Recommended Practice on Light Product Quality
Terminal Operations
FOREWORD
This recommended practice has been prepared by the API Fuels Marketing Subcommittee with
technical participation and feedback from other industry stakeholders, and is intended to provide
guidance on the minimum equipment standards and operating procedures for the receipt, storage
blending and delivery of light products, their blend components, and additives at distribution and
intermediate storage terminals, including related operations of pipeline, marine vessel (barge or
ship) and road/rail transport.
This publication is intended to provide recommendations for safe practice, rather than set rigid
guidelines. Users of this publication shall be aware that due consideration shall be given to the
effect of any unusual or abnormal circumstance, on which it is not possible to generalize within
the scope of this publication. Specialist advice shall be sought in these cases.
In addition, in some areas local or national statutory regulations may also apply. This publication
is intended to be complementary to these established controls and practices.
The API is not undertaking to meet the duties of employers to warn and equip their employees,
and others exposed, concerning health and safety risks and precautions, nor undertaking their
obligations under local and regional laws and regulations.
Nothing contained in any API publication is to be construed as granting any right, by implication
or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by
letters patent. Neither should anything contained in the publication be construed as insuring
anyone against liability for infringement of letters patent.
It is hoped and anticipated that this publication will assist those involved in fuel handling at
distribution and intermediate storage facilities. Every effort has been made by API to assure the
accuracy and reliability of the data contained in this publication; however, API makes no
representation, warranty, or guarantee in connection with this publication and hereby expressly
disclaims any liability or responsibility for loss or damage resulting from its use or for the violation
of any local or regional laws or regulations with which this publication may conflict.
This document was produced under API standardization procedures that ensure appropriate
notification and participation in the developmental process and is designated as an API standard.
Questions concerning the interpretation of the content of this publication or comments and
questions concerning the procedures under which this publication was developed should be
directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street,
N.W., Washington, D.C. 20005. Requests for permission to reproduce or translate all or any part
of the material published herein should also be addressed to the director.
Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five
years. A one-time extension of up to two years may be added to this review cycle. Status of the
publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A
catalog of API publications and materials is published annually and updated quarterly by API,
1220 L Street, N.W., Washington, D.C. 20005.
Suggested revisions are invited and should be submitted to the Standards and Publications
Department, API, 1220 L Street, NW, Washington, DC 20005, standards@api.org.
CONTENTS
1 GENERAL
1.1 Scope and Purpose
Global vs. US Basis
Regulatory Applicability
Use and meaning of shall, should and may
1.2 Non-applicability and Retroactivity
Pipeline terminals, but not pipeline operations
Hardware requirements are not retroactive but for retrofits and new builds
1.3 References
1.4 Management Responsibility and Accountability
Regulatory requirements
Safety Health and Environment
Risk assessments
Management of Change
1.5 Quality Assurance System
Goal - product the meets all regulatory requirements, customer
specifications and is fit for purpose
Auditable
Organization
Roles and Responsibilities
Record Keeping
Self Audits
Data Handling
Oversight Programs
Risk assessments
Testing
Frequency
Communication of Results
1.6 Incident Management
Initial Response
Communication
Investigation
Corrective Actions
Post Incident Reporting
2 SAMPLING and TESTING
2.1 General
Purpose/Goals
Contamination Testing
Certification
2.2 Sampling
Standard practices
Basic Requirements
2.3 Testing
2.4 Sample Retains
Size
Duration
Storage Requirements
3 STORAGE TERMINALS EQUIPMENT DESIGN
3.1 General
Safety
Environmental Concerns
Product Integrity
3.2 Tankage
General
Labeling
Containment
Dikes
Vertical
Sample Taps/Tubes
Bottom configurations
Sumps
Water Draws
Inlet
Outlets
Roof
Vents
Manholes
Mixers/Jet Nozzles
Horizontal
Drain
Vents
3.3 Pipelines
Physical Integrity
Batch Cutting
Product Segregation
Communications
3.4 Pipework within Storage and Distribution Terminals
Product Segregation
Dead Legs
Product Grade Markings
3.5 Tank Recirculation Piping
3.6 Static Relaxation Design Considerations
Flow Rates
Product Height
3.7 Fuel Additive Systems
Type
Calibration
Reconciliation
3.8 Loading Couplings/Swivels for Road/Rail Transports
Bottom Loading
Dry breaks
3.9 Filtration
Loading
Strainers
Static
3.10 Paved Areas, Drainage, Oil Water Separators and Spill Collection Tanks
3.11 Emergency Shut Down (ESD), Level Alarm and Fire Alarm Systems
3.12 Cathodic Protection
4 RECEIPT PROCEDURES
4.1 Receipt—General
Line-up controls
Sampling
Testing
Communications
4.2 Receipts by Pipeline
Sampling
4.3 Receipts by Ocean Tanker Coastal/Inland Waterway Vessel
Sampling
4.4 Receipts by Road or Rail Tank Car
Sampling
4.5 Other receipts
4.6 Interface
Interface
Transmix
5 FUEL QUALITY CONTROL
5.1 Segregation
Types of segregation
Tank to tank
Rack
lane to lane
lane to tank
Additive
During shut down
Effects of cross contamination
Inventory variations
5.2 Settling
Tank bottom configuration
Mixers
5.3 Testing
Tank after Receipt
Location
Number of samples
Type of samples
5.4 Release
Procedures
Release from Running Tanks
5.5 Product Blending (in Tank)
6 STORAGE PROCEDURES
6.1 Routine Checks
Before receipt
After receipt
Seasonal Changes
Biological Growth
6.2 Change of Grade in Storage Tanks
6.3 VRU Procedures
6.4 Product Returns
6.5 Water Management
7 DELIVERY PROCEDURES
7.1 Documentation
7.2 Product Delivery from Running Tanks (Live to the Rack)
7.3 Blending during Delivery
7.4 Product Transfer
Tank trucks
Railcar
Waterborne Vessels
Pipeline
8 DOCUMENTATION
8.1 Records
8.2 Signature and Retention
9 TRANSPORTATION EQUIPMENT FROM STORAGE TERMINALS
9.1 General
9.2 Pipelines
Screening
Verification
Piping Line-ups
Interface Management
Sampling
Retains
9.3 Coastal/Inland Waterway Vessels
Screening
Verification
Piping Line-ups
Interface Management
Sampling
Retains
9.4 Road Vehicles/Rail Tank Cars
Screening
Verification
Piping Line-ups
Interface Management
Sampling
Retains
9.5 Grade Change Procedures for Road and Rail Vehicles
10 GENERAL OPERATING, MAINTENANCE, INSPECTION & TEST
REQUIREMENTS
10.1 Bonding
10.2 Filling of Empty Tanks, Vehicles and Filters
10.3 Planned `Maintenance, Inspection and Testing
10.4 Filtration Equipment
10.5 Tank Level Alarms
10.6 Tank Vents
10.7 Tank Inspection and Cleaning
10.8 Pipelines
11 HEALTH, SAFETY, SECURITY, ENVIRONMENT & TRAINING
11.1 Health and Safety Permit to Work System
11.2 Security
11.3 Protecting the Environment
11.4 Drainage
11.5 Maintaining the Integrity of Fuel Tanks and Systems
11.6 Training
12 FUEL ADDITIVES/DYES/MARKERS
13 STRAINER & FILTRATION EQUIPMENT MAINTENANCE CHECKS
13.1 Routine Checks—Strainers
13.2 Routine Checks—Filters
13.3 Element Change Criteria
13.4 Filter Vessel Change Out Procedure
1 GENERAL
1.1 Scope and Purpose
This recommended practice contains basic requirements for the design, construction, operation
and maintenance of light products storage and distribution terminals
Mandatory requirements in this standard are designated by the word “shall.” Recommendations
are designated by the word “should.” Optional items are designated by the word “may.” This
standard incorporates by reference a number of other standards and recommended practices that
need to be referred. The distinction between mandatory, recommended and optional provisions in
the referenced documents is not changed by nature of their reference in this standard.
The values stated for this standard are in U.S. Customary units (SI/cgs).
A glossary of terms is contained in Appendix XX.
1.2 Non-applicability and Retroactivity
This recommended practice is intended to provide guidance on the minimum equipment
standards and operating procedures for the receipt, storage, blending of fuels at distribution and
storage terminals, and its shipment directly via a pipeline, marine vessel (barge or ship) or
road/rail transport.
This recommended practice does not address pipeline, marine vessel, or rail/road tanker
operations except where there is an operational interface with receipt, storage and delivery
terminals.
The design and construction provisions of this standard are intended for application at new
facilities. Application of the design and construction provisions of this standard to facilities,
equipment, structures or installations that are already in place, that are in the process of
construction or that are installed before the date of this publication should be evaluated when
circumstances merit. Such an evaluation should consider the site-specific circumstances and
detailed accounting for both the potential and tolerance for risk, existing conditions at the
installation and overall benefit for applying the required design and construction provisions.
1.3 References
Unless otherwise specified, the most recent edition of the following standards, codes and
specifications shall be used. The provisions of these publications are incorporated into this
recommended practice only as explicitly specified in the text.
1.4 Management Responsibility and Accountability
The Management of storage and distribution terminals is responsible for ensuring that the facility
design and operation conform to acceptable industry standards and the applicable legislative
regulations with respect to health, safety, environmental protection and security are applied.
The operating procedures for storage and distribution terminals shall be maintained in a manual
or handbook or other media that is readily available for reference by staff. It is desirable that
conformance to agreed-upon procedures be tied in to a recommended quality assurance system
like the one outlined below.
Any change to operating procedures or physical equipment (unless replacing like with like) at the
existing facilities shall be supported by a management of change (MOC) process with appropriate
risk assessments/hazard reviews performed by trained and experienced staff. For changes that
have the potential to impact product quality, there shall be procedures to ensure testing or other
means of validation are performed. These changes include, but are not limited to:
· blend recipe changes
·
·
·
·
additive changes
new product introduction
hardware/software changes , and
basic logistic changes such as:
· product source changes
· receipt/delivery mode changes
· tank change of service
1.5 Quality Assurance System
The potential fit-for-use and regulatory consequences of a failure to supply the correct, onspecification products are such that it is essential for each organization to have an effective
quality assurance system, which shall be designed to ensure the following:
The Quality Assurance System is established and all the expectations are communicated to all
personnel who can have an impact on product quality.
There is Seamless and visible product quality improvement work processes are established
Management sets clear objectives, demonstrates leadership and promotes commitment to
improving product quality performance through active and visible participation.
Managers at all levels accept responsibility for effective product quality controls, and early
identification of potential customer problems
All employees, suppliers and contractors that can impact product quality are involved in
maintaining and improving product quality performance.
Managers at all levels provide an environment that fosters the early identification and mitigation of
changes or upsets in the production, supply chain, or the final product use, that may produce
product quality issues
Management will ensure that product quality performance is evaluated and the degree to which
expectations, and customer requirements, are met is assessed.
Management will ensure that products are designed and specified to both comply with applicable
regulations and be fit for service
Management will ensure the provision and maintenance of appropriate facilities and equipment
for the safe and uncontaminated delivery of light products through the supply chain and ultimately
to the end use customer.
Management will ensure there is an auditable documentary record demonstrating the correct
handling, storage, blending and delivery of product at the intermediate and distribution terminal.
1.5.1 Product Quality Assurance Organization
Each terminal shall have a product quality assurance organization. The specific details of such an
organization may be varied according to the nature of the operating unit. The organization shall
have individuals nominated to carry out the following roles; nomenclature and specific titles may
vary according to local requirements. At each level of the structure, records shall be kept of the
responsible individuals in the succeeding level together with details of training received.
1.5.1.1 Site Product Quality Manager
At each site that stores or handles light products, blend components, and additives, there shall be
a nominated site product quality manager responsible for the efficient operation of the quality
assurance system at that site. At intermediate storage and distribution terminals, this role would
usually be taken by the terminal manager (or operations manager of a large facility).
The Site Product Quality Manager shall be accountable for:
Implementation of correct quality control procedures
Maintenance of satisfactory documentation
Release of product only of satisfactory quality
Training of all staff at the site who are nominated as Product Quality Inspectors
1.5.1.2 Product Quality Inspectors
All staff whose duties include tasks critical to the quality assurance system shall be fully trained in
such tasks and nominated as approved Product Quality Inspectors. Such tasks include, but may
not be limited to, the following:
Checking that the documentation on incoming consignments is correct and that it corresponds to
the transport/container concerned.
Visually inspecting and conducting control checks and on-line sampling from pipelines and dock
lines on incoming material, including checking seals on vehicles, if present.
Product receipt into storage and post receipt testing.
Loading of material, including control checks on marine vessels/road or rail transports/containers
and pipelines, unless these tasks are performed by non-terminal staff (i.e. independent
inspectors, road transport operators), to ensure that they are clean and uncontaminated and on
line sampling from pipelines, loading racks and dock lines unless these tasks are performed by
non-terminal staff.
Maintaining appropriate records of inventory/quality/equipment checks.
1.5.2 Oversight Programs
Risk assessments
Receipt storage and delivery operations shall be risk assessed to determine the frequency and
depth of oversight testing. The Risk Assessment will consider:
· Any previous Product Quality audit, assessment or review of the facility
· Any history of incidents at the facility or with product from the facility
· The terminal procedures for receipt testing (abbreviated testing) and additive reconciliation
· If blending operations are performed
· Is the operation using pipelines discharging to working tanks (live to the rack)?
· Contract volume and service of products (i.e. consider the business impact if the product is not
fit for service)
· For changes that have the potential to impact product quality, there shall be procedures to
ensure testing or other means of validation are considered. These changes include, but are not
limited to:
· blend recipe changes
· additive changes
· new product introduction
· hardware/software changes, and
· basic logistic changes such as:
· product source changes
· receipt/delivery mode changes
· tank change of service
Testing
Basic testing for management of change and oversight testing should include
Product
All Products
Mogas
Specification
Appearance
No Blending
except midgrade
octane, diesel
blends
X
Blending
(Ethanol, FAME,
Bio-components)
X
Butane
Blending
X
Octane
X
X
X
Volatility (seasonal) e.g. RVP, distillation, T
V/L20, DI, FVI etc.
X
X
X
Sulfur (systems with
high sulfur e.g. heating
oil, jet fuel, etc.)
X
X
X
X
Oxygenates
Diesel and Heating Oil
Flash point
X
X
FAME Content
Diesel
X
Sulfur (systems with
high sulfur e.g. heating
oil, jet fuel, etc.)
X
X
Cetane/Index
X
X
Other tests may be included as necessary to mitigate regulatory risks or to ensure compliance
with contractual obligations
Frequency
Products shall be sampled at least once every three months, or when changes to the operation
dictate additional risk mitigation
All delivered products shall be sampled and tested at a time and place as to provide
representative samples and results, of the products delivered.
Communication of Results
Results shall be kept and made available to receiving parties upon request
1.6 Incident Management
It is the goal of incident management to identify events where there is a variation to the expected
product quality, manage/mitigate the impact, learn from the incident and share what has been
learned to prevent future incidents.
1.6.1 Initial Response
There shall be a nominated communication chain, with designated out-of-hours backups for
product quality incidents. The goal of the initial response should be to verify the incident,
determine the scope, and minimize further impact of incident.
1.6.2 Communication
Once the incident is verified, affected customers shall be notified so additional mitigation steps
may be taken.
1.6.3 Investigation
Following notification, an assessment of the incident shall be carried out and management shall
be notified. A Product Quality Incident Investigation shall be initiated, with an investigation owner.
There shall be documented procedures for customer complaints and quality incidents that ensure
timely and regular stakeholder communication
There shall be documented procedures in place to ensure that all incidents are recorded and
investigated in a timely manner.
The investigation should address the failure mode(s), contributing factors, root causes and
corrective actions.
1.6.4 Corrective Actions
The investigation process shall result in corrective actions that address each of the failure modes,
contributing factors and root causes. Each corrective action should be sustainable and once
implemented, it should be verified.
1.6.5 Post Incident Reporting
For ongoing learning, summaries of PQ investigations, including an assessment of the business
impact, shall be circulated according to predetermined guidelines
2 SAMPLING and TESTING
2.1 General
Standard Practices
Sampling shall be undertaken by competent, trained personnel using clearly defined and
documented procedures and appropriate apparatus to ensure that the sample obtained is truly
representative of the material from which it has been drawn.
Sample Types
The various types of samples are defined below. If further details are required, e.g., sampling for
specific tests, consult your supervisor or Fuels Technical Support in Fairfax.
An all-levels sample is secured by submerging a closed sampler to a point as near as possible
to the draw-off level, opening it and raising it at such a rate that it is about three-fourths full when
withdrawn. The sampler should never be lowered to the tank bottom.
A running sample is similar to the all-levels sample, except that no cork is used and the bottle
fills on the way down through the product and continues to fill on the way back up. The rate of
lowering and raising the sampler should be such that the bottle is about three-fourths full when
withdrawn.
An upper sample is one taken from the middle of the upper third of the tank contents.
A middle sample is one taken from the middle of the tank contents.
A lower sample is one taken from the middle of the lower third of the tank contents.
A single tank composite sample is a mixture of one part each of upper, middle, and lower
samples.
A multiple tank composite sample is a blend of individual all-levels samples taken from each
compartment (containing the material being sampled) on ocean tanker, barge, tank car or truck
transport.
A top sample is one taken at a point 6 inches below the top surface of the tank contents.
A bottom sample is one taken from the material on the bottom surface of the tank.
An outlet sample is one taken at the level of the tank outlet.
A continuous pipeline sample is one obtained from a pipeline in such a manner as to give a
representative average of the product stream during its transit.
Samples for certification testing
Samples to be taken for; certification testing, where the results are required to be reported to
others such as customers or regulators, or for the purposes of supporting claims, shall be taken in
accordance with practices outlined in test method or by accepted industry practices such as:
• ASTM D 1265: Standard Practice for Sampling Liquefied Petroleum (LP) Gases, Manual
Method,
• ASTM D 4057: Standard Practice for Manual Sampling of Petroleum and Petroleum Products,
• ASTM D 4177: Standard Practice for Automatic Sampling of Petroleum and Petroleum
Products,
• ASTM D 5842: Standard Practice for Sampling and Handling of Fuels for Volatility
Measurement,
• EN 58: Bitumen and bitumous binders - Sampling bitumous binders,
• SAI AS 2008 Residual Bitumen for Pavements or
• Equivalents of these standards
Samples for contamination testing
In cases where samples are taken for in-house confirmation that no unacceptable contamination
has taken place, it is recommended that standard industry practices be followed, but alternative
measures that adequately ensure the samples are representative of the product being tested may
be used.
2.2 Sampling
Basic Requirements
Before sampling, the sampling apparatus (including ropes or cords to suspend the sampler or
other ancillary equipment) and containers shall be dry and free of any contaminating substance.
All metal sampling gear shall be constructed from non-spark generating materials.
Sample containers shall conform to the requirements listed in 2.4.
The operator carrying out the sampling shall have hands free from any contaminating material.
Clean gloves impervious to finished fuels, components and additives shall be worn to protect the
operator from any health hazards.
Sampling points for drain samples shall be designed to prevent the intrusion of water, dirt, and
other foreign material.
During sampling operations, the material being sampled shall be protected, as far as possible,
from the effects of rain, sun, blown dust, etc. Sample containers shall be securely closed
immediately after the sample has been taken.
It is important that samples are truly representative of the material being sampled. Samples from
tanks shall be taken from a gauge hatch or other suitable opening that gives unrestricted access
to the bulk of the liquid, or from a suitably designed piped sampling system.
Prior to sampling, apparatus for sampling liquids including the sample container shall be flushed
and rinsed thoroughly with the product to be sampled and allowed to drain before use. This
requirement shall not apply when such flushing and rinsing would nullify the purpose for which the
sample is being obtained or by the nature of the material being sampled, e.g. drain samples for
water and dirt content.
If it is suspected that a sample or set of samples is not fully representative, a further sample or
set of samples shall be taken.
Samples for laboratory testing shall be free from dirt and water except in the case of samples
specifically taken to determine the presence of such contaminants.
No sample container shall be completely filled with liquid. The ullage space required for certain
samples and testing can be found in ASTM D4057 or API, MPMS, Chapter 8.
Records shall be maintained of all samples taken. Sample containers shall be clearly labeled for
identification and sealed immediately after sampling. The following information shall be available
as appropriate, either on the label or on associated documentation:
Location (Terminal)
Product Name
Date Sampled
Sample Source (i.e. Tank No, Pipeline Batch No., Vessel name and compartment)
Sample Type (composite, line, etc.)
Sampler's Initials
When samples are required from levels in a tank or bulk container, the order of sampling shall be
from the top downwards.
Samples of materials that could be affected by light or heat shall be stored in a cool, dark place.
When a sample of gasoline or gasoline blend components are taken for laboratory analysis,
especially at high ambient temperatures, care must be taken immediately after sampling and
during sample transport. Samples shall remain cool and protected from direct sunlight to avoid
the loss of light ends and excessive oxidation. The sample shall, if at all possible, be taken
directly into the container, and not transferred from sampler to container. The container shall be
examined closely for leaks, so as to avoid the loss of light ends through the cap sealing material.
2.3 Testing
To provide confidence that product has not been contaminated nor has an unacceptable level of
inter-product mixing, sampling and testing shall be established. The minimum sampling for interproduct mixing and contamination testing is defined in sections 4.1 through 4.5. The minimum
parameters to be included in the receipt testing are shown in below.
The acceptable standards (including test method and acceptable results) for each parameter may
be defined by:
- an absolute maximum or minimum, and/or by an allowable variation from the original
certified value
or
- by a pass/fail criteria such as for visual inspection
The design of the receipt testing standards should consider:
- the likelihood of contamination or inter-product mixing
- the likelihood of microbial growth or other degradation due to instability of product
- the consequences of contamination and inter-product mixing, e.g. regulatory and
customer requirements including need for defense during claims resolution.
with the outcome defining the testing required to control the risk to acceptable levels
If an allowable variation from the original certified value is used as the standard:
- the standard should be no more restrictive than the acceptance limit defined by ASTM D3244 or
ISO 4259 (0.59R) of the laboratory testing the received product.
- when sampling tank after receipt, the value of the parameter for heel should be prorated with the
original certified value of the new volume to determine the expected value for the parameter in
the tank
All receipt samples shall be tested for the following minimum receipt tests
Product
LPG
Gasoline (Note 1)
Ethanol
Distillate (Non-Aviation Kerosene,
Diesel #1 and #2, Autodiesel,
Heating Oil, Marine Gasoil, etc.)
Note 2
Residual Fuel Oils
Minimum Receipt Tests
Density
Density
Visual
Density
Visual
Density
Visual
Flash Point
Density
Note 1 – It is also recommended that samples be tested for vapor pressure during seasonal volatility control
periods
Note 2 – It is also recommended that samples be tested for sulfur content where contact with higher sulfur
products may have occurred.
2.4 Sample Retains
When investigating complaints, disputes or incidents retained samples are often tested to
establish the actual product quality and the presence of any cause of failure at that point in the
supply chain. Traceability of batches enables the investigation to focus on the samples particular
to the product in question.
Due to safety and liability consequences, retained samples are of particular importance. Retained
samples are also useful in establishing the extent of a PQ event to determine any requirements
for product recall.
Retained samples may be taken and stored at a number of points in the supply chain including
refinery finished product tank, entry into 3rd party pipeline, jetty when loading a ship or barge,
barge when bunkering a ship, terminal tank/pipeline on receipt of product into terminal and from
trucks before delivery to customer. For all points in the supply chain, retained samples should be
taken in accordance with ASTM, API MPMS standards or international equivalent.
Recommended sample size, storage container type and retention time are outlined below.
Sample Type
Container Size
Container Type
Retention Time
Gasoline/Components
and Distillate Pipeline
Receipt (beginning,
middle, end)
Gasoline/Components
and Distillate Marine
Receipt Product
Composite
Gasoline/Components
and Distillate Marine
Receipt During
Discharge
Gasoline/Components
and Distillate Live to
Rack Sample
Gasoline/Components
All Level Tank
Composite Sample
Post – Receipt
Distillate All Level
Tank Composite
Sample Post –Receipt
1-Quart
Clear Glass
Until tank is certified
1-Gallon
1-Quart
Metal Can
(Glass or Epoxy
lined can for
uLSD)
Clear Glass
1-Quart
Clear Glass
Retain only if test results
indicate off-spec product
1-Gallon
Metal Can
30 days
(or until next receipt if
longer than 30 days)
1-Quart
Clear Glass
or Metal Can
(Glass or Epoxy
lined can for
uLSD)
Metal Can
(Glass or Epoxy
lined can for
uLSD)
30 days
(or until next receipt if
longer than 30 days)
Gasoline and Distillate
Marine Loading
Product
Composite/Pipeline
shipping sample
composite
1-Gallon
30 days
(or until next receipt if
longer than 30 days)
Discard after testing
unless off- spec product is
detected
30 days
Additive Tank Car
1-Quart
Clear Glass
60 days
(or until tank car is empty)
Monthly Tank
Composite
Additive Tank Truck
1-Quart
Clear Glass
30 days
1-Quart
Clear Glass
Additive Tank Bottoms
1-Quart
Clear Glass
6 months
(or until next receipt if
longer than 6 months)
Retain only if test results
indicate off-spec product
(poor appearance)
Note – Retention times should be extended in case of product quality disputes
3 STORAGE TERMINALS EQUIPMENT DESIGN
3.1 General
The observance of certain fundamental practices in the design, construction and commissioning
of facilities used for the storage, handling and transport of fuels, components and additives is
considered essential to ensure that health and safety of staff, environmental protection and
product quality are maintained.
3.1.1 Segregation of Fuels and Components
All facilities utilized for handling fuels and components shall be fully grade-segregated. This
requirement may be relaxed only in the case of pipework upstream of storage tanks used for the
receipt of multiple products from ships/barges or pipelines, or in the case of component blending
where movement of each component can be monitored and controlled, and then only provided
the system is so designed to facilitate the detection and appropriate downgrading of product
interfaces (see section 4.6).
3.1.2 Materials of Construction
Pipework, vessels and tanks shall be fabricated from either carbon steel, internally epoxy-lined
carbon steel or from stainless steel.
The choice of construction materials and equipment components is an important factor,
particularly new or novel blend components are being introduced.
Particular attention should be paid to issues such as; elastomer compatibility, sulfate deposition,
pitting, corrosion and stress fractures, associated with the use of some biofuels.
Changes in diesel fuel composition have been shown to cause some seal material degradation.
Some dyes have acidic components that may result in accelerated corrosion in dye storage
tanks.
3.2 Tankage
3.2.1 Working Capacity
The number and size of aboveground tanks shall be sufficient to provide adequate working
capacity to deal with peak demands of each product grade handled, with due allowance for
settling, testing and tank cleaning and maintenance requirements. Allowance shall also be made
for the reliability of the method of supply, batch volumes and delivery frequency.
3.2.2 Vertical Tanks
a. Newly constructed vertical tanks shall be fixed-roof type with a downward sloping
conical floor (slope shall be 1:30) to a central drain sump. Where lap welds are used in floor
construction they shall be designed such that the laps do not impede the flow of water to the drain
sump.
b. Existing vertical tanks in service shall be inspected to insure existing sumps are
located in the low point(s) of the tank to insure water/sediment removal via the tank water
drain(s).
c. Existing vertical tanks in service where a replacement double bottom is to be installed
shall be designed with the maximum slope mechanically allowed for the design (not greater than
1:30) and low point sump(s) installed in the low point(s) of the tank to insure water/sediment
removal via the tank water drain(s).
3.2.3 Horizontal Tanks
Horizontal tanks shall be installed on foundations that will ensure maintenance of a minimum 1:50
positive slope to a drain sump at the lower end
3.2.4 Tank Lining
All new vertical tanks, existing having new bottoms installed shall have at least the floor and first
(bottom) 3 feet of the walls internally coated per API Publication 652. This shall preferably be
white or light colored to aid inspection. All new horizontal and small vertical (less than or equal to
30,000 U.S. gallons) shall be coated internally throughout.
3.2.5 Tank Fittings
a. Vents
Middle Distillates
All tanks shall be free vented unless local legislation specifies that pressure/vacuum valves (P&V)
shall be used. All vents shall have screens to prevent the ingress of contaminants.
Gasolines
The vents of all horizontal and small vertical gasoline (component) tanks shall be fitted with P&V
valves. Large vertical tanks shall be equipped with an internal floating pan/blanket and a fixed
cone roof.
b. Sumps, Drain Lines and Sampling Systems
A low point sump with a drain line and a suitable valve for draining water and sediment shall be
installed in all tanks. The drain line shall preferably be a non-rusting material, selected to avoid
galvanic action created by dissimilar metals (i.e. stainless steel lines shall only be used in
internally lined storage tanks and internally/externally coated mild steel in unlined tanks) of
approximately two inches in diameter and fitted with an inline sampling valve.
c. Manholes/Gauging and Sampling Hatches
Sufficient manholes shall be provided to facilitate entry for gas-freeing, inspection and cleaning.
Provision shall also be made for representative samples to be drawn at all product depths. Fill
connections and gauge openings shall be provided with tightly fitting covers to prevent entry of
water and/or solid contaminants and evaporative loss.
d. Inlet and Outlet Connections
All tanks shall be fitted with separate inlet and outlet pipe work. This is to ensure that only fully
batched product is dispensed from storage facility.
e. Positive Segregation
Provision shall be made so that tanks can be positively segregated for product quality control
purposes. The inlet and outlet to each tank in multi-tank storage terminals and the inlet [or at
some other location on the segregated receipt line to the single storage tank] in single tank
storage terminals shall be fitted with either:
a valve arrangement designed to isolate product and prevent bypass via pressure build
either by temperature changes within isolated sections of pipe or due to static head pressure.
a removable distance piece (pipe spool and blind flanges), or
a spade or spectacle blind.
Note that these requirements are set for quality control purposes to isolate the tank from
unintended movement of products; separate arrangements approved by an authorized person will
be made to make the tank safe for any personnel entry into the tank.
f. Overfill Protection
Storage tanks shall have provision for overfill protection using two independent sensors.
g. Tank Signs
All tanks shall be prominently numbered and clearly marked with the grade stored as described in
API Standard 1542 and provisions made for the dates of the last cleanliness inspection and tank
cleaning (see 10.7) to be added. Tanks that have in the past contained leaded product shall be
permanently marked with suitable signs to that effect.
h. Water Bottoms
The carrying of excessive water bottoms is not permitted in product tanks. In an emergency, due
to a real or suspected tank bottom leak, a water bottom may be used only to allow for time to
remove the aviation product from the storage tank in a timely manner so the tank can be repaired.
3.2.6 Tank Dike/Dike/Bunds
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
3.3 Pipelines
3.3.1 Integrity Measures
For all pipelines, the following integrity measures shall be provided:
For all buried pipelines a means of isolating the pipe section(s) and performing a
pressure (leak) test(s) shall be provided. For longer (cross-country or feeder) pipelines, an
automatic leak detection system shall also be provided.
Wherever practicable, all pipelines should be designed to accommodate cleaning or
“intelligent” pigs.
3.3.2 Links with the Receiving Storage/Distribution Terminals
Where a pipeline supplies tankage in storage/distribution terminals, the interface between the two
shall be arranged to ensure the integrity of both. For instance, the following measures shall be
considered:
Interface pressures and change of pressure ratings for components, such as filtration equipment.
Relief of thermal and surge pressures.
Facilities to collect product discharged for thermal or pressure relief systems and cloudy fuel
arising from pipe pigging.
Automatic shutdown of the pipeline in the event of a tank high-high level, or if an emergency stop
button is activated.
Information on the total flow rate and volume of fuel received during a transfer, information
product properties (e.g. density) and batch change volume and timing (especially if from more
than one source at the same time).
3.4 Pipework within Storage and Distribution Terminals
3.4.1 Separation and Segregation of Fuels and Components
Except for pipework upstream of fuel and component tankage used for discharge of mixed
cargoes, coastal/inland waterway vessels, or for receipts from multi-product pipelines, each grade
of fuel shall be handled in a grade-separated/segregated system, with no interconnecting lines
between piping handling different products.
Provision shall be made so that lines can be positively segregated for product quality control
purposes. The inlet and outlet lines to/from each tank in multi-tank storage terminals shall be
fitted with either:
a valve arrangement designed to isolate product and prevent bypass via pressure build either by
temperature changes within isolated sections of pie or due to static head pressure.
a removable distance piece (pipe spool and blind flanges), or
a spade or spectacle blind.
Note that these requirements are set for quality control purposes; separate arrangements
approved by an authorized person will be made for maintenance isolation.
3.4.2 Piping Low Point Drains
Long piping shall incorporate means for drainage at low points.
3.5 Tank Recirculation Piping
The advantage of recirculation piping, which allows product to be pumped from the storage tank
through a filtration train (if wet or dirty fuel is expected) or through a fuel additive system to meet
customer requirements, or for the purposes of mixing, should be reviewed to see if it offers
advantages during design or modification of a site. Use of recirculating piping with appropriate
controls to ensure water, dirt, rust and sediment that maybe in the bottom of tanks are not carried
out with the product during delivery.
3.6 Static Relaxation Design Considerations
Static relaxation shall be incorporated into the loading terminal design as outlined in API
Recommended Practice 2003.
3.7 Fuel System Additive Systems
Fuel system additive systems shall be designed to automatically dispense the additive at the
desired dosage. The additive system shall be designed to shut down the loading if over or under
dosage is encountered. The fuel system additive systems should be designed to inject the
additive after all filtration vessels and strainers in the loading line.
3.8 Loading Couplings/Swivels for Road/Rail Transports
Couplings
Bottom loading into road/rail transports of all fuels should be performed through an API 4-inch
coupling.
Top loading should only be performed under cover to avoid weather hazards and contamination
associated with top loading from entering a road/rail transport. Other design considerations are
addressed in API RP 2003.
Swivels and loading hoses
Pipe work fittings such as swivels used on loading hoses shall be self-lubricating and under no
circumstances should not be fitted with grease nipples or similar devices into which grease or oils
can be injected and consequently contaminate the fuel due to seal leakage. Existing loading arm
swivels may be lightly greased by hand when the swivel is disassembled in accordance with the
manufacturer’s instructions provided that the packing seal/diaphragm to prevent grease from
contacting the fuel is intact.
3.9 Filtration
It is recommended that filter banks shall be installed on truck, rail, pipeline and marine
movements with ability to sample both pre and post filtration and monitor pressure drop across
the bank. It is highly recommended the bank include at least two vessels in either lead lag or
parallel configuration to allow for bypassing vessels for maintenance without interruption to
movement operations.
The following are the minimum requirements for filtration, by product at a minimum of 95%
efficiency.
Diesel, Biodiesel and FAME- Ten micron (10μm)
Gasoline and Blend Components ex. Ethanol (30μm)
Ethanol - Five micron (10μm)
Outlet filtration from a distribution terminal to road/rail transport loading rack shall include:
Air eliminators
The risk of internal fire or explosion is increased if product is pumped into a filter/strainer vessel
that contains air. Therefore, automatic air eliminators shall be installed on vessels (except small
single-element vessels). The operation of such air eliminators requires the discharge piping to be
open at all times when the vessel is in service. Any isolation valves in the air elimination
discharge system shall be wire-sealed in the open position during normal operations. The
discharge pipework from the eliminator shall be arranged such that any product escaping is
returned to a recovery system. Where necessary, soft-seat nonreturn valves (check valves) shall
be installed in the air eliminator to prevent vessels draining down into storage where there is a
chance the filter vessel might drain down allowing air to enter the vessel.
A water defense system (as described in API/IP 1581) that would shut flow down or set off an
alarm may be fitted to all filter water separators.
Drains
All filter and strainer vessels shall have a drain connection at the lowest point of each chamber.
The main sump drain shall be fitted with a valve permitting regular check samples to be
conveniently taken. The drain sample shall be taken into an open container (such as a glass jar
or stainless steel bucket, which shall be internally coated with white porcelain or epoxy and
equipped with a bonding cable and clip) or a suitable closed circuit sampler utilizing a transparent
collection container. A pipe sight flow indicator (sight glass) shall not be used for this purpose.
All filters shall have a thermal relief valve, which vents to a recovery tank and shall never be
closed off while the filter is in operation.
Except for mesh strainers, all filters shall be equipped with direct reading differential pressure
gauges to indicate pressure loss across the vessel. The direct reading gauge shall be fitted with a
deflection test apparatus. Filter vessels shall also be fitted with a thermal relief valve.
Flow Rate Control
Since the use of filters/strainers can increase the creation of static charge, flow rates should be
set such that a sufficient relaxation may take place before discharge into the delivery vessel.
Alternatively conductivity improvers may be added to increase the conductivity.
(Do we have guidance here charts/tables)
3.10 Paved Areas, Drainage, Oil Water Separators and Spill Collection tanks
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
3.11 Emergency Shutdown (ESD), Level Alarm and Fire Alarm Systems
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
3.12 Cathodic Protection
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
3.13 Grade markings
All piping work and valves on receipt and loading systems shall be clearly marked in accordance
with API/IP Std 1542. The product name and color coding, and flow directional arrows shall be
indicated.
4 RECEIPT PROCEDURES
4.1 Receipt—General
Petroleum products are normally distributed in bulk and hence there is opportunity for
contamination by water, sediment or microbial growth, or by mixing with other products. The risk
associated with a product quality event can be mitigated by safeguards which can vary from
engineering solutions (e.g. segregation of product piping) and/or regularly scheduled testing, to
written procedures, depending on the risk versus the cost involved. For example: the testing may
be reduced or eliminated when there is lower risk (such as dedicated single product pipelines).
To provide confidence that product has not been contaminated nor has an unacceptable level of
inter-product mixing, a sampling and testing regime shall be developed. The minimum sampling
for inter-product mixing and contamination testing is outlined in section 5.3
Product receipt tanks should be quarantined whenever possible, after the receipt and until
appropriate sampling and testing has been completed and the tank has been released.
Tank inventories, water levels and available safe fill, volume to be received and any product
specific data including specifications such as gravity, and receipt arrival/delivery time should be
confirmed and documented prior to receipt
Wherever possible, product-to-product pumping shall be adopted, without the introduction of
water to separate products or to clear lines handling fuels or components. If lines handling fuels
or components must be left full of water, it shall not be sea water but shall be fresh or suitably
treated water.
4.2 Receipt by Pipeline
Fuels and components shall only be received through clean product pipelines. It is preferable that
gasolines and distillates be received through their own segregated line. Where this is not the
case, interface handling procedures shall be developed and documented to minimize the amount
of interface directed to either type of product.
During receipt of product/components, samples shall be drawn from the incoming pipeline at the
receiving terminal. As a minimum, samples shall be drawn at the commencement and the end of
the transfer. It is recommended that samples also be taken at the middle of the receipt.
* - Middle sample specifics:
 Should be taken as close to the middle of the receipt as manning allows. If middle
sample occurs during unmanned hours, sample should be taken either prior to
unmanned period or when manning resumes.
 Not required for dedicated pipeline receipts (see definition below).
Contamination check testing shall be conducted to ensure product integrity. In the case that a
transfer consists of more than one batch, then an additional control check shall be carried out at
the time of the arrival of each batch. For large batch receipts (in excess of 25,000 bbl), the
frequency of sampling should be increased (i.e. sampling every 4 hours). The samples shall be
taken as close as practicable to the receiving tank.
If any of the samples fail any contamination check then the receipt shall be quarantined and the
problem investigated. Delivery shall only be resumed after clearance has been given by the site
product quality manager.
Samples shall be tested as indicated in section 5.3. Record results and compare to the
applicable specifications.
Pipeline receipt samples should be retained until the receiving tank has been certified. They
can then be discarded.
Definitions:
"Dedicated pipeline receipt" = Pipeline receipt comes directly from a single source or refinery
(no other inputs along the pipeline)
"Segregated pipeline receipt" = Receipt is not fungible, but is sent along a pipeline with multiple
inputs and draw-offs.
In addition to the pipeline receipt test protocols, a C of A shall accompany each receipt into the
pipeline. The C of A shall include all tests as required by the pipeline specifications including test
designation and revision number. Receipt test data should be compared against the C of A to
confirm no variation in the product has occurred. Any variation in product, specifications or test
results should be reported for possible waiver by management if necessary. Where no sampling
is required under other guidelines, periodic sampling of delivery tanks and full compliance testing
shall be performed to assure product quality. Samples should be taken at least once a month
and full tested to confirm compliance.
Any new source location or shipper that desires to transport products through the system must
first be risk assessed and approved by management to confirm suitable production, controls, and
handling practices to ensure products are fit for purpose, suitable for combination with similar
products and will meet the physical requirements for transport within the system.
4.3 Receipt by Ocean Tanker Coastal/Inland Waterway Vessel
Receipts of product via marine vessel have a significant potential for contamination. There are
many sources of contamination, such as off-specification product in vessel compartments, offloading the wrong sequence of compartments when multiple products are aboard, and offloading of water or ballast during product transfer. The following quality requirements contain
the MINIMUM standards for distribution terminals that shall be followed. Terminals are
encouraged to adopt additional quality checks to minimize the risk of not detecting product
contamination during marine receipts.
Upon arrival of the vessel, verify with the crew the product/grade in each compartment and
document the products and configuration. During gauging, note any water present in the
compartments, bringing any quantity present to the attention of the management.
For each vessel, take one-quart all-levels or composite samples from each compartment and
prepare a one-gallon composite of these for each product. For vessels with more than 4
compartments of any given product, the 1-gal composite can be made with equal size portions
of each compartment. Individual compartment samples shall be checked for appearance prior
to making the composite.
Test composite as noted below. Record the results and compare to the specifications. Each
vessel should arrive with a C of A or similar document listing test results. These results should be
compared against the specifications prior to off-loading. For vessels loaded from a single shore
tank and for vessels with a reported composite gravity, the API gravity should be compared
against those reported on the loading papers within 1oAPI. Vessel composite samples should be
retained for 30 days or until the next receipt, whichever is longer.
Multiple shore tanks are often used for loading, reported compartment gravities are often
different, and a vessel composite gravity is not always reported. In this case (varying gravities
from compartment to compartment without a reported composite gravity), a weighted-average
loading gravity should be calculated and compared to the composite within 1 oAPI. The terminal
supervisor must be notified if any off-specification product is detected upon testing the
composite.
At the beginning of pumping take a one-quart line sample and test as indicated in the table
below. For vessels with more than 1 product aboard, repeat line sampling/testing every hour, or
at least once per compartment for compartments that will take less than 1 hour to off-load. If
several compartments are off-loaded simultaneously, the hourly frequency is acceptable. For
vessels with a single product aboard, line sampling shall be repeated at the middle and near the
end of vessel off-loading. The following tests are required for line samples:
Single Product
Multiple Products
Gasoline/BOB
Appearance
Distillates
CPL Haze Rating
API Gravity*
Appearance
API Gravity*
ASTM/Hellige Color
CPL Haze Rating or Appearance
Flash (for split loads of gasoline &
distillate only)
Ethanol
API Gravity*
Appearance
Water Content
If any off-specification product is detected during testing of the line samples, product transfer
from the vessel must be stopped, and the terminal supervisor shall be notified. Line samples
should be retained until the receiving tank has been certified and can then be discarded.
Upon completion of the receipt, the receipt tank shall be tested (see section 5.3). If the water in
the receipt tank has increased significantly due to the marine receipt, management shall be
notified. Tracking excessive water off-loaded from marine vessels is important for the
prevention of future occurrences.
*API gravity should be compared to the value obtained on the product composite within 1 oAPI.
For vessels loaded from multiple shore tanks (or those having varying gravities from
compartment to compartment), the line sample gravities and at least one of the product loading
compartment gravities should agree within 1oAPI.
4.4 Receipt by Road or Rail Tank Car
The seals, release certificate, and grade plates shall be checked on arrival.
Drain samples shall be drawn from each compartment and a control check carried out. Up to
three compartments may be combined for the API Gravity determination. This API Gravity
determination shall be compared with the API Gravity of the originating batch as shown on the
release certificate. If a difference of more than 1.0 API degrees is found, a possibility of
contamination exists and the matter shall be investigated further before the product is accepted.
If water and/or sediment are present in significant quantities (more than 2 quarts), the product
shall be allowed to settle for 10 minutes; then a fresh sample is taken. This process shall continue
until clean, clear, water-free samples are obtained before continuing with receipt. Failure to
achieve such clear samples after withdrawal of a reasonable quantity from any one compartment
shall be reported promptly to the supply source and the vehicle quarantined awaiting the results
of an investigation.
In cases where deliveries are made during unmanned hours or are made on a regular basis
multiple times during each shift, C of As and seals may be left in a designated location at the site
for review at least once/day. Tank samples should be taken and tested for contamination as
defined in section 5.3 once/day.
4.5 Other Receipts
Composite tanks samples and retains should be taken once per month from all tanks not
otherwise covered under the following specific protocols and/or oversight programs. These
samples should be tested against contract or regulatory requirements. E.g. Tank cars and tank
trucks should be received only if sealed and accompanied by a C of A or other appropriate
transfer paperwork.
4.6 Interface
Procedures for receiving multi-product cargoes or pipeline receipts shall be clearly defined and
documented, and rigorously followed to ensure that interface contamination is minimized. All
grade interfaces, both leading and trailing, shall be diverted into slop tanks, or the lower grade
product tank at a concentration that ensures the product/component tank remains on specification
and fit for use.
Limits for acceptable inter-product mixing shall be established and procedures shall be
documented to avoid unacceptable inter-product mixing of any product by interfaces created
when dissimilar products are moved via common pipework (transmix). The procedures shall
define acceptable times or volumes for arming or activating valves prior to product receipt and
interface cutting. The time/volume should be for no longer or greater than required to ensure the
valve is open.
5 FUEL QUALITY CONTROL
5.1 Segregation
For quality control, regulatory compliance, and safety purposes, it is vital to ensure that fuels are
not contaminated beyond allowable levels with any other products. The following means are used
to ensure such contamination does not occur.
Segregation refers to a physical barrier that prevents one type or grade of product from entering
other systems, intermixing of different fuels and components. Segregation is usually achieved by
means such as:
Completely separate pipework and tankage, with no connections to any other pipework system.
This is the safest and, therefore, the preferred method.
Isolation using spectacle blinds.
Isolation using a double block and bleed valve arrangement.
A segregated loading system is defined as piping from the shipping tank to loading flange that is
dedicated exclusively to product being loaded with no interconnecting lines present. If
interconnecting lines exist, a single gate valve shall not be relied upon. A twin seal valve with a
bleed valve checked periodically is acceptable for segregated loading systems. However, gate
valves shall be supplemented with either a blind flange or by another gate valve with a bleed
valve (between the gate valves), checked periodically.
Effects of cross contamination
CONTAMINANT
Leaded
Gasolines
Unleaded
Gasolines
Gasoline
Base Jet
Fuel
(Wide-cut)
Kerosene
Middle
Distillates
2
2
2,3
3, 4, 5
2, 3, 5
2
3, 4, 5
Unleaded Gasolines
2, 7
2
2, 3
3, 4, 5
2, 3, 5
2
3, 4, 5
Kerosene
1, 2
1
1
2, 5
2
2, 5
Middle Distillates
1
1
1
1,8
Residual or Heavy
Distillate Fuels
1
1
1
1,8
1, 6
1, 6
1, 6
6
PRODUCT
Leaded Gasolines
ULSD
1
2
3
4
5
6
7
8
Flashpoint.
Color.
Octane value.
Gum residue.
Distillation end point.
Sulfur free requirement.
Lead-free requirement
Viscosity
Residual
or Heavy
Distillate
Fuels
2
6
2, 6
ULSD
Additives
While it is intended that additive systems be tied into product lines so additives can be introduced
to meet regulatory or contractual requirements related to product performance and safety, care
should be taken to ensure the additives are not allowed to enter the product system unchecked.
In order to ensure over additization does not occur, check valves and/or recycle systems shall be
installed to ensure additives are not introduced during shut down situations
Inventory variations
Inventory variations can provide early information about possible contamination after receipts, in
storage, and during loading. Any inventory variation of greater than 0.25% shall be investigated
to ensure no contamination that could degrade the product has occurred.
Possible causes of unintended product movement include:
Improper valve closure from conveyance after receipt completion
Tank to tank movement due to pump or static head pressure
Line to line movement due to failed check valves during loading
*Note inventory variations may also be due to improper tank lineups or blend component
setups.
5.2 Settling
After product has been received into storage tanks and the tank positively segregated, a “settling”
status indicator shall be positioned at the outlet valve or otherwise indicated in the tankage
electronic control system, until product release is approved.
The normal settling periods shall be as follows:
Distillates: 1 hour per foot depth of fuel or 24 hours, whichever is less.
Gasoline: 5 minutes per foot depth of fuel.
However, where fast turnaround of product is essential (see “live to the rack” operations), special
precautions shall be taken to ensure tank bottoms (water, sediment, dirt and rust) are not
delivered along with the product. Procedures may be varied based on the tank bottom
configuration ( e.g. cone down tank bottoms are less susceptible to delivery of contaminants from
the bottom of the tank.)
In cases where externally controlled mixers (paddle mixers, recirculation pumps, etc.) are in use
to ensure uniform product throughout the tank, settling times shall begin after the mixers have
been turned off.
5.3 Testing
Tank after Receipt
Product
Gasoline/Components
Distillate (Non-Aviation Kerosene,
US Diesel #1 and #2, Autodiesel,
Heating Oil, Marine Gasoil,
Japanese Fuel-Oil A, etc.) and
components
Residual Fuel Oils
Gravity and Flash Comparisons:
Minimum Abbreviated/Contamination Tests
Density
Visual
Density
Visual
Flash Point
Density
All Terminals:
The tank gravity after receipt values should lie between the receipt
product gravity and the prior tank gravity within 1.0° API. Flash results
should lie between the receipt flash and tank prior flash within 5°F.
5.4 Release
Product can only be released for shipment or pipeline delivery when product is on specification as
defined by contractual agreement and/or regulatory requirements. When product is found to be off-test
it should be immediately re-sampled and re-tested. If the off-spec condition is confirmed, management
shall be contacted. The release of product from storage terminals shall be supported by a signed
release form or electronic release document. The signature shall confirm that all necessary procedures
(inventory validation, sampling testing, settling times water draws, etc.) have been carried out and the
results are acceptable. The release shall only be approved or signed by authorized personnel.
Waivers/Off Spec Products
The product quality procedures in this recommended practice are intended to result in products
that always meet specifications and customers' needs. It is recognized, however, that there will
be occasions when products are blended or manufactured that do not fully meet all specifications.
When this occurs, a waiver is required before the product can be transferred to the next customer
in the distribution chain. (Alternatively, off specification product may be dealt with by re-blending,
downgrading or disposal).
The customer or regulatory authority retains waiver approval authority for all products not meeting
core, minimum standards, all products not meeting government legislative, regulatory or
procurement requirements and all products where a waiver may impose a health risk.
It should be a goal to minimize waivers. However, it should also be recognized that some waiver
situations reflect the balance between margin setting and product quality giveaway. For that
reason, a zero-waiver goal is not appropriate, as it may just result in inefficiency through
giveaway. From this perspective, a waiver feedback loop can be used to help fine-tune
production efficiency.
An important part of any waiver management procedure is documentation and review. This
provides the mechanisms to not only follow a specific product, but also to develop the necessary
feedback that can be used to continuously improve the production and distribution systems.
Waivers may be granted via hard copy, electronically, or verbally. However, all waivers shall be
documented and be available for review. It is the responsibility individual with authority to release
the product to ensure this information is maintained. Documentation shall include the product(s),
volume, specification not met, cause and reason for the waiver.
Release from Running Tanks
If the tank receiving product is "live" to the rack, care must be exercised to ensure the quality of
the product being loaded. Due to the increased turbulence in the receiving tank, the chances of
water bottoms and/or sediment to be carried over to the loading rack are higher during this type
of operation.
Water shall be gauged prior to receipt into a live tank (see water management section for use of
the "after receipt" water gauge in some cases). If any water is detected upon gauging, the
water shall be drained, if possible. If water could be present in the tank below the gauging
location, a check of the water draw should be used to confirm the presence/absence of water.
If water is present in the tank and cannot be drained, or if the absence of water cannot be
confirmed, a one-quart sample shall be taken (at a point downstream of the live tank) after the
live tank begins to receive product. Terminals should ensure that the sample is representative
of the live tank, taking into account appropriate line fill volumes. Some possible sample points
are the following: 1.) Loading Rack, 2.) Sample port at rack pumps, 3.) Loaded Truck.
The sample shall be tested for appearance (gasoline) or haze (distillates). If any water or
sediment is detectable in the sample, notify management immediately.
5.5 Product Blending (in-tank)
In tank blending of components, additives, and different grades of the same product may be
accomplished via various methods. In most in-tank blending operation the components are
added sequentially which depending on the volume of each component may not lead to a
homogeneous blend. Where past practices that have been shown to result in homogeneous
blends, are used, abbreviated testing of upper lower and middle samples may be used to confirm
sufficient homogeneity. In cases where the effectiveness of the blending operation has not been
confirmed, upper, middle, and lower samples shall be taken and tested for each parameter that
differs from the expected finished product. In cases where the volatility of the two components
differ by more than one grade, a top sample shall be used in place of the upper sample.
6 STORAGE PROCEDURES
6.1 Routine Checks
Static Stock
Periodic recertification testing shall be carried out on all grades of fuels remaining in storage over
six months (at ambient conditions, <90F) after the date of the last replenishment. This testing
shall be repeated at the same intervals until the stock is replenished. If the periodic test results
are unsatisfactory, the tank shall be quarantined until the matter is resolved. Tanks need not be
quarantined while awaiting periodic test results.
Piping, such as storage tank recirculation lines or tank transfer lines, left unused longer than 3
months, shall be flushed back to storage. If the line contains fuel that has not been recertified,
and it is flushed back to a storage tank, the tank shall be recertified after the transfer prior to
being released for use.
Biological Growth
Storage terminal operators shall perform a test for microbiological contamination, which shall be
carried out on all grades of fuel on a bottom sample from each tank. It is recommended that this
testing be carried out on an annual basis, when water draw samples indicate microbiological
activity or when downstream microbiological growth is reported. Specialist advice shall be
obtained to determine the most applicable test and what constitutes acceptable and unacceptable
results. Additional guidance on the subject of microbiological contamination can be found in the
ASTM Manual 47: Fuel and Fuel System Microbiology: Fundamentals, Diagnosis and
Contamination Control and the Energy Institute (EI) document Guidelines For The Investigation
Of The Microbial Content Of Petroleum Fuels And For The Implementation Of Avoidance And
Remedial Strategies.
This testing shall be repeated at six-monthly intervals if the test results are unsatisfactory. The
cause of the unsatisfactory results shall be investigated. Cleaning of the tank may be one result.
Treatment of tank microbiological problems by shock treating with biocide additives is an
acceptable method of control.
6.2 Change of Grade in Storage Tanks
Converting tankage to different products depends upon which products are involved and the
many applicable regulations. It can be as simple as receiving the new product on top of the old
and rebranding the tank heel to the new product. In the other extreme, it may involve the
emptying and cleaning of the tank prior to receiving the new product. Allowable admixtures of
products identified for interface handling, in this recommended practice should be referred to for
general guidance.
In general, distillate tanks can be converted to gasoline by emptying the tank, drawing the heel
out of the water draw and then filling the tank with gasoline. Going from gasoline to distillate
entails the same process plus a small distillate wash of the tank bottom prior to filling with
distillate.
Once the physical conversion has been completed samples should be taken to confirm the tank
has been converted as planned.
6.3 VRU Procedures
The vapors from vapor recovery units can change the properties of the gasoline to which it is
directed. The vapor pressure in particular, can be raised, sometimes beyond contractual or
legal limits. For some Vapor Recovery Units, a stream of gasoline is used to transport the
vapors to a tank, a stream that cannot be allowed to inadvertently mix (e.g. finished and
unfinished gasoline). It is therefore very important to properly manage these systems.
While not an absolute requirement, the vapor recovery unit condensate should be directed to a
high throughput gasoline tank, ideally one that accounts for 20 to 25% of the terminal’s
throughput. Special care should be taken in cases where the recovery tank is low on product
or is not turned over frequently. Also, testing of these tanks should be considered to ensure
necessary compliance.
6.4 Product Returns
Pumping back to storage tanks with finished products or certified blend components should be
avoided whenever possible. If slopping or reprocessing of product that is not fit for use is not
possible pumping back may be necessary, but care must be taken especially in cases where
product may been intentionally blended with other components or unintentionally mixed with other
products. In addition there may seasonal regulatory requirements that make the product to be
pumped back, unsuitable for blending.
In general, gasoline and mixed gasoline pumpbacks should be directed to the tank containing
the lowest octane grade of unleaded mogas. When pumping back any off-spec, mixed, or
contaminated product, care should be exercised to ensure the pumpback line is not common to
the line moving product to the rack. A pumpback of all distillate product should be directed to a
High Sulfur No. 2 Fuel, or Gas Oil tank. These directions apply to clean product only, from onsight recovery systems as well as product returned from service stations.
In the following situations, where specific procedures are not available, consult management for
guidance:
- dirty product
- mixed (gasoline/distillate) product
- product which was oxygenate blended at the terminal
- large amounts of product
- product which does not represent the current RVP season
- product which does not represent the current oxygenate blending
As with all receipts, product shall meet the minimum receipt specifications.
Product which has been loaded onto a truck and then needs to be off loaded, where no chance
of cross contamination can occur, may be pumped back to the source tank without further
testing.
6.5 Water Management
Prior to receipt, document the amount of water present in the receiving tank. After receipt,
gauge for water and document the amount of water present in the tank. For tankage that does
not have the potential for water intrusion, such as fixed cone roof tanks, closed internal floating
roof tanks, or similar, the after receipt water gauge for the previous receipt may substitute for
the before receipt water gauge of the current receipt.
If the water level is above 2 inches, drain water prior to the receipt. If no fixed water drain
system is available, initiate process/steps to drain the water as soon as possible. Note: 2"
draining requirement is measured at the side gauge or datum plate, near the outlet of the tank.
Draining shall remove as much water as possible given the physical constraints of the tank.
All product tanks shall be checked for water at least once per month. Water shall be removed
from the tank when the level reaches 2 inches (see note above). In any case where the tank
configuration does not allow for the above required measurements of the water level, the water
should be drained before and after each receipt.
Water bottoms checks shall be recorded including volume, appearance and any noticeable
changes in appearance from prior samples. Significant changes shall be investigated.
7 DELIVERY PROCEDURES
7.1 Documentation
All transfers of product from storage terminals shall be supported by a signed release. The
signature shall confirm that all necessary procedures, inventory validation, sampling testing,
settling times water draws, etc.) have been carried out and the result are acceptable. The
release shall only be signed by authorized personnel.
7.2 Product Delivery from Running Tanks (Live to the Rack)
Terminals shall avoid receipt of product into live tanks whenever possible. If receipt of product
into a live tank is necessary due to tankage or supply restrictions, appropriate steps for ensuring
product quality during receipt of product shall be taken. Terminals are encouraged to adopt
additional checks for this type of operation; some suggestions are as follows:




Sample incoming receipt at a specified frequency, such as every hour or every 10002000 bbls, ensuring minimum specifications are met throughout entire receipt.
Sample tank bottoms prior to receipt and analyze for sediment.
Monitor sight glasses at loading arms for water during loading operations.
Sample downstream of live tank throughout receipt at a specified frequency, ensuring
no water or sediment is detectable.
7.3 Product Blending
The proper blending of components at the terminal should always be controlled as closely as
possible. This control should be designed to ensure the applicable specifications and regulatory
requirements are always met and that give-away is minimized to the greatest extent possible.
Whenever changes to blending operations are made, (new blending operations, component
changes, meter calibrations, hardware repairs/upgrades, etc.) it is recommended that validations
be performed to ensure the change was made as intended. Validation may include increased
inventory verifications, downstream testing, independent verification of changes, documentation
reviews, etc.
7.4 Product Transfer
Release Testing of Conveyances
1. All shipping locations are responsible for:
a.
Inspecting the shipping conveyances to ensure cleanliness and suitability for loading,
except as described in paragraph 1-b.
b.
Compliance with the attached Minimum Cleaning Requirements for tank trucks and tank
cars (ensuring cleanliness of tanks compartments) is the primary responsibility of the
transportation company. Terminals are not expected or required to inspect tank trucks for
compliance with cleaning requirements prior to loading product.
The Marine organization vetting the vessel has the primary responsibility for ensuring
cleanliness of marine vessel compartments. Marine vessel masters are responsible for
their vessels' condition, and they should ensure that the cleaning is adequate to protect
product quality and to satisfy the requirements of loading port inspectors and refinery or
terminal inspectors. However, this does not reduce the loading locations' responsibility to
inspect the compartments of non-inert Gas System (IGS) marine vessels. Upon
inspection, if a vessel does not appear to meet minimum cleaning requirements, product
should not be loaded until the vessel is cleaned appropriately.
c.
2.
Sampling and release testing of loaded products from each compartment, detailed in the
attached tables, prior to release of the conveyance to ensure that the correct products are
loaded without contamination from the loading system or the conveyance. For marine
vessels, see paragraph 5 below. The results of such release testing shall be recorded and
retained.
The release testing requirements outlined in the attached tables are the minimum
requirements for all shipping locations. Furthermore, these requirements assume a typical
multi-product loading system of similar grades of products.
For example, release testing is not required for pipeline shipments if the shipping line is
dedicated (segregated) from the on-specification shipping tank to the point of custody transfer
to the pipeline with no possibility of shipping wrong product or of contamination from other
products. Conversely, locations with multi-product loading systems of dissimilar grades of
products should carefully review their loading configurations and procedures and may require
additional testing to ensure that the correct products are loaded without product mixing or
contamination.
Segregated loading system is defined as piping from the shipping tank to loading flange that is
dedicated exclusively to product being loaded with no interconnecting lines present. If
interconnecting lines exist, a single gate valve shall not be relied upon. A twin seal valve with
a bleed valve checked periodically is acceptable for segregated loading systems. However,
gate valves shall be supplemented with either a blind flange or by another gate valve with a
bleed valve (between the gate valves), checked periodically.
3. The specification ranges and limits for each of the release testing requirements in the attached
tables are subject to contractual and regulatory requirements.
4. Release test results shall comply with the above limits. Furthermore, it is recommended that
selected tests, e.g. API Gravity and Flash, be compared with the shipping tank certification to
check for variation that could indicate product mixing or contamination that should be
investigated further prior to release.
5. For marine shipments of the same product, multiple compartments composite sample may be
used for release testing. Individual compartment samples should be checked for appearance
in the field prior to compositing. If the multiple compartments composite sample fails,
individual compartment samples should be tested. Note: Vessel is not required to wait at
loading port for composite test results. However, results shall be at destination location prior to
off-loading.
6. For each pipeline shipment or for multiple, contiguous pipeline shipments from the same tank
blend, the shipping location shall take periodic shipping line samples as close to the point of
custody transfer as possible to ensure that the correct product is released on-specification.
Note: "Periodic" shall be determined by the shipping location.
For pipeline shipments with dedicated (segregated) shipping lines, i.e., no interconnections
with other product piping, shipping line samples are not required. Each location shall develop
procedures for line displacements and line sampling and testing to ensure that product
released meets the contractual specifications and applicable regulatory requirements.
Minimum Cleaning Requirements
Minimum Cleaning Requirements For Tank Trucks and Tank Cars
Scheduled Cargo
Previous
Cargo
Jet A, JP-5
JP-8
Mogas/
RBOB
LSD #1 ULSD #1 LSD #2 ULSD #2 HSD #2 Heating Ethanol
Kero
Oil
D
A
D
A
D
A
D
Avgas
D
D(1)
D(1)
D(1)
D(1)
D(1)
D
Mogas/
RBOB
Kero,
LSD #1
ULSD #1
A
D(1)
D(1)
D(1)
D(1)
D(1)
D
D
A
D
D
D
D
D
D
A
A
A
A
D
D
LSD #2
D
A
D
A
D
D
D
ULSD #2
D
D
A
A
A
D
D
HSD #2 ,
Heating Oil
Ethanol
D
D(2)
D(2)
D(2)
D(2)
A
D
D
D(1)
D(1)
D(1)
D
D(1)
A
A - Add new product with no cleaning required. Commingle new product with negligible quantity
of previous cargo remaining in compartment. "Negligible quantities" will be defined as no
standing product.
D - Drain compartments and lines completely. If this is not possible, i.e., "drain dry" trucks,
compartments shall be flushed with product to be loaded.
(1) Give particular attention to safety precautions for prevention of static electricity.
(2) Visually inspect complete system to ensure no residual red dye. Personnel fall protection
should be used to inspect interior of compartments.
LPG Note:
Diesel note :
Flushing required when switching from butane to propane. No flushing required
when switching from propane to butane unless butane needs to be free of odorant.
HSD = <5000ppm Sulfur
LSD = <500ppm Sulfur
ULSD = <50ppm Sulfur
Minimum Cleaning Requirements for Marine Vessels
Scheduled Cargo
Previous
Cargo
Jet A, JP-5
JP-8
Mogas/
BOB
LSD #1 ULSD #1 LSD #2 ULSD #2 HSD #2 Heating Ethanol
Kero
Oil (Dyed)
D
A
D
A
D
A
D
Avgas
S
C(2)
C(2)
C(2)
C(2)
C(2)
D
Mogas/
RBOB
Kero,
LSD #1
ULSD #1
A
C(2)
C(2)
C(2)
C(2)
C(2)
D
D
A
D
A
D
A
D
A
A
A
A
A
A
D
LSD #2
A
A
D
A
D
A
D
ULSD #2
A
A
A
A
A
A
D
HSD #2 ,
Heating Oil
(Dyed)
Ethanol
S
S(3)
S(3)
S(3)
S(3)
A
D
D
D(2)
D(2)
D(2)
D(2)
D(2)
A
A - No cleaning required. Commingle new product with negligible quantity of previous cargo.
"Negligible Quantities" will be defined as a cargo tank whose bottom is dry at the gauging
standpipe.
D - Drain lines and thoroughly strip compartments. On barges use tank vacuuming procedures.
Essentially liquid-free.
C - Machine wash lines, pumps, and compartments thoroughly after draining or stripping.
Systems shall be free of water, dirt, or other material. Inspect for cleanliness and dryness.
S - Steam or hot water wash lines, pumps, and compartments thoroughly after draining or
stripping. Systems shall be free of water, dirt, or other material. Inspect for cleanliness and
dryness.
(1) Oxygenated mogas and MTBE are to be treated as motor gasoline for loading on top of
previous cargo issues and/or cleaning requirements.
(2)
"D" is for inerted tanks. Non-inerted tanks should also ensure compliance with appropriate
safety guidelines for switchloading.
(3) Visually inspect complete system to ensure no residual red dye.
Note: See this section, paragraph 1-b for further information regarding responsibilities for
compliance of minimum cleaning requirements and inspection. For cargoes not listed,
management should be consulted.
Release Testing
Product
Fuel Oils
Heating Oil/
Diesel 2
Kerosene/
Diesel 1
Motor Gasoline/
BOB
MINIMUM RELEASE TESTING REQUIREMENTS
Tank Cars/Tank
Pipeline Shipments
Marine Shipments
Trucks
None**
N/A
API Gravity (D-287)
Flash, PM (D-93)
Viscosity, see Spec
None**
Appearance
Appearance
API Gravity (D-4052 or D-1298)
API Gravity (D-4052 or D-1298)
Color, Visual
Color, Visual
Dye, Petrospec for RSD
Flash
Heating Oil, (D-93; D-3828 or D- Flash
56)
Heating Oil (D-93; D-3828 or D56)
Diesel 2 (D-93 or D-3828)
Diesel (D-93 or D-3828)
Haze, (D-4176 Procedure 2)
Haze, (D-4176 Procedure 2)
Sulfur,(D-2622, D-7039 or D4294)
None**
Appearance
Appearance
API Gravity (D-4052 or D-1298)
API Gravity (D-4052 or D-1298)
Color
Color
Kerosene, ASTM (D-156)
Kerosene, ASTM (D-156)
Diesel 1, Visual
Diesel 1, Visual
Flash
Flash
Kerosene, (D-56 or D-3828)
Kerosene, (D-56 or D-3828)
Diesel 1, (D-93 or D-3828)
Diesel 1, (D-93 or D-3828)
Sulfur (D-2622 or D-4294 or DSulfur (D-2622 or D-5453 or D7039) for Kero, uLSD and LSD
7039) for LSD, uLSD and Kero
None**
Appearance
Appearance
API Gravity (D-4052 or D-1298)
API Gravity (D-4052 or D-1298)
Vapor Pressure (EPA equation
Vapor Pressure (EPA equation
with D-5191 or D-6378) &
with D-5191 or D-6378) &
****Volatility requirements during ****Volatility requirements during
regulatory control periods
regulatory control periods
Sulfur (D-7039 or D-2622 or DSulfur (D-7039 or D-2622 or D5453)
5453)
MINIMUM RELEASE TESTING REQUIREMENTS (Cont.)
Notes
Alternative IP, EI or industry standard methods may be used as required by contract or regulatory
requirements
Sulfur and Volatility are US regulatory requirements and may vary depending on location and
jurisdiction
*
Only requirements for dedicated compartments.
** Note specific requirements in Loading Rack section if receiving into live tanks.
*** Marine vessels may be released prior to completion of gum test, if completed within 24
hours or before vessel arrives at destination, whichever occurs first.
****Not required if terminal an oversight program that ensures these specifications.
8 DOCUMENTATION
8.1 Records
The results of all significant checks and testing shall be recorded on documents that are readily
available and kept up-to-date. The records shall be retained for a minimum of one year. The
records shall include the following:
8.1.1 RECORDS—CONSTRUCTION & COMMISSIONING
Each storage terminal shall have readily available the following, maintained up to date:
a. A schematic process flow diagram or piping and instrumentation diagram for fuel systems and
drainage systems identifying key items of equipment, valves, etc.
b. A general arrangement / emergency plan showing the location of all key items of equipment,
safety and environmental protection equipment and escape routes in case of emergency.
c. Lease/ownership drawings showing plot boundaries and ownership limits and planning
approvals.
d. Reference map of the surrounding area showing water courses and access roads.
e. Site geological and environmental data.
f. Drawings for area classification (hazardous areas), electrical power supplies, control systems,
fire prevention, emergency shutdown and alarm systems, detailed piping layouts (in particular
buried pipes), tank layouts, drainage and interceptor systems, and cathodic protection. Records
of any modifications, which shall also be reflected in updated ‘as-built’ drawings.
g. Equipment specifications for all pieces of equipment, including suppliers’ or manufacturers’
drawings, operations and maintenance instructions and other relevant literature and
documentation.
h. Design and sizing calculations, including design year and ultimate design capabilities (which
shall be specified in the statement of requirements).
i. Material and test or compliance certificates.
j. Loss control reviews.
k. Commissioning report.
It is recognized that an existing operation (which may have been established by others) may not
have all the above information available.
8.1.2 RECORDS—QUALITY CONTROL
a. Stock data, including daily product gauges and details of incoming quantities and delivered
quantities.
b. Import quality data, including full details of incoming consignments with relevant quality
certificates.
c. All testing results, including test certificates showing results of testing carried out on terminals
stocks, and the results of control checks.
d. Batch records and release documentation.
e. Tank settling and draining records. Draining records should record the observation of the
sample from the tank sump including observation of solids (i.e. clean, slight, particulate, heavy)
and water content (i.e. bright, hazy, cloudy, wet) and if microbiological growth and surfactants are
present.
f. Other draining records (e.g. filter sumps). Draining records should record the observation of the
sample from the tank sump [i.e. observation of solids (i.e. clean, slight, particulate, heavy) and
water content (i.e. bright, hazy, cloudy, wet) and if microbiological growth and surfactants are
present.
g. All equipment used for fuel testing shall be inspected prior to use. All equipment needing
calibration as recommend by the manufacture shall have this undertaken.
8.1.3 RECORDS—MAINTENANCE
Tank inspection and cleaning records. (These shall be readily available for at least six years and
ideally for the life of the tank.)
Filter/strainer differential pressure graphs and element change records.
Floating suction check records.
Routine checks on other fixed equipment, e.g. meter calibration, level alarms, mesh strainers,
hoses, bonding wire continuity etc.
Serviceability checks on health safety environment safety equipment.
Checks on pumps, motors, etc.
8.2 Signature and Retention
All records shall be signed by the person who carried out the checks/inspections. In the case of
electronic data systems, it shall always be possible to identify the originator of the records.
Records of all daily, weekly and monthly checks shall be retained for at least one year for
reference purposes and to allow any seasonal trends to be observed.
Records of all less frequent routine checks (tank inspections, filter records) and records of all
non-routine matters shall be retained for at least six years.
9 TRANSPORTATION EQUIPMENT FROM STORAGE TERMINALS
9.1 General
Wherever possible, dedicated single grade transport shall be used for the transportation of clean
products. If this is not possible, grade changing of products shall be kept to a minimum and the
transport shall provide a record of cleaning or documentation of the previous product carried.
The use of seals on compartments on marine vessels and railcars/truck transports may provide
extra assurance to maintain the integrity of the products. On pipelines efforts should be made to
minimize the number of interfaces and avoid interfaces between products that cannot be easily
downgraded to one product or the other (transmix).
9.2 Pipelines
Screening
There shall be procedures that ensure the pipeline is suitable for carrying the product and the
operating organization has the necessary controls, training, experience, skills and awareness to
assure product quality. (Existing third party pipeline arrangements are "grand-fathered" except
when new risks are identified or when a terminal is receiving from the pipeline into working tanks.)
Verification
There shall be responsibility defined for screening verification. The frequency of verification
should be commensurate with the perceived risk, based on the performance history of the
pipeline operator.
Preparation and product compatibility
Sequencing of product into pipelines, and the line-clearing of pipelines and pipeline spurs prior to
commencing of transfers, shall be consistent with interface management strategy as per section
4.6
9.3 Coastal/Inland Waterway Vessels
Screening
There shall be procedures that ensure the ship/barge is suitable for carrying the product and that
the ship/barge officer supervising the custody transfer of product has the necessary training to
assure product quality.
Verification
When a vessel arrives at a port where there is custody transfer of product, there shall be
responsibility defined for verification that the vessel is the one that was screened and approved
and the required minimum vessel preparations have been carried out. This responsibility may rest
with local employees or with independent inspectors
Preparation and Product Compatibility
For loading to owned or chartered ship/barge, the tanks shall be prepared according to section
7.4. There shall be procedures for communicating the preparation requirements to the ship
operator and (if applicable) to the third party inspector, and for ensuring that the requirements
have been met.
For both loading and receipt from ship, there shall be procedures to ensure the product loading
and offloading sequence is agreed between the terminal and ship prior to commencing product
discharge.
9.4 Road Vehicles/Rail Tank Cars
Screening
There shall be procedures that ensure the road vehicle/railcar is suitable for carrying the product
and the operating organization has the necessary controls, training, experience, skills and
awareness to assure product quality.
Verification
There shall be responsibility defined by the operating organization for screening verification. The
frequency of verification should be commensurate with the perceived risk, based on the
performance history of the operating organization.
Preparation and product compatibility
Road tankers and railcars shall be prepared for loading according to section 7.4. There shall be
procedures for communicating the preparation requirements to the tank truck/railcar operator and
for ensuring that the requirements have been met.
Road and rail tank vehicles shall be designed such that tanks can be completely drained. For
multi-compartment vehicles, each compartment shall be capable of being drained independently.
Road and rail tank vehicles shall be constructed of aluminum or stainless steel. (If constructed of
mild steel, they shall be coated internally.)
Road and rail tank vehicles shall be bottom loaded (Section 3.8) and if practical, through grade
selective couplings. All top manhole and gauge point covers shall seal completely against the
ingress of water or dirt. Where top filling is practiced, this shall be through a drop/gauge pipe to
eliminate splash filling (Section 3.8).
The use of grade dedicated equipment reduces the opportunity of product contamination during
shipment.
Grade dedicated equipment is always preferable as described above but for emergency service
or where grade dedicated road vehicle tanks/trailers and rail tank cars are not available, the
grade change requirements described in Section 9.5 shall be followed.
9.5 Grade Change Procedures for Road and Rail Vehicles
Switch Loading
Storage terminals shall have agreed procedures for switch loading (see API RP 2003) that shall
be followed in all cases. The most dangerous situation exists when a medium or high flash
product (e.g. diesel fuel) is loaded into a tank that has previously contained a low flash product
(e.g. gasoline) without flushing or gas freeing because the atmosphere in the tank may pass
through the explosive range during filling and could be ignited by a static electrical discharge. The
reverse is also true and, although in this case the vapor concentration passes through the
explosive range rapidly the same precautions are still necessary.
Switch loading precautions shall be applied where fuels having a flash point of less than 100°F
are mixed with fuels with a flash point above 100°F either by addition of the higher flash fuel to
the lower flash fuel or vice versa. Precautions shall also be applied for products with a flash point
of 100°F or above where either the fuel to be loaded or the last grade carried is at a temperature
equivalent to or above its flash point.
10 GENERAL OPERATING, MAINTENANCE, INSPECTION & TEST
REQUIREMENTS
10.1 Bonding
When discharging or loading road and rail vehicles, the vehicles shall always be bonded to the
fixed facilities which shall be suitably grounded. Bonding connections shall be made to clean,
unpainted metal surfaces.
Bonding connections shall be completed before hoses are connected and prior to opening fill
caps, gauge hatches, etc. and remain in position until hoses are disconnected and hatches and
fill caps are closed.
Bonding wires, clips and reels shall be checked weekly for electrical continuity. For reel-type
bonding wires continuity shall be checked over at least one complete revolution of the wheel.
Buckets and metal containers used for fuel sampling and draining shall be bonded to the vehicle
or tank pipework prior to and during draining operations.
The use of plastic or galvanized containers should not be permitted.
10.2 Filling of Empty Tanks, Vehicles and Filters
When filling an empty tank, vehicle or ship compartment or filter vessel, the initial fill rate shall be
maintained at a low value until the filling point is submerged to minimize the possibility of
generating excessive static charge and product mists. This is especially important where the
product contains no static dissipater additive (SDA).
Additional precautions to eliminate air in filter vessels and to provide adequate relaxation time
after product without SDA flows through a filter vessel is also required (see API RP 2003).
10.3 Planned `Maintenance, Inspection and Testing
For all fixed and mobile plant and equipment, a system of planned maintenance, inspection and
testing shall be established and records kept for all activities.
10.4 Filtration Equipment
10.4.1 Strainers and Filters
All strainers, filtration and water separation equipment shall be checked and maintained regularly
(Section 13).
10.4.2 Filter Vessels
All filter vessels shall have the dates of last inspection, and the last element change date applied
on the body of the vessel or physically attached on an information plate.
All filter vessels should have filter element and vessel bolt torque data applied on the body of the
vessel or physically attached on an information plate. If data is not applied to the vessel it shall be
documented and kept on site.
10.5 Tank Level Alarms
Level alarms shall be tested at least annually. The test shall include checks on:
• The integrity of the electrical sensing circuit for each tank, and
• All components of the “high” and “high-high” controls for each tank, based upon a controlled
filling of the tank to the alarm levels, unless the level controls have been designed such that all
their components can be tested in another manner.
The associated electrical circuits shall be arranged to allow regular tests to be easily conducted.
The test of all level alarm components may require significantly more effort, but nevertheless this
shall be carried out at least annually; if this test is carried out by controlled filling sufficient staff
shall be present to maintain full observation and control of the operation.
10.6 Tank Vents
All tank vents shall be inspected at six month intervals. For free vents the covers shall be
removed and the mesh screens inspected and cleaned, if necessary. Damaged or corroded mesh
screens shall be replaced. For P&V vents normally fitted to gasoline tankage, in addition to
inspecting the mesh screens, the sealing faces on weighted components and the mating surfaces
shall be inspected and cleaned annually. At the same time pressure weights shall be checked to
ensure that they conform to the design pressure rating of the tank.
10.7 Tank Inspections and Cleaning
10.7.1 Inspection Frequency
All tanks that can be internally inspected from tank manways or gauge hatches should be
thoroughly inspected one year after first commissioning. Thereafter, inspection for cleanliness
shall be undertaken every three years, and thorough cleaning carried out if indicated by
inspection results. If the inspection reveals microbial growth or build up of sediment exceeding
approximately 1/5 of the tank bottom surface, cleaning of the tank shall be undertaken. More
frequent inspections shall be carried out if there are indications that fuel quality downstream of
the tank is unsatisfactory; e.g. short filter lives, discolored water drainage or slimy deposits.
For all tanks that cannot be internally inspected from tank manways or gauge hatches (i.e.
internal floating roof /blanket or other obstructions that may prevent visual inspection of the tank
interior from outside the tank), cleaning shall take place every three years. This three-year
cleaning requirement can be extended provided the tank meets the following criteria:
a. The tank is equipped with an internally coated bottom and coated approximately three (3) feet
up the side walls from the bottom (section 4).
b. The tank is equipped with a tank sump drain system (section 3).
c. There are no indications that fuel quality downstream of the tank is unsatisfactory (e.g. short
filter life, discolored water drainage
or slimy deposits) or if the condition of the tank drain samples suggest the presence of unusual
signs of microbiological growth or surfactants.
d. If satisfactory results are obtained from the 6 monthly microbiological tank bottom samples (as
described in section 6).
Inspection of the external mechanical condition of the tank and fittings shall be carried out
annually.
Inspection for internal mechanical condition shall be carried out in accordance with local
regulatory requirements or at least every 10 years.
10.7.2 Inspection Procedures
a. Cleanliness
Internal tank surfaces shall be thoroughly visually inspected for the presence of sediment,
bacterial growth, surfactant-type contaminants and, if relevant, the condition of the lining. An
assessment shall be made as to whether cleaning is necessary.
b. External Condition
The tank structure and all relevant fittings shall be inspected and repairs or servicing carried out
as necessary. Checklists shall be
prepared to ensure a thorough inspection is conducted; the following items shall receive particular
attention:
• Tank base and foundation (e.g. for evidence of tank settlement or water “wash-out” damage).
• Stairs and ladders (e.g. for corrosion, stair to shell welds).
• Paintwork.
• Roof surfaces, including any treads or non-slip areas.
• Vent valves, mesh screens, gauge hatches and gauging systems.
• Tank-side valves drain lines, sampling systems.
• Tank floor leak detection.
• Tank grounding.
c. Internal Mechanical Condition
This inspection is intended as a thorough check of the structural integrity of the tank. It shall be
carried out by a suitably qualified
engineer. A full report shall be prepared and be available for inspection at the site.
10.7.3 Tank Cleaning
Tank cleaning shall be conducted whenever an inspection reveals the need for such cleaning, i.e.
by the discovery of bacterial contamination, surfactant-type contaminants or significant quantities
of sediment. Simple flushing techniques and mopping out
are recommended for cleaning; no chemicals or cleaning materials shall be used unless
previously approved for such purposes as they could contaminate the fuels to be stored in the
tanks.
10.7.4 Inspection and Cleaning Records
Records shall be kept and made available for reference of the condition of the tank on inspection
and cleaning. The records shall clearly indicate the type and amount of any contaminants found.
The dates of the most recent inspection and cleaning shall be stenciled on the tank shell.
10.8 PIPELINES
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
11 HEALTH, SAFETY, SECURITY, ENVIRONMENT & TRAINING
11.1 Health and Safety Permit to Work System
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
11.2 Security
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
11.3 Protecting the Environment
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
11.4 Drainage
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
11.5 Maintaining the Integrity of Fuel Tanks and Systems
Guidance can be found in API Standard 2610 Design, Construction, Operation, Maintenance, and
Inspection of Terminal and Tank Facilities.
11.6 Training
11.6.1 General
The nature of operations work is such that it is essential that all those involved understand the
consequences of any lapses in maintaining correct procedures. It is therefore a requirement that
personnel are fully trained to undertake all routine operational tasks and can respond adequately
to emergency situations.
11.6.2 Recruitment
Procedures shall exist and be followed to ensure that new employees are fully capable of carrying
out the required duties. Formulation and implementation of these procedures is the responsibility
of local operational management, since they will clearly differ from place to place. However,
certain basic factors shall be addressed, including the following:
a. Literacy
b. Numeracy
c. Physical condition
d. Eyesight and hearing
11.6.3 Training
New personnel shall be thoroughly trained in all operations and procedures that they will be
called upon to perform in the course of their duties and in all actions to be taken in the event of an
emergency. Existing personnel called upon to undertake new tasks shall be similarly trained
before undertaking the new task without supervision.
An employee training record shall be maintained for every employee that indicates (i) for which
tasks training has been given and the date of such training, (ii) the signature of the trainer, (iii) a
“yes/no” assessment of whether the trainee demonstrated satisfactory understanding of the
training, and (iv) the signature of the trainee. Where necessary training records for existing
personnel shall be established.
Follow-up job observation (with refresher training if it is found to be necessary) shall be
undertaken by supervisory or training staff at a frequency determined by the Installation manager
based on his assessment of on-going operator performance.
The dates and results of these follow-up observations shall be recorded on the operator’s training
record.
Training is to cover routine standard tasks such as sampling, tank and filter draining etc., and
tasks that are specific to a location such as pipeline fuel receipts and tank management. The
latter tasks shall be the subject of specific written procedures which also form the basis of the
training given. Where appropriate some of these written procedures may be displayed at the work
location.
12 FUEL ADDITIVES/DYES/MARKERS
General
There shall be written additive injection instructions for all proprietary and third party products for
which the facility conducts the additive operation. Injection instructions should include a minimum
and maximum dosage and target when specified by the customer, applicable products and
volume to which the dosage applies (per gallon, batch, truckload, weekly etc.). The target,
minimum and maximum should be set via agreement between the operating organization and the
customer, taking into account any legal requirements.
Receipt and Storage
A Certificate of Analysis (C. of A.) shall accompany each receipt. The C. of A. can be faxed from
the supplier at the time of delivery. If the C of A is not present, the additive shall not be off-loaded
until the C. of A. is obtained. Check all results on the C. of A. against the product specifications.
Do not off-load the additive if results are not on specification. Report discrepancies to local
management
One sample shall be taken from each receipt. Use a clear, one- (1) quart glass bottle. Either of
the following two methods are acceptable for taking an additive sample:
- From the discharge port of the vehicle prior to off-loading.
- From a compartment of the delivery vehicle prior to off-loading, using a 1-quart basket sampler.
This option cannot be used if opening of domes on loaded vehicles is prohibited by local
or state regulations.
- From line fill or off-loading manifold prior to off-loading truck into additive tank.
For terminals receiving additive in drums, a 1-quart sample from each lot or batch shall be taken.
For terminals receiving additive in railcar, obtain a one- (1) quart bottom sample from the tank car
upon arrival and prior to unloading. Label the sample with the date and tank car number. Record
appearance and color and retain for a minimum of one year. The sample should be retained for a
minimum of 60 days or until the tank car is empty.
Test the sample described above for API Gravity (density) and appearance. Compare the results
to those reported on the C. of A. Report variations of more than +/- 1.0° API Gravity or product
that is not clear and bright to local management. Record and retain the results for a minimum of
one year.
Retain additive receipt samples in an approved, closed cabinet (out of the light) for six months as
follows:
- Retain all samples from the current month, and one sample from each of the preceding five
months. Discard all other samples or return them to the additive tank.
- If longer than 6 months between additive receipts, retain until next receipt.
At terminals receiving more than one type of additive, establish procedures to prevent delivery of
the additive into the wrong tank. Some key elements to consider in the procedures are:
- Clearly label all tanks, pumps, and off-loading lines.
- Lock each additive receipt line with a unique lock, label the keys appropriately and identify an
individual to control the keys.
- Supervise all additive off-loading.
Monitor the condition of all retains at least quarterly using the following procedure. Swirl each
sample bottle to form a vortex. Check for sediment. Record appearance and presence/absence
of sediment. Report any unusual observations (sediment, phase separation, extreme changes in
color, etc.) to local management.
On a quarterly basis, check the additive tank bottoms for water and sediment. Bottoms samples
can be obtained either by using a bacon bomb or using a tank bottom draw. If no top hatch or
bottom port is available, a line sample may be substituted.
Record appearance and presence/absence of sediment. Report any unusual observations
(sediment, phase separation, extreme changes in color, etc.) to local management. Retain the
sample if anything unusual is noted. Clear and bright samples can be returned to the additive
storage tank.
The following operating procedures apply to loading truck transports from a tank car.
- A capped, dedicated hose should be used.
- Visually inspect each truck and obtain certification document, from the carrier regarding
cleanliness and prior load. In no case shall a truck be loaded which is not dry and vapor free
including pump and hoses.
- Top-loading transfer hose, if used, should be submerged in the additive to reduce emissions.
- After loading, cap the dedicated hose.
- A copy of the supplier’s C. of A. shall accompany each transport shipment.
- Prior to off-loading, obtain a one (1) quart sample and test the sample for API Gravity and
appearance. Compare the results to those reported on the C. of A. Report variations of more
than +/- 1.0° API Gravity or product that is not clear and bright to Fuels Technical Support.
Record results on the Terminal Additive Quality Assurance form and retain the results in an
additive notebook for a minimum of one year.
- Retain all samples from the current month, and one sample from each of the preceding five
months (estimated at 5 to 15 samples total per terminal). Discard all other samples or return
them to the additive tank.
Reconciliation
Physical inventory reconciliations shall be used to assess compliance with agreed targets,
minimums and maximums unless an alternative measurement scheme has been risk assessed
and endorsed by the Area PQAs The frequency of reconciliation should be determined in
consultation with the customer, but shall be no greater than every 30 days.
Inventory Control
Procedures shall be documented to ensure that additives do not exceed the manufacturers
recommended shelf during storage or in use.
Safety
When sampling additives, wear chemical goggles (or approved safety glasses) and chemically
resistant gloves (viton gloves). Check product MSDB if you have any questions about handling
the additive.
Follow safety awareness practices when climbing trucks and additive tanks.
Follow environmentally safe practices when sampling from the discharge port of delivery vehicles
or the additive tank bottom draw.
13 STRAINER & FILTRATION EQUIPMENT MAINTENANCE CHECKS
13.1 Routine Checks—Strainers
All fine mesh strainers used for product quality purposes shall be drained, opened and inspected
monthly. Strainers used for pump and valve inspection should be opened and inspected yearly.
13.2 Routine Checks—Filters
13.2.1 Drain Checks
A visual check for water and sediment shall be made on a sample drawn from the filter drain with
the filter under pressure every 24 hours of use. If water or sediment is found during draining it
shall continue until a clear sample is obtained. The quantities of water and sediment and any
visible signs of microbiological growth in the sump draining shall be recorded. Where facilities are
unused for seven (7) days or longer, a visual check and purge, as above, shall be done at weekly
intervals. For facilities used infrequently where routine purging would result in partial emptying of
the filter vessel, local procedures to safeguard fuel quality and operational safety shall be
established.
13.2.2 Differential Pressure Checks
Differential pressure shall be observed daily during routine operations to ensure that the
maximum limit is not exceeded. At weekly intervals the observed differential pressure shall be
recorded at the maximum achievable flow. A weekly graph should be prepared showing the
differential pressure at, or corrected to, the maximum achievable flow.
The filter used in direct reading differential pressure gauges shall be checked and replaced as
needed whenever filter vessels are inspected or filter element replaced.
13.2.3 Internal Inspection
All filter vessels shall be opened at yearly intervals and inspected internally for cleanliness of
vessel, element appearance, and condition of internal lining, proper fitting of elements, which
shall include confirmation of torque settings, and inspection for proper operation of the vessel air
eliminator and thermal relief system.
During inspection of the filter vessel attention shall be paid to:
• Any gelatinous or “slimy” contaminants or sludge that could indicate the presence of surfactants.
• Any “leopard spotting”, indicating the presence of microbiological growth.
• The condition of seals, gaskets, “O” rings and the torque on element securing bolts.
• The condition of ancillary equipment such as air eliminators, pressure relief valves, etc.
• Any elements showing signs of mechanical damage. These shall be replaced.
A record shall be maintained of the results of the inspection.
13.2.4 Electric and Mechanical Water Defense System Check
All electronic and mechanical Water Defense Systems shall be checked quarterly for proper
operation.
13.3 Element Change Criteria
13.3.1 Microfilter Elements
These shall be replaced:
• If the differential pressure reaches the maximum limit set by the manufacturer.
• If element failure is indicated by a sudden drop in differential pressure.
• If samples from the downstream side of the filter contain significant quantities of particulate
contaminants.
• After a maximum of three (3) years in service.
13.3.2 Filter/Water Separators: Coalescer Elements
These shall be replaced:
a. If the differential pressure reaches 15 psi.
b. If element failure is indicated by a sudden drop in differential pressure.
c. If membrane tests downstream of the filter exceed acceptable limits of greater than 3 wet/2 dry
color membrane filtration test rating on a 1 U.S. gallon sample. (If one test exceeds the limit, a
repeat shall be carried out before replacing elements.)
d. If samples from the downstream side of the filter contain significant quantities of particulate
contaminants.
e. After a maximum of three (3) years in service.
13.3.3 Filter/Water Separator Elements
TFE coated or synthetic separator elements may continue in service indefinitely provided that
they satisfy the manufacturers test requirements on ability to repel water. Paper separators shall
be changed out when the vessels’ coalescer elements are changed out
13.3.4 Filter Monitor Elements
These shall be replaced:
a. If the differential pressure reaches maximum limit set by the manufacturer.
b. If element failure is indicated by a sudden drop in differential pressure.
c. For fuel if membrane tests downstream of the filter exceed acceptable limits of greater than 3
wet/2 dry color membrane filtration test rating on a 1 U.S. gallon sample. (If one test exceeds the
limit, a repeat shall be carried out before replacing elements.)
d. If samples from the downstream side of the filter contain significant quantities of particulate
contaminants.
e. After a maximum of one (1) year in service.
13.4 Filter Vessel Change Out Procedure
a. A filter element change out shall only be performed by trained staff using manufacturer’s
recommended procedures and tools.
All filtration vessel change out work shall be risk assessed, completely isolated and a work permit
issued before starting inspection or maintenance work.
b. The lid of the vessel securing bolts shall be torqued in place to the manufacturer’s
recommended settings while filling takes place. To minimize the risk of fire and explosion, all filter
vessels shall be filled carefully and slowly. All air shall be bled off from the unit while filling is in
progress. The use of heavy greases to help with sealing shall not be used.
c. Filling shall be supervised throughout by a trained operator. After filling, all joints and gaskets
shall be carefully examined for signs of leakage.
Recommended Changes
1. General
- move many clauses on management activity/expectation in 1.5 to 1.4 instead
- remove last paragraph of 1.4, repeat of 1.5.2.
- frequency of oversight testing in 1.5.2 should be risk-based per RA rather than fixed every 3 months.
2. Sampling & Testing
- delete minimum receipt testing for residual fuel oils from the table, as this document is for clean products
5. Fuel Quality Control
- this section is in odd place, probably due to borrowing from JIG document format
- additives & inventory reconciliation should be removed, and include into section 12 instead
- is settling (5.2) a mandatory requirement for ground fuels? suggest to drop 5.2
- delete minimum testing for residual fuel oils from the table 5.3. Is it same as the table in section 2.3?
- remove formal release approval process, we do not practice this for ground fuels
6. Storage Procedure
- drop 6.1 requirements to recertify static stock in storage over 6 months and to test MBG of all tanks every
6 month interval.
- remove 6.5 requirements to record water drain appearance and volume.
7. Delivery Procedure
- remove 7.1 requirement on product release documentation
- the wording in 7.2 should be under section 4 instead
- expand 7.3 Product Blending to include biofuels blending guide
8. Documentation
- remove 8.1.2 requirements for aviation fuels but not applicable to ground fuels.
10. General Operating, Maintenance, Inspection & Test Requirements
- suggest to review 10.7 tank inspection requirements, to remove aviation requirements not applicable to
ground fuels
13. Strainer & Filtration
- remove requirements relevant to aviation fuels
Other comments:
- should have page number at the bottom of each page
- if intended to be adopted globally, should:
+ use metric units (e.g. liter instead of gallon/quart)
+ remove US specific terms, requirements, abbreviation (e.g. vapor pressure - EPA equation, ULSD #1,
LSD #2 )