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1 Title Licensee Conditions of use This is a licensed electronic copy of a document where copyright is owned or managed by Standards Australia International. Your licence is a single user licence and the document may not be stored, transferred or otherwise distributed on a network. You may also make one paper copy of this document if required. Web Check-up

2 AS AS Australian Standard Road tank vehicles for dangerous goods Part 5: Tankers for bitumen-based products

3 This Australian Standard was prepared by Committee ME-057, Road Tanker for Hazardous Liquids and Gases. It was approved on behalf of the Council of Standards Australia on 14 August 2001 and published on 8 October The following interests are represented on Committee ME-057: Australasian Fire Authorities Council Australian Chamber of Commerce and Industry Australian Gas Association Australian Industrial Gas Manufacturers Association Australian Industry Group Australian Institute of Petroleum Australian Liquefied Petroleum Gas Association Australian Valve Manufacturers Association Commercial Vehicle Industry Association of Australia Department for Administration and Information Services, S.A. Department of Defence (Australia) Environment Protection Authority of N.S.W. Queensland Transport Victorian WorkCover Authority WorkCover New South Wales Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased. Detailed information about Standards can be found by visiting the Standards Australia web site at and looking up the relevant Standard in the on-line catalogue. Alternatively, the printed Catalogue provides information current at 1 January each year, and the monthly magazine, The Australian Standard, has a full listing of revisions and amendments published each month. We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via at mail@standards.com.au, or write to the Chief Executive, Standards Australia International Ltd, GPO Box 5420, Sydney, NSW This Standard was issued in draft form for comment as DR

4 AS Australian Standard Road tank vehicles for dangerous goods Part 5: Tankers for bitumen-based products Originated as AS Second edition COPYRIGHT Standards Australia International All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher. Published by Standards Australia International Ltd GPO Box 5420, Sydney, NSW 2001, Australia ISBN

5 AS PREFACE This Standard was prepared by the Standards Australia Committee ME-057, Road Tankers for Hazardous Liquids and Gases to supersede AS While certain grades of bitumen-based products are flammable liquids, and AS , Road tank vehicles for dangerous goods, Part 2: Tankers for flammable liquids, was intended to cover all types of flammable liquids, there are certain peculiarities of bitumen that necessitated special treatment, not the least of these being the complex and variable method of operation of the industry. In field and operational matters, it is recommended that reference be made to the procedural guidelines in the Austroads Bitumen Sealing Safety Guide. Amongst other aspects requiring special consideration are the tank design requirements, which differ substantially from other flammable liquids tankers. Bulkheads are not used, and the options for construction material are fewer, so the table of shell thickness has been simplified. It seems possible to simplify it further as more thought is given to the special case of bitumen. A complex relationship between longitudinal and circumferential stiffeners has been dropped. A new appendix has been added in this revision to expand the details of burners and controls. These details would cover the necessary safety issues should permission be given by the appropriate authority to allow heating in transit. The term normative has been used in this Standard to define the application of the appendix to which it applies. A normative appendix is an integral part of a Standard.

6 3 AS CONTENTS Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE APPLICATION NEW DESIGNS AND INNOVATIONS INTERPRETATIONS REFERENCED DOCUMENTS DEFINITIONS VEHICLE REQUIREMENTS... 6 SECTION 2 TANKS, ACCESSORIES AND COMPONENTS 2.1 MATERIALS TANK DESIGN AND CONSTRUCTION MANHOLES, VALVES AND VENTS FILLING/DIPPING PROVISIONS PIPEWORK AND PIPE FITTINGS PUMPS IDENTIFICATION (TANK AND ANCILLIARIES) VEHICLE CABLING AND ELECTRICAL EQUIPMENT TESTING IDENTIFICATION SECTION 3 TANK TESTING AND MAINTENANCE PROCEDURES 3.1 GENERAL PRECAUTIONS ENTRY INTO TANK GAS-FREEING OPERATIONS TANK REPAIRS OR MODIFICATION REGULAR TESTING AND MAINTENANCE APPENDIX A BURNERS AND CONTROLS FOR TANKERS CARRYING BITUMEN BASED PRODUCTS...21

7 AS STANDARDS AUSTRALIA Australian Standard Road tank vehicles for dangerous goods Part 5: Tankers for bitumen-based products SECTION 1 SCOPE AND GENERAL 1.1 SCOPE This Standard specifies requirements for the design and construction of tankers for the transport of bitumen-based products including bitumen sprayers. It is complementary to AS APPLICATION Tankers for the transport of bitumen-based products shall comply with Parts 1 and 5 of this Standard. Where any requirement of Part 5 differs from a similar requirement in Part 1, Part 5 shall take precedence. 1.3 NEW DESIGNS AND INNOVATIONS Any novel materials, designs, methods of assembly, procedures etc, which do not comply with specific requirements of this Standard, or are not mentioned in it, but which give equivalent results to those specified, are not necessarily prohibited. The Standards Australia Committee ME-057, Road Tankers for Hazardous Liquids and Gases can act in an advisory capacity concerning equivalent suitability, but the specific approval remains the prerogative of the relevant Authority. 1.4 INTERPRETATIONS Questions concerning the meaning, application, or effect of any part of this Standard may be referred to the Committee ME-057, Road Tankers for Hazardous Liquids and Gases for explanation. The authority of the Committee is limited to matters of interpretation and it will not adjudicate in disputes. 1.5 REFERENCED DOCUMENTS The following documents are referred to in this Standard: AS 1160 Bituminous emulsions for construction and maintenance of pavements 1210 Pressure vessels 1375 Industrial fuel-fired appliances (known as the SAA Industrial Fuel-fired Appliances Code) 1449 Wrought alloy steels Stainless and heat-resisting steel plate, sheet and strip 1657 Fixed platforms, walkways, stairways and ladders Design, construction and installation 1853 Automatic oil and gas burners Mechanical draught Standards Australia

8 5 AS AS 1940 The storage and handling of flammable and combustible liquids 2008 Residual bitumen for pavements 2157 Cutback bitumen 2380 Electrical equipment for explosive atmospheres Explosion-protection techniques Part 9: Type of protection Non-sparking 2430 Classification of hazardous areas Part 1: Explosive gas atmospheres 2470 Steel cylinders for compressed gases Welded three piece construction with longitudinal joint 11 kg to 150 kg 2475 Threaded hose connection fittings for bituminous materials 2809 Road tank vehicles for dangerous goods Part 1: General requirements Part 2: Tankers for flammable liquids 2865 Safe working in a confined space 3814 Industrial and commercial gas-fired applicances 4100 Steel structures D26 Tube fittings with Dryseal American standard taper pipe and unified threads for automotive and industrial use AS/NZS 1020 The control of undesirable static electricity 1425 LP Gas fuel systems for vehicle engines 1554 Structural steel welding Part 1: Welding of steel structures Part 5: Welding for steel structures subject to high levels of fatigue loading 1596 Storage and handling of LP Gas 1869 Hose and hose assemblies for liquefied petroleum gases (LP Gas), natural gas and town gas 2053 Conduits and fittings for electrical installations Part 1: General requirements Part 2: Rigid plain conduits, and fittings of insulating material Part 7: Rigid metal conduits, and fittings 3509 LP gas fuel vessels for automotive use 3678 Structural steel Hot-rolled plates, floorplates and slabs 3679 Structural steel Part 1: Hot-rolled bars and sections BS Specification for cables for vehicles Cables with copper conductors UL 21 Standard for safety LP Gas hose AIP CP13 ADR Manual of petroleum measurement standards Australian Design Rules for Motor Vehicles and Trailers Standards Australia

9 AS DEFINITIONS For the purpose of this Standard, the definitions given in AS apply. 1.7 VEHICLE REQUIREMENTS Spillage hazards The appropriate requirements of AS and the following requirements shall apply: (c) (d) Any portion of an engine or exhaust system which, by reason of its location, can be reached by spillage from above, whether the tanker is parked or moving, or which is within 1 m of a liquid-carrying component of the pumping system, shall be protected from such spillage by a metal shield. The distance between the shield and any hot part of the engine or exhaust shall be not less than 50 mm. The distance between the shield and any cargo-carrying component shall be not less than 75 mm. The shield for a vertical exhaust pipe shall extend as nearly as practicable to the full height of the pipe, but not lower than the top of the cabin, and shall be sealed to it liquid-tight at the top. The shield shall be at least 100 mm larger in diameter than the exhaust pipe. Any openings or perforations for ventilation shall be located on the side remote from the tank Propulsion engine exhaust The engine exhaust system shall comply with the appropriate requirement of AS and the following requirements: The exhaust system shall not run beneath a tank unless shielded, see Clause The exhaust shall discharge behind the cabin and forward of the tank, at a level not lower than the top of the cabin and at least 1 m from the tank opening, or on the righthand side of the vehicle, sideways and forward of the front wheels, or not more than 150 mm behind the front wheels. NOTE: Other authorities may require special exhaust arrangements to suit their defined area of operation, such as airports Auxiliary engines, intake and exhaust terminations The intake and exhaust of an auxiliary engine shall not terminate at a level lower than the top of the cabin, nor in a hazardous zone as described in AS For portable or trailer units, the terminations shall be above the tank top and at least 2 m from any opening into the tank Rear impact protection For sprayers only, the rear work platform, spray piping system and other fittings may be taken into account in assessing the need for a rear bumper. For tankers other than bitumen sprayers, see AS Standards Australia

10 7 AS SECTION 2 TANKS, ACCESSORIES AND COMPONENTS 2.1 MATERIALS Standards Materials used in the construction of tanks shall be not less than the grades specified in AS 1449, AS/NZS 3678 and AS/NZS Suitability Materials shall be suitable for the conditions of use, and in particular shall be compatible with adjacent materials and with the cargo. 2.2 TANK DESIGN AND CONSTRUCTION Design criteria The tank and its supports and connections shall be designed in accordance with AS 4100, as appropriate, with the following qualifications: (c) The design load for the tank and its attachments shall be not less than twice the total mass of the tank, its accessories, and its cargo. The mass of the cargo shall be calculated from its actual density or 1000 kg/m 3, whichever is the greater, and the maximum safe filling level. Loadings caused by the weight of equipment, the reactions at supports, and thermal gradients shall be taken into account. The thickness of the shell, heads, bulkheads and baffles shall be not less than that specified in Table 2.1. NOTE: The thicknesses for tank heads may be reduced to equal the shell thickness provided that a calculation for head thickness carried out in accordance with AS 1210 indicates that it is safe to do so Stiffening of heads and baffles Heads and baffles shall be stiffened, either by dishing or by another approved method Circumferential reinforcement The tank shall be reinforced circumferentially by stiffeners or baffles (or in any combination) in accordance with the following requirements: Reinforcements shall be located so that the maximum unreinforced length (L) shall not exceed that specified for the particular shell thickness in Table 2.1. The reinforcements shall be located within 25 mm of points where the longitudinal alignment of shell sheets changes direction by more than 10 degrees, unless otherwise reinforced sufficiently to keep stresses within the specified limits. Standards Australia

11 Standards Australia Rated capacity per metre of tank lengh L 1400 > > >2700 Tank details Maximum shell radius m LCS TABLE 2.1 MINIMUM PLATE THICKNESS DESIGN MAXIMUM DENSITY 1000 kg/m 3 Shell Unreinforced length of shell*, m Minimum nominal thickness, mm Large compartment circular tanks <0.9 (L1) > (L2) > (L3) LCS HSLA SS HSLA SS * Distance between heads, bulkheads, baffles or ring stiffeners. LEGEND: LCS = low carbon steel HSLA = high strength low alloy steel SS = austenitic stainless steel LCS HSLA SS LCS HSL SS Heads and bulkheads Non-circular tanks LSC HSLA SS Baffles Non-circular tanks LCS HSLA SS Heads and bulkheads Large compartment circular tanks LCS HSLA SS Baffles Large compartment circular tanks LCS HSLA SS AS

12 9 AS (c) (d) Ring stiffeners shall be continuous, and shall have a section modulus about the neutral axis of the ring section parallel to the shell not less than that determined from the following equation: where Z = KbL Z = section modulus, in millimetres cubed K = for all steels b = tank width or diameter, in millimetres L = ring spacing, i.e. the maximum distance from the midpoint of the unsupported shell on one side of the ring stiffener to the midpoint of the unsupported shell on the opposite side of the ring stiffener, in millimetres Where a ring stiffener is welded to the shell in accordance with Item (d) below, the maximum portion of the shell which can be used as part of the ring for computing the section modulus shall be as described in Table 2.2. The welding which attached stiffening members shall be not less than 50 percent of the total circumference, and no unwelded length of the joint shall exceed 40 times the shell thickness. Number of circumferential ring stiffener to tank shell welds TABLE 2.2 PARTS OF SHELL IN RING STIFFENER Distance between parallel circumferential ring stiffener to shell welds Maximum shell section credit 1 20t 2 Not over 20t s + 20t 2 Over 20t 40t LEGEND: t = Shell thickness s = Distance between parallel circumferential ring stiffener to shell welds Access through baffles Each baffle shall have a manhole-sized opening where no other means exists for gaining access to tank space on both sides of the baffle. Openings through which heater tubes and other internal pipework can pass without attachment to the baffles shall have enough clearance to permit deflection of the tubes without contact Distribution of loads The loads from supports should be taken on stiffening members and should be distributed as widely as possible through pads, gussets, and the like Roll-over protection Where any component is of such a design, or is located in such a way, that it is vulnerable to damage in a roll over, the tank shall be provided with roll-over protection which shall comply with the following requirements as appropriate: The protection shall consist of one of the following: (i) A guard in the form of inverted U-coamings, the thickness of which shall be not less than the appropriate value given in Table Standards Australia

13 AS (c) (d) (e) (f) (ii) Guards or domes as provided in Items, (c) and (d) below. NOTE: For demountable tanks where the capacity does not exceed 2500 L, a vertical metal strip not less than 4.5 mm thick surrounding the fittings may be used. (iii) The locating of the component, or fittings, within the body of the tank. (iv) The design of the component itself to provide sufficient inherent resistance to damage to obviate the need for further protection. Any guard, dome, or coaming shall project at least 25 mm above the top of the fitting which it protects. Any guards or domes not specifically defined in Item above shall be designed and installed to withstand without failure a load of twice the mass of the loaded tank, in any direction. The calculation of strength shall be based on the ultimate strength of the material. NOTES: 1 If two or more guards are provided, the load may be proportioned between them. 2 These design loads may be considered independently. The material of a guard shall be compatible with that of the tank shell. Any air space enclosed inside a coaming, guard or dome, shall have openings to permit draining and purging before repair. Where the enclosed space is used to transfer vapour, the openings shall be plugged. A tank which exceeds 2500 L capacity shall incorporate drains to prevent liquid from collecting on top of the tank. Drains shall discharge to a safe place. TABLE 2.3 THICKNESS OF MATERIAL FOR U-COAMINGS Type of tank Large-compartment Non-circular-compartment LEGEND: LCS = Low carbon steel HSLA = High strength low alloy steel SS = Austenitic stainless steel Component attachment LCS 5 3 Thickness, mm HSLA/SS The attachment of auxiliary components and accessories should be to the subframe or skirting wherever practicable. Where attachment to the tank shell is unavoidable, the following requirements shall apply: The design of the component or its method of attachment shall be such that the component will break before damage is caused to the shell. Where the attachment is to a mounting pad welded to the tank, the following requirements apply: (i) The mounting pad shall be no thicker than the shell at that point, and shall extend at least 25 mm beyond the perimeter of the component attachment, and shall be shaped so as to avoid stress concentrations at sharp corners Standards Australia

14 11 AS (ii) Welding The means of attachment shall not create pockets which could initiate corrosion. The welding of mounting and reinforcing pads to the tank shall be continuous unless a gap for drainage is provided at the bottom. All pads shall be formed to closely follow the tank contour at the point of attachment. Welding for structural joints or the attachment of accessories, mounting pads and the like shall comply with AS/NZS and AS/NZS Butt welds in the shell shall be full penetration. Welding consumables shall be suitable for the material being welded and for any conditions due to the cargo, in particular the possibility of stress-corrosion cracking Fire tube design Fire tube systems for tank heating shall be designed so that either the tube or a flame tube insert is readily removable for replacement or service. Where pipework passes through, or is attached to tank shells or baffles, appropriate reinforcing shall be provided. Such reinforcement shall not exceed the thickness of the tank shell, and shall follow the contours of the tank at the point of attachment. Return passes shall be as low as practicable. NOTE: AS 1375 gives design guidance for combustion systems. 2.3 MANHOLES, VALVES AND VENTS General Every tank opening except a vent shall be provided with an effective means of closure in accordance with one of the requirements of this Clause (2.3), as appropriate Manholes Tanks with a capacity below 5000 litres shall be accessible through at least one manhole, not smaller than 300 mm 400 mm and fitted with a cover capable of passing the tank pressure test (see Clause 2.9.1). Where the manhole cover incorporates a hatch, it shall also comply with the requirements for hatch assemblies (see AS ). Manhole coamings shall extend no further than 50 mm into tank vapour space. Tanks with a capacity of 5000 litres and above shall be provided with a manhole. The manhole shall be a minimum of 400 mm diameter and may be located on the rear head of the tank or within a recess or shroud on top of the tank Valves Each opening in a tank below the safe fill level shall be provided with a shut-off valve suitable for service at the piping design temperatures and pressures. Such valves shall be located as close to the tank shell as practicable, and be positioned so as to minimize accidental damage Sampling valves Sampling valves, and caps, where fitted shall comply with AS 1160, AS 2008 and AS 2157 as appropriate. Sampling valves shall be situated in a convenient location for sampling and a permanent platform attached to the tanker to support the sampling container during filling. Material used in the manufacture of valves and sampling cocks shall be compatible with the material of the tank, and the product being transported, and shall be suitable for the maximum service temperature Vents and venting systems Each tank shall be provided with a normal vent and an emergency vent. The normal vent shall have sufficient capacity for normal loading and emptying, and the volume changes associated with heating, circulation, and the like. The normal vent shall be designed so that in the event of a roll over at least half the liquid contents remain in the tank. Standards Australia

15 AS The emergency vent shall be capable of relieving a boil-over during filling. An open filling hatch may be taken into account for this purpose. NOTE: Figure 2.1 illustrates a typical free vent. The vent pipe passes from the top through the bottom of the tank, where it discharges. The clearance between the open top of the vent pipe and the coverplate on the housing equals the vent area of the pipe. Removal of the vent coverplate will allow regular maintenance/cleaning of vent openings in the tank shell and the base of the vent pipe. The height of the vent pipe above the tank shell is designed to cope with product slop during vehicle braking. The design will retain all the cargo without spillage in a roll over of 180 degrees, but will allow a variable amount of spillage at lesser angles, the maximum being half the cargo at 90 degrees Loading and unloading protection A tank which is intended to be loaded or unloaded with the hatch covers closed, shall be provided with enough liquid-venting capacity to discharge the whole of the liquid delivery rate of the pump, and with enough air inflow capacity to match the liquid withdrawal rate. NOTE: The free vent design illustrated in Figure 2.1 will provide adequately for the usual rate of pumping. 2.4 FILLING/DIPPING PROVISIONS Loading Tankers shall be designed to be filled either through open hatches (at refineries and major bulk depots) using an overhead filling nozzle or by means of the tanker pump and circulating pipework (at intermediate or site storages) Dipstick Any dipstick indicating system shall comply with the following requirements: The full indication on the dipstick shall allow an ullage space of at least 5%. (c) (d) A dipstick shall measure from a point of contact at the top of the tank. Any dipstick which measures by contacting the bottom of the tank shall be provided with a durable striker pad of thickness not less than that of the tank shell or 5 mm, whichever is the greater, attached firmly to the tank bottom below the dip opening. A dipstick shall be provided with a stayed vertical guide. A clear indication on the dipstick shall show a level of product that will allow the fuel-fired burner to operate safely. 2.5 PIPEWORK AND PIPE FITTINGS Strength of piping Piping and associated fittings shall be designed for the pressure to which they may be subjected in service, and shall be designed and supported to allow for expansion, contraction, and vibration. Unrestrained slipjoints shall not be used for this purpose. Valves or fittings directly attached to the tank that support attached pipework shall be capable of supporting the loadings. External piping shall be located so that it is protected from damage that could occur in the normal operation of the tanker Circulating pipework Where recirculation pipework discharges into the vapour space, the velocity of discharge into the vapour space shall not exceed 5 m/s, the atomization or spraying of product into vapour spaces or onto heater tubes or hot surfaces shall be minimized, and all product discharged into a tank shall be discharged in a downward direction. Standards Australia

16 13 AS Hoses and hose couplings DIMENSIONS IN MILLIMETRES FIGURE 2.1 TYPICAL TANK VENT Hoses shall be capable of withstanding both pressure and suction operation at temperatures up to 230 C. Hose connections shall comply with AS NOTE: Detailed information concerning bitumen hoses may be obtained from Code of Practice for Bitumen Transfer Hoses issued by the Australian Asphalt Pavement Association, Melbourne, Victoria Access ladders/walkways Access ladders shall be provided for safe access from the tank walkway to ground level. Access ladders/walkways shall comply with AS Flushing system Flushing liquid (such as high flash point kerosene or distillate) may be kept on a sprayer in a container of less than 250 L capacity. The formation of spray in the vapour space shall be avoided. The container shall be vented in such a manner as to avoid the presence of potentially combustible vapour in the vicinity of an ignition source. These flushing tanks shall be designed and mounted to the appropriate ADR rules for side mounted fuel tanks. Each flushing tank shall be fitted with an outlet valve, with an appropriate removable secured sealed cap. The flushing system shall be so designed to prevent accidental discharge of flushing fluid into the bulk product tank compartments. NOTE: Equipment and ancillaries required to enable the full immersion of spray bars are not required to meet the Australian Design Rules. Standards Australia

17 AS PUMPS Suitability A pump intended for handling the product shall be suitable for use with the product and for the required pressures, flow rates, and temperatures. A sprayer pump shall be of a non-pulsating type Pressure regulation A pumping system shall be provided with automatic means to ensure that the design pressure of any component within the system will not be exceeded Pump-driving engines A compression engine or a new spark ignition engine may be used for propulsion. The propulsion engine of the road tank vehicle and or an auxiliary engine may be used as the pump engine. The engine shall be provided with a shutdown system which shall be easily identified and complies with the following: An approved manually operated strangler shall be fitted to the air intake (see Note 1). There shall be provision to isolate the field circuit of a generator, or of an alternator unless it is of a non-sparking (brushless) type (see Note 2). (c) The air intake shall comply with Clause NOTES: 1 A strangler may take the form of a valve which closes the air intake passage to the engine. In such a case, account must be taken of the effects of vacuum on the intake piping and of other passages (such as sump breather pipes) through which air may pass to the air intake of the engine. A fire extinguisher of not less than 2.7 kg filled with the appropriate extinguishant may be used as a strangler provided that the extinguisher is a 100 percent discharge type and is arranged to discharge into the air intake close to the intake manifold. 2 The isolation function may be provided either by a separate switch or by the battery-isolating switch. If a separate switch is used, a warning light to indicate whether the switch is open is desirable, as a reminder to resume charging after pumping is finished. However, the use of a battery-isolating switch will have the effect that no electrical equipment of any sort will be functional during pumping. This is something which is not otherwise required or necessary, and may be undesirable or impracticable in certain cases. It is important that the resumption of battery charging is not overlooked, and it may be desirable to interlock the isolating arrangement with the starting or engagement controls for the pump Protection of auxiliary engines Auxiliary engines shall be located or shielded so as to comply with Clause 1.7 and shall be at the remote end of the vehicle from the spraybar Location of controls Power driven pumps shall be provided with controls which shall comply with the following requirements: Controls shall be clearly marked, easily accessible, and located in a position remote from the pump. A strangler-operating device or an emergency stop for the engine or motor shall be provided. All such devices shall be clearly identified and easily accessible. Standards Australia

18 15 AS IDENTIFICATION (TANK AND ANCILLIARIES) General All emergency equipment and valves on the tanker shall be clearly labelled as to their function Identification An identification plate bearing the following information shall be provided on each tank: The tank manufacturer's name. The tank design approval/registration number as issued by the authority with jurisdiction. (c) The number of this Standard, i.e. AS (d) (e) (f) (g) (h) (i) (j) (k) The serial number of the tank. Date of manufacture. Date of manufacturer s test. Design pressure, in kilopascals. Head material (grade, and thickness in millimetres). Shell material (grade, and thickness in millimetres). Tank capacity (litres) by compartments (front to rear). Maximum liquid load, in kilograms. The plate shall be made of a metal which is compatible with the material of the tank and is not subject to corrosion. It shall be permanently fixed to the tank or attached structure. It should be located on the non-driver side of the tank, near the front, in a place readily accessible for inspection. The information shall be stamped, embossed, or applied by other suitable means, into the material of the plate in characters at least 5 mm high. The plate shall not be painted over or obscured in any fashion. The tank serial number shall also be stamped on a substantial part of the tank structure in letters at least 10 mm high Burner operation procedures Signs shall be provided adjacent to burner equipment to indicate (c) normal start up and shutdown procedures; restarting procedures after flame-failure shutdown; and minimum safe product level while using the burner. 2.8 VEHICLE CABLING AND ELECTRICAL EQUIPMENT Application The requirements of this Clause 2.8 shall apply when the cargo is flammable or the tanker is to operate in hazardous areas. Cables shall comply with BS , and shall be installed in accordance with the Australian Design Rules for Motor Vehicles and Trailers. Cabling to the rear of the cab shall have protection complying with Clause Cabling to intrinsically safe equipment can be protected by means other than conduit. Standards Australia

19 AS Protection of wiring Cables outside and to the rear of the cabin shall be protected in accordance with AS/NZS 2053, Parts 1, 2 and 7, or AS D26 (flared fittings), or by an alternative means having at least equivalent effectiveness. When a tank trailer is being towed by a vehicle which is not a road tank vehicle or which is a road tank vehicle for classes of dangerous goods which are not flammable, the requirements of this Clause apply to the tank trailer only unless the tanker is to operate in hazardous areas. Cables shall be securely fastened and located, such that all wiring and fittings are adequately protected against vibration, impact, abrasion and any other types of mechanical and thermal stresses (see AS for some acceptable methods of cable protection). All circuits, with the exception of the main battery supply, the starter and alternator circuits, shall be protected by an appropriate fuse or other circuit breaker. The fuse shall be mounted in the cab or in a junction box complying with Clause and shall be of a non-sparking type as described in AS Battery The battery shall have a substantial and well secured acid resistant cover, electrically insulated on the side adjacent to the batter terminals Battery-isolation switch A battery isolation switch shall be provided for use in an emergency only. In such a case, it is necessary to isolate the battery. Reconnection should only be made when the hazard has been removed. The means of operating the isolating switch shall be located on the driver s side and to the immediate rear outside of the cabin, in such a position that is clearly visible and easily accessible to a person outside the vehicle, and shall be clearly labelled. The battery isolation switch shall have fully enclosed contacts and be weather-proof. NOTES: 1 The switch should only be turned on, (supplying power) or turned off (no power), when the hazard has been removed. 2 Where an engine is fitted with an alternator, and the battery is isolated before the engine is stopped, damage to the alternator is likely unless its field coils have been first disconnected Vehicle rollover device Purpose-built road tank vehicles designed to carry dangerous goods in bulk shall be fitted with a rollover device which automatically shuts down the engine and all power sources in the case of a rollover, by activating the battery isolation switch. The device shall not be activated at less than 45 to the vertical. The rollover device is only required to be fitted on the prime mover of a combination or on rigid chassis vehicles Hazardous locations Any electrical equipment activated during cargo transfer and is located within a hazardous area (see AS ) shall be suitable for use in such an area. The following hazardous areas shall be deemed to exist during the whole period of cargo transfer and for 5 min thereafter: Within 500 mm of any point of product release shall be as Class 1, Zone 1. Rear of the cabin and 8 metres radially from any uncapped valve or transfer connection from ground level to a height of 500 mm shall be Zone 2. NOTES: mm allows the use of rear lights in bumper bars on vehicles with rear-mounted hose reels. It also allows the removal of the limitation concerning the vertical exhaust outlet from being in range of a manhole or vent. 500 mm also removes the limitation of side clearance lights mounted on the barrel being in range of valves or drop hoses. It also allows cable running on the opposite chassis rail to avoid the Zone 1 area. 2 All zoning is for the transfer plus five minutes only. Standards Australia

20 17 AS Cabling to hazardous areas of Zone 2 Cabling to the tanker rear of the cabin shall be deemed to be suitable for temporary use in Zone 2 if it complies with the following: (c) Conduit and fittings shall have weatherproof level of protection. Where equivalent protected cabling is used instead of conduit, sealing glands shall be used. Junction boxes for electrical cable other than intrinsically safe cabling shall be weatherproof and use threaded gland or bonded entries. If proprietary equipment such as transmission temperature probes does not readily allow the use of proprietary connectors the hazard shall be assessed and an equivalent technique employed. NOTE: Also refer to Clause Cabling to hazardous areas of Zone 1 Cabling shall be suitable, or in conduit suitable, for Zone 1, together with any associated glands and junction boxes Sparking equipment Any sparking equipment such as relays or switches with make and break contacts mounted 500 mm or greater from the rear of the cabin or in a hazardous location as defined in Clause shall be suitable for use in Zone 1. Switches installed in the electronic flame supervision are exempted from this requirement Electrical bonding The electrical resistance between the tank and the tanker chassis, prime mover chassis, or trailer undercarriage, and between the tank and the connection of the tanker pipework to the delivery hose, shall not exceed 10 Ω Earthing point At least one non-corrodible bare metal lug shall be welded to an integral part of the tank for use as an earthing point, unless the tanker incorporates an earth wire reel system the lug shall be in a position convenient for the operator but shall not be within the space enclosed by the coaming, and shall be as far away as practicable from points where flammable vapour could emerge. Additional lugs may be placed at convenient points. The filling or loading connection for a tank larger than 8 kl shall be provided with a facility for attaching the bond or static wire of a tanker in accordance with AS/NZS TESTING Tanks initial test and after any repair A tank or an individual tank compartment shall not leak, distort, or show evidence of impending failure when filled with water, the temperature of which does not exceed 30 C, and hydrostatically pressurized to 30 kpa for small-compartment tanks and non-circular tanks, or 45 kpa for large-compartment circular tanks and the pressure maintained without leaks for 10 minutes. Each compartment shall be tested individually with adjacent compartments empty and at atmospheric pressure. Relief devices which could prevent the test pressure being reached shall be made inoperative during testing. The vapour-recovery transfer system shall not leak when subjected to a pressure of 30 kpa and the pressure maintained without leaks for 10 minutes Hatch assembly initial test A hatch assembly shall pass the test described in AS Standards Australia

21 AS Piping initial test and after any repair Piping systems shall be tested in accordance with the following: A piping system subject to pumping pressure shall be tested to a pressure 1.5 times the maximum working pressure or 200 kpa whichever is the greater. Valves, manifolds, piping and fittings which can be subjected to surge pressures due to the closure of some valve in the system, shall be tested to 1600 kpa. All tests designated in Items and shall have the test pressure maintained for 10 minutes without any leakage occurring. All other and auxiliary equipment shall be tested to the appropriate Standard or the manufacturer s requirements, whichever has the safest outcome Records A record of all tests performed on the tanker, or its associated equipment, shall be kept for not less than three years IDENTIFICATION An identification plate bearing the information required by the Australian Design Rules for Motor Vehicles and Trailers shall be provided on each tanker, together with the following: The tank design approval number as issued by the Statutory Authority. The number of this Australian Standard, i.e. AS Standards Australia

22 19 AS SECTION 3 TANK TESTING AND MAINTENANCE PROCEDURES 3.1 GENERAL PRECAUTIONS Tanker servicing and repair which can be conducted on a scheduled basis at pre-arranged times shall be carried out in workshops in which the staff have had prior training in the precautions and emergency procedures required for tankers for flammable liquids. Where, because of breakdown at a remote location, a workshop without such trained staff is used, the owner s representative shall instruct the workshop staff of the nature of the cargo and the precautions to be taken. In all circumstances the conditions given in AS and the following requirements shall apply: (c) (d) (e) (f) The tank shall be gauged to determine that it is not filled beyond the maximum filling level. Any overfilled condition shall be corrected. No hot work shall be conducted either indoors or outdoors on the tank or on any component that has contained liquid or vapour unless the tank and the component are gas-free and a work permit has been issued. The vehicle shall not be parked near a source of heat of sufficient intensity to risk causing a discharge from the vents due to heating of the cargo. For hot work to be carried out on parts of the vehicle when the tank is not gas-free the following shall apply: (i) (ii) The surroundings shall be checked and shown to be gas-free for the whole period of the risk. Fire-extinguishers shall be deployed in the area. (iii) A fire hose or hose reel, shall be in reach. Extreme caution shall be observed when a degassing procedure is being undertaken. Extreme caution shall be observed when pressure testing tank and components. See Clause ENTRY INTO TANK Where it is necessary that personnel enter a tank, a work permit shall be issued prior to commencing, and the requirements of AS 2865 shall apply. NOTE: Examples of typical work permits are illustrated in AS 1940, AS 2865, and AIP CP GAS-FREEING OPERATIONS Gas-freeing operations shall be conducted, either in the open air or under a specifically designed shelter, with no ignition sources in a hazardous area all as complying with AS TANK REPAIRS OR MODIFICATION Where a tank is repaired or modified, the following requirements shall apply: The tank and its appurtenances shall be tested in accordance with Clause 2.9 before it is approved for re-use. NOTE: Where a tank is ruptured as the result of an accident, it may be rebuilt and replated to its original design. If the basic tank design is changed, or there is a change in the basic structure, the design shall be re-assessed and re-approved to current Standards. Standards Australia

23 AS REGULAR TESTING AND MAINTENANCE Hatches At intervals not exceeding two and a half years, the pressure-tightness of every hatch shall be tested at 25 kpa, either on the tank with the pressure-vacuum vents blanked off, or after removal from the tank, i.e. as a bench test. Where equipment is bench-tested, no further tests are required when reinstalled on the tank Vents At intervals not exceeding one year, vents shall be removed and completely dismantled and cleaned. The vent shall be assembled, inspected and checked to ensure free passage Product heating system At intervals not less than 3 months, the product heating system shall be inspected, tested and checked that it operates within the original manufacturer s specification Precautions necessary prior to work Work shall proceed only if the following conditions apply: (c) It has been established that there is no leakage of cargo. All valves are shut (P/V vents excepted), and all outlets including hoses are capped shut. No hatches will be opened, and no vents, valves, or piping will be removed. (d) No ignition source will exist within the hazardous zone defined in Figure 3. (e) The ventilation rate for the area is at least four air changes per hour Safe work procedure Work shall proceed only under the conditions specified in Clause Items to (e) above and there is no ignition source existing within 15 m of the tanker. FIGURE 3 HAZARDOUS ZONE FOR P/V VENT Standards Australia

24 21 AS APPENDIX A BURNERS AND CONTROLS FOR TANKERS CARRYING BITUMEN BASED PRODUCTS A1 GENERAL (Normative) This Appendix specifies requirements for burner types and controls suitable for use on tankers carrying bitumen based products. A2 LIQUEFIED PETROLEUM GAS (LP Gas) SUPPLY A2.1 Installation of fuel vessels LP Gas on the tanker shall either be in cylinders or vessels. Cylinders shall comply with AS 2470 with cylinders sizes of 45 kg, 90 kg and 190 kg water capacity being the recommended sizes. Vessels for LP Gas shall comply with AS/NZS 3509, carbon steel vessels which are manufactured up to 500 kg water capacity, whilst stainless steel vessels are limited to 200 kg water capacity. The whole installation, either with cylinders or vessels, shall comply with AS/NZS A2.2 Interconnecting pipework between gas storage and burner The interconnecting pipework between gas storage and the burner shall comply in all respects with AS/NZS The use of copper pipework and fittings on these installations is prohibited. Flexible connections between the gas storage cylinders or vessel to the fixed pipework and from the fixed pipework to the burner is permitted, provide these two flexible connections shall each be limited to one and a half metres in length. Flexible connections shall comply with AS/NZS 1869 or UL 21. A3 BURNERS A3.1 Burners types Burners shall either be those requiring mechanical draft or natural draft atmospheric burners. Burner requiring mechanical draft shall be considered as automatic burners and shall comply in all respects with AS Burners designed for natural draught and are considered as an atmospheric burner, shall comply with the necessary aspects of AS 1375 as appropriate. A3.2 Manual ignition system Burners requiring natural draught and manual ignition shall be installed and arranged so that the operator can simultaneously operate the fuel valve, initiate ignition, and also observe the flame in safety. A flame failure device to initiate the operation of a shut-off valve or valves fitted in the fuel line shall be installed. This device shall comply with appropriate requirements given in AS A3.3 Electronic ignition Where an electronic ignition system is installed, the burner start sequence shall be initiated by a start switch fitted as close as practical to the burner. Standards Australia

25 AS During the firing sequence, the operator shall remain in attendance to ensure pilot flame establishment and subsequently main flame establishment. Upon main flame establishment, the operator shall then follow the normal company procedures for bitumen-based product use. In the event of an abnormal shutdown, the burner is to sequence to a safe lockout condition. The burner controls shall be so arranged that a restart is not possible until the cause of the abnormal shutdown is located, corrected and made safe for a restart. An over-temperature device shall be fitted to operate within the product. The device to have a preset limit and when activated, it shall shutdown the burner to the lockout condition. A3.4 Burner operation The tanker owner shall initiate and ensure that the operator undertakes sufficient training to enable the whole of the operating tasks required to be carried out in a safe and reliable manner. The tanker owner to ensure that instructions and procedural aids are available to the operator, that at all times the owner shall ensure that the operator follows the latest safe procedures. For further information, see Clauses and Care shall be taken to ensure the fire tubes are always beneath the lowest level of the product, with sufficient allowance being made for any inclines that may be met during transit. A3.5 Heating in transit systems Use of heating in transit systems is currently prohibited by the majority of State and Territory regulatory authorities. Any owner of plant wishing to operate such a system shall apply for permission to do so from the relevant authority in the State or Territory of operation. The use of a heating system whilst in transit shall only apply to residual bitumen. For residual bitumen details, see AS Owners receiving permission to operate such a system shall comply with the following additional safety conditions and controls: (c) System status indicators shall comprise the following: (i) (ii) System in operation (main flame established). System lockout (abnormal condition). (iii) System lockout (sensor activated). (iv) Product temperature indicator (digital or analog). These indicators shall be situated in the driving cab in easily readable positions. NOTE: Indicators described in Items (i), (ii) and (iii) may be LEDs or low voltage bulbs in colours to be decided by the owner. Driving cab controls Shutdown switch to shutdown heating system shall be situated in an easily accessible position reachable from the driver s seat. The heating in transit system shall not be capable of being initiated from the driving cab. Other controls the following apply: (i) (ii) In the event of an abnormal shutdown, the burner shall be placed in a safe stand-by condition ready to restart when permitted to do so, or in the lockout condition appropriate to the situation. An indication of abnormal shutdown cause, such as a fuel or electrical fault. Standards Australia