Design and Handling of Chemical Tanks

Guidance
 • BS EN 12079: 1999 - Offshore Containers - Design, Acknowledgments 1 INTRODUCTION 1
Construction, Testing, Inspection & Marking
Step Change would like to thank the following
• Control of Substances Hazardous to Health Regulations organisations for their contributions in developing this 2 SCOPE 2
SI 1999/437 (COSHH) guidance:

• DNV Certification Notes 2.7-1 AMEC 3 SUMMARY / RECOMMENDATION 3

• IMDG Code - International Maritime Dangerous Goods 3.1 Design 3
Baker Petrolite
Code 3.2 Handling 3
BP
3.3 Tank Access 4
• International Maritime Organisation
Conserve Oilfield Services Ltd 3.4 Contents Measuring Gauge 4
• Lifting Operations and Lifting Equipment Regulations
3.5 Contents Management 4
SI 1998 / 2307, (LOLER) Elected Safety Representatives Network
3.6 Checklists 4
• Manual Handling Operations Regulations SI 1992 / 2793 Ferguson Seacabs Ltd
3.7 Risk Assessment 4
• Merchant Shipping (Dangerous Goods and Marine Harran Ltd 3.8 Document Pouches/Load Security Tagging 5
Pollutants) regulations SI 1998 / 2367 3.9 Responsibilities and Training 5
Marathon
• PUWER - Provision and Use of Work Equipment 3.10 Documentation and Labelling of Tanks 6
Marathon Oil
Regulations SI 1998 / 2306 3.11 Tank Life Cycle Flowchart 6
Nalco Ltd 3.12 Backloading of Chemicals and Waste 6
• Regulation 9 of LOLER, Approved Code of Practice,
(HSE Books L113) Shell Exploration and Production UK
4 LOAD SECURITY INSPECTION PROCEDURE 7
• Step Change in Safety Fatality Report Suretank Ltd
4.1 Introduction 7
• Step Change in Safety Lifting and Mechanical Handling Swire Oilfield Services Ltd 4.2 Purpose 7
Guidance (re-issue 2004)
Talisman Energy 4.3 Scope 7
• Step Change in Safety Task Assessment Guidance (2nd 4.4 Definitions 7
edition 2003) Transocean
4.4.1 Cargo 7
• The Carriage of Dangerous Goods by Road Regulations, 4.4.2 Transportation 7
SI 1996 / 209
4.4.3 Responsibilities 8
• UKOOA / Chamber of Shipping Guidelines for the Safe 4.4.4 Procedure Description 8
Management and Operation of Offshore Support Vessels 4.4.5 Cargo Integrity Tagging 9
(Issue 4th November 2002)
4.4.6 Vendor Premises 9
• UKOOA Guidance for the safe Packing and Handling of 4.4.7 Quayside 9
Cargo to and from Offshore Installations (latest edition)

• Working at Height Regulations SI 2005 / 735 5 SAFETY CONSIDERATIONS AND CHECKS 10

5.1 Good Practice Chemical Tank Inspection Illustrated Checklist 10
5.2 Recommended Checks - Prior to Tank Fill for Preparation for Dispatch Onshore/Offshore 11
5.3 Safety Considerations Associated with Tank Use and Risk Assessment 12

• Step Change in Safety website: www.stepchangeinsafety.net

22
6 TANK PRACTICES 13 7.5 Bottom Outlet Valve Arrangement
6.1 Accessing the Tank 13
6.2 Tank and Contents Handling 13
6.2.1 Sampling 13
6.2.2 Discharging 14
Main Discharge Valve
6.2.3 PV valve/Relief valve operation 14
6.2.4 Tank Ancillaries Intervention 14 Lever Operated Foot Valve
6.3 Hooking On/Off 15
Sampling Point Valve
6.4 Stacking 15
End Cap
End Cap
6.5 Labelling And Documentation 15
6.6 Receipt and Dispatch 16
6.7 Lifting Assemblies and Slinging 16

7 APPENDICES 17 Bottom outlet valve arrangement highlighting the main discharge valve,
7.1 Outbound/Inbound Tank Checklist 17 the sample point and the control handle for the secondary tank discharge valve.

7.2 Load Security Inspection Procedures Flowchart 18

7.3 Pre - Fill Tank Checklist 19 7.6 Ancillaries on the Tank Top
7.4 Tank / Vessel Types and General Arrangements 20
7.5 Bottom Outlet Valve Arrangement 21
7.6 Ancillaries on the Tank Top 21

8 REFERENCES AND ACKNOWLEDGMENTS 22

Manway Lid
(Tank Top Lid / Man Lid)

Air Inlet Valve

Pressure Vacuum
Relief Valve (not to be
manually operated)

View of the Manway Lid and and Pressure / Tank Vacuum Valve (grating removed for picture clarity).

21
 7.4 Tank / Vessel Types and General This Guideline, Design and Handling of Chemical Tanks From an operational aspect, key issues addressed include
Arrangements has been compiled as part of the Step Change In Safety recommendations to eliminate:
overall objective of improving safety within the Oil & Gas
industry. • access to the top of a tank,
INSPECTED BY:
SIGNATURE: • manual operation of the pressure/vacuum valve.
The Guideline was commissioned due to offshore industry
DATE:
concerns over the design and safe use of cargo carrying Further recommendations on :
units and portable chemical tanks, and fatalities offshore
• contents measurement,
relating to the handling of these units (See Step Change in
Safety Fatality Report). • tank access
• back loading fluids from offshore facilities are also
The objective of this Guidance is to provide information to included.
Designer, Manufacturer, Owner and End User of IMO
Chemical Transport Tanks, which will lead to rationalisation The Guidance also outlines the risk assessment approach
of equipment and practices used within the industry thus for any operations out with the Guidance.
reducing accidents or incidents during handling
The Guidance provides assistance to meet these
operations.
recommendations by providing:
Example of 600 gallon, (2900 litres), vertical tank.
From a design perspective, the guidance looks at key
• a Tank Lifecycle Flowchart,
issues. It recommends that:
• Tank Inspection Checklists,
• valves requiring manual operation,
• an Outbound/Inbound Chemical Tanks Checklist
• the lifting accessories master link, outlining competency levels for personnel.

be accessible from deck or ground level. This will reduce

the need to access the top of the tank in the offshore
environment.

Example of 1000 gallon, (4800 litres), horizontal tank.

20 Example of 500 gallon tank. Comparison of new and old tank design (600 imperial gallons). Horizontal Chemical Tank. Supply Vessel Offloading. Vertical Chemical Tank. 1
 The guidance identified within this publication is aimed at 7.3 Pre-Fill Tank Checklist
ensuring personnel, whose duties involve the handling and
transportation of chemical tanks and their contents at The following checklist is a generic checklist for use prior to tank filling.
offshore installations, are aware of the hazards and
precautions which must be considered during tank
PRE-FILLING TANK CHECKLIST
operations.
Tank ID: Date:
The objective of this guidance is to increase awareness of
key factors relating to chemical tanks and contents
handling and to reinforce existing knowledge with 1 CHECK SERIAL NUMBERS, TARE & BLACK PATCH STICKER q
additional information.
2 CONDITION OF TANK FRAME FOR DAMAGE ETC q
To achieve maximum impact, supervision should follow up
safety presentations by talking to appropriate personnel 3 EXAMINE TANK VESSEL & CRADLES q
about tank handling techniques, and their understanding 4 CHECK END CAPS ARE SUPPLIED AND SECURED q
of the required safety standards. Subsequent monitoring
of chemical tank operations should be undertaken to 5 CHECK CONDITION / OPERATION OF FOOT VALVE & OPERATING LEVER q
ensure safety considerations have been raised to, and
6 CHECK CONDITION OF DISCHARGE VALVE q
maintained at, an acceptable level.
7 CHECK CONDITION OF SAMPLE / DRAIN VALVE q

8 CHECK DUST CAP & SECURING WIRE ON DISCHARGE / SAMPLE VALVES q

9 CHECK CONDITION OF EARTHING POINT q

10 CHECK CONDITION OF DOCUMENT TUBE HOLDER q

11 CHECK CONDITION OF DIP STICK HOLDER & DIP STICK WHERE FITTED q

12 CHECK LIFTING LUGS FOR DAMAGE q

13 CHECK LIFTING SLINGS, SHACKLES & SPLIT PINS q

14 CHECK TANK MANWAY LID q

15 CHECK CONDITION OF TANK MANWAY LID, SWING BOLTS & HINGE PIN q

16 CHECK CONDITION OF TANK-LID, INCLUDING LID SEAL q

17 CHECK TANK INTERIOR FOR CLEANLINESS INCLUDING FOOT VALVE & SAMPLE VALVE q

18 CHECK CONDITION OF PRESSURE VACUUM RELIEF VALVE & GAUZE q

19 CHECK CONDITION OF DIP VALVE, DUST COVER & RETAINING WIRE q

20 CHECK THAT TEST DATA PLATE IS FIXED & TANK MARKINGS / CHEVRONS ARE LEGIBLE q

21 COMPLETE CERTIFICATE OF CLEANLINESS & PASS TO RELEVANT PERSON FOR ACTION q

DETAILS OF DAMAGE OR DEFECTS FOUND:

Step Change in Safety Fatality Report

2 19
www.stepchangeinsafety.net
 7.2 Load Security Inspection Procedures (LSIP)
The following flowchart depicts the procedure to be followed prior to any movements of chemical tanks.
This procedure has been adapted from the Talisman Energy (UK) Ltd. process for ensuring the safety and security of cargo during transportation to and
To this end, the term ‘Unit’ can be taken to be CCU’s (Cargo Carrying Units both closed and open top), Tubulars (slung or in frames), Waste Skips,
Helifuel Tanks, Chemical Tanks, Specialist Loads (wire line units and other well service packages) Suppliers/Users of the above should nominate a Load
Checker within their organisation to ensure that the procedure is carried out and suitable verification methods implemented to provide an audit trail.
Start
Onshore Load Checker
Prior to loading of
Container/Tank, nominated
Load Checker shall carry
out a visual inspection of
the unit to ensure that all
items are properly packed,
container doors are
securely closed, and that
no loose items are left lying
on the unit in any place.
Onshore Load Checker
Informs the relevant
person that the unit has
been checked and the
Load Security Tag and
Label attached.
Transporter/Shipper
Prior to loading
(Vehicles/Vessel)
Transporter/Shipper
checks to ensure that
YELLOW Load Security
Tag and Label have been
attached to unit.
End of Process
18
The points made within this section apply to all new and 3.2 Handling
existing tanks, with an overall objective that all current tank
stock can fall in line with this guidance by the end of 2005. The practice of double stacking tanks offshore is not
recommended and should be avoided. Where deemed
necessary it should be by exception only and a formal risk
Load Security Inspection Procedure 3.1 Design assessment is recommended followed by direct
supervision of the activity.
All valves should be suitably placed to allow safe access
from offshore installations.
and be accessible from ground/deck level. When double stacking is being practiced then access to
the crane master link must be independent of the tank, by
All tanks to have fully grated or flat plate tops to ensure
means of a suitable access platform or ladder.
complete closure
There will be no crane movement other than attaching the
All tanks to have non-slip paint coated to access ladders
crane hook to the master link until all personnel have
where fitted.
withdrawn from the immediate vicinity of the tank and the
Onshore Load Checker All pipefittings will be to a recognised standard banksman/loadhandler has given the all clear to the crane
Is the unit packed
Does the problem Arrangers for the person/s operator.
properly with no No concern loose No responsible for
loose items found packing/securing the unit All tanks to have a sling configuration that allow easy
items left on unit?
anywhere on unit? to carry out necessary access to the master ring without accessing/climbing on
remedial action.
the tank in any way
All tanks will have a functional sealable document pouch
Yes Yes
fitted
Onshore Load Checker Onshore Load Checker Note: The Design of Chemical Tanks is primarily covered
Affixes YELLOW Load Removes any loose items by the IMDG code.
Security Tie and Label to from unit prior to loading
the unit. operations.
End-User of Cargo
Unloads/Empties unit and,
Has Load Security Transporter/Shipper where applicable, packs
Tag and Label Yes the unit for return to
Transports/Ships unit to
been attached to Beach and informs
relevant destination.
unit? Offshore Load Checker
that unit is ready for
shipping.
No
Offshore Load Checker
Transporter/Shipper Prior to loading, Offshore
Load Checker carries out
Refuses to transport/ship Is the unit packed a visual inspection of the
unit until Load Security securely with no unit to ensure that all
Tag and Label is attached
loose items found items are securely
(thereby indicating that
anywhere on unit? packed, container doors
the load has been
are closed, and that no
security checked).
Yes loose items are left lying
on the load in any place.
No
Offshore Load Checker Offshore Load Checker
Attaches ORANGE Load Arranges for the person
Security Tag and Label responsible for
informs relevant person packing/securing the unit
that unit is ready to be to carry out the necessary
shipped back to beach. remedial action. Typical view of a fully grated tank. Typical access ladder. Positioning of Masterlink. 3
 3.3 Tank Access 3.7 Risk Assessment 7.1 Outbound/Inbound Chemical Tanks Checklist

Working on the top of the tank should only be undertaken It is recommended that risk assessments should be carried The following checklist is a revision of the existing UKOOA tank checklist, which both updates and clarifies requirements and
as a last resort AND IS NOT RECOMMENDED. However out for the following established operations: checklist contents to further enhance the management and safety associated with the use of tanks.
should this be absolutely necessary then a risk
assessment must be conducted and all appropriate safety • Accessing the tops A key point and change recommended is that for every tank there exists a single corresponding checklist, which follows the
precautions be implemented. Reference should be made • Sampling and Dipping tank in its journey.
to the Working at Height Regulations. • Stacking
Tank ID: Product Name:

Access to the top of the tank should be via the permanent • Discharging & Filling Customer Details Offshore Location:

access ladder (if fitted), portable ladder or a suitable work • Filling, Discharging and including Hose Assembly
Does Test Plate have at least a full month remaining? Yes/No Tank Supplier:
platform and appropriate fall arrest equipment must be Manual Handling
Last Test Date:
worn. • Crane lifts inbound/outbound Collection Address (if different from above): Ready for Collection:
Date:
Access requirements to both valving and lifting assembly • Backloading of chemicals/waste Time:

must be considered when positioning or laying down • Opening of manlid for loading of chemicals
tanks. • Access to the lifting assembly master link when tanks Item No Cargo Ref Cargo ID Product Total “Lift” IMDG Class / UN Customs Status
Quantity litres Weight (Kg) No
are stacked 1
Opening of the tank manway lid is not permissible offshore
unless access is required for backloading, which would • Chemical compatibility
Check Tank / Cargo Checklist Chemical Shipper Offshore Back Shipper Onshore
No Provider Outbound Receiver Load Inbound Receiver
then fall under special circumstances and should be Note: Such assessments should include worker exposure Operative
subject of a risk assessment. Confirm that (a) Tank is clean (and dry depending on the product to be filled),
risk, the Control Of Substances Hazardous To Health or (b) Tank is “dedicated” and previously contained the SAME product.
(Chemical Provider and Back Load Operative only, as appropriate)
(COSHH), and reference the appropriate Material Safety
1 Have all old labels been removed?
3.4 Contents Measuring IMDG Code Data Sheets (MSDS’s). 2 Have copies of all relevant certificates, dangerous goods, MSDS’s and TREM
cards been dispatched with the tank?
3 Are there any signs of leaking chemical?
Any contents measuring device fitted to tank must conform 4 Are all valves closed, and caps refitted?
to current IMDG Code requirements. 5 Has the main valve been tagged and tie wrapped closed?
6 Is manlid closed and fully secured and has security tag been fitted?
7 Is special coupling attached (if applicable)? (Chemical Provider and Back
Loader only)
3.5 Contents Management 8 Have you checked the gross weight against SWL?
9 Does the lifting set details match those on the Data / Inspection plate?
Clarity of tank contents being dispatched or returned must 10 Where appropriate, has dangerous goods cargo been completed and relevant
authorities notified as per IMDG Code?
exist through labelling and documentation.
11 Product Label is on each side?
12 Hazard Label is on each side?
Offshore procedures regarding the return of good or spent 13 Has Tank been visually checked for any obvious damage (frame, gratings,
chemicals must be clear and supported by correct slings, lifting points, fittings etc)?
14 Have you checked for and removed any loose objects / debris on the unit or in
labelling and accompanying documentation to ensure the forklift pockets and fitted / checked the Load Security Inspection Tag?
waste legislation compliance and to facilitate handling/ 15 Have appropriate declarations been made for waste backload?
*Any “No” above will result in non-shipment
disposal on return.
Sign Off For All Of the Above Checks

All tanks should be fitted with a telltale, (tiewrap or similar), Name of Yard Operative: Name of Shipper Inbound Operative:
Signature of Yard Operative: Signature of Shipper Inbound Operative:
on the tank manway lid and main discharge valve to verify
Date: Date:
the tank has not been opened.
Name of Shipping Outbound Operative: Name of Offshore Receiver:
Signature of Shipping Outbound Operative: Signature of Offshore Receiver:
3.6 Checklists Date: Date:

Name of Back Load Operative: Name of Onshore Receiver:

A checklist for tanks is included in the “UKOOA guidance
Signature of Backload Operative: Signature of Onshore Receiver:
for Safe Packaging and Handling of Cargo to and from Date: Date:
Offshore Locations”, however this has been expanded
upon with the Outbound/Inbound summary ticket Step Change in Safety Task Risk Assessment Guide
4 17
(appendix 7.1) www.stepchangeinsafety.net
 6.6 Receipt and Despatch
Upon receipt of any tank always ensure:
• The lifting accessories and padeyes are in good
condition and not damaged.
• The tank has not been damaged in transit.
• The product and hazard labels are visible and intact.
• A Health and Safety data sheet is available for the
contents.
• Retrieve all documents from document pouch.
Prior to dispatch from offshore always ensure:
• The tank and frame are undamaged.
• The tank manway lid is securely fastened.
• The discharge valve and sampling point end caps are
fitted.
• The product and hazard labels are appropriate for the
contents and are visible or where the tank is empty all
labels have been removed.
• All relevant documentation has been inserted into
document pouch.
The instructions identified above, are for general guidance.
It is the ultimate responsibility of all users and handlers to
ensure that all operating and safety procedures are strictly
observed.
Refer to Outbound/Inbound Tank Summary Checklist
(Appendix 7.1).
16
6.7 Lifting Assemblies and Slinging
The lifting and slinging of tanks falls within regulations
below and as such will not be covered in this document.
For reference the key documents are:
• Lifting Operations and Lifting Equipment Regulations
1998 SI2307, (LOLER).
• Regulation 9 of LOLER, Approved Code of Practice,
(HSE Books L113).
• Step Change in Safety Lifting and Mechanical
Handling Guidelines.
3.8 Document Pouches/Load
Security Tagging
Marshalling of tanks utilising a tagging method, (Load
security Inspection Procedure See section 4), carried out
by the nominated responsible person for freight forwarding
and return is a recommended practice.
Document pouches should be present and clearly
identified on the tank. Where this is not the case, remedial
action to ensure the effective communication of the tank
contents details must be arranged.
There shall be a designated responsible person offshore to
both accept and dispatch chemical tanks.
Contents documentation shall be kept in the document
pouch and remain with the tank throughout it’s cycle and
be updated as and when appropriate (reference
flowchart).
3.9 Responsibilities and Training
Training of personnel with ‘hands on’ responsibility for
tanks (including content) is considered essential.
It is recommended the information contained in this
guidance document be used only as a supplement to
further training.
These guidelines are aimed at providing supervision with
sufficient training material from which they can develop
their own specific training programme, for personnel who
are expected to work with chemical tanks or their contents.
Example of Document Pouch.
It is recommended that there are nominated persons with
assigned responsibilities for the management and
handling of all aspects of chemical tanks both onshore and
offshore. Ideally this person should also be responsible for
baskets, CCU’s (Cargo Carrying Units) etc. to ensure a full
overview of the freight situation, risks and controls from an
organisational and management perspective.
Typical duties would include:
• Receipt and dispatch
• Lifting and discharging of contents
• Document control
• Participation in associated risk assessments
• Contents and tank monitoring & management
• Tank labelling compliance and update/change
management
• Integrity of the manway lid and discharge valve telltale
In conjunction with the above offshore personnel handling
or using tanks should receive appropriate training, which
includes:
LIFTING AND MECHANICAL HANDLING OPERATIONS
MANUAL HANDLING
RISK ASSESSMENT
CHEMICAL HANDLING (COSHH)
ENVIRONMENTAL ISSUES
SAFETY OBSERVATION SYSTEMS
The Step Change in Safety Lifting and Mechanical
Handling Guidance contains further information on training
and competency.
Inspection Security Tag. 5
 3.10 Documentation and Labelling
of Tanks
Tank contents labels are to be clear and visible on all sides
to facilitate deck loading and avoid incorrect decanting.
On completion of all checks, an Outbound/Inbound Tank
summary checklist should be completed for each load
being dispatched offshore or returned onshore. The
checklist should then be placed in the document pouch
along with relevant shipping details.
3.11 Tank Life Cycle Flowchart
Enclosed Tank Lid.
Attached for reference (front cover) is a flowchart which
represent the life cycle of a tank, it also identifies the
persons associated with each stage; their duties and key
information to ensure that operations and works associated
with it are managed safely and effectively.
3.12 Backloading of Chemicals
and Waste
Where backloading of chemicals or waste is required then
it is recommended dedicated tanks should be requested to
avoid cross contamination.
Clear labelling and documentation are essential, however
there may be occasions when previously used tanks must
be used. In all cases of backloading, a risk assessment is
required which would consider all aspects in section 5.3 as
a minimum and requires the authority of the offshore duty
holder.
Where waste or contaminated chemical is to be
backloaded, appropriate labelling MSDS should be
obtained and fixed to the tank that correctly identifies the
tank contents and hazards. All waste or contaminated
chemicals should be sent to your responsible Waste
Management Contractor for disposal. Only part used and
non contaminated chemicals should be returned to the
original Provider in the tank with original labels and MSDS.
Offshore Unloading, demonstrating potential for snagging
(open tanks not meeting guidelines).
6 15
6.3 Hooking On/Off
When in the stowed position, the tank lifting accessories
should be located hanging down the outside of the tank
frame. This allows easy access to the master link, when
hooking on/off the crane hook. This also avoids the
necessity for climbing on top of the tank.
Particular care must be taken to ensure that the lifting
accessories and crane hook does not inadvertently
snag on the tank framework or ancillaries causing the
possibility of premature movement of the tank.
View showing the correct position and height of the master link
and the tank slinging arrangement.
Storage Areas.
6.4 Stacking
Double stacking of chemical tanks offshore should be
actively discouraged and only sanctioned where it
becomes absolutely essential and following an appropriate
risk assessment.
Personnel should never climb on to a double-stacked
chemical tank. Where deemed required a thorough and
robust risk assessment process with mitigating measures
and actions is required.
IDEALLY THE TANKS SHOULD BE UNSTACKED.
6.5 Labelling and Documentation
All cargos, including backloaded cargos of dangerous
goods shall be correctly declared, packaged and labelled,
secured, placarded and documented, and segregated in
accordance with the regulations and MGN 282(M) and
IMDG Code plus subsequent notices issued by the
Maritime and Coastguard Authority.
To assist the Master of the Offshore Supply Vessel in
planning the cargo stowage to ensure that segregation of
dangerous goods is maintained, it is a requirement that:
• The Offshore Supply Vessel is advised by the quayside
service provider of the quantity and nature of dangerous
goods prior to loading.
• The Offshore Supply Vessel is advised by the OIM
(Offshore Installation Manager) / Duty Holder or
nominated deputy, of the quantity and nature of
backloaded dangerous goods prior to loading.
In the case of the backload, it is the responsibility of the
consignor/packer to ensure that the backloaded goods are
backloaded in accordance with the requirements of the
IMDG code. That means correctly declared, packaged,
labelled, secured, placarded and with the correct
documentation. In addition consideration must also be
given to the order of backloading to ensure that the
segregation requirements can be complied with.
It is the responsibility of the consignee/receiver of any
dangerous goods to remove any old placards affixed to the
container prior to its re-use.
 6.2.2 Discharging
When discharging tanks containing flammable product,
the tank should be bonded, (earthed by a competent
person) in order to prevent a build up of static electricity
and subsequent danger of ignition/explosion.
• Remove drip cap from the main discharge outlet and
connect hose to the main discharge outlet valve.
• Remove end caps from air inlet valve, then open air inlet
valve manually.
• Open the lever operated foot valve and main discharge
valve, (in that order), to allow the tank to discharge.
When discharging the tank, the following actions should be
considered:
• Ambient temperature, viscosity and specific gravity, all
may inhibit free flow.
• Poor flow - on no account should pneumatic air be used
to assist with the process.
Note: Operators should be aware of the following hazard.
The design of the manual air inlet valve is such that any
build up of pressure will be vented clear of personnel when
the valve is opened.
Upon completion of discharging the tank contents:
• Ensure all valves are closed, end caps are refitted and
secured accordingly.
14 Example of vacuum/relief valve fitted with flame arresting gauze.
Where tanks are fitted with manual Air Inlet Valves (AIV) as
recommended by these guidelines this valve will be
marked air inlet valve for venting purposes only.
6.2.3 Pressure Vacuum Valve/Relief
Valve Operation
At no time during the tank life cycle shall the pressure /
vacuum relief valve be manually operated (only exception
being onshore tank maintenance routine).
Any interference with this valve will affect its operational
functionality and thereby compromise safety and tank
integrity.
Note: The design of Chemical Tanks is primarily covered
by IMDG Code.
6.2.4 Tank Ancillaries Intervention
Intervention on any tank ancillary equipment is not
recommended. Intervention may only be permitted
following consultation with the tank manager/owner and
after a suitable risk assessment.
Example of Air Inlet Valve.
(Diagram of flowchart can be found in appendix 7.2)
4.1 Introduction
This describes the procedures to be followed to ensure
the safety and security of cargo during transportation to
and from sites.
4.2 Purpose
The purpose of the document is to ensure as far as is
reasonably practicable that cargo, as defined in section
4.4.1, is in a secure condition and free from any loose
items that could, if they fell, cause injury to people or
damage to plant, equipment, trucks, offshore supply
vessels and other road users.
4.3 Scope
The procedures shall apply at all sites both on and
offshore. It shall also apply at the premises of other
parties such as fabricators and vendors that are
responsible for packaging and preparing equipment for
delivery to sites that need to be lifted by crane or other
mechanical means.
Load Inspection Security Tagging Procedure Flowchart.
4.4 Definitions
4.4.1 Cargo
For the purposes of this guidance document cargo is
any item that is to be lifted by crane or other mechanical
means. The range of such items is diverse therefore it
is not practicable to attempt to list them all in this
document. However some examples are:
• CCU’s (Cargo Carrying Unit’s both closed and
open top)
• Tubulars (Slung or in frames).
• Specialist Vendor packages (Wire line units and other
well service packages).
• Waste skips.
• Helifuel tanks.
• Chemical tanks.
• Special loads (Fabrications).
4.4.2 Transportation
For the purposes of this guidance document
transportation shall be any means of conveying the
above items e.g. a truck or offshore Supply Vessel.
7
 4.4.3 Responsibilities
Management shall ensure that a competent person is
nominated to act as a Load Checker with the
responsibility to carry out a check of cargo prior to it
being lifted onto a means of transport.
As far as reasonably practicable such checks shall
ensure, that the cargo has been properly packed. This
does not absolve the person responsible for packing the
consignment from carrying out the task with all
reasonable care.
The checker shall not be responsible for the correct
packaging of the cargo unless they have personally
carried out the task. In the event that the checker does
suspect a load has not been properly packed he shall
bring this to the attention of the packer so that remedial
action can be taken.
Tank Inspection prior to loadout
8 13
4.4.4 Procedure Description
Before cargo is transferred to the supply vessel, the
checker shall carry out a visual inspection to ensure:
• There are no loose items on or beneath the loads,
which may fall. Items which are required for the
operations offshore that are not an integral part of the
tank should be shipped separately in closed
containers.
Note: this does not absolve the equipment originator
from taking all reasonable precautions to ensure the
load is fit for lifting in the first place.
• All securing mechanisms should be properly
engaged.
• The design of tanks is such that there should be no
protrusions out with the tank frame which would
present a snagging hazard.
• That nothing has been added to the tank to present a
snagging hazard.
Further information on carrying out safety checks is
contained in the UKOOA Guidance for the Safe
Packing and Handling of Cargo to and from Offshore
Installations.
6.1 Accessing the Tank
Access/climbing on top of a chemical tank should only be
undertaken as a last resort AND IS NOT
RECOMMENDED.
However, should this become absolutely necessary,
access should be gained by using the tank’s built in ladder,
(if fitted), or by utilising a custom-made tank access ladder.
Note: All tanks should have a fully enclosed grated or
plated top and where not in place then access to the top of
the tank should be avoided and only carried out following
a risk assessment and if the activity is accompanied by a
watchperson.
Suitable height safety arrangements in line with Working at
Heights Regulation must be in place should access to the
top of a tank be necessary.
Example of grated tank top.
Example of fall protection equipment.
6.2 Tank and Contents Handling
Among the reasons given for climbing on top of tanks are,
• Accessing the dip tube.
• Opening the tank lid to determine level.
• To take samples.
• To operate the vacuum breaker or open the hatch to
assist flow.
• To hook the crane on to the master link.
With the new design there is no actual reason to climb on
top of the tank. By the end of 2005, when the design
criteria and the application of the procedures within these
guidelines are implemented, the need to access the top of
the tank will be eliminated.
6.2.1 Sampling
Sampling of the tank contents should be carried out
through the 3/4” sample valve, an off-take from the main
discharge line at the base of the tank.
• Remove the cap, open the lever-operated foot valve.
• Place clean sample jar at sample valve discharge and
drain off sample carefully ensuring all potential for
drips/spillages/splashes are catered for in the risk
assessment.
• Replace protective cap, close valves.
• Adhere to precautions identified on Health and Safety
Data Sheets and the COSHH and Risk Assessments.
Note: No intervention on Air Inlet valve or Pressure/Vacuum
breaker valve is required for sampling.
 5.3 Safety Considerations Associated 4.4.5 Cargo Integrity Tagging INBOUND TAG
with Tank Use and
Once the load checker is satisfied the cargo is safe to
Risk Assessment be lifted he will attach a coloured security tie and label
to a suitable and conspicuous point on the load. The
Prior to undertaking any work associated with chemical
label must be initialled and dated by the checker.
tanks and their contents, personnel must consider all
aspects of safety and ensure safe working practices are The checker will not be responsible for ensuring that
adhered to. loads have been prepared properly. That will be the
responsibility of the packer/filler. The purpose of the
This can be effectively achieved by carrying out a Risk
security tie and label is to signify that the load is safe for
Assessment, which should consider as a minimum the
transportation. The packer/filler will confirm that he has
following safety questions:
properly packed the load on the manifest.
Tank condition and clear markings.
• Is a formal Risk Assessment required?
The packer/filler and checker may be the same person
• Is the tank located at the correct stowage point or
but where they are not, the checker must be satisfied as
designated area?
far as is reasonably practical that the packer has
• Is it a danger to other operations? prepared the load properly.
• Is it too close to the edge of a facility, equipment or other
Copies of the pre shipment checklist must be retained
cargo unit?
for audit purposes.
• Has the segregation of products been considered?
• When stowed are all the valves and fittings accessible? 4.4.6 Vendor Premises
• How can the contents be sampled and measured?
Prior to cargo being collected from the vendor’s
• Is it clear what the contents of the tank are? premises, the vendor shall ensure it is safe to be loaded
• Are the contents labelling clear and visible? on to the transporting vehicle. Once the vendor is
Onshore tank filling facility showing means of satisfied that the cargo is secure, the person appointed
• Is the lifting sling master link accessible without climbing
safe access. as checker must attach a yellow security tie and label to
on top of the tank frame?
the load and initial and date same.
• Is there a MSDS sheet available for the tank contents?
• Is there a danger of radiant heat from a flare or other 4.4.7 Quayside
source?
Once the cargo has been loaded and is in transit, there
• Has the tank been checked for loose items?
should be no occasion that should cause its security or
• Is double stacking unavoidable and if so are tanks and integrity to be jeopardised. However the following
Stacking posts compatible? checks that are good practice must be carried out at
• Is there any visible mechanical damage? mid points in the delivery of the cargo although the
• Is the tank load within the storage area weight limit? fitting of additional security ties and labels is not
required.
• Has backload product compatibility been established to
ensure hazardous chemical by products have not been • Outbound cargo arriving at the quayside shall be OUTBOUND TAG
formed? subjected to a further inspection prior to it being
• Is it possible for flammable vapours to escape to loaded onto the supply vessel.
atmosphere?
• Inbound cargo destined for onward shipping to a
• Has the tank been properly earthed by a competent Details on purchasing inspection tags can be obtained
vendor shall be inspected prior to it being loaded onto
person? from www.stepchangeinsafety.net (company specific tags
the transporting vehicle
may differ)
A flowchart depicting the Load Security Inspection
Procedure (LSIP) can be found in appendix 7.2 of this
12 guidance. 9
 5.1 Good Practice Chemical Tank Inspection Illustrated Checklist 5.2 Recommended Checks - Prior to
Tank Fill for Preparation for
Dispatch Onshore/Offshore
The following checks when working with tanks and their
contents should be carried out as a minimum but not
limited to:
• Check the condition of the frame and ensure there are no
signs of excessive corrosion or deformation.
• Ensure that the tank is not overloaded, (volume of product
in tank x product density = payload)
• Ensure there is no evidence or signs of leakage.
• Check that all certification is fully in date at the time of use,
and has sufficient test period remaining so as to prevent
certification expiring when offshore.
• Ensure that any old hazard and supply labelling has been
removed
• Affix all relevant hazard and supply labelling (where
required).
• Ensure all unit markings clear and legible
• Ensure there is no obvious damage to lifting pad-eyes,
etc.
• Ensure there are no obvious structural defects or
mechanical damage
• Check all valve assemblies for damage and ensure end
caps are in place. Plastic ties as indicators of valve
closure are recommended.
Chemical Tank Illustrated Checklist
10
Pre-filling Tank Checklist.
• Check the manlid is securely closed and in good
condition, plastic indication ties are recommended.
• Check the lifting equipment for any signs of damage.
• Ensure the master link or fifth leg of the lifting assembly is
stowed on the outside of the tank frame for ease of
connection to the crane both onshore and offshore.
Ensure this is secured to the tank prior to transportation
once onshore.
• Check the grating for any signs of damage or loose
fittings.
• Check the top surfaces for any potential loose or potential
dropped objects.
• Check the forklift pockets for loose items such as tools,
stones, timber, etc.
Note: Offshore tanks are being fitted with air inlet valves at
the same end as the main bottom discharge valve. This is
to remove the need for personnel to climb on top of the
tank to vent prior to discharge. This valve is sometimes
difficult to see through the frame of the tank and must be
checked for security.
Defects: - any defects noted within the above are to be
formally reported. Thereafter the tank should be isolated
and remedial action taken in accordance with the duty
holders responsibilities. (Refer to Outbound/Inbound Tank
summary checklist appendix 7.1 and Pre-fill tank checklist
7.3)
11
 5.1 Good Practice Chemical Tank Inspection Illustrated Checklist 5.2 Recommended Checks - Prior to
Tank Fill for Preparation for
Dispatch Onshore/Offshore
The following checks when working with tanks and their
contents should be carried out as a minimum but not
limited to:
• Check the condition of the frame and ensure there are no
signs of excessive corrosion or deformation.
• Ensure that the tank is not overloaded, (volume of product
in tank x product density = payload)
• Ensure there is no evidence or signs of leakage.
• Check that all certification is fully in date at the time of use,
and has sufficient test period remaining so as to prevent
certification expiring when offshore.
• Ensure that any old hazard and supply labelling has been
removed
• Affix all relevant hazard and supply labelling (where
required).
• Ensure all unit markings clear and legible
• Ensure there is no obvious damage to lifting pad-eyes,
etc.
• Ensure there are no obvious structural defects or
mechanical damage
• Check all valve assemblies for damage and ensure end
caps are in place. Plastic ties as indicators of valve
closure are recommended.
Chemical Tank Illustrated Checklist
10
Pre-filling Tank Checklist.
• Check the manlid is securely closed and in good
condition, plastic indication ties are recommended.
• Check the lifting equipment for any signs of damage.
• Ensure the master link or fifth leg of the lifting assembly is
stowed on the outside of the tank frame for ease of
connection to the crane both onshore and offshore.
Ensure this is secured to the tank prior to transportation
once onshore.
• Check the grating for any signs of damage or loose
fittings.
• Check the top surfaces for any potential loose or potential
dropped objects.
• Check the forklift pockets for loose items such as tools,
stones, timber, etc.
Note: Offshore tanks are being fitted with air inlet valves at
the same end as the main bottom discharge valve. This is
to remove the need for personnel to climb on top of the
tank to vent prior to discharge. This valve is sometimes
difficult to see through the frame of the tank and must be
checked for security.
Defects: - any defects noted within the above are to be
formally reported. Thereafter the tank should be isolated
and remedial action taken in accordance with the duty
holders responsibilities. (Refer to Outbound/Inbound Tank
summary checklist appendix 7.1 and Pre-fill tank checklist
7.3)
11
 5.3 Safety Considerations Associated 4.4.5 Cargo Integrity Tagging INBOUND TAG
with Tank Use and
Once the load checker is satisfied the cargo is safe to
Risk Assessment be lifted he will attach a coloured security tie and label
to a suitable and conspicuous point on the load. The
Prior to undertaking any work associated with chemical
label must be initialled and dated by the checker.
tanks and their contents, personnel must consider all
aspects of safety and ensure safe working practices are The checker will not be responsible for ensuring that
adhered to. loads have been prepared properly. That will be the
responsibility of the packer/filler. The purpose of the
This can be effectively achieved by carrying out a Risk
security tie and label is to signify that the load is safe for
Assessment, which should consider as a minimum the
transportation. The packer/filler will confirm that he has
following safety questions:
properly packed the load on the manifest.
Tank condition and clear markings.
• Is a formal Risk Assessment required?
The packer/filler and checker may be the same person
• Is the tank located at the correct stowage point or
but where they are not, the checker must be satisfied as
designated area?
far as is reasonably practical that the packer has
• Is it a danger to other operations? prepared the load properly.
• Is it too close to the edge of a facility, equipment or other
Copies of the pre shipment checklist must be retained
cargo unit?
for audit purposes.
• Has the segregation of products been considered?
• When stowed are all the valves and fittings accessible? 4.4.6 Vendor Premises
• How can the contents be sampled and measured?
Prior to cargo being collected from the vendor’s
• Is it clear what the contents of the tank are? premises, the vendor shall ensure it is safe to be loaded
• Are the contents labelling clear and visible? on to the transporting vehicle. Once the vendor is
Onshore tank filling facility showing means of satisfied that the cargo is secure, the person appointed
• Is the lifting sling master link accessible without climbing
safe access. as checker must attach a yellow security tie and label to
on top of the tank frame?
the load and initial and date same.
• Is there a MSDS sheet available for the tank contents?
• Is there a danger of radiant heat from a flare or other 4.4.7 Quayside
source?
Once the cargo has been loaded and is in transit, there
• Has the tank been checked for loose items?
should be no occasion that should cause its security or
• Is double stacking unavoidable and if so are tanks and integrity to be jeopardised. However the following
Stacking posts compatible? checks that are good practice must be carried out at
• Is there any visible mechanical damage? mid points in the delivery of the cargo although the
• Is the tank load within the storage area weight limit? fitting of additional security ties and labels is not
required.
• Has backload product compatibility been established to
ensure hazardous chemical by products have not been • Outbound cargo arriving at the quayside shall be OUTBOUND TAG
formed? subjected to a further inspection prior to it being
• Is it possible for flammable vapours to escape to loaded onto the supply vessel.
atmosphere?
• Inbound cargo destined for onward shipping to a
• Has the tank been properly earthed by a competent Details on purchasing inspection tags can be obtained
vendor shall be inspected prior to it being loaded onto
person? from www.stepchangeinsafety.net (company specific tags
the transporting vehicle
may differ)
A flowchart depicting the Load Security Inspection
Procedure (LSIP) can be found in appendix 7.2 of this
12 guidance. 9
 4.4.3 Responsibilities
Management shall ensure that a competent person is
nominated to act as a Load Checker with the
responsibility to carry out a check of cargo prior to it
being lifted onto a means of transport.
As far as reasonably practicable such checks shall
ensure, that the cargo has been properly packed. This
does not absolve the person responsible for packing the
consignment from carrying out the task with all
reasonable care.
The checker shall not be responsible for the correct
packaging of the cargo unless they have personally
carried out the task. In the event that the checker does
suspect a load has not been properly packed he shall
bring this to the attention of the packer so that remedial
action can be taken.
Tank Inspection prior to loadout
8 13
4.4.4 Procedure Description
Before cargo is transferred to the supply vessel, the
checker shall carry out a visual inspection to ensure:
• There are no loose items on or beneath the loads,
which may fall. Items which are required for the
operations offshore that are not an integral part of the
tank should be shipped separately in closed
containers.
Note: this does not absolve the equipment originator
from taking all reasonable precautions to ensure the
load is fit for lifting in the first place.
• All securing mechanisms should be properly
engaged.
• The design of tanks is such that there should be no
protrusions out with the tank frame which would
present a snagging hazard.
• That nothing has been added to the tank to present a
snagging hazard.
Further information on carrying out safety checks is
contained in the UKOOA Guidance for the Safe
Packing and Handling of Cargo to and from Offshore
Installations.
6.1 Accessing the Tank
Access/climbing on top of a chemical tank should only be
undertaken as a last resort AND IS NOT
RECOMMENDED.
However, should this become absolutely necessary,
access should be gained by using the tank’s built in ladder,
(if fitted), or by utilising a custom-made tank access ladder.
Note: All tanks should have a fully enclosed grated or
plated top and where not in place then access to the top of
the tank should be avoided and only carried out following
a risk assessment and if the activity is accompanied by a
watchperson.
Suitable height safety arrangements in line with Working at
Heights Regulation must be in place should access to the
top of a tank be necessary.
Example of grated tank top.
Example of fall protection equipment.
6.2 Tank and Contents Handling
Among the reasons given for climbing on top of tanks are,
• Accessing the dip tube.
• Opening the tank lid to determine level.
• To take samples.
• To operate the vacuum breaker or open the hatch to
assist flow.
• To hook the crane on to the master link.
With the new design there is no actual reason to climb on
top of the tank. By the end of 2005, when the design
criteria and the application of the procedures within these
guidelines are implemented, the need to access the top of
the tank will be eliminated.
6.2.1 Sampling
Sampling of the tank contents should be carried out
through the 3/4” sample valve, an off-take from the main
discharge line at the base of the tank.
• Remove the cap, open the lever-operated foot valve.
• Place clean sample jar at sample valve discharge and
drain off sample carefully ensuring all potential for
drips/spillages/splashes are catered for in the risk
assessment.
• Replace protective cap, close valves.
• Adhere to precautions identified on Health and Safety
Data Sheets and the COSHH and Risk Assessments.
Note: No intervention on Air Inlet valve or Pressure/Vacuum
breaker valve is required for sampling.
 6.2.2 Discharging
When discharging tanks containing flammable product,
the tank should be bonded, (earthed by a competent
person) in order to prevent a build up of static electricity
and subsequent danger of ignition/explosion.
• Remove drip cap from the main discharge outlet and
connect hose to the main discharge outlet valve.
• Remove end caps from air inlet valve, then open air inlet
valve manually.
• Open the lever operated foot valve and main discharge
valve, (in that order), to allow the tank to discharge.
When discharging the tank, the following actions should be
considered:
• Ambient temperature, viscosity and specific gravity, all
may inhibit free flow.
• Poor flow - on no account should pneumatic air be used
to assist with the process.
Note: Operators should be aware of the following hazard.
The design of the manual air inlet valve is such that any
build up of pressure will be vented clear of personnel when
the valve is opened.
Upon completion of discharging the tank contents:
• Ensure all valves are closed, end caps are refitted and
secured accordingly.
14 Example of vacuum/relief valve fitted with flame arresting gauze.
Where tanks are fitted with manual Air Inlet Valves (AIV) as
recommended by these guidelines this valve will be
marked air inlet valve for venting purposes only.
6.2.3 Pressure Vacuum Valve/Relief
Valve Operation
At no time during the tank life cycle shall the pressure /
vacuum relief valve be manually operated (only exception
being onshore tank maintenance routine).
Any interference with this valve will affect its operational
functionality and thereby compromise safety and tank
integrity.
Note: The design of Chemical Tanks is primarily covered
by IMDG Code.
6.2.4 Tank Ancillaries Intervention
Intervention on any tank ancillary equipment is not
recommended. Intervention may only be permitted
following consultation with the tank manager/owner and
after a suitable risk assessment.
Example of Air Inlet Valve.
(Diagram of flowchart can be found in appendix 7.2)
4.1 Introduction
This describes the procedures to be followed to ensure
the safety and security of cargo during transportation to
and from sites.
4.2 Purpose
The purpose of the document is to ensure as far as is
reasonably practicable that cargo, as defined in section
4.4.1, is in a secure condition and free from any loose
items that could, if they fell, cause injury to people or
damage to plant, equipment, trucks, offshore supply
vessels and other road users.
4.3 Scope
The procedures shall apply at all sites both on and
offshore. It shall also apply at the premises of other
parties such as fabricators and vendors that are
responsible for packaging and preparing equipment for
delivery to sites that need to be lifted by crane or other
mechanical means.
Load Inspection Security Tagging Procedure Flowchart.
4.4 Definitions
4.4.1 Cargo
For the purposes of this guidance document cargo is
any item that is to be lifted by crane or other mechanical
means. The range of such items is diverse therefore it
is not practicable to attempt to list them all in this
document. However some examples are:
• CCU’s (Cargo Carrying Unit’s both closed and
open top)
• Tubulars (Slung or in frames).
• Specialist Vendor packages (Wire line units and other
well service packages).
• Waste skips.
• Helifuel tanks.
• Chemical tanks.
• Special loads (Fabrications).
4.4.2 Transportation
For the purposes of this guidance document
transportation shall be any means of conveying the
above items e.g. a truck or offshore Supply Vessel.
7
 3.10 Documentation and Labelling
of Tanks
Tank contents labels are to be clear and visible on all sides
to facilitate deck loading and avoid incorrect decanting.
On completion of all checks, an Outbound/Inbound Tank
summary checklist should be completed for each load
being dispatched offshore or returned onshore. The
checklist should then be placed in the document pouch
along with relevant shipping details.
3.11 Tank Life Cycle Flowchart
Enclosed Tank Lid.
Attached for reference (front cover) is a flowchart which
represent the life cycle of a tank, it also identifies the
persons associated with each stage; their duties and key
information to ensure that operations and works associated
with it are managed safely and effectively.
3.12 Backloading of Chemicals
and Waste
Where backloading of chemicals or waste is required then
it is recommended dedicated tanks should be requested to
avoid cross contamination.
Clear labelling and documentation are essential, however
there may be occasions when previously used tanks must
be used. In all cases of backloading, a risk assessment is
required which would consider all aspects in section 5.3 as
a minimum and requires the authority of the offshore duty
holder.
Where waste or contaminated chemical is to be
backloaded, appropriate labelling MSDS should be
obtained and fixed to the tank that correctly identifies the
tank contents and hazards. All waste or contaminated
chemicals should be sent to your responsible Waste
Management Contractor for disposal. Only part used and
non contaminated chemicals should be returned to the
original Provider in the tank with original labels and MSDS.
Offshore Unloading, demonstrating potential for snagging
(open tanks not meeting guidelines).
6 15
6.3 Hooking On/Off
When in the stowed position, the tank lifting accessories
should be located hanging down the outside of the tank
frame. This allows easy access to the master link, when
hooking on/off the crane hook. This also avoids the
necessity for climbing on top of the tank.
Particular care must be taken to ensure that the lifting
accessories and crane hook does not inadvertently
snag on the tank framework or ancillaries causing the
possibility of premature movement of the tank.
View showing the correct position and height of the master link
and the tank slinging arrangement.
Storage Areas.
6.4 Stacking
Double stacking of chemical tanks offshore should be
actively discouraged and only sanctioned where it
becomes absolutely essential and following an appropriate
risk assessment.
Personnel should never climb on to a double-stacked
chemical tank. Where deemed required a thorough and
robust risk assessment process with mitigating measures
and actions is required.
IDEALLY THE TANKS SHOULD BE UNSTACKED.
6.5 Labelling and Documentation
All cargos, including backloaded cargos of dangerous
goods shall be correctly declared, packaged and labelled,
secured, placarded and documented, and segregated in
accordance with the regulations and MGN 282(M) and
IMDG Code plus subsequent notices issued by the
Maritime and Coastguard Authority.
To assist the Master of the Offshore Supply Vessel in
planning the cargo stowage to ensure that segregation of
dangerous goods is maintained, it is a requirement that:
• The Offshore Supply Vessel is advised by the quayside
service provider of the quantity and nature of dangerous
goods prior to loading.
• The Offshore Supply Vessel is advised by the OIM
(Offshore Installation Manager) / Duty Holder or
nominated deputy, of the quantity and nature of
backloaded dangerous goods prior to loading.
In the case of the backload, it is the responsibility of the
consignor/packer to ensure that the backloaded goods are
backloaded in accordance with the requirements of the
IMDG code. That means correctly declared, packaged,
labelled, secured, placarded and with the correct
documentation. In addition consideration must also be
given to the order of backloading to ensure that the
segregation requirements can be complied with.
It is the responsibility of the consignee/receiver of any
dangerous goods to remove any old placards affixed to the
container prior to its re-use.
 6.6 Receipt and Despatch
Upon receipt of any tank always ensure:
• The lifting accessories and padeyes are in good
condition and not damaged.
• The tank has not been damaged in transit.
• The product and hazard labels are visible and intact.
• A Health and Safety data sheet is available for the
contents.
• Retrieve all documents from document pouch.
Prior to dispatch from offshore always ensure:
• The tank and frame are undamaged.
• The tank manway lid is securely fastened.
• The discharge valve and sampling point end caps are
fitted.
• The product and hazard labels are appropriate for the
contents and are visible or where the tank is empty all
labels have been removed.
• All relevant documentation has been inserted into
document pouch.
The instructions identified above, are for general guidance.
It is the ultimate responsibility of all users and handlers to
ensure that all operating and safety procedures are strictly
observed.
Refer to Outbound/Inbound Tank Summary Checklist
(Appendix 7.1).
16
6.7 Lifting Assemblies and Slinging
The lifting and slinging of tanks falls within regulations
below and as such will not be covered in this document.
For reference the key documents are:
• Lifting Operations and Lifting Equipment Regulations
1998 SI2307, (LOLER).
• Regulation 9 of LOLER, Approved Code of Practice,
(HSE Books L113).
• Step Change in Safety Lifting and Mechanical
Handling Guidelines.
3.8 Document Pouches/Load
Security Tagging
Marshalling of tanks utilising a tagging method, (Load
security Inspection Procedure See section 4), carried out
by the nominated responsible person for freight forwarding
and return is a recommended practice.
Document pouches should be present and clearly
identified on the tank. Where this is not the case, remedial
action to ensure the effective communication of the tank
contents details must be arranged.
There shall be a designated responsible person offshore to
both accept and dispatch chemical tanks.
Contents documentation shall be kept in the document
pouch and remain with the tank throughout it’s cycle and
be updated as and when appropriate (reference
flowchart).
3.9 Responsibilities and Training
Training of personnel with ‘hands on’ responsibility for
tanks (including content) is considered essential.
It is recommended the information contained in this
guidance document be used only as a supplement to
further training.
These guidelines are aimed at providing supervision with
sufficient training material from which they can develop
their own specific training programme, for personnel who
are expected to work with chemical tanks or their contents.
Example of Document Pouch.
It is recommended that there are nominated persons with
assigned responsibilities for the management and
handling of all aspects of chemical tanks both onshore and
offshore. Ideally this person should also be responsible for
baskets, CCU’s (Cargo Carrying Units) etc. to ensure a full
overview of the freight situation, risks and controls from an
organisational and management perspective.
Typical duties would include:
• Receipt and dispatch
• Lifting and discharging of contents
• Document control
• Participation in associated risk assessments
• Contents and tank monitoring & management
• Tank labelling compliance and update/change
management
• Integrity of the manway lid and discharge valve telltale
In conjunction with the above offshore personnel handling
or using tanks should receive appropriate training, which
includes:
LIFTING AND MECHANICAL HANDLING OPERATIONS
MANUAL HANDLING
RISK ASSESSMENT
CHEMICAL HANDLING (COSHH)
ENVIRONMENTAL ISSUES
SAFETY OBSERVATION SYSTEMS
The Step Change in Safety Lifting and Mechanical
Handling Guidance contains further information on training
and competency.
Inspection Security Tag. 5
 3.3 Tank Access 3.7 Risk Assessment 7.1 Outbound/Inbound Chemical Tanks Checklist

Working on the top of the tank should only be undertaken It is recommended that risk assessments should be carried The following checklist is a revision of the existing UKOOA tank checklist, which both updates and clarifies requirements and
as a last resort AND IS NOT RECOMMENDED. However out for the following established operations: checklist contents to further enhance the management and safety associated with the use of tanks.
should this be absolutely necessary then a risk
assessment must be conducted and all appropriate safety • Accessing the tops A key point and change recommended is that for every tank there exists a single corresponding checklist, which follows the
precautions be implemented. Reference should be made • Sampling and Dipping tank in its journey.
to the Working at Height Regulations. • Stacking
Tank ID: Product Name:

Access to the top of the tank should be via the permanent • Discharging & Filling Customer Details Offshore Location:

access ladder (if fitted), portable ladder or a suitable work • Filling, Discharging and including Hose Assembly
Does Test Plate have at least a full month remaining? Yes/No Tank Supplier:
platform and appropriate fall arrest equipment must be Manual Handling
Last Test Date:
worn. • Crane lifts inbound/outbound Collection Address (if different from above): Ready for Collection:
Date:
Access requirements to both valving and lifting assembly • Backloading of chemicals/waste Time:

must be considered when positioning or laying down • Opening of manlid for loading of chemicals
tanks. • Access to the lifting assembly master link when tanks Item No Cargo Ref Cargo ID Product Total “Lift” IMDG Class / UN Customs Status
Quantity litres Weight (Kg) No
are stacked 1
Opening of the tank manway lid is not permissible offshore
unless access is required for backloading, which would • Chemical compatibility
Check Tank / Cargo Checklist Chemical Shipper Offshore Back Shipper Onshore
No Provider Outbound Receiver Load Inbound Receiver
then fall under special circumstances and should be Note: Such assessments should include worker exposure Operative
subject of a risk assessment. Confirm that (a) Tank is clean (and dry depending on the product to be filled),
risk, the Control Of Substances Hazardous To Health or (b) Tank is “dedicated” and previously contained the SAME product.
(Chemical Provider and Back Load Operative only, as appropriate)
(COSHH), and reference the appropriate Material Safety
1 Have all old labels been removed?
3.4 Contents Measuring IMDG Code Data Sheets (MSDS’s). 2 Have copies of all relevant certificates, dangerous goods, MSDS’s and TREM
cards been dispatched with the tank?
3 Are there any signs of leaking chemical?
Any contents measuring device fitted to tank must conform 4 Are all valves closed, and caps refitted?
to current IMDG Code requirements. 5 Has the main valve been tagged and tie wrapped closed?
6 Is manlid closed and fully secured and has security tag been fitted?
7 Is special coupling attached (if applicable)? (Chemical Provider and Back
Loader only)
3.5 Contents Management 8 Have you checked the gross weight against SWL?
9 Does the lifting set details match those on the Data / Inspection plate?
Clarity of tank contents being dispatched or returned must 10 Where appropriate, has dangerous goods cargo been completed and relevant
authorities notified as per IMDG Code?
exist through labelling and documentation.
11 Product Label is on each side?
12 Hazard Label is on each side?
Offshore procedures regarding the return of good or spent 13 Has Tank been visually checked for any obvious damage (frame, gratings,
chemicals must be clear and supported by correct slings, lifting points, fittings etc)?
14 Have you checked for and removed any loose objects / debris on the unit or in
labelling and accompanying documentation to ensure the forklift pockets and fitted / checked the Load Security Inspection Tag?
waste legislation compliance and to facilitate handling/ 15 Have appropriate declarations been made for waste backload?
*Any “No” above will result in non-shipment
disposal on return.
Sign Off For All Of the Above Checks

All tanks should be fitted with a telltale, (tiewrap or similar), Name of Yard Operative: Name of Shipper Inbound Operative:
Signature of Yard Operative: Signature of Shipper Inbound Operative:
on the tank manway lid and main discharge valve to verify
Date: Date:
the tank has not been opened.
Name of Shipping Outbound Operative: Name of Offshore Receiver:
Signature of Shipping Outbound Operative: Signature of Offshore Receiver:
3.6 Checklists Date: Date:

Name of Back Load Operative: Name of Onshore Receiver:

A checklist for tanks is included in the “UKOOA guidance
Signature of Backload Operative: Signature of Onshore Receiver:
for Safe Packaging and Handling of Cargo to and from Date: Date:
Offshore Locations”, however this has been expanded
upon with the Outbound/Inbound summary ticket Step Change in Safety Task Risk Assessment Guide
4 17
(appendix 7.1) www.stepchangeinsafety.net
 7.2 Load Security Inspection Procedures (LSIP)
The following flowchart depicts the procedure to be followed prior to any movements of chemical tanks.
This procedure has been adapted from the Talisman Energy (UK) Ltd. process for ensuring the safety and security of cargo during transportation to and
To this end, the term ‘Unit’ can be taken to be CCU’s (Cargo Carrying Units both closed and open top), Tubulars (slung or in frames), Waste Skips,
Helifuel Tanks, Chemical Tanks, Specialist Loads (wire line units and other well service packages) Suppliers/Users of the above should nominate a Load
Checker within their organisation to ensure that the procedure is carried out and suitable verification methods implemented to provide an audit trail.
Start
Onshore Load Checker
Prior to loading of
Container/Tank, nominated
Load Checker shall carry
out a visual inspection of
the unit to ensure that all
items are properly packed,
container doors are
securely closed, and that
no loose items are left lying
on the unit in any place.
Onshore Load Checker
Informs the relevant
person that the unit has
been checked and the
Load Security Tag and
Label attached.
Transporter/Shipper
Prior to loading
(Vehicles/Vessel)
Transporter/Shipper
checks to ensure that
YELLOW Load Security
Tag and Label have been
attached to unit.
End of Process
18
The points made within this section apply to all new and 3.2 Handling
existing tanks, with an overall objective that all current tank
stock can fall in line with this guidance by the end of 2005. The practice of double stacking tanks offshore is not
recommended and should be avoided. Where deemed
necessary it should be by exception only and a formal risk
Load Security Inspection Procedure 3.1 Design assessment is recommended followed by direct
supervision of the activity.
All valves should be suitably placed to allow safe access
from offshore installations.
and be accessible from ground/deck level. When double stacking is being practiced then access to
the crane master link must be independent of the tank, by
All tanks to have fully grated or flat plate tops to ensure
means of a suitable access platform or ladder.
complete closure
There will be no crane movement other than attaching the
All tanks to have non-slip paint coated to access ladders
crane hook to the master link until all personnel have
where fitted.
withdrawn from the immediate vicinity of the tank and the
Onshore Load Checker All pipefittings will be to a recognised standard banksman/loadhandler has given the all clear to the crane
Is the unit packed
Does the problem Arrangers for the person/s operator.
properly with no No concern loose No responsible for
loose items found packing/securing the unit All tanks to have a sling configuration that allow easy
items left on unit?
anywhere on unit? to carry out necessary access to the master ring without accessing/climbing on
remedial action.
the tank in any way
All tanks will have a functional sealable document pouch
Yes Yes
fitted
Onshore Load Checker Onshore Load Checker Note: The Design of Chemical Tanks is primarily covered
Affixes YELLOW Load Removes any loose items by the IMDG code.
Security Tie and Label to from unit prior to loading
the unit. operations.
End-User of Cargo
Unloads/Empties unit and,
Has Load Security Transporter/Shipper where applicable, packs
Tag and Label Yes the unit for return to
Transports/Ships unit to
been attached to Beach and informs
relevant destination.
unit? Offshore Load Checker
that unit is ready for
shipping.
No
Offshore Load Checker
Transporter/Shipper Prior to loading, Offshore
Load Checker carries out
Refuses to transport/ship Is the unit packed a visual inspection of the
unit until Load Security securely with no unit to ensure that all
Tag and Label is attached
loose items found items are securely
(thereby indicating that
anywhere on unit? packed, container doors
the load has been
are closed, and that no
security checked).
Yes loose items are left lying
on the load in any place.
No
Offshore Load Checker Offshore Load Checker
Attaches ORANGE Load Arranges for the person
Security Tag and Label responsible for
informs relevant person packing/securing the unit
that unit is ready to be to carry out the necessary
shipped back to beach. remedial action. Typical view of a fully grated tank. Typical access ladder. Positioning of Masterlink. 3
 The guidance identified within this publication is aimed at 7.3 Pre-Fill Tank Checklist
ensuring personnel, whose duties involve the handling and
transportation of chemical tanks and their contents at The following checklist is a generic checklist for use prior to tank filling.
offshore installations, are aware of the hazards and
precautions which must be considered during tank
PRE-FILLING TANK CHECKLIST
operations.
Tank ID: Date:
The objective of this guidance is to increase awareness of
key factors relating to chemical tanks and contents
handling and to reinforce existing knowledge with 1 CHECK SERIAL NUMBERS, TARE & BLACK PATCH STICKER ❑
additional information.
2 CONDITION OF TANK FRAME FOR DAMAGE ETC ❑
To achieve maximum impact, supervision should follow up
safety presentations by talking to appropriate personnel 3 EXAMINE TANK VESSEL & CRADLES ❑
about tank handling techniques, and their understanding 4 CHECK END CAPS ARE SUPPLIED AND SECURED ❑
of the required safety standards. Subsequent monitoring
of chemical tank operations should be undertaken to 5 CHECK CONDITION / OPERATION OF FOOT VALVE & OPERATING LEVER ❑
ensure safety considerations have been raised to, and
6 CHECK CONDITION OF DISCHARGE VALVE ❑
maintained at, an acceptable level.
7 CHECK CONDITION OF SAMPLE / DRAIN VALVE ❑

8 CHECK DUST CAP & SECURING WIRE ON DISCHARGE / SAMPLE VALVES ❑

9 CHECK CONDITION OF EARTHING POINT ❑

10 CHECK CONDITION OF DOCUMENT TUBE HOLDER ❑

11 CHECK CONDITION OF DIP STICK HOLDER & DIP STICK WHERE FITTED ❑

12 CHECK LIFTING LUGS FOR DAMAGE ❑

13 CHECK LIFTING SLINGS, SHACKLES & SPLIT PINS ❑

14 CHECK TANK MANWAY LID ❑

15 CHECK CONDITION OF TANK MANWAY LID, SWING BOLTS & HINGE PIN ❑

16 CHECK CONDITION OF TANK-LID, INCLUDING LID SEAL ❑

17 CHECK TANK INTERIOR FOR CLEANLINESS INCLUDING FOOT VALVE & SAMPLE VALVE ❑

18 CHECK CONDITION OF PRESSURE VACUUM RELIEF VALVE & GAUZE ❑

19 CHECK CONDITION OF DIP VALVE, DUST COVER & RETAINING WIRE ❑

20 CHECK THAT TEST DATA PLATE IS FIXED & TANK MARKINGS / CHEVRONS ARE LEGIBLE ❑

21 COMPLETE CERTIFICATE OF CLEANLINESS & PASS TO RELEVANT PERSON FOR ACTION ❑

DETAILS OF DAMAGE OR DEFECTS FOUND:

Step Change in Safety Fatality Report

2 19
www.stepchangeinsafety.net
 7.4 Tank / Vessel Types and General This Guideline, Design and Handling of Chemical Tanks From an operational aspect, key issues addressed include
Arrangements has been compiled as part of the Step Change In Safety recommendations to eliminate:
overall objective of improving safety within the Oil & Gas
industry. • access to the top of a tank,
INSPECTED BY:
SIGNATURE: • manual operation of the pressure/vacuum valve.
The Guideline was commissioned due to offshore industry
DATE:
concerns over the design and safe use of cargo carrying Further recommendations on :
units and portable chemical tanks, and fatalities offshore
• contents measurement,
relating to the handling of these units (See Step Change in
Safety Fatality Report). • tank access
• back loading fluids from offshore facilities are also
The objective of this Guidance is to provide information to included.
Designer, Manufacturer, Owner and End User of IMO
Chemical Transport Tanks, which will lead to rationalisation The Guidance also outlines the risk assessment approach
of equipment and practices used within the industry thus for any operations out with the Guidance.
reducing accidents or incidents during handling
The Guidance provides assistance to meet these
operations.
recommendations by providing:
Example of 600 gallon, (2900 litres), vertical tank.
From a design perspective, the guidance looks at key
• a Tank Lifecycle Flowchart,
issues. It recommends that:
• Tank Inspection Checklists,
• valves requiring manual operation,
• an Outbound/Inbound Chemical Tanks Checklist
• the lifting accessories master link, outlining competency levels for personnel.

be accessible from deck or ground level. This will reduce

the need to access the top of the tank in the offshore
environment.

Example of 1000 gallon, (4800 litres), horizontal tank.

20 Example of 500 gallon tank. Comparison of new and old tank design (600 imperial gallons). Horizontal Chemical Tank. Supply Vessel Offloading. Vertical Chemical Tank. 1
6 TANK PRACTICES 13 7.5 Bottom Outlet Valve Arrangement
6.1 Accessing the Tank 13
6.2 Tank and Contents Handling 13
6.2.1 Sampling 13
6.2.2 Discharging 14
Main Discharge Valve
6.2.3 PV valve/Relief valve operation 14
6.2.4 Tank Ancillaries Intervention 14 Lever Operated Foot Valve
6.3 Hooking On/Off 15
Sampling Point Valve
6.4 Stacking 15
End Cap
End Cap
6.5 Labelling And Documentation 15
6.6 Receipt and Dispatch 16
6.7 Lifting Assemblies and Slinging 16

7 APPENDICES 17 Bottom outlet valve arrangement highlighting the main discharge valve,
7.1 Outbound/Inbound Tank Checklist 17 the sample point and the control handle for the secondary tank discharge valve.

7.2 Load Security Inspection Procedures Flowchart 18

7.3 Pre - Fill Tank Checklist 19 7.6 Ancillaries on the Tank Top
7.4 Tank / Vessel Types and General Arrangements 20
7.5 Bottom Outlet Valve Arrangement 21
7.6 Ancillaries on the Tank Top 21

8 REFERENCES AND ACKNOWLEDGMENTS 22

Manway Lid
(Tank Top Lid / Man Lid)

Air Inlet Valve

Pressure Vacuum
Relief Valve (not to be
manually operated)

View of the Manway Lid and and Pressure / Tank Vacuum Valve (grating removed for picture clarity).

21
 • BS EN 12079: 1999 - Offshore Containers - Design, Acknowledgments 1 INTRODUCTION 1
Construction, Testing, Inspection & Marking
Step Change would like to thank the following
• Control of Substances Hazardous to Health Regulations organisations for their contributions in developing this 2 SCOPE 2
SI 1999/437 (COSHH) guidance:

• DNV Certification Notes 2.7-1 AMEC 3 SUMMARY / RECOMMENDATION 3

• IMDG Code - International Maritime Dangerous Goods 3.1 Design 3
Baker Petrolite
Code 3.2 Handling 3
BP
3.3 Tank Access 4
• International Maritime Organisation
Conserve Oilfield Services Ltd 3.4 Contents Measuring Gauge 4
• Lifting Operations and Lifting Equipment Regulations
3.5 Contents Management 4
SI 1998 / 2307, (LOLER) Elected Safety Representatives Network
3.6 Checklists 4
• Manual Handling Operations Regulations SI 1992 / 2793 Ferguson Seacabs Ltd
3.7 Risk Assessment 4
• Merchant Shipping (Dangerous Goods and Marine Harran Ltd 3.8 Document Pouches/Load Security Tagging 5
Pollutants) regulations SI 1998 / 2367 3.9 Responsibilities and Training 5
Marathon
• PUWER - Provision and Use of Work Equipment 3.10 Documentation and Labelling of Tanks 6
Marathon Oil
Regulations SI 1998 / 2306 3.11 Tank Life Cycle Flowchart 6
Nalco Ltd 3.12 Backloading of Chemicals and Waste 6
• Regulation 9 of LOLER, Approved Code of Practice,
(HSE Books L113) Shell Exploration and Production UK
4 LOAD SECURITY INSPECTION PROCEDURE 7
• Step Change in Safety Fatality Report Suretank Ltd
4.1 Introduction 7
• Step Change in Safety Lifting and Mechanical Handling Swire Oilfield Services Ltd 4.2 Purpose 7
Guidance (re-issue 2004)
Talisman Energy 4.3 Scope 7
• Step Change in Safety Task Assessment Guidance (2nd 4.4 Definitions 7
edition 2003) Transocean
4.4.1 Cargo 7
• The Carriage of Dangerous Goods by Road Regulations, 4.4.2 Transportation 7
SI 1996 / 209
4.4.3 Responsibilities 8
• UKOOA / Chamber of Shipping Guidelines for the Safe 4.4.4 Procedure Description 8
Management and Operation of Offshore Support Vessels 4.4.5 Cargo Integrity Tagging 9
(Issue 4th November 2002)
4.4.6 Vendor Premises 9
• UKOOA Guidance for the safe Packing and Handling of 4.4.7 Quayside 9
Cargo to and from Offshore Installations (latest edition)

• Working at Height Regulations SI 2005 / 735 5 SAFETY CONSIDERATIONS AND CHECKS 10

5.1 Good Practice Chemical Tank Inspection Illustrated Checklist 10
5.2 Recommended Checks - Prior to Tank Fill for Preparation for Dispatch Onshore/Offshore 11
5.3 Safety Considerations Associated with Tank Use and Risk Assessment 12

• Step Change in Safety website: www.stepchangeinsafety.net

22
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