Code of practice for petroleum road tanker vapour collection systems and equipment used in unloading operations

Code of practice for petroleum road tanker vapour collection systems and equipment used in unloading operations

CODE OF PRACTICE FOR PETROLEUM ROAD TANKER VAPOUR COLLECTION SYSTEMS AND EQUIPMENT USED IN UNLOADING OPERATIONS December 2008 Published by ENERGY INSTITUTE, LONDON The Energy Institute is a professional membership body incorporated by Royal Charter 2003 Registered charity number 1097899

The Energy Institute (EI) is the leading chartered professional membership body supporting individuals and organisations across the energy industry. With a combined membership of over 13 500 individuals and 300 companies in 100 countries, it provides an independent focal point for the energy community and a powerful voice to engage business and industry, government, academia and the public internationally. As a Royal Charter organisation, the EI offers professional recognition and sustains personal career development through the accreditation and delivery of training courses, conferences and publications and networking opportunities. It also runs a highly valued technical work programme, comprising original independent research and investigations, and the provision of IP technical publications to provide the international industry with information and guidance on key current and future issues. The EI promotes the safe, environmentally responsible and efficient supply and use of energy in all its forms and applications. In fulfilling this purpose the EI addresses the depth and breadth of energy and the energy system, from upstream and downstream hydrocarbons and other primary fuels and renewables, to power generation, transmission and distribution to sustainable development, demand side management and energy efficiency. Offering learning and networking opportunities to support career development, the EI provides a home to all those working in energy, and a scientific and technical reservoir of knowledge for industry. This publication has been produced as a result of work carried out within the Technical Team of the Energy Institute (EI), funded by the EI s Technical Partners. The EI s Technical Work Programme provides industry with cost-effective, value-adding knowledge on key current and future issues affecting those operating in the energy sector, both in the UK and internationally. For further information, please visit http://www.energyinst.org The EI gratefully acknowledges the financial contributions towards the scientific and technical programme from the following companies: BG Group BHP Billiton Limited BP Exploration Operating Co Ltd BP Oil UK Ltd Centrica Chevron ConocoPhillips Ltd ENI E. ON UK ExxonMobil International Ltd Kuwait Petroleum International Ltd Maersk Oil North Sea UK Limited Murco Petroleum Ltd Nexen Saudi Aramco Shell UK Oil Products Limited Shell U.K. Exploration and Production Ltd Statoil (U.K.) Limited Talisman Energy (UK) Ltd Total E&P UK plc Total UK Limited Copyright 2008 by the Energy Institute, London The Energy Institute is a professional membership body incorporated by Royal Charter 2003. Registered charity number 1097899, England All rights reserved No part of this book may be reproduced by any means, or transmitted or translated into a machine language without the written permission of the publisher. ISBN 978 0 85293 526 2 Published by the Energy Institute The information contained in this publication is provided as guidance only and while every reasonable care has been taken to ensure the accuracy of its contents, the Energy Institute cannot accept any responsibility for any action taken, or not taken, on the basis of this information. The Energy Institute shall not be liable to any person for any loss or damage which may arise from the use of any of the information contained in any of its publications. Further copies can be obtained from: Portland Customer Services, Commerce Way, Whitehall Industrial Estate, Colchester CO2 8HP, UK. Tel: +44 (0) 1206 796 351 e: sales@portland-services.com Electronic access to EI and IP publications is available via our website, www.energyinstpubs.org.uk. Documents can be purchased online as downloadable pdfs or on an annual subscription for single users and companies. For more information, contact the EI Publications Team e: pubs@energyinst.org

CONTENTS Page Foreword... v Acknowledgements...vi 1 Introduction... 1 2 Scope... 3 3 Petroleum road tanker vapour collection equipment... 4 3.1 General... 4 3.2 Functionality of key road tanker components for vapour collection... 4 3.2.1 Pressure and vacuum (PV) breather vent... 4 3.2.2 Vapour transfer valve... 4 3.2.3 Vapour manifold... 5 3.2.4 Vapour manifold vent valve... 5 3.2.5 Vapour down pipe... 5 3.2.6 Vapour collection adaptor... 5 3.2.7 Liquid detection device... 6 3.2.8 Interlock for hose coupler... 6 3.3 Vapour transfer hose and hose couplers... 6 3.3.1 Vapour transfer hose... 6 3.3.2 Vapour transfer hose couplers... 6 4 Requirements for the operation of service equipment by the tanker control system 8 4.1 General... 8 4.2 Operation of vapour transfer valves... 8 4.3 Control of vapour transfer valves... 8 5 Forecourt vapour connection point... 10 5.1 Vapour transfer hose forecourt connection... 10 6 Model procedure for vapour collection delivery... 11 6.1 General... 11 6.2 Sequence of unloading operations involving vapour collection... 11 Annex A Key hazards associated with vapour collection deliveries... 14 A.1 General... 14 A.2 Excessively high (or low) pressure in the filling stations USTs and vapour collection system... 14 A.3 Failure of the liquid seal in storage tanks... 15 A.4 Liquid in vapour systems... 15 A.5 Diesel deliveries... 16 iii

Contents Cont... Page Annex B References... 18 Annex C Road tanker vapour transfer hose connection... 20 Annex D Filling station vapour transfer hose connection... 21 iv

FOREWORD This publication has been prepared by Robert Harris, Amber Engineering Consultancy Ltd, at the request of the Energy Institute's (EI s) Distribution and Marketing Committee and the UK Health & Safety Executive (HSE). This code provides recommendations for the design and operation of vapour transfer equipment and control systems on petroleum road tankers used during the unloading of petrol at filling stations. It is particularly applicable to the designs of tankers operated in the UK. At the time of publication, vapour collection has been practised for some 15 years in the UK. During that period, experience has been gained in system designs and operation and road tanker equipment has evolved. This publication draws on those experiences to document good practice. The EI is not undertaking to meet the duties of employers to warn and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local and regional laws and regulations. The information contained in this publication is provided as guidance only, and while every reasonable care has been taken to ensure the accuracy of its contents, the EI cannot accept any responsibility for any action taken, or not taken, on the basis of this information. The EI shall not be liable to any person for any loss or damage which may arise from the use of any of the information contained in any of its publications. The above disclaimer is not intended to restrict or exclude liability for death or personal injury caused by own negligence. Suggested revisions are invited and should be submitted to the Technical Department, Energy Institute, 61 New Cavendish Street, London, W1G 7AR. v

ACKNOWLEDGEMENTS The author wishes to acknowledge the assistance and support given by the following: Geoff Easton Peter Godfrey John Hazeldean Trevor Mason Cobham Fluid Systems Wright Engineering HSE Purfleet Forecourt Services An earlier draft of this publication was reviewed by members of the EI s Distribution and Marketing Safety Committee, Road Tanker and Distribution Contractor s Panels, Service Station Panel and Vapour Recovery Working Group. The EI gratefully acknowledges the contributions made by those during the development of this publication. The EI also acknowledges comments received by Roger Marris (West Yorkshire Fire and Rescue Service). Project co-ordination and technical editing was undertaken by Andrew Sykes (EI). vi

1 INTRODUCTION EU Directive 94/63/EC made vapour recovery a requirement from 31 December 1998 for existing distribution terminals loading more than 150 000 tonnes of petrol per annum, and for filling stations handling more than 1 000 m 3 of petrol per annum 1. These thresholds were reduced to 25 000 tonnes and 500 m 3 respectively from 31 December 2001 and were further reduced to 10 000 tonnes and 100 m 3 respectively from 31 December 2004. The principles of vapour collection are very simple 2. When bottom loading a road tanker, incoming fuel (driven by the terminal/refinery pumps) forces gases (including petrol vapour) from the tanker compartments into the tanker s vapour manifold, down the vapour transfer line to the loading gantry connection and from there to the terminal vapour recovery unit, where the petrol vapour is returned to the liquid state before being pumped back to storage. When unloading at a filling station the process is reversed. Petroleum product leaving the road tanker flows under gravity to the site s underground storage tank(s) 3, driving vapour from the filling station s storage tanks into its vapour manifold, through the vapour transfer hose and back into the tanker (figure 1). Despite the apparent simplicity of the process, experience has shown that a number of factors can exacerbate latent problems in a system that has poor design, installation, or maintenance. The pressures and vacuums involved with the transfer of thousands of litres of vapour per minute are modest and inevitably the vapour does not necessarily flow as anticipated, particularly if restrictions or leaks exist anywhere in the system. Information relating to potential hazards during deliveries is given in annex A. Process safety considerations (including those required by, for example, the Dangerous Substances and Explosive Atmosphere Regulations 2002) and potential effects on health and the environment when handling petroleum products and their vapour, have led to a reassessment of the equipment, control systems and procedures for stage 1b vapour collection. In developing this code, consideration has been given to a number of tanker system designs used in service, general process safety recommendations and the specific legal requirements on road tanker operators to operate tankers that have vapour collection systems 4. The guidance in this code is primarily intended for new road tanker vapour collection systems. However, as modifications to a tanker control system are not onerous, operators may wish to consider adopting its recommendations retrospectively. 1 European Parliament and Council Directive 94/63/EC of 20 December 1994 on the control of volatile organic compound (VOC) emissions resulting from the storage of petrol and its distribution from terminals to service stations. 2 EI Guidelines for the design and operation of gasoline vapour emission controls at distribution terminals, 3rd edition. 3 A very small number of filling stations have above-ground storage of petrol requiring pumped deliveries; this does not alter the recommendations given in this publication. 4 As detailed in HSE L93 Approved Tank Requirements: The provisions for bottom loading and vapour recovery systems of mobile containers carrying petrol. Page 1

P/V valve STAGE 1b VAPOUR COLLECTION Free (atmospheric) venting Note: On some sites the diesel may be connected to the vapour collection system P/V breather vent Vapour transfer valve Coaming manifold Vapour transfer hose Vapour collection adaptor Petrol delivery hose Fill pipe cap Poppet valve Vapour transfer pipe/connection point Bottom loading adaptor Foot valve Legend: Diesel Petrol Petrol Petrol Vapour Petrol P/V Pressure/vacuum Figure 1: Stage 1b vapour collection Page 2