Tanks Definition Training

Tanks Definition Training
6. The specific additional provisions applicable to the use of tanks 6.1 Examination Questions: 7 Training units: Initial 10 x 45 minutes Refresher 2 x 45 minute 6.1.1 The definition of tanks in terms of construction and size Explain: Road tankers are defined as fixed tanks or as a Tank – vehicle within context of ADR, there capacity must exceed 1 m3, Battery-vehicles, tank-containers, portable tanks and MEGCs have an individual capacity exceeding 450 litres. Explain: "Mobile explosives manufacturing unit" (MEMU) means a unit, or a vehicle mounted with a unit, for manufacturing and charging explosives from dangerous goods that are not explosives. The unit consists of various tanks and bulk containers and process equipment as well as pumps and related equipment. The MEMU may have special compartments for packaged explosive Specialist Training State: Drivers of vehicles or MEMUs carrying dangerous goods in fixed tanks or demountable tanks with a capacity exceeding 1 m3, drivers of battery-vehicles with a total capacity exceeding 1 m3 and drivers of vehicles or MEMUs carrying dangerous goods in tank-containers, portable tanks or MEGCs with an individual capacity exceeding 3 m3 on a transport unit, shall attend a specialization training course for carriage in tanks. For a Tank container, portable tank, MEGC, MEMU Battery vehicle, that exceeds 450ltr and up to and including 3000ltr the driver must have a Driver Training Certificate valid in the relevant class in “other than in Tanks”. Note these are not classed as packages and the exemptions in ADR do not apply. For quantities below 450ltr these must be classed as packages and the exemptions in ADR may apply. ROAD TANKERS AND TANK CONTAINERS – DESIGN AND INSPECTION Design State: That ADR contains design requirements for tankers which are to carry dangerous substances and that all tankers operating in countries that comply with ADR must be built in accordance with these requirements. Explain: That there are a number of different terms used within the industry and shipping to describe tank containers, e.g. ISO tanks, demountable tanks, lift tanks, swap bodies etc. Explain: That many tank containers used for the transport of dangerous substances are large portable tanks fixed within a frame, designed to comply with the International Organisation for Standardisation (ISO) recommendations, which enables them to be lifted on and off vehicles for transport by road, rail and sea. Others, still capable of being lifted when loaded but not within an ISO frame, are usually called “swap tanks”. The tank in the frame may be built to a UN standard, which is usually referred to as a UN portable tank or “T” tanks.

Tanks Specific training
6.1.2 The responsibilities of employers to provide training on specific vehicles, specific equipment and mechanisms, and with specific loads INTRODUCTION Explain: That the driver of a road tanker or tank container carrying dangerous goods has even greater duties with regard to health and safety than that of packaged goods drivers because: larger tonnages per vehicle are carried. The tank unlike a package cannot be removed to deal with any hazard. The driver may be responsible for: The filling and emptying of the tanker or tank container. Operating and using certain ancillary equipment such as pumps, compressors, couplings and hoses. Ensuring that the tank is depressurised, cleaned, purged and in other ways made safe, as relevant, to receive the next load with the avoidance of danger. Transporting a liquid which will move inside the tank during the journey calling for greater awareness and driving skills It is therefore vitally important that drivers of tankers and tank containers understand the responsibilities which are imposed on them by virtue of the work they set out to do. State: That the purpose of the training is to provide the necessary knowledge which will enable drivers safely to transport dangerous substances in road tankers or tank containers. Emphasise: That the “carrier” has a responsibility to ensure that drivers are trained to operate any vehicle (including its equipment and fittings), that they may be expected to drive and that this training does not replace that responsibility.

Tanks Inspection Certification Documentation Plate
6.1.3 The national and international requirements for tanks and vehicles to be inspected and certified, the documentation and plating of vehicles, and the information displayed on the data plate INSPECTION AND CERTIFICATION UK Old Tanks Explain: That old tanks are tanks constructed prior to (the introduction of the carriage regulations). An old tank may be carried on national carriage in Great Britain provided that it remains safe and suitable for purpose and the following requirements have been complied with. However the requirements do not need to be complied with in respect of an old tank that: is being used for the carriage of gas oil, diesel or heating oil with a flash point of more than 60 degrees C and not more than 100 degrees C (UN 1202), and remains safe and suitable for that purpose: or is not being used at work. Tanks Before tanks are put into service they require an initial inspection and certification Explain: Every tank shall be fitted with a corrosion-resistant metal plate permanently attached to the tank in a place readily accessible for inspection. The following particulars at least shall be marked on the plate by stamping or by any other similar method. These particulars may be engraved directly on the walls of the shell itself, if the walls are so reinforced that the strength of the shell is not impaired. - approval number; - manufacturer’s name or mark; - manufacturer’s serial number; - year of manufacture; - test pressure (gauge pressure); - external design pressure (see ); - capacity of the shell – in the case of multiple-compartment shells, the capacity of each compartment –, followed by the symbol "S" when the shells or the compartments are divided by surge plates into sections of not more than litres capacity; - design temperature (only if above +50 ºC or below -20 ºC); - date and type of the most recent test: "month, year" followed by a "P" when the test is the initial test or a periodic test in accordance with and , or "month, year" followed by an "L" when the test is an intermediate leakproofness test in accordance with ; - stamp of the expert who carried out the tests; Explain: That for the periodic inspection and certification of tanks used for the carriage of dangerous substances on UK journeys, this is carried out by an appointed person who is appointed by the Department of Transport. Explain: That following periodic inspection on the road tanker/tank container (including fittings), a certificate will be issued by the “Appointed Person” responsible for that examination. This certificate will indicate the suitability of the road tanker/tank container for the purpose specified. Display: An example of such a plate.

Tanks Operation UN Portable Tanks
6.1.4 The general application of national and international (ADR, IMDG, RID) requirements to the operation of tanks and tank containers UK REGULATIONS Explain: That in Great Britain road tankers and tank containers carrying dangerous substances are regulated by the Carriage of Dangerous Goods and Use of Transportable Pressure Equipment Regulations 2009 and the Approved Derogations and Transitional Provisions. These refer to ADR. Explain: That “the Carriage Regulations” apply to: - All road tankers when carrying listed dangerous substances or when empty but not cleaned risk free (notionally or nominally empty tanks). - Tank containers containing listed dangerous substances or when empty and not cleaned after those substances, and when mounted on a vehicle. Explain: The regulations are also supported by approved codes of practice for Unloading Petrol From Road Tankers (L133) and the Dangerous Goods Emergency Action Code List. Display and Examine: The “Dangerous Goods Emergency Action Code List” and L 133 Define: There are a number of different tanks used in industry: ADR tanks, demountable tanks, multiple-element gas containers (MEGC’s), tank-containers, fixed tanks, FRP (Fibre Reinforced Plastic) tanks, UN portable tanks, vacuum-operated waste tanks, swap tanks, lift tanks, Mobile Explosive Manufacturing Units (MEMU’s). State: There are a number of persons involved in the transport chain as explained in the Core Module. In the Tank Module we have the manufacturer/consignor, carrier, filler (who may or may not be the driver), tank container/ portable tank operator, driver and consignee. SUBSTANCES AND LOADS UNDER REGULATIONS State: That the responsibility for determining whether the substance can be carried in tanks lies with the consignor and filler. However the driver should also be aware of the criteria. Explain: That consignors have a duty to assist the carrier to determine if the goods are in scope of regulations by providing sufficient information about them. Explain: That the carriage regulations are supported by ADR, which specifies the goods, or type of goods, which may be carried in road tankers, tank containers or UN portable tanks. Explain: That to find out if dangerous goods can be carried in road tankers and tank containers, the carriage regulations make use of table A, of ADR. UN Portable Tanks For UN portable tanks, if there is a portable tank instruction identified in column 10, then that substance can be carried in UN portable tanks. ADR Road Tanks and Tank Containers Dangerous goods can be carried in fixed tanks or tank containers only when a tank code is given in column 12. Explain: The UN portable tank instruction for the dangerous substance gives a “T” number. The “T” number establishes the design, construction, inspection and testing requirements. This portable tank instruction is the minimum standard of portable tank to be used; a more stringent “T” number may be used. (e.g. T1 is the minimum requirement for Portable Tanks; as an alternative you could use any other T number tank up to T22.) Explain: For ADR tanks there is also a hierarchy of tanks. Column 12 of Table A gives a tank code for the substance to be transported. This tank type must be used unless ADR permits a higher spec. tank. The four-part code (tank codes) given in column 12 has the following meaning: 1 Types of tank L = tank for substances in the liquid state (liquids or solids handed over for carriage in the molten state); S = tank for substances in the solid state (powdery or granular). 2 Calculation pressure G = minimum calculation pressure according to the general requirements of ; or 1.5; 2.65; 4; 10; 15 or 21= minimum calculation pressure in bar (see ). 3 Openings (see ) A = tank with bottom-filling and discharge openings with 2 closures; B = tank with bottom-filling and discharge openings with 3 closures; C = tank with top-filling and discharge openings with only cleaning openings below the surface of the liquid; D = tank with top-filling and discharge openings with no openings below the surface of the liquid. 4 Safety valves/devices V = tank with a venting system, according to , but no flame trap; or non-explosion-pressure proof tank; F = tank with a venting system, according to , fitted with a flame trap; or explosion-pressure proof tank; N = tank with a safety valve according to or and not hermetically closed; these tanks may be fitted with vacuum valves; H = hermetically closed tank (see 1.2.1). Example: UN1230 Methanol has the tank code L4BH which means: L: tank for substances in the liquid state (liquids or solids handed over for carriage in the molten state) 4: 4 bar minimum calculation pressure in bar B: tank with bottom filling and discharge openings with 3 closures H: hermetically closed tank (either means there are no safety valves fitted or if there are safety valves then they are proceeded by a bursting disc) Exemptions Certain nominally empty storage tanks Goods intended for use solely in connection with the operation of the vehicle, e.g., the fuel in the fuel tank, and goods for use in the operation of any on-board equipment intended to ensure the safety of the load or the vehicle. Explain: That the HSE also issue various guidance notes to provide advice on the operation of road tankers and tank containers. Recall: That the regulations apply to road tankers from the moment when loading starts until the tank has been cleaned and purged of any hazardous vapour or liquid so that no danger remains to health or safety. Recall: That for vehicles carrying tank containers the regulations apply as follows:- For pre-loaded containers – from the moment that the container is lifted on to the carrying vehicle until the tank container is lifted from the vehicle or until the container has been discharged, cleaned and purged, For vehicles arriving for loading carrying empty tank containers – from the moment that loading starts until the container is lifted from the vehicle or until the container has been discharged, cleaned and purged. INTERNATIONAL REGULATIONS ADR Explain: That an agreement exists in Europe, which regulates the conditions of the road transport of dangerous substances across the boundaries of the signatory countries. This agreement is known by the initials “ADR”. Display: A copy of the ADR book. Explain: That road tankers and tank containers on an “ADR journey” within the meaning of the treaty are totally exempt from the UK carriage regulations providing ADR is complied with in full. Explain: That the UK has introduced the ADR framework directive and therefore in practice, there are now only a few differences IMDG Recall: That another international agreement exists for regulation of dangerous goods traffic by sea – the IMDG Code. Re-emphasise: That the IMDG Code governs ALL movements by sea including for example, ferry journeys to the Isle of Wight and other off-shore islands and even to the gas and oil rigs in the North Sea and Irish Sea. Explain: That tanks complying with the IMDG code must be fitted with a corrosion-resistant metal plate permanently attached in a place readily accessible for inspection. Display: An example of this plate with clear details of the information required or a picture of such a plate. Explain: That the particulars on the plate must be in characters at least 3mm in height and marked by stamping, engraving, embossing or any similar method. Emphasise: That all plates containing information of this type must be securely attached and kept free of paint or other substances to ensure that the markings will be legible at all times. RID Recall: That RID is yet another international agreement for the regulation of the movement of dangerous substance. RID applies to the international movement of dangerous substances by rail. Explain: That a road tanker or tank container properly labelled in accordance with RID is exempt from the marking requirements only of the carriage regulations if (a) it has been used for an international transport operation subject to RID, has discharged its load but has not been cleaned or purged, OR, (b) it is carrying a dangerous substance to or from a rail-head as part of an international movement by rail. Explain: That many rail movements begin or end with a road leg to move the materials for the producer unit to the rail-head or from the rail-head to the user. Explain: That movements of this nature, i.e., involving the use of more than one transport mode, are described as multi-modal movements and that, due to the UK being surrounded by water, all international road or rail dangerous goods movements involve a sea leg and are thus examples of multi-modal operations.

Tanks Fire Extinguishers Vehicle Equipment
6.1.5 The requirements for vehicles to carry fire extinguishers and other safety equipment Fire Extinguishers Explain: That both the UK regulations and ADR require fire extinguishers as discussed in the core State: That it is the carrier’s responsibility to ensure that the fire extinguisher are suitable. Explain: That it has already been stated in the Core Module that all fire extinguishers should be checked by drivers frequently to make sure that: They have not been damaged. They have not been accidentally or maliciously tampered with. They remain fully pressurised and that seals are intact. They have not corroded, particularly around the base. They remain fully protected from the weather. The vehicle crew have access to them. Recall: The need to shake dry powder extinguishers regularly to stop the powder compacting. Explain: That drivers need to be aware of the date when inspection of all extinguishers is due and to see that this takes place. Emphasise: That the extinguishers must therefore bear an inscription giving the date when the next inspection is due, and should also be sealed. Explain: Every dangerous goods vehicle shall now be equipped with: (a) The following general-purpose safety equipment: -For each vehicle, at least one chock of a size suited to the weight of the vehicle and to the diameter of the wheels; -Two self-standing warning devises -A suitable warning vest or warning clothing (e.g. as described in European Standard EN 471) for each member of the vehicle crew; A pocket lamp (no metal surface liable to produce a spark) for each member of the vehicle crew. Eye rinsing liquid Eye protection A pair of protective gloves A shovel, drain seal, and a collecting container made of plastic (for classes 3,4.1,4.3,8 and 9) (b) When displaying placard number 2.3 or 6.1(as a primary or secondary hazard), a respiratory protective device (A1B1E1K1-P1 or A2B2E2K2-P2,) for each member of the vehicle crew. (c) The personal protection and the equipment necessary to take the additional and/or special actions referred to in the instructions in writing.

Tanks Documentation 6.1.6 The requirement for vehicles to carry documentation, including instructions in writing about the load, ADR driver training certificate, transport documentation, certificate of approval Explain: The provisions of ADR, which address and cover all the following points, which particularly affect the tanker/tank container vehicle, to include: - A “transport document”, commonly a CMR note or dangerous goods shipping note, filled out in the correct way. - Driver Training Certificate . - Photographic Identification - “Instructions in writing”. These instructions shall be provided by the carrier to the vehicle crew in language(s) that each member can read and understand before the commencement of the journey. The carrier shall ensure that each member of the vehicle crew concerned understands and is capable of carrying out the instructions properly. - Type approval certificate/s for the tractor unit and tank trailer . - A copy of any special agreements (known as a derogation) covering that movement must be carried when applicable. Display: Examples of all the documents to be carried. Emphasise: That FULL compliance with the ADR requirements is necessary to claim exemption from any domestic regulations of the country you’re in. Recall: That nominally empty tanks come within the scope of the regulations. Explain: With nominally empty tanks, documentation is now required. It may also be left to the driver to complete this documentation. Examples of this would be: “EMPTY TANK-CONTAINER, LAST LOAD: UN 1230 METHANOL, 3 (6.1), II, D ” “EMPTY TANK-VEHICLE, LAST LOAD: 1203 PETROL, 3, II, D” Type Approval Explain: As well as vehicles engaged on an ADR journey the following vehicle types would require ADR technical certification: Vehicles or trailers to be used for transport of liquid or gaseous dangerous goods in fixed or demountable tanks or fixed batteries of pressure vessels over one cubic metre capacity. Vehicles or trailers transporting liquid or gaseous dangerous goods in tank containers or UN portable tanks over three cubic metres capacity. ADR technical inspections are carried out at most VOSA test stations. It is often done at the same time as the annual test. New vehicles and trailers will also need a first annual inspection BEFORE use. Explain: Articulated or drawbar vehicles and trailers are treated as two vehicles, each with its own certificate and test fee. Explain: That vehicles constructed in accordance with ADR will be subject to an annual technical inspection in the country of registration, and providing the inspection is satisfactory a certificate of approval will be issued by the competent authority of the country of registration. Explain: For vehicles with fixed tanks exceeding 1,000lts and for tank containers exceeding 3,000lts there are requirements for the construction of the vehicle as one of types FL, OX or AT. Type FL: Flammable liquid tanks Type OX: > 60% Hydrogen Peroxide Type AT: Any tanker other than above Explain: That the type of vehicle used for tank carriage will determine the standards and requirements for the annual inspection Display: A technical inspection certificate.

Tanks Loading and unloading Segregation Security of containers
Equipment 6.1.7 The safety precautions to be taken in the course of loading, unloading and during the journey, including segregation of loads, checks of the vehicle and load including the secure fastening of containers, and the use of certain equipment Loading Unloading and During the Journey During filling and discharge of tanks, battery-vehicles and MEGCs, appropriate measures shall be taken to prevent the release of dangerous quantities of gases and vapours. Tanks, battery-vehicles and MEGCs shall be closed so that the contents cannot spill out uncontrolled. The openings of bottom-discharge tanks shall be closed by means of screw threaded plugs, blank flanges or other equally effective devices. The leakproofness of the closures of the tanks, and of the battery-vehicles and MEGCs shall be checked by the filler after the tank is filled. This applies in particular to the upper part of the dip tube. Where several closure systems are fitted in series, that nearest to the substance being carried shall be closed first. No dangerous residue of the filling substance shall adhere to the outside of the tank during carriage. Foodstuffs shall not be carried in tanks used for dangerous substances unless the necessary steps have been taken to prevent any harm to public health. Often comprehensive safety checks are carried out before during and after the journey, you may be required to complete this. Segregation Substances which may react dangerously with each other shall not be carried in adjoining compartments of tanks. Substances which may react dangerously with each other may be carried in adjoining compartments of tanks, when these compartments are separated by a partition with a wall thickness equal to or greater than that of the tank itself. They may also be carried separated by an empty space or an empty compartment between loaded compartments. Security of Containers Check must be made before the start of a journey to make sure any container is securely fastened to the trailer. This is usually achieved by twist locks, one on each corner and should be turned to the locked position. Twist locks should be in the unlocked position before the container is lift off the trailer. Equipment All hoses, pumps, compressors, valves etc should be in the appropriate positions and or disconnected prior to vehicle movement.

UK Marking Hazard Warning Panels Subsidiary risk placards
Environmentally hazardous substance mark Low hazard substances 6.1.8 The UK emergency action code system, the layout and content of hazard warning panels, emergency action codes, the number and positioning of panels/plates on tankers and tank containers, for both single and multiple loads and the voluntary scheme for low hazard substances Vehicle Marking Explain: That it is the duty of the carrier to ensure that the danger labels and markings prescribed for the vehicle have been affixed and kept clean and unobstructed at all relevant times. Emphasise: That the driver must ensure that the markings are displayed at all relevant times and are kept clean and unobstructed. Marking Road Tankers and Tank Containers – UK State: That road tankers and vehicles carrying tank containers must display a plain orange plate to the front when in scope of the carriage regulations. Display: An example of the orange plate and list dimensions, fixing point etc. (The instructor should note the requirements for construction of all panels for road tankers and the future requirement for legibility after fire engulfment). Single substance loads in Road Tankers State: That the vehicle must display on both sides and at the rear an orange plate bearing the UN number and the appropriate emergency action code as detailed in the Emergency Action Code (EAC) List. Display: a Copy of the EAC list Explain: How it works using a UN number and show the alphabetical list at the rear to obtain the UN number. Explain: how to decode the meaning of the numbers and letters State: That the vehicle must display on both sides and at the rear, the appropriate danger and subsidiary hazard signs which shall have sides measuring not less than 250mm. State: That, as an alternative, existing U.K. hazard warning panels may continue to be used. Display: Hazard warning panel for a single substance Emphasise: That, where this alternative is used, provision must be made to display subsidiary (and tertiary) danger labels (diamonds) at the rear and on both sides. Secondary (and tertiary) danger labels displayed in conjunction with U.K. hazard warning panels must be the same size as the diamonds shown on the Hazard warning panel, i.e. 200mm by 200mm. Explain: The requirement for, and manner of, display of telephone numbers, (or consult local depot) on hazard warning panels or orange labels/plates on both sides and the rear. Explain: That the specialist advice telephone number must also be displayed at the rear and on both sides of the vehicle. Describe: The location of the plates, size of panel, size of lettering, etc. Multi-load in Road Tanker Explain: For tank-vehicles or transport units having one or more tanks carrying substances with UN Nos. 1202, 1203 or 1223, the orange-coloured plates which bear the Emergency Action Code and the UN number prescribed for the most hazardous substance carried, i.e. the substance with the lowest flash-point. Explain: That for multi load tanks with different classes / UN numbers other than petroleum substances as described above the EAC is worked out using the instructions and table in the front of the EAC list, show how this is done. Explain: that this code covers the vehicle as a whole not just individual substances and is different from the ADR HI system. Explain: The UK EAC code system can only be used on UK national journeys. Explain: That the vehicle must display an orange plate with the composite emergency action code in the top half, with the lower half left plain at the rear of the vehicle. Explain: That, in addition, orange plates must be displayed on both sides, in line with the relevant compartments. One of the orange plates on each side must show the composite emergency action code in the top half and the UN number for the product in that compartment, the other orange plates show only the relevant UN numbers. State: That the appropriate danger and subsidiary placards must also be displayed on both sides and at the rear of the vehicle. State: Tankers carrying dangerous goods which have also been classified as environmentally hazardous substances (EHS) must display the EHS mark adjacent to the class placard(s). Display: EHS mark Explain: That the specialist advice number must be displayed at the rear of the vehicle and on both sides of each tank. Tank Container State: The marking and Placarding of tank containers under the carriage regulations is the same as for road tankers.. Black and White Marking System Explain: That the Chemical Industries Association (CIA) in the UK suggests that all substances have some degree of danger whether they are regulated or not. The CIA has therefore recommended the use of a voluntary system of marking tanks based upon the “Hazchem System”. This voluntary system uses a panel of black on white. Display: An example of a black and white “voluntary panel”. Explain: That the CIA handbook for this system of marking stresses that it is only applicable to domestic transport and therefore black and white markings should not be used on tanks for international journeys.

IMDG Marking Placards Subsidiary UN numbers Proper shipping name
Marine pollutant mark 6.1.9 Placarding and marking of tankers and tank containers under the IMDG code for journeys by sea (including those to islands off the UK mainland), the number, positioning and use of placards for primary and subsidiary risks and for single and multiple loads, proper shipping names, UN numbers and marine pollutant labels, and resistant to sea water Placards Explain: The IMDG marking system, namely: - That placards (hazard diamonds) to be displayed externally on tanks and containers. That the placards must not be less than 250mm in size. That there are two methods of displaying the UN number. These are: - In black digits not less than 65mm high on a white background in the lower half of the primary hazard placard, or In black digits not less than 65mm high on an orange rectangular panel, not less that 300mm wide and 120mm high with a 10mm black border, placed immediately adjacent to the primary hazard placard. Positioning / UN numbers That road tankers must be marked on both sides and the rear with the UN number of the substance, the appropriate placard(s) and marine pollutant mark if required. That tank containers must be marked on the front, the rear and on both sides with the UN number, the placard(s) and the marine pollutant sign if required. Subsidiary placards These have to be shown and displayed adjacent to the primary placard. Proper Shipping Name That, in addition, tankers and tank containers must display the proper shipping name of the substance on each side. That multi-compartmented tankers and tank containers carrying more than one substance must display the appropriate UN number, placards, and the proper shipping name on each compartment. Resistance to Sea Water Explain: That all marks and placards must be capable of withstanding total immersion in sea water for a period of not less than 3 months Explain: That under the carriage regulations, a vehicle which was going to, or collecting from a dock can use an alternative to UK markings provided the vehicle was fully placarded in accordance with IMDG and orange plates are displayed to the front and rear.

ADR Marking Hazard Identification Number (HIN) Hazard warning panels
Placards Placarding and marking of tankers and tank containers under ADR, the size, layout and content of orange coloured plates, hazard identification numbers, fire resistance, positioning and use of placards. Placarding/Positioning/Marking State: That tank vehicles with a single load may display an orange plate on the front and rear, with the HIN in the top half and UN number in the lower Half. Placards (diamond) for the major and subsidiary hazards must also be shown on the rear and both sides of the vehicle. State: That vehicles carrying multi-loads must display plain orange plates font and rear with orange plates on either side of each compartment. The compartment plates show the HIN Code and UN number for the substance in each relevant compartment. Placards (diamonds) must also be displayed at the rear and on both sides. Size, Layout and Content The hazard identification number and the UN number shall consist of black digits 100 mm high and of 15 mm stroke thickness. The hazard-identification number shall be inscribed in the upper part of the plate and the UN number in the lower part; they shall be separated by a horizontal black line, 15 mm in stroke width, extending from side to side of the plate at midheight. Hazard Identification Number State: That ADR and the carriage regulations, vehicle markings are very similar, the major difference being that in place of the UK emergency action code, ADR uses a Hazard Identification Number (HIN). Explain: That ADR plates (orange plates) show the Hazard Identification Number in the top half and the UN number in the lower half for each different product, in line with the relevant compartment. Explain: That the HIN is a two or three-digit code, which MAY be preceded by an “X”. The use of the “X” indicates that the substance will react dangerously with water. Explain: The significance of each of the digits in the two or three digit code. Fire resistance The hazard identification number and the UN number shall be indelible and shall remain legible after 15 minute’ engulfment in fire. Interchangeable numbers and letters on plates presenting the hazard identification number and the UN number shall remain in place during carriage and irrespective of the orientation of the vehicle.

Tank Types LPG Flammable liquid Cryogenic Powders and Granules
Heated loads Refrigerated Loads Foodstuffs Corrosive Wastes 6. The specific requirements of the vehicles. Examination Questions: 5 6.2.1 The types of loads for which tanks may be designed, including liquefied petroleum gas, flammable liquids, gases transported at very low temperatures, powders and granules, insulated or heated loads, refrigerated loads, foodstuffs (e.g. certain alcoholic beverages), corrosive substances, and wastes. Explain: Tanks are designed to carry many different substances including those in the list below. Expand on the specific requirements of each tank type for each substance, these are covered in more detail in section 6.4 Liquid Petroleum Gas (LPG) Flammable liquid Cryogenic gas Powder and granules Heated loads Refrigerated loads Foodstuffs Corrosive Wastes

Tank Construction Materials Linings
6.2.2 The materials from which tanks and tank containers may be constructed, including stainless steel, mild steel, aluminium, nickel, fibre reinforced plastic, and the various linings which may be used Materials of construction and tank linings Explain: That stainless steel is the most common material of construction for chemical tankers but it is attacked by some chemicals e.g. hydrochloric acid and sodium hypochlorite (bleach). For products such as these, carbon steel is sometimes used with a suitable lining, e.g. rubber or plastic for hydrochloric acid and sodium hypochlorite, lead or glass lined for bromine. Aluminium is rarely used for chemical tankers but is used for petrol tankers. Titanium has been used for tankers carrying nitric acid but it was found cheaper to use stainless steel barrels made of thicker plates and replace them or down grade them to other duties when the corrosion allowance had been used up. Glass Reinforced Plastics (GRP) tanks with suitable plastic liners were used for some corrosives in the 1970s but did not “flex” in the same way as steel tanks with the result that cracking occurred and their use was eventually discontinued. However some FRP tankers are now being used for petroleum products. Explain: FRP (Fibre Reinforced Plastic) Tanks are now being manufactured

Tank Construction Atmospheric Pressure Compartments Baffles
6.2.3 The construction of tanks and tank containers; “atmospheric” and pressure tanks, compartments and baffles Atmospheric Non-pressure road tankers Explain: That tankers making deliveries of petrol (petroleum spirit) to garage forecourts will be of this type and they are often referred to as “spirit tanks” and sometimes as “solvent tanks”. State: That requirements governing the design and construction of this type of (new) road tanker in the UK is given in ADR. Explain: That the majority of tanks of this type which are used for the delivery of petroleum products and certain flammable solvents are constructed from aluminium alloys which make the vehicle lighter and allow a larger payload. Other vehicles, particularly those used on solvents, are constructed from mild steel or, where product quality is important, from stainless steel. Explain: That the principle feature of these tanks is that they are not designed to withstand any internal pressure and thus they should never be operated in any way likely to cause a build-up of pressure inside them Emphasise: That these tanks are for loading and discharge by pump or gravity. Explain: That these tanks are not normally round in cross-section but are often elliptical or max. section (rectangular with rounded corners) to keep centres of gravity down. Explain: That, for petrol etc., the tank is usually divided into compartments. Pressure discharge tankers Explain: That because of the range of products that are carried in this type of tanker there are a variety of different designs. By far the most common of this type is the “General Purpose” (GP) tanker which is easily cleaned and thus suitable for carrying return loads, when they are available. Explain: That a GP tanker will usually, but not always, be constructed from stainless steel and be round in cross-section since this is the best shape to withstand pressure. The typical maximum allowable working pressure (MAWP) of this type of tanker is 2 bar (30 p.s.i.) Compartments Explain: That many tanks are divided into compartments. This enables different products to be carried at the same time, it also enables segregation of incompatible products. Baffles (Surge Plates) Explain: That in a single compartment tanker, baffles are often fitted inside the barrel to help reduce the forces created by liquid surge when the tanker brakes or accelerates. Explain: That there are usually two baffles fitted in a single compartment tanker equidistant along the length of the barrel. Explain: That the majority of the baffles fitted are dished with a central hole (off-set to prevent plug flow) but some are of the vertical corrugated type [see background notes]. ADR requires that the baffle shall be at least 70% of the cross-sectional area of the tank. Remind: That where no baffles are fitted and the tank is in excess of 7500 litres capacity, national and international rules specify a minimum fill of 80% of the tank capacity.

Tank Construction Vehicle construction
6.2.4 The application of regulations concerning the construction and approval of tanks and vehicles, including stipulations regarding engines and fuel systems, exhausts, electrical systems, stability, rear end projection, fire resistant cabs, and ullage space Engines / fuel systems Engine The engine propelling the vehicle shall be so equipped and situated to avoid any danger to the load through heating or ignition. In the case of EX/II and EX/III vehicles the engine shall be of compression-ignition construction. Fuel tanks The fuel tanks for supplying the engine of the vehicle shall meet the following requirements: (a) In the event of any leakage, the fuel shall drain to the ground without coming into contact with hot parts of the vehicle or the load; (b) Fuel tanks containing petrol shall be equipped with an effective flame trap at the filler opening or with a closure enabling the opening to be kept hermetically sealed. Exhausts Exhaust system The exhaust system (including the exhaust pipes) shall be so directed or protected to avoid any danger to the load through heating or ignition. Parts of the exhaust system situated directly below the fuel tank (diesel) shall have a clearance of at least 100 mm or be protected by a thermal shield. Electrical Systems Explain: ADR states Electrical equipment The rated voltage of the electrical system shall not exceed 24V. Any lighting in the load compartment of EX/II vehicles shall be on the ceiling and covered, i.e. with no exposed wiring or bulb. In the case of Compatibility Group J, the electrical installation shall be at least IP65 (e.g.flame-proof Eex d). Any electrical equipment accessible from the inside of the load compartment shall be sufficiently protected from mechanical impact from the inside. The electrical installation on EX/III vehicles shall meet the relevant requirements of , , , and The electrical installation in the load compartment shall be dust-protected (at least IP54 or equivalent) or, in the case of Compatibility Group J, at least IP65 (e.g. flame-proof Eex d). Stability of tank-vehicles Explain: ADR states The overall width of the ground-level bearing surface (distance between the outer points of contact with the ground of the right-hand tyre and the left-hand tyre of the same axle) shall be at least equal to 90% of the height of the centre of gravity of the laden tank-vehicle. In an articulated vehicle the mass on the axles of the load-carrying unit of the laden semi-trailer shall not exceed 60% of the nominal total laden mass of the complete articulated vehicle. In addition, tank-vehicles with fixed tanks with a capacity of more than 3 m3 intended for the carriage of dangerous goods in the liquid or molten state tested with a pressure of less than 4 bar, shall comply with the technical requirements of ECE Regulation No for lateral stability, as amended, in accordance with the dates of application specified therein. The requirements are applicable to tank-vehicles which are first registered as from 1 July 2003. Note1 ECE Regulation No. 111: Uniform provisions concerning the approval of tank-vehicles of categories N and O with regard to rollover stability. Rear protection of vehicles Explain: ADR states a bumper sufficiently resistant to rear impact shall be fitted over the full width of the tank at the rear of the vehicle. There shall be a clearance of at least 100 mm between the rear wall of the tank and the rear of the bumper (this clearance being measured from the rearmost point of the tank wall or from projecting fittings or accessories in contact with the substance being carried). Vehicles with a tilting shell for the carriage of powdery or granular substances and a vacuum-operated waste tank with a tilting shell with rear discharge do not require a bumper if the rear fittings of the shell are provided with a means of protection which protects the shell in the same way as a bumper. NOTE 1: This provision does not apply to vehicles used for the carriage of dangerous goods in tank-containers, MEGCs or portable tanks. NOTE 2: For the protection of tanks against damage by lateral impact or overturning, see and or, for portable tanks, and Fire resistant cabs Vehicle cab Explain: ADR states that Unless the driver's cab is made of materials which are not readily flammable, a shield made of metal or other suitable material of the same width as the tank shall be fitted at the rear of the cab. Any windows in the rear of the cab or in the shield shall be hermetically closed and made of fire-resistant safety glass with fire-resistant frames. Furthermore, there shall be a clear space of not less than 15 cm between the tank and the cab or the shield. Ullage space Ullage space is dealt with in ADR by reference to Maximum and Minimum filling levels and is dealt with in the next section. Ullage is referred to as the space above the liquid in a tank to allow for expansion of the liquid due to temperature change.

Tanks Filling Ratio 6.2.5 The requirements for maximum filling ratios and when minimum filling ratios apply Explain: That ADR filling ratios are now used in the UK for NEW TANKS. There are now more precise filling ratios which are obtained from Sub section of ADR. An example is: For a flammable substance without additional dangers: Degree of filling = _____ % of capacity 1 +  (50 – tF ) Where  = d15 – d50 _______ d50  Being the mean co efficient of cubical expansion of the liquid between 15oC and 50oC where d15 and d50 are the relative densities of the liquid at 15 °C and 50 °C respectively; tF is the mean temperature of the liquid during filling. Explain: That dipsticks, ullage bars, sight glasses, gauges, meters and loading on a weighbridge are all methods which may be used to monitor the quantity of product being charged into a road tanker/tank container. However it should be noted that dipsticks and ullage bars could not be used where closed filling is being used. Explain: Different rules apply to determining the maximum degree of filling of gas tanks and MEGCs. These will depend on whether the gas is carried merely in the compressed state, whether it has been liquefied at ambient temperatures or whether it has been liquefied by being deeply refrigerated. Explain: Minimum fill levels apply to ADR and UK NEW tanks over 7500 litres without baffles. Sub section of ADR states: Where shells intended for the carriage of liquids are not divided by partitions or surge plates into sections of not more than 7500 litres capacity, they shall be filled to not less than 80% or not more than 20% of their capacity. Slightly different formulae apply to the calculation of the maximum degrees of filling for UN portable tanks.

Tanks Maximum allowable working pressure
6.2.6 The significance to the loading, unloading and transport of materials of the Maximum Allowable Working Pressure Emphasise: That during pressure discharge no part of the system must be pressurised above the Maximum Allowable Working Pressure. That although there is a relief valve on both the tanker pressurising line and on the tanker itself the driver must monitor the pressure during discharge in case of malfunction of these valves. This is also known as maximum working pressure in ADR.

Tanks Sun shields 6.2.7 The fitting and use of sun shields
Sun Shields (Thermal insulation) Explain: That ADR states that if tanks intended for the carriage of liquefied gases are equipped with thermal insulation, such insulation shall consist of either: - a sun shield covering not less than the upper third but not more than the upper half of the tank surface and separated from the shell by an air space at least 4 cm across; -a complete cladding, of adequate thickness, of insulating materials.

Equipment Man lids Outlet valves, manifolds, and valve controls
Seals and bolts Dip sticks Pressure relief, and pressure & Vacuum relief valves Bursting discs Flame traps and gauzes Pressure connections and Pressure gauges temperature gauges Fusible elements Outlet valves, manifolds, and valve controls Seals Hoses Hose connections and blanking caps Emergency shut off valves Excess flow valve 6.2.8 The purpose, operation, precautions and drivers’ responsibilities in relation to items of equipment, including: man lids, seals and bolts, dip sticks, pressure relief, and pressure & vacuum relief valves, bursting discs, flame traps and gauzes, fusible elements, pressure connections and pressure gauges, temperature gauges, outlet valves and manifolds, and valve controls, seals, hoses, hose connections and blanking caps, emergency shut off valves, excess flow valves Man lids Explain: Tankers are fitted with manlids and hatches to access the tank as a means of filling and cleaning. Petrol tanks have filling hatches, modern day petrol tankers do not have filling hatches or ladders to access the tanker top and therefore the hatches have been replaced by bolted blank plates. General purpose tanks have manlids for access for filling, dipstick loading and splash loading. The opening will allow monitoring of the load. The manlid is also used when the tanker needs cleaning this allows easy access for cleaning and inspection after tank cleaning. The manlid can also be used to gain entry to the tank for service work and repairs. Seals and bolts Explain: To close the manlid securely they have lid keys/bolts as additional safety features the modern tanker has safety bolts fitted to the manlid. usually tank manlids are fitted with six securing bolts, modern day tanks are fitted with To close the manlid securely they have lid keys/bolts as additional safety features the modern tanker has safety bolts fitted to the manlid. usually tank manlids are fitted with six securing bolts, modern day tanks are fitted with safe bolts these are fitted to prevent the manlid being accidentally opening a tank under pressure, it will also prevent the tank manlid from being closed without locating the safety bolt first. The sequence for the safe bolt is last bolt off first bolt on. Dip sticks Explain: That some tanks are fitted with dip sticks to ascertain the contents of the tank or compartment. State: Before climbing on to the top of the tank, it is necessary to ensure that all safety devices which are designd to prevent falls from the tank must be in place Pressure relief, and pressure & Vacuum relief valves Explain: Pressure vacuum valves are fitted to tankers for safety reasons, they are fitted to prevent the tank from bursting and imploding. The valve are generally called pre-vac (pressure vacuum valve) which allow the tank to breath. The vacuum side of the valve works if the product cool’s and creates a vacuum within the tank, this will open the internal valve (vacuum side) which will allow air vapour into the tank preventing the tank from implosion. When a balance has been obtained in the tank the inter relief valve (vacuum side) will close this is done with assistance from the light spring on the valve sealing the tank (hermetically). If the tank exceeds (maximum allowable working pressure) MAWP will be at risk of bursting. The pre-vac valve has a set working pressure, if the tank is subjected to excessive pressure the valve will operate opening the valve allowing the excess pressure to escape from the tank, once a safe pressure has been obtained the valve will close re-sealing the tank and preventing any escape of product or vapour from the tank. The tank must have the correct type of pre-vac valve fitted to the tank preventing the tank from imploding or bursting. Bursting discs Explain: Some tanks not all are fitted with bursting disc, there are two requirements for the disc to be fitted. Discs are fitted for certain types of products and are fitted to prevent external air or moisture damaging the load. This provides the tank with a hermetic seal and escape of vapours from the tank. Some types of products that have bursting disc are (TDI) Toluene Di-isocyanate UN Olefins, Highly Flammable UN Bursting discs are also fitted to tanks in for emergency pressure relief for certain products such as Hydrogen Peroxide UN1415 Class 5.1, the disc will break at the pre-determined pressure setting. The bursting discs are mounted between the safety valve and the tank. The only way of telling if the tank is fitted with a bursting disc is by the data tag protrudes between the safety valve and the tank. A tank fitted with a bursting disc will only allow excessive pressure from within the tank this will cause the disc to rupture. A bursting disc will not allow external pressure into the tank, the designed of this type of disc is to protect the load against damage form air or moisture which could contaminate the load. The cost of the disc is about £200 to £300 each. The reason is that the manufacture of disc will make ten, test eight and sell two. This is to ensure they work correctly when in use. Extra note: some bursting disc will allow a 10% air flow into the tank if it a vacuum were caused these are usually to comply with IMDG requirements for sea transport. Flame traps and gauzes State: Tanks may be fitted with flame traps and gauzes to help prevent sources of ignition from entering the tank. Pressure connections and Pressure gauges, temperature gauges Explain: That is necessary for the driver to understand the correct use of the pressure connections and gauges. State: That some loads have to be kept within defined temperature ranges and that if this is the case, the tank will be fitted with a temperature gauge. Fusible elements State: The purpose of a fusible element or plug, is to release pressure if the contents of the tank become overheated. Explain: That the centre section of a fusible plug usually consists of a low melting point substance which melts at a predetermined temperature Outlet valves and manifolds, and valve controls State: That is necessary for the driver to be trained in the correct sequence of opening and closing all valves and manifolds. Explain: The importance of understanding the control mechanism for all valves and manifolds. Seals Explain: That it is the drivers responsibility to check that all seals are in good condition and correctly fitted where required. Hoses Explain: That hoses used for loading and discharge must be suitable in all respects for the substances being handled i.e. resistant to product and suitable for the temperature, and must be kept in good condition so that there are no leaks from the hose or the hose connections. Emphasise: That drivers should regularly inspect hose connections and seals and report any defects immediately. Explain: That at regular intervals hoses should be subjected to more detailed inspection including a pressure test, measurement of elongation and an electrical continuity test. That records should be kept of this inspection and any “failed” hoses should be destroyed to prevent their accidental use at a later date. State: That the British Standards institute are co-operating with their EC counterparts to produce a mutually acceptable system for the inspection, identification and testing of flexible hoses. Hose connections and blanking caps State: The importance of the driver checking that all hose connections and blanking discs are in good condition and do not allow any loss of product. Emergency shut off valves State: The purpose of emergency shut off valves is to stop all loading/unloading in the event of an incident or emergency Explain: That the driver must be familiar with the operation of any emergency shut off valves which may be fitted to the vehicle and/or site equipment Excess flow valves Explain: Excess flow valves are fitting as an additional safety feature to gas tanks and highly volatile substances. An excess flow valve prevents a large escape of product form within the system should there be a break in the connection. It also slows or stops the discharge if the flow rate were too fast. when unloading flammable gases from a tank friction is created, if there were sufficient air and flammable vapours in the system then all you require would be a spark for an explosion, the excess flow valve would slow the rate of discharge or in some cases even stop unloading procedure to prevent the explosion risk.

Tanks Loading 6. The procedures to be followed in relation to the operation of tanks and tank containers. 5 Questions 6.3.1 Loading vehicles, including the responsibilities of the driver for obeying site rules, reporting to a responsible person, locating emergency equipment, obtaining Instructions in Writing, securing the vehicle against accidental movement, ensuring that the correct substance is loaded, taking precautions against contamination of the load, using the appropriate personal protective equipment, earthing the vehicle and taking appropriate action in case of danger or an electrical storm, ensuring that there is sufficient capacity for the load and the vehicle is not overloaded and that there is adequate ullage space, controlling the rate of filling, and taking all necessary precautions against fire or explosion. Recall the following from previous slides: Obeying site rules Recall from core module Reporting to a responsible person, Locating emergency equipment, Recall from site rules in core module Obtaining Instructions in Writing, Securing the vehicle against accidental movement, State: The importance of ensuring the vehicle does not move during loading. Explain: Wheel chocks and barriers may be used. State: The vehicle keys must be kept secure Ensuring that the correct substance is loaded State: That a final check that the correct substance is to be loaded into the tank or tank compartment. Taking precautions against contamination of the load. Explain: That the driver must ensure that the correct compartment is being loaded. State: Extra care must be taken when filling through an open hatch to ensure that no foreign matter could enter the tank. Using the appropriate personal protective equipment Recall from the core section that personal protective equipment must be worn during loading and unloading tanks. Emphasis: Site rules will probably require additional personal protective equipment to be worn than the minimum requirements of the road regulations Earthing the vehicle and taking appropriate action in case of danger or an electrical storm, Explain: That when an electrical storm occurs all “open loading” and “open discharge” of vehicles with flammable liquids should stop because of the risk of the static electricity in the air at such times providing a source of ignition. Explain: That the loading/discharge of a flammable substance MUST be halted if it is realised that the vehicle has not been earthed. Emphasise: That the earth lead must not be connected whilst the operation continues. Explain: That time must elapse (at least 5 minutes, but this time could be for very much longer) after cessation of the operation to allow any static to dissipate before the earth connection is made otherwise a static discharge may occur. Ensuring that there is sufficient capacity for the load and the vehicle is not overloaded and that there is adequate ullage space State: That the driver must check that there is sufficient capacity in the tank for the load and that the correct ullage space will be left. Controlling the rate of filling Explain: The importance of using the correct rate of filling, especially at the start of loading when excess static electricity could be generated Taking all necessary precautions against fire or explosion. Explain: The requirement to ensure all sources of ignition have been removed from the area and that the tank is earthed where necessary.

Tanks Checks during journey
6.3.2 Checks during the journey, including ensuring that hoses are secured and have blanking caps in place, that there are no leaks, that components are not overheating, that all documentation is available, and that vehicle markings are in place, clean and clearly visible Explain: After use hoses should be drained; cleaned where possible, and capped to avoid contamination of product, personnel and other equipment. State: Before setting off on a journey the driver should check that all the documentation is in place, the vehicle is displaying the correct marks and placards and that they are clean and visible. Explain: That checks should be made that the hoses are secure and blanking caps are in place where required. State: That the driver must check that the tank is sealed, has been depressurised where required and that there are no leaks. Explain: That during the journey, the driver must make checks to ensure that the tank is not leaking, that the equipment is secure and that there is no heat build up anywhere on the vehicle.

Tanks Discharge 6.3.3 Discharging tanks, including the drivers’ responsibility for: reporting to the person in charge, following site rules, locating the emergency equipment, using the appropriate personal protective equipment, ensuring that the load is discharged into the correct tank, and that there is sufficient space for it, providing a sample of the load if required, making the correct connections, taking precautions against accidental movement, fire or explosion or implosion due to the formation of a vacuum, and following the correct procedures for unattended driver discharge or attended driver discharge including obtaining a certificate from a responsible person. (Inc - reference to Tanks Status Document - Confirmation of Last Load) Unloading Explain: That the principal methods of discharge are by gravity, by pump and by pressure. Explain: That where discharge is by pump or compressor theses are usually, but not always, provided on the vehicle. The vehicle’s engine is normally used to drive the compressor and the pump, which is often hydraulically driven. Explain: That excessive speed can lead to “cavitation” of the pump causing wear and reduction of pumping rate and thus care must be taken to use the correct speed for unloading. Explain: That precautions must be taken when discharging by gravity or by pump to ensure that the tank does not implode i.e. by opening the man lid on the tank/tank container. Demonstrate: The implosion of a PET [clear plastic soft drinks] bottles. Part fill the bottle with hot water, shake until the bottle is thoroughly warmed, pour out the water and immediately close the bottle with an air-tight seal. Explain: That closed systems are also used for discharge as well as filling. Display: A sketch of a closed discharge system and explain its operation. Explain: That the driver of the vehicle is often asked to draw product samples from the vehicle. He should do this only if (a) he has been provided with equipment which will allow him to do it safely and (b) he has sufficient training and knowledge of the product to carry out the sampling safely. Explain: That a tank must be tightly closed during pressure discharge except for the discharge line and the connection to the pressuring medium. Emphasise: That during pressure discharge no part of the system must be pressurised above the Maximum Allowable Working Pressure. That although there is a relief valve on both the tanker pressurising line and on the tanker itself the driver must monitor the pressure during discharge in case of malfunction of these valves. Explain: That tanks should be depressurised after discharge before going back onto the public highway. That the excess vapour should be vented in a safe manner, which does not create any health risk or pollution to the environment. Emphasise: That care must be taken, both during the discharge of product and the depressurisation of the road tank/tank container, to ensure that the receiving tank is not over pressurised i.e. towards the end of a pressure discharge the rate of discharge should be reduced and if depressurisation is via the storage tank it should be in a slow and controlled manner. Explain: That some liquids and liquefied gases may have to be discharged through a top discharge siphon pipe. Display: A sketch of a top discharge delivery system and explain how it operates. Explain: That some tanks may be tipped to assist discharge e.g. powder tanks. Emphasise: The need to ensure the stability of tipped tanks – especially in high winds or on uneven ground. Basic Safety Precautions Explain: That certain basic safety precautions should be taken during loading and discharge, regardless of the type of tank and the substances(s) being carried and these include: - Site rules must be obeyed and the driver should know what to do in the event of an emergency. Display: Display a list of typical site rules. Positioning the vehicle so that it can be driven forward from the unloading point in an emergency rather than reversing. Positioning the vehicle so that its discharge connections face the inlet point of the storage tank and thus avoid the need to run a flexible hose around the rear, or beneath the vehicle. Where possible use only one short length of flexible hose to connect the tankers outlet to the inlet on the storage tank. Precautions should be taken to prevent the vehicle moving during all tank loading, unloading and cleaning operations. That this can be achieved by such actions as removing the ignition key and applying tractor and trailer handbrakes or the use of crook locks, barriers or systems of linking the vehicle brakes to the filling or discharge point. Movement of personnel, other than those involved in the operation, and other vehicles in the vicinity of the loading/unloading operation should be prohibited. The tank should be earthed – where relevant. The appropriate protective clothing and equipment should be put on. Determine the system to be used to stop loading in order that overfill may be prevented. Ensure that the correct flexible hose is being used for the product being loaded or discharged. When discharging, ensure that the hose is connected to the correct receiving tank. Do not assume that the connection may be made to the inlet used on the last visit since the tanks use may have changed. Before starting discharge ensure that there is sufficient free space in the receiving tank to accept the load. Explain: That when making deliveries by tanker many companies used a “double signature” delivery note. This requires the driver to obtain two signatures from the customer on the delivery note. The first signature must be obtained before discharge commences and confirms that (a) the tankers hose is connected to the correct tank inlet and (b) that there is sufficient space in the storage tank to receive the load. The second signature is obtained after the delivery and confirms that the full and correct load has been delivered. After use hoses should be drained; cleaned where possible, and capped to avoid contamination of product, personnel and other equipment. Explain: That some dangerous substances are incompatible with one another. Give examples, e.g. flammable liquids and oxidisers, strong acids and alkalis, acids and hypochlorites. Emphasise: Substances, which may react dangerously with each other, shall not be carried in adjoining compartments of tanks. Substances, which may react dangerously with each other, may be carried in adjoining compartments of tanks, when these compartments are separated by a partition with a wall thickness equal to or greater than that of the tank itself. They may also be carried separated by an empty space or an empty compartment between loaded compartments. . Care of Vehicle Equipment Explain: That hoses used for loading and discharge must be suitable in all respects for the substances being handled i.e. resistant to product and suitable for the temperature, and must be kept in good condition so that there are no leaks from the hose or the hose connections. Emphasise: That hoses, drivers should regularly inspect hose connections and seals and any defects reported immediately. Explain: That at regular intervals hoses should be subjected to more detailed inspection including a pressure test and measurement of elongation and an electrical continuity test. That records should be kept of this inspection and any “failed” hoses should be destroyed to prevent their accidental use at a later date. State: That the British Standards institute are co-operating with their EC counterparts to produce a mutually acceptable system for the inspection, identification and testing of flexible hoses. Explain: That all other items of equipment such as pressure/vacuum relief valves, pressure gauges, thermometers, control valves, etc. should be regularly inspected by drivers and defects or suspected defects, reported. State: That there is a statutory requirement for pressure relief valves to be tested on a routine basis.

Tanks BLEVE 6.3.4 The causes and effects of Boiling Liquid Expanding Vapour Explosions BLEVE Explain: That BLEVE stands for Boiling Liquid Expanding Vapour Explosion. That such an explosion is likely to occur when flammable liquid or gas in a tank boils due to fire engulfment of the tank or a fire very close to the tank. Explain: That due to the fire the metal shell of the tank is likely to be weakened and the liquid will boil off very quickly creating a very high pressure in the tank causing it to rupture. The gases released normally ignite causing a “fire ball”. State: That ADR and subsequently UK rules specify certain requirements for fire engulfment relief. Explain: That in the event of a fire, tanks containing highly flammable liquids or gases are usually sprayed with water in an attempt to cool them and prevent a BLEVE. That loading/unloading bays for liquid flammable gases are usually provided with water drench systems, as occasionally are some for flammable liquids That insulated tanks are much less likely to have a BLEVE.

Tanks Static electricity
6.3.5 The causes of static electricity, and the specific precautions to be taken to avoid its dangers, including the use of anti-static and non-sparking tools and clothing Static Electricity Explain: That one of the greatest dangers in the handling and transportation of flammable substances arises from the generation and accumulation of static electricity charge. Explain: That static electricity is generated when two dissimilar substances rub together. Recall: Examples which most people have experienced at first hand, e.g. the crackling and even visible sparks when removing clothing (particularly clothing containing man made fibre), shock which may be experienced when a door handle or other metal object is touched after walking across a carpet (especially a carpet incorporating synthetic fibres), and the childhood trick of causing bread crumbs or pieces of paper to ‘dance’ under the influence of a comb after combing one’s hair. State: That static charges are generated in a number of ways including, for example, when droplets of liquid fall through air (splash filling) or when a liquid flows through a pipeline or hose – particularly if turbulence is present. Turbulence may be caused by a number of factors including restrictions to the flow caused by changes in the diameter of the pipeline, bends in the hose or pipeline and flow through a filter. Explain: That these charges may build up to such a level that they will arc across to any good conductor of electricity. Emphasise: That the energy in the spark may be sufficient to complete the fire triangle and cause a fire or explosion. Explain: That precautions have to be taken to minimise the generation of static electricity and the accumulation of the charge. State: That charges measured literally in tens of thousands of volts are quite commonly accumulated when the precautions are ignored. Explain: That the precautions should include: - Earthing the vehicle. Splash filling should never be used i.e. the loading arm must extend to the bottom of the tank and actually rest on the bottom. Restriction in the pumping rate at the commencement of the loading/discharge operation. The flexible hose should contain a flexible spiral continuity wire connected to both end couplings. Avoid wearing clothing made from 100% synthetic fibres; cotton overalls or those containing a high percentage of cotton are best. Clothing should not be put on or removed in areas where flammable vapours may be present e.g. loading/unloading area, because these actions generate more static than the wearers normal movement. Personnel in these areas should not be permitted to wear footwear with iron or steel nails. The wearing of anti-static boots. The tanker should not be dipped or sampled until at least 5 minutes after loading in order to allow any static electricity that has built up to dissipate. Sampling cords of synthetic fibre should not be used. State: That for products such as petrol anti-static additives are added to reduce the generation of static, but for most chemicals, product quality is very important and this rules out the use of such additives.

Tanks Overfilling 6.3.6 The avoidance of overloading and overfilling, including the use of dipsticks, ullage bars, sight glasses, gauges, meters and weigh-bridges Explain: That ADR filling levels are now used in the UK for NEW TANKS e.g. Fill Levels for Tanks Filled with Liquids There are now more precise filling ratio which are obtained from Sub section of ADR an example is: For a flammable substance without additional dangers: Degree of filling = / 1 +  (50 – tF ) % of capacity Where  = d15 – d50 /35d50 where d15 and d50 are the relative densities of the liquid at 15 °C and 50 °C respectively. tF is the mean temperature of the liquid during filling. Explain: That dipsticks, ullage bars, sight glasses, gauges, meters and loading on the weighbridge are all methods which may be used to monitor the quantity of product being charged into a road tanker/tank container. However it should be noted that dipsticks and ullage bars could not be used where closed filling is being used. Explain: Different rules apply to determining the maximum degree of filling of gas tanks and MEGCs. These will depend on whether the gas is carried merely in the compressed state, whether it has been liquefied at ambient temperatures or whether it has been liquefied by being deeply refrigerated.

Tanks Cleaning 6.3.7 The cleaning and purging of tanks and ancillary equipment, e.g. pumps, hoses etc, including the driver’s individual responsibilities; techniques, precautions (with particular reference to tank entry), avoidance of implosion, and compliance with COSHH or awareness of COSHH Cleaning of tanks and ancillary equipment Explain: That cleaning and purging may take place at loading or unloading points but that general purpose tanks are more usually taken to commercial cleaning stations where the tanks are cleaned and a “Certificate of Cleanliness” issued. Explain: That there are various cleaning methods and that the one used must be appropriate for the substance and vehicle concerned. Emphasise: That dangerous reactions may occur if the wrong cleaning method is used and incorrect neutralising or cleaning chemicals are added to the liquid or vapour residues. Explain: That drivers should forewarn cleaning stations of what has been carried in the tank previously, the inherent dangers, any precautions to be taken against spillage or fire and of any first aid advice. Explain: That all parts of the tank should be cleaned together with any ancillary equipment, e.g. pumps, hoses, couplings, which have been used in loading or discharging. State: That the danger labels may not be removed before cleaning and purging, but that labels MUST be removed after cleaning and purging. Emphasise: That any part or item not cleaned means that the full the carriage regulations may still apply, and that there might be a dangerous reaction between the residues and the next substance to loaded or discharged. Explain: That inert gases may be used to purge a tank which removes the dangerous vapours but also results in an oxygen deficient atmosphere in the tank. Explain: That sometimes tanks have to be entered for cleaning purposes but that drivers would not be expected to do so. Emphasise: That additional precautions e.g. tank entry procedures must be followed, before any one enters a tank. Breathing air sets are often used for tank entry and someone remains on watch on the tank top all the time someone is inside. Explain: That sometimes tanks have to be entered for cleaning purposes but that drivers would not be expected to do so. COSHH State: That COSHH stands for the “Control of Substances Hazardous to Health Regulations 1994”. Explain: That these regulations oblige employers to take account of both short term and long term risks to health e.g. cancer causing substances. That such risks have to be assessed by employers and the necessary steps taken to avoid or reduce risks. Emphasise: That even employers in the transport industry have to carry out assessments on all substances used or processes undertaken at work. Explain: That road tanker and tank container vehicles drivers are more likely to be exposed to substances both short term and continuously. That drivers regularly loading and discharging the same substances face different risks which need to be assessed under COSHH. That drivers may be more regularly exposed to substances dangerous to health during cleaning operations and therefore there is a need for particular care when cleaning takes place.

Tanks Routing 6.3.8 Using appropriate routes, avoiding built up areas, low bridges and routes with restrictions relating to the transport of dangerous goods. ROUTING State: That some local authorities and chemical manufacturers have voluntary agreements for the routeing of dangerous goods vehicles to the major factories in the area e.g. in Grangemouth, Cleveland, Barry and Kings Lynn. Drivers should follow these recommended routes. Emphasise: That in Europe, there may be “no go” signs for dangerous goods vehicles e.g. through certain tunnels, under rivers and through mountains. Goods may be banned totally or restricted to quantity, class, time of day and may only be allowed through under escort. That also in Europe, the movement of dangerous goods may be banned by some countries on certain days of the week or times of the year and in bad weather. State: That in the UK, British Toll Tunnels publish a combined set of regulations as to what, when and how dangerous goods may pass through: Dartford, Tyne/Tees and Merseyside tunnels. Explain: ADR Tunnel codes: Tunnel Category A - No restrictions for the transport of dangerous goods Tunnel Category B - Restrictions for dangerous goods which may lead to a very large explosion (Hot BLEVE) Tunnel Category C - Restrictions for dangerous goods which may lead to a very large explosion, a large explosion or a large toxic release Tunnel Category D - Restrictions for dangerous goods which may lead to a very large explosion, to a large explosion, to a large toxic release or to a large fire Tunnel Category E - Restrictions for all dangerous goods other than UN Nos , 3291, 3331, 3359 and 3373 State: That there are separate rules for the Channel Tunnel.

Tanks Loading and discharge Open Closed
6. Knowledge of the various and different loading and discharge systems. 3 Questions 6.4.1 Closed and open systems Loading Explain: That there are two principal methods of loading liquids – by open fill and closed system filling. Explain: That, regardless of the loading method in use, the vehicle must be earthed when flammable liquids, flammable gases and combustible powders are being handled in order to minimise the build up of static electricity. Explain: That in order to limit the generation and accumulation of static electricity the vehicle should be positioned so that the filling arm reaches the bottom of the tank compartment and that the liquid flow rate should be restricted until the end of the filling arm is covered by the product. Explain: That when an electrical storm occurs all “open loading” and “open discharge” of vehicles with flammable liquids should stop because of the risk of the static electricity in the air at such times providing a source of ignition. Explain: That, with a multi-compartment vehicle which may carry both flammable and non-flammable materials, it is good practice to earth the vehicle since non-flammable materials can still generate static electricity e.g. phthalate plasticisers (used in PVC manufacture). Explain: That the loading/discharge of a flammable substance MUST be halted if it is realised that the vehicle has not been earthed. Emphasise: That the earth lead must not be connected whilst the operation continues. Explain: That time must elapse (5 minutes) after cessation of the operation to allow any static to dissipate before the earth connection is made otherwise a static discharge may occur. Describe: How open filling takes place through an open man lid. Emphasise: That the open fill system should be used only where the escape of vapours does not create a significant danger to health or to the environment. Explain: That highly dangerous liquids, gases and some petroleum tankers are filled by a closed system method. Filling of petrol tankers is often driver controlled and that bottom filling is quite common. State: That when this system is used the tank is not open to the atmosphere. Emphasise: That unless suitable precautions are taken, i.e. by linking the vapour space of the storage tank to the ullage space of the road tanker/tank container, there is a risk that the one may become over-pressurised and the other under-pressurised. Explain: That with this type of filling system there is likely to be some product left in the filling line at completion of filling. To prevent this from spilling out when the filling arm/hose is disconnected then either (a) facilities must be provided on the filling line to allow it to be blown clear before disconnection e.g. with nitrogen or (b) “dry break” couplings could be fitted on the tanker inlet and on the end of the filling arm/hose. State: That alternatively vapour displaced from the road tanker/tank container may be passed to a suitable scrubber or flare system if available. Explain: That care must be taken not to overfill a tank no matter which filling system is used. Explain: That dipsticks, ullage bars, sight glasses, gauges, meters and loading on the weighbridge are all methods which may be used to monitor the quantity of product being charged into a road tanker/tank container. However it should be noted that dipsticks and ullage bars could not be used where closed filling is being used.

Tanks Loading and discharge Gravity Pump Pressure
6.4.2 Loading and discharging using gravity or pumps, including the use of pumps or compressors either on the vehicle or external to it Unloading Explain: That the principal methods of discharge are by gravity, by pump and by pressure. Explain: That where discharge is by pump or compressor theses are usually, but not always, provided on the vehicle. The vehicle’s engine is normally used to drive the compressor and the pump, which is often hydraulically driven. Explain: That precautions must be taken when discharging by gravity or by pump to ensure that the tank does not implode i.e. by opening the man lid on the tank/tank container. Consider: Demonstrating the implosion of a PET [clear plastic soft drinks] bottles. Partly fill the bottle with hot water, shake until the bottle is thoroughly warmed, pour out the water and immediately close the bottle with an air-tight seal. (Take care- use water that is not excessively hot in order to avoid scalds) Explain: That closed systems are also used for discharge as well as filling. Display: A sketch of a closed discharge system and explain its operation. Explain: That the driver of the vehicle is often asked to draw product samples from the vehicle. He should do this only if (a) he has been provided with equipment which will allow him to do it safely and (b) he has sufficient training and knowledge of the product to carry out the sampling safely. Explain: That a tank must be tightly closed during pressure discharge except for the discharge line and the connection to the pressuring medium. Emphasise: That during pressure discharge no part of the system must be pressurised above the Maximum Allowable Working Pressure. That although there is a relief valve on both the tanker pressurising line and on the tanker itself the driver must monitor the pressure during discharge in case of malfunction of these valves. Explain: That tanks should be depressurised after discharge before going back onto the public highway. That the excess vapour should be vented in a safe manner which does not create any health risk or pollution to the environment. Emphasise: That care must be taken, both during the discharge of product and the depressurisation of the road tank/tank container, to ensure that the receiving tank is not over pressurised i.e. towards the end of a pressure discharge the rate of discharge should be reduced and if depressurisation is via the storage tank it should be in a slow and controlled manner. Explain: That some liquids and liquefied gases may have to be discharged through a top discharge siphon pipe.

Tanks Tipping tanks 6.4.3 The use of tipping tanks, including the use of pressure, use of stabilising legs, precautions in high winds, the dangers of sticking loads and overhead obstructions Explain: That some tanks may be tipped to assist discharge e.g. powder tanks. Emphasise: The need to ensure the stability of tipped tanks – especially in high winds or on uneven ground. Emphasise: That it is essential to ensure that there are no overhead projections in the discharge area which could be struck by the tank when it is tipped. Tipping tankers Explain: That the tank is cylindrical with an outlet at the bottom rear through which discharge takes place. Explain: That an aeration pad is fitted on the tank outlet to help the product to flow freely from the tank, and an outlet valve is fitted beneath the aeration pad. That the aeration pads are fixed on some tankers, mainly flour, but quickly detachable pads are fitted on most others for cleaning purposes, and are removed completely when used on plastic granules. Explain: That discharge is by means of compressed air from a compressor carried on the vehicle. Explain: That air is applied to the vapour space of the tanker and to the aeration pad to help product flow from the tank. That more air is passed, via an inverted ‘T’ piece, beneath the outlet valve to convey the product to the customers silo. The tanker is tipped increasingly during the discharge. Explain: For stability reasons the following should be complied with during discharges with tipping tankers: - The tanker should stand on firm and level ground. The tractor unit and tank should be in a straight line. Stabilising legs should be used where fitted. Where the vehicle has air suspension, release the air if possible. Explain: That there have been a number of incidents where tipping tankers have fallen over due to instability and crosswinds.

Tanks Power Take Off 6.4.4 The use of the prime mover engine to drive, through power take off, a pump or compressor, and the proper control of engine speed Explain: The PTO is usually the method of operation for ancillary equipment. Typically (but not always) the PTO is engaged by depressing the clutch and engaging the PTO. This then operates the piece of equipment the PTO is engaged to. Explain: The vehicle engine is used to regulate the speed. Explain: That excessive speed can lead to “cavitation” of the pump causing wear and reduction of pumping rate and thus care must be taken to use the correct speed for unloading.

Tanks Decompression 6.4.5 Decompression before disconnection, and the avoidance of implosion Recall: That tanks should be depressurised after discharge before going back onto the public highway. That the excess vapour should be vented in a safe manner which does not create any health risk or pollution to the environment. Recall: That precautions must be taken when discharging by gravity or by pump to ensure that the tank does not implode e.g. by opening the man lid on the tank/tank container.

Tanks Pump 6.4.6 Discharge by pump, including pump priming
Recall: Discharge by pump in section 6.4.2 State: Some pumps may not operate unless primed e.g. centrifugal pumps. State: Where a pump requires priming, the pump casing must be filled with the product before it is started. If the casing becomes filled with vapours or gases, the impeller will become gas bound and the pump will not work. State: In order to avoid this situation most centrifugal pumps are located below the level of the bottom of the tank. State: Instructions on pump priming should be obtained from the tank operator. Explain: That excessive speed can lead to “cavitation” of the pump causing wear and reduction of pumping rate and thus care must be taken to use the correct speed for unloading. Most pumps are speed restricted as cavitation can cause severe damage to the pump. In some cases, increasing the speed of the pump will result in a slower pumping rate and longer discharge time.

Tanks Connections 6.4.7 The correct connection of hoses, pumps and siphons, and the correct sequence for valve opening

Tanks Specific precautions
6.4.8 The specific precautions to be taken when loading and unloading dangerous substances (top discharge), LPG, cryogenic gases and dangerous wastes. Top discharge State : Before working on the top of a tank, all guard rails and other safety measures must be put in place. Outline: Typical procedures for top discharge of a tank - Remove top outlet blank flange, bolt hose couplings to top outlet flange. Open manlid or airline connection to vent tank. Open tank outlet valve or valves and commence discharge. Check constantly for leaks in hose and connections. Drain tank. When discharging is complete- Drain hose; Close top outlet valve and remove hose from tank; Replace top outlet blank flange. Close manlid and tighten down, or close airline connection, replacing blanking cap. LPG State: When a LPG tank becomes heated e.g. by fire or direct sunlight, the pressure can rise quickly. State: Under normal circumstances, a relief valve on the tank will release the gas in a controlled manner to prevent the tanker from exploding due to over-pressurization. However, if the tank and valve are not properly maintained and/or the pressure build-up is very rapid, such as when the tank may be directly exposed to fire, a tank failure and subsequent explosion can occur (see BLEVE section). State: When LPG is released it is extremely cold. If you physically contact escaping gas, or anything around it, you could suffer cold burns or frost bite State: That LPG is heavier than air. If it leaks it will tend to spread along the ground. State: That ignitable mixtures can extend beyond the visible area.. Explain: Excess flow valves are fitting as an additional safety feature to LPG tanks and highly volatile substances. An excess flow valve prevents a large escape of product form within the system should there be a break in the connection. It also slows or stops the discharge if the flow rate were too fast. when unloading flammable gases from a tank friction is created, if there were sufficient air and flammable vapours in the system then all you require would be a spark for an explosion, the excess flow valve would slow the rate of discharge or in some cases even stop unloading procedure to prevent the explosion risk. Cryogenic gases State: That due to the extremely low temperature,cryogenic liquid, if allowed to escape, could cause damage or injury. Damage may be as a result of embrittlement of the material due to the extreme cold, and injury may be the effect of extreme cold on external tissues or internal damage to the lungs. State: That because of the large temperature difference between the gas and the ambient temperature, all valves should be operated slowly Dangerous wastes Explain: These tankers are built of stronger materials than a standard GP tanker. The tanks are used for self-loading under vacuum and unloading through pressure. The tank has to be made of thicker metals than a standard GP tank 8-10 mm because of the vacuum loading system. Other features of these tanks, the materials use for the construction of tank will have to resist the types of chemicals loaded, so the operator has to ensure that prior to loading that the chemicals are tested for suitability for the type of tank used. Waste tanks can be made of various metals aluminium, mild steel, stainless steel and some cases maybe lined with rubber or PVC. Most will have a large rear opening door to assist with tank cleaning for sludgy products. Any waste movements will be subject to the waste regulations. Explain: That as well as the carriage regulations, other regulations apply to the movement and disposal of hazardous wastes and that they require additional documentation and procedures. Emphasise: That these controls are intended to ensure that no waste is moved without knowledge of the authorities and that it is not transferred from one holder to another without prior consent. That these controls are designed to ensure traceability of each consignment once it is handed over from one carrier to another. Display: A consignment note for the carriage and disposal of hazardous wastes note. Explain: That when drivers arrive to collect the waste they should check that the following information in Parts A and B of this note is correct: After loading, drivers complete Part C with carriers business name, registration number and vehicle registration number. The consignee completes part D and retains a copy

Tanks Product movement
6. The behaviour of vehicles, tankers and tank containers on the road, including movements of the load. Questions: Nil 6.5.1 Surge during braking and acceleration, and the need for the driver to anticipate and acclimatise THE EFFECT OF A MOVING LOAD Explain: That liquids and liquefied gases are free to move inside a tank and surge forward when the brakes are applied and rearwards when the vehicle accelerates. Demonstrate: This movement by using a PET [clear soft drinks bottle] containing water. Explain: That in a single compartment tanker, baffles are often fitted inside the barrel to help contain the forces created by liquid surge when the tanker brakes or accelerates. Explain: That there are usually two baffles fitted in a single compartment tanker equidistant along the length of the barrel.

Tanks Clutch control Braking
6.5.2 The need for clutch control and appropriate braking techniques, with and without ABS Stress: The importance of proper clutch control, particularly when accelerating and decelerating, in order that the problems of surge are not exacerbated. Emphasise: That the clutch must not be disengaged when braking. Lack of power into the driving wheels can easily lead to wheel lock and consequential problems of control. Discuss: The proper driving techniques with or without ABS / EBS braking systems.

Tanks Lateral product movement Rollover
6.5.3 Lateral movement due to sudden steering manoeuvres and roll-over Emphasise: That drivers should acclimatise themselves to the effect of surge remembering that it may continue after the vehicle has come to a halt thus renewing some forward momentum if precautions are not taken. Explain: That lateral surge may be induced by sudden lane switching, cornering and negotiating roundabouts and “S” bends, that this lateral surge is increased and aggravated by speed and may result in the vehicle overturning. Emphasise: The importance of ensuring that the vehicle is travelling at the correct speed for the manoeuvre contemplated. Show: Video on the effects of product movement in the tanker.

Tanks Baffles Filling ratio
6.5.4 The roles and limitations of baffles and rules on minimum loading ratios Remind: That where no baffles are fitted and the tank is in excess of 7500 litres capacity, national and international rules specify a minimum fill of 80% of the tank capacity if filled over 20% of capacity

Tanks Definition Training

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