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Standard Procedures for Tank Cleaning, Purging and Gas free Operation for Oil tankers
Tank cleaning – The process of removing hydrocarbon vapours, liquids or residues. Tank cleaning may be required for one or
more of the following reasons:
To load a different and not compatible grade of cargo. Washing in between carrying different grades of cargo is the
most common reason for tank cleaning. In most cargo sequences on product tankers, the cleaning may consist of no
more than a simple hot or cold seawater wash.
A simple water wash will disperse many types of chemicals and has been found effective between clean petroleum
products such as gasoil and kerosene. However, it should be noted that there is a number of grade sequences,
particularly in the petroleum product trade, where no washing at all needs to be be carried out. Thus the decision for
necessary tank cleaning required in such trades is often made only when knowledge of the next grade to be loaded is
obtained.
Responsibility : The Chief Officer is in charge of and shall supervise as the person in charge of the Tank Cleaning,
Hydrocarbon Gas (HC) Purging, Gas Freeing & Re-Inerting operations. He shall ensure that all activities carried out during
such operations are in compliance with the latest edition ICS/OCIMF International Safety Guide for Oil Tankers and Terminals
(ISGOTT).
Cargo Tank entry shall not be permitted unless the Oxygen Content is 21% and the hydrocarbon vapor content is less than 1%
of the Lower Flammable Level (LFL). Follow company’s “Procedure for Entry into Enclosed Spaces” with related permits.
If the previous cargo contains Hydrogen Sulfide (H2S) or other toxic contaminants which could evolve toxic gases (eg
benzene, toluene, Mercaptans, etc), the tank should be checked for such gases. Refer to “Guidelines for Toxic Gases Hazards”
Carrying out “Hot Work” inside Tanks within the ‘Dangerous Area’ need special caution as per “Procedures for Hot Work” and
carry out preparation accordingly.
Gas-Freeing or Purging for the Reception of Cargo If the intention of Gas-Freeing or Purging operations is to prevent the next
cargo to be loaded from contamination due to the previous cargo oil hydrocarbon gas, use the gas content indicated by the
Charterer as standard, but go on with the operations mentioned in (2) of Article 1 until the LFL decreases down to 40% or
under.
Safety Precautions
For the operations to be followed, (Tank cleaning, HC Gas Purging, Gas Freeing and Re-Inerting), the Chief Officer shall carry
out the following precautions . Detailed guidance on preparations and safety precautions are also described within relevant
sections of ISGOTT.
Have persons engaged in the operations observe the necessary precautions as described in this section and the “Precautions
during Gas-freeing Operations”
Complete the necessary sections of “Tank Cleaning, Purging and Gas Freeing Checklist” to confirm safety strictly at the
appropriate time.
On Tankers using the inert gas systems, the Chief Officer shall carry
out the operations mentioned in Article 1 and should maintain the
cargo tanks in a “Non Flammable” condition at all times.
These substances, can heat to incandescence on contact with air. This risk is minimized, by following the correct purging
procedure.
Such procedures serve as a general guidance for the preparation procedures required and may differ as per ship type.
Tanker Explosions
In the course of investigations into electrostatics, certain new factors have emerged which are relevant to the safety of tank
cleaning operations, not only in very large tankers but in tankers of all tonnage’s. It has been demonstrated that electrostatic
charging to the water mist, present in the tanks, exists under any cleaning condition, and that when washing operations are
stopped the level of charge decreases only slowly in the tank, and can remain present for a long time, especially in the
absence of ventilation. The following factors therefore need to be considered:-
In studying "charge concentration mechanisms", it has been found that insulated objects are not normally present in
ship's tanks, but the use of sounding rods might present such a hazard.
When a sounding rod is lowered into a tank filled with charged mist, a high static charge can be fed into the operator
via the wet suspension rope if the operator is insulated by the deck paint or his footwear. Such a charge accumulation
has been shown to be sufficient to cause incendive sparking when the operator, the sounding rod, or rope, comes into
contact with the ship's structure. This, of course, does not apply if the rod is lowered into a sounding pipe extending to
the bottom of the tank.
Portable tank cleaning machines are normally bonded to the ship's structure and furthermore, when in operation the
washing water provides a path for the electrostatic charge to dissipate. However, these machines may sometimes
become insulated objects and a potentially hazardous situation may exist in at least the two following cases;-
Where the hose is disconnected from the hydrant before lifting the machine out of the tank.
a) Such disconnection, prior to lifting, is commonly done in order to drain water from the hose. A coat of paint in good
condition is sufficient to insulate the hose flange from the steel of the deck. Under these conditions, when the machine
is lifted an incendive spark may jump to the lip of the tank cleaning hole, either from the machine or from the securing
rope or from the operator who guides the machine through the hole.
Not to use sounding rods through any deck opening other than the sounding pipe, either during tank cleaning, or for
one hour after cessation of washing if the tank is being blown, or five hours if the tank is not being blown.
To carry out checks on the electrical continuity of bonding wires on the tank cleaning hoses before each use.
To keep the hoses connected to the hydrants until the machines are out of the tank. The draining of the hose can be
done by loosening the coupling of the hose carefully to let the air in and by tightening the coupling again.
It is emphasised that while the likelihood of all the factors necessary to lead to an incendive spark being present at any
one time is remote, the fact that neglect of the foregoing precautions might lead to an explosion remains a possibility.
Tank atmospheres can be any of the following, However, ships fitted with an inert gas system, shall carry out the operations
under the Inerted Condition, unless otherwise as instructed: It should be met with atmosphere containing less than 8%
oxygen, and tank pressure of minimum 200 mmAq. Refer details to “ISGOTT”
Inerted Tanks
An atmosphere made incapable of burning by the introduction of inert gas and the resultant reduction of the overall oxygen
content. For the purposes of this procedure, the oxygen content of the tank atmosphere should not exceed 8% by volume.
This is a condition where the tank atmosphere is known to be at it’s the lowest risk of explosion by virtue of its atmosphere
being maintained at all times Non-Flammable through the introduction of inert gas and the resultant reduction of the overall
oxygen content in any part of any cargo tank to a level not exceeding 8% by Volume, while being under positive pressure at all
times.
(a) For reduction in hydrocarbon (HC) content in tank atmosphere for Cargo / Vapor contamination reasons:
After tank cleaning operations the cargo tanks may be purged with inert gas to reduce the concentration of the hydrocarbon
gas inside the tank atmosphere.
Follow the procedures as laid out in the operation and equipment manual.
Purge pipes, with proper flame screens shall be fitted, where provided.
Carry out the operations of replacing the tank atmosphere by introducing IG of which oxygen content is 5% by Volume or less
into the tanks.
Go on with purging by IG until the hydrocarbon content reduces to the required / desired level.
Note
Since the main purpose of HC gas purging is displacement HC gas with IG, the procedure first priority shall be supply IG with
full capacity of IG Blowers. Under the procedure, Oxygen content in Inert Gas for purging may be permitted by 8% by Volume
or less.
After cargo discharge / tank cleaning, whenever it is necessary to gas free an empty tank containing hydrocarbon gas
mixtures or a mixture of IG + HC gases, it shall first be purged, using inert gas, until the HC (hydrocarbon) content reaches to
below the critical dilution line or HC concentration in the tank atmosphere is less than 2% by volume.
This is done so that during the subsequent gas freeing no portion of the tank atmosphere is brought within the flammable
range.
This inert gas used for purging shall contain Oxygen, less than 5% by volume, to ensure the above.
The replacement of a tank atmosphere by inert gas can be achieved by either Inerting or Purging. In each of these methods
one of two distinct processes, Dilution or displacement, will predominate.
For more details on gas evolution, venting and dispersion criteria and precautions, refer to the relevant ISGOTT chapters.
Distinct process
1) Dilution: It takes place when the incoming inert gas mixes with the original tank atmosphere to form a homogeneous
mixture through the tank so that, as the process continues, the concentration of the original gas decreases progressively.
It is important that the incoming inert gas has sufficient entry velocity to penetrate to the bottom of the tank. To ensure this a
limit must be placed on the number of tanks which can be inerted simultaneously.
If dilution method of purging is used, it should be carried out with the inert gas system set for Maximum capacity to give the
maximum turbulence in the atmosphere, within the tank.
2) Displacement : It depends on the fact that inert gas is slightly lighter than hydrocarbon gas so that, while the inert gas
enters at the top of the tank, the heavier hydrocarbon gas escapes from the bottom through suitable piping.
When using this method it is important that the inert gas has a very low velocity to enable a stable horizontal interface to be
developed between the incoming and escaping gas although, in practice, some dilution inevitably takes place owing to the
turbulence caused in the inert gas flow. This system generally allows several tanks to be inerted or purged simultaneously. If
displacement method is used, the gas inlet velocity should be lower, to prevent undue turbulence.
A mixture of inert gas and petroleum gas when vented and mixed with air can become flammable. The normal safety
precautions required as described under “Procedures for Cargo Oil Operations” shall be followed.
i) Before starting to Gas free, the tank should be isolated from other tanks.
ii) Do not commence forced air ventilation (Gas free) until it has been confirmed that the oxygen level is less than 8% and the
hydrocarbon vapor content is less than 2% by Volume.
iii) To ensure the dilution of the toxic components of inert gas to below their Threshold Limit Values (TLV), Gas freeing should
continue until tests with an oxygen analyzer show a steady oxygen reading of 21% by volume and tests with a flammable gas
indicator show not more than 1% LFL.
iv) If the presence of a toxic gas such as benzene or hydrogen sulfide is suspected, Gas freeing should be continued until
tests indicate that its concentration is below its TLV.
After completion of man entry or repair work (in dry docks / lay-up berth) Cargo tanks shall be prepared for Loading as
follows:
i) An Officer shall confirm each tank free of waste & material used in maintenance & inspection. Related pipelines and
supports, including hydraulically operated valves, H.P. pipes and flanges are all in place and tightly secured.
ii) All personnel out of tank & close tank dome or access, only keep designated vent ports open. Inert tanks to 8% of Oxygen
level.
iii) Replace the tank’s atmosphere by an inerted atmosphere, using IG with the oxygen content of less than 5% by Volume.
This gas replacement should continue, until the average measured oxygen content in the tanks drops to below 8% by Volume.
In case that proper IG can not be supplied, which could cause the oxygen content in tanks to exceeds 8% by Volume, or
making it difficult to keep the internal pressure of tanks positive due to troubles in the IG system or other reasons during tank
cleaning or hydrocarbon gas purging operations, suspend the operations immediately, and do not restart the operations until
proper supply of IG is secured.
Provided that the atmosphere in tanks is not under control, do not put improper IG (the oxygen content of which exceeds 8%).
If the recovery of the IG system is difficult, notify the Technical Superintendent in charge for consultation.
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