Tanker Inspection
Contents
1. WARNING PRIOR TO ENTERING TANK ENSURE THE INTERIOR IS FREE OF FLAMMABLE VAPORS AND HAS SAFE LEVEL OF OXYGEN PRESENT COMPLY WITH THE INDUSTRY AND REGULATORY REQUIREMENTS FOR WORK IN CONFINED SPACES ITEM INSPECTION REQUIREMENTS COMPLIANCE CORRECTIVE ACTION REMARKS IF FAIL Shell Inspect and ensure that the tank shell interior is clean of sludge debris and any foreign Pass 0 Cleaning Required Cleanliness material that can cause product contamination Fail O Y Shell Check for corrosion dents cracking pitting or distortion at manhole area around Pass Repair Required Condition emergency bottom inlet valves sumps and joints throughout tank Look for Fail O Cleaning Required L1 Interior discoloration and bleeding check entire shell for deformation Y Welds Inspect welds in tank making hand contact to ensure that sharp edges and gaps are not Pass oO Repair Required LI present Inspect thoroughly the bulk head and baffle welds and the welds in the area Fail O Cleaning Required LI above fifth wheel upper coupler Check if the weld surface is smooth Baffles Inspect Baffles for Product flow opening at bottom vapor flow opening at top and Pass Enlargement of access opening in the centre Recommended openings are shown in Appendix gt Fail O Openings Required Spark Inspect to ensure that conductive devices such as gauging rods metal clips weld plates Pass m Repair Required LI Promote2. Adapters comply with SASO Standards are located at the right curb side of the tanker and forward of the rear axle OPTION I Configuration or behind the rear axle where installation at forward location is not possible OPTION II Configuration limited to short trucks Horizontal spacing of the two adapters comply with SASO Standards is amp mm min to mm max between centerlines The face of the adapters is located at a distance of mm inwards from the side of the tank truck The centerline height of the adapters tank truck in unloading condition is vo mm min to mm max from ground Vapor Control System SAUDI ARABIAN STANDARD SASO YA Y o 0 The vapor adapter is located at the right curbside of the tank truck and forward of the rear axle OPTION I Configuration or behind the rear axle where installation at forward location is not possible OPTION Configuration limited to short trucks Y 0 0 Y Centerline of vapor adapter is at a horizontal distance of V mm min to Y mm max from the adjacent adapter and at a height of Y mm from the horizontal centerline of the adapters comply with SASO Standards as shown in Appendix Y o o Y Face of the vapor adapter is in the same vertical plane as load unload adapters comply with SASO Standards Y o o t Vapor control piping is installed with standard piping elbow fitting Mitered joints are not present Y 0 0
3. THE WORKSHOP ASSUMES FULL RESPONSIBILITY FOR ANY DEFECTS IN THE MATERIALS AND WORKMANSHIP FOR BOTTOM LOADING MODIFICATIONS THE THIRD PARTY INSPECTION CONTRACTOR CERTIFIES THAT THE TANKER SHELL COMPLIES WITH THE BOTTOM LOADING DESIGN REQUIREMENTS Work Shop Stamp Third Party Inspection with Signature Stamp with Signature SAUDI ARABIAN STANDARD ORGANIZATION SASO Y 4 Time tn Appendix VY External Inspection Checklist Six Monthly Inspection Customer Hauler Company ID No Volumetric Capacity Liters Truck No SAP Trailer No SAP Government Registration Documents are available and valid MVPI inspection sticker is displayed on the windshield Hood latch is functional and secured adequately External batteries secured in an insulated covered box 4 i Electrical wiring 15 free of bare wires loose and poorly taped connections Air brake hoses are connected are in good condition and free of worn spots and leaks Primary and Parking brakes are functional Headlights brake lights and signal lights are free of damage and operational v Fifth Wheel connection is without rust or corrosion damage amp deformation X Fifth Wheel assembly bolts are intact no missing bolts and free of rust and damage 5 Exhaust system is in good condition The chassis frame is free of cracks and loose connection bolts The spring leaves are free of damage and witho
4. Manhole enclosure box if provided has openings meshed cover or round openings at sides to allow for venting through Pressure Vacuum vent and Pressure Actuated Fill PAF Cap N The Tank Shell INTERIOR is free of residual product Verify using an Explosion Proof source of light Ya SAUDI ARABIAN STANDARD Piping Work Piping is free of damage corrosion and sign of leaks Bolted joints are without missing bolts Bolts appear properly tightened Welded joints have smooth surface and are free of crack incomplete fusion or damage lt 4 Piping is supported structurally by the tank shell structure and not by bottom Emergency Valves and loading vapor adapters No mitered bends are present in the product and vapor piping Standard elbow fittings are used at bends and changes in path of the piping o Piping from emergency valve s to loading Adapters is provided with nominal slope to facilitate the flow of product to the adapter s Housekeeping Box ex Based upon visual examination welded joints are free from cracks and structural defects Weld surfaces are smooth and free of sharp edges and discontinuities The bottom loading adapters vapor adapter and overfill prevention grounding socket fittings are housed in a lockable housekeeping box constructed of steel as s
5. for Confined Space Work in the Petroleum Industry API RPY Y Protection against Ignitions arising out of Static Lightning and Stray Currents e AMERICAN SOCIETY OF MECHANICAL ENGINEERS ASME ASME V Non destructive Examination NDE ASME VIII Pressure Vessels ASME IX Welding Qualifications e AMERICAN WELDING SOCIETY AWS ANSI AWS F 4 Recommended Safe practices for the Preparation for welding and cutting of containers and Piping AWS Structural Welding Code Steel e NATIONAL FIRE PROTECTION ASSOCIATION NFPA NFPA 4 Hazardous Chemicals Data NFPA Y National Electrical Code NFPA YY Recommended Practice on Static Electricity NFPA YYeM Fire Hazard Properties of Flammable Liquids Gases and Volatile Solids NFPA Tank Vehicles for Flammable and Combustible Liquids e SAUDI ARABIAN STANDARDS ORGANIZATION SASO SASO SSA Transportation of Dangerous Substances by Road General Safety Requirements SASO SSA YAY Transportation of Dangerous Substances by Road Petroleum Liquids SASO SSAYYAA Truck design standard YY
6. loading modification work is from an approved source and is in accordance with the approved material list of the same supplier Mix and match of materials from different approved sources shall not be permitted Items Specific to Option I Configuration Pneumatic System The TPIC shall inspect and ensure Modified tank trucks are fitted with two Y 5 x V mm x emergency valves one emergency valve located in the vicinity of the low point of the tank shell and the other close to middle of the tank shell Gasket seats are free from scratches and weld spatter Emergency valves are installed squarely on the sump flange at the bottom of the tank shell Welding is performed avoiding distortion Weld encroachment does not exceed the greater of Y mm Y f or three times the material thickness The pneumatic operation components are installed in accordance with the supplier installation manual Lifting of guard bar assembly for tank trucks equipped with this feature or loading arm connection activates the air interlock and facilitates full not partial and simultaneous opening of SAUDI ARABIAN STANDARD SASO YA Y o Y o Y o Y Y o Y Y o V Y Y o Y Y Y o Y t Y o Y o Y o Y 1 Y o Y v Y o Y A Y o f Y o Y o Y Y o Y Y o t Y o 0 The pneumatic air supply lines are installed free of sharp bends and routed clear of sharp edged mountings and protrusions on the tank truck
7. open correctly SAUDI ARABIAN STANDARD SASO YA MECHANICAL SYSTEM OPTION II CONFIGURATION ITEM DESCRIPTION OF SERVICE Bottom Operator Check the operating handle for ease of movement Check the bottom operator assembly for signs of damage rust and or corrosion Grease the components as required Y Y Cable assembly Check the cable assembly connecting bottom operator to emergency valve cam bracket for slackness and damage Adjust cable tension to ensure full opening of the emergency valve Grease the moving parts in accordance with instructions in the supplier manual Y Vapor vent rod assembly Check the alignment to ensure the vapor vent push rod stem and emergency valve rod adapter are in line in vertical plane Adjust as required in accordance with the supplier instruction manual HOUSE KEEPING BOX ITEM DESCRIPTION OF SERVICE V Box frame Check box frame for structural integrity and dents damage during road transportation Repair as required V Y Box lid Check the box lid for operability Check hinges latches and support hooks for integrity Ensure the box lid frame is provided with a protective rubber seal around it Replace damaged seal as required Y V Y Dust cap and chain on API fittings Check dust caps and chain for API fittings in the box for integrity Replace damaged or missing par
8. 0 Reinforcement pads are provided at penetration points for vapor line installation through the tank shell OPTION I Configuration Y o 1 Overfill Prevention amp Grounding System The optic probe for overfill prevention is installed close to the longitudinal center of tank shell top or alternatively fitted in the spare accessory port of the new manhole cover located close to the longitudinal center of tank shell top 0 1 Y The length of the optic probe is adjusted in accordance with the calibration requirements outlined in this document Overfill prevention grounding socket is installed to the right of centerline of the adapter in accordance with Appendix 5 0 1 Wiring and connections are made in accordance with the supplier s Installation Manual 0 1 0 Wiring is enclosed in metallic conduit routed on the outside of tank shell and adequately supported at the tank shell o 1 4 The ground bolt is installed on the tank shell or on the chassis frame on tank trucks where chassis frame is integral with or welded to the tank shell Ye The ground bolt installation surface is free from grease paint weld spatter and debris The mounting hole is protected from the formation of corrosion by application of a silicone sealant or suitable material adequate for this application Y O 1 A The ground bolt is wired to the designated receptacle pin in accordance with supplier s Installation Manua
9. Items Specific to Option 1 Configuration Mechanical System The TPIC shall inspect and ensure A sump mounted e x Y V x emergency valve is installed at the rear most bottom end of the tank shell and is located in the vicinity of the low point of the tank shell Gasket seats are free from scratches and weld spatter Emergency valve is installed squarely on the sump flange at the bottom of the tank shell Welding is performed avoiding distortion Weld encroachment does not exceed the greater of Y mm Y f or three times the material thickness Vapor vent mounting pad is welded to the top of the tank on the centerline directly above amp parallel to the mounting sump for emergency valve Operating rod is properly aligned between emergency valve and vapor vent ensuring free movement Length of operating rod is adjusted to provide a minimum clearance of Y mm at the collar of vent valve stem with the emergency valve amp vapor vent valve in closed position The cable path between the emergency valve cam and the bottom operator is straight and free of sharp radii bends Operation of the mechanical bottom operator ensures full not partial and simultaneous opening of emergency valve and vapor vent valve Bottom Loading Components Common to Both Option I amp Option II The TPIC shall inspect ensure satisfactory installation and compliance with the following requirements Loading amp Unloading Adapters
10. KINGDOM OF SAUDI ARABIA SAUDI ARABIAN STANDARDS ORGANIZATION SASO SAUDI STANDARD DRAFT No BOTTOM LOADING TANK TRUCK INSPECTION AND PERIODIC MAINTENANCE SAUDI ARABIAN STANDARDS ORGANIZATION THIS DOCUMENT IS A DRAFT SAUDI STANDARD CIRCULATED FOR COMMENT IT IS THEREFORE SUBJECT TO CHANGE AND MAY NOT BE REFERRED TO AS A SAUDI STANDARD UNTIL APPROVED BY THE BOARD OF DIRECTORS SAUDI ARABIAN STANDARD ORGANIZATION SASO Y 4 TABLE OF CONTENTS iud Matisse o acti e e ute tinus Eligibility requirements third party inspection contractor P RE Rer e Dae ae d a RE MR A Initial inspectiofizs 2 od deque ee ete te Eae ede SEP M vex ba shat General VENICE Internal visual inspection S External visual nis peetOnss cctv oo ee ette ico sh ioca te a bee dec dpi ya F nctionality check oso H v3arostatte te SEPT ad Tanner cett iod TOTO o eot acorde e B Periodic maintenance inspection ohne WIN ped auster M eh C Frequency of inspections and pm tests APPENdIRES creaire e T Raed N o Appendix 1 piping amp emergency valve configurations sese o Appendix Y ta
11. Notes on Functionality Checks Item Nos 7 and This will require a test stand comprising of a loading arm and a vapor arm Y No Vapor vent functionality should be verified by opening the PAF Cover slowly to release any pressure and feeling by hand the inward opening of vent bottom seat The opening size is approximately V mm The inspector is required to wear protective mask to avoid vapor inhalation Also see 5 below Y Item No W Overfill Grounding system should be verified using a commercially available Optic Overfill System Tester unit 5 General Inspection of Manhole Cover amp Tank Truck Venting System will require access to the top of the tank truck The inspection contractor should use a mobile ladder platform with safety rails to ensure safety during inspections on the roof of the tanker The tank truck shell shall be emptied of product prior to conducting the inspections Acceptable Results Of Inspection Dents cuts digs and gouges a For dents at welds or in an area that include a weld the maximum allowable depth is mm 75 inch v4 SAUDI ARABIAN STANDARD SASO YA b For dents away from welds the maximum allowable depth is 1 1 of the largest dimension of the dent but in no case the depth shall exceed Y mm one inch Y Weld or structural defects All structural welds are free of defects such as visually noticeable cracks pinho
12. PE IN ACCORDANCE WITH API RP BOTTOM LOADING ARM Overfill Sensing Probe Wire System VERTICAL OPERATING ENVELOPE Overfill Prevention Grounding Receptacle Vapor Adapter Max Liquid Level 4 of full tank capacity Height for rollover protection Above all tanker top fittings Housekeeping Box TANKER MODIFICATIONS OPTION II SAUDI ARABIAN STANDARD SASO APPENDIX Load Unload Load Only Adapter Rounded Edges Typ NOTE PNEUMATIC FITTINGS CONNECTIONS AND HINGED FAUCET GUARD BAR NOT SHOWN FOR CLARITY RECOMMENDED ARRANGEMENT OF ADAPTERS IN HOUSEKEEPING BOX UNLADEN CONDITION ALL DIMENSIONS IN MILLIMETERS SAUDI ARABIAN STANDARD Appendix SAUDI ARABIAN STANDARD ORGANIZATION SASO 4 Appendix Company Name company logo Company Name In English In Arabic Certificate Serial No Tractor Head Trailer SAP Nos Inspection Certificate THIS CERTIFICATE IS ISSUED TO CONTRACTOR CUSTOMER NO UPON COMPLETION OF THE INSPECTION REQUIREMENTS OF THE TANKER WITH SAP NUMBERS AS SHOWN THIS TANKER WILL BE EXCLUSIVELY OPERATED WITH TRACTOR HEAD NO HAVING FIFTH WHEEL HEIGHT OF MM UNLADEN THE VOLUMETRIC CAPACITY OF TANKER IS LITERS THIS TANKER WAS INSPECTED amp CERTIFIED ON AN INSPECTION STICKER EVERY SIX MONTHS WOULD BE REQUIRED AFTER THIS DATE TO MAINTAIN VALIDITY OF THIS CERTIFICATE
13. amage and cleanliness Check socket housing for installation tightness Apply silicone sealant at connection points as required Y Functionality Check for system functionality using a Scully or equivalent tester Additionally perform an electrical continuity test between the Ground Bolt connection point at the tank and Grounding Pin at the Optic socket Using a low resistance ohm meter verify that the circuit resistance does not exceed ohms Y o PNEUMATIC SYSTEM OPTION I CONFIGURATION ITEM DESCRIPTION OF SERVICE Y 6 Pneumatic circuit airlines and hoses Check for leaks using a water soap spray Check for kinks and damage Replace damage parts Y o Y FRL Unit Check filter bowl and drain any accumulated condensate liquid Replenish with the lubricant as required and check air pressure setting as per supplier manual and instructions Air Intake Valve Check valve operability to ensure air supply to FRL valve Air Interlock valve Check for functionality activation of air interlock valve via a guard bar mechanism or loading arm coupler connection Check if the brakes of the truck are applied by trying to drive away with air interlock in activated position Y 5 Opening and closure of bottom loading fittings Check opening of emergency valves and vapor vent valve by opening the manhole cover fill cap to ensure these
14. ap of the manhole cover is set to open at a pressure of Y mb Y psig and tested accordingly for functionality under simulated pressure of Y Y psig Manhole enclosure box if provided has meshed openings to allow for operation of pressure vacuum vent and manhole fill cap for emergency venting Piping Work Piping is cleared of debris and all foreign materials prior to installation of bottom loading fittings Piping is supported structurally by the tank shell structure The tank shell structure is reinforced at support locations No mitered bends are present in the piping Standard elbow fittings are used at bends and change in path of the piping Piping from emergency valve s to loading Adapters is provided with nominal slope degrees to Horizontal to facilitate the flow of product to the adapter s Undercarriage piping is pressure tested to V bar 117 psig as SASO Standards Vapor piping is tested to V mb 1 psig minimum To follow API RP Specifications American Petroleum Institute until the approval of Saudi standards SAUDI ARABIAN STANDARD SASO YA Y o 3 Y o 0 9554353 Y o Y NY Y o YV Y Y o Y o 1 Yo WELDING Inspect all welding for bottom loading fittings and piping for cracks and defects in workmanship Weld encroachments less than Y mm 54 shall not be permitted Ensure that the we
15. cal System Loading amp Unloading Adapters Yy API adapters are equipped with product level indicator and with protective caps with chain API adapter faceplate is free of damage and aligns with outer rim of adapter No signs of leak are present at the junction of rim and faceplate Yt Operating handle of load unload adapter is free of damage and opens the adapter fully when operated Vapor Control System Vapor adapter 15 equipped with product level indicator and protective caps with chain Y Vapor adapter poppet is free of damage without sign of leak at the outer rim and aligns with the outer rim of the adapter YN Vapor Vent Valve external surface and mounting plate is free of damage corrosion and securely bolted in place Pneumatic air connection is secured in the inlet port and 15 free of broken or chipped ends SAUDI ARABIAN STANDARD YA Flexible connection between vapor vent and vapor piping if used 15 equipped with steel wire helix for electrical connectivity and strength Overfill Prevention amp Grounding System Ya The Optic probe housing is free of damage corrosion and signs of leak Overfill Grounding socket installed to the right of load only API adapter in the Housekeeping Box inspector facing
16. ck any other internal fittings for bolt tightness correct alignment and other defects Baffle Requirements The TPIC shall inspect and certify compliance with the following baffle requirements Anti surge baffles ends and divisions shall be fabricated from the same material as the tank shell and free of defects and damage Baffles shall be installed in a vertical attitude with respect to the longitudinal axis of the cargo tank and shall be welded to the tank shell The thickness of the baffles shall not be less than the thickness of shell material Support brackets or any temporary hardware used for installation of baffles shall be removed from the tank shell since these can act as spark promoters The cross sectional area of each baffle after deducting the area of all openings shall not be less than of the cross sectional area of the tank see Figure HALF HOLES mm DIA ACCESS OPENING 3 O CLOCK 1 BAFFLE AREA TO BE GREATER THAN BAFFLE AREA 80 OF BAFFLE OPEN AREAS 2 BAFFLE TO SHELL WELD LENGTH TO BE EE OPEN AREA GREATER THAN 50 OF BAFFLE PERIMETER LENGTH xox BAFFLE TO SHELL WELD Figure Baffle Requirements SAUDI ARABIAN STANDARD SASO YA Teens Y o Y 1 Y o Y o Y Y Y o Y Y Y o Y Y o Y Y o Y Y Y o Y Y Y o Y f Baffles shall be provided with sufficiently sized opening
17. conforming to the fifth wheel height The TPIC shall maintain a database for all inspection records and associate these with the unique bar code for every tank truck The database shall include the expiration date of the first or initial inspection and the date of tank shell hydro test The database shall be in a format suitable for electronic transfer to the Terminal Management System TMS A test report shall be jointly completed by the TPIC and workshop for every tank truck that is modified Data shall be recorded for all tests conducted The report shall include the test date information regarding the owner and the operating location of the tank truck the serial number of the tank truck bar code and the type of test conducted The TPIC shall provide an Inspection Certificate for first time inspection for each tank truck modified to bottom loading The Inspection Certificate shall be similar in format to the one shown in Appendix 1 f PERIODIC MAINTENANCE INSPECTION Y General Mandatory Periodic Maintenance Work and Inspection shall be performed on modified tank trucks after a maximum months from the date tank truck is put into service and continued on a semi annual basis thereafter see table below Specific work description Product Loading Un Loading System SAUDI ARABIAN STANDARD SASO YA ITEM DESCRIPTION OF SERVICE Y Loading Adapter Check for functionality usin
18. d Load only Load only OPTION OPTION II PNEUMATIC SYSTEM MECHANICAL SYSTEM PIPING amp EMERGENCY VALVE EV CONFIGURATIONS SAUDI ARABIAN STANDARD DESCRIPTION Vapor Vent Y Mounting Pad for Vapor Vent Y Vapor Piping Emergency Valve Mounting Sump for Emergency Valve API Load Only Adapter API Loading Unloading Adapter Vapor Adapter Manhole Cover with Pressure Vacuum Vents TTMA Pipe Flange mm nominal size Overfill Prevention Grounding Receptacle Overfill Sensing Probe Wire System Minimum Slope from Horizontal Max Liquid Level 5 7 of full tank capacity APPENDIX Max Liquid Level TANKER MODIFICATIONS OPTION YO mm SIDE OF TRUCK API ENVELOPE IN ACCORDANCE WITH API RP BOTTOM LOADING ARM VERTICAL OPERATING ENVELOPE Height for rollover protection Above all tanker top fittings SAUDI ARABIAN STANDARD SASO YA APPENDIX DESCRIPTION Vapor Vent Mounting Pad for Vapor Vent Max Liquid Level Vapor Vent Operating Cable Assembly Emergency Valve SIDE OF TRUCK Mounting Sump for Emergency Valve Vapor Vent Rod Assembly Bottom Operator API Load Only Adapter API Loading Unloading Adapter Manhole Cover with Pressure Vacuum Vents TTMA Pipe Flange nominal size API ENVELO
19. d verified functional utilizing a standard optic system testing device Scully tester or equivalent Tank Shell Pressure Test After completion of bottom loading modifications the tank shell shall be either tested by air pressure or hydro tested by sweet water for leaks and pressure sustaining capability Pressure Gauges Gauges used for pressure testing shall be of mb 1 psi division with the test pressure falling in the range between 7 to Y of the full scale deflection of the gauge All pressure gauges shall be calibrated To follow API RP Specifications American Petroleum Institute until the approval of Saudi standards SAUDI ARABIAN STANDARD SASO YA Y V f Y5Y 3 t 6 Y V Y V A Method for testing single compartment tank truck The tank shell shall be thoroughly cleaned and drained of all dangerous and flammable product and residues prior to testing Tank shell shall be rendered completely gas free prior to the commencement of test The following procedure shall be used The tank shell shall be supported adequately by a sturdy support under the fifth wheel plate if it is not connected to a tractor Care should be exercised in providing a support under the fifth wheel area that allows for inspection but is not so concentrated that it damages the cargo tank frame rails The landi
20. e horns are operational Fifth wheel connection plate is free of rust corrosion and without deformations warping damage Connection bolts are intact and free of rust and damage The vehicle exhaust system is in good condition and discharges at ground level Chassis structural frame spring leaves and shock absorbers are free of damage operational and secured properly Vehicle tires are in good condition and with a minimum of V YY inch tread across the full width Wheel mounting bolts are intact and without rust or corrosion damage Wheel frame is free of broken wells or damage Spare tire is secured adequately Windshield is without cracks and in good condition Windshield wipers are functional and without wear damage SAUDI ARABIAN STANDARD SASO YA Tey Y Y Y Y vY YS Vedas Y Y 1 Side view mirrors and rear view mirror inside the drivers cab are without damage and mirror adjustment mechanisms are functional Fuel tanks are free of damage and secured adequately to the tank truck support frame Auxiliary fuel tank if provided is equipped with a pressure relief device Seat belts in drivers cabin are without damage and in good working condition Toolbox for minor repairs is secured properly in an accessible location and is labeled Tank truck mounted portable fire extinguishers a
21. free of cuts and gouges in excess of mm in length and dents in excess of Y mm in depth No signs of leak are observed around tank shell repair work if present and at joints between tank shell mountings and tank shell Emergency Valve No signs of leak or damage observed at junction between Emergency Valve and tank shell and Emergency Valve and piping SAUDI ARABIAN STANDARD Emergency valves are installed squarely on mounting sump without welding distortion and weld encroachment in excess of Y mm Y 48 Emergency Valve Operating System The pneumatic air supply lines are free of sharp bends and clear of sharp edged mountings and protrusions on the tank truck chassis and shell support structure Pneumatic System FRL unit Pressure Gauge is set to V psig Y psig Y The Filter Regulator Lubrication FRL unit bowl is not more than 34 full with the condensate liquid Pneumatic System FRL unit lubrification bowl is full with lubricating oil between the gage marks Pneumatic System The cable path between the emergency valve cam and the bottom operator is straight and free of sharp bends Mechanical System Y Travel distance of bottom operator emergency valve cam 15 approximately mm to ensure full opening of vapor vent and emergency valve Mechani
22. g a loading arm coupler connection Check the adapter face plate for wear abrasion and damage Check poppet travel Inspect and replace damaged seals O rings and gaskets if leak is discovered otherwise replace as per supplier Service Manual after initial inspection Check sight glass for cleanliness Clean and or replace as required Y V Y Load Unload Adapter Same as for Loading Adapter Additionally inspect and check the operating handle function for proper opening and closure Y Y Emergency Valves Check for functionality using the operating mechanism of OPTION I or OPTION II Configuration as applicable Perform undercarriage inspection for visible damage loose connections and or corroded parts Apply silicone sealant at connection points as required Inspect and replace damaged seals O rings and gaskets if leak is discovered otherwise replace as per supplier Service Manual after initial inspection Y f Product Piping Check undercarriage piping and flanges for integrity Check condition of structural supports and perform repair work if required Check bolted flanged connection for integrity Inspect and replace damaged seals O rings and gaskets if leak is discovered otherwise replace as per supplier Service Manual after initial inspection Y Y Vapor Venting System ITEM DESCRIPTION OF SERVICE Y Y Vapor Vent Valve OPTION I Configuration Check vapor vent valve for co
23. hown in Appendix ot Protective caps are provided for vapor adapter loading unloading adapters and overfill prevention grounding socket oo Minimum vertical clearance of mm tanker in unladen condition is provided from the underside of the housekeeping box to Grade No part of the housekeeping box interferes with or prevents connection to the loading unloading adapters vapor adapter and overfill prevention receptacle YN SAUDI ARABIAN STANDARD SASO Yond The bottom operator as shown in Appendix Y in its installed position does not interfere with other bottom loading fitting connections in the housekeeping box Horizontal spacing between centerlines of the two adapters comply with SASO Standards is mm min to mm max The face of the API adapters is located at a distance of 19 mm inwards from the side of the tank truck The centerline height of the adapters comply with SASO Standards empty tank shell condition is V mm min to mm max from grade level Centerline of vapor adapter is at a horizontal distance of Y mm min to Y mm max from the adjacent adapter comply with SASO Standards and at a height of mm from the horizontal centerline of the API adapters Welding Based upon visual examination welded j
24. l Minimum wiring size is AWG or equivalent Y o v Calibration Y o V Simulated fifth wheel height is used during calibration to account for slope of the tank truck To follow API RP Specifications American Petroleum Institute until the approval of Saudi standards SAUDI ARABIAN STANDARD SASO YA Y o V Y Y o V Y Y o Y 0 A Y o Y Y o A Y Y o A t 4 0 4 Y 0 8 Y 0 4 7 0 4 Y 0 3 0 The maximum liquid level after calibration and corresponding to the new tank shell volumetric capacity is at least mm below the lowest point of the vapor vent The sensing tip of the optic probe is no more than Y mm to Y mm above the maximum liquid level corresponding to new volumetric capacity of tank shell and at the same time below the lowest point of the vapor vent MANHOLE COVER amp TANK TRUCK VENTING SYSTEM Manhole cover is located along the longitudinal centerline of the tank shell in the proximity of the center of the tank shell The pressure vacuum vent s on manhole cover have the following setting See Note e V mb psig for pressure Y mb Y psig for vacuum The vent is tested for functionality under simulated pressure and vacuum setting Note Different manufacturers may have variations to these settings It is deemed mandatory to check the supplier manuals and check the settings accordingly The pressure actuated fill c
25. lding work is carried out in accordance with American Welding Society AWS or equivalent industry standards and practices Housekeeping Box The bottom loading adapters vapor adapter and overfill prevention grounding socket fittings are housed in a lockable housekeeping box constructed of steel Appendix 5 Protective caps are provided for vapor adapter loading unloading adapters and overfill prevention grounding socket Minimum vertical clearance of mm tanker in unloading condition is provided from the underside of the housekeeping box to Grade Minimum clearance of V mm is provided between the edge of housekeeping box and the rear tire fender for the housekeeping box installations at the rear of the tank truck OPTION II Configuration No part of the housekeeping box interferes with or prevents connection to the loading unloading adapters vapor adapter and overfill prevention receptacle The bottom operator OPTION II Configuration in its installed position does not interfere with other bottom loading fitting connections in the housekeeping box Functionality Checks The TPIC shall perform the functionality tests for the installed bottom loading fittings and equipment on the modified tank truck The functionality tests shall include but not be limited to verifying the operability fit up check cross compatibility mix and match of fittings provided by different suppliers and leak pressure testing of fi
26. les incomplete fusion or discontinuity Road tankers displaying weld structural defects shall be taken out of service until repairs and re inspection for satisfactory workmanship of repair work is performed Y Leakage No signs of leak are evident around bottom loading vapor recovery fittings piping and joints between piping and bottom loading vapor recovery fittings All sources of leakage shall be properly repaired prior to returning road tanker to service Pressure Relief System a Pressure Vacuum P V valve is free of surface deposit and appear clean Inspection requires unscrewing the housing cap and taking the P V Valve out P V valve that appear corroded damaged or plugged with dirt or grime shall be replaced prior to returning road tanker to service b PAF cap is free of damage the fill cap opens fully and the locking mechanism is functional Seal is free of damage and provides complete closure Inspector Name Inspector Signature Inspector Badge ID Date Print No SAUDI ARABIAN STANDARD ORGANIZATION SASO Appendix Appendix Tank Shell Three Year Internal Inspection Check List Customer Hauler Date of Shell Manufacture Date modified to Bottom Loading Tank Shell Calibrated Capacity Liters Fifth Wheel Height Meters Inspection Date Trailer Registration No SAP No Test Pressure If available Bottom Loading Equipment Supplier
27. mplete opening and closure for pneumatic operation Check gaskets and disc seals and replace if found damaged otherwise replace as per supplier Service Manual after initial inspection OPTION II Configuration Check vapor vent valve for complete opening and closure simultaneous with the Emergency Valve Check poppet travel Check gaskets disc seals and replace if found damaged Otherwise replace as per supplier Service Manual after initial inspection Strip and grease the fittings as required Y Y Y Flexible Hose Check the flexible vapor hose connection for damage and or distortion and leaks Check clamps for tightness Y V Y Vapor Adapter Check for functionality using a vapor coupler connection Check the adapter face plate for wear abrasion and damage Check poppet travel Inspect and replace damaged seals O rings and gaskets if leak is discovered otherwise replace as per supplier Service Manual after initial inspection Check sight glass for cleanliness Clean and or replace as required Y Y f Vapor Piping Check vapor piping for damage Check bolted flange connections for tightness Check shell reinforcement pads OPTION I Configuration for corrosion or rust damage at vapor pipe penetrations through the shell SAUDI ARABIAN STANDARD SASO Youd MANHOLE COVER amp EMERGENCY VENTING SYSTEM ITEM DESCRIPTION OF SERVICE Y Y Pressure Vacuum Vents Remo
28. n Petroleum Institute until the approval of Saudi standards SAUDI ARABIAN STANDARD SASO YA INITIAL INSPECTION Y Y Y Tiat Y Y o Y Y a Y Y Y v 3 YN TY Introduction Initial inspection of a tank truck modified to bottom loading shall be carried out by TPIC The TPIC shall have the responsibility to validate and certify the modification work to comply with the requirements The TPIC shall ensure the following are in place Suitable test area facilities Suitable pressure measuring devices Suitable calibration methods Adequate hydrostatic test equipment Adequate water pumping equipment Procedure for entry into confined spaces Procedures for testing certification and reporting General Vehicle Inspection The TPIC shall perform General Vehicle Inspection as follows Ensure that the Saudi Arab Government Inspection documents are available and in order and the vehicle has a valid Government Inspection sticker in place Engine hood latch is functional and secured in place Batteries are secured in a covered box and electrically insulated Air brake hoses are in good condition properly connected and secured and free of leaks Primary brakes and parking brakes are functional Electrical circuit wiring is free of damage and properly secured Head lights brake lights and signal lights are operational and free of damage Vehicl
29. n of the shell material cracks in shell material cracked welds on internal components and deformation over support areas Inspect the tank shell interior for prior repairs such as repair welds section inlays added structural components and patches Inspect and ensure that conducting objects such as loose floats or screens are removed from the tanker shell Inspect and ensure that gauging rods and other conductive devices which can act as spark promoters are removed SAUDI ARABIAN STANDARD SASO Youd Y Y v Y Y 1 2 7 N NOTES 9 O CLOCK 4 Inspect the tank shell interior for presence of un bonded foreign objects e g metal clips brackets plates etc which can act as a spark promoter during product loading operation The presence of such objects should be reported and action taken to remove these from tank shell prior to starting work on bottom loading modifications or resumption of tank truck operation Welding inspection shall be based on the welding type and as per SASO Standards or international standard in case of there is no Saudi Standard Cracks in shell seams shell to head welds or fitting welds if found present shall be repaired prior to start of modification work Inspect internal Tank Fittings including valves high level sensor vapor vent valve internal vapor or drain line connecting linkage between emergency valve and vapor vent OPTION II specific and che
30. ng gear should not be relied on for the sole support of the loaded tank shell but if it is a load bearing type landing gear it should be used in conjunction with the front end support Pressure vacuum and other operative relief devices shall be clamped plugged or otherwise rendered inoperable If the vents are removed a suitable blanking cap with a gasket shall be used to close the opening The hose connecting the vapor vent to the vapor piping shall be removed at the vapor vent If water is used it shall be sweet and uncontaminated water The temperature of the water shall not exceedYV F The tank shell shall be filled completely with water All efforts shall be made to remove any entrapped air The test equipment shall be connected and the pressure applied gradually to mb Y psig If air pressure used it shall be coated with solution of soap and water heavy oil or other material suitable for the purpose foaming or bubbling of which indicates the presence of leaks Pressure shall be introduced through a bottom fitting or alternatively through a top fitting however the test pressure must be measured at the top of the tank A second gauge at the pressure inlet source will be useful in raising the tank test pressure without climbing on top of the tank Pressurizing the tank shell from ground level through a bottom fitting is desirable from a safety and convenience standpoint Valve shall be provided dow
31. nker modifications option 1 o Appendix Y tanker modifications option 11 sse o Appendix housekeeping box 6 8115 sese o Appendix baffle o Appendix inspection 8 Appendix Y external o ee oett o Appendix internal check Dist aee tra d peo EP d tup SAUDI ARABIAN STANDARD SASO YA BOTTOM LOADING TANK TRUCK INSPECTION AND PERIODIC MAINTENANCE SCOPE This standard establishes the scope of work and outlines the requirements for initial inspection and subsequent periodic maintenance inspections by qualified Inspection Personnel or alternatively by a Third Party Inspection Contractor TPIC on tank trucks modified to bottom loading Y TPIC ELIGIBILITY REQUIREMENTS Y The TPIC shall possess demonstrable past experience in bottom loading tank truck modification and shall be capable of providing inspection services in all of the Kingdom including remote locations Y Y The TPIC shall be approved organization familiar with the Engineering Standards Inspection Procedures and Quality Assurance Quality Control requirements Y Y The TPIC shall possess the necessary equipment certified crafts men and resources for carrying out the bench tests to determine the operability of the installed components and verifying the adequacy of the con
32. nstream the pressure control valve to dump accidental overpressure The tank shell shall remain under pressure for a period of at least minutes After this period has elapsed a check of all fittings outlet piping and joints shall be made The pressure gauge manometer shall be checked to ensure that no pressure drop has occurred Any loss of pressure or observed leakage shall constitute a test failure By either testing methods mentioned above testing shall be repeated following any alterations or repairs that involve tank integrity If there is any leakage undue distortion or if failure impends or occurs the tank truck shall SAUDI ARABIAN STANDARD SASO YA 8 ie Y Y Y Y A Y Y f not be placed in service unless an adequate repair is made The adequacy of the repair shall be determined by the same method of test The tank shell shall be completely drained and rendered free of water prior after completion of test Fuel Tankers in jet fuel applications shall be tested using pneumatic method only Tanker Certification The TPIC shall assign a unique bar code a string of alpha numeric characters to every fuel tanker modified to bottom loading and inspected and certified by the TPIC The bar code shall also be recorded on an Aluminum Plate and affixed to the tank shell along with information relating to the tank truck volumetric capacity the fifth wheel height and type of tractor head
33. oints are free from cracks and structural defects Weld surfaces are smooth and free of sharp edges and discontinuities Functionality Checks The load unload API adapters engage properly without a gap and disengage without getting stuck when coupled with a loading arm coupler The vapor adapter engages properly without a gap and and disengage without getting stuck when coupled with a vapor coupler SAUDI ARABIAN STANDARD SASO YA Vapor vent valve opens completely approximate opening size V mm by activating the pneumatic control push button lifting of guard bar or pressing the air interlock valve mounted on load unload adapter comply with SASO Standards and feeling by hand via Manhole cover opening the opening of valve Also see Note Y on Page Note This is applicable only to tank trucks equipped with pneumatic system Air supply must be activated by starting engine prior to test Lifting of Guard bar assembly loading arm coupler connection or push button control activates the air interlock sound of air escaping to brakes is heard for few seconds only opens the vapor vent valve and applies the vehicle brakes on check by attempting to drive away Note This is applicable only to tank trucks equipped with pneumatic system The Overfill Grounding system is verified by an Optic System Tester Unit for functionality
34. re in operable condition easily accessible inspected every 5 months tagged sealed and not wired on Fire extinguisher shall be comply with SASO standards Tank truck top access ladder is in good condition and adequately secured to the tank shell structure Ladder rungs frame and support clips are free of damage Tank truck overturn protection containment curb on tank top is in good condition and free of damage Walkway is provided with a skid resistant surface Internal Visual Inspection every three years The internal visual inspection requires entry into the tank truck shell by the inspector and shall be performed prior to the installation of bottom loading fittings on the tank shell The tank shell shall be rendered free of any flammable poisonous or otherwise harmful commodities including vapors All work shall be performed in accordance with sound industry practice applicable to working in confined space The TPIC shall perform internal visual inspection as follows The integrity of the lining for lined tank shells only If defective areas are found in lining these shall be removed and the shell underneath inspected for its condition Corners seams recesses and where structure is joined baffles bulk heads etc inspect for stains or discoloration in the parent material blisters separation and liner material termination for lined tank shells only at valves and drains Inspect the tank shell interior for corrosio
35. rs brackets which can act as spark promoters are not present inside the tank shell Fail O Cleaning Required LI Vapor Vent Check installation inspect visually for damage Inspect internal vapor line for damage Pass 0 Repair Required Overfill Sensor amp and weld joint with shell for gaps surface imperfections and smoothness Fail O Cleaning Required Emergency Valve Hydrotest Fill tank shell with clean water Apply psig pressure and inspect entire tank shell Pass LJ Repair Required including seams and joints for leaks PAF cap and P V vent need to be removed prior Fail O Cleaning Required L1 to performing hydro test General Remove all equipment brought into tank then inspect again before leaving the tank Pass LJ Cleaning Required Fail O Inspection Company Certification Tank Truck Owner or Representative Disposition of Tank Truck Name Name Return to Service Signed Signed Remove from Service H Date Date SAUDI ARABIAN STANDARD SASO Youd REFERENCE CODES AND STANDARDS The following codes standards are used to develop this standard e AMERICAN PETROLEUM INSTITUTE API 8 Bottom Loading and Vapor Recovery for MC Y Tank Motor Vehicles API Publication Cleaning Mobile Tanks in Flammable or Combustible Liquid Service API Publication Guidelines
36. s on their vertical center line at bottom and at top to permit flow of product and flow of product vapors between compartments see Figure The openings shall have a minimum cross sectional area of square meters square inches Additional baffle half semi circular holes on the horizontal centerline shall be provided to allow the drainage of trapped liquid in an overturned tank truck The half holes shall be 17 mm diameter located on each side of the baffle the Y o clock and 4 o clock positions as shown in Figure Access opening of mm Y diameter in size Figure shall be provided close to the centerlines of baffle to provide means of access into baffled compartment for inspection and maintenance purposes External Visual Inspection General The TPIC shall Inspect the exposed area of shell and heads for dents gouges scrapes cracks and poorly performed repairs like patches Cuts and gouges shall not be longer than mm and the material thickness underneath the damage shall not be less than the tank shell thickness Dents with depth equal to or exceeding one tenth of the greatest bridge dimension of the dent area but in any case deeper than Y mm 1 shall be repaired Inspect the fifth wheel plate tractor head attachment area to the tank truck shell for deformation or caving in of the fifth wheel plate and loose corroded or missing bolts Verify that all material installed for bottom
37. the Housekeeping Box is provided with protective cap with chain The connecting pins are clean and free of any sign of surface damage The ground bolt is secured on the tank truck shell or shell chassis structure frame The ground bolt is installed on surface free from grease paint weld spatter and debris Y Wiring is encased in insulating jacket free of splits and exposed surface at connection points of the optic probe socket and ground bolt respectively ey Wiring jacket is routed in metallic conduit outside of the tank shell and is supported by steel clips at the tank shell structure Manhole Cover amp Tank Shell Venting System t Bolted on Manholes Manhole cover base plate has no missing loose or damaged bolts Fill cap is in good operating condition and locking mechanism is functional Sealing surface of fill cap is without damage Fill cap gasket is without signs of degradation swelling or cracking There is no evidence of leak corrosion or damage at junction of Manhole assembly and weld collar Manholes with Clamp Ring Same as for bolted manholes Additionally check that the clamp ring is installed snug tight and the clamp ring attachment bolt is tightened to in Ib torque verified by a handheld torque tester o The Pressure Vacuum vent assembly appears clean and has a valid certification of replacement after Y month interval 1
38. ts as required Y Periodic Maintenance Sticker After successful Periodic Maintenance check of the tank truck the TPIC workshop shall issue a sticker indicating the issue date the expiration dates and the bar code of the tanker The sticker shall be affixed at a prominent location on the body of the tank shell Tank trucks failing to pass the Periodic Maintenance inspection shall be taken out of service pending repairs and TPIC workshop certification of satisfactory compliance SAUDI ARABIAN STANDARD SASO YA 2 FREQUENCY OF INSPECTIONS AND PERIODIC MAINTENANCE TESTS Item No Item description Frequency Initial inspection When ever a modification done to the tanker truck Y External Inspection 1 month Y PM inspection 1 month Service Of BL bottom Yearly See Note loading VR vent relieving Fittings Certification Sticker 1 month Internal Inspection Three Years 1 Hydrostatic test Three Years Note Seals Gaskets and O rings shall be replaced at minimum interval specified in the Supplier Service Manual or in the event of leaks or damage which ever occurs first SAUDI ARABIAN STANDARD SASO YA APPENDIX EMERGENCY VALVE EMERGENCY VALVE x EMERGENCY VALVE BOTTOM OPERATOR API ADAPTER Load Unload API ADAPTER API ADAPTER API ADAPTER Load Unloa
39. ttings comply with SASO Standards The bottom loading fittings comply with SASO Standards and the required functionality tests are summarized in the following table To follow RP Specifications American Petroleum Institute until the approval of Saudi standards SAUDI ARABIAN STANDARD Fitting description Functionality test Load Unload Adapters comply with SASO Standards Opening amp Closure Operability Loading Arm coupler fit check compatibility Leak test Vapor Adapter Opening amp Closure Operability Vapor Hose Coupler fit check compatibility Leak test Vapor Vent Valve Opening amp Closure Emergency Valve s Opening amp Closure Leak test Overfill Prevention Grounding Operability and compatibility with loading rack Control Monitor Brake Interlock System Activation of brake interlock valve by lifting of guard bar or mating of loading arm coupler Pressure Vacuum Vent Pressure Vacuum setting test Manhole Cover Fill Cap Pressure setting test Product Piping Leak test Pressure test Vapor Piping Leak test Pressure test Notes Load Unload adapters are compatible with and open completely when connected to a standard mm loading arm coupler comply with SASO Standards Vapor adapter open completely when connected to a vapor coupler The optic probe and the ground bolt connections are tested an
40. ut leaks at shock absorber mountings Tires are in good condition free of missing chunks and bulging and with minimum Y YY inch Y mm tread depth across the full width SAUDI ARABIAN STANDARD SASO YA Tire rims are in good condition and without dents or warping Tire stems do not extend past the rim edge Windshield is without cracks and is in good condition Wipers are functional and without worn out blades Fuel tank is in good condition free of damage and secured adequately Fill cap is free of damage and closes the fuel tank properly Auxiliary fuel tank If present is in good condition and equipped with a pressure relief device The valve in fuel supply line from the auxiliary fuel tank is in closed position Seat belts in driver cabin are functional and in good condition Toolbox for minor repairs is available and labeled and is secured properly in an accessible location Two Y Portable fire extinguishers properly tagged and sealed are provided Tank top access ladder is in good condition and well secured without loose or missing bolts Ladder rungs frame and support clips are free of rust and corrosion damage The tank top containment curb is in good condition and walkway with skid resistant surface is provided EXTERNAL INSPECTION General Tank shell Condition No shell damage is observed No signs Exposed shell and head areas are
41. ve and thoroughly clean the vent by removing trapped dust and foreign material Replace gaskets as required Check for operability under V mb pressure and mb vacuum settings Replace defective vent with new vent if required Y Y Y Manhole Cover Check manhole cover neck ring for damage seal tightness rust and or corrosion V Y Y Fill cap Check the fill cap base spring mechanism for functionality as a pressure relief and emergency venting device Check seal for leaks Check the fill cap cover arm for damage loose connection and operability Overfill Prevention amp 5 Grounding System ITEM DESCRIPTION OF SERVICE Y Y Optic Sensor Check for functionality using a Scully or equivalent tester Check housing for loose or damaged connections and replace as required Apply silicone sealant at connection points as required Y Y Ground Bolt Check installation surface for corrosion damage and the pointed tip of the bolt for damage Check the installation for tightness Apply silicone sealant around the top of the bolt wire side where the hex nut meets the shell chassis structure Y Y Wiring Inspect and check the wiring size Minimum acceptable is AWG Check wiring path for damage Check for proper tightening of wire around the compression fittings on the optic sensor ground bolt and socket housing Y f Optic Socket Check socket pins for d
42. version work for tank trucks modified to bottom loading The following equipment is deemed essential in carrying out the bench tests A bench prototype system simulating the actual loading rack connections the loading arm coupler the vapor hose coupler and the overfill prevention control monitor plug at the bulk plant loading rack tank truck interface The bench type prototype system shall be utilized for the bottom loading tank truck fit up check and also to verify the cross compatibility of the bottom loading fittings manufactured by different suppliers at the loading rack tank truck interface connection The bottom loading fittings shall comply with the SASO Specifications Pun Equipment to detect presence of hydrocarbon vapors inside the tank truck e g an Explosimeter or Gas Snubber All vapor detection equipment shall be calibrated according to the manufacturer recommendations YY Y Equipment to hydro test tank truck shell for leaks and pressure testing testing of pressure vacuum vents for operability and verification of pressure vacuum setting Y Y Equipment for testing the manhole cover for structural integrity leaks and spring loaded fill cap for pressure relieving and emergency venting Testing equipment Scully Tester or equivalent to verify the operability of the 5 overfill prevention and tank truck grounding system To follow API RP Specifications America
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