top loading tank truck/trailer construction, inspection

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الهيئة السعودية للمواصفات و المقاييس و الجودةSaudi Standards, Metrology and Quality Org (SASO)

DRAFT: FINAL

SASO /FDS/ 28965:2017

Top Loading Tank Truck/Trailer Construction, Inspection,

Maintenance

“Trucks with Elevated Temperature Materials”

ICS: 43.040.01

THIS DOCUMENT IS A DRAFT SAUDI REGULATION CIRCULATED FOR COMMENT. IT IS, THEREFORE SUBJECT TO CHANGE AND MAY NOT BE REFERRED TO AS A SAUDI REGULATION UNTIL APPROVED BY THE BOARD OF DIRECTORS.

SASO STANDARD SASO 28965/2017

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TABLE OF CONTENTS

# Title Page 1. Scope………………………………………………… 3 2. References ……………………..……………………. 3 3. Definitions…………………………………………… 4 4. General Requirements……………………………….. 6 5. Material & Material Thickness……………………… 7 6. Structural Integrity…………………………………... 8 7. Welding Requirements……………………………… 9 8. Closures (Manholes)………………………………… 10 9. Tank Outlets ………………………………………… 12 10. Heating System……………………………………… 13 11. Pressure Control…………………………………….. 14 12. Gauging Device……………………………………... 15 13. Supports and Anchoring …………………………… 15 14. Accident Damage Protection………………………... 15 15. Rollover Damage Protection Requirements………… 16 16. Ladder …...………………………………………….. 16 17. Walkways…………………………………………… 17 18. Markings...…………………………………………... 17 19. Certification…………………………………………. 18 20. Fire Extinguisher……………………………………. 18 21. HAZCOM Label…………………………………….. 19 22. Safety Tools…………………………………………. 19 23. Inspections…………………………………………. 20 24. Maintenance & Repairs……………………………… 21 25. Illustrations…………………………………………... 23 26. References ……………………..……………………. 27


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1. Scope

1.1 This standard covers the design, construction, inspection, testing, and maintenance of

Top Loading road tankers that carry high elevated temperatures materials, i.e. Asphalt and molten sulfur.

1.2 This standard shall apply to all Top Loading road tank truck/trailer licensed for service in the Kingdom of Saudi Arabia.

1.3 This standard does not cover trailer frame components including chassis frame, suspension system, trailer brake system, wheels, air supply reservoir, and other trailer components.

1.4 Any Top Loading Tank truck/trailer shall be manufactured by an accredited manufacturer. This Truck Manufacturer shall be accredited by SASO against this standard and other related standards and regulations.

1.5 It is required to achieve the highest axle’s payload possible within the allowed Gross Combination Weight (GCW) of 45 metric tons with conformance to Saudi Arabian Government safety standards.

1.6 The Tank-trailer new proposed components must withstand all harsh operational condition and meet all industry safety and durability standards.

1.7 All Tractors and Tank-trailers shall conform to Saudi Arabian Government safety standards and all Tractors shall have a valid Motor Vehicle Periodic Inspection (MVPI) sticker and 3rd Party Truck Inspection.

2. References:

SAUDI ARABIAN STANDARDS ORGANIZATION (SASO)

SASO 1284 Motor Vehicle Periodic Technical Inspection Manual

SASO 1285 Transportation of Dangerous Substances by Road – General Safety Requirements

SASO 1287 Transportation of Dangerous Substances by Road – Petroleum Liquids

SASO 469 (GS 159) Motor Vehicles Dimensions and Weights

SAUDI ARABIAN GOVERNMENT REGULATIONS

Traffic Regulation 1429H


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3. Definitions

Appurtenance: Any cargo tank accessory attachment that has no lading retention or containment function and provides no structural support to the cargo tank.

Baffle: A non-liquid-tight transverse partition device that deflects, checks or regulates fluid motion

in a tank. Bulkhead: A liquid-tight transverse closure at the ends of or between cargo tanks. Charging line: A hose, tube, pipe, or similar device used to pressurize a tank with material other

than the lading. Companion flange: One of two mating flanges where the flange faces are in contact or separated

only by a thin leak sealing gasket and are secured to one another by bolts or clamps.

Connecting structure: The structure joining two cargo tanks. Constructed and certified in conformance with the ASME Code: The cargo tank is constructed

and stamped in accordance with the ASME Code, and is inspected and certified by an Authorized Inspector.

Constructed in accordance with the ASME Code: The cargo tank is constructed in accordance

with the ASME Code with the authorized exceptions and is inspected and certified by a Registered Inspector.

External self-closing stop-valve: A self-closing stop-valve designed so that the self-stored energy

source is located outside the cargo tank and the welded flange. Extreme dynamic loading: The maximum single-acting loading a cargo tank motor vehicle may

experience during its expected life, excluding accident loadings. Flange: The structural ring for guiding or attachment of a pipe or fitting with another flange

(companion flange), pipe, fitting or other attachment. Inspection pressure: The pressure used to determine leak tightness of the cargo tank when testing

with pneumatic pressure.

Internal self-closing stop-valve: A self-closing stop-valve designed so that the self-stored energy

source is located inside the cargo tank or cargo tank sump, or within the welded flange, and the valve seat is located within the cargo tank or within one inch of the external face of the welded flange or sump of the cargo tank.

Lading: The hazardous material contained in a cargo tank.


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Loading/unloading connection: The fitting in the loading/unloading line farthest from the loading/unloading outlet to which the loading/unloading hose or device is attached.

Loading/unloading outlet: The cargo tank outlet used for normal loading/unloading operations. Loading/unloading stop-valve: The stop valve farthest from the cargo tank loading/unloading outlet

to which the loading/unloading connection is attached. Multi-specification cargo tank motor vehicle: A cargo tank motor vehicle equipped with two or

more cargo tanks fabricated to more than one cargo tank specification. Normal operating loading: The loading a cargo tank motor vehicle may be expected to experience

routinely in operation. Nozzle: The subassembly consisting of a pipe or tubular section with or without a welded or forged

flange on one end. Outlet: Any opening in the shell or head of a cargo tank, (including the means for attaching a closure),

except that the following are not outlets: A threaded opening securely closed during transportation with a threaded plug or a threaded cap, a flanged opening securely closed during transportation with a bolted or welded blank flange, a manhole, or gauging devices, thermometer wells, and safety relief devices.

Outlet stop-valve: The stop-valve at the cargo tank loading/unloading outlet. Pipe coupling: A fitting with internal threads on both ends. Rear bumper: The structure designed to prevent a vehicle or object from under-riding the rear of a

motor vehicle.

Rear-end tank protection device: The structure designed to protect a cargo tank and any lading retention piping or devices in case of a rear end collision.

Sacrificial device: An element, such as a shear section, designed to fail under a load in order to

prevent damage to any lading retention part or device. The device must break under strain at no more than 70 percent of the strength of the weakest piping element between the cargo tank and the sacrificial device. Operation of the sacrificial device must leave the remaining piping and its attachment to the cargo tank intact and capable of retaining lading.

Self-closing stop-valve: A stop-valve held in the closed position by means of self-stored energy,

which opens only by application of an external force and which closes when the external force is removed.

Shear section: A sacrificial device fabricated in such a manner as to abruptly reduce the wall

thickness of the adjacent piping or valve material by at least 30 percent. Shell: The circumferential portion of a cargo tank defined by the basic design radius or radii

excluding the closing heads.


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Stop-valve: A valve that stops the flow of lading. Sump: A protrusion from the bottom of a cargo tank shell designed to facilitate complete loading

and unloading of lading. Tank: A container, consisting of a shell and heads, that forms a pressure tight vessel having openings

designed to accept pressure tight fittings or closures, but excludes any appurtenances, reinforcements, fittings, or closures.

Test pressure: The pressure to which a tank is subjected to determine pressure integrity. Toughness of material: The capability of a material to absorb the energy represented by the area

under the stress strain curve (indicating the energy absorbed per unit volume of the material) up to the point of rupture.

Variable specification cargo tank: A cargo tank that is constructed in accordance with one

specification, but which may be altered to meet another specification by changing relief device, closures, lading discharge devices, and other lading retention devices.

Void: The space between tank heads or bulkheads and a connecting structure.

Welded flange: A flange attached to the tank by a weld joining the tank shell to the cylindrical outer

surface of the flange, or by a fillet weld joining the tank shell to a flange shaped to fit the shell contour.

4. General Requirements

(a) Weight & Size Requirements

The tank truck or trailer shall comply with the size and weight restrictions specified in SASO SSA 1285, SASO SSA 1287, SASO 469 (GS 159) and Traffic Regulations (1429H) of Saudi Arabia. The requirements are as follows:

The maximum gross weight shall not exceed 45 tons The maximum height shall not exceed 4.2 meters The maximum width shall not exceed 2.6 meters The maximum length shall not exceed 20 meters

No part of the cargo tank and its fittings and equipment shall project beyond the overall width of the tank truck.

(b) Each constructed tanker must be certified by 3rd Party Truck Authorized Inspector or by a Registered Inspector as applicable to the cargo tank in accordance with approved checklists.

(c) Each cargo tank shall be manufactured by an Accredited Manufacturer. The Manufacturer shall be accredited by SASO against this standard and other related standards and regulations.


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(d) Unless stated otherwise, the cargo tank structural design shall be in accordance with the requirements of ASME XII code. In case of conflict, the more stringent criteria shall control. The design shall take into consideration loads caused during loading; off-loading; transportation loads including thermal effects, vibration and torsion. Additionally, the environmental conditions of Saudi Arabia should be considered in design.

(f) Trucks used for transient purposes shall follow Customs Regulations of Saudi Arabia and get all required approval documentations from government authorities. Changes used for smuggling purposes in truck compartments’ designs & dimensions, piping, fittings without pre-approval from the sending/receiving authorities are prohibited and shall be subjected to penalties and legal claims.

(g) Truck Tractor shall be equipped with standard fuel tank (s) as per tractor manufacturer. No additional or fabricated fuel tank to be used in the truck tractor.

(h) No additional or fabricated auxiliary tanks shall be used unless used for its original purposes per the design (i.e. water tank). Also, no fabricated tanks inside tanker compartment.

5. Material and Material Thickness

(a) The cargo tank shell shall be constructed using Mild Steel (MS); High Strength Low Alloy (HSLA) Steel; Austenitic Stainless Steel (SS) or Aluminum (AL) Alloys suitable for fusion welding. The following ASTM Grades of Steel and Aluminum alloys are acceptable for construction of cargo tank shell.

Carbon Steel Aluminum alloys

Conforming with the 0, H32 or H34 tempers

ASTM A572 Gr.50 ASTM B-209 Alloy 5052

ASTM B-209 Alloy 5086






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All heads, bulkheads and baffles must be of 0 temper (annealed) or stronger tempers. All shell materials shall be of H 32 or H 34 tempers except that the lower ultimate strength tempers may be used if the minimum shell thicknesses in the tables are increased in inverse proportion to the lesser ultimate strength.

(b) The minimum thickness for the shell and heads (or baffles and bulkheads when used as tank reinforcement) expressed in millimeters (decimals of an inch) must be no less than:

MS HSLA / SS AL Material

4.0 (0.158) 4.0 (0.158) 5.0 (0.197) Thickness (Shell)

4.5 (0.178) 4.5 (0.178) 4.5 (0.178) Thickness (End Heads and Baffles)

Cargo tanks shall be circumferentially reinforced with internal rings or baffles. The maximum un-reinforced section of the shell shall not exceed 1.5 meters.

(c) Corrosion or abrasion protection. When required by 49 CFR part 173 for a particular lading, a cargo tank or a part thereof, subject to thinning by corrosion or mechanical abrasion due to the lading, must be protected by providing the tank or part of the tank with a suitable increase in thickness of material, a lining or some other suitable method of protection.

(1) The shell manufactured from steel material shall be coated with Epoxy Coating compatible and suitable for use with the product transported in the shell. For asphalt, it is recommended to have (APCS-2A, APCS-2E, APCS-3, APCS-2H, APCS-2I). For molten Sulfur, use APCS-2E. Truck Manufacturer shall cross check the selected coating product to be used for its compatibility providing the service conditions with the coating manufacturer

(2) If required, lining material must consist of a nonporous, homogeneous material not less elastic than the parent metal and substantially immune to attack by the lading. The lining material must be bonded or attached by other appropriate means to the cargo tank wall and must be imperforate when applied. Any joint or seam in the lining must be made by fusing the materials together, or by other satisfactory means.

(d) Shell shall be insulated with high grade fiber-glass with a heat transmission “k” factor of 0.054 Watts per meter at 100 degrees Celsius mean temperature.

6. Structural Integrity

(a) Cargo tank shall be designed to sustain External Load corresponding to a wind velocity of 137 km/h (85 mph). The design wind pressure shall be calculated in accordance with ANSI A58.1, Exposure C requirements. Cargo tank under un- laden condition shall be checked for stability against overturning moments from wind pressure.


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(b) The cargo tank shall be either an integral part of the chassis or securely attached to it. Adequately designed Reinforcement Pads shall be provided at shell attachment locations.

(c) Mounting structures for the cargo tank shall be designed to withstand maximum operating loads and loads imposed by horizontal and vertical acceleration and retardation encountered in normal road transportation; and to limit movement of the cargo tank in relation to the chassis.

(d) Adequately designed lifting lugs shall be provided at the front and rear of the cargo tank to facilitate lifting of the tank in an empty condition by an overhead crane in the event of a rollover situation.

(e) When a ring stiffener is used as a circumferential reinforcing member, the Section Modulus I/C (m³) about the neutral axis of the ring section parallel to the shell must be at least equal to that derived from the applicable formula as follows:

I/C (m³) = 0.00027 WL (For MS, HSLA and SS materials); or

I/C (m³) = 0.000467 WL (For Aluminum alloys)

Where, W = Tank width or diameter in inches

L = Spacing of ring stiffener in inches

A portion of the shell may be used for computing the Section Modulus of the ring stiffener provided at least 50% of the total circumference of the tank is welded and the length of any unwelded space on the joint does not exceed 40 times the shell thickness. The maximum portion of the shell to be used in these calculations, is as follows:

No. of circumferential ring stiffener to Shell Welds

Longitudinal distance between parallel circumferential ring stiffener-to-shell welds “J”

Shell Section

1 20t 2 Less than 20t 20t + J 2 20t or more 40t

Where: t=Shell thickness, inches; J=Longitudinal distance between parallel circumferential ring stiffener-to-shell welds.

7. Welding Requirements

(a) Steel Tank Shell

All welded joints in mild steel (MS), high strength low alloy (HSLA), and / or austenitic stainless steel (SS) between the tank shell, heads and anti-surge baffles shall be made in accordance with the provisions of ASME Boiler and Pressure Vessel Code, Section


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IX. The efficiency of any joint shall not be less than 85 percent of the mechanical properties of adjacent metal in tank.

(b) Aluminum Tank Shell

All welded Aluminum alloy joints shall be made in accordance with recognized good practice, and the efficiency of a joint shall not be less than 85% of the properties of adjacent material. Aluminum alloys shall be joined by an inert gas arc welding process using aluminum-magnesium type of filler metals consistent with material supplier recommendations.

(c) Electrodes or filler rods used in welding shall be suitable for use with the grade of steel used for the construction of tank shell.

(d) Where practical all welds must be easily accessible for inspection.

(e) Welded joints shall be free of surface imperfections and protrusions from the finished surface.

(f) All welding shall be performed in accordance with the Manufacturer’s welding procedure specifications, which have been qualified by the Manufacture.

(g) The welding procedure and welders or welding operators shall be qualified in accordance with the requirements of ASME XII, Section TF-2 and ASME Section IX.

(h) The Manufacturer shall maintain a record of the qualified welding procedures, the supporting procedure qualification records, and the qualification records of the Welders and Welding Operators qualified by him, showing the date and results of tests and the identification mark assigned to each welder. These records shall be reviewed, verified, and certified by the Manufacturer by signature or some other method of control in accordance with the Quality System and shall be accessible to the Inspector.

(i) Continues longiditional welding on tank shell is prohibited.

8. Closures (Manholes)

(a) Manhole assembly shall provide secure closures of the openings. The Manhole Assembly

shall be structurally capable of withstanding, without leakage or permanent deformation that would affect its structural integrity, a static internal fluid pressure of at least 36 psig, or cargo tank test pressure, whichever is greater. The manhole shall be tested with the venting devices blocked.

(b) Each cargo tank used in asphalt service shall be provided with a vent having an effective opening at least equivalent to a nominal 2 in. (50 mm) pipe.

(c) Each cargo tank shall be equipped with two manholes. One for loading and another for inspection purposes and one located at the center and one at rear if applicable.

(d) Manhole(s) shall have a minimum clear opening size of 500 mm in diameter.


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(e) The location of the fill manhole shall be at the top of the tanker and it shall be surrounded by a splash box and walkway of galvanized grip strut with connecting curb side ladder.

(f) The tank shall be provided with a remote, manually operated, venting mechanism that will relieve any excess tank pressure to atmosphere prior to fill manhole being opened.

(g) Each manhole, fill opening and washout assembly must be structurally capable of withstanding, without leakage or permanent deformation that would affect its structural integrity, a static internal fluid pressure of at least 36 psig, or cargo tank test pressure, whichever is greater.

(h) Each manhole, filler and washout cover must be fitted with a safety device that prevents the cover from opening fully when internal pressure is present.

(i) Each manhole and fill cover must be secured with fastenings that will prevent opening of the covers as a result of vibration under normal transportation conditions or shock impact due to a rollover accident on the roadway or shoulder where the fill cover is not struck by a substantial obstacle.

(j) The manhole assembly manufacturer shall verify compliance with this requirement by hydrostatically testing. Each manhole assembly must be permanently marked on the outside by stamping or other means in a location visible without opening the manhole assembly or fill opening, with at least:

(1) Manufacturer's name; (2) Test pressure __ psig; (3) Certification statement

(k) All components mounted on a manhole cover that form part of the lading retention structure of the cargo tank wall must withstand the same static internal fluid pressure as that required for the manhole cover. The component manufacturer shall verify compliance using the same test procedure and frequency of testing recommended by the manufacturer.

(l) The manhole assembly shall comprise of the following:

• A hinged inspection cover;

• High Capacity Pressure / Vacuum (P/V) vent for Normal Venting & Vacuum Protection;

• Pressure actuated fill (PAF) cap for emergency venting;

• Mounting plates for vapor vent valve and overfill prevention probe

(m) The hinged inspection cover shall be self-latching type and leak proof in the event of tank overturn.

(n) Overflow protection for asphalt tank vehicles shall be provided in the form of reservoirs or flashing around fill and vent pipes.


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9. Tank Outlets

(a) Each cargo tank shall be equipped with one 4 inch (10 cm) Heavy Duty Steam Jacket Flush Valve 60 Degree with gasket seat & flanged outlet 316 stainless steel or equivalent valve.

(b) The valve shall be mounted on the rear head. Valve body and steam connections shall be enclosed in an insulation cabinet. Steam connection shall be 1.5 inch NPT female and condensate connection I inch NPT female.

(c) Unloading valve end piping to have 3/8 inch hinge cover with adequate heavy duty metal strap lock. The cover shall be of free spooling with chain lock and shall flush the unloading nozzle by at least ½ inch. Delivery of Class I liquids to underground tanks of more than 1000 gal (3800 L) capacity shall be made by means of tight connections between the hose and the fill pipe.

(d) Each cargo tank shall be loading/unloading outlet must be equipped with an internal self-closing stop-valve, or alternatively, with an external stop-valve located as close as practicable to the cargo tank wall. Each cargo tank loading/unloading outlet must be in accordance with the following provisions:

(1) Each loading/unloading outlet must be fitted with a self-closing system capable of closing all such outlets in an emergency within 30 seconds of actuation. During normal operations the outlets may be closed manually.

(2) The self-closing system must be designed according to the following:

(i) Each self-closing system must include a remotely actuated means of closure located more than 10 feet from the loading/unloading outlet where vehicle length allows, or on the end of the cargo tank farthest away from the loading/unloading outlet. The actuating mechanism must be corrosion-resistant and effective in all types of environment and weather.

(ii) If the actuating system is accidentally damaged or sheared off during transportation, each loading/unloading outlet must remain securely closed and capable of retaining lading.

(iii) When required for materials which are flammable, pyrophoric, oxidizing, or Division 6.1 (poisonous liquid) materials, the remote means of closure must be capable of thermal activation. The means by which the self-closing system is thermally activated must be located as close as practicable to the primary loading/unloading connection and must actuate the system at a temperature not over 250 °F. In addition, outlets on these cargo tanks must be capable of being remotely closed manually or mechanically.

(e) Any loading/unloading outlet extending beyond an internal self-closing stop-valve, or beyond the innermost external stop-valve which is part of a self-closing system, must be fitted with another stop-valve or other leak-tight closure at the end of such connection.


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(f) Each cargo tank outlet that is not a loading/unloading outlet must be equipped with a stop-valve or other leak-tight closure located as close as practicable to the cargo tank outlet. Any connection extending beyond this closure must be fitted with another stop-valve or other leak-tight closure at the end of such connection.

(g) Where a dry disconnect vapor recovery adapter is used, provisions shall be made to ensure that the vapor recovery system is fully vented before unloading to prevent collapse of the tank

10. Heating System

There are two types of heating systems to be used for heating the product during transportation to prevent product of solidification:

(a) Steam system

This type of heating is used for Molten Sulfur transportation. The system shall be located externally and shall consist of minimum of five half round steam tubes (Steam Jackets) welded along the full length of the bottom of the tank with an area of 10 m² (± 10%). The steam system shall be capable of liquefying sulfur/asphalt in a period of six (6) hours. The steam connection shall connect both the tank steam pan and the steam jacket surrounding the off-loading valve to have one steam inlet and one steam outlet. The steam system shall have a safety relief valve that shall activate at 2 bar (29 psi).

(b) Electrically heated coil or Fired Burner

This type of heating is used for Asphalt steel transportation. Burners shall be located remotely from fuel tanks for the vehicle engine and fuel tanks for the burners, or a noncombustible shield shall be provided between the burner and the fuel tanks to prevent flashback. Burner tubes shall be properly installed and maintained. The bottom of internal burner tubes shall be located as low in the tank as proper design and functioning permit. They consist of a large diameter “U” tube inserted horizontally through the rear head, and are nearly the length of the tank. The outlet is connected to a vertical stack at the rear head. They are fired by diesel/propane burner.

Important Notes:

1. Any Tank-trailer without this facility in working order shall be considered as out of service.

2. Never operated the burner unless product covers the burner tube by at least 6 inches.

3. When covering the tube with product, make sure the tank level, or that you compensate for the slope and cover the high end of the tube.

4. Never leave a tank unattended with the burner running.


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5. Never operate a burner while unloading or while in transporting. 6. Never operate a burner while the tank is in confined space. 7. A warning sign or label that meets the requirements of ANSI Z535.1, Safety Color

Code, shall be permanently attached near the burners on any tank vehicle equipped with burners and shall include at least the following information:

WARNING:

This burner equipment must not be operated while the vehicle is being loaded or is in transit or when the burner tubes are not completely submerged.

11. Pressure Control

(a) Each cargo tank must have a self-reclosing design, must prevent package rupture or collapse due to pressure, must prevent significant release of lading due to packaging overturn or splashing or surging during normal transport conditions, and may be external to the packaging.

NOTES:

(i) Pressure control equipment is not required if pressure in the packaging would increase less than 10 percent as a result of heating the lading from the lowest design operating temperature to a temperature likely to be encountered if the packaging were engulfed in a fire. When pressure control equipment is required, it must prevent rupture of the packaging from heating, including fire engulfment.

(ii) Vacuum control equipment is not required if the packaging is designed to withstand an external pressure of 100 kPa (14.5 psig) or if pressure in the packaging would decrease less than 10 percent as a result of the lading cooling from the highest design operating temperature to the lowest temperature incurred in transport. When vacuum control equipment is required, it must prevent collapse of the packaging from a cooling-induced pressure differential.

(iii) If require a reclosing pressure relief device, the lading must not render the devices inoperable (i.e. from clogging, freezing, or fouling). If the lading affects the proper operation of the device, the packaging must have:

(A) A safety relief device incorporating a frangible disc or a permanent opening,

each having a maximum effective area of 22 cm2 (3.4 in.2), for transportation by highway.

(B) For transportation of asphalt, a safety relief device incorporating a frangible disc or a permanent opening, each having a maximum effective area of 48 cm 2 (7.4 in 2);

(iv) Reclosing pressure relief devices, rupture discs or permanent openings must not

allow the release of lading during normal transportation conditions (i.e., due to splashing or surging).


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(b) Certification of pressure relief devices. The manufacturer of any pressure relief device, including valves, frangible (rupture) disks, vacuum vents and combination devices must certify that the device model was designed and tested in accordance with this section and the appropriate cargo tank specification. The certificate must contain sufficient information to describe the device and its performance. The certificate must be signed by a responsible official of the manufacturer who approved the flow capacity certification.

(c) Rated flow capacity certification test. Each pressure relief device model must be successfully flow capacity certification tested prior to first use. Devices having one design, size and set pressure are considered to be one model. The testing requirements are as follows:

(1) At least 3 devices of each specific model must be tested for flow capacity at a pressure not greater than the test pressure of the cargo tank. For a device model to be certified, the capacities of the devices tested must fall within a range of plus or minus 5 percent of the average for the devices tested.

(2) The rated flow capacity of a device model may not be greater than 90 percent of the average value for the devices tested.

(3) The rated flow capacity derived for each device model must be certified by a responsible official of the device manufacturer.

(d) Marking of pressure relief devices. Each pressure relief device must be permanently marked with the following:

(1) Manufacturer's name; (2) Model number; (3) Set pressure, in psig; and (4) Rated flow capacity, in SCFH at the rating pressure, in psig.

12. Gauging Devices

Each cargo tank, except a cargo tank intended to be filled by weight, must be equipped with a gauging device that indicates the allowable expansion of 3%. These trucks are weighted by weight scale.

13. Supports and Anchoring A cargo tank with a frame not integral to the cargo tank must have the tank secured by restraining devices to eliminate any motion between the tank and frame that may abrade the tank shell due to the stopping, starting, or turning of the cargo tank motor vehicle.

14. Accident Damage Protection (a) Side and rear under-run protection steel crash barriers shall be provided. The crash

barriers shall be designed to protect all appurtenances on the tank while still providing easy access.

(b) A rear bumper shall be provided in order to protect the tank and piping in the event of a rear-end collision. The bumper shall be located at least 150 mm to the rear of any


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component located at the rear of the tank truck. The height between the underside of the bumper and the road surface shall not exceed 750 mm.

(c) The bumper shall be designed to successfully absorb the impact of the vehicle with rated payload, with a deceleration of 2g (two times the rated payload) using a factor of safety of two - (2) based on the ultimate strength of the bumper material. The impact shall be considered uniformly distributed and applied horizontally from any direction at an angle not exceeding 30 degrees to the longitudinal axis of the tank truck.

(d) The minimum road clearance of any tank-truck component located between any two adjacent axles on the tank truck shall be at least 15 mm for each 300 mm separating such axles, and in no case shall the clearance be less than 300 mm.

15. Rollover Damage Protection Requirements

(a) Each closure for opening, including but not limited to the manhole, filling or inspection opening, and each valve, fitting, pressure relief device, vapor recovery valve or product retaining fittings located in the upper two third of the cargo tank circumference (or cross section perimeter for non-circular tanks) shall be protected by being located within or between adjacent rollover damage protection devices or by being 125 % of the strength that would be provided by the otherwise required damage protection device.

(b) The rollover damage protection shall be designed to withstand a vertical load of twice the weight of the loaded tank, and a horizontal load of one half the weight of the loaded tank applied in any direction. These design loads may be considered as uniformly distributed and independently applied. The stresses shall not exceed the ultimate strength of the material of construction.

(c) The rollover damage protection shall run the full length of the tank top and shall be integral with the tank. To prevent accumulation of liquid, drains shall be provided to direct the liquid to a safe point of discharge away from any structural component of the cargo tank vehicle.

(d) Overflow and drain pipes shall have thicknesses heavier than the tank shell and shall be designed so that hot asphalt will not spill onto tires, brakes, burner equipment, or the vehicle’s exhaust system.

16. Ladder

(1) Access to top of cargo tank shall be provided by a non-slip-rung ladder at the rear of the tank.

(2) Ladder side rails shall be of uniform cross section with no sharp protrusions or edges. If round, side rail diameter shall not be less than 20 mm (¾ inch) nor more than 25mm (1inch) diameter.

(3) The side rail shall be designed to sustain a static vertical load of 450 pounds to any step.

(4) Minimum clearance of 100 mm (4 inches) shall be provided to the outside of each side rail.


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(5) Steps shall be slip resistant capable of withstanding a static vertical load of 450 pounds.

(6) If round, step diameter shall be 20 mm (¾ inch) to 25mm (1 inch) in diameter.

(7) Step width shall not be less than 300 mm (12 inches) nor more than 400 mm (16 inches).

(8) Minimum depth of top step shall be 90 mm (3.5 inches).

(9) The bottom or access step shall be no more than 650mm (26 inches) from the ground or no more than 550mm (22 inches) from access area such as trailer frame or bumper.

(10) Vertical spacing of steps shall be uniform and not less than 250mm (10 inches) nor more than 300mm (12 inches) except near bumpers.

(11) Minimum toe clearance shall be 150mm (6 in.).

(12) The horizontal step across distance from the nearest edge of the step to the nearest edge of the structure shall not be more than 12 in. (300mm).

(13) Handhold shall be capable of withstanding a 200 pound static load applied in any direction.

(14) Handhold diameter shall be 20 mm (¾ inch) to 25mm (1in.) in diameter.

(15) Hand clearance beneath a handhold shall not be less than 75mm (3 in.) nor more than 150mm (6 in.).

(16) A handhold shall not protrude beyond the steps on the climbing side of the ladder.

(17) A handhold at the top of tank shall be no further than 300mm (12 in.) from the outside edge of the step.

17. Walkways

(1) Non-slip platform (fabricated of slip resistant material or coated with slip resistant surface) shall be provided on the roof of the tank.

(2) The walkway shall be of sufficient length to provide easy access for a person to Manholes and other tank roof mounted fittings, which require periodic inspection and maintenance.

(3) Minimum width of walkway between rollover protection curb shall be 1.0 meter (3.28 feet).

18. Markings

(1) A specification nameplate shall be provided in accordance with NFPA 385, CHAPTER 4 requirements.

(2) The plate shall be painted, not be subject to corrosion. The plate shall be permanently affixed to the tank by soldering, brazing, welding, or other equally suitable means.

The plate shall be marked in characters at least 3⁄16 in. (5 mm) high by stamping, embossing, or other means of forming letters into or on the metal of the plate itself at least the following information:


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(1) Vehicle manufacturer (2) Manufacturer’s serial number (3) Specification identification (4) Date of manufacture (5) Original test date (6) Certificate date (7) Design pressure (psi) (8) Test pressure (psi) (9) Head material (10) Shell material (11) Weld material (12) Lining material (13) Nominal tank capacity by compartment (front to rear) (U.S. gal) (14) Maximum product load (lb) (15) Loading limits (gpm and/or psi) (16) Unloading limits (gpm and/or psi)

(3) The plate shall be located on the right side near the front, in a place readily accessible for inspection. Tank truck markings and customer logos, signs and decals shall be of fluorescent / reflective finish.

(4)

(5) If a cargo tank is to be altered physically to meet another specification (or to accommodate a commodity not requiring a specification tank), such combinations shall be indicated beside the specification identification.

19. Certification

At or before the time of delivery, the manufacturer of a cargo tank motor vehicle must provide certification documents to the owner of the cargo tank motor vehicle. The registration numbers of the manufacturer, the Design Certifying Engineer, and the Registered Inspector, as appropriate, must appear on the certificates. A certificate shall be procured certifying that each such cargo tank is designed, constructed, and tested in compliance with this standard. The certificate shall be signed by a responsible official of the manufacturer of the cargo tank or from a competent testing agency and shall be retained in the files of the carrier during the time that such cargo tank is employed by the carrier, plus 1 year.

20. Fire Extinguishers (a) Each tanker must be equipped with at least two portable fire extinguishers, one fire

extinguisher on each side of the tanker. (b) All provided fire extinguishers shall be 25 lbs. (12 kg) dry chemical fire extinguishers

with BC rating.


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(c) They shall be firmly mounted at each side of the Tank-trailer with proper protection to save it from damage.

21. HAZCOM Label (a) Any tanker shall have at least three warning signs provided on each side of cargo tank

;one at the rear of the Tank-trailer and the other two near the front of the Tank-trailer both sides.

(b) All provided HAZCOM labels shall be in accordance with the requirements of the Director General of Civil Defense.

(c) All provided HAZCOM labels shall be in both Arabic and English. (d) The United Nations (UN) hazardous material code number for asphalt/Bitumen is

(3257) and Molten Sulfur (2448).

22. Safety Tools (1) Reflectors shall be provided on the following locations:

Around the end head

Spare tire metal guard

Rear Bumper

Any other sharp edges, i.e. countered fenders (2) Truck shall be provided with a ready means of towing the vehicle.

(3) All wiring shall be installed in conduits or otherwise physically protected.

(4) All Tractors and Tank-trailers shall be equipped with either 12 or 24 Volt electrical systems. Lighting shall be an LED type and conform to Saudi Arabian Government regulations. The electrical connection between a Tractor and Tank-trailer shall be through an SAE J560b 7 pin connector, or equivalent DIN, ISO or SMMT connector.

(5) Reverse lights shall be installed as well as a back-up alarm for reversing.

(6) All Tractors shall be equipped with spare wheel and tire, jack and lug wrench and spare tire carrier, and tire pressure monitor.

(7) Antilock-Brake System (ABS) shall be installed as minimum.

(8) The Roll Stability Control System (RSC) shall be installed in both the Tractor and the Tank Trailer to reduce the possibility of the roll-over accidents. The RSC shall be triggered only when the system detects roll instability by going too fast into a turn or maneuvers too quickly.

(9) All Tank-trailers shall be equipped with a suitable receptacle located on the left hand side of the chassis to hold Tank-trailer inspection records and safety stickers.

(10) Steel channel type rear bumper, rear fenders, and mud flaps shall be provided.


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(11) Side protection collision beams shall be installed if needed.

(12) Landing gear to be adequately braced and gusted and of sufficient capacity to allow coupling and uncoupling of Tank-trailer when fully loaded. Landing gear shall have a minimum ground clearance of 35 cm’s when in the travel position. Landing gear shall be manually operated, two speeds, crank type.

(13) Landing gear to be adequately braced and gusted and of sufficient capacity to allow coupling and uncoupling of Tank-trailer when fully loaded. Landing gear shall have a minimum ground clearance of 35 cm’s when in the travel position. Landing gear shall be manually operated, two speeds, crank type.

(14) Kingpin shall be compatible with the Tractor fifth wheel. 2.0 inches diameter (SAE J848a) kingpin is preferable size.

(15) Ladder to be provided at the right curb of the tanker for access.

(16) Delivery hose, when attached to a tank vehicle, shall be considered to be a part of the tank vehicle.

(17) During transfer of Class I liquids, motors of tank vehicles or motors of auxiliary or portable pumps shall be shut down during the making and breaking of hose connections. Where portable pumps are used for transferring Class I liquids, the portable pumps shall comply with the applicable transferred material.

(18) Where loading or unloading is done without requiring the use of the motor of the tank vehicle, the motor shall be shut down throughout the transfer operations of Class I liquids.

23. Inspections (a) All equipment shall be subject to inspection and tests during the course of

manufacture, fabrication, assembly, and prior to delivery to the customer. Subsequent Inspections and Testing shall be in accordance with the following table:

(b) Inspection shall be conducted by accrediated 3rd Party truck inspection agency.

Frequency Inspection

Six Months 1. External Visual Inspection

Five - (5) Years 2. Internal Visual Inspection

Annual 3. Lining Inspection (Only for lined tank shells)

Annual 4. Leakage Test

Five - (5) Years 5. Pressure Test

Annual 6. Thickness Test (All unlined tank shells in service corrosive to shell)


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(c) Any rejection by an authorized inspector based on inspections or tests shall be final. Any acceptance made by the authorized inspector shall in no way release the manufacturer from his guarantees as to design, material, workmanship and performance.

(d) The minimum extent of NDE shall be in accordance with ASME Boiler and Pressure Vessel Code, Section VIII, but not less than 10% radiography.

(e) The first weld pass of all pressure-containing weld joints shall be examined using dye penetration method.

24. Maintenance & Repairs

(a) Periodic maintenance of the top loading road tanker equipment shall be performed in accordance with the following table:

Component description

Six month Replacement

Axles √ Replace when damagedHeating burner or coils √ Replace when damagedVAPOR FITTINGS Vapor Adapter √ Replace when damagedVapor Vent Valve √ Replace when damagedPressure relief fittings High Capacity Pressure / Vacuum Vent

√ Replace Every Year

Manhole with PAF Cap √ Replace Every Five YearsAntistatic Internal Cable Conductor

√ Replace when damaged

Overfill Prevention System Optic Sensing Probe √ Replace when damagedGround Bolt √ Replace when damagedOptic Overfill / Grounding Socket

√ Replace when damaged

Wiring √ Replace when damagedPneumatic System Air Interlock Valve √ Replace when damagedFilter Regulator (FRL) Unit √ Replace when damagedPressure Protection Valve √ Replace when damagedBrake Interlock Pilot Valve √ Replace when damaged3-Way Ball Valve √ Replace when damagedAir lines and Fittings √ Replace when

damaged or leaking Hinged Guard Bar √ Replace when damagedJacketing’s √ Replace when damaged

(b) Truck owner is fully responsible for the above PM checks.


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(c) Documentations of conducting truck periodic maintenance evidence shall be present, updated and ready up on request.


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25. Illustrations

Truck Dimensions

Truck with Burner Port


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Truck with Steam Heating System

Ladder Details


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Reflectors and Placard Details

Name Plate Details


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UN Placards


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References

AMERICAN DEPARTMENT OF TRANSPORTATION (DOT) & ASME

DOT PART 49 CFR 173.247 ASME XII Rules for Construction and Continued Service of Transport

Tanks

US TANK TRUCK MANUFACTURER’S ASSOCIATION (TTMA)

TTMA RP9 Location of Lighting Devices for Trailers TTMA RP14 Design and Installation of Lighting Systems for Trailers TTMA RP23 Graphic Illustrations of Motor Carrier Tank

Specifications TTMA RP28 Flange and Emergency Valve Dimensional

Information TTMA RP33 Clean-Out Nipples on Tank Trailers TTMA RP39 Method for Determining the Gross Axle Weight Rating

(GAWR) and the Gross Vehicle Weight Rating (GVWR) for Truck Trailer Certification

TTMA RP40 Seven Conductor Electrical Connector for Truck Trailer Jumper Cable

TTMA RP50 Leak Testingof New Cargo Tank Vapor Recovery Systems

TTMA RP59 Tank Trailer Ladders and Walkways TTMA RP61 Performance of Manhole and / or Fill Opening Assemblies

on MC-306 Cargo Tanks TTMA RP76 Highway Trailer Kingpin and Upper Coupler

Assembly

NFPA - National Fire Protection Association

NFPA 70 National Electrical Code NFPA 385 Tank Vehicles for Flammable and Combustible Liquids

top loading tank truck/trailer construction, inspection

Documents