Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale
DEP 31.06.11.11-Gen.
February 2011
(DEP Circular 83/11 has been incorporated)
DEM1
DEP 31.06.11.11-Gen.
February 2011
Page 2
PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global
Solutions International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference
international, regional, national and industry standards.
The objective is to set the recommended standard for good design and engineering practice to be applied by Shell
companies in oil and gas production, oil refining, gas handling, gasification, chemical processing, or any other such
facility, and thereby to help achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at
each locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1)
Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by
these Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2)
Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part
of a Service Agreement or otherwise).
3)
Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI
disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or
person whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination
of DEPs or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell
Company. The benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies
affiliated to these companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and
the DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be
returned after use, including any copies which shall only be made by users with the express prior written consent of
Shell GSI. The copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe
custody and Shell GSI may at any time require information satisfactory to them in order to ascertain how users
implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
DEP 31.06.11.11-Gen.
February 2011
Page 3
TABLE OF CONTENTS
1.
1.1
1.2
1.3
1.4
1.5
1.6
1.7
INTRODUCTION ........................................................................................................5
SCOPE........................................................................................................................5
DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........5
DEFINITIONS .............................................................................................................5
CROSS-REFERENCES .............................................................................................9
SUMMARY OF MAIN CHANGES...............................................................................9
COMMENTS ON THIS DEP .......................................................................................9
DUAL UNITS...............................................................................................................9
2.
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3.
3.1
3.2
3.3
3.4
3.5
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
5.
5.1
5.2
AUTOMATION..........................................................................................................24
ADVANTAGES OF AUTOMATION ..........................................................................24
ASSESSMENT OF FUNCTIONAL REQUIREMENTS .............................................24
6.
6.2
6.3
6.4
7.
7.1
7.2
7.3
7.4
8
8.1
8.2
8.3
9
9.1
9.2
9.3
9.4
9.5
9.6
MISCELLANEOUS...................................................................................................32
EMERGENCY AND FIRE PROTECTION ................................................................32
PIPING ......................................................................................................................33
LOADING PUMPS ....................................................................................................34
ELECTRICAL REQUIREMENTS, EARTHING AND BONDING ..............................34
ILLUMINATION.........................................................................................................36
PAINTING .................................................................................................................36
DEP 31.06.11.11-Gen.
February 2011
Page 4
9.7
9.8
10.
REFERENCES .........................................................................................................38
APPENDICES
APPENDIX A
APPENDIX B
FIGURES.........................................................................................................42
DEP 31.06.11.11-Gen.
February 2011
Page 5
1.
INTRODUCTION
1.1
SCOPE
This DEP specifies requirements and gives recommendations for the design of loading
facilities for bulk road vehicles for common white and black oil products. Today, these fuels
may contain considerable amounts of bio components (specifically blends of gasoline with
ethanol, and blends of Automotive Gas Oil (AGO) with FAME (Fatty Acid Methyl Esters)).
This DEP may also be applied to other hydrocarbon and chemical products such as
bitumen and solvents, however, the Principal should be consulted for such applications.
This DEP clarifies the design issues and describes the hardware required but it does not
cover detailed design or engineering.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual DEM 1 Application of Technical Standards.
This is a revision of the DEP of the same number dated January 2010; see (1.5) regarding
the changes.
1.2
1.3
DEFINITIONS
1.3.1
General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
DEP 31.06.11.11-Gen.
February 2011
Page 6
1.3.2
Specific definitions
Term
Definition
air eliminator
bay
(1)
(2)
bio component
biodiesel
diesel fuel derived from vegetable oil or animal fat consisting of longchain alkyl (methyl, propyl or ethyl) esters
biofuel
a blend of main fuel grade (typically gasoline or diesel fuel) with a bio
component.
bonding
bottom-loading
envelope
class III oil products such as heavy fuel oils and residual fuel oils
NOTE:
NOTES
This excludes bitumen and contaminated products (e.g. products with free
water, particle matter, H2S).
This excludes:
1. contaminated products, e.g. with free water, particulate matter H2S;
2. products with true vapour pressures above 0.86 bar (12.5 psi), e.g. LPG,
pentanes;
3. very toxic substances (see DEP 01.00.01.30-Gen);
4. chemicals, e.g. ketones, alcohols, ethers, MTBE.
denatured ethanol
ethanol that has been rendered unfit for human consumption (often
by adding unleaded gasoline).
DEP 31.06.11.11-Gen.
February 2011
Page 7
Term
Definition
ethanol
Ethyl alcohol made primarily from corn, various other grains and non
grain feedstock. Ethanol comes in hydrous and anhydrous form.
Anhydrous is the most pure type and is preferred for blending.
FAME is an acronym for Fatty Acid Methyl Ester, the most common
type of biodiesel produced from natural oil. The natural oils react with
methanol and form the FAME. The type of FAME depends on the
type of natural oil used (rapeseed, soy, tallow etc).
flame arrestor
device used in gas vent lines to prevent the passage of flames into
enclosed spaces
foot valve
gantry
hose loader
assembly
loading area
area comprising all filling islands and bays but excluding vehicle
waiting areas.
loading arm
loading island
loading terminal or
facilities
meter pre-set
control
neat biofuels
is the term used for pure biofuels (before any mixing with main grade
fuels, such as gasoline or diesel, has taken place)
neat ethanol
occupancy ratio
proportion of any particular period for which the loading bay is in use
for the loading of bulk road vehicles
overfill protection
static electricity
ullage
vapour
DEP 31.06.11.11-Gen.
February 2011
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1.3.3
Term
Definition
vent
device for the release of hydrocarbon vapour or air from pipes, tanks,
or fittings, and for the entry of air
vent lines
working platform
area of the gantry structure from which the person loading the vehicle
from the top operates the meters, loading arms etc., and from which
access is gained to the top of the tank of the bulk road vehicles
Abbreviations
ADR
AFFF
AGO
AR
Alcohol Resistant
BOL
Bill of Lading
Bxx
COPS
CROSS
EPA
ERP
ESD
Exx
FAME
IGO
JDE
MTBE
NRV
Non-Return Valve
OEL
PD
Positive Displacement
pS/m
ppm
PVC
SAP
SDA
STEL
SWA
TMS
VFD
VOC
VRU
XLPE
DEP 31.06.11.11-Gen.
February 2011
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1.4
CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced by this DEP are listed in (10).
1.5
1.6
Old
section
New
section
Change
General
General
General
Gerneral
1.7
DUAL UNITS
Amended per
Circular 83/11
Dual units have been incorporated throughout this DEP.
This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
DEP 31.06.11.11-Gen.
February 2011
Page 10
2.
2.1
GENERAL
In the design of a loading terminal, the total cost of loading vehicles should be minimised.
The costs of the loading terminal include:
capital charges for the loading facilities (e.g. gantry, structures, pumps, lines,
automation system, VRU etc.).
manpower costs for the administration and surveillance of the loading activities.
the cost of vehicle time while in the yard, queuing for a loading bay, occupying the
loading bay and exiting the terminal.
Wherever possible, for products lighter than diesel fuel, Bottom Loading configurations shall
be used for all new gantry development works including refurbishment to achieve maximum
possible loading efficiency and truck utilisation, reduce group HSSE risks by improving
occupational health and minimise VOC emissions to the environment.
Top loading shall only be used when bottom-loading alternatives are not available and only
after carrying out an HSE risk assessment of the operations. Approved fall protections
systems shall be installed and used as designed.
2.1.1
Biofuels
When introducing neat biofuels, or fuels containing biofuels, into a Terminal, there are
several issues that shall be checked at the design stage, such as: product contamination;
materials compatibility with piping, pump seals and vapour recovery units; reduction of
conductivity with certain mixtures of FAME; product classification; type of fire fighting
systems and foam required; and spill containment facilities to deal with ethanol mixtures.
Usually conventional slops are fed back to refinery for reprocessing. Slops containing
Ethanol, FAME, MTBE, ETBE etc. shall not be fed back to the refinery and should be
treated differently than conventional slops (eg. incineration). The terminal shall implement a
proper Slops Management System for oxigenized products.
At terminals, any contamination of Jet Fuels with FAME (or with diesel containing FAME)
shall be avoided to ensure that the average level of FAME in a batch of jet fuel is below the
maximum level as specified in DEFSTAN91-91 for Jet A-1.
FAME shall be handled using procedures that do not allow the temperature to drop below
6C above the FAMEs cloud point to avoid formation of solids that can cause blockages of
fuel lines and filters. In areas of cold climate, depots should consider whether heating of
transfer lines is necessary to maintain the temperature at the correct level.
2.2
PEAK DEMAND
Any loading facility should be designed to meet the forecast loading demand during peak
periods. A statistical analysis of historical figures should be the starting point, but the effects
of planned improvements in methods and loading equipment and any changes likely to
occur in working hours, shift patterns, vehicle sizes and types, variations in demand growth
of different products, requirements for additional or fewer grades etc., shall be taken into
account.
2.3
2.3.1
DEP 31.06.11.11-Gen.
February 2011
Page 11
High loading flow rates reduce the time spent by a vehicle at a loading gantry, resulting in
the following:
(i)
(ii)
a reduction in the bay occupancy time, which could reduce the total number of
required loading bays.
On the other hand, the additional costs of pumps, larger bore piping, loading arms, flow
meters and other equipment, together with increased energy consumption, shall also be
taken into account.
For bottom loading, a 4-inch system should be employed (see 3.4.1).
2.3.2
2)
3)
4)
Detemine whether the vehicle / tanker is suitable for high speed loading
There are High Speed Loading vehicles / tankers that allow for higher loading rates and are
designed to meet certain specific requirements. If a vehicle/tanker is to be classed as
suitable for high speed loading, then all compartments on that vehicle SHALL [PS] be high
speed loading compartments.
DEP 31.06.11.11-Gen.
February 2011
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2.3.3
Flowchart for determining the maximum safe loading velocity for road tankers
Flammable atm
possible in
compartments?
No
Yes
Yes
No
Middle
distillate?
=<10 pS/ m or
unknown
Yes
Conductivity?
>50 pS/m
>10 pS/m
No
S
content?
S
content ?
>=50 mg/kg
<50 mg/kg
>=50 mg/kg
<50 mg/kg
H igh speed
loading
vehicle?
High speed
loading
vehicle?
No
Yes
vd<0.25,
v<7?
vd<0.35,
v<7?
No
vd<0.5,
v<7?
vd<0.38,
v<7?
Yes
Yes
No
Yes
No
Reduce loading
speed till
vd<0. 25, v<7
Yes
Reduce loading
speed till
vd<0.35, v<7
O K to load
Yes
No
No
Reduc e loading
speed till
vd<0.38, v<7
OK to load
Reduce loading
speed till
vd<0.5, v<7
OK to load
O K to load
v is the velocity in m/s and d is the internal pipe diameter in metres, and the variable (vd) is
the velocity times the internal pipe diameter expressed. The variable vd is expressed in
m2/s.
Flow limits
a)
a non-high-speed-loading vehicle,
loading speed SHALL [PS] give vd 0.25 m2/s ( 2.7 ft2/s); (max.
1200 L/min (11 ft3/min) with standard 10 cm (4 in) pipework).
II.
DEP 31.06.11.11-Gen.
February 2011
Page 13
b)
II.
c)
With:
I.
no flammable atmosphere; or
II.
III.
ii.
iii.
loading speed SHALL [PS] give vd 0.5 m2/s ( 5.4 ft2/s) (max. 2400 L/min (85
ft3/min) with standard 10 cm (4 in) pipework).
Diameter d should normally be the diameter of the smallest section upstream of the tank
being filled, but if the smallest section is less than 10 m (33 ft) long and has a diameter of at
least 67 % of the next smallest section, the diameter of the next smallest section may be
taken. This commonly allows the use of 3 inch meters (10 in ft) in DN 100 (NPS 4) bottom
loading systems, where vd>0.5 m2/s (5.4 ft2/s), but pipe length is limited to around 2 m (6 ft)
where flow conditioning straighteners are used.
If contaminated non-conductive liquids are loaded, the loading velocity should be limited to
1 m/s (3 ft/s). For liquids with a conductivity of more than 50 pS/m (50 micromhos/cm), no
loading velocity restrictions apply for static electricity reasons, but the loading velocity
should still be limited to 7 m/s (23 ft/s).
2.4
2.5
2.5.1
General
Depending on local circumstances the design of loading facilities should distinguish
between two design concepts as detailed below:
2.5.2
(i)
(ii)
DEP 31.06.11.11-Gen.
February 2011
Page 14
where all the vehicles have to be loaded in two hours (resulting in an average waiting time
of one hour for those vehicles which cannot be served immediately).
2.5.3
2.5.4
2.6
in the 'morning peak period' method, the peak period demand is the offtake by
those vehicles which queue outside the gate and which shall be loaded in the first
morning period (one or more hours).
in the 'waiting time' design method, the peak period demand is defined as the
offtake during (any) one hour in a period, which has the highest vehicle arrival
frequency. This period may be longer than one hour and can occur on more than
one occasion in any one day.
2.7
PUMP CAPACITIES
2.7.1
2.7.2
2.7.3
DEP 31.06.11.11-Gen.
February 2011
Page 15
3.
3.1
INTRODUCTION
Wherever possible, for products with a flash point lower than diesel fuel, Bottom Loading
configurations shall be used for all new gantry development works including refurbishment.
This Section describes the choice between the two systems and the construction details of
the loading arms/hoses including the provisions for vapour collection. Typical flow schemes
are also presented.
3.2
loading pump: pumps the product to the gantry to one or more loading arms (see
9.3);
b) emergency Shut Down (ESD) system and (optional) ESD valve: to isolate the
loading system rapidly in an emergency (see 4.4.4);
c) air eliminators: to eliminate air from the product if there is an operational need or
required by regulations. (see 4.3.7);
d) a filter or strainer: to ensure product cleanliness and to protect the flow meter and
couplings (see 4.3.6);
e) additive injection system (see 6.);
f)
flow meter (see 4.4);
g) flow control valve: to control the flow (see 4.4);
h) loading arm connected to a dry-break coupling (see 3.4);
i)
vapour return hose to VRU or to move vapours to a low risk location without
receptors. (see 3.4);
j)
overfill protection sensor: to give a signal if the road vehicle is overfilled (see 4.5);
k) bonding connection (combined with overfill protection connection): to discharge
static electricity generated during loading (see 4.6);
l)
interlock system: to prevent loading unless all conditions for safe operation are
fulfilled (earth connected, no overfill, vapour return hose connected etc.) (see 4.7);
m) isolation valves: to make maintenance possible and to stop the product flow in
emergencies (see 9.2.9);
n) drains and vents: to empty the system in case of maintenance (see 9.2.6);
o) meter prover connections: to connect a meter prover flow meter (see 4.3.5);
p) relief valves: to protect the system against overpressure, especially against thermal
expansion (see 9.2.10);
q) temperature sensors for volume correction (see 4.3.2);
r) pressure point: to enable the connection of a pressure gauge (see 4.3.5)
The flow scheme of a top loading facility is similar, apart from the loading arm and the
"dead man" valve, see Figure B.1c.
Figures 3.2, 3.3 and 3.4 clarify the special symbols used for bulk road loading vehicle flow
schemes.
3.3
DEP 31.06.11.11-Gen.
February 2011
Page 16
Top loading shall only be used for black oil products and heated oils in combination with a
dedicated vehicle fleet. In case of switch-loading, vapour collection and treatment shall be
installed, see also 7.3.1. A HSE risk assessment should be performed of the operations
including but not limited to:
working at heights
manual handling
escape routes
Approved fall protections systems shall be installed and used as designed. Preffered fall
protections are adequate posisionned guard rails. Ropes (life lines) should be used in case
existing guard rails would not offer sufficient protection against falling. Bottom loading
should be employed for solvents and common white oil products.
If changing over to bottom loading is considered, the following costs should be taken into
consideration:
a)
b)
c)
Top loading may be employed for the loading of black oil and heated products and for
locations where operating conditions would not allow any alternative. This should be based
solely on economics taking into account health/safety and future legislative requirements
(Fuel Oils can be loaded via bottom fill gantries).
3.4
3.4.1
Couplings
Liquid and vapour shear or break away couplings for loading systems and vehicles should
be in accordance with API RP 1004 (or equivalent).
No widely accepted standards for nominal DN 80 (NPS 3) loading couplings are yet
available. If couplings of nominal DN 80 (NPS 3) size have to be used, similar provisions to
those described in API RP 1004 should be applied.
Although operational reasons may justify the DN 80 (NPS 3) size system, the DN 100 (NPS
4) API system is generally preferred due to its higher loading rates and wide acceptance.
3.4.2
3.4.4
DEP 31.06.11.11-Gen.
February 2011
Page 17
Regardless of which type of loading arm is used, all arms/hoses etc. should be electrically
conductive with a resistance less than 10 .
3.4.5
3.4.7
3.5
3.5.1
Loading arms
A wide variety of loading arm configurations is available. The main points governing
selection are:
a)
b)
c)
loading rates,
d)
e)
accessories,
f)
The two main types of loading arms that should be employed are:
a)
b)
Provisions should be made to secure the arms during loading. When loading any volatile
product, the operator shall load from the platform and not while standing on the truck top.
DEP 31.06.11.11-Gen.
February 2011
Page 18
The use of loading arms at both bays of a loading gantry SHALL [PS] be allowed for in any
automatic interlocking earthing systems.
3.5.2
3.5.3
DEP 31.06.11.11-Gen.
February 2011
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4.
4.1
4.2
4.3
FLOW MEASUREMENT
4.3.1
4.3.2
4.3.3
4.3.4
Meter proving
Meters, particularly those used for custody transfer, should be proved periodically to
determine whether the indicated quantity in relation to actual quantity has changed as result
of wear or other factors. Any inaccuracies that have developed can be corrected by
adjustment of the calibrating mechanism, or by use of a factor derived from the proving
runs.
DEP 31.06.11.11-Gen.
February 2011
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Generally, bulk meters are proved 'in situ' by one of the following methods:
1) volumetric proving tanks;
2) reference master meters;
3) mechanical displacement provers including pipe and captive displacers.
4) small volume loop provers
Methods (1), (2) and (4), using mobile proving equipment, are generally applied to road
loading gantry meters, with method (4) being the preferred method. It is essential that a
gantry be designed to accommodate and safely operate the proving equipment. This
means that suitable connections/stubs with double block and bleed valves, in between
should be provided for easy connection. Double block and bleed valves should be located
between the two stub connections, not on the stub. For bottom and for top loading
applications with appropriate adapters, the proving valves and stubs are not required (i.e.,
proving is accomplished through the loading arms). Alternatively it shall be possible to
correctly position a mobile proving tank in order to achieve easy and safe filling and pump
out the contents. The layout of the proving system shall also allow easy and safe access to
sight glasses, thermometers, registers and scales for accurate measurement.
If a meter prover is installed the following applies:
a) The meter prover SHALL [PS] be bonded to the truck and the gantry.
b) All prover components SHALL [PS] be electrically connected with a constant
resistance of less than 10 .
c) The meter prover SHALL [PS] not incorporate a fine filter (< 150 m) to protect the
reference meter although a coarse strainer (> 150m) is acceptable. This is
essential as there will not be an adequate residence time between the meter prover
and the truck for the dissipation of any excess charge generated in the prover
system.
d) Meters should be proved under conditions of temperature, pressure and flow rate
closely resembling those of actual operation. This would encompass the usual
delivery flow rate into a tank prover. Another acceptable consideration is to prove
via pipe prover with the prover return line delivering to the transport truck. Some
designs include terminal return lines where, following the proving, the fluid is
delivered back to the originating tank. Further information can be found in the API
Manual of Petroleum Measurements Standards Chapter 6 Metering Assemblies
Section 2 Loading Rack Metering Systems.
e) Meters should be proved with products having a viscosity similar to those for which
they are normally used.
f) When using proving equipment, there is always a chance of introducing air or
vapour into the system. Air or vapour shall be eliminated before proving.
g) Since product and proving equipment temperatures and pressures have to be taken
into account, thermometers and pressure gauges traceable to the local standards
organization shall be used for accurate measurement.
h) To ensure proper operating performance, meters should be installed according to
manufacturers recommendations. Make certain that any areas that may trap or
build up with debris are avoided. Avoid installing the meter at high point in the piping
to prevent trapping air in pockets and causing problems with equipment and
perhaps creating safety issues.
i) Standard national or internationally accepted equipment and procedures shall be
rigorously adopted.
j) In the absence of clear national procedures the guidelines given in the EI Petroleum
Measurement Manual Part X (Meter Proving), or Petroleum Measurement Paper
Number 4 Code of Practice for the Proving of loading Gantry Meters should be
followed. Alternatively, API MPMS 4.1, 4.2, 4.4, 4.5, 4.6, 4.8 and 5.6 may be
applied.
DEP 31.06.11.11-Gen.
February 2011
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4.3.5
Filters/Strainers
Where fuels are loaded through a micro filter or filter water-separator, the residence time of
the liquid in the line between the outlet of the filter and the receiving tank should be
sufficient for any exess charge they generate to be dissipied before the fuel reaches the
receiving tank. The maximum velocity of the liquid in the line should be determined in
accordance with section 2.3.3.
4.4
CONTROL VALVES
4.4.1
4.4.2
4.4.3
Flow-limiting valves
At non-automated loading gantries, flow-limiting valves SHALL [PS] be fitted on each of the
loading arms because pump output is not controlled to match product demand. These
valves are used to protect equipment against excessive flow rates, which can occur when
only one loading arm out of several delivering similar product is used and more than the
required number of pumps are running.
4.4.4
4.4.5
Surge pressure
The piping system shall be designed to allow for the maximum surge pressure expected,
see DEP 31.38.01.11-Gen.
To reduce the maximum surge pressures and thus the design pressure of the pipe system,
the following measures shall be considered:
Valve characteristic
DEP 31.06.11.11-Gen.
February 2011
Page 22
No surge pressure alleviator shall be installed between a PD meter and the control
valve, because this will result in extra pulses being generated by the pulse
transmitter as the alleviator first absorbs product and then pushes it back down the
line. In such cases the alleviator (or 'T' piece) should be installed directly upstream
of the PD meter.
4.5
4.5.1
4.5.2
4.5.3
4.5.4
a)
b)
use hydraulic analysis of the loading system to minimise the likelihood of pressure
surges. If high pressure surges cannot be avoided, consider fitting flow control
valves with 'equal percentage' characteristic to reduce surge pressure;
c)
d)
allow for appropriate ullage in the design of new bulk vehicle compartments.
DEP 31.06.11.11-Gen.
February 2011
Page 23
4.5.5
4.6
BONDING INTERLOCK
A bonding cable SHALL [PS] be connected to the vehicle before any other operations are
carried out (e.g. opening manlids, connecting hoses etc.). The bonding resistance between
the vehicle and the gantry SHALL [PS] be less than 10 , and this bonding SHALL [PS]
remain in position until all other loading operations have been completed.
Loading SHALL [PS] not be permitted by the flow control system/interlock system if the
vehicle is not bonded effectively. If an overfill protection system is provided, the overfill
protection connection should be combined with the earthing connection.
The driveaway traffic light turn green and/or the exit barrier shall only open after the
bonding cable has been disconnected. A similar requirement exists for:
the position of the ramps providing access to the top of the road truck (see 8.3.2.2).
For non-automated loading gantries (e.g. top loading with mechanical pre-set), the bonding
cable between the loading facilities and the road car SHALL [PS] be clearly visible and
equipped with a status warning light indicating its connection/non-connection to the road
car. Further information can be found in: API RP 2003 Protection against ignitions arising
out of static, lightning and stray currents and NFPA 30 Flammable and combustibles liquids
code.
4.7
INTERLOCK SYSTEM
On the vehicle the following interlocks shall be considered:
a)
driveaway interlock, e.g. a lift bar normally covers all product connections: when
lifted the brakes are applied.
b)
air pressure interlock: a pressure switch contact should be connected to the overfill
detection system, so that a loss of vehicle air pressure will cause the gantry loading
valve to be closed.
c)
vapour vent interlocks: the vapour vent valves which connect each compartment to
the vapour collection manifold on the vehicle should be open before loading is
permitted.
d)
DEP 31.06.11.11-Gen.
February 2011
Page 24
5.
AUTOMATION
5.1
ADVANTAGES OF AUTOMATION
Automation offers many advantages over manual systems. New installations shall be
automated and the automation of existing installations should be considered at the earliest
opportunity. Automation should be fit for purpose and follow a standard approach in terms
of vendor, system functionality and implementation.
5.2
DEP 31.06.11.11-Gen.
February 2011
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6.
ADDITIVE INJECTION
6.2
DOSING LOCATION
Before it is decided to inject additives at the loading gantry the advantages and
disadvantages of dosing at other locations should be considered.
When loading gantry dosing is selected, the following aspects shall be implemented:
the injector control system to incorporate a feedback signal that confirms that
dosing is taking place. If dosing does not take place within the specified limits,
loading should be interrupted;
additive volume totaliser meters, in order to enable a periodic check on the correct
injection ratio (at least daily, but preferably at the end of each shift).
6.3
6.3.1
Additive type
The pump seals should be compatible with the type of additives to be used.
6.3.3
Injection methods
When different additives can be selected, care should be taken to avoid crosscontamination of additives. For these applications modified flow-proportional additive
injection should be employed. With this method no additive is injected during the final
amount (say 200 L) (say 7 ft3) of the batch, thus leaving the loading linework purged of all
additivated products.
6.4
6.4.1
6.4.2
a)
b)
the systems for different types of additives and additives of competitors shall be
kept completely segregated. Thus separate connections and pumping systems
shall be used. Valve cross-overs shall be avoided. Dedicated connections should
be employed wherever possible.
DEP 31.06.11.11-Gen.
February 2011
Page 26
6.4.3
Injection system
The following Injection systems may be applied. Requirements depend on the system
selected:
6.4.4
Mechanical systems
Gantry Blending
Where blending is performed downstream of the final meter, the blending
component meter shall be considered as a custody transfer meter and tested
accordingly.
Injection nozzle
The additive injection point shall be positioned upstream of the flow meter.
The simultaneous injection of multiple additives/components at the same location in the
pipe shall be avoided to assure a homogenous mixture
DEP 31.06.11.11-Gen.
February 2011
Page 27
7.
7.1
7.2
7.3
Direct system
With bottom loading of road tankers the vapours from all compartments will be
collected, including those from non-gasoline loading (e.g. automotive gasoil).
These additional vapours, plus the vapours generated during the loading itself (e.g.
by evaporation of the product), shall be taken into account when sizing the vapour
collection and vapour recovery unit or incinerator.
7.3.1
Carbon adsorption
Liquid absorption
Refrigeration/Condensation
Membranes
throughput profile (peak, 15 minutes, hourly, four hourly and daily capacity);
b)
c)
d)
DEP 31.06.11.11-Gen.
February 2011
Page 28
7.3.2
e)
availability of utilities at the site (steam, electricity, cooling water, hot oil, sewage
system, absorption liquid, instrument air, nitrogen etc.);
f)
g)
h)
accuracy of recovered gasoline measurement (to allow the prepaid duty on the
recovered gasoline to be reclaimed);
i)
j)
safety.
k)
Design of VRUs
VRUs should be designed and sized according to the IP Guidelines for the Design and
Operation of Gasoline Vapour Emission Controls.
Area classification SHALL [PS] be in accordance with IP-Part 15 or alternative recognised
codes. The electrical requirements SHALL [PS] be in accordance with (9.4).
Most Manufacturers build their VRUs according to a standardised design. If a
Manufacturers design is proven in practice in similar situations, that design should be
adopted (as far as possible) in order to avoid redesign which would result in excessive cost
and the risk of improperly functioning units.
7.4
Containment
Explosion venting
Explosion venting should only be applied if no other feasible alternative exist. The
vents should be placed at intervals less than the predicted run-up distance to
detonation and should be at least equal to the cross sectional area of the pipe. In
normal operation the discharge of flame and pressure from the pipe can be
considerable; therefore great care should be taken with the location of the vent and
the direction in which the flame will be released.
DEP 31.06.11.11-Gen.
February 2011
Page 29
8
8.1
8.1.1
8.1.2
Safety distances
The minimum safety distances SHALL [PS] comply with the IP Part 2 or NFPA 30, and local
regulations.
Where possible, larger safety distances should be provided, particularly for separation from
areas where personnel may be present.
8.1.3
8.1.4
Product grouping
Similar products should be grouped together at loading facilities, e.g. common white oil
products together and common black oil products together. Where both common white oil
and common black oil products are filled at the same loading facilities, one side of the
available area should be reserved for each group of products and to allow space for future
extension in both directions, see Figures 8.5 and 8.6.
For safety reasons and operational convenience it may be desirable to separate some
Class I and special products (e.g. cutbacks) from others, and always ensure that aviation
products are properly separated from other grades with top loading installations. For bottom
loading, care should be exercised with the installation of aviation grades in high volume
bays due to the extra time required to load and test aviation fuels.
Loading facilities for all products should be concentrated in one area to minimise traffic
movement within refineries/depots. If storage facilities for heated black products are distant
from the planned loading centre, it may be advisable for economic and operational reasons
(to prevent long heated and insulated pipes) to provide separate facilities for these products
close to the storage areas. However, where separate loading areas are used, vehicles
should follow the same traffic pattern so that the documentation for all products can be
handled at one office.
8.1.5
Dispatch office
Supervision and documentation of road vehicle loading operations can be carried out most
effectively from an office overlooking the loading operations and located near the
installation boundary or between the incoming and outgoing vehicle streams.
Office facilities should be designed and constructed taking into account the higher-thannormal noise levels caused by nearby vehicles. They should be large enough to
accommodate at least all personnel involved in order-taking (bulk and packed), road vehicle
routing, scheduling and dispatching, and stock control, and also include a waiting room for
drivers, social areas and space for document files and automation equipment.
DEP 31.06.11.11-Gen.
February 2011
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8.2
8.2.1
General
The loading system layout should not permit more than one vehicle in line on either side of
any island. In the loading position, vehicles shall face the exit gate at all times so they can
be driven away quickly in an emergency.
8.2.2
8.2.3
8.2.4
8.2.5
a)
provision of a kerb, at least 200 mm (8 in) high, on loading islands. This step
between the island and the ground level should be clearly marked (i.e. properly
painted) to warn personnel working in the area against tripping;
b)
where modular pre-fabricated bottom loading gantries are installed they can be
positioned flush with the surrounding concrete, thus avoiding trip hazards whilst the
gantry steelworks still provides protection;
c)
d)
e)
ensuring that no parts of the equipment or pipes protrude over the edge of the
islands.
DEP 31.06.11.11-Gen.
February 2011
Page 31
it is recommended to separate binding with spillage containment pits instead of applying
interceptors.
Paving and drainage facilities shall comply with local regulations.
8.3
GANTRY DESIGN
8.3.1
8.3.2
Roofs/shelters
Shelters, where installed, shall have suitable ventilation to prevent accumulation of vapour
within the roof space. Similarly, ventilation at ground level is also essential to dissipate any
vapour pockets.
8.3.3
Other requirements
Meter heads or meter pre-set readings should be clearly visible and readable from the
product loading control points.
Control valve equipment should be within easy reach of the operator in normal loading
positions. All handles of valves should be operated in the same direction.
Bays and loading islands should be clearly numbered to enable vehicles to be directed to
filling points. Product grade plates should be provided at the entry side of the gantry to
clearly indicate product availability at the bay concerned. Loading arms, meters and
connections should be clearly marked for product identification.
Sufficient illumination should be provided for night operations (see 9.5).
The construction of barriers at the exit of loading bays (when used) should be such that
they can be driven through in an emergency (e.g. barrier bends or snaps off).
DEP 31.06.11.11-Gen.
February 2011
Page 32
9
MISCELLANEOUS
9.1
9.1.1
General
Typically foam deluge systems are not employed or if the facility is assessed to constitute a
significant business risk in the event of total loss and alternatives are not available.
Where such systems are deemed to be required, they shall be in accordance with
DEP 80.47.10.30-Gen. and DEP 80.47.10.31-Gen.
9.1.2
9.1.3
9.1.4
9.1.5
9.1.6
top loading:
Two extinguishers per loading island: one positioned on the working
platform adjacent to the top of the stairway, and one at ground level
adjacent to the stairway.
bottom loading:
One extinguisher per island at a convenient location (e.g. shelter).
b)
one 70 kg (150 lbm) dry-powder chemical extinguisher (or one 90 L (3 ft3) AFFF
unit) per four loading bays.
DEP 31.06.11.11-Gen.
February 2011
Page 33
c)
9.1.7
one or more fire blanket(s) should be provided at a strategic point close to the
loading facilities.
at no less than two easily accessible locations in the loading area, at least 30 m (
100 ft) away from the nearest loading gantry,
The emergency switch SHALL [PS] override all other controls and immediately cease all
product flow by stopping the loading pumps and closing flow control valves.
If there is any risk of product gravitating to the loading area after the pumps have been
stopped, clearly indicated isolation valves SHALL [PS] be fitted at a safe distance from the
loading gantry.
Restarting of product flow should only be possible after manually resetting the appropriate
shutdown system (i.e. systems should not be self-resetting).
The fire alarm system should also initiate an emergency shutdown and, where automatic
entry/exit gates are installed, cause the gates to open.
The fire alarm signal SHALL [PS] be directly relayed to the local fire brigade in case of
unmanned depot operations.
9.1.8
9.2
PIPING
Piping shall be in accordance with DEP 31.38.01.11-Gen. and DEP 31.38.01.12-Gen.
9.2.1
Delivery piping
For the purposes of sizing the delivery piping at loading terminals, the maximum product
velocity in main piping should be 5 m/s (16 ft/s). If lines are long, consideration shall be
given to using a lower velocity to avoid an excessive pressure drop and limit surge
pressures.
To prevent static electricity hazards the flow velocities in delivery piping, including loading
arms, is limited as required in (2.3.2). Where no hazards exist, a maximum velocity of 7 m/s
(23 ft/s) may be applied in short lengths of connecting pipework, loading arms and hoses.
Piping shall be designed to allow for maximum loading rates at the loading gantry.
9.2.2
DEP 31.06.11.11-Gen.
February 2011
Page 34
9.2.3
Routing
To minimise pressure losses, pressure surges and heat losses, the shortest practicable
route should be chosen for pipes, with a minimum use of bends, tees, valves and other
fittings.
Pipes should not be laid in open trenches below the adjacent ground level.
9.2.4
Piping material
Aluminium, copper or plastic pipes SHALL [PS] not be used at the loading gantry because
of their lower survivability in fire. Aluminium may only be used and is acceptable for loading
arms downstream of the metering system and control valve.
9.2.5
9.2.6
9.2.7
Isolating valves
The isolation valves should be fitted with bypass (thermal) pressure relief valves (see
9.2.10).
9.2.10
Relief valves
Vent points of relief valves and automatic vents of piping systems SHALL [PS] not
discharge directly into atmosphere. These points should be piped away to the nearest
drainage (liquid) or to a safe location (gas phase).
Cascading relief systems (relief valves discharging into another closed system) should not
be used without proper detailed design.
9.3
LOADING PUMPS
If a location outside the bund is not practical, pumps may be elevated on plinths to reduce
exposure in the event of a spill and shall be positioned away from drains.
9.4
9.4.1
General
Electrical equipment, electrical power distribution systems, and systems for protection
against lightning or the accumulation of static electricity SHALL [PS] comply with
DEP 33.64.10.10-Gen or applicable local statutory and industry codes.
9.4.2
Electrical installations
Electrical equipment should be located in the least hazardous area (see 8.1) as far as
practical and economical.
Where electrical equipment has to be installed in hazardous areas, equipment with a type
of protection suitable for the relevant zones as classified in (8.1.1) SHALL [PS] be selected,
specified and installed in accordance with recognised standards.
Electrical cables associated with loading arms (e.g. heating cables for black oils, cables to
limit switches, cables to switches for electronic earthing units etc.) shall allow full movement
of the loading arm without stretching the cable, sufficiently flexible to allow frequent
movement, even at the lowest possible ambient temperature and resilient against external
DEP 31.06.11.11-Gen.
February 2011
Page 35
damage. Stops shall be fitted to prevent excessive movement, which otherwise could
damage cables
In existing facilities where improvements are planned, the electrical requirements
associated with the installation of automatic data capture and transmission facilities
(automation) shall be considered. Whether or not automation is likely, a pipe (duct) of at
least 150 mm diameter shall be installed at normal cable laying depth between the gantries
and the edge of the loading area near the office location, to accommodate future cabling for
automation, if required.
Cabling for automation shall be laid separately from power supply cables and shall be
suitably shielded. Consideration should be given to the use of fibre optic cables to allow for
efficient long distance communications.
Pipe ends shall be sealed to prevent ingress of hydrocarbons or water. All cable pipes at
new facilities should be large enough to allow 50 % spare capacity for future extension of
electrical systems.
9.4.3
DEP 31.06.11.11-Gen.
February 2011
Page 36
For most top-filling applications (for exceptions), the drop-tube SHALL [PS] be metal and
SHALL [PS] be long enough to reach the base of all compartments that might be loaded.
There should be a T-piece on the end of the drop-tube to deflect the flow along the base of
the compartment. The T-piece should preferably be made of a dissipative rubber to avoid
mechanical damage.
NOTE:
The usual long-tube requirement is for cases where there could be a flammable atmosphere. It may be
permissible to use a short drop tube to splash-load flammable liquids of low volatility (e.g. luboils) that
are incapable of producing a flammable vapour atmosphere at the maximum handling temperature.
However with this approach it is essential that there is no switch-loading or other possible source of
flammable vapour, and that the loading process does not produce enough mist or suspended droplets
to render the atmosphere flammable.
Filter socks (as sometimes used for conductive solvents such as alcohols) SHALL [PS] not
be used on the end of loading arms for hydrocarbon fuels. It is particularly important that
the drop tube meets the general earthing or bonding requirements outlined above. Where
drop tubes are removable from the loading arms, e.g. with camlock fittings, adequate
electrical contact across the joint SHALL [PS] be established and checked each time the
arm is re-connected.
Plastic materials can be classified by their electrical resistivity as non-conductive
(insulating), dissipative or (rarely) conductive. The use of dissipative or conductive plastics
does not generally give rise to concerns arising from static electricity but the use of
insulating plastics needs to be carefully controlled.
Within hazardous areas and where the materials could be subjected to electrostatic
charging (most commonly by the flow of product but also, possibly, by rubbing)
either:
o
the maximum area of plastic SHALL [PS] not exceed the values given in
Appendix A; or
NOTE:
9.5
Larger areas can be tolerated for subdivided sheets because the presence of the earthed
mesh holds potentials lower than for a completely isolated piece of plastic of the same
size.
ILLUMINATION
Lighting fittings should conform to the area requirements as specified in (8.1.1). Generally,
in Zone 1 and 2 hazardous areas, fluorescent luminaries with type of protection Exe
SHALL [PS] be used. In these areas, high pressure discharge luminaries are also
acceptable and if used, SHALL PS] have type of protection Exd. Low pressure sodium
discharge lamps SHALL [PS] not be used because of the potential fire hazard in the event
of breakage.
To allow safe movement of personnel in the event of a power failure, consideration should
be given to the installation of at least one emergency light fitting per loading bay with
battery back up of 30 minutes.
9.6
PAINTING
DEP 30.48.00.31-Gen. should be applied.
Colour schemes should be chosen according to:
DEP 31.06.11.11-Gen.
February 2011
Page 37
9.7
9.8
DEP 31.06.11.11-Gen.
February 2011
Page 38
10.
REFERENCES
In this DEP, reference is made to the following publications:
NOTES:
1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
Definition of temperature, pressure and toxicity levels
DEP 01.00.01.30-Gen.
DEP 30.48.00.31-Gen.
DEP 31.38.01.11-Gen.
DEP 31.38.01.12-Gen.
DEP 33.64.10.10-Gen.
DEP 34.19.20.11-Gen.
DEP 80.47.10.30-Gen.
DEP 80.47.10.31-Gen.
AMERICAN STANDARDS
Bottom loading and vapour recovery for MC-306 and DOT406 tank motor vehicles
API RP 1004
API RP 1637
API RP 2003
Issued by:
American Petroleum Institute
Publications and Distribution Section
1220 L Street Northwest
Washington DC. 20005
USA.
ASME B73.1
DEP 31.06.11.11-Gen.
February 2011
Page 39
Specification for vertical in-line centrifugal pumps for
chemical process
ASME B73.2
Issued by:
American Society of Mechanical Engineers
Three Park Avenue, M/S 10E
New York NY 10016
USA.
NFPA 16
NFPA 30
Issued by:
National Fire Protection Association
One Batterymarch Park
PO Box 9101
Quincy, MA 02269-9101
USA
ASTM D 2624
Issued by:
American Society of Testing Materials (ASTM) International
100 Barr Harbor Drive
PO Box C700
West Conshohocken, PA 19428-2959
USA
BRITISH STANDARDS
Flame arresters for general use
BS 7244
Issued by:
British Standards Institution
389 Chiswick High Road
London W4 4AL
UK.
IP Part 2
IP Part 15
DEP 31.06.11.11-Gen.
February 2011
Page 40
Issued by:
Defence Equipment and Support
UK Defence Standardization
Kentingem House
65 Brown Street
Glasgow G2 8EX
UK
EUROPEAN STANDARDS
Flame arresters Performance requirements, test methods
and limits for use.
EN 12874
EN 50014
ADR
Issued by:
United Nations Economic Commission for Europe
Information Office
Palais des Nations
CH-1211 Geneva 10
Switzerland
Issued by:
CEN Secrtariat Central
Rue de Stassart 36
B-1050 Brussels
Belgium.
Copies can also be obtained from national standards organizations
INTERNATIONAL STANDARDS
Technical specifications for centrifugal pumps, class II
ISO 5199
Issued by:
ISO Central Secretariat
1, ch. de la Voie-Creuse
Case postale 56
CH-1211 Genve 20
Switzerland
Copies can also be obtained from national standards organizations.
DEP 31.06.11.11-Gen.
February 2011
Page 41
APPENDIX A
PLASTIC MATERIALS
A.1
Definitions
Conductive: Will not retain a significant electrostatic charge when in contact with earth and
can transmit electric shocks from power systems. These materials have a volume resistivity
lower than or equal to 104 m (for certain items e.g. conductive hose there are special
definitions).
Dissipative (previously known as anti-static): Will not retain a significant amount of
electrostatic charge when in contact with earth but too resistive to transmit electric shocks
from power systems. These materials have a volume resistivity higher than 104 m but
equal to or lower than 109 m, or a surface resistivity less than 1010 (or surface
resistance less than 109 ) measured at ambient temperature and 50% relative humidity.
Non-conductive (insulating): Neither conductive nor dissipative. Electrostatic charges can
accumulate and will not readily dissipate even if part of the material is in contact with earth.
These materials have a volume resistivity higher than 109 m, and a surface resistivity
more than 1010 (or a surface resistance more than 109 ) measured at ambient
temperature and 50% relative humidity. Most common plastics are insulating.
A.2
Size Limits
Large areas of plastic can hold enough charge to produce electrostatic discharges capable
of igniting flammable materials. To avoid this possibility it is essential that wherever nonconductive plastics are used in hazardous areas at locations where they could be subject to
charging mechanisms (e.g. liquid flow or rubbing), they SHALL [PS] not exceed certain size
limits. These limits SHALL [PS] be adopted unless it can be shown that hazardous
electrostatic charges are not to be expected and that charging mechanisms will not occur at
any time.
A sheet of insulating plastic that exceeds the size limits given in Table A.1 may be used if it
is subdivided into smaller areas by a closed mesh or grid of earthed conductive or
dissipative material at or near the plastic surface. In this case, the maximum area of any
cell in the mesh SHALL [PS] not exceed 4 times the areas given in Table A.1. (Mesh cell
areas can be larger than the areas of isolated pieces of plastic because the presence of the
earthed mesh holds potentials down.)
Table A.1
Maximum area
2
Maximum width
50 cm (7.8 in )
No limit
No limit
DEP 31.06.11.11-Gen.
February 2011
Page 42
APPENDIX B
FIGURES
FIGURE B.1a
DEP 31.06.11.11-Gen.
February 2011
Page 43
Figure B.1b
DEP 31.06.11.11-Gen.
February 2011
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Figure B.1c
DEP 31.06.11.11-Gen.
February 2011
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Figure B.2 Symbols for bulk road vehicle loading installation flow schemes