Training Module

Loading / Unloading of tankers / ISO

tanks
 Agenda

• Risk and Hazards involved in the activity

• Safety precautions
• Procedure
• Do’s and Don'ts
• Check list
🎃 Identify Hazards
→ Identify hazards before loading or unloading
• All personnel involved with a loading or
unloading operation should assess the potential
hazards before the operation begins. A clear
understanding of the procedures and Do we know the
communication between workers must be hazards involved?
What are they?
established.
• Site and freight specific knowledge is important.
• Avoid overhead power lines or steep grades.
• Visiting drivers should be made aware of their
responsibilities.
 Hazards
• Possibilities of overflowing of tanker / ISO tank or storage tank
while loading / unloading
• Possibilities of static charge generation while tanker /ISO tank
loading / unloading
• Gasket failure/line/Hose leakage of tanker / loading /unloading
Are we aware
line leading to material leakage / spillage / splash of these?
• Leakages from tanker / ISO tank / storage tank while loading /
unloading
• Sudden material spillage due to puncture of loading / unloading
line
• Corrosion of container/vessel/storage tank
• Tanker/Vehicle dash to structure/person while placing vehicle
at designated place
 Risk Involved in the activity
• Leakages of liquefying gases resulted into an emergency
• Leakages of liquefying gases lead to environmental pollution
• Fire due to generation of static charge
• Toppling of tanker / ISO tank while reversing / placing at place
• Leakages due to failure of safety valve, hoses
• Inhalation hazard in case respiratory protection is not used/damage
• Personal injury due to fall from height (while venting, sampling)
• Hazardous material (Toxic, Corrosive) overflow from tanker/ISO tank/vessel
resulting in spillage, release of hazardous vapour/gas may come in contact with
body part leading to serious injury
• Fire/Explosion and in case of flammable vapour/gas released
• Flammable material leakage/spillage may lead to fire
• Cross contamination leading to Hazardous waste generation
• Air/Land/Water pollution in case of environmental release of hazardous material
 Safety precautions/PPE'S Used :

• In case of excess leakages of toxic and corrosive vapours (emergency

situation), use self contained breathing apparatus.
• Use close loop system (pipe line), in case of hose connection-use
composite hoses.
 Procedure
• Ensure , the tank and ISO tanker has sufficient space to accommodate the
unloading quantity and tanker for loading quantity
• Ensure that the tanker / ISO tanker checklist if followed
• Ensure that the engaged person is given task based training prior to start the job
• Ensure the availability and required pressure of nitrogen / liquid nitrogen
(wherever required)
• Send the tanker / ISO tanker at the designated location for Q C sampling
• Check the workability of fire fighting appliances and safety shower of work station.
• Ensure that spill control kit is readily available at work station / nearby location.
• Ensure that the sampling person is well equipped with required PPEs specially
with safety belt and fall protection system while sampling
• In case of an emergency situation, wait for the announcement on P A system and
then act accordingly.

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 Do's
• Tool box talk to the person engaged in the activity
• Ensure that the tanker / ISO tank is provided with spark arrestor
• Ensure that the tanker tires are blocked with stoppers / chokes
• Ensure that the tanker's / ISO tank's ignition keys are removed
• Check that the good quality gaskets are provided to the flanges
• Ensure that connected scrubber (wherever applicable) is in good working condition
• In case of tanker unloading, open vent of each compartment and check for right
nozzle valve is open (there may be two nozzles for compartment as local vent and
filling nozzle with dip pipe)
• If high level alarm is provided and blown, stop transferring immediately and inform
to concern person.
 Do's
• Ensure level is rising during unloading, if not then stop the unloading and inform
to Engineering department for correction."
• Ensure that telephone and public address system of work station is in order.
• Ensure that the tanker / ISO tank driver is briefed about the actions to be taken
during an emergency situation
• Connect the bonding and earth connector points on top /bottom of tanker.
Always use a suitable crocodile clip for such earth connection and ensure that
the paint coating on the tanker body does not disturb earth connections
 Do's
• Ensure ISO tank received for filling work is provided with cleaning certificate
• While filling the tanker / ISO tank, start the filling at slow rate for a short while, so
that the fill pipe in the tank compartment get immersed in the product. Thereafter
the filling rate can be increased.
• Ensure that the leakage and spillage does not take place while disconnecting
loading arms or hose pipes and also while changing them from one compartment
to another
• In case to approach the tanker top, ensure that the safety belt and fall arrest
system is used.
• After completing filling operation, remove the loading assembly and return it to its
original place, close the fill pipe, dip point and master valve.
 Do's
• Remove the bonding and earth connection at top and bottom of the tanker and
the tire chokes placed in front/back of the vehicles.
• While loading / unloading corrosive chemical's tanker / ISO tanker, wear full
PVC suit with other recommended PPEs.
• In case of spillage of hazardous chemical on floor, cover the area with sand/
spill control material and send the waste to ETP for safe disposal.
• Ensure tanker / ISO tanker key is available near the vehicle so that he can
remove the vehicle if any emergency arises in the area
• Check master valve for its opening of road tanker (having compartment) before
loading the tanker
 Don'ts
• Do not do tanker / ISO tanker filling work without permit
• Do not allow any untrained person for loading / unloading work
• Do not allow tanker driver to start tanker's ignition while loading / unloading work
• Do not work without personal protective equipment
• Do not start the loading /unloading activity if the static dissipation system does
not work
• Do not do horseplay during work. Concentrate on the work only.
• During unloading / loading, do not allow the driver to sit inside the cabin
• Do not allow extra person to approach on the top of the tanker / ISO tanker
• Do not do any mechanical repairs or adjustments to the tanker, while loading
operation is in progress
 Don'ts
• Do not load any tanker / ISO tank, which is leaking or is in an unsafe
condition. If there is any doubt about the condition of the tanker, report that
immediately to the supervisor.
• If transfer activity is performed by applying Air/Nitrogen pressure, do not over
pressure/exceed than container's working/rated pressure
• Do not move/transfer container along with hose connected
• Do not leave the work area till the completion of transferring of material. In
case, if leaving the area is unavoidable, hand over the charge to other
authorized person using charge handing over slip.
• Do not rely/depend on driver for any operation related to tanker loading and
unloading activity
 Checklist
• Whether PPEs - Organic Vapour Mask, Nitrile hand gloves, Safety Helmet, Safety
shoes, Safety glass, protective clothing, high visible jacket available?
• Antidote available inside tanker without expiry date ?Name of Antidotes available :
• Driver is physically fit and knows about the Hazardous Waste.
• Driver has not consumed any Alcohol or Narcotics during reporting ?
• Driver is trained & aware about the antidote availability, its selection and its use by
authorized agency.
• Whether emergency kit like Jumbo bag, Saw dust, shovel etc. are available with
the driver to take care of emergency in enroute & in operable condition?
• Sources of ignition are not present inside driver cabin. Whether vehicle’s cabin is
checked for presence of any flammable / explosive substance being carried by the
crew?
• Whether tools and material inside the Cabin is secured properly to take care of
injury in case of toppling of vehicle?
 Checklist
• Whether vehicle fitted with Spark Arrestor?
• Whether the starter is flameproof
• Condition of seat belt for driver and conductor side
• Whether all the first aid items with valid expiry date are available in first aid box
• Whether the keys are send at Plant for unlocking
• Whether emergency information panel at three location as per norms painted
• Pollution Under Control Certificate (PUCC)
• Whether GPS is fitted in the vehicle for tracking of driver behaviour and in
working condition
• Approval copy of vehicles from PCB is available in Vehicle
• Owner books copy is available

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 Checklist
• Driver have valid & applicable driving license and he authorized to carry the
hazardous Material
• Valid vehicle fit certificate is provided by RTO
• Valid Insurance copy of the vehicles are available
• Whether the vehicles have valid road permit?
• Emergency Contact Nos of Fire Stn, Ambulance, Police - available at tanker and
Driver made aware
• Brake condition
• Wiper in working condition (Mandatory in rainy season)
• Self starter condition of Vehicle
• Head light condition of vehicle
• Side indicator condition
• Drivers Side Rear View Mirror
 Checklist
• Vehicle Permit per Central Govt. Motor Act 1988
• Copy of Pollution control boards available
• Availability of TREM Card
• Whether driver is trained on TREM cards
• Defined transport route, Tracking Mechanism in place - GPRS/ Check at identified
halts/ nodal points
• Whether seals valves and connections are airtight
• Whether there is any leakage of chemical from the tanker
• Spill response and Emergency Plan known and in place to driver
• Drivers trained on handling waste in case of emergency like leakage, fire,
spillage, accident etc.
• Instruction class taken in Hindi & Local Languages as understood by driver
 Checklist
• Two Stoppers
• Brake Light
• Side Indicator
• Reverse light
• Left Side Rear View Mirror
• Reverse Light
• Tire Condition-Good/ Average
• Hand brakes are working
• Three point retractable seat belts are available
• Whether driver is DDT Trained?
• Whether reflective tape is fitted as per CMVR 1989 Rules 104
• Whether the breather valve fitted at top cover is operating
• Calibration chart of tanker is available
• Whether Vent valve is fitted or not
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