1. Design, construction and operation of Workshops for Petroleum road tanker maintenance
Robert Harris

2. The 2007 Code How we made the decision to update it
How it’s different from the 1998 Code
What’s in it
How it’s useful to you

3. Why bother to update the Code?
Current ‘IP’ edition dates from 1998
Need perceived to continue publishing guidance:
Changes in UK petroleum industry to contracted distribution, sub contracted maintenance
Maintenance provider now removed from source of expertise and safety culture associated with oil industry

4. Opportunity to re-assess:
The practice of working on tankers inside workshops, with the possibility of creating a flammable atmosphere within an unventilated space.
The hazard from petrol vapour release having become several times greater than historically:
Capacity of tankers (42000 litres)
Their leakproofness
Higher pressure setting of PV valves

5. Opportunity to increase awareness:
The hazards of maintaining tankers
Perception that hazard awareness
not being ‘passed down the chain’ to subcontractors and their employees
not being passed down from previous ‘generation’ of technicians
Proposal of a hierarchy of controls for working on tankers

6. Expertise rests within EI
Risks from Petroleum products
Sources of ignition
Hazardous areas and certified electrical equipment

9. Hazardous area calculation for tanker in a workshop using dispersion modelling:
8 000 litre compartment
60 mbar over pressure
Stable atmosphere:
Dip cap (if fitted) orifice release ~ 1 metre radius
Fill cover release ~ 10 metre radius

10. EI is only guidance from any source for petroleum tanker workshops.
EI’s Petroleum Tanker Workshop Code is apparently only guidance available worldwide:
no guidance listed by
Australia (AIP) or
US (American Petroleum Institute - API)
EI is only guidance from any source for petroleum tanker workshops.

11. 2007 edition relevance
Changes in legislation since 2001 – particularly concerning
Explosive atmospheres, requiring drawings that define ‘Hazardous Areas’.
Working at height
Control of pollution

13. Product Flash point Auto ignition temp Propane Butane Petrol Kerosene
Gas oil
All temperatures degrees Celsius
* For LPGs, boiling point

14. Product Flash point Auto ignition temp Petrol - 40 Kerosene 38 Gas oil
Propane
- 45 *
Butane
- 6 *
Petrol
- 40
Kerosene 38
Gas oil 55

15. Product Flash point Auto ignition temp Petrol - 40 Kerosene 38 Gas oil
Propane
- 45 *
468
Butane
- 6 *
450
Petrol
- 40
Kerosene 38
Gas oil 55

16. Product Flash point Auto ignition temp Petrol - 40 Kerosene 38 250
Propane
- 45 *
468
Butane
- 6 *
450
Petrol
- 40
Kerosene 38
250
Gas oil 55
260

17. Video clip here Andrew

18. From the report of the Ladbroke Grove train crash, 5th October 1999

19. 4.36 It was agreed that the source of fuel for the fireball was finely dispersed diesel fuel.
Much of it came from the contents of the fuel tank of the front car of the Turbo which contained 688 litres at the time of the crash.

20. 4.37 The horrific effects of the fire were most pronounced in coach H.
Witnesses described seeing, just after the coach had come to a stop, a fireball travelling from near the rear of coach H to about halfway into the carriage; this probably then rolled back again towards the rear.
Mrs Pam Warren was sitting at the rear of coach H. She described what happened just after the carriage had come to a halt:

21. There were many potential sources of ignition.
4.46
There were many potential sources of ignition.
The most likely were the overhead line equipment, the onboard electrical systems and thermite sparking.
Almost certainly all three were present and were particularly potent sources.

22. The 2007 Code How we made the decision to update it 
How it’s different from the 1998 Code
What’s in it
How it’s useful to you

23. 1998: 23 pages
2007: 60 pages

24. The changes (additions):
Location and security
Hazardous area classification – DSEAR *
Storage / disposal of drained products
Facility maintenance management
Fleet maintenance management
Admission of tankers to workshops
Hot work and cold work
Permit to work

25. DSEAR *
Dangerous
Substances and
Explosive
Atmospheres
Regulations
2002

26. The 2007 Code How we made the decision to update it 
How it’s different from the 1998 Code 
What’s in it
How it’s useful to you

27. How the Code is laid out:
Two parts – A and B (as before):
Design and construction of the workshop
Procedures and practices

28. Part A
Location, layout and security.
Workshop design, construction and maintenance
Installed equipment

29. Location, layout and security:
Site location (and access)
Site layout
Security
Example of a layout

31. Workshop design, construction and maintenance
General statutory requirements
Hazardous Area classification
Overall design considerations
Electrical Installation
Access doors
Inspection pits
Heating and artificial ventilation

33. Workshop design, construction and maintenance cont’d
Site drainage
Facilities for residual liquid
Facilities for personnel
Facility maintenance management regime

34. Workshop equipment Fire extinguishers and fire alarm system
Facilities for working at height
Compressed air
Fume extraction
Work benches
Tanker venting
Bulk storage tanks
Hand held / portable equipment

37. Part B Maintenance and repair operations
Health, welfare and protection of personnel
Fleet maintenance management
Training and qualification of personnel
Admission of tankers into workshops
Workshop operations
Gas freeing

38. Health, welfare, protection of personnel
References to specific legislation
Emergency response, First Aid and accident reporting
Legionella
Contact with petroleum products
Clothing and PPE

39. Fleet maintenance management
In house workshops
Contracted maintenance
Breakdowns and exceptional repairs

40. Training and qualification of personnel
Records
ADR requirements
Working on tankers
Safe use of equipment
Road testing
Emergency response

41. Admission of tankers into workshops
Controls and procedures concerning flammable atmospheres and sources of ignition
Emptying residual liquid
Venting system for tankers in workshops
Controls to minimise sources of ignition
Controls on hot and cold work

42. Workshop operations General housekeeping and workshop inventory
Permit to work system
Parking and movement of tankers
Working on tankers – general precautions
Working under tankers
Working on tanker product containment systems

43. Typical Permit-to-Work
Number of staff present:
Description of work
Work tasks
Method statements
Risk assessments
Location
Tools
Products contained
Personal protective equipment
Additional safety equipment
Special conditions

44. P-t-W ‘Special conditions’
Work areas to be kept clean and tidy, free from accumulations of flammable materials
All tools to be maintained in good condition
Any specialist contractors to be inducted in accordance with procedures for visitors, and workshop personnel are to accompany them at all times
Any parts removed from tankers are to be stored in the designated area
No hot work of any nature may be carried out without a separate Permit-to-Work

45. Workshop operations cont’d
Electrical repairs to tankers
Battery charging

46. Gas freeing procedure
General
Preparation
Using an air eductor
Using wet, low pressure steam
Using water power wash
Gas testing and gas free certification

47. Annexes Requirements in ADR for supervision of a laden tanker.
Typical Permit to Work
Typical gas-free certificate
Glossary
Audit checklist
References

48. Audit checklist
Useful tool for verification of design and equipment of new workshop
and an existing one.

49. Summary Need confirmed for updated Workshop CoP
No other source of guidance for petroleum tanker workshops
Petrol and diesel are dangerous products to handle, particularly in an enclosed space
Hazardous areas need to be identified and recognised

50. All Sources of ignition should be recognised and controlled
Workshop operations and procedures need to recognise the risk of possible presence of flammable vapours OR mists
Procedures should be in place for containment of product in planned and unplanned releases (including disposal)

51. Know your drains
Working at height is here to stay – so are the controls
Occasionally stand back

52. The 2007 Code How we made the decision to update it 
How it’s different from the 1998 Code 
What’s in it 
How it’s useful to you 

53. Particular thanks to: Paul Whitehead FTA Cliff Yarney Scania
Dave Rowlands Wincanton
John Hazeldean HSE
Mark Scanlon Energy Institute
Martin Hunnybun Energy Institute