting and Mechanical Handling Guidelines.
3.8 Document Pouches/Load Security Tagging Marshalling of tanks utilising a tagging method, (Load security Inspection Procedure See section 4), carried out by the nominated responsible person for freight forwarding and return is a recommended practice. Document pouches should be present and clearly identified on the tank. Where this is not the case, remedial action to ensure the effective communication of the tank contents details must be arranged. There shall be a designated responsible person offshore to both accept and dispatch chemical tanks.
It is recommended that there are nominated persons with assigned responsibilities for the management and handling of all aspects of chemical tanks both onshore and offshore. Ideally this person should also be responsible for baskets, CCU’s (Cargo Carrying Units) etc. to ensure a full overview of the freight situation, risks and controls from an organisational 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
Contents documentation shall be kept in the document pouch and remain with the tank throughout it’s cycle and be updated as and when appropriate (reference flowchart).
• Tank labelling compliance and update/change management • Integrity of the manway lid and discharge valve telltale
• The product and hazard labels are appropriate for the contents and are visible or where the tank is empty all labels have been removed.
3.9 Responsibilities and Training
In conjunction with the above offshore personnel handling or using tanks should receive appropriate training, which includes:
• All relevant documentation has been inserted into document pouch.
Training of personnel with ‘hands on’ responsibility for tanks (including content) is considered essential.
LIFTING AND MECHANICAL HANDLING OPERATIONS
The instructions identified above, are for general guidance. It is the ultimate responsibility of all users and handlers to ensure that all operating and safety procedures are strictly observed.
It is recommended the information contained in this guidance document be used only as a supplement to further training.
Refer to Outbound/Inbound Tank Summary Checklist (Appendix 7.1).
These guidelines are aimed at providing supervision with sufficient training material from which they can develop their own specific training programme, for personnel who are expected to work with chemical tanks or their contents.
MANUAL HANDLING
Example of Document Pouch.
RISK ASSESSMENT CHEMICAL HANDLING (COSHH) ENVIRONMENTAL ISSUES SAFETY OBSERVATION SYSTEMS The Step Change in Safety Lifting and Mechanical Handling Guidance contains further information on training and competency.
Inspection Security Tag.
5
3.3 Tank Access
3.7 Risk Assessment
7.1 Outbound/Inbound Chemical Tanks Checklist
Working on the top of the tank should only be undertaken as a last resort AND IS NOT RECOMMENDED. However should this be absolutely necessary then a risk assessment must be conducted and all appropriate safety precautions be implemented. Reference should be made to the Working at Height Regulations.
It is recommended that risk assessments should be carried out for the following established operations:
The following checklist is a revision of the existing UKOOA tank checklist, which both updates and clarifies requirements and checklist contents to further enhance the management and safety associated with the use of tanks.
• Accessing the tops • Sampling and Dipping • Stacking
Access to the top of the tank should be via the permanent access ladder (if fitted), portable ladder or a suitable work platform and appropriate fall arrest equipment must be worn.
• Discharging & Filling
Access requirements to both valving and lifting assembly must be considered when positioning or laying down tanks.
• Backloading of chemicals/waste
Opening of the tank manway lid is not permissible offshore unless access is required for backloading, which would then fall under special circumstances and should be subject of a risk assessment.
3.4 Contents Measuring IMDG Code
• Filling, Discharging and including Hose Assembly Manual Handling • Crane lifts inbound/outbound
Product Name: Offshore Location:
Does Test Plate have at least a full month remaining? Yes/No Last Test Date: Collection Address (if different from above):
Tank Supplier:
• Access to the lifting assembly master link when tanks are stacked • Chemical compatibility Note: Such assessments should include worker exposure risk, the Control Of Substances Hazardous To Health (COSHH), and reference the appropriate Material Safety Data Sheets (MSDS’s).
Item No
Ready for Collection: Date: Time:
Check No
1 2
8 9 10
Clarity of tank contents being dispatched or returned must exist through labelling and documentation.
11 12 13
Offshore procedures regarding the return of good or spent chemicals must be clear and supported by correct labelling and accompanying documentation to ensure waste legislation compliance and to facilitate handling/ disposal on return.
Cargo Ref
Cargo ID
Product Quantity litres
Total “Lift” Weight (Kg)
IMDG Class / UN No
Customs Status
1
3 4 5 6 7
3.5 Contents Management
14 15
Tank / Cargo Checklist
Chemical Shipper Offshore Provider Outbound Receiver
Back Shipper Onshore Load Inbound Receiver Operative
Confirm 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) Have all old labels been removed? Have copies of all relevant certificates, dangerous goods, MSDS’s and TREM cards been dispatched with the tank? Are there any signs of leaking chemical? Are all valves closed, and caps refitted? Has the main valve been tagged and tie wrapped closed? Is manlid closed and fully secured and has security tag been fitted? Is special coupling attached (if applicable)? (Chemical Provider and Back Loader only) Have you checked the gross weight against SWL? Does the lifting set details match those on the Data / Inspection plate? Where appropriate, has dangerous goods cargo been completed and relevant authorities notified as per IMDG Code? Product Label is on each side? Hazard Label is on each side? Has Tank been visually checked for any obvious damage (frame, gratings, slings, lifting points, fittings etc)? 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? Have appropriate declarations been made for waste backload?
*Any “No” above will result in non-shipment Sign Off For All Of the Above Checks
All tanks should be fitted with a telltale, (tiewrap or similar), on the tank manway lid and main discharge valve to verify the tank has not been opened.
3.6 Checklists
4
Tank ID: Customer Details
• Opening of manlid for loading of chemicals
Any contents measuring device fitted to tank must conform to current IMDG Code requirements.
A checklist for tanks is included in the “UKOOA guidance for Safe Packaging and Handling of Cargo to and from Offshore Locations”, however this has been expanded upon with the Outbound/Inbound summary ticket (appendix 7.1)
A key point and change recommended is that for every tank there exists a single corresponding checklist, which follows the tank in its journey.
Step Change in Safety Task Risk Assessment Guide www.stepchangeinsafety.net
Name of Yard Operative:
Name of Shipper Inbound Operative:
Signature of Yard Operative:
Signature of Shipper Inbound Operative:
Date:
Date:
Name of Shipping Outbound Operative:
Name of Offshore Receiver:
Signature of Shipping Outbound Operative:
Signature of Offshore Receiver:
Date:
Date:
Name of Back Load Operative:
Name of Onshore Receiver:
Signature of Backload Operative:
Signature of Onshore Receiver:
Date:
Date:
17
7.2 Load Security Inspection Procedures (LSIP)
The points made within this section apply to all new and existing tanks, with an overall objective that all current tank stock can fall in line with this guidance by the end of 2005.
The following flowchart depicts the procedure to be followed prior to any movements of chemical tanks.
Load Security Inspection Procedure
3.1 Design
This procedure has been adapted from the Talisman Energy (UK) Ltd. process for ensuring the safety and security of cargo during transportation to and from 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
Onshore Load Checker Is the unit packed properly with no loose items found anywhere on unit?
No
Yes
Does the problem concern loose items left on unit?
No
Arrangers for the person/s responsible for packing/securing the unit to carry out necessary remedial action.
Onshore Load Checker
Onshore Load Checker
Affixes YELLOW Load Security Tie and Label to the unit.
Removes any loose items from unit prior to loading operations.
End-User of Cargo
Prior to loading (Vehicles/Vessel) Transporter/Shipper checks to ensure that YELLOW Load Security Tag and Label have been attached to unit.
Unloads/Empties unit and, where applicable, packs the unit for return to Beach and informs Offshore Load Checker that unit is ready for shipping.
Transporter/Shipper Yes
Transports/Ships unit to relevant destination.
When double stacking is being practiced then access to the crane master link must be independent of the tank, by means of a suitable access platform or ladder. There will be no crane movement other than attaching the crane hook to the master link until all personnel have withdrawn from the immediate vicinity of the tank and the banksman/loadhandler has given the all clear to the crane operator.
All tanks to have a sling configuration that allow easy access to the master ring without accessing/climbing on the tank in any way
Note: The Design of Chemical Tanks is primarily covered by the IMDG code.
Transporter/Shipper Has Load Security Tag and Label been attached to unit?
All pipefittings will be to a recognised standard
The practice of double stacking tanks offshore is not recommended and should be avoided. Where deemed necessary it should be by exception only and a formal risk assessment is recommended followed by direct supervision of the activity.
All tanks will have a functional sealable document pouch fitted
Yes
Onshore Load Checker Informs the relevant person that the unit has been checked and the Load Security Tag and Label attached.
All tanks to have fully grated or flat plate tops to ensure complete closure All tanks to have non-slip paint coated to access ladders where fitted.
Onshore Load Checker Prior to loading of Container/Tank, nominated Load Checker shall carry out a visual inspection of the unit to ensure that all items are properly packed, container doors are securely closed, and that no loose items are left lying on the unit in any place.
All valves should be suitably placed to allow safe access and be accessible from ground/deck level.
3.2 Handling
No Offshore Load Checker Transporter/Shipper Refuses to transport/ship unit until Load Security Tag and Label is attached (thereby indicating that the load has been security checked).
Is the unit packed securely with no loose items found anywhere on unit? Yes
Prior to loading, Offshore Load Checker carries out a visual inspection of the unit to ensure that all items are securely packed, container doors are closed, and that no loose items are left lying on the load in any place.
No
End of Process 18
Offshore Load Checker
Offshore Load Checker
Attaches ORANGE Load Security Tag and Label informs relevant person that unit is ready to be shipped back to beach.
Arranges for the person responsible for packing/securing the unit to carry out the necessary remedial action.
Typical view of a fully grated tank.
Typical access ladder.
Positioning of Masterlink.
3
The guidance identified within this publication is aimed at ensuring personnel, whose duties involve the handling and transportation of chemical tanks and their contents at offshore installations, are aware of the hazards and precautions which must be considered during tank operations. The objective of this guidance is to increase awareness of key factors relating to chemical tanks and contents handling and to reinforce existing knowledge with additional information. To achieve maximum impact, supervision should follow up safety presentations by talking to appropriate personnel about tank handling techniques, and their understanding of the required safety standards. Subsequent monitoring of chemical tank operations should be undertaken to ensure safety considerations have been raised to, and maintained at, an acceptable level.
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:
2
Step Change in Safety Fatality Report www.stepchangeinsafety.net
19
7.4 Tank / Vessel Types and General Arrangements INSPECTED BY: SIGNATURE: DATE:
This Guideline, Design and Handling of Chemical Tanks has been compiled as part of the Step Change In Safety overall objective of improving safety within the Oil & Gas industry.
From an operational aspect, key issues addressed include recommendations to eliminate: • access to the top of a tank, • manual operation of the pressure/vacuum valve.
The Guideline was commissioned due to offshore industry concerns over the design and safe use of cargo carrying units and portable chemical tanks, and fatalities offshore relating to the handling of these units (See Step Change in Safety Fatality Report). The objective of this Guidance is to provide information to Designer, Manufacturer, Owner and End User of IMO Chemical Transport Tanks, which will lead to rationalisation of equipment and practices used within the industry thus reducing accidents or incidents during handling operations. Example of 600 gallon, (2900 litres), vertical tank.
From a design perspective, the guidance looks at key issues. It recommends that:
Further recommendations on : • contents measurement, • tank access • back loading fluids from offshore facilities are also included. The Guidance also outlines the risk assessment approach for any operations out with the Guidance. The Guidance provides assistance to meet these recommendations by providing: • a Tank Lifecycle Flowchart, • Tank Inspection Checklists,
• valves requiring manual operation, • the lifting accessories master link,
• an Outbound/Inbound Chemical Tanks Checklist outlining competency levels for personnel.
be accessible from deck or ground level. This will reduce the need to access the top of the tank in the offshore environment.
Example of 1000 gallon, (4800 litres), horizontal tank.
20
Example of 500 gallon tank.
Comparison of new and old tank design (600 imperial gallons).
Horizontal Chemical Tank.
Supply Vessel Offloading.
Vertical Chemical Tank.
1
6 TANK PRACTICES
13
6.1 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
7.5 Bottom Outlet Valve Arrangement
Main Discharge Valve
Lever Operated Foot Valve Sampling Point Valve
7 APPENDICES
17
7.1 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
End Cap
End Cap
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
22 Manway Lid (Tank Top Lid / Man Lid)
Air Inlet Valve Pressure Vacuum Relief Valve (not to be manually operated)
View of the Manway Lid and and Pressure / Tank Vacuum Valve (grating removed for picture clarity).
21
Acknowledgments
1 INTRODUCTION
1
• Control of Substances Hazardous to Health Regulations SI 1999/437 (COSHH)
Step Change would like to thank the following organisations for their contributions in developing this guidance:
2 SCOPE
2
• DNV Certification Notes 2.7-1
AMEC
3 SUMMARY / RECOMMENDATION
3
• IMDG Code - International Maritime Dangerous Goods Code
Baker Petrolite
• BS EN 12079: 1999 - Offshore Containers - Design, Construction, Testing, Inspection & Marking
BP • International Maritime Organisation Conserve Oilfield Services Ltd
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
• Lifting Operations and Lifting Equipment Regulations SI 1998 / 2307, (LOLER)
Elected Safety Representatives Network
• Manual Handling Operations Regulations SI 1992 / 2793
Ferguson Seacabs Ltd
• Merchant Shipping (Dangerous Goods and Marine Pollutants) regulations SI 1998 / 2367
Harran Ltd
3.8 Document Pouches/Load Security Tagging
5
Marathon
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
• PUWER - Provision and Use of Work Equipment Regulations SI 1998 / 2306 • Regulation 9 of LOLER, Approved Code of Practice, (HSE Books L113)
Marathon Oil Nalco Ltd Shell Exploration and Production UK
4 LOAD SECURITY INSPECTION PROCEDURE
7
• Step Change in Safety Fatality Report
Suretank Ltd 4.1 Introduction
7
• Step Change in Safety Lifting and Mechanical Handling Guidance (re-issue 2004)
Swire Oilfield Services Ltd
4.2 Purpose
7
Talisman Energy
4.3 Scope
7
4.4 Definitions
7
• Step Change in Safety Task Assessment Guidance (2nd edition 2003)
Transocean
4.4.1 Cargo
7
• The Carriage of Dangerous Goods by Road Regulations, SI 1996 / 209
4.4.2 Transportation
7
4.4.3 Responsibilities
8
• UKOOA / Chamber of Shipping Guidelines for the Safe Management and Operation of Offshore Support Vessels (Issue 4th November 2002)
4.4.4 Procedure Description
8
4.4.5 Cargo Integrity Tagging
9
4.4.6 Vendor Premises
9
• UKOOA Guidance for the safe Packing and Handling of Cargo to and from Offshore Installations (latest edition)
4.4.7 Quayside
9
• Working at Height Regulations SI 2005 / 735
• Step Change in Safety website: www.stepchangeinsafety.net 22
3.1 Design
5 SAFETY CONSIDERATIONS AND CHECKS
10
5.1 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
GRAMPIAN P
website www.stepchangeinsafety.net email
[email protected] address 3rd Floor The Exchange 2 62 Market Street Aberdeen AB11 5PJ
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