Loading and unloading operations

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The last edit to this post was made by skzjz on 2019-3-30 at 09:35. Operating Procedures for Loading Finished Oil I. Inspections Before Loading Finished Oil 1. Pre-loading inspections ① Visual inspection: After the vehicle designated for loading stops in the designated parking area, inspectors should examine its external conditions. If any obvious abnormalities are detected, they should inform the driver and the dispatch staff immediately; only after understanding the situation can it be decided whether to proceed with the loading process； ②Check whether all the required documents and licenses are in order: The permit for the use of mobile pressure vessels, the permit for transporting hazardous materials, as well as the licenses for drivers and escorts must all be available. Filling operations cannot be carried out if any of these documents or licenses are missing or have expired and not been renewed ； ③Inspection of filling vehicle facilities: Check whether there is residual pressure in the containers of the filling vehicles, whether the shut-off valves and drain valves operate smoothly, and whether there are any leaks ； Filling is strictly prohibited for vehicles with severe leaks or abnormal meter readings ； ④Inspect the safety equipment on tank trucks: check whether the vehicles are equipped with qualified flame arresters and safety valves, whether they have grounding wires, and whether the fire extinguishers are in good condition. In cases where the flame arresters, safety valves, or grounding wires are substandard, or if there are defects in the fire extinguishers, loading must be prohibited. Loading may proceed only after necessary corrections have been made. 2. Inspection during filling: ① Check whether there are any leaks at the interfaces of the filling connection pipes, valves, and gauges. Upon detecting any leak points, immediately halt the filling process; after rectifying the issues in accordance with requirements, proceed with the filling again ； ②Check whether the filling metering display is working properly ； Check whether the filling equipment is working properly ； 3. Inspection after filling: ① Check whether there are any leaks at the filling connection pipes, valves, and meters ； ②Vehicle exterior inspection ； ③Is the filling inspection record form completed fully? ； II. Loading of refined oil: Naphtha, heavy naphtha, mixed benzene, and hexane flow by gravity to the oil transfer pump room; there, the pumps are activated to load the products at the loading stations. 1) The finished oil loading area is a hazardous location; open flames and smoking are strictly prohibited, and no unauthorized vehicles are allowed to enter. 2) Before loading, contact should be made with the tank farm to drain the water from the blended refined oil, and then open the appropriate valves. 3) The loading arm should be equipped with a grounding electrode; once the oil tanker is in place, this grounding electrode must be connected to the tank itself, so that the static electricity generated during the flow of oil can be quickly conducted into the ground. The personnel at the loading station are responsible for overseeing this process, checking whether the driver follows the procedures, and ensuring that the grounding system is not damaged. 4) Adjust the oil transfer hose to the proper position, control the opening degree of the valves, and keep the flow rate within 2 m/s in order to prevent excessive generation of static electricity and significant loss of oil and gas. 5) Once oil filling is complete, disconnect the dip pipe and put on a seal to prevent leaks. All of the above operations must be supervised on-site by the duty personnel, to ensure that the drivers do not commit any violations or rules, and to guarantee that the industrial processes are carried out correctly and that the equipment is in good condition. III. Management System for Loading Finished Products 1) Vehicles coming to pick up goods must enter the loading area in order, according to the sequence indicated on the delivery orders. Before entering the area, they must clean off any oil or dirt from their vehicles before being allowed to enter. 2) All valves on the vehicle’s tank must be tight; any leakage is not allowed, otherwise the vehicle will not be permitted to enter the plant for loading. If the site is contaminated during entry to the warehouse or loading, they shall be ordered to clean it up. 3) The vehicles used for picking up the goods must have all necessary documents (such as a driver’s license, vehicle registration certificate, permit for transporting hazardous materials, and certification for handling hazardous materials), and the license numbers must match those on the vehicle. Safety equipment such as fire suppression devices must also be present in proper condition; otherwise, loading the goods is strictly prohibited. 4) After the empty vehicle has been weighed, the customer shall hand the delivery note (vehicles carrying light oil must also provide the “Registration Form for Inspection and Approval of Hazardous Chemicals Loading”) to the operator on duty. If a single type of refined oil is stored in multiple tanks, this information should be communicated to the operator on duty, who will then indicate the amount of oil in each tank in the upper right corner of the delivery note; the customer can then go to the designated loading area to pick up the oil. 5) Once the truck arrives at the designated loading point, shift into gear, turn off the engine, and engage the handbrake. Place shims under the tires on both sides of the tank truck, and connect the static electricity grounding alarm device. Prevent the vehicle from rolling backward. 6) Before loading, the duty officer must carefully verify the delivery documents to confirm the name of the oil product and the loading station, check the safety facilities, and only after confirmation can the bill of lading number be entered. Report any issues promptly; unauthorized shipping is strictly prohibited. During the loading process, the duty personnel must go to the loading port to inspect the quality of the oil. The receiver should stand at a safe distance from the loading port to keep watch. After loading is complete, the oil collection drum should be properly hung up (ensuring all residual oil is drained before hanging). Finally, the swivel joint, ladder, static grounding wire, and other components must be returned to their original positions. Otherwise, the duty officer has the right to retain the shipper’s delivery documents. 7) After refueling is completed, remove the fuel hose and return the loading arm and static grounding device to their original positions before starting the vehicle. It is prohibited to leave the refueling hose on the platform, as this may cause contamination of the platform. 8) Customers are prohibited from taking samples from the warehouse without permission; if sampling is necessary, it must be done under the supervision of a staff member on duty. 9) Before shipping, the warehouse management staff should inform the drivers, passengers, and customers of the safety rules to be followed in the warehouse (such as: no use of mobile phones, no smoking, no wearing shoes with nails, etc.). Customers must respect and comply with the instructions of the shipping staff; they are not allowed to enter the control room unless there are special circumstances, and they must wear the appropriate protective equipment. 10) At each fixed loading crane location within the factory premises, only one loading vehicle is allowed at a time; that is, while one vehicle is being loaded, only one other vehicle may wait to be loaded. Operating Procedures for Loading Liquefied Hydrocarbons I. Inspection Before Loading Liquefied Hydrocarbons 1. Pre-loading inspection tasks ① Visual inspection: After the vehicle designated for loading is parked in the designated area, inspectors should examine its external conditions. If any obvious abnormalities are detected, they should inform the driver and the dispatch staff immediately; only after understanding the situation can it be decided whether to proceed with the loading process ； ②Check whether all the required documents and licenses are in order: The permit for the use of mobile pressure vessels, the permit for transporting hazardous materials, as well as the licenses for drivers and escorts must all be available. Filling operations cannot be carried out if any of these documents or licenses are missing or have expired and not been renewed ； ③Inspection of filling vehicle facilities: Check whether there is residual pressure in the containers of the filling vehicles, whether the shut-off valves and drain valves operate smoothly, and whether there are any leaks ； Check whether the pressure gauges and thermometers on the containers of the refueling vehicles are intact and functioning properly ； Filling is strictly prohibited for vehicles with severe leaks or abnormal meter readings ； ④Inspect the safety equipment on tank trucks: check whether the vehicles are equipped with qualified flame arresters and safety valves, whether they have grounding wires, and whether the fire extinguishers are in good condition. In cases where the flame arresters, safety valves, or grounding wires are substandard, or if there are defects in the fire extinguishers, loading must be prohibited. Loading may proceed only after necessary corrections have been made. 2. Inspection during filling: ① Check whether there are any leaks at the interfaces of the filling connection pipes, valves, and gauges. Upon detecting any leak points, immediately halt the filling process; after rectifying the issues in accordance with requirements, proceed with the filling again ； ②Check that the pressure and temperature are within the allowable ranges; filling under conditions of excessive temperature or pressure is prohibited ； ③Check whether the filling metering display is working properly ； Check whether the filling equipment is working properly ； ④The static grounding device and emergency shutdown device are functioning properly ； 3. Inspection after filling: ① Check whether there are any leaks at the filling connection pipes, valves, and meters ； ②Check whether the pressure and temperature of the tank truck are normal ； ③Are all the vehicle’s safety accessories and loading/unloading attachments in good condition? ； ④Is the filling inspection record form completed fully? ； ⑤Whether the vehicle is overweight after loading, and whether it needs to be unloaded again ； ⑥Has the static grounding device for the vehicle been removed? Are the blocking blocks placed in their designated positions? ； ⑦Are all the connectors between the tank and the loading/unloading platform detached? ； II. Loading of liquefied hydrocarbons using shielded pumps 1) After the tank truck arrives at the loading platform and is aligned, open the valve box of the tank truck, firmly connect the gas and liquid phase pipes of the dip pipe to the corresponding valves on the tank truck, and install the anti-static grounding wire for the tank truck. 2) Open the valves on the liquid-phase pipe and gas-phase pipe between the tank truck and the dip pipe. 3) Improve the process, start the shielded pump, and begin loading. 4) During loading, the liquid phase is drawn from the storage tank using a shielded pump for loading. If the pressure inside the tank rises, the gas phase in the tank returns to the storage tank via the gas line. 5) Once loading is complete, close the liquid-phase valve and the gas-phase valve, and at the same time remove the loading dip pipe and static grounding wire connected to the tank truck. 6. Gas recovery: The remaining gas in the tanker enters the spherical tank from the freight yard via the gas-phase return line. III. Management System for Loading Liquefied Hydrocarbons 1) Personnel responsible for loading at the warehouse must first receive specialized safety and technical training; they must pass the relevant assessments to obtain a safety operation certificate. In addition, they need to pass evaluations by their superior supervisory authorities to get a “Mobile Pressure Vessel Filling Certificate” before they can carry out filling operations, with everyone working only after holding such a certificate. 2) Persons entering the liquefied hydrocarbon storage area are strictly prohibited from bringing any kind of ignition sources; they are also not allowed to wear shorts, tank tops, shoes (boots) with metal studs, or clothing that may generate static electricity ； Turn off non-explosion-proof communication devices such as mobile phones. 3) Vehicles entering the liquefied hydrocarbon storage area must not exceed a speed of 5 km/h; the exhaust pipes must be equipped with appropriate fireproof caps, and audio devices such as car radios and CD players must be turned off. 4) Safety inspection before filling liquid hydrocarbons. The on-duty shift leader is responsible for conducting a thorough inspection of the tank truck, and filling out the inspection and registration forms for hazardous materials loading as required. Shipment will not be permitted under any of the following circumstances: (1) The quality marking text does not comply with regulations or is difficult to identify. (2) Users who modify the tank truck or apply color to it on their own. (3) Vehicles without a tank filling certificate, or whose filling certificate has been altered or does not match the information on the vehicle’s nameplate. (4) The tank truck filling certificate, transportation permit or usage license, driver’s license, and escort permit have exceeded their valid period of use. (5) No transport permit or driving license; no escort, or an escort is present but without a transport permit. (6) Tank trucks that have exceeded their maintenance period without undergoing regular inspections, as well as those without a copy of the regular inspection report for the tank truck. (7) The remaining pressure in the tank car is < 0.1 MPa. (8) The tank truck shows obvious mechanical damage, deformation, and severe external corrosion, rendering it unsafe for use. (9) Tank car tanks that are missing accessories or parts, are damaged or do not meet the specified requirements, and those without a gauge indicating the relationship between liquid level and volume. (10) Protective equipment, clothing, specialized maintenance tools, as well as spare parts must be carried with the vehicle; any items that are missing are not allowed ； (11) Road tank vehicles that are put into use for the first time or after being inspected and repaired must undergo vacuum pumping or nitrogen purging; the vacuum level must be below 86.7 kPa, or the oxygen content inside the tank must be greater than 1%. (12) Check that the tank, safety accessories, valves, and fire-fighting equipment are complete and show no abnormalities. (13) In summer, the pressure in the tank truck should be greater than 0.7 Mpa; in winter, it should be greater than 0.3 Mpa. (14) There are other impurities such as water inside the tank truck. 4. Specific requirements for filling operations: (1) After the tank truck has come to a stop at the designated location, the crew should turn off the engine, apply the hand brake, and close the doors. Place shims under the tires on both sides of the tank truck, and connect the static electricity grounding alarm device. (2) The tank truck crew is responsible for connecting the gas-liquid two-phase quick connector to the vehicle and securing the double grounding wires. (3) After all inspections have been completed as required and found to be satisfactory, open the relevant filling valves and the emergency shut-off valves of the tank truck. Pumping and filling can begin only after verification, and the vapor line valve is opened when the pressure in the tank equals the pressure in the storage tank. (4) During the filling process, the operator must remain at their post at all times, must not leave, must not be on the vehicle, and must not engage in any activities unrelated to the work. They should also conduct regular checks (to ensure that pressure is normal, that there are no leaks in the tank or valves, and that connections are secure), address any issues found promptly, and report to the workshop and the company if necessary. (5) During the filling process, the operator should regularly check the pressure gauge of the tank truck (1.5 MPa for liquefied gas). The maximum filling capacity specified on the purchase party’s tank truck certificate must match the maximum filling capacity indicated on the tank truck’s nameplate. Otherwise, the minimum filling volume of the two shall apply, and overfilling is strictly prohibited. (6) After filling is complete, the tank truck crew closes the relevant valves on the tank truck and the loading arm, disconnects the quick connectors, and returns the static electricity grounding alarm device and the double grounding wires to their proper positions. (7) After filling is completed, the original filling record must be carefully filled out (user of the tank truck, vehicle type, medium, date, filling volume, specified load capacity, filler, and escort person), and kept in a proper manner. (8) Before starting the tank truck, the driver and operator must ensure that all connections between the tank truck and the loading arm are properly disconnected. And leave the filling area as soon as possible. (9) Contact the security guard based on the conditions at the freight yard to control vehicles entering the site. After entering the factory, vehicles awaiting loading must stay in designated areas after passing inspection by the operators; they are not allowed to be parked randomly in the cargo yard. (10) The operator shall use the pump in accordance with its specified parameters; the purchaser shall not harass the warehouse staff on the grounds of quick installation and disassembly. (11) It is strictly prohibited to perform vehicle maintenance in the freight yard (including cleaning the vehicles). (12) It is strictly prohibited to start the vehicle during the filling process. (13) It is strictly prohibited for persons other than those working at the freight yard to enter the pump house, and it is even more forbidden to start or stop the equipment without permission. (14) It is strictly prohibited for anyone to “sleep on the floor” within the freight yard. (15) After the loading/unloading operations are completed, a standing time of at least 2 minutes is required before proceeding with tasks such as removing the swivel joint and disconnecting the grounding wire. (16) After the tanker arrives at the designated loading/unloading bay, the engine must be turned off and the keys placed in the designated location. 5. If any of the following situations occurs during the filling process, stop filling immediately and identify the cause. (1) When filling with liquefied gas, the pressure in the tank truck has reached 1.5 MPa. (2) During the filling process, the static electricity alarm went off suddenly. (3) Encountering thunderstorms, bad weather, and open flames in the vicinity. (4) In the event of a leakage of flammable, explosive, or toxic substances in the vicinity, as well as in the event of fires or explosions in the surrounding area. (5) Leaks in the loading pipes and tank cars, as well as sudden activation of the safety valves. (6) The emergency shut-off valve of the tank truck suddenly malfunctioned. Unloading Procedures I. Unloading Operations 1. Pre-unloading inspections 1) Before unloading, it is necessary to check the “four certificates” (i.e., the tank truck usage certificate, the chemical hazardous materials transportation certificate, the driver’s license, and the escort’s license). 2) Those without valid permits or with incomplete permits are not allowed to enter the loading area. Only after the procedures are completed can loading be permitted. 3) Before unloading from the tank truck, it is necessary to first check the quality of the product, verify that the seal number on the tank truck is correct, and inspect whether there are any impurities such as water inside the tank. Unloading is only permitted after these checks confirm that everything is in order. 2. Unloading operation: 1) After the tank truck arrives at the unloading platform and is aligned, open the valve box of the tank truck, firmly connect the liquid-phase pipe of the storage tank to the corresponding valves on the tank truck, connect the anti-static grounding wire of the tank truck, and place shims in place. 2) Open the valve on the liquid-phase pipe between the tank truck and the storage tank. 3) Improve the process, adjust the valves, start the centrifugal pump, and begin unloading. 4) During unloading, pay constant attention to the reading on the pressure gauge and adjust the opening degree of the outlet valve to prevent the pump from running dry. 5) Once unloading is complete, close the liquid phase valve, and at the same time remove the unloading hose and static grounding wire connected to the tank truck. II. Precautions: 1. Unloading management system 1) Unloading at the fueling station is permitted only after verifying that the documents match. If the duty personnel at the oil platform detect that the lead seals are incorrect or damaged, they should inform the driver or contact the Production and Environmental Protection Department for verification. 2) After the oil transport vehicle is weighed for the first time at the loading platform, the personnel on duty at the unloading platform are required to supervise the removal of all surface water on site. Once it is confirmed that there is no surface water left, they must record the details of this water removal process, after which the oil tanker can be allowed to return for another weighing. 3) During oil unloading, the personnel on duty at the unloading platform must be present to regularly check the quality of the oil being unloaded (including levels of water and impurities). If any issues are detected, unloading must be stopped immediately, and a report must be submitted. 4) After the unloading is complete, the driver is responsible for cleaning up any debris such as wires, gloves, plastic sheets, etc., that remain in the unloading tank from the process of unloading his own vehicle, and placing these items in the designated area on the unloading platform ； 5) After the oil unloading is complete, the driver must place the lead seals on this vehicle (a total of 2) in the location designated by the personnel in charge of the unloading area; it is strictly prohibited to discard them arbitrarily. Otherwise, the personnel in charge of the unloading platform have the right to refuse to process the relevant procedures and impose penalties on the driver involved. The personnel in charge of the unloading platform must check whether the tank truck has been completely unloaded; only after confirming that the unloading is complete can they sign to grant permission for departure. 6) Before the oil-unloading vehicle leaves the unloading platform, the platform supervisor must go to the site in person to conduct an inspection. Only after confirming that the site cleanliness, the placement of pads, and the repositioning of static electricity discharge grounding wires/clamps are all in compliance with requirements can the \"communication form\" be handed over to the driver, after which the vehicle is allowed to depart. 7) The personnel in charge of the oil unloading area should check whether the oil transport vehicles are equipped with qualified fireproof caps, and vehicle maintenance or other activities that may generate sparks are prohibited in the oil unloading area. 8) It is prohibited for the personnel in charge of the oil unloading platform to deliberately create difficulties for drivers, accept money or goods from them, or use their positions for personal gain. 9) The personnel in charge of the unloading platform should maintain timely contact with the tank farm to monitor the liquid level of the oil there, and use this information to determine the unloading speed, thereby ensuring proper unloading of the oil and preventing any leaks. 10) The personnel in charge of the oil unloading area have the right to detain the vehicle carrying the oil if they detect problems with its quality (in the absence of prior notification from the relevant authorities), and to inform the workshop or relevant departments to handle the matter. 11) The personnel in charge of the oil unloading platform must remain at their posts and provide services for oil unloading day and night; sampling and unloading operations must not be delayed on account of meals, shift changes, or other reasons. 12) When unloading vehicles, the personnel in charge of the unloading platform should remain at their posts to control the unloading speed and prevent oil leakage accidents ； In the event of an oil leakage accident, penalties are imposed in accordance with regulations. 14) The personnel in charge of the oil unloading platform should properly store the tools distributed, and maintenance records should be kept for the shared tools. 15) Provisions for sampling and sample retention in the oil unloading system: (1) There is no requirement to take samples from each oil-unloading vehicle; sampling is carried out in accordance with the instructions issued by the Production and Environmental Protection Department. The specific timing for sampling is communicated by the duty personnel to the laboratory staff, who then carry out sampling as required ； (2) When the oil unloading vehicle detects water content, the on-duty personnel responsible for unloading the oil should immediately inform the laboratory staff to take samples together. Samples should be stored properly at night; the container holding the samples should be labeled with information such as the type of oil, the time of sampling, the vehicle license plate number, and the location where the oil was unloaded. Records should also be kept in the operation log. Once the laboratory staff arrive at work, the samples should be handed over to them, with proper handover records made. The sample retention containers are provided by the testing laboratory, and are kept by the oil unloading duty personnel.