A.

SOP for wagon Decantation Shed

After placement of tank wagons

• Place 'CAUTION' and 'NO SMOKING' board at ends of tank wagon decantation siding.
• Check that breaks are applied before engine is disconnected from the TW and dummy is attached at
both the ends of the rake then put stop board on the track.
• During placement of TW instruct security personnel that no unauthorized person or miscreant enters
the terminal. Check for explosive material entering terminal through the rake. Obtain placement
memo from railways and close siding gate.
• Connect bonding wire of pipelines with Tank Wagons at regular intervals.
• Check the product and dispatch location from the paste on label.
• Check for ownership, stray connected wagons & match the details with the SAP.
• Check the tank wagons for leakage/dripping and ascertain that the manhole covers are in closed
position with all seals intact.
• Check the sealing and nut bolts on both the manhole covers and all four discharge headers dummies.
• While opening of the tank wagon manhole cover ensure that no suspected material is kept inside or
fitted with tank wagon fittings.
• A bottom sample from white oil tank-wagons shall be drawn and tested for Test “A’ as per IQCM -
visual color, appearance, density @ 15 Deg C for grade identification, In case of non-aviation density
variation allowed is +-3.0 kg/m3 whereas for aviation it is +- 2.5 kg/m3.
• When taking the dip, presence/absence of water should be checked. The observations made after
doing the checks and the corrective action taken shall be recorded in the register.
• Check top and bottom seals of tank wagons and if found broken/ missing,
• Issue memo to Railways for open delivery.
• While taking open delivery, point out to the railway staff the defects in the tank
• wagons and after opening the tank wagon in their presence record the gross dip, water dip and
temperature.
• A joint certificate with the stamp and signature of railway officials should be obtained giving all these
particulars and then forwarded to the Regional Office to enable the Claims Section to file a claim on
the railways for any shortage that may have been observed at the time of open delivery. After
confirmation from regional office, book claimable shortage in SAP.

Unloading operation
• Check whether track is free and no materials are placed, Retractable ladders are in retracted
position.
• After confirmation from SAP/S&D, check the product for density and visual appearance.
• After confirmation of product and ownership plan to decant the TW.
• Always wear safety belt and safety goggles while going on top of Tank wagon.
• Open the manhole covers. Check that the person on the job is using proper PPE’s and non-sparking
tools etc.
• Brief manpower for connection of hoses in the specified product unloading line.
• Ensure that jumper connection is available between TW dummy flange & unloading hose and tank
wagons and pipeline header point is connected with earthling wire.
• Place bonded bucket/half cut barrel below TW flange for collection of spilled product, if any.
• Check the dips of TW using oil finding paste and water finding paste. If any water found record in the
unloading sheet.
 • After checking dips and ensuring product qty, connect the hose to the correct unloading line, open
the master valve from top of the TW, then open the bottom audco valve and line Ball valve and
ensure that there is no leakage.
• After T/W receipt, corresponding storage tank Upper, Middle and Lower samples shall be individually
subjected to Test ‘A’ (Appendix 2 of IQCM) and the observations recorded before
commencement of delivery from the tank. Simultaneous receipt and dispatch from the same tank is
not permitted. If the density variation of UML is more than +3.0 Kg/m3 between any two layers,
density shall be closely monitored at filling point during dispatches and record maintained.
• When 3 or more T/W of each grade are received, sample should be drawn from initial, middle and
last wagons. When less than 3 T/Ws of each grade are received, sampling are to be done from
individual wagons. Such samples shall be retained for a period of 15 days (Appendix 2A of IQCM)
and record to be maintained.
• Upon completion of decantation, remove the hose connection, Bonding wire.
• Decantation Hoses shall be capped after completion of decantation.
• Check whether all the retractable ladders are in proper retracted position.
• Check whether the track is free, and no materials are placed on track.

Unloading pumphouse operation

• Ensure product hoses are properly connected with wagon.

• Nominate tank(s) for decantation.
• Line-up nominated tank and pump for wagon decantation.
• To remove pipeline air, open air venting valve of designated product near siding pump house and
then gradually open audco valves of wagons one by one.
• After complete removal of air, close air venting line and open valves starting from wagon pump
house to nominated tank.
• To Start pump for decantation: Ensure that Red push button is released. Press the green button to
start pumping.
• Continuously monitor pump suction and discharge pressure.
• On completion of decantation, Press red push button to stop pumping operation.
• Close all the valve on decantation line which are numbered in the reverse sequence that was used
for start of operation
 B. SOP for Ethanol Handling Facility
Ehtanol Decantation Pumphouse

• On arrival of Ethanol Tank Truck & after doing necessary quality checks of samples, Connect earthing
& decanting hose with bottom discharge valve of first compartment.
• Line-up nominated tanks and pump and open valves
• Care must be taken to avoid any ingress of water/moisture during decantation of tank truck. These
samples are to be tested for quality assurance as per laid guidelines.
• Open the bottom discharge valve and decant the tank truck compartments one after the other.
• To Start pump for decantation: Ensure that Red push button is released. Press the green button to
start pumping.
• Check TT crew is at unloading platform near valves to handle any emergency.
• On completion of decantation, Press red push button to stop pumping operation.
• Close all the valve on decantation line which are numbered in the reverse sequence that was used
for start of operation.

SOP for Quality Checks during ehtanol Decantation:

• On arrival of Ethanol Tank Truck, after checking for safety & Fitness requirement, one litre top and
bottom sample from each compartment of the tank truck shall be drawn after the line content is
drained off. Care must be taken to avoid any ingress of water/moisture during decantation of tank
truck/tank wagon. These samples are to be tested for the following parameters:

SN Sample Tests to be carried out as per IS: 15464

1 Top & Bottom Samples Visual Appearance
2 Individual sample of Top & Bottom Relative density/ Specific Gravity at 15.6/15.6°C
3 Composite Sample of all 1. Appearance
compartments 2. Colour (Visual)
3. Ethanol Content % Vol.
4. Relative Density/ Specific Gravity at
15.6/15.6°C,
5. Hydrocarbon Contamination check*

• For Hydrocarbon Contamination checks, to ensure that there is no

• contamination of hydrocarbon with Ethanol, take 50 ml of water in 100 ml
• clean graduated stoppered glass cylinder (A class), put 50 ml of Ethanol at
• the top of it. Stopper the cylinder and shake thoroughly for 15 sec. Set aside
• the cylinder. Observe that water is fully soluble with Ethanol and no layer is
• formed. This ensures no contamination of hydrocarbons with Ethanol.
• For determining Ethanol Content IS 2302 Tables for Alcoholometry by hydrometer method should be
used.
• Specific gravity can be derived by using the Ethanol Content and the Appendix B of IS 321. The
specification, however, includes option to determine specific gravity by the method given in IS 321.
 • If the sample meets the requirements as mentioned above, then one litre composite sample of
Ethanol from the tank truck shall be drawn (one litre composite sample to be prepared from Top and
bottom samples of all the compartments), sealed, labelled and jointly signed by the
driver/authorized representative of the transporter and the receiving officer of the oil company.
These samples shall be retained for a period of 30 days. Only glass or stainless steel sample
containers should be used.
• Aluminium containers should not be used for storing Ethanol samples.
• Product from the tank truck can be decanted into tank if found satisfactory, after comparing the
quality certificate of the consignment with that of the requirement of the characteristics. Relative
density/specific gravity at 15.6/15.6°C of Ethanol received at location shall be within (±) 0.0005 of
the dispatching location.
• Appropriate recommended dosage of corrosion inhibitor and anti-oxidant (if applicable) shall be
added during the decantation of Ethanol from tank truck into the storage tank. Ensure homogeneity
of additives with Ethanol in the storage tank.
• In case of failure of composite sample in any of the test parameter(s) mentioned above, the tank
truck shall be rejected for decantation.

SOP for ehtanol Decantation Shed

• Always wear safety belt and safety goggles while going on top of Tank Truck.
• Check all the safety & fitness requirement of the Tank Truck. Check dip of each compartment.
• One litre top and bottom sample from each compartment of the tank truck shall be drawn after the
line content is drained off. Necessary quality tests to be done as per guideline.
• Care must be taken to avoid any ingress of water/moisture during decantation of tank truck/tank
wagon.
• Product from the tank truck can be decanted, if quality & quantity found satisfactory.
• Unloading operations shall be carried out through special nitrile rubber hoses. Check that decanting
hose is electrically continuous.
• Remove the cap on decantation hose & connect with bottom discharge valve of first compartment.
• Connect earthing wire with Tank Truck properly.
• Place Fire Extinguishers at designated place before start of decantation.
• Open the bottom discharge valve and decant the tank truck compartments one after the other.
• TT crew must be at unloading platform near valves to handle any emergency.
• On completion of decantation, check the compartment emptiness by physical check.
• After completion of unloading, close master valve, remove unloading hose, close top fittings and
dome covers. Remove earthing connections.
• Both the ends of the hoses after use shall be capped.
• Drive out the empty TT from unloading area. Speed of TT inside terminal area shall not be more than
10 KMPH.
 C. SOP for NMA (Octane Booster) Unit:
SOP for TT Unloading
• On arrival tank lorry of N-Methyl Aniline (Octane Booster) of a new batch, verify
• the quantity and quality certificate of the Batch. After settling of TT for 10 minutes,
• one litre Top and bottom samples from each compartment of the tank truck shall be
• drawn after the line content is drained off.
• The unloading operations shall be carried out with the hose compatible for N-methyl Aniline.
• Remove the cap on decantation hose & connect with bottom discharge valve of first compartment.
• Connect earthing wire with Tank Truck properly.
• Open the bottom discharge valve and decant the tank truck compartments one after the other.
• TT crew must be at unloading platform near valves to handle any emergency.
• On completion of decantation, check the compartment emptiness by physical check.
• After completion of unloading, close master valve, remove unloading hose, close top fittings and
dome covers. Remove earthing connections.
• Both the ends of the hoses after use shall be capped.
• Drive out the empty TT from unloading area. Speed of TT inside terminal area shall not be more than
10 KMPH.

SOP for NMA (Octane Booster) quality check:

• The consignment of N-Methyl Aniline (Octane Booster) must carry manufacturer's Quality Certificate
and also Quality certificate of TPI if available. The manufacturer's Quality Certificate should contain
details of consignment viz. Tank no, Batch number & Quantity etc.
On arrival tank lorry of N-Methyl Aniline (Octane Booster) of a new batch, verify
the quantity and quality certificate of the Batch. After settling of TT for 10 minutes,
one litre Top and bottom samples from each compartment of the tank truck shall be
drawn after the line content is drained off. Sample shall be drawn in Glass or
Stainless-Steel container. Sample shall be checked for test parameters given in table
below:-

TT Number: Sample Drawn date:

Batch No. Quantity:
Suppliers Test Report Number: Relative Density at 15.60C:
SN Test Requirement Comp-1 Comp-2 Comp-3 Comp-4
1 Visual Clear &
Appearance Bright
2 Visual Pale Yellow
Colour to red brown
liquid
3 Density 0.9604 to
g/cm³ at 0.9904
15°C
Remark: Product Accepted / Rejected
Signature
• Refer the conversion table for comparison of RD with Density @ 15 deg centigrade.
• Density difference of +/- 0.0020 max between manufacturer's Batch test report density and
observed density at receiving location shall be accepted.
• sample passes in above mentioned requirements as per Table, TT shall be accepted, and record of
above quality checks shall be maintained. If all chambers density is with-in +/- 0.0020, two composite
samples of TT (one litre each) shall be prepared, sealed, labelled, jointly signed by the driver/
authorized representative of the transporter and the receiving Officer of the Location. If there is
density variation in respective chambers, chamber-wise composite samples shall be prepared. The
composite sample shall be retained at location for a period of 30 days. One joint sample may be
provided to Manufacturer / his authorized representative.
• In case product does not meet the requirement of any test parameter proper investigation shall be
carried out before accepting the product.
• The unloading operations shall be carried out with the hose compatible for Nmethyl Aniline. End of
the hoses after use, shall be capped when not in operation.
 D.SOP for Mechanized OWS

• Check the bar screen assembly. If there is any choke then remove it properly.
•
• Initially prime the all pumps though corresponding ball valves. ( B.V- 5 for feed pumps , B.V-20 for oil
transfer pump, B.V-21 for sludge pump)
• Check the input power supply and earth connection then Release the emergency push button and
Switch ON the Main switch in OWS Panel (R, Y, B and VAF meter will get ON).
• Now the system is ready to operate. First switch ON the Compressor to operate the EPV valves. Once
required pressure is achieved compressor will stop automatically.
• To run the oil skimmer select the switch auto / manual. If manual then select the respective ON/ OFF
switch. If auto then the system will run automatically based on the respective level switch
• To run the feed pump, first select the pump to be run (Working / Standby). Select the switch auto /
manual. If manual then select the respective ON/ OFF switch. If auto then the system will run
automatically based on the respective level switch – 01
•
• For Electro Pneumatic Valves select the switch Auto/Manual. If auto then the valve will be worked
based on oil sensor. If manual option it will work manually so as to remove the separated oil from
filters.
• Then switch ON the Purimeter (DOMS) to check the output treated water PPM. It will show the oil
content present in the output treated water.
• To run the floating skimmer pump, switch ON the floating skimmer pump.
• Then select the AUTO mode in oil transfer pump AUTO/MANUAL switch. If Oil level touches the top
level of the oil tank means it will start automatically otherwise select Manual mode and switch ON
the on/off switch to operate the oil transfer pump.
•
• To remove the sludge/solid from the tank, switch ON the sludge pump On/Off switch.
• Whenever emergency condition occurred press the Emergency push button switch. It will stops the
entire system operation.
 E. SOP for Vapour Recovery System (VRS)
A BRIEF DESCRIPTION

The vapour recovery system (VRS) is installed to recover the MS vapours generated
during loading at the TLF to prevent it from escaping into the atmosphere. It receives
the vapour through vapour inlet line and it is then adsorbed by activated carbon beds.
The dry screw vacuum pump regenerates the activated carbon by sucking MS vapour
from the bed. This vapour is then passed through an Absorption column where it is
mixed with the sprinkling MS liquid received from the tank and the mixture as a whole
is pumped back to MS tank.
B ALAWAYS ENSURE THE FOLLOWING BEFORE START THE UNIT
1. The Hand Valve (HV601) near the Flame Arrester(FA 601) is OPEN.
2. All inlet and outlet Valves of Pumps (MS Supply (HV 111, HV 112, HV 121, HV 122))
and MS Return(HV 211, HV 212, HV 221, HV 222) are OPEN
3. Condensate drain valve of absorption column (HV 314) should be CLOSED

C START OF THE UNIT

1. Through SCADA, select Auto mode to start operation of the unit
2. The VRU runs fully automatically. In the automatic mode, the units start and stop
according loading signal, received from Customer
3. If there is no loading signal and the activated carbon beds are sufficiently cleaned,
the units switch automatically to the “stand-by” mode.
D EMERGENCY SHUT DOWN
Four ESD provisions are provided in our system
A. Two ESD buttons provided at Skid
B. One ESD buttons provided at PLC Panel
C. One ESD (Soft) buttons provided at supervision PC
E MAINTENANCE
1. A daily check to be performed on the VRU for abnormal noises and vibrations in any
of its parts.
2. The pressure reading of the adsorber vessel regeneration must not fall below80
mbar absolute.
3. The temperature reading in the system should not exceed the following:-
a) For the elements installed inside the beds : 80°C
b) For the elements installed in the outlet of the adsorber vessels : 60°C