IQCM 2009

Note of Ministry of Petroleum and Natural Gas, Govt. of India, New Delhi

letter No. P-45011/54/2007- Dist, Dated 11th Sept ’2008

INDUSTRY QUALITY CONTROL MANUAL

FOR NON-AVIATION PETROLEUM PRODUCTS

EFFECTIVE – JANUARY 2009

Printed by Bharat Petroleum Corporation Limited

INDUSTRY QUALITY CONTROL

MANUAL

FOR

NON AVIATION PETROLEUM PRODUCTS

Note of Ministry of Petroleum and Natural Gas, Govt. of India, New Delhi

letter No. P-45011/54/2007- Dist , Dated 11 Sept 2008

EFFECTIVE – JANUARY 2009

INDUSTRY QUALITY CONTROL MANUAL FOR

NON-AVIATION PETROLEUM PRODUCTS

INDUSTRY QUALITY CONTROL WORKING GROUP

Sr. No.

Name Designation Company

1. Mr. P. D. Bahukhandi GM (QC) IOCL MKT DIV 2. Mr. R. J. Patel DGM (QC) IOCL MKT DIV 3 Dr. Tapan De CQCM IOCL MKT DIV 4 Mr. Anil Vijapure SR MGR (QC) IOCL MKT DIV 5. Mr. K. Hariharan Manager (QC) IOCL MKT DIV 6. Dr.P.V.S.L Narasimham Ch. Manager QC BPCL MKT 7. Mr. V. R. Nage Sr. Manager QC BPCL MKT 8. Mr. C. S.Krishnaswamy GM-R&D and QC HPCL MKT 9. Mr. S. N. H. Wasti Ch. Manager (QA) HPCL MKT 10 Mr. D. Roy Ch. Manager (QC) HPCL MKT 11 Mr. S. W. Khadilkar Sr. Manager QC, HPCL MKT

INDUSTRY QUALITY CONTROL MANUAL FOR NON AVIATION PETROLEUM PRODUCTS

AMENDMENT RECORD AMENDMENTS No. DATE

SECTION/ (PAGE)

EMBODIED BY

DATE

CONTENTS

SECTIONS SECTION : 1 INTRODUCTION SECTION : 2 PRODUCT QUALITY AND SPECIFICATIONS SECTION : 3 RECEIPT SECTION : 4 STORAGE SECTION : 5 DESPATCH SECTION : 6 ADDITIONAL CONTROLS FOR HIGHLY QUALITY SENSITIVE PRODUCTS SECTION : 7 SAMPLING SECTION : 8 LABORATORY SUPPORT

ANNEXURE ANNEXURE : 1 PRODUCT QUALITY FAILURE INVESTIGATION

APPENDICES APPENDIX : 1 SPECIFICATIONS FOR NAPHTHA, MOTOR GASOLENES, KEROSENE,

AUTOMOTIVE DIESEL, LIGHT DIESEL OIL AND FUEL OILS. APPENDIX : 2 QUALITY CONTROL CHECKS. APPENDIX : 2A ACTIVITIES & RETENTION OF SAMPLES. APPENDIX : 3 PREDISCHARGE TESTS FOR OCEAN TANKERS/ BARGES. APPENDIX : 4 QUALITY CONTROL CHECKS – TANK WAGON AND TANK TRUCK OPERATIONS. APPENDIX : 5 QUALITY CONTROL CHECKS – BARRELS (OTHER THAN LUBES) APPENDIX : 6 TANKER TANK CLEANING KEY APPENDIX : 7 TANKER TANKS FITNESS CERTIFICATE APPENDIX : 8 STORAGE TANKS/TANK TRUCK CLEANING DATA APPENDIX : 9 LOG BOOK – TANKER / PLT OPERATIONS APPENDIX : 10 INLAND PIPELINE TRANSFER LOG BOOK APPENDIX : 11 SAMPLE LABEL – TANK WAGON FILLING POINT APPENDIX : 11A SAMPLE LABEL – TANK TRUCK FILLING POINT APPENDIX : 12 RECORD OF SAMPLES RETAINED / DISPOSED APPENDIX : 13 BATCH CONTROL LOG BOOK APPENDIX : 14 CODE LETTERS OF REFINERIES/TERMINALS/INSTALLATIONS/DEPOTS APPENDIX : 15 BATCH FORMATION TESTS APPENDIX : 16 PROCEDURES FOR TANK TRUCK OR TANK WAGON GRADE CHANGE OVER APPENDIX : 17 INSPECTION GUIDE FOR NON-AVIATION PRODUCTS STORAGE POINTS APPENDIX : 18 AREAS OF RESPONSIBILITY FOR MAINTAINING THE QUALITY OF PRODUCTS APPENDIX : 19 PRODUCT ACCEPTANCE LIMITS EX REFINERIES/PIPE LINES/IMPORTS APPENDIX : 20 GLOSSARY OF TERMS

SECTION – 1

INTRODUCTION

SUBJECT PAGE NO.

Objective 1 Purpose & Scope 1 Quality Control Organisation 2 Quality Control Responsibilities 2 Role of Quality Control Department and Quality Audit Inspections

2

Product Specification 2 Documentation 3

Section 1 Introduction INDUSTRY

QUALITY CONTROL MANUAL Clauses

1.0 to 1.3.2 Page No. 1 of 3

1.0 INTRODUCTION

1.1 OBJECTIVE

To evolve a uniform Quality Control procedure for handling of the Non Aviation Petroleum Products viz. Naphtha, Motor Gasoline and its variants, Kerosene, High Speed Diesel and its variants, Light Diesel Oil, Fuel Oils and its variants, applicable to the entire Oil Industry (including Refineries, Pipelines and Marketing Companies) in Public and Private Sectors, covering the existing as well as future such networks.

1.2 PURPOSE The purpose of procedures outlined in this manual is to ensure that;

1.2.1 All non-aviation petroleum products, whether indigenously produced in Indian refineries or imported, are received in accordance with the respective specifications laid down from time to time and they enter the marketing and distribution system in “Refinery-Good” condition.

1.2.2 They are stored and handled with due care so as to keep them 'on-specification' and in “Refinery- Good condition” at all times.

1.2.3 They are delivered from various storage points by different modes of transportation in good condition and conforming to respective specifications laid down from time to time.

1.2.4 A well-defined system of quality control checks and documentation exists to achieve this purpose.

1.3 SCOPE

1.3.1 The procedures outlined in this manual are only the minimum requirements in order to ensure product quality of the non-aviation petroleum products. Therefore, the standard operating procedures with due regard to the safety in handling of petroleum products in general, have to be followed as laid down in the respective “Safety and Operations Manuals” and also in the "Industry Manual on Acceptance of Product by Marketing Companies and Related Issues”. It is expected that such standard procedures will be followed at all times in addition to the instructions contained in the following pages which are with reference to quality aspects only.

The procedures outlined in this manual are applicable to the entire Oil Industry (including Refineries, Pipelines and Marketing Companies) in Public Sector Undertakings, Joint Ventures and Private Sector, covering existing as well as future such networks.

With the introduction of Bio Fuels i.e. Ethanol doped Motor Gasoline, Bio Diesel etc., the Industry group shall prepare and update Operation, Safety and Quality guidelines to ensure that the product of requisite quality as per the laid down standards is delivered. Similarly the respective companies shall ensure that a system is in place for quality monitoring of their branded fuels. The committee comprising “PSU Industry QC group” shall develop, update, and review the Industry Quality Control Manual as per the requirements under intimation to MOP&NG.

1.3.2 Any changes in the laid down procedures, before inclusion in the manual, shall be forwarded to MOP&NG for their advice / notice. Such changes shall be issued in the form of amendments, with serial number and the same shall be recorded in the amendment record of this manual.



1.4 to 1.6.1 Page No. 2 of 3

1.4 QUALITY CONTROL ORGANISATION

1.4.1 All those associated with the handling of petroleum products bear the responsibility to ensure that the product delivered is in a clean and good condition, meeting the relevant quality standards. Consequences of delivering "off-specification, contaminated and wrong product” are extremely serious.

1.5 QUALITY CONTROL RESPONSIBILITIES

1.5.1 The responsibility for ensuring proper quality control at various Terminals, Installations, Depots etc., rests with the Operations Department. While the primary responsibility for implementation of quality control practices rests with the concerned officers of each location, the overall responsibility for quality control implementation will be that of the Location-In-charge. Each Terminal & Installation shall identify an officer as Quality Control Co-ordinator. In case of Depots; the Depot In-charge shall be the Quality Control Co-ordinator. Operations department shall maintain the list of such Quality Control Co-ordinators duly updated from time to time.

1.5.2 Quality Control Implementation officers of the Location or Operations Department / Controlling office, shall carry out Audits to ensure implementation of the laid down Quality Control procedures. Such Audits shall be carried out at least once in a year at each location and observations shall be recorded in Inspection guide covering the major area of activities at the location. (Appendix-17).

1.5.3 Role of Quality Control Department and Quality Audit Inspections The quality control department shall formulate quality control guidelines / policies required under

Clause 1.3 in coordination with the requirement of operations or sales department etc.

Officers of the Quality Control department shall carry out quality control audit of storage points. Such audits shall be carried out at least once in a year, and observations recorded in Quality Control Inspection guide covering the major area of activities at the location. (Appendix 17)

Location In charge in association with QC co-ordinator shall ensure to enlist location-specific quality procedures as applicable. Location In-charge and QC Co-ordinator shall also carry out self-Audit on quarterly basis (Appendix-17) and shall discuss with the concerned at location about corrective action on the observed lapses.

Minimum 10% of locations shall be audited jointly in a year on surprise basis by Operations Department / Controlling office (Head Office) as well as Quality Control department (Head Office) officials for better implementation of quality control procedures at location.

1.6 PRODUCT SPECIFICATION 1.6.1 Most of the Non Aviation Petroleum products covered in this Manual are marketed to current BIS

Specification (Appendix 1) and / or as per the requirements of the Gazette Notification issued by Government of India from time to time and / or guidelines issued by MOP&NG / Regulatory authorities from time to time. In case of branded automotive fuels supplied by Oil companies, the fuel shall also meet the relevant BIS Specification.



1.7 to 1.7.3 Page No. 3 of 3

1.7 DOCUMENTATION

1.7.1 All Quality control activities shall be duly documented in standard formats. The documents under normal circumstances shall be preserved for one year or till next QC Audit inspection, whichever is later.

1.7.2 In case of any product quality failure, the relevant QC documents and test reports shall be retained for 3 years or till the completion of the investigation of the case whichever is later and shall be disposed off only after the necessary approval from controlling department. Such documents shall be maintained in a separate file for records. The investigation reports shall be retained for further period of one year. The documents shall ensure the traceability to the relevant batch of the product for investigation in case of any deviation observed or for product failure. The samples shall be retained as per Appendix 2A.

1.7.3 Any amendments issued to Industry Quality Control Manual (IQCM) shall be incorporated in the IQCM and implemented by the location In-Charge.

SECTION – 2 PRODUCT QUALITY

AND SPECIFICATIONS

SUBJECT PAGE NO. Manufacturing Specifications 1 Marketing Specifications 1

Section 2 Product Quality & Specifications

INDUSTRY

QUALITY CONTROL MANUAL Clauses 2.0 to 2.2.2

Page No. 1 of 1

2.0 PRODUCT QUALITY AND SPECIFICATIONS

2.1 MANUFACTURING SPECIFICATIONS

2.1.1 All products mentioned in this manual are either manufactured in PSU / Private / JV Refineries or imported from foreign sources. It is therefore of utmost importance to ensure that all products enter the marketing system from indigenous refineries or from import sources with a quality level within the specification limits and / or as per the requirements of the Gazette Notification issued by Government of India and / or guidelines issued by MOP&NG / Regulatory Authorities from time to time. The concerned Location-in-charge shall be responsible for ensuring this.

2.1.2 Marketing Companies / Parallel Marketers shall keep sufficient margin in respect of sensitive characteristics of the product specifications while procuring product from the PSU / Private / JV Refineries and through import. This is in order to meet the required specifications of products on receipt at marketing storage and at consumers’ end as the product moves through different modes of transportation. Accordingly manufacturing specification is to be worked out separately for rail, road, sea or pipeline transportation.

2.1.3 Manufacturing Specification shall be worked out considering the various factors that include mode of transport, batch size, stringency of specifications, requirement for doping the bio-fuels, ageing and special customer requirements etc. Reproducibility of the test method or ISO 4259 may also be considered for arriving at the manufacturing specifications. However, directionally the requirements in Appendix –19 may be maintained at the manufacturing end for the products mentioned therein.

2.2 MARKETING SPECIFICATIONS

2.2.1 Release of products shall be aligned with the manufacturing specifications from the storage point conforming to the latest BIS specifications (Appendix – 1) and / or Gazette Notification issued by Government of India / Regulatory Authorities from time to time.

2.2.2 Wherever BIS specifications do not exist for a product (for example Naphtha); respective Marketing Oil companies in consultation with the consumer, shall draw the guaranteed specification.

SECTION – 3

RECEIPT

SUBJECT PAGE NO.

Responsibilities 1 Sampling of tanks nominated for receiving product

1

Receipt by Ocean Tankers (Imported/Coastal) 1 Pre-discharge tests (Receipt by Ocean Tankers) 2,3 & 4 Receipt by Pipeline Transfers 4, 5 & 6 Receipt by Tank-Wagons 6 Unconnected Tank-Wagons 6 Receipt by Tank Trucks 7 Receipt by Barrels 7 Receipt of Additives / Dye / Marker 7 Batch Number 8

Section 3 Receipt INDUSTRY


3.0 to 3.2.3 Page No. 1 of 8

3.0 RECEIPT

3.0.1 RESPONSIBILITIES Responsibilities for maintaining the quality of products are as given in Appendix 18 of this Manual

and in "Industry Manual on Acceptance of Product by Marketing Companies and Related Issues".

3.1 SAMPLING OF TANKS NOMINATED FOR RECEIVING PRODUCT

3.1.1 Before receiving product through multi-product pipeline / dedicated pipeline / local dedicated pipeline / water flush pipe line / ocean tankers, UML composite samples from individual tanks nominated for receiving the product shall be taken, labelled, sealed and retained (Appendix 2A). Ensure that bottom of the receiving tank is free from water and observation is to be recorded In case of receipt through cross country / feeder pipeline, UML samples as mentioned above shall be taken jointly by Officers of Refinery or Marketing / Pipeline Divisions from the individual nominated tanks.

3.1.2 If the sample, after receipt, conforms to the specification requirement in respect of tests carried out, samples taken under Clause 3.1.1 may be disposed off.

3.1.3 Location receiving Kerosene by Rail / Road shall carry out Flash Point & Density tests on top sample of the tank after each receipt. Subsequently Density & Flash Point test shall be carried out in line with Clause 4.1.5 and record shall be maintained. A Composite sample from this kerosene tank shall be retained for a period of one month (Appendix 2A). In the event the Flash Point does not meet the specification requirement, concerned department and / or controlling office shall be intimated immediately for further necessary action

3.1.4 In the event of the sample after receipt not conforming to specification, these retained samples (Appendix 2A) shall not be disposed off till the investigation is over.

3.2 RECEIPT BY OCEAN TANKERS (COASTAL / IMPORTED)

3.2.1 When a common line is used for receiving products, all tanks excepting the tank receiving the product, shall be positively segregated by dropping spool pieces or hammer-blind valves or by means of spectacle flanges / liners etc.

3.2.2. Load port test report shall be checked to ensure conformity to the required specifications. Load port shore tank(s) and tanker tank(s) samples (Appendix 2A) shall be collected from the master, and retained. The density recorded on the label shall be verified with the observed density at 15°C for the tanker tank samples. Discharge arrangements shall be so adjusted to avoid any possible contamination.

3.2.3 Tanker tank ullages shall be taken. An all-level sample (bottom sample on need basis) from individual tanker tanks shall be checked for test A (Appendix 2).

In the event the observations are found unsatisfactory, concerned department shall be informed for further advice. Individual tanker tank samples shall be sent to laboratory for PD Test and retained (Appendix 2A, Annexure 1).

In case of multi-product receipt through Ocean tanker the ullage shall be taken once again before the commencement of pumping of the next product and verified with the earlier recorded ullage to ensure that there is no inter tank leakage.



3.2.4 to 3.2.6 Page No. 2 of 8

3.2.4 PRE-DISCHARGE TEST 3.2.4.1If the above (Clause 3.2.3) observations are satisfactory, in case of indigenous product, a

proportionate (on volumetric ratio) composite of the tanker tank samples shall be prepared at laboratory and tested for the relevant Pre-Discharge tests (Appendix 3) and discharge shall commence if the test results are satisfactory.

3.2.4.2If the above (Clause 3.2.3) observations are satisfactory, in case of imported product a proportionate (on volumetric ratio) composite of the tanker tank samples shall be prepared at laboratory and tested for full specification test in case of first port of call and for the relevant Pre-Discharge tests (Appendix 3) at subsequent ports of call and discharge shall commence if the test results are satisfactory.

3.2.5 If the composite sample fails, then individual tanker tank samples shall be checked for the failing quality parameter and the individual tanker tanks for which the sample does not meet specification shall be isolated and only those tanks that meet the Pre-Discharge test requirements shall be declared fit for discharge. The concerned department shall be intimated of the failure immediately.

3.2.5.1In the event of any product quality failure noted, it shall be investigated immediately as per the procedure laid down in the Industry Manual on Acceptance of Products by Marketing Companies and in line with Clause 4.6 of the IQCM.

3.2.6 Interface Accommodation

The interface of Product tank to

Accommodate Interface

Interface Quantity (Front + Rear)

Acceptable (%) ** MS BS II & SRN/MRN MS BS II 1.0 MS BS III & SRN/MRN MS BS III 0.5 MS BS II & SRN/MRN MRN 3.0 MS BS III & SRN/MRN MRN 3.0 SRN & SK MRN OR SRN 3.0 # MRN & SK MRN 3.0 # MS BS II / MS BS III & SK MS BS II 2.0 * SK & ATF SK No limit SK/ATF & HSD BS II / LSHF/HF HSD HSD BS II 3.0 # SK/ATF & HSD BS III / LSHF/HF HSD HSD BS III 2.0 LSHF/HF HSD HF HSD No limit HSD BS II & LSHF/HF HSD HSD BS II

$

HSD BS III & LSHF/HF HSD HSD BS III $

HSD & LDO LDO 3.0 # LDO & FO FO 5.0

$ Case to case basis in consultation with QC Department

** The figures indicated, as interface percentage acceptable grade wise, are directional.

The interface front and rear-end together not to exceed the percent (%) quantity of product received in the tank as indicated above. However, product carrier shall be responsible for positioning the product as per required specification. Therefore, the interface management is to be worked out by pipeline carrier in co-ordination with Refiners and Marketers either by absorption or by insertion of suitable pig or by segregating into an isolated tank for re-processing at Refinery in consultation with the Quality Control Department.



3.2.6 to 3.2.9 Page No. 3 of 8

# Interface, front and rear end together shall not exceed 3% of product received in the tank.

However, with regard to HSD / LDO, care should be taken to see that the flash point of LDO is protected to be within specifications.

* A composite of equal quantities of TMB samples shall be tested for the Batch Formation Test

(Appendix – 15) and the bottom sample shall be tested for Density and Distillation Test separately. In case of any deviation, Batch formation test shall be carried out on bottom sample. The reasons shall be ascertained before its correction and release. If the results conform to the specification, the product may be released.

The record of all the Interface disposals / management shall be maintained.

3.2.7 Before commencement of discharge, ship’s manifold and line content shall be identified. In case of a product different from that to be discharged, the same shall be drained out in to slop tank of the tanker.

3.2.7.1 Pipeline samples are to be monitored from both the end for its suitability for discharge of the product. In case the product lying in the pipeline is dormant for a month or more, samples such drawn shall be subjected to monthly monitoring tests as per Clause 4.4.1 (Appendix 2)

3.2.7.2 For first five (05) minutes the tanker discharge shall be closely monitored (i.e. Test ‘A’), to ensure the quality of product that is being discharged and record maintained.

3.2.7.3 Subsequently for the next half an hour of product pumping, samples (white oils only) shall be taken from top and bottom sampling cocks at jetty end / Ship's manifold every 10 minutes (at 00-10-20-30 Minutes) and Test ‘A’ (Appendix 2) done. From the shore end, samples shall be tested for Test-A every ten minutes, for half an hour (at 00-10-20-30 Minutes) after displacement of the line content. If this test is unsatisfactory (the variation in density is more than 3.0 Kg/m

3 (0.003

gm/ml) at 15oC when compared to each batch / tanker tank density range). In case individual

tanker tanks are having different densities, then the jetty end / shore end sample shall have a density of within (+) 3.0 kg/m

3 / (+) 0.003 gm/ml of the highest and (-) 3.0 kg/m

3 / (-) 0.003 gm/ml

of the lowest density of the tanker tank(s).

3.2.7.4 These checks shall be chronologically recorded in the shore end and jetty end tanker log book (Appendix 9). Test ‘A’ (Appendix 2) shall be done every hour during the pumping and chronologically recorded thereafter.

3.2.7.5 The pumping shall be stopped if density variation is found beyond the limit mentioned in Clause 3.2.7.3. The pumping shall be resumed only after the reason for the variation has been established and necessary corrective action taken.

3.2.8 Two litres retention sample each shall be taken both from jetty end and shore end during commencement, middle and end of the discharge, sealed, labelled and retained until quality of the product after receipt is established (Appendix 2A). In case of density variation, Clause 3.2.7.3 shall be followed.

3.2.9 Sampling facility on receipt pipeline shall be so located that the top and bottom samples can be drawn from the same location of the pipeline. Facility to collect top and bottom sample from the pipeline / pipeline manifold shall be available at the jetty end and inside installation premises.

3.2.10 On completion of transfer, and after allowing a minimum settling time of one hour, a Top, Middle, and Bottom (TMB) sample shall be drawn (Appendix 2A) from tank and individually subjected to Test ‘A’ (Appendix 2) and recorded in the respective log book. The above Top, Middle and Bottom sample shall be sent separately along with Test ‘A’ observations to the laboratory. The Laboratory shall also carry out Test ‘A’ and a composite of Top, Middle and Bottom samples shall be subjected to batch formation test (Appendix 15). If the density variation of TMB is more than 3.0 Kg/m

3 /

0.003 gm/ml between any two layers, batch formation test shall be carried out individually for layers having lowest and highest density. The product from the tank shall be released only if the Lab confirms that the product meets specification requirement in respect of the tests carried out.

In case of Kerosene, additionally Flash Point test also shall be carried out on top sample. A composite sample of Kerosene shall be retained for three months and record maintained as per Appendix 12.

In case of multi product discharge of tanker through a single pipeline, for Motor Gasoline, additional Test ‘J’ (Appendix 2) also shall be carried out on Bottom sample from tank and for HSD, additional Test ‘K’ (Appendix 2) also shall be carried out on Top sample.

3.2.11 If dedicated barges are used for product transportation, all QC checks outlined for tank-wagon

loading / discharge shall be followed (Appendix 2A).

3.3 RECEIPT OF PIPELINE TRANSFERS

3.3.1 a Pipeline samples are to be monitored from both the ends for its suitability for discharge of the product. In case the product lying in the pipeline is dormant for a month or more, samples such drawn shall be subjected to monthly monitoring tests as per Clause 4.4.1 (Appendix – 2)

3.3.1 b Pipeline transfers are either through multi-product pipeline or a dedicated pipeline / local dedicated pipeline. When transfers take place through a multi-product pipeline, care has to be exercised to correctly ascertain the interface cutting in line with Clause 3.2.6.

3.3.2 For the first half an hour of each product being pumped through a multi-product pipeline or a dedicated pipeline / local dedicated pipeline samples shall be drawn from the top and bottom of the pipeline near the manifold at intervals of ten minutes (at 00-10-20-30 Minutes), and Test-A (Appendix 2) done for each batch / tank and to be recorded (Appendix 10). If the test results are satisfactory (the density variation shall be within that given in Clause 3.2.7.3) when compared to each batch density range, the interval of sampling shall be every hour. In case, the density variation is outside the permissible limits, then the pumping shall be stopped, reasons for the variation established, corrective action taken and then pumping could be resumed.

Whenever pumping of the product is stopped, and then restarted, the procedure of the sampling during the first half an hour and then hourly sampling shall be followed.

Two litres retention sample shall be taken, both from despatching end and receiving end, during commencement, middle and end of the product transfer for each batch / tank, sealed, labelled and retained (Appendix 2A) until quality of the product after receipt is established and record maintained. The sampling points shall be as per Appendix-18.



3.2.10 to 3.3.2 Page No. 4 of 8

3.3.3 Before a Pipeline transfer is effected through a multi-product pipeline or a dedicated pipeline / local dedicated pipeline, it is to be ensured that the tank nominated for transfer of product is having homogeneous product with a certified density / batch test report. An upper, middle & lower sample from the individual tank/s nominated for transfer / receipt shall be jointly drawn. Measure the density of UML samples separately and record the density range observed for the tank/s. If the densities of the samples are within the tolerance limits a composite sample is retained (Appendix 2A) till the batch is established by the receiving location. In case variation in density is observed because of earlier receipt of different batches it is to be ascertained that the variation of density is within the tolerance limit of earlier batches.

3.3.4 When a transfer takes place from a Refinery / Marketing certified tank(s) through dedicated pipeline, representative sample from the tank(s) shall be jointly drawn, sealed and retained (Appendix 2A). A valid test report from the Refinery / Marketing certified tank(s) shall be obtained for support. After receipt of the product a batch control log shall be maintained (Appendix 13). In case of inter company product transfer, additional test for quality monitoring as per Appendix 15 may be carried out.

3.3.5 On completion of transfer, the procedure given in Clause 3.2.10 shall be adopted (Appendix 2, 2A, 12 & 15).

3.3.6 At Tap-off Point tanks in which product/s along with interface is accommodated, a sample shall be drawn (Appendix 2A) from Top, Middle and Bottom (Bottom sample to be drawn from a height of 15 cms. from the bottom of the tank or above the level of water that may be present in the tank) after receipt and tested for density individually to ensure homogeneity of the product. If not satisfactory [density variation is more than 3.0 kg/m

3 (0.003 gm/ml) at 15°C between any two

layers], it is to be investigated and reasons for density variation to be recorded in batch control Log and an individual layer batch formation test shall be carried out (Clause 3.2.10). If satisfactory [density variation is not more than 3.0 kg/m

3 (0.003 gm/ml) at 15°C between any two layers] the

composite sample of TMB shall be subjected to batch formation test. The product from the tank shall be released only if the lab confirms that the product meets the requirements.

In case of Kerosene, additionally Flash Point test also shall be carried out on top sample. A composite sample of Kerosene shall be retained for three months and record maintained as per Appendix 12.

For Motor Gasoline, additional Test ‘J’ (Appendix 2) also shall be carried out on Bottom sample from tank and for HSD, additional Test ‘K’ (Appendix 2) also shall be carried out on Top sample.

3.3.7 When the transfer is through a dedicated pipeline, (refer glossary of terms) a UML composite sample shall be taken jointly from the nominated tanks, Test ’A’ done and retained (Appendix 2A) till the quality of the product has been established, as per Clause 3.3.9, by the receiving location

3.3.8 During receipt through dedicated pipelines samples from the top and bottom of the pipeline near the manifold shall be drawn at intervals of one hour at the despatching and receiving end, Test ‘A’ (Appendix 2) done and the observations recorded chronologically (Appendix 10).

3.3.9 After receipt, through dedicated pipelines, samples from Top, Upper, Middle, Lower and Bottom levels (Appendix 2A) of storage tank shall be individually subjected to Test ‘A’ (Appendix 2) and the observations recorded. If the density variation at 15oC is within limits (Clause 3.2.10), the product may be released. In case of SKO, Flash Point test shall be carried out as per Clause 3.2.10 and a composite sample of Kerosene shall be retained for three months and record maintained as per Appendix 12.



3.3.3 to 3.3.9 Page No. 5 of 8

3.3.10 When stock transfer is effected from Other Oil Marketing Company through local dedicated

pipelines such transfers shall commence from valid stock having batch formation test certificate. Joint samples shall be taken from the nominated tanks (Appendix 2A) and Test ‘A’ to be carried out and record maintained.

The density variation of such stock during transfer shall not be beyond 3.0 kg/m

3 (0.003 gm/ml) at

15°C at any time. Sample shall be drawn and observations recorded as applicable in Clause 3.3.2.

3.3.11 In case of product quality failure, Clause 4.6 and Annexure 1 shall be applicable.

3.4 RECEIPT BY TANK-WAGONS

3.4.1 Ensure that the seals of the tank-wagon are intact.

3.4.2 A bottom sample from White Oil tank-wagons shall be drawn and tested for Test ‘A’ (Appendix 2) for grade identification. It shall be ensured that the relevant batch formation test report (Appendix 15) shall be obtained for support and batch control log shall be maintained (Appendix 13).

3.4.2.1 For SKO receipts, it shall be ensured that the relevant Flash Point information from the loading location is available before commencement of discharge. The density of the top sample of the individual tank-wagon shall be checked and compared with the despatch density at 15oC and recorded. If variation is beyond permissible limits, the product shall be segregated and concerned department informed.

3.4.3 When taking the dip, presence / absence of water shall be checked.

3.4.4 After T/W receipt, corresponding storage tank Upper, Middle and Lower level samples shall be individually subjected to Test ‘A’ (Appendix 2) and the observations recorded. If the density variation of UML is more than 3.0 Kg/m

3 (0.003 gm/ml) between any two layers, density shall be

closely monitored at filling point during despatches and record maintained 3.4.4.1 Location receiving Kerosene by Rail / Road shall carry out flash point & density tests on top sample

of the tank after each receipt. Subsequently density & flash point test shall be carried out in line with Clause 4.1.5 and record shall be maintained. A composite sample from this kerosene tank shall be retained for a period of one month (Appendix 2A). In the event the flash point does not meet the specification requirement, concerned department and / or controlling office shall be intimated immediately for further necessary action.

3.4.5 Record of the observations made after doing the checks in Clauses 3.4.1, 3.4.2, 3.4.2.1 3.4.3 and 3.4.4 above and the corrective action taken shall be maintained.

3.5 UNCONNECTED TANK-WAGONS

3.5.1 On receipt of an unconnected tank-wagon, TMB samples shall be taken and sent to the nearest laboratory of the Industry for critical tests for identification of the product.

3.5.2 The laboratory will advise the test results to the controlling office and location. The location will then, depending upon the test result, decant the product if facilities are available for storing it. In case, facilities are not available for storing it, then they shall await instructions from the controlling office.



3.3.10 to 3.5.2 Page No. 6 of 8

3.6 RECEIPT BY TANK TRUCKS

3.6.1 Procedure given in Clauses 3.4.1 to 3.4.5 is applicable with the need to check each compartment for presence / absence of water while taking the dip. After draining sufficient quantity of the product from the pipeline of each compartment, a sample from each compartment shall be drawn and Test 'A' done. Density variation shall be within 3.0 Kg/m

3 (0.003 gm/ml) of the despatch density. All

these checks are to be recorded (Appendix 4).

3.7 RECEIPT BY BARRELS

3.7.1 The seals on each barrel shall be checked.

3.7.2 Any sweating / leaking barrels shall be identified and action taken to transfer the product into sound barrels.

3.7.3 Samples on cube root basis shall be drawn. If there are 20 barrels, samples from randomly selected three barrels shall be taken and subjected to Test ‘C’ (Appendix 2). The result of the observations and the corrective action taken shall be recorded in a register as per format given in (Appendix 5).

3.7.4 In case the result is unsatisfactory, individual barrels shall be subjected to Test ‘C’ (Appendix 2).

3.7.5 Barrels shall be kept on wooden planks in a covered godown with proper ventilation. Barrels shall be stored horizontally with bungs at 3 o'clock - 9 o'clock position.

3.7.6 Receipt of Additives / Dye / Marker from Vendor or Location

3.7.6.1 Receipt of the barrels of Additive / dye / marker consignment at location shall be accepted in conformity with the supplier test report against tender / agreed technical specification.

3.7.6.2 All level random samples on cube root basis from the barrels shall be drawn and checked for density. It shall be compared with technical specification / supplier’s batch test report of the additive / dye / marker. Any variation beyond 0.002 gm/ml at 15

oC shall be investigated before acceptance

of the consignment.

3.7.6.3 Samples so drawn as per Clause 3.7.6.2 shall be made composite (3 x 1 litre) properly labelled, jointly signed with representative of the vendor and sealed. One sample will be retained by location, second sample shall be handed over to the vendor and the third sample shall be subjected to laboratory test against the technical specification of the additive.

3.7.6.4 Any deviation on observations as per Clauses 3.7.6.2 and 3.7.6.3 shall be dealt as per tender condition. On conformity with the requirement the retained samples shall be bulked with the same batch of additive in barrels for use.

3.7.6.5 Onward dispatches to upcountry locations from the certified batch (Clause 3.7.6.3) shall be accompanied by both the test reports and shall further be subjected to test as per Clause 3.7.6.2. Location shall segregate the batch and use on “first in first out” basis. The barrel shall be handled in line with the standard laid down practice for handling barrels.

3.7.6.6 Location shall maintain daily stock logbook for additive / dye / markers. It shall be reviewed along with the stock loss by the location in-charge.



3.6 to 3.7.6.6 Page No. 7 of 8

3.8 BATCH NUMBER

3.8.1 A Batch Number shall be assigned for each receipt of product through multi-product pipeline / dedicated pipeline / Ocean tanker / Tank Wagons / Tank Trucks in a location. Batch formation test (Appendix 15) shall be carried out after each receipt of product through multi-product pipeline and ocean tanker. In case of the receipt through dedicated pipeline / tank wagon / tank truck batch formation test is not mandatory.

3.8.2 The batch so established will carry the batch test report of the batch of dispatching location. The other quality control checks & documentation shall be carried out as per Section 3. Entry shall be made as per batch control log book (Appendix 13).

3.8.3 For example, the batch number HSD/TW/IOC/TAH/3/2 shall indicate that HSD of IOC received through Tank Wagon has been stored in Allahabad Terminal tank number 3 as the second batch after tank cleaning. i.e.,

Product Code / Mode (Ocean Tanker/PL//TW/TL etc.) / Name of Organisation / Code letter of Location originating the Batch Code letters / Tank Number / Serial Number of the batch established in that tank since its last cleaning.

3.8.4 After every tank cleaning, the batch number will revert to 1 (One).



3.8. to 3.8.4 Page No. 8 of 8

SECTION – 4

STORAGE

SUBJECT PAGE NO.

Facilities (Main) 1 Other Facilities 2 Colour Coding 2,3,4 & 5 Quality Monitoring 6 Disposal of Product used for Grade change over

6

Product Quality Failures 6

4.0 STORAGE

4.1 FACILITIES (MAIN)

4.1.1 Above ground tanks with saucer bottom shall have minimum 25 mm. diameter water draw off line at the lowest portion of the tank.

4.1.2 All white oils tanks may be provided with 100 mesh filter strainer at inlet of the tank and an appropriately designed coalescer at outlet to ensure the product quality. In case of black oils inlet may be provided with 60 mesh filter strainer. (Clause 4.2.1)

Sampling facility shall be provided at the top and bottom of the receiving line, before the receiving tank valve, to draw line samples at locations receiving product by tanker and / or pipeline. The top and bottom sampling facility shall be available at the pipeline manifold at the jetty / delivery manifold and / or custody transfer point at refinery / pipeline transfer / receipt locations.

Same line for different generations of fuel of the same grade should be avoided. In case of the

operational constraint, such type of operation shall be carried out in consultation with QC department. The line content shall be properly displaced and the interface shall be downgraded into lower generation of the grade and record to be maintained.

4.1.3 Spectacle flanges / liners / hammer blinds or spool pieces of standard size and thickness shall be provided for attaining positive segregation in the pipelines whenever a common manifold is used. The spectacle flanges / liners / hammer blinds shall be periodically checked for their soundness and record maintained.

4.1.4 Storage tanks shall be cleaned once in every five years or more frequently, depending on the need, like change of product, sludge formation etc. However, with the specific approval of Quality Control Department, cleaning of the tank may be initially extended for a maximum period of three years and subsequently by two years under monitoring of sample at the suction and datum plate level as per monitoring tests (Appendix 2) read with (Clause 4.4.1). Storage tank cleaning data as per Appendix 8 shall be maintained. Date of tank cleaning and the due date of next cleaning shall be painted on or near the manhole cover along with the information on the extensions obtained. For Under Ground tanks, details of tank cleaning shall be displayed on a suitable display board.

An all-level sample after receipt of first parcel in a newly commissioned tank / after Tank cleaning /

after any grade change over shall be sent to the laboratory for batch formation test (Appendix 15). The product from the tank shall be released only after the product meets specification requirement in respect of recommended parameters. Copper corrosion test to be carried out on a bottom sample of LSHF HSD storage tanks after cleaning.

4.1.5 When there is no fresh receipt into a Kerosene tank for 7 days, a top sample shall be drawn and tested for Density and Flash Point Test. This shall be continued subsequently on every 7 days basis till fresh receipt. If the flash point is lower than the specification requirements / found lower than the previous observed flash point, despatches from this tank shall be suspended and the concerned department to be informed immediately. Despatches from this tank shall be resumed only after necessary instructions are received from the concerned department. In case of operational requirement if inter tank transfer or acceptance of pipeline content is necessary, SKO shall be released based on the flash point and density test of receipt tank. The observations shall be recorded.

Section 4 Storage INDUSTRY


4.0 to 4.1.5 Page No. 1 of 6



4.1.6 to 4.3.2 Page No. 2 of 6

4.1.6 FO / LDO shall be circulated within the tanks fortnightly for at least two hours, when there is no

fresh receipt into the tanks during this period. At the Locations where MS / HSD or any interface is being received through multi-product pipeline, it is to be ensured that the product in the tank is made homogeneous by providing adequate facility. Such operations shall be recorded in a register.

4.1.7 If for operational constraints, water bottom is maintained in the tank, Test ‘E’ (Appendix 2) shall be carried out on the water sample on fortnightly basis. In case the test indicates presence of sulphide, water shall be replaced. The record shall be maintained.

4.2 OTHER FACILITIES 4.2.1 Strainers : All box strainers / line strainers shall be opened once in three months and internally

cleaned. The date on which the strainer had been last cleaned shall be painted on the body of the strainer and record of cleaning shall be maintained.

4.2.2 Hoses : Hoses when not in use shall be properly stored, with their ends blanked. Hoses on black oil shall be earmarked and shall not be used for white oils.

4.3 COLOUR CODING

4.3.1 Pipelines shall be colour coded to indicate the product that is being carried. Colour coding for all products shall have band(s) of 100 mm on each side with a gap of 300 mm in between. The band shall be painted near both sides of the valves and thereafter every 20 meter length of Pipeline. Aluminium paint shall be applied on white oil lines and black oil lines shall be painted black. The product carried shall be written in a gap of 300 mm in white letters for black oils and black letters for white oils in the direction of flow. The size of letters shall be half the diameter of the pipelines. Colour coding chart is shown under Clause 4.3.3.

The width of the arrow shall be one third of the diameter of pipeline and 300mm long arrow (Clause 4.3.3) shall be painted after each band on the pipeline with respective colour code in the direction of flow. A Brilliant green colour circle will be added at the tail portion of arrow for Bharat Stage-IV Grade of products.

In case of any change in use of pipeline w.r.t product, relevant colour coding shall be changed immediately.

4.3.2 The recommended colour coding for bands shall be: - Product Colour of

gap Colour of bands (total width 100mm) Isc

no.** MS BS II-93 Aluminium Signal red 537 MS BS III-95 Aluminium A pair of brilliant green* rings either side with signal red ring in the centre 537

MS BS IV-95 Aluminium A pair of brilliant green* rings either side with signal red ring in the centre and one brilliant green* circle at the tail of arrow

537

MS BS II -88 Aluminium Dark orange 591 MS BS III-91 Aluminium A pair of brilliant green* rings either side with dark orange ring in the centre 591

MS BS IV-91 Aluminium A pair of brilliant green* rings either side with dark orange ring in the centre and one brilliant green* circle at the tail of arrow

591

Ethanol Aluminium Purple 796

HSD BS II Aluminium Oxford blue 105 HSD BS III A pair of brilliant green* rings either side with oxford blue ring in the centre

HSD BS IV Aluminium A pair of brilliant green* rings either side with oxford blue ring in the centre and one brilliant green* circle at the tail of arrow

105

SKO Aluminium Golden yellow 356

LSHF HSD, HF HSD, ELS HSD

Aluminium Oxford blue 105

FO, LDO Black Aluminium --- Naphtha LAN & HAN Aluminium Dark brown 412

** Refer - Indian Standard Colour No. of IS 5:2004 * IS Colour Code No. for Brilliant Green is 221 as per IS 5:2004.



4.3.3 to 4.5.1 Page No. 3 of 6

4.3.3 TYPICAL COLOUR CODING CHART

(All dimensions in mm)

The locations required to camouflage product pipelines, shall camouflage product pipelines accordingly and set of colour bands shall be as per Clause 4.3 of the manual.

Colour coding Chart for individual grades of MS /HSD are enclosed as under

MS Bharat Stage II

100 mm

300 mm

MS BS II - 93

MS BSII - 88

45 -50 mm thick and 300 mm long

D/2 NAME OF PRODUCT

Co

lou

r Band

Colo

ur B

and

100 mm

100 mm

300 mm

300 mm

D/3



4.3.3 to 4.5.1 Page No. 4 of 6

MS Bharat Stage IV

100 mm

300 mm 45 - 50 mm thick and 300 mm long

50 mm centre band

MS BS IV - 91

2/3 D

10 mm bands

5 mm gap

BS IV

MS Bharat Stage IV

100 mm

300 mm 45 - 50 mm thick and 300 mm long

50 mm centre band

MS BS IV - 95

2/3 D

BS IV

10 mm bands

5 mm gap

MS Bharat Stage III

100 mm

300 mm 45 -50 mm thick and

300 mm long

50 mm centre band

MS BS III - 91

10 mm bands

5 mm gap

MS Bharat Stage III

100 mm

300 mm 45 -50 mm thick and

300 mm long

50 mm centre band

MS BS III - 95

10 mm bands

5 mm gap



4.3.3 to 4.5.1 Page No. 5 of 6

HSD Bharat Stage II

100 mm

300 mm

HSD BSII

45 -50 mm thick and

300 mm long

HSD/ HF/ LSHFHSD

HSD Bharat Stage III 100 mm

300 mm 45 -50 mm thick and 300 mm long

HSD BS III

10 mm bands

5 mm gap 50 mm centre

band

HSD Bharat Stage IV 100 mm

300 mm 45 -50 mm thick and 300 mm long

BS IV HSD BSIV

10 mm bands

5 mm gap 50 mm

centre band

2/3 D



4.3.3 to 4.5.1 Page No. 6 of 6

4.4 QUALITY MONITORING

4.4.1 At location where batch formation test is not specified, a composite sample from the stock of each product tank shall be subjected to monthly monitoring tests. The locations while sending the samples shall indicate density at 15°C for all products and also flash point for SKO tank-wise. MS all grades shall be tested for Test ‘D’, Naphtha for Test ‘F’, SKO for Test ‘G’, HSD all grades and LDO for Test ‘H’ and FO for Test ‘I’ (Appendix 2). Copper strip corrosion test shall be carried out fortnightly on a bottom sample from LSHF HSD tanks. In a location carrying out batch formation test, if there is no fresh receipt in a particular storage tank for 30 days, sample from such tank shall be sent for monthly monitoring tests and separate records maintained.

A corresponding set of the above samples shall be retained till receipt of the test report and record maintained. The monthly tank monitoring test reports shall be obtained within 30 days from the date of sampling / despatching and retained month-wise.

4.4.2 When no fresh product is received for three months into a tank, Upper Middle & Lower composite sample from the vertical tank / an all-level sample from the horizontal tank shall be sent for batch formation tests (Appendix 15). Inter tank transfer to avoid this is not permitted.

4.4.3 Supplies can be made from the tank under monitoring.

4.5 DISPOSAL OF PRODUCT USED FOR GRADE CHANGE OVER

4.5.1 The "On specification" product used for grade washing of tank-wagons or tank trucks shall be disposed off in line with Appendix 16 and record maintained.

4.6 PRODUCT QUALITY FAILURES

4.6.1 In case any stock fails to meet the specification during monitoring or otherwise, the stocks shall be frozen and the concerned departments suitably intimated immediately. Failure shall be investigated immediately as per the procedure laid down in the Industry Manual on Acceptance of Products by Marketing Companies as well as directionally in line with Annexure 1. Sampling & testing as part of the investigation shall be done jointly by investigating team.

4.6.2 Corrective action to salvage the product shall be initiated by the concerned department in consultation with Quality Control Department and appropriate instructions issued. The record of product salvaged and corrective action shall be chronologically recorded.

4.6.3 Under no circumstance shall a location on their own attempt to correct the product by mixing in storage tank, ocean tankers, tank trucks, etc for releasing the stocks.

4.6.4 Any suspected quality failure during receipt, storage and despatches has to be investigated in detail as per Annexure 1.

4.6.5 The record of the Interface if segregated in an isolated tank and its disposal shall be maintained.

SECTION – 5

DESPATCH

SUBJECT PAGE NO.

Ocean tanker loading and despatch 1 Pipeline despatches 2 Tank-Wagon despatches 2 Tank-Truck despatches 3 Barrels despatches 3 Retention of samples 4

Section 5 Despatch INDUSTRY


5.0 to 5.1.8 Page No. 1 of 4

5.0 DESPATCH

Tank(s) nominated for despatch shall as far as possible, be free of water. If for operational reasons, water bottom is being maintained, adequate care shall be exercised to ensure that this water does not enter the delivery stream. UML composite samples from individual tanks, nominated for despatching the product, shall be taken, labelled, sealed and retained (Appendix 2A). Ensure that bottom of the receiving tank is free from water & observation is to be recorded.

5.1 OCEAN TANKER LOADING AND DESPATCH

5.1.1 The tanker on black oil service shall not be used on white oil service, as far as possible. Product doped with marker for the purpose of checking the adulteration and SKO doped with Blue dye shall not be transported through tanker.

5.1.2 The product previously carried in the tanker tanks shall be known to decide the type of cleaning. Looking into the history of the earlier voyages, record the grades of the products carried by the tanker in previous three voyages

5.1.3 Tanker tanks, depending on the product previously carried, and the proposed product to be loaded, shall be cleaned as indicated in Appendix 6. Similarly the connecting pipelines and pumps are also to be cleaned & flushed out.

5.1.4 A certificate as given in Appendix 7 shall be obtained from the Master / Surveyor, confirming that the nominated tanks are clean, dry and fit to carry the product.

5.1.5 Product in the shore tank earmarked for loading shall have valid test report. 4x2 Litres of UML composite samples shall be drawn and retained under the custody of all concerned (Appendix 2A).

5.1.6 Pipeline content samples are to be monitored from both the end for its suitability for discharge of the product. In case the product lying in the pipeline is dormant for a month or more, samples such drawn shall be subjected to monthly monitoring tests as per Clause 4.4.1 (Appendix 2)

For the first half an hour of product pumping, running samples from top and bottom of the pipeline shall be taken from shore end every ten minutes (at 00-10-20-30 Minutes) and Test ‘A’ (Appendix 2) done and recorded.

From the jetty end / ship's manifold, running samples from top and bottom of the pipeline shall be tested for Test ‘A’ (Appendix 2) every 10 minutes for half an hour after the line content has been displaced. If this test is unsatisfactory [the variation in density is beyond + 3.0 kg/m

3 (0.003 gm/ml)

at 15oC of the highest and -3.0 kg/m

3 (0.003 gm/ml) at 15

oC of the lowest density of the shore

tank], the pumping shall be stopped. The pumping shall be resumed only after the reason for this has been established and necessary corrective action taken. These checks shall be chronologically recorded in the shore end and jetty end tanker logbooks (Appendix 9). Test ‘A’ (Appendix 2) shall be done every hour and chronologically recorded thereafter (Appendix 9). Joint samples 2 litres each shall be drawn at the commencement, middle and end of the pumping, sealed and retained (Appendix 2A).

5.1.7 On completion of loading, 4 sets of composite sample of tanker tanks (Appendix 2A) shall be taken, 2 sets to be handed over to the master (one for the personal custody of the master and the second set for handing over at the disport), one set to be retained at the loading location till satisfactory completion of discharge and one set to be sent to the lab at the loading location for batch formation test (Appendix 15). Disport shall be advised test results by quickest mode of communication. Tanker may be allowed to sail and need not wait for test report.

5.1.8 Clause 4.6 shall be applicable in case of product failure.



5.2 to 5.3.7 Page No. 2 of 4

5.2 PIPELINE DESPATCHES

5.2.1 The tank nominated for transferring the product shall have a valid test report.

5.2.2 The Clauses 3.3.1 to 3.3.5, 3.3.7, 3.3.8 and 3.3.10 are applicable while transferring the product

through a pipeline (Appendix 2A). Product doped with marker for the purpose of checking the adulteration and SKO doped with Blue dye shall not be transported through Dedicated / Multi product pipeline.

5.3 TANK-WAGON DESPATCHES

5.3.1 The selection of a tank-wagon suitable for loading is important. The procedure for changeover of grade of tank-wagon depending upon the product that it previously carried and the nominated product is as per Appendix 16. Open the bottom valves completely and ensure from the manholes that tank wagon is completely dry. Record the same in the log book. The black oil tank wagon shall not be used for loading white oil product. While change over of black oil grade of tank wagon, ensure that tank wagons are empty and no sludge is left over at the bottom. Product / SKO doped with marker for the purpose of checking the adulteration shall not be transported through tank wagon.

5.3.2 Care shall be taken to ensure that the fittings of a tank-wagon are in serviceable condition and that the tank-wagon is completely empty before loading.

5.3.3 A sample, product wise (only white oil products), shall be drawn from the tank-wagon filling line before commencement of loading in each shift and whenever there is a switchover of tank and subjected to Test ‘A’ (Appendix 2). The observation shall be logged as per Appendix 4 and samples to be retained as per Appendix 2A.

Whenever there is a switch over of tanks, care must be exercised to ensure that the entire quantity

of the previous product in the pipeline has been displaced.

Same line for different generations of fuel of the same grade should be avoided. In case of the operation constraint, such type of operation shall be carried out in consultation with QC department and the line content shall be properly displaced and the interface shall be downgraded into lower generation of the grade and record to be maintained.

For automated / semi-automated locations, the sample shall be drawn from the delivery line at a

point closer to tank wagon filling gantry after displacement of previous product in the line.

5.3.4 After filling of the tank-wagon, presence of water shall be checked while taking the dip. If presence of water is observed, the water shall be drained out before sealing. A sample shall be drawn and tested for colour visual for grade identification. If results are satisfactory, the tank-wagon shall be sealed and despatched. All the observations shall be logged as per Appendix 4.

5.3.5 In case of SKO despatch, the density shall be checked for individual tank wagons after loading and to be recorded in Appendix 4.

5.3.6 Flash point of the SKO of the despatch tanks and density at 15°C of the SKO of the individual tank wagons shall be documented and intimated to receiving locations.

5.3.7 In addition to the above, batch formation test report of the said product shall be sent to respective receiving locations and record maintained.



5.4 to 5.5.4 Page No. 3 of 4

5.4 TANK TRUCK DESPATCHES:

5.4.1 Tank truck shall as far as possible be on one grade of product. However, any change of grade, shall be done only after following procedure given at Appendix 16. The tank truck shall be cleaned and calibrated once in a year and record maintained (Appendix 8).

5.4.2 Mixed loading shall not be done in a tank truck having common manifold. Mixed load of different generations of the same grade should be avoided.

5.4.3 A sample, product wise (only white oil products), shall be drawn from the tank truck filling line before commencement of loading in each shift and whenever there is a switchover of tank as well as during every two hours of the tank truck filling operation, subjected to Test ‘A’ (Appendix 2). The observation shall be logged as per Appendix 4 and samples to be retained as per Appendix 2A. The density at 15

oC shall be recorded in the challan / delivery documents.

For automated / semi-automated locations the sample shall be drawn from the delivery line at a point closer to tank truck filling bay after displacement of previous product in the line. After filling of the tank-truck, presence of water shall be checked in each compartment while taking the dip. Any presence of water observed shall be reported to location in-charge and investigated before taking corrective action. A sample shall be drawn from each compartment and tested for colour visual for grade identification. If results are satisfactory, the tank-truck shall be sealed and despatched. All the observations shall be logged as per Appendix 4.

5.4.4 Whenever there is a switch over of tanks, care must be exercised, to ensure that the entire quantity of the previous product in the pipeline has been displaced. Sampling shall be done immediately after ensuring that line content has been displaced and Clause 5.4.3 shall be followed.

Same line for different generations of fuel of the same grade should not be used. In case of operational constraint such type of operation shall be carried out after prior approval from the head of the Regional / Zonal QC and the line content shall be downgraded into the lower generation of the grade.

5.4.5 The quantity of samples drawn as against Clause 5.4.3 shall be as follows:-

1) MS - 4 x 1 litre 2) MS - 4 x 1 litre after change over of tank

3) HSD - 2 x 1 litre each 4) HSD - 2 x 1 litre after change over of tank 5) SKO - 1 x 1 litre each 6) SKO - 1 x 1 litre after change over of tank

5.5 BARREL DESPATCHES

5.5.1 Clean, grade flushed and leak free barrels shall be used for filling the product. The bungs shall have washer so that when fully tight even sweating is eliminated.

5.5.2 After all the barrels have been filled; samples on cube root basis shall be drawn and subjected to Test ‘C’ (Appendix 2). The observations and corrective action shall be recorded in the filling register as per format given in Appendix 5.

5.5.3 The grade of product, Batch no., date of filling and the serial no. of the barrel shall be painted on the top of the barrel. The barrel shall then be sealed.

5.5.4 If the barrels are to be stored before despatch, they shall be stored as given in Clause 3.7.5.



5.6 to 5.6.5 Page No. 4 of 4

5.6 RETENTION OF SAMPLES

5.6.1 MS, SKO & HSD samples shall be collected from the tank truck filling and tank wagon filling line under Clauses 5.3.3 & 5.4.3 in the morning at the commencement of operations, changeover of the shift and also whenever there is a switch over of tanks. Care must be exercised while sampling for tank switchover, to ensure that the entire quantity of the previous product in the pipeline has been displaced.

5.6.2 These MS, SKO & HSD samples shall be retained for a period of 30 days.

5.6.3 Samples shall be collected in Aluminium containers of 1 Litre capacity, closed, sealed and labelled with the details as per Appendix 11 for tank wagon filling point samples and Appendix 11A for tank truck filling point samples. Such Aluminium sample containers shall preferably be kept in wooden box, properly sealed and labelled.

5.6.4 Samples shall be retained date-wise for a period of 30 days at a safe place in the location in a suitably fabricated rack to hold the sample containers and record maintained (Appendix 12).

5.6.5 At all hospitality locations the assisting company shall make available TLF / TWF retention samples or corresponding test reports to assisted company as and when required.

SECTION –6

ADDITIONAL

CONTROLS FOR HIGHLY QUALITY

SENSITIVE PRODUCTS

SUBJECT PAGE NO. Naphtha 1 Batch Number 1 Use of Tank-Wagons 1 Use of Tankers 2 Low Sulphur High Flash HSD 2

Section 6 Additional Controls for Highly Quality Sensitive Products

INDUSTRY


Page No. 1 of 2

6.0 ADDITIONAL CONTROLS FOR HIGHLY QUALITY SENSITIVE PRODUCTS

6.1 NAPHTHA

6.1.1 Naphtha is used mainly as a fertiliser feed stock and is a highly quality sensitive product. Even contamination in traces with other products is likely to lead to process problems in utilisation as a feedstock. Therefore, following special attention right from product receipt from refinery / import till delivery to the customer(s) shall be taken.

6.1.2 Batch Numbers Naphtha receipt shall be assigned batch number for identification. All subsequent reports and

checks shall refer to the product by the batch number that will trace the entire history of control exercised on the subject batch.

6.1.3 The batch numbering system shall be as follows:

First Product code - NAP Second Mode of receipt – OT or TL or TW or PL

(Ocean Tanker, Tank Lorry, Tank Wagon or Pipeline) Third Name of the Organisation - IOC/HPC/BPC etc as applicable Fourth Code letter of Refinery or Terminal forming the batch (Appendix 14) Fifth Tank number in which the product is stored Sixth Serial Number of the batch established in the tank since its last cleaning.

This shall revert to No.1 after every tank cleaning. Example Batch no. NAP/TW/IOC/TKD/4/3 indicates that Naphtha received through

TW in Indian Oil Corporation in tank No. 4 at Kandla Terminal is the third batch established in the tank since its last cleaning.

Each new cargo receipt by ocean tanker or multi-product pipeline or tank-wagons shall be

assigned a new batch number on the basis of the batch formation test report as per Appendix 15.

6.1.4 Whenever tank-to-tank transfer of two approved batches of the same grade takes place, the batch number of the product in the receiving tank shall be changed. A Batch Control Logbook as per Appendix 13 shall be maintained in the location. This Batch Control Logbook shall be maintained tank-wise. In this Batch Control Logbook the name of the originating refinery or vessel from which the product is received shall be indicated in Column No.1, in Column No. 2 the date of receipt shall be given, in Column Nos. 3 & 4 the batch number and test report number respectively of the originating refinery or the vessel which has brought the product shall be indicated and in Column Nos. 5 & 6 the batch number established by the location and test report number shall be indicated.

Use of Tank-wagons Tank-wagon, which has previously carried Naphtha, shall be preferred. The procedure given in

Appendix 16 shall be followed, for loading Naphtha into tank-wagons and tank trucks.

Section 6 Additional Controls for Highly Quality Sensitive Products

INDUSTRY

QUALITY CONTROL MANUAL Clauses 6.1.4 to 6.2.4

Page No. 2 of 2

Use of Tankers

Tanker tank cleaning key shall be followed (Appendix 6) for loading Naphtha. The Naphtha in the shore tank, nominated for loading a tanker, shall have a valid test report. After loading one-meter product in a tanker tank samples shall be drawn and tested for Test ‘F’ (Appendix 2) while pumping need not be stopped. If the results are unsatisfactory the pumping shall be stopped and controlling office informed for further advice. The clauses in Section 5 in regard to loading of ocean tankers shall be followed.

6.2 LOW SULPHUR HIGH FLASH HSD

6.2.1 LSHF HSD is used in the High Speed Coast Guard Boats and other sensitive Marine Vessels and therefore, extra precaution in quality maintenance is essential. Tanks storing LSHF HSD have to be drained daily to remove any water present. Copper corrosion test on a bottom sample of the product has to be carried out on a fortnightly basis. In case a water bottom is being maintained in the tank for operational reasons, a sample from a height of 15 cms from the top of the water level shall be tested for Copper corrosion test.

6.2.2 If for operational convenience, a water bottom is being maintained, Sulphide test (Test E) shall be done on the bottom water sample on a fortnightly basis (Appendix 2).

6.2.3 In case the test indicates presence of Sulphide, water shall be replaced.

6.2.4 All observations on samples drawn as per the Clauses 6.2.1 & 6.2.2 and operation as per Clause 6.2.3 shall be documented.

SECTION – 7

SAMPLING

SUBJECT PAGE NO.

Purpose 1 Sampling Aids 1 Sample Container 1 Types of Samples 1 & 2 Sampling Procedure 3 Retention of Sample 3 Sample Label 3

Section 7 Sampling INDUSTRY QUALITY CONTROL MANUAL Clauses

7.0 to 7.4.4 Page No. 1 of 3

7.0 SAMPLING

7.1 PURPOSE

7.1.1 Sampling is a very important aid to Quality Control. Samples are drawn for the purpose of ascertaining the conformity of the stock to the relevant specifications.

7.1.2 Various methods for obtaining different types of samples have been stipulated in IS-1447 (Methods of sampling of petroleum and its products).

7.2 SAMPLING AIDS

7.2.1 Weighted sampling Cage, Can, Sampling thief, Sampling facility, etc. are the aids / devices to enable proper sampling.

7.3 SAMPLE CONTAINER

7.3.1 Stainless steel / aluminium / glass containers of one litre capacity may be used for all white oils. For the purpose of air freighting, it is necessary to use aluminium containers meeting IS 733:1986 (3rd revision) / IS 737:1986 (3rd revision) or its latest version for 'Aluminium' alloy specifications, with an approved, lined, wooden box to ensure that the sample reaches safely.

Glass container may be used, under specified conditions, as required by specific test, with new

cork (the cork is to be used only once), or good quality metal screw caps. For black oils, any clean metal container may be used. However, container made of aluminium is

preferable.

7.3.2 Sealing wax and paraffin wax shall not be used for sealing the sample containers.

7.4 TYPES OF SAMPLES

7.4.1 The prescribed methods for obtaining an average / representative sample for purpose of tests or examinations have been spelt out in IS 1447 (Part 1): 2000.

7.4.2 All Level Sample

A sample obtained by submerging a closed sampler to a point as near as possible to the draw off level, then opening the sampler and raising it at a uniform rate such that it is nearly, but not quite full as it emerges from the liquid.

7.4.3 Top Sample

Sample drawn not more than 15 cms below the top surface of the product in a tank / sample collected from the sampling facility at the top of a pipeline.

7.4.4 Upper Sample An upper sample is one taken at a level of 1/6th of the depth of product below the top surface in a

tank.


7.4.5 to 7.4.9 Page No. 2 of 3

7.4.5 Middle Sample Sample taken at a level of ½ the depth of product below the top surface in tank.

7.4.6 Lower Sample Sample taken at a level of 5/6

th the depth of product below the top surface in a tank.

7.4.7 Composite Sample For a vertical tank, the composite sample shall be a mixture of an equal quantity of

- Upper, middle and lower samples OR Top, middle, bottom samples (as the case may be) for product depth above 4 meters

- Upper and lower samples - for product depth between 2 meters to 4 meters

- Middle sample - for product depth below 2 meters

For a horizontal tank, composite sample shall be an all-level sample. For tanker tanks composite sample, an all-level sample from each tanker tank shall be drawn and

mixed in amounts proportional to the quantity of the product, in each of the tank sampled.

7.4.8 Bottom sample Sample taken with the aid of sampling thief from the lowest part of the tank / sample collected from

sampling facility at the bottom of the pipeline if not otherwise specified. This sample is usually taken to check the presence of any extraneous matter such as water, sediments etc.

In case of presence of water in the tank, the bottom sample of product is to be drawn from a height

of 15 cms above the level of water present in the tank for quality check of the product.

7.4.9 Drain sample

A drain sample is one taken from the drain cock or valve.

7.5 SAMPLING PROCEDURE

Observance of correct sampling procedure is of utmost importance since the quality of the product stock is very much dependent on the test results of the representative sample. Incorrect sampling procedure could therefore, result in costly repercussions, like down-grading, non-availability of product, loss of customers' confidence and unnecessary worry all around. The following precautions shall be sincerely followed when sampling:

7.5.1 The sampling bottle and sample containers shall always be kept clean.

7.5.2 Before use, they shall be rinsed with the product under sampling.

7.5.3 Only the type of sample required for the relevant specification to be tested, shall be taken.

7.5.4 The sample quantity collected shall be sufficient for carrying out the relevant tests.

7.5.5 Sample shall be taken preferably during the cooler part of the day and under shade.

7.5.6 The sample container shall be filled maximum 95% of the container capacity, properly closed and it shall be ensured that there are no leaks.

7.5.7 Sample details shall be entered in the form (Appendix 11 / Appendix 11A) as applicable and fixed to the container.

7.5.8 An officer well conversant with the procedures shall personally supervise sampling and filling of the sample container.

7.5.9 In case of specific requirement, the sample container may be resealed / relabelled / codified and proper record is to be maintained. A separate guideline is to be made in this regard, by concerned departments.

7.6 RETENTION OF SAMPLES

7.6.1 It becomes necessary to retain counter samples for a specific period for reference purpose.

7.6.2 Sample(s) and documents are to be retained only at specific stages that are mentioned in Appendix 2A and in case of failure is noticed.

7.6.3 The counter samples meant for retention shall be properly sealed and identified so that there is no doubt about the authenticity of the sample at a later stage. All the relevant details of the sample shall be mentioned in the sample label and attached to the container.

7.6.4 The retention samples shall be stored in the location premises and a proper record shall be kept.

7.6.5 The retention period shall be strictly adhered to.

7.6.6 Details of samples retained shall be recorded as per Appendix 12.

7.7 SAMPLE LABEL

Formats for labelling samples is as per Appendix 11 / Appendix 11 A. Whenever joint sampling is being carried out, the sample label shall be signed jointly. This activity is normally carried out at the time of transfer of custody of consignment viz among refineries / pipelines / tanker / marketing / OMCs etc. as the case may be.

SEALING OF SAMPLE CONTAINER Unique random numbered tamper-proof plastic seals, sealing wire, pliers are to be used for sealing of sample containers under Clauses 7.5.9 & 7.6.3 as well as in case of joint sample under Clause 7.7. Proper record is to be maintained about the inventory and issuance of seals.


7.5 to 7.7 Page No. 3 of 3

SECTION – 8

LABORATORY SUPPORT

SUBJECT PAGE No. Purpose 1 Field Laboratories 1, 2 & 3

Section 8 Laboratory Support INDUSTRY QUALITY CONTROL MANUAL Clauses

8.0 to 8.2.1 Page No. 1 of 3

8.0 LABORATORY SUPPORT 8.1 PURPOSE

8.1.1 Quality Control Laboratories are conveniently located at the field level for tests to be carried out on

various types of samples as required. These laboratories shall be manned by qualified Laboratory Officers who are familiar with standard procedures of testing of petroleum products. The laboratories shall be properly equipped with standard apparatus in line with the relevant specifications. Laboratory shall issue suitable laboratory reports for samples tested.

8.1.2 Test Certificates issued by these Refineries/ Marketing Laboratories will only be acceptable for the

purpose of this manual.

8.2 Field Laboratories

8.2.1 Refinery Laboratories

East West North South Total A): IOC

Barauni Koyali Mathura Guwahati Panipat

Haldia Digboi

04 01 02 00 07

B): BPC Mumbai

00 01 00 00 01

C): HPC Mumbai Visakh

00 01 00 01 02

D) Other Bongaigaon RPL, Jamnagar Cochin Numaligarh ONGC,

Ankleshwar CPCL

ONGC, Hazira MRPL ONGC, Uran Narimanam Essar, Vadinar

02 05 00 04 11

Total 06 08 02 05 21

Section 8 Laboratory Support

INDUSTRY QUALITY CONTROL MANUAL Clauses

8.2.2 to 8.2.2 Page No. 2 of 3

8.2.2 Marketing Laboratories: The Field Laboratories of the Marketing Division are located at the

following locations:

East West North South Total

A): IOC Budge Budge Sewree Agra Bangalore Gouripur Kandla Allahabad Irumpanam Haldia Nishatpura Ambala Korukkupet Paradeep Sabarmati Bhatinda Mangalore Patna Vasco Bijwasan Tuticorin Port Blair Nagpur Jaipur TOP Vizag Rajbandh Hazira Jallander Sanathnagar Siliguri Bareja Kanpur Nagapattinam Mourigram Mughalsarai Kondapalli Barauni Panipat Trichy Rewari Madurai Salawas Sankari Roorkee TOP Sangrur Shakurbasti Chitaurgarh TOP Amousi Manesar, (Lube) Mathura Partapur

10 08 20 12 50 B): BPC: Budge Budge Kandla Mathura Tondiarpet Patna Panewadi Mughalsarai Vizag Haldia Sewree Sanganer

(Jaipur) Irumpanam, Kochi

Paradeep Nagpur Jallandhar Devangonthi (Bangalore) Siliguri (NRL) Indore Bijwasan Baikampady (Mangalore) Loni (Lube) Cherlapalli (Hyderabad) Irugur (Coimbatore) Karur

05 05 06 08 24

Section 8 Laboratory Support

INDUSTRY QUALITY CONTROL MANUAL Clauses

8.2.2 to 8.4 Page No. 3 of 3

C): HPC Budge Budge Pune (Loni) Shakurbasti Devangunthi Paradeep Mumbai(Mazagaon) Jalandhar Irumpanam, Kochi Ramnagar Vasco Ghatkesar Haldia Vashi Mangalore Kandla Chennai (Tondiarpet) Sewri, Mumbai Vijaywada Silvassa Vizag Raipur Hasan Rajamundry Suryapet

04 07 01 10 22 D) RPL Haldia Bhopal Rewari Chennai Hazira Kanpur

01 02 02 01 6

8.3 The list of the laboratories shall be updated as and when required by Regulatory Authorities based

on the self-certification of the concerned laboratories about having the required standard testing equipment as per BIS / IP/ ASTM test methods and adequately qualified / trained manpower.

8.4 The lab In-charge shall be adequately qualified / trained Officer.

ANNEXURE – 1 PRODUCT QUALITY

FAILURE INVESTIGATION

SUBJECT PAGE NO.

Introduction 1 Investigation Team 1 Tanker Operations (Failure in Pre-discharge Test)

1

Tanker Operations (Failure after Receipt) 1 Pipe Line Operations (Failure after Receipt)

2

Tank-Wagon/Tank-Truck Operations (In case of SKO Failure)

2

Recommendation on disposal of off Specification Products

2

Disposal of off-spec MS/ HSD at Retail Outlets

2

Annexure 1 Product Quality failure Investigation

INDUSTRY


Page No. 1 of 2

1.1 INTRODUCTION: Reference Clauses 3.2.5.1, 3.3.11 and 4.6 of IQCM and Section 6 & 7 of “Industry Manual on Acceptance of Product by Marketing Companies and Related Issues”, any suspected quality failure during receipt, storage or despatch shall be investigated in detail.

1.2 INVESTIGATION TEAM :The investigation shall be conducted by a team consisting of the following:-

a) Tanker Failures: Representatives from Operations and QC Dept. of the concerned Oil Companies, Surveyors and Tanker Owner.

b) Pipeline Failures: Representatives from Operations, QC Dept. of Concerned Oil Companies, Refinery & Pipelines.

c) Tank Wagon / Tank Truck Failures: Representatives from Operations and QC Dept. of concerned oil Companies.

d) Failures during Storage: Representatives from Operations and QC Dept. of concerned oil Companies.

1.2.1 The investigating team, as part of the investigation, shall collect / draw all relevant samples as detailed below and get them tested at the Laboratory in their presence. Team shall also collect the load-port / loading location test reports for the product used for loading. The test report for tanker tanks after loading shall also be collected in case of tanker failures.

1.2.2 The tests shall be conducted in an approved / mutually agreed Laboratory.

1.3 TANKER OPERATIONS (FAILURE IN PRE-DISCHARGE TESTS)

1.3.1 Load-port samples of individual nominated shore tanks and load-port samples from tanker tanks shall be collected (Appendix 2A).

1.3.2 Retention samples drawn from jetty end manifold and ship’s manifold during loading of the tanker shall be collected.

1.4 TANKER OPERATIONS (FAILURE AFTER RECEIPT)

1.4.1 Samples as in Clause 1.3 above shall be collected.

1.4.2 The retention samples from the nominated tanks drawn before receipt of the product (Appendix 2A) shall be collected.

1.4.3 The retention samples drawn for pre-discharge tests (Appendix 2A) shall be collected

1.4.4 All level samples from the individual tanker tanks drawn in case of quality failure noticed during discharge.

1.4.5 Retention samples drawn from pipeline manifolds at shore / jetty end drawn during tanker receipt (Appendix 2A) shall be collected.

1.4.6 Top, middle and bottom samples from the suspected contaminated stock received in the tank

shall be drawn.

Annexure 1 Product Quality failure Investigation

INDUSTRY

QUALITY CONTROL MANUAL Clauses 1.5 to 1.8

Page No. 2 of 2

1.5 PIPELINE OPERATIONS (FAILURE AFTER RECEIPT)

1.5.1 Retention samples drawn from despatch storage tanks shall be collected (Appendix 2A).

1.5.2 Retention samples drawn from the manifolds at despatching end shall be collected (Appendix 2A).

1.5.3 Retention samples drawn from receiving end manifolds shall be collected (Appendix 2A).

1.5.4 Retention samples drawn from the receiving tanks before receipt of the product shall be collected (Appendix 2A).

1.5.5 Top, upper, middle, lower, bottom samples, as per the requirement, from the suspected stock shall be drawn.

1.6 TANK WAGON / TANK TRUCK OPERATIONS

1.6.1 Retention samples from loading location Tank-Wagon / Tank Truck filling point for the date of loading. (Appendix 2A) shall be collected.

1.6.2 All level sample from the suspected stock in tank wagon / tank truck shall be drawn.

1.6.3 The retention sample of the despatch Tank(s) shall be collected (Appendix 2A).

1.6.4 In case of Tank Truck, the sample from the individual compartments shall be drawn.

1.7 The investigation team shall recommend the disposal of the product and the disposal to be done only after approval of the competent authority.

1.8 Disposal of off-spec MS / HSD at Retail Outlets:

As per the directive from Deputy Secretary to Govt. of India. MOP&NG [Ref. No. P-21027/29/2001-Dist.dated 21st December 2001, MS and HSD found off-spec at Retail Outlets would be sent to the nearest Refinery location for re-processing.

APPENDIX – 1

SPECIFICATIONS

SUBJECT PAGE NO.

Naphtha 1 Motor Gasoline 2 & 3

Motor Gasoline - E10 4 SKO 5

Automotive Diesel 6 & 7 Light Diesel Oil 8

Fuel Oil 9

Appendix 1 Specifications

INDUSTRY QUALITY CONTROL MANUAL Naphtha Page No. 1 of 9

TYPICAL SPECIFICATION FOR NAPHTHA

Sl. No. Characteristic General Requirement**

Test Method

1 Appearance Clear & Bright Visual 2 Colour Visual Colourless Visual 3 Density @ 15 oC, g/ml Report P: 16 4 Distillation: P: 18 a) Initial Boiling Point oC Report b) 50% Recovered @ oC 130 Max. c) Final Boiling Point, oC 180 Max.

5 Reid Vapour Pressure (RVP) at 37.8 oC, kg/cm 2

0.7 Max. P : 39

6 Residue on evaporation mg/100 ml, 5.0 Max P : 29 7 Non-Volatile Matter mg/100 ml, 5.0 Max. P : 64 8 Sulphur, Total % by mass, 0.15 Max. P : 34 9 Aromatic, % by Volume 20.0 Max. P : 23 10 Olefins, % by Volume 1.0 Max. P : 23 11 Calorific Value (Calculated) BTU/lb (Gross) 18,360 Min. P : 7 12 Carbon and Hydrogen Ratio (Calculated),

6.5 Max. *

13 Lead Content, PPB 200 Max. IP-224 * Estimated by using the following formula: WL, % Hydrogen = 26 - (15 x Density @ 15

oC)

WT, % Carbon = 100 - (Weight % Hydrogen + Weight % Sulphur) NOTE: ** All specification requirements shall be subject to the agreement between the purchaser/consumer and supplier.



Motor Gasoline

Page No. 2 of 9

INDIAN STANDARD SPECIFICATION FOR MOTOR GASOLINES - IS 2796:2008

Sl. Characteristic Requirements Test No. BS II BS III Method 01 Grade MG 88 MG 93 MG 91 MG 95 02 Colour, Visual As decided by Refiners / Marketers - 03 Density @ 15

oC, Kg/m3 710 – 770 720 - 775 P:16 */ ISO 3675 / D 4052

Distillation: P:18* / ISO3405 / D86 Recovery up to 70

oC (E-70), % by Vol. 10 – 45

Recovery up to 100oC(E-100), % by Vol. 40 – 70

Recovery up to 150oC(E150), % by Vol. Min. --- 75

Recovery up to 180oC(E-180), % by Vol. Min 90 ---

Final Boiling Point, oC, Max. 215 210

04

Residue, % by Vol. Max. 2.0 05 Research Octane Number (RON), Min. 88 93 91 95 P:27 / ISO 5164 /D2699 06 Motor Octane Number (MON), Min. --- 81 85 P26 / ISO5163 / D2700 07 Anti-Knock Index,(AKI), Min 84 88 (RON+MON)/2 08 Existent Gum, g/m3, Max. 40 P : 29 / ISO 6246 /D381

09 Potential Gum (*1)

, g/m3 max 50 --- P : 147 (*1)

10 Sulphur, Total Percent by mass, Max. 0.050 0.015 P: 34* / D1266 / P: 83 /

ISO4260 /D2785 /D5433 /D2622 /ISO14596/D3120 /ISO20847

11 Lead Content (as Pb ), g/l, Max 0.013 0.005 P: 80*/IP224/ D-3237 / IP352

12 Reid Vapour Pressure (RVP) (*2)

at 38oC

kPa 35 – 60

(35 – 67) 60 Max.

(67) Max. P : 39*

(3) / ISO3007 / D

323 /D 5191 / EN 13016 Vapour Lock Index (VLI) (VLI = 10 RVP + 7 E 70)

(*3), Max.

Summer (*5) 750 (900)

13

Other months 950 (1050)

Calculated

14 Benzene content, % by Vol. Max. 3 1 D-3606* (4)

/ D5580 / D6277 / D6730

15 Copper Strip Corrosion, (for 3 hrs at 50oC) Max. Not more than No. 1 P:15 /ISO2160/D130

Water tolerance of Gasoline - alcohol Blends, Temp. for phase separation,

oC, Max.

Summer 10

16

Winter (*6)

0

Annex-B

17 Engine intake system cleanliness (*7)

Report MFA used As per IS 2796 18 Olefin Content %Vol. Max. --- 21 18 P23* / D1319 / D3738 /

D6730 19 Oxidation Stability, Minutes, Min --- 360 P:28 / ISO 7536 / D 525 / IP

40

20 Aromatics Content %Vol. Max. --- 42 P23* / D1319 / D3738 / D6730 /D5580

21 Oxygen Content, percent by Mass, Max.. 2.7 EN 1601 / IP 408 / D 4815 22 Oxygenates % By Vol. Max.

a) Methanol Nil b) Ethanol

(*8) 5

c) Iso-Propyl Alcohol 10 d) Iso Butyl Alcohol 10 e) Tertiary Butyl Alcohol 7 f) Ethers containing 5 or more “C” atoms

per molecule 15

g) Other Oxygenates(*9)

8

D 4815 / Annex C

Note : Refer BIS Specification for complete details



Motor Gasoline

Page No. 3 of 9

*1. The test shall be carried out on the gasoline before addition of multifunctional detergent / dispersants

additives, as these may interfere with the test. *2. Limits given in ( ) shall be applicable to 5 % (v/v) ethanol blended gasoline only. Those areas where

blending of ethanol in gasoline is compulsory, the dosage of ethanol shall be 4.75 +/- 0.25 (v/v). *3. For the gasoline-alcohol blends, the dry vapour test method given in Annex A shall be followed. *4. It is applicable for non-alcoholic motor gasoline. *5 Winter shall be the period from November to February in Central and Northern States of India (both

months inclusive) and rest of months of the year shall be called as summer. *6. In winter it is expected that temperature may be lower than 0

oC in the northern hilly region and hence

phase separation shall not take place till (-) 10oC. *7 Use of multi-functional additive (MFA) is a requirement for assuring adequate fuel system and intake

system cleanliness performance in engines. Refiners/Marketers of motor gasoline have to ensure the MFA** have proper credentials from internationally accepted test laboratories/authorities, of having passed a minimum of one of the tests in each of the two categories of deposit control performance indicated below:-

Deposit Type Tes

t No.

Test Equipment Test Method Pass Limit (Average IVD weight)

1 BMW IVD Test ASTM D: 5500-97 100 mg/valve, Max. 2 MB M102E IVD CEC F-05-A-93 50 mg/valve, Max. 3 FORD 2.3 Litre IVD ASTM D 6201 90 mg / valve, Max.

a) Intake Valve Deposit (IVD)

4 MB M 111-IVD Test CECF-20-A-98 50 mg/valve, Max. Limit (% Injector Flow Loss) Pass Limit (% Injector Flow Loss)

1 Chrysler PFI Test

ASTM D : 5598-95A 5, Max. b) Port Fuel Injector Deposit (PFI)

2 PFI Deposit Rig ASTM D : 6421-99 10 %, Max. Other performance tests may be added as and when they reach qualified / standard test status. ** MFAs which are certified against National Generic Certification Option as per US EPA-97 final rule

(40 CFR part 80 certification standards for deposits controlled additives) can also be used by fuel refiners / marketers at treatments level not less than the Lowest Additives Concentration (LAC) limits, as these MFAs meet the criteria for acceptance mentioned above.

*8 Stabilizing agents may be added. For determination of ethanol content ASTM D-5599 or ASTM D-4815 shall be employed. For routine analysis, water extraction method may be employed (See Annex E)

*9 Acetone is not permitted except when present as a by-product of the manufacture of certain oxygenate compounds and then only up to 0.8% (v/v)

* In case of dispute, referee method shall be used.

Note: Refer BIS specification for complete details.



Motor Gasoline

Page No 4 of 9

IS SPECIFICATION FOR 10% ETHANOL BLENDED MOTOR GASOLINES - IS 2796: 2008

Sl. Characteristic Requirements Test No. BS II BS III Method

01 Grade MG 88 MG 93 MG 91 MG 95 02 Colour, Visual As decided by Refiners / Marketers - 03 Density @ 15

oC, Kg/m3 710 – 770 720 - 775 P:16 */ ISO 3675 / D

4052 Distillation : P:18* / ISO3405 / D86 Recovery up to 70

oC (E-70), % by Vol. 10 – 55 (Summer), 10-58 (Winter)

Recovery up to 100oC(E-100), % by Vol. 40 – 70

Recovery up to 150oC(E150), % by Vol.

Min. --- 75

Recovery up to 180oC(E-180), % by Vol.

Min 90 ---

Final Boiling Point, oC, Max. 215 210

04

Residue, % by Vol. Max. 2.0 05 Research Octane Number (RON), Min. 88 93 91 95 P:27 / ISO 5164 /D2699 06 Motor Octane Number (MON), Min. --- 81 85 P26 / ISO5163 / D2700 07 Anti-Knock Index,(AKI), Min 84 88 (RON+MON)/2 08 Existent Gum, g/m3, Max. 40 P : 29 / ISO 6246 /D381

09 Potential Gum (*1)

, g/m3 max 50 --- P : 147 (*1)

10 Sulphur, Total Percent by mass, Max. 0.050 0.015 P: 34* / D1266 / P: 83 /

ISO4260 /D2785 /D5433 /D2622 /ISO14596/D3120 /ISO20847

11 Lead Content (as Pb ), g/l, Max 0.013 0.005 P: 80*/IP224/ D-3237 / IP352

12 Reid Vapour Pressure (RVP) (*2) at 38oC kPa

35 – 67 67 Max. P : 39* (3) / ISO3007 / D 323 /D 5191 / EN 13016

Vapour Lock Index (VLI) (VLI = 10 RVP + 7 E 70)

(*3), Max.

Summer (*5)

1050

13

Other months 1100

Calculated

14 Benzene content, % by Vol. Max. 3 1 D-3606* (4)

/ D5580 / D6277 / D6730

15 Copper Strip Corrosion, (for 3 hrs at 50oC)

Max. Not more than No. 1 P:15 /ISO2160/D130

Water tolerance of Gasoline - alcohol Blends, Temp. for phase separation,

oC,

Max.

Summer 10

16

Winter (*6)

0

Annex-B

17 Engine intake system cleanliness (*7)

Report MFA used As per IS 2796

18 Olefin Content %Vol. Max. --- 21 18 P23* / D1319 / D3738 / D6730

19 Oxidation Stability, Minutes, Min --- 360 P:28 / ISO 7536 / D 525 / IP 40

20 Aromatics Content %Vol. Max. --- 42 P23* / D1319 / D3738 / D6730 /D5580

21 Oxygen Content, percent by Mass, Max.. 3.5 EN 1601 / IP 408 / D 4815

22 Oxygenates % By Vol. Max. Ethanol 10 Annex C

Note: Refer BIS Specification for complete details


INDUSTRY QUALITY CONTROL MANUAL Kerosene Page No 5 of 9

INDIAN STANDARD SPECIFICATION FOR KEROSENE IS : 1459 : 1974 ( Amendment No. 03, September 1993 )

* Where Saybolt Chromometer is not available, Lovibond colour of the sample kept in an 18 inch cell may be measured according to IS : 1448 (P:13) "Methods of test for petroleum and its products, Colour by Lovibond Tintometer" in which case, the colour shall not be deeper than Standard White (IP - 4.0).

** For supplies to Railway & Defence, the smoke point of the product shall be 22 min. *** For supplies to Defence, total sulphur content, % by mass, of the product shall be 0.20 max.

Note : Refer BIS specification for complete details.

Sr. No.

Characteristic Requirements Test Method

1 Acidity, Inorganic Nil P : 2 Burning Quality

a) Char Value, mg/kg of oil consumed, Max 20 P : 5 2

b) Bloom on glass chimney Not darker than grey Colour

a) Saybolt, Min. *(in case of un- dyed Kerosene)

+10 P : 14 3

b) Visual (in case of dyed Kerosene) Blue 4 Copper Strip Corrosion for 3 hrs @ 50

oC Not worse than No. 1 P : 15

Distillation a) Percent recovered below 200

oC , Min. 20 P : 18

5

b) Final Boiling Point oC, Max. 300

6 Flash Point (Abel), oC, Min. 35 P : 20

7 Smoke Point, mm, Min. ** 18 P : 31 8 Total, Sulphur % by mass, Max***. 0.25 P : 34



Automotive Diesel Fuel

Page No 6 of 9

INDIAN STANDARD AUTOMOTIVE DIESEL FUEL - SPECIFICATION IS: 1460—2005 (Fifth Revision)

Sr. No.

Characteristics Bharat Stage II

Bharat Stage III

Test Method

i Acidity, Inorganic Nil P : 2 Ii Acidity, Total, mg of KOH/g, Max. To Report P : 2 Iii Ash, % by Mass, Max. 0.01 P : 4 / ISO 6245 iv Carbon Residue (Ramsbottom) on 10

percent residue 1),

, Percent by mass, Max. 0.30

P : 8 / ISO 10370

v Cetane Number 2)

, Min 48 3)

51 3)

P : 9 / ISO 5165 vi Cetane Index

2), Min. 46

3) 46

3) D 4737 / ISO 4264

vii Pour Point,4)

oC, Max . .

a winter 3oC

b summer 15oC

P : 10 / D 5949 / D 5950 OR D 5985

viii Copper Strip Corrosion for 3 hrs @ 100 oC Not worse than No.1 P : 15 / ISO 2160

ix Distillation, percent (v/v), recovered: P : 18 / ISO 3405 a at 350°C, Min 85 --- b at 360°C, Min --- 95 c at 370°C, Min 95 ---

x Flash Point * :

a Abel , °C , Min. 35 P : 20 b Pensky Martens Closed Cup

5) ,

oC, Min. 66 P : 21

xi Kinematic Viscosity, cSt at 40 oC 2.0 to 5.0 2.0 to 4.5 P : 25 / ISO 3104

xii Sediments, % by mass, Max. 0.05 --- P : 30 xiii Total contamination, mg/ kg --- 24 EN 12662 xiv

Density @ 15 oC

6) , Kg/m

3 820 - 860 820 - 845

P : 16/ P : 32 7)

/ D 4052 / ISO3675 or ISO12185

xv Total Sulphur 8)

, mg/kg, Max 500 350 IP 336 or D 4294 9)

/ ISO 14596 or ISO 8754 / P 83 / D 2785 /D

5433 /D2622 /D 3120

Water Content, percent (v/v) 0.05 P 40/ ISO 3733 / ISO 6296

xvi

Water Content, mg / kg, max. --- 200 ISO12937 xvii Cold Filter Plugging Point, (CFPP)

4) , Max

a winter 6 oC

b summer 18 oC

P : 110 / D 6371

xviii Total Sediments 10)

mg per 100 ml, Max. 1.5 --- Annex A / ISO11205 / D 2274

10)

xix Oxidation Stability, g/m3, Max. --- 25 ISO 12205 or D 2274

xx Polycyclic aromatic hydrocarbon (PAH), percent by mass, Max.

--- 11 IP 391 or EN 12916

xxi Lubricity corrected Wear Scar Diameter (WSD 1.4) at 60°C, micron, Max.

460 ISO 12156 - 1

xxii Oxygen content 11) percent by mass, Max. 0.6 Annex B



Automotive Diesel Fuel

Page No. 7 of 9

1) This limit is applicable prior to addition of ignition improvers, if used. In case a value exceeding the

limit is obtained on finished fuels in the market, ASTM D 4046 / ISO 13759 shall be used to establish the presence of nitrate containing compound. In such case the present limit for carbon residue cannot be applied. However, the use of Ignition Improvers does not exempt the manufacturer from meeting this requirement prior to the addition of additives.

2) Fuel meant for vehicle meeting Bharat Stage II emission norms is required to meet either of these

two parameters.

3) For fuel processed from Assam crude, Cetane number and Cetane index is relaxed by 3 units. 4) Winter shall be the period from November to February in Central and Northern plains of India (both

months inclusive) and rest of the months of the year shall be called as summer. 5) Applicable for Naval applications and fishing vessels requiring high flash HSD. 6) For fuel processed from Assam crude, the density range is relaxed to 820-870 and 820-855 for

Bharat Stage II and Bharat Stage III grade respectively. 7) In case of dispute (P: 32) shall be the referee test method. 8) For HSD supplied to Indian Navy, the limit of sulphur shall be in agreement between the buyer and

the supplier. 9) In case of dispute, ASTM D-4294 shall be the referee test method. 10) This test shall be carried out only at the refinery or manufacturer's end. As an alternative, the test

method given in Annex A can also be used with a limit of 1.6 mg / 100ml. In case of dispute ASTM D 2274 shall be the referee method.

11) Shall be applicable only for HSD blended with 5% (v/v) Bio-diesel and the limit shall proportionately

vary as and when the different blending percent of bio-diesel is permitted.

* Under review.

Note: Refer BIS specification for complete details.



Light Diesel oil

Page No 8 of 9

INDIAN STANDARD SPECIFICATION FOR LIGHT DIESEL OIL (LDO)

IS: 1460—2000

Sl. No.

Characteristic Requirements Test Method

1 Acidity, Inorganic Nil P : 2 2 Ash, % by Mass, Max. 0.02 P : 4 3 Carbon Residue (Ramsbottom) Percent by

mass, Max. (on whole sample) 1.5

P : 8

Pour Point, (*1) oC, Max. P : 10 winter 12

4

summer 21 5 Copper Strip Corrosion for 3 hrs @ 100 oC Not worse than No. 2 P : 15 6 Flash Point Pensky Martens Closed Cup oC, Min 66 P : 21

7 Kinematic Viscosity, cSt at 40 oC, 2.5 to 15.7 P : 25 8 Sediments, % by mass, Max. 0.10 P : 30 9 Density @ 15 oC, Kg/m3 To be reported P : 16

10 Total Sulphur, % by mass. Max 1.8 P : 33 11 Water Content, % by Vol., Max 0.25 P : 40

*1 Winter shall be the period from November to February in Central and Northern plains of India (both

months inclusive) and rest of the months of the year shall be called as summer.



INDUSTRY QUALITY CONTROL MANUAL Fuel Oils Page No 9 of 9

INDIAN STANDARD SPECIFICATION FOR FUEL OILS IS 1593: 1982, Second revision (Re affirmed 2004)

Sr. No.

Characteristic LV Grade MV1 Grade MV2 Grade HV Grade Test Method

1 Acidity, Inorganic Nil Nil Nil Nil P : 2 2 Ash, % by mass, Max. 0.1 0.1 0.1 0.1 P: 4 3

Gross, calorific value Not limited, but to be reported ( See NOTE 1)

P : 6 (For ref.) & P : 7

(for routine)

4 Relative Density @ 15/15

oC

Not limited, but to be reported (See NOTE 2) P: 16 or P :

32 5 Flash Point, [Pensky

Martens Closed Cup]

oC, Min.

66 66 66 66 P : 21

Kinematic Viscosity at 50

oC, cSt , Above

-- 80 125 180 P: 25 6

Up to 80 Max. 125 180 370 P : 25 7 Sediments, % by

mass, Max. 0.25 0.25 0.25 0.25 P:30

8 Sulphur, Total % by mass. Max

(See NOTE 3) 3.5 4.0 4.0 4.5

P:33 [Reference]

P:35 [Routine]

9 Water Content,% by Vol., Max

1.0 1.0 1.0 1.0 P:40

NOTE 1: Normally the gross calorific value is of the order of 10,000 cal/g. NOTE 2: Fuel oil for marine uses in diesel engines shall not exceed a limit of 0.99.

NOTE 3: Recognizing the necessity for low-sulphur fuel oils in some specialized uses, a lower limit may be specified by mutual agreement between the purchaser and the supplier.


APPENDIX – 2

QUALITY CONTROL

CHECKS

SUBJECT PAGE NO. Test Category for each

product 1

Appendix 2 Quality Control Checks


Tests A to K

Page No 1 of 1

QUALITY CONTROL CHECKS

Sr. No.

Test Category

Check Quantity of

sample required Minimum

1 A Appearance, Density @ 15°C, Colour -Visual (White Oils Only.)

500 ml

2. B Batch formation test – As per Appendix 15

(2 x 1) Litre

3 C Appearance Presence of water, Colour –Visual (White Oils Only)

500 ml.

4 D *

(MS)

Density Distillation, Colour, Existent gum Sulphur RON

(2 x 1) Litre

5 E Sulphide on water 500 ml.

6. F *

(Naphtha)

Density, Distillation, Colour, NVM (P:64)

One litre

7. G *

(SKO)

Density, Colour, Distillation, Flash Point

One litre

8.

H * (HSD all Grades &

LDO)

Density, Flash Point, Kinematic Viscosity Sulphur (For all HSD Grades) Copper strip corrosion test (For all HSD Grades)

One litre

9. I *

(FO)

Density Flash Point Kinematic Viscosity Water, Sediment

One litre

10 J Density, Distillation, Sulphur 500 ml 11 K Density, Viscosity, Sulphur 500 ml

• Under Monthly Monitoring Tests (Clause No. 4.4.1)

APPENDIX – 2A

ACTIVITIES & RETENTION OF

SAMPLES

SUBJECT PAGE NO. Tanker Operations 1 Pipeline Operations 2 Tank Wagon/Tank Truck Operations 3

Appendix 2A Activities & Retention of Samples

INDUSTRY

QUALITY CONTROL MANUAL Sr No 1 to 12

Page No. 1 of 3

RETENTION OF SAMPLES (BULK PRODUCT TRANSFER)

SR. NO.

EVENT/ ACTIVITIES

SOURCE OF SAMPLE

QUANTITY OF

SAMPLE

TYPE OF SAMPLE

SAMPLES TO BE

DRAWN BY

IQCM REFERENCE

CLAUSE NUMBER

REF. CLAUSE NO. OF PROD ACCEPTANCE

MANUAL

RETENTION PERIOD

1 Before receipt Individual

Nominated tanks 2X2 litres

UML composite

Marketing Co.

3.1.1 2.3.5.4 - (a) 3.3.2.4 - (iv)

Till batch established and/or next receipt

2 Pre Discharge

test Individual tanker

tanks 1x1 litre

All level (bottom

sample on need basis)

Marketing Co.

3.2.3 2.3.5.1, (iii) Till batch established,

3 Pre Discharge

test Individual tanker

tanks 2x1 litre All level

Marketing Cos.

3.2.5. & 3.2.5.1

2.3.5.1 (iii) Till investigation is

over in case of failure

4 During tanker

receipt Mani fold at shore end

2x1 litre 2x1 litre 2x1 litre

Initial Middle & End of product pumping

Marketing Cos.

3.2.7 & 3.2.8

2.3.5.3 (b) Till batch established,

5 During tanker

receipt Mani fold at jetty end



Marketing Cos.

3.2.7 & 3.2.8

2.3.5.2 (a) Till batch established,

6

Batch formation after tanker

receipt With interface

Storage tank (MS)


Top Middle Bottom

Marketing Co.

3.2.6 2.3.5.4 (d) Till batch established,

7 Batch formation

after tanker receipt

Storage tanks 1x1 litre 1x1 litre 1x1 litre

Top Middle Bottom

Marketing Cos.

3.2.10 2.3.5.4 (d) Till batch established,

for SKO 3 months after batch estd.

8 Before Tanker

loading

Nominated individual tanks at

Refinery 4x2 litres

UML Composite

Refinery & Mktg Co.

5.1.5 3.2.2

2.3.1(C) Till batch

established at disport

9 Before tanker

loading

Nominated Individual tanks at

Marketing Terminals

4x2 litres UML

Composite Mktg Co.

5.1.5 3.2.2

3.3.1 Till batch


10 During Tanker

loading Manifolds at

jetty end

1X1 litre 1X1 litre 1X1 litre


Refinery & Mktg OR Marketing

Co.

5.1.6 2.3.2 (b)

2.3.3 Till batch


11 During Tanker

loading / despatching

Ships manifolds 1X1 litre 1X1 litre 1X1 litre


Marketing Co./Ships

Represent- tative

5.1.6 2.3.4 (d) Till batch


12 After tanker

loading Tanker tanks 4x2 litres

UML Composite

Master of tanker/oil Co./

surveyor 5.1.7 2.3.4(e)

Till batch established at disport

Appendix 2A Activities & Retention of Samples

INDUSTRY

QUALITY CONTROL MANUAL Sr No 13 to 21

Page No. 2 of 3


SR. NO.

EVENT/ ACTIVITIES

SOURCE OF SAMPLE

QUANTITY OF

SAMPLE

TYPE OF SAMPLE

SAMPLES TO BE

DRAWN BY

IQCM REFERENCE

CLAUSE NUMBER


MANUAL

RETENTION PERIOD

13 Before receipt through multi-

product pipeline

Individual Nominated tanks

2X2 litres UML

composite Pipeline & Mktg Co.

3.1.1 2.1.3(a) 2.2.3(a)

Till batch established

14

Before transfer through multi-

product pipeline (Mktg Terminals)

Individual tanks Nominated for

transfer 2X2 litre

UML Composite

Marketing & Pipeline Divn.

3.3.3 2.1.1(b) Till batch established

15 Before Transfer from Refinery through MPPL

Individual Tanks nominated for

transfer 3X2 litre

UML Composite

Refinery, Mktg. and Pipeline

3.3.4 2.1.1(b) Till batch established

16

Transfer through MPPL

a) Mktg Terminal b) Refinery

Manifold at despatching end

1X1 litre 1X1 litre 1X1 litre

Initial Middle End of product pumping

a) Pipeline

Divn. b) Refinery &

Pipeline Division

3.3.2 &

5.2.2

2.2.2(b)

2.1.1 (d) Till batch established

17 Transfer through

Multi-product pipeline

Manifold at receiving end


Initial Middle End of product pumping

Pipeline Divn.

& Marketing Division

3.3.2 &

5.2.2

2.1.2 (e) &

2.2.2 (b) Till batch established

18

After receipt through

Multi-product pipeline

Tanks at TOP


Top, Middle Bottom

Marketing Cos.

3.3.5 3.3.6

3.2.10

2.1.3 (f&g) and

2.2.3(f)

Till batch established, for SKO 3 months

after batch established.

19 Receipt through

dedicated pipeline

a) Despatching tanks

b) Receiving tanks

2x2 litres 2x2 litres

UML composite

Ref/Mktg. Cos.

Marketing Cos.

3.3.7 3.2.4 Till quality

established

20 After receipt

through dedicated pipeline

Storage tanks 2x2 litres T UML B

Composite Marketing

Cos. 3.3.9 3.2.4

Till quality established.

21 Transfer through local dedicated

pipelines

Nominated tanks at

a) receiving locations.

b) transferring

locations.

2x2 litres 2x2 litres

UML Composite

UML Composite

a) Marketing Cos.

b) Refinery/ Marketing

Cos.

3.3.10 3.2.2 (a)

3.2.1 ( c ) Till quality

established.

Appendix 2A Activities & Retention

of Samples

INDUSTRY QUALITY CONTROL MANUAL Sr No

22 to 24 Page No. 3 of 3


SR. NO.

EVENT/ ACTIVITIES

SOURCE OF SAMPLE

QUANTITY OF

SAMPLE

TYPE OF SAMPLE

SAMPLES TO BE

DRAWN BY

IQCM REFERENCE

CLAUSE NUMBER


MANUAL

RETENTION PERIOD

22 SKO after tank

wagon/ tank truck receipt

Storage tanks 1x1 litre Composite

Top Marketing Co.

3.1.3, &

3.4.4

NOT APPLICABLE

One month/till investigation in case

of failure.

23 Tank wagon

loading Tank Wagon filling point

2x1 litre (MS) 1x1 litre (SKO)

1x1 litre (HSD)

Running Refinery/

Marketing Co. 5.3.3 2.4.1 (f)

30 Days/in case of failure till

investigation is over.

24 Tank truck

loading Tank truck filling

point

4x1 litre (MS) 1x1 litre (SKO)

2x1 litre (HSD)

Running Refinery/

Marketing Co. 5.4.3 2.5.1 (f)

30 Days/in case of failure till

investigation is over.

* MPPL = MULTI PRODUCT PIPELINE

** UML COMPOSITE SAMPLE =

COMPOSITE OF UPPER, MIDDLE & LOWER SAMPLES (REFER SECTION - 7)

APPENDIX – 3

PREDISCHARGE TESTS FOR OCEAN TANKERS / BARGES

Appendix 3 Pre-Discharge Tests

INDUSTRY QUALITY CONTROL MANUAL Naphtha, MS, SKO,

HSD, LDO, FO Page No 1 of 1

PREDISCHARGE TESTS APPLICABLE FOR OCEAN TANKERS /BARGES

PRODUCT TESTS FOR

INDIGENOUS PRODUCTS TESTS FOR

IMPORTED PRODUCTS

Naphtha

a) Appearance b) Colour (Visual) c) Density d) Distillation e) NVM (only for feed stock) - P:64

a) Appearance b) Colour (Visual) c) Density d) Distillation e) NVM (only for feed stock) - P:64

MS

a) Appearance b) Colour (Visual) c) Density d) Distillation e) Sulphur

a) Appearance b) Colour (Visual) c) Density d) Distillation e) Sulphur f) Copper Corrosion @ 50oC for 3 Hrs. g) Lead Content

SKO

a) Appearance b) Colour (Saybolt / Lovibond) c) Density d) Flash Point e) Distillation

a) Appearance b) Colour (Saybolt / Lovibond) c) Density d) Flash Point e) Distillation

HSD (All grades)

a) Appearance b) Colour (Visual) c) Density d) Flash Point e) Kinematic Viscosity f) Sulphur g) Distillation h) Cetane Index

a) Appearance b) Colour (Visual c) Density d) Flash Point e) Kinematic Viscosity f) Sulphur g) Distillation h) Cetane Index i) Pour Point

LDO

a) Density b) Flash Point c) Kinematic Viscosity

a) Density b) Flash Point c) Kinematic Viscosity d) Water Content

FO

a) Density b) Flash Point c) Kinematic Viscosity d) Water Content

a) Density b) Flash Point c) Kinematic Viscosity d) Water Content e) Sediments by Extraction f) Ash

APPENDIX – 4

QUALITY CONTROL CHECKS FOR

TANK WAGON AND TANK TRUCK OPERATIONS

Appendix 4 Quality Control Checks for TT/TW Operations

INDUSTRY

QUALITY CONTROL MANUAL TT/TW Operations Page No. 1 of 1

QUALITY CONTROL CHECKS FOR TANK WAGON AND TANK TRUCK OPERATIONS

Date Time Source

Product

Appear ance

Visual Colour

Observed Den. /Temp.

Density 15

oC

Water Seal No./ Remarks

Signature

NOTE: 1) Source means – Tank/Tank Wagon/Tank Truck/TLF/TWF. 2) Presence of water shall be recorded in Cms. 3) Presence of water shall be recorded by ‘ X ’ in relevant column. 4) Absence of water shall be recorded ‘ ( ’ in relevant column. 5) Corrective action shall be recorded under Remarks.

6) In case of T/T receipts, individual compartment’s observation shall be

recorded.

(Signature)

Reviewed by

Location I/C……………….

APPENDIX – 5 QUALITY CONTROL

CHECKS FOR BARRELS

(Other than Lubes)

Appendix 5 Quality Control Checks for

Barrels Other than Lubes

INDUSTRY

QUALITY CONTROL MANUAL Barrels other

than Lubes Page No 1 of 1

QUALITY CONTROL CHECKS – BARRELS (OTHER THAN LUBES)

No. Of Barrels

No. Of Samples Drawn

Sr. No. Of Barrels Drawn

Appearance Colour Water Remarks Signature

(Signature) Reviewed by Location I/C

APPENDIX – 6

TANKER TANK CLEANING KEY

Appendix 6 Tanker Tank Cleaning Key


Tanker Tank Cleaning Key Page No. 1 of 1

TANKER TANKS CLEANING KEY

LAST SERVICE TO LOAD AV

GAS ATF NAP MS SKO HSD LSHF

HSD LDO FO CRUDE LSHS LUBES

NAPHTHA 3 2 1 1 2 4 4 X X X X X MS 1 2 1 1 2 2 2 X X X X X SKO 2 1 3 3 1 1 1 X X X X 4 HSD 2 1 2 2 1 1 1 5 X X X 2 LSHFHSD 2 2 2 2 1 1 1 X X X X 2 LDO 2 1 2 2 1 1 1 1 1 2 1 1 FO 2 1 2 2 1 1 1 1 1 2 1 1 CRUDE 1 1 1 1 1 1 1 1 1 1 1 1 LSHS 2 1 2 2 1 1 1 1 1 2 1 1 LUBES 3 3 3 3 3 3 3 X X X X 1 CODE : 1. Tanks, Pumps and Pipelines to be well drained.

2. Flush pipelines, pumps and tank bottom with water and drain well, gas free if last service was crude, AVGAS, Naphtha or MS.

3. a) Cold water butter worthing for 4 Hrs. (2Hrs. when the tanks are painted) b) Flush lines, pumps and tank bottoms with water and drain well. 4. Carry out item 3(a) & 3(b) but use hot water @ 60

oC instead of cold water for butter worthing.

5. Seek prior approval from HO-Shipping. If approved, carry out code 4.

X. Loading not permitted without special cleaning instructions/ clearance from HO-Shipping. NOTE : I. Previous three cargoes

a) Black oils, lube oils and vegetable oils should not have been carried in previous three voyages by the vessels nominated for loading Naphtha.

b) At least three voyages of HSD should be carried by a vessel, which was on LDO service

before loading SKO. NOTE : II. Choice of last service.

a) For loading Naphtha: Vessels with last service on AVGAS, HSD & LSHFHSD shall be avoided as far as possible.

b) Tankers carrying vegetables oils in their previous load shall not be used for white oils

loading.

APPENDIX – 7

TANKER TANKS FITNESS

CERTIFICATE

Appendix 7 Tanker Tank Fitness Certificate

INDUSTRY QUALITY CONTROL MANUAL Tanker Tank

Fitness Certificate Page No. 1 of 1

TANKER TANKS FITNESS CERTIFICATE*

The tanker tanks __________ nominated to carry the product(s) bulk heads/manifolds, etc., has/have been jointly inspected and it is certified that the tanks(s), bulk heads/manifolds, etc., are clean dry and fit to carry the product to be loaded into the tanker tank. SIGNATURE SIGNATURE NAME NAME SURVEYOUR MASTER

* Tanker tank fitness certificate to be issued either by the master or jointly by the master and surveyor,

wherever surveyor has been appointed.

APPENDIX – 8

STORAGE TANKS/

TANK TRUCK CLEANING DATA

Appendix 8 Storage Tank / Tank Truck

Cleaning Data

INDUSTRY

QUALITY CONTROL MANUAL Storage Tank / Tank Truck

Cleaning Data Page No. 1 of 1

STORAGE TANKS CLEANING DATA

LOCATION:

Tank Cleaning After Tank Cleaning

Signature of

Tank No.

Capacity

(KL) Grade

Date Of

Last Clean

ing

Extension Approval

If any

Cleaning was

due on

Emptied

on

Boxed up on

1st

Parcel Received

on

BF Test Report No. /

Date *

Supervisor

Location In-

Charge

1 2 3 4 5 6 7 8 9 10 11 12

* Attach copy for each storage tank.

______________________________________________________________________

TANK-TRUCK CLEANING DATA LOCATION :

TT No Capacity (KL) Date Of Last Cleaning Cleaning due on Cleaned on Location In- charge

APPENDIX – 9

LOG BOOK – TANKER / PLT OPERATIONS

Appendix 9 Log-Book for Tanker / PLT Operations

INDUSTRY

QUALITY CONTROL MANUAL Log-Book for Tanker / PLT Ops Page No. 1 of 1

LOG BOOK – TANKER / PLT OPERATIONS

Name of Tanker / PLT No.: ___________________________ Date: _____________

Product Density at 15°C

Tanker tank / Storage Tank

Density Range

(Clause 3.2.7)

Signature

Lowest Highest MS SKO HSD

PIPELINE MANIFOLD

JETTY END / REFINERY / PIPELINE

SHORE END / RECEIVING LOCATION

DENSITY DENSITY

DATE

TIME

PRO- DUCT APPEA-

RANCE NAT TEMP

°C 15

oC

APPEA- RANCE

NAT TEMP °C

15oC

REMARKS IF

ANY

SIGN ATURE

First Five Minute Samples

00 05-10-20-30 Minutes Samples 05 10 20

30 Commencement Sample

(2 Ltrs)

Middle Sample (2 Ltrs) Final Sample (2 Ltrs) Hourly Samples details Tank Sampling after settling of One Hour.

Appearance

Colour Den. Obs Den. 15°C

Top / Upper Middle Bottom / Lower

Maximum Density Variation between any two layers Batch Number established after receipt:

Signature of Location In-Charge / Date

APPENDIX – 10

INLAND PIPELINE TRANSFER LOG BOOK

Appendix 10 Inland Pipeline Transfer Log Book

INDUSTRY

QUALITY CONTROL MANUAL Inland Pipeline Transfer Logbook Page No 1 of 1

INLAND PIPELINE TRANSFER LOG BOOK

PLT Number: ___________________________ Date: _____________

Product Density at 15°C Storage Tank

Density Range

(Clause 3.2.7.3)

Signature

Lowest Highest MS SKO HSD

PIPELINE MANIFOLD

REFINERY / PIPELINE

RECEIVING LOCATION

DENSITY

DENSITY

DATE

TIME

PRO- DUCT

APPEA- RANCE

TEMP.

NAT 15oC

APPEA- RANCE

TEMP.

NAT 15oC

REMARKS

SIGNATURE

Batch Number established after receipt:

(Signature) Reviewed by Location I/C

APPENDIX – 11

SAMPLE LABEL TANK WAGON FILLING POINT

Appendix 11 Sample Label Tank Wagon Filling Point

INDUSTRY

QUALITY CONTROL MANUAL Sample Label TW Filling Point Page No. 1 of 1

SAMPLE LABEL – TANK WAGON FILLING POINT LOCATION

TESTING LAB

PRODUCT

DATE OF SAMPLING

TANK NO./ SOURCE OF SAMPLE

TIME OF SAMPLING (IN HRS.)

QUANTITY IN TANK (IN KL)

TYPE OF SAMPLE

BATCH NO. SEAL NUMBER: DENSITY AT 15°C: FLASH POINT °C (For SKO):

REASONS FOR TESTING:

SAMPLE DRAWN BY : NAME ……………………………………………….

SIGNATURE …………………………………………

APPENDIX – 11A

SAMPLE LABEL

(TANK TRUCK FILLING POINT)

Appendix 11A Sample Label Tank Truck Filling Point

INDUSTRY

QUALITY CONTROL MANUAL Sample Label

Tank Truck Filling Point

Page No. 1 of 1

SAMPLE LABEL – TANK TRUCK FILLING POINT

LOCATION: ________________ 1. Product: 2. Source of sample: a) Tank No. __________ b) Tank Lorry filling bay No. __________ 3. Samples drawn on ____________ at __________ hrs 4. Quantity: 4 x 1 Litres for MS / 2 x 1 Litre for HSD / SKO 5. Density at 15°C __________Kg/m

3 / gm/ml

6. Seal nos. for the Aluminium container: _____________

Wooden Box: _____________

Certified that empty containers had been rinsed with the product before drawing , labelling & sealing of samples.

Signature of the Operations Officer: ______________ Name : ______________ Place and Date : _______________

APPENDIX – 12

RECORD OF SAMPLES RETAINED/ DISPOSED

Appendix 12 Record of Samples Retained / disposed

INDUSTRY

QUALITY CONTROL MANUAL Record of Samples Retained / Disposed Page No. 1 of 1

RECORD OF SAMPLES RETAINED / DISPOSED

A} In case of TLF / TWF and SKO after receipt samples: The samples shall be retained for 30 days.

LOCATION

Sr. No.

DATE & TIME OF SAMPLE DRAWN

SOURCE

* PRODUCT

PURPOSE

**

DESNITY AT 15°C

SEAL NUMBER

SAMPLE DRAWN

BY SIGN

DISPOSED ON

SIGN

B) In case of SKO after receipt by Ocean Tanker / Pipeline transfer.

The sample shall be retained for 3 months

LOCATION

Sr. No.

DATE & TIME OF SAMPLE DRAWN

SOURCE

* PRODUCT

PURPOSE

**

DESNITY AT 15°C

SEAL NUMBER

SAMPLE DRAWN

BY SIGN

DISPOSED ON

SIGN

* Indicate name of Tanker and Tanker Tank No. /Storage Tank No. /TLF /TWF/ pipeline transfer etc. as

applicable. ** For Purpose: Ref Appendix 2 and 2A

APPENDIX – 13

BATCH CONTROL LOG BOOK

Appendix 13 Batch Control Log Book

INDUSTRY QUALITY CONTROL MANUAL Batch Control

Log Book Page No. 1 of 1

BATCH CONTROL LOG BOOK

REGION / TERRITORY:

Tank Number:

PRODUCT

LOCATION:

LAST

LOADING POINT RELEASED AGAINST

NAME OF VESSEL/ ORIGINATING/

REFINERY TERMINAL / DEPOT

DATE OF RECEIPT

BATCH NO.

TEST REPORT

NO.

BATCH NO.

TEST REPORT

NO. **

DATE

LOC. I/C

SIGNATURE

**: Test Report Number of the batch shall be mentioned. If the location is not equipped to

test as per the IQCM, then a copy of previous location’s Test report shall be filled.

APPENDIX – 14

CODE LETTERS OF REFINERIES/ TERMINALS/

INSTALLATIONS/ DEPOTS

Appendix 14 Code Letters for Refineries/ Terminals/Installations/Depots

INDUSTRY

QUALITY CONTROL MANUAL Code Letters Page No. 1 of 7

[List to be updated & maintained by individual oil companies] Refineries:

East West North South Location / Code Letters Location / Code Letters Location / Code Letters Location / Code Letters A) IOCL Haldia RH Koyali RK Panipat RP Chennai CPCL

Barauni RB Mathura RM Narimanam CBR

Guwahati RG Bongaigaon BRPL Digboy RD B) BPCL Numaligarh NRL Mumbai BPCR Kochi KRL C) HPCL Mumbai HRM Vizag HRVZ D) Others: Ankleshwar ONGC(A) Manglore MRPL Hazira ONGC(H) Tadipakka ONGC(T) Uran ONGC(U) Jamnager RPL Essar Vadinar

06 08 02 06


INDUSTRY


IOCL Terminals / Installations:

East West North South Location / Code Letters Location / Code Letters Location / Code Letters Location / Code Letters Budge Budge TBB Asoj TAJ Agra TAG Chennai, FST TCHF Betkutchi TBC Ahmedabad TAB Ambala TAB Bangalore TBL Bongaigaon TBG Antop Hill TAL Amousi TAS Ernakulam TGK Barauni TBN Bassein TBS Allahabad TAH Rjahmundhry TRJ Guwahati TGH Dumad TMD Bhatinda TBD Kochi TKC Haldia THA JNPT TJP Delhi TDI Kakinada TKD

Mourigram TMM Kandla (FST/NFST) TFST Jodhpur TJD Korukkupet TKK

Patna TPA Hazira THR Jalandhar TJL Vijayvada TVJ Port Blair TPB Kandla (Main) TKD Jaipur TJP Karwar TKR Paradeep TPD Loni TLN Kanpur TKP Mangalore TMG Rajbandh TRB Okha TOA Mathura TMA Tuticorin TTC Siliguri TSG Panewari TPW Mughalsarai TMS Tondiarpet TTP Sidhpur TSD Panipat TPP Vishaka TVZ Sewree TSE Rewari TRW Wellingdon

Island TWI

Sabarmati TSM Roorkee TRK Coimbatore TCM Trombay TTB Sangrur TSA Madurai TMD Vashi TVI Shakurbasti TSB Secunderabad TSC Vasco TVS Sanganer TSR Trichy TTY Wadala TWD Salawas TSW


INDUSTRY

QUALITY CONTROL MANUAL Code Letters Page No 3 of 7

IOCL Depots:

East West North South Location / Code Letters Location / Code Letters Location / Code Letters Location / Code Letters Along DAG Akolner DAN Ambabai DAB Bijapur DBJ Behrampur DBH Bhitoni DBH Aonla DAL Kannur DKN Chitraganj DCG Bhillai DBI Ajmer DAR Kadapa DKD Dhanbad DDB Bilaspur DBL Banthara DBT Belgam DBE Dharmanagar DDN Bisrampur DBM Bhatinda DBD Kozhikode DKZ Dimapur DDM Gaigaon DGG Bikaner DBK Guntakkal DGL Hasimara DHS Jayant DJY Bharatpur DBP Ramagundam DRM

Imphal DIH Khapri (Nagpur) DKH Baitalpur Depot DBR Mysore DMS

Jeypore DJP Mangliagaon DMG Chandigarh DCG Gulbarga DGL Kantapukur DKP Miraj DMJ Damtal DDT Ongole Depot DOL Lakhimpur (North) DLP

Nishatpura (Bhopal) DNP Gonda DGD Hyderabad DHY

Malda DMD Pakni DPI Hanumangarh DHG Sankari DSK Missamari DMI Rajkot DRA Hissar DHR Tada DTD

Nagaon DNA Ratlam DRL Jodhpur DJD Thiruvananthapuram DTV

Namkum DNK Rairu DRR Jammu DJU Paradeep DPD Shirud DSD Kathgodam DKD

Visakha Fishing Harbour

DVF

Passighat DPG Sagar DSG Kullu DKL

Rangpo DRG Tadalli (Chandrapur) DTI Kota DKK

Rourkela DRK Chittaurgarh TCG Raxaul DRX Leh DLH Yellahanka DYH Najibabad DNJ Sambalpur DSB NSEZ Noida DNZ Silchar DSR Partapura DPP Somnathpur DSN Pathankot DPT South Bolanda DSB Parwanoo DPW Tatanagar DTN Srinagar DSN Tinsukia DTS Udaipur DUP

Appendix 14 Code Letters for Refineries/

Terminals/Installations/Depots INDUSTRY


BPCL INSTALLATIONS, TOPS, DEPOTS:

East West North South Location / Code Letters Location / Code Letters Location / Code Letters Location / Code Letters BPCL INSTALLATIONS Budge Budge BGB Kandla KA Mathura MI Irimpanam IRM Haldia HA Koyali KOY Kakinada KKD Paradeep PA Sewree SEW Mangalore MN Tondiarpet TN Vizag VI BPCL TOP Barauni BN Manglia MG Bhatinda BD Devangunthi DV NJP NJ Navegaon NG Bijwasan BJ Irugur IR Patna PT Panewadi PD Jalandhar JL Karur KR Rajbandh RJ Sidhpur SD Mughalsarai MG Kondapalli KN Panipat PT Rewari RE Salawas SW Sanganer SN Sangrur SR Piyala PL BPCL DEPOT Balasore BS Bakania BK Aonla AN Cannanore CN Berhampur BR Bhilai BL Baitalpur BI Cherlapalli CH Dhanbad DH Bhitoni BT Banthara BN Desur DS Katihar KA Borkhedi BK Bharatpur BP Mysore MY Muzaffarpur MZ Gaigaon GA Chandigarh CH Ongole OG Ranchi RN Hazira HZ Durai DR Raichur RC Sambalpur SM Manglia MG Gonda GD Tada TA Tatanagar TT Miraj MJ Hisar HS Tirunelveli TN Rangpoo RP Pakni PK Jammu JA Trivandrum TV Rairu RR Karari KR Warangal WR Rajkot RJ Kathgodam KI Kota KO Meerut MI Najibabad NJ Panki PN Pathankot PT Udaipur UD Channi CN Parwanoo PO Roorkee RK Srinagar SR Lalru LR


INDUSTRY


HPCL TERMINALS, DEPOTS:

East West North South Location / Code Letters Location / Code Letters Location / Code Letters Location / Code Letters HPCL Terminals Budge Budge I HTBB1 Mahul MTMH Visakh HTVZ Budge Budge II HTBB2 Sewree I HTS1 Kakinada HTKKN Ramnagar HTRM Sewree II HTSII Rajahmundhry HTRJMD

Haldia HTH Wadala HTWD Vijayawada HTVW Paradeep HTP Vashi HTV Suryapet HTSYP Loni HTLN Ghatkesar HTGHT

Vasco HTVS Chennai HTCH Kandla HTKD Cochin HTCO Mangalore HTMN Hassan HTHSN

Irumpanam HTIRPM

GMR Vasavi HTGRV

Cassimode HTCSMD


INDUSTRY


HPCL DEPOTS:

East West North South Location / Code Letters Location / Code Letters Location / Code Letters Location / Code Letters

Rajbandh HTRBD Kaligam HTKGM Rewari HTR K.R.puram HTKRPM

Cuttack HTCTK Nandaseri HTND Sanganer HTSGN Devangonthi HTDNGDI

Sambalpur Mini HTSBL Vapi HTVPI Amousi HTAM Desur HTDSR

Rourkela HTRKL Hazira HTHZR Sangrur HTSRR Irugur HTIRG Somnathpur HTSMPR Rajkot HTRJKT Nalagarh HTNGR Ramagundam HTRGTM

Semliguda HTSMGD Bhitoni HTBTN Haldwani HTHLD Nandur/Gulbarga HTGBR

Patna HTPTN Nishatpura HTNST Bhatinda HTBTD Guntakal HTGNTL

Barauni HTBRN Rairu HTRRU Ambala Cant. HTABL Elathur HTELTH

Tatanagar HTTNG Sagar HTSGR Jammu HTJMU Cuddapah HTCDPA

Dhanbad HTDNBD Satna HTSTN Meerut HTMRT Navalur HTNVL Ranchi Road HTRCH Manglia HTMGL Panipat HTPPT Kappalur HTKPLR

Betkuchi HTBTCH Ratlam HTRTL Pampore HTPPR Shillong HTBLG Bilaspur HTBSP Hanumangarh HTHMG

Visakh Fishing Harbour

HTVSFH

Mandir Hasud HTMDHD Najibabad HTNBD Jagdalpur HTJGPR Karari HTKRI Gevra HTGVR Jalandhar HTJLD Panewadi HTPWD Hissar HTHSR Pakni HTPKN Gonda HTGDA Hazarwadi HTHZW Shogi HTSGI Khapri HTKPR Udaipur HTUDP Gaigaon HTGGN Baitalpur HTBTP Palanpur HTPLNP Bharatpur HTBHT Mundra HTMD Bijwasan HTBJW Shakurbasti HTSKB Roorkee HTRKE Jaipur HTJPR Salawas HTSLW Ajmer HTAJM Kota B.O HTKT Aonla HTANL Jodhpur HTJDH Kota Mini HTKTA Mathura HTMTH Mogulsarai HTMSR Bahadurgarh HTBDG


INDUSTRY


IBP DIVISION, ESSAR, RPL

East West North South Location / Code Letters Location / Code Letters Location / Code Letters Location / Code

Letters IBP Division Terminal: Budge Budge TBB Sewree TSR Mathura TMR Nagapattinam CBMT

Haldia THLD Wadala TWL Amousi TAM Kondapalli TKP Barauni TBR Hazira THZ Panipat TPP Cherlapalli TCP Sidhpur TSP Rewari TRW Partapur TPR Sangrur TSGR ESSAR Haldia JNPT Faridabad Kakinada Mundra Ludhiana Cochin Vadinar Hathras Coimbatore Hazira Indore Sirohi Silvassa RPL Haldia T207 Bhopal T206 Rewari T204 Chennai T205 Hazira T203 Kanpur T213

APPENDIX – 15

BATCH FORMATION TESTS

Appendix 15 Batch Formation Tests

INDUSTRY QUALITY CONTROL MANUAL Batch Formation

Tests Page No. 1 of 1

BATCH FORMATION TESTS

Sr. No.

Characteristic NAPHTHA MS SKO HSD LDO FO

01 Appearance √ √ √ √

02 Colour (Visual) √ √ √

03 Colour (Visual, for Blue dyed / Saybolt / Lovibond)

√

04 Density @ 15oC √ √ √ √ √ √

05 Flash Point √ √ √ √

06 Smoke Point √

07 Kinematic Viscosity @ 40oC

√ √ √/ 50

oC

08 Pour Point √ √

09 Distillation √ √ √ √

10 Cetane Index √

11 Existent Gum mg/100ml. (solvent washed)

√

12 RVP @ 37.8OC, kg/cm2/psi.

√

13 Copper Strip Corrosion for 3 hrs. @ 50oC

√ √ √ /

100°C

14 NVM √

15 Sulphur √ √

16 Total Sulphur % w √

17 Lead ppb √ √

18 Water content % by vol √ √

19 Sediments by Extraction % by wt

√

20 Aromatics % v √

21 Olefine % v √

22 Gross Calorific Value √

23 C/H ratio (calculated) √

24 RON √

APPENDIX – 16

PROCEDURE FOR TANK TRUCK & TANK WAGON

GRADE CHANGE OVER

Appendix 16 Procedure for TT/TW Grade Change Over

INDUSTRY

QUALITY CONTROL MANUAL Procedure for TT/TW Grade Change Over Page No. 1 of 1

PROCEDURE FOR TANK TRUCK & TANK WAGON GRADE CHANGE OVER

Sr. No.

FROM TO Tank-wagon Tank Truck

01 Naphtha MS A A 02 Naphtha SKO A C 03 Naphtha HSD A A 04 MS SKO A C 05 MS HSD A A 06 SKO MS A* D 07 SKO HSD A* D 08 SKO Naphtha A* D 09 HSD MS A A 10 HSD SKO A A 11 HSD Naphtha B B 12 ATF MS A A

- Codes for changeover procedure:

A) Empty out the previous contents completely. Inspect from top manhole as well as bottom manifold.

A*) Empty out the previous contents completely. Inspect from top manhole as well as bottom manifold SKO doped with marker shall not be loaded in T/Ws. (Clause 5.3.1)

B) Empty out the previous contents completely. Flush from top through each manhole cover with 200 (TW) /20 (TT) litres of Naphtha per Manhole Cover The entire Naphtha shall be drained out and shall be checked for visual colour.

In case the flushed Naphtha sample is not clear and is discoloured repeat the procedure of flushing till the bottom sample is clear and colourless. The entire product shall be drained.

Thereafter, the tank wagon or tank truck can be filled with Naphtha.

In Refinery Terminals where SKO is not doped with Marker, instead of Naphtha, SKO may be used for flushing.

C) Completely drain out the previous product from each compartment of Tank Truck, lines, manifold etc. and ensure that the tank truck is bone dry. Fill each compartment with 50 litres of HSD, allow standing for 15 minutes and drain out HSD completely from each compartment, lines, manifold etc. The flushed HSD shall be tested for Flash Point and can be put back into HSD storage tank if the flash point meets the respective specification requirement. In the event the Flash Point does not meet the requirement, concerned department shall be intimated for advice regarding disposal. Fill with SKO

D) Guideline and approval is to be obtained from QC department on case-to-case basis.

APPENDIX – 17

INSPECTION GUIDE FOR

NON-AVIATION PRODUCTS

STORAGE POINT

Appendix 17 Inspection Guide for Non-Aviation Storage

Locations

INDUSTRY

QUALITY CONTROL MANUAL Inspection Guide Page No. 1 of 10

TERMINAL / DEPOT STORING NON-AVIATION PRODUCTS

Name of Location / Region Name of Location’s QC Coordinator Date of Inspection Inspected by Last Inspected by & on…………..QC Last Inspected by & on…………..Ops

FM: Fully Met AM: Almost Met PM: Partly Met NC: Not Complied

SR. NO.

DESCRIPTION FM AM PM NC REMARKS

1 QC MANUAL AND CIRCULARS:

a Is QC Manual (updated with incorporation of all amendements) on Non Aviation Fuels available ?

b Is “Industry Manual on Acceptance of Product by marketing Companies and Related Issues” available?

c Are all QC Circulars / Bulletins available and filed in separate indexed file? Record the reference number of the latest circular

d Is Location Specific Work Instruction available?

2 ARE THE FOLLOWING AVAILBLE AND ARE THEY IN GOOD CONDITION?

a Sampling Bottle / grabber / Thief / Cage / Can / Chain b Hydrometers / Thermometers c Aluminum Samples containers d Glass Cylinder

e Check Flash Point Apparatus and confirm whether the apparatus, is in good working condition?

f Is Marker test kit available and segregated?

g Are Master Hydrometers / Thermometers with valid Calibration certificate available?

h Are Hydrometers / Thermometer in use verified against the masters and records available?

i When the Hydrometers / Thermometers were last checked for their accuracy?

Appendix 17

Inspection Guide for Non-Aviation Storage

Locations

INDUSTRY


SR. NO.


3 QC FACILITIES

a In case of common manifold are spectacle flanges / hammer blinds / spool pieces used for positive segregation?

b Is colour coding done as per Manual?

c Do all above ground tanks have minimum one inch diameter water draw-off line?

d Do all FO and LDO tanks have product circulation facility?

e In absence of any fresh receipt in FO / LDO tank for 15 days or more, is the product circulated within the tank for at least 2 hours and every 15 days thereafter?

f Is the operation recorded?

g Are all box strainers opened once in 3 months and cleaned internally?

h Is the last cleaning date painted on the body? Are the cleaning records maintained?

4 STORAGE TANKS

a Is 100 mesh filter strainer at inlet & coalescer at outlet provided for all white oil storage tanks?

b Is 60 mesh strainer at inlet provided for black oil tanks?

c Are all storage tanks cleaned as per stipulated frequency? .

d If not, has approval been obtained from QC dept for any extensions? Enter approval details in Annexure

e Are the tanks cleaned more frequently due to product change, sludge formation etc.?

f Are records maintained for tank cleaning including tank cleaning certificates?

g Is adequate circulation facility for MS / HSD in storage tanks available at Tap-off-points?

h Are the last date of cleaning / date of commissioning and next due date of cleaning painted on / near the manhole cover of each above ground tank?

i For underground tanks, are the details of tank cleaning displayed suitably?

j

Are samples after receipt of the first parcel in the newly commissioned tanks, after tank cleaning & grade change over sent to lab for testing and test reports maintained?

SR. NO


5 RETENTION OF SAMPLES

a Are samples from storage tanks retained as per the Manual? Are records maintained as per Appendix 12?

b Are MS / SKO / HSD samples collected from T/T, T/W filling line and retained for 30 days?

c Are records maintained as per Appendix 12?

d Is storage of retention samples standardized? Check for leaks / seal / label condition.

6 PRODUCT MONITORING

a Are flash point / density tests carried out on Kerosene samples as per manualised requirements and records maintained?

b Are these results entered in challan as required?

c Are Marker presence & efficiency tests carried out and records maintained?

d Is the inventory of Marker maintained & reviewed by Location In-charge?

e Are samples of various products sent to Lab, periodically, to monitor the product in tank as per Manual (clause 4.4.1) including RON for MS?

f Are test reports available?

g Are values for density & flash point (SKO) sent to lab along with monitoring samples?

h Are test values comparable?

i Are retention samples kept for the samples sent to lab for monitoring test till receipt of test report?

j In the absence of any fresh receipt for three months into a tank, is an UML Composite / all-level sample sent to Lab for batch formation test?

k Are the test reports available?

l Are samples drawn products wise (white oil products) from T/W, T/T filling points, tested and record maintained as per manual?

m Are water samples from tanks with water bottom tested for sulphide fortnightly and record maintained?

n Is the water replaced whenever presence of sulphide is observed?

o Is observation on reporting of density in challans compared with the storage tank density?

Appendix 17 Inspection Guide for Non-Aviation

Storage Locations

INDUSTRY


SR. NO.


7 TANK WAGONS/TANK TRUCK OPERATIONS

a In case of white oil, is sample from TW/TT (each compartment) checked for colour (visual) and water, before decanting / loading?

b Are these observations recorded as per Manual? c Do TT challans carry storage tank & Bay numbers?

d Are T/Ts cleaned / calibrated yearly and records maintained?

e Is the selection of TW / TT for loading done as per Manual?

f Are different lines used for different generations of same grade of fuel?

g If not, is QC approval obtained for the same & is the interface downgraded to the lower generation fuel & record maintained?

h Is B/F test report dispatched with TW to the receiving location & record maintained?

i Are tank trucks with a common manifold permitted for mix load? (any 2 grades)

j Is TW checked for presence of water and grade identification after loading?

k Are these recorded as per Manual?

8 FAILURES

a Has there been a failure of any product during receipt / storage / dispatch at the location?

b How was the product disposed off?

c Confirm if the instructions as per Manual have been followed before disposal.

d Are documents related to QC failure retained for 3 years or till completion of investigation whichever is later?

e Are the investigation reports retained for further period of one year?

f Is approval of controlling department obtained before disposal of these documents?

g Is record maintained for salvaged product & corrective action taken?


Storage Locations

INDUSTRY


SR. NO.


9 PIPELINE TRANSFER

a Is a sample from despatching tank jointly taken and retained till the batch is established by receiving location?

b Are the tanks nominated for receipts made free of water before receipt?

c Before PLT, is monthly monitoring test carried out for pipeline product if dormant for 1 month or more?

d Is sample from the tanks nominated for receipt taken jointly, sealed, labeled with joint signature and retained in case of pipeline transfer?

e For local pipeline transfer are samples taken as per manualised guidelines?

f During transfer, are:

i. Samples checked as per Manual and records maintained?

ii. Samples collected during commencement, middle and end of discharge and retained until batch established?

g After receipt, are the following done :

i. Minimum one hour settling time given before sampling as per requirement?

ii Samples (Top/Upper/Middle/Lower/Bottom) taken and checked as per requirements?

iii. Composite sample sent for batch formation tests?

h

Are following tests carried out on tank samples after receipt of product through multi-product pipeline : -MS (Bottom sample) : Density, Distillation, Sulphur content -SKO (Top sample) : Density, Flash point -HSD (Top sample) : Density, Sulphur, Kinematic viscosity

i Is the product released only after the lab confirmed that the product meets specification?

j Is Storage of retention samples standardized? Check for leaks/seal/label condition.


Storage Locations

INDUSTRY


Appendix 17

Inspection Guide for Non-Aviation Storage Locations

INDUSTRY


SR. NO.


10 TANKER RECEIPT:

a Are load port test reports / samples available?

b Is storage of retention samples standardized? Check for leaks/seal/label condition.

c Are individual tanker tank samples tested for Test A? Are the records maintained?

d Are the tanks nominated for receipts made free of water before receipt?

e Were pre-discharge tests carried out before discharge operations started?

f During transfer, are the samples checked as per Manual and records maintained?

g Is sample from tanks nominated for receipt, taken labeled and retained?

After tanker receipt: i. Is adequate settling time given before sampling as per requirements?

ii. Are samples (Top/Upper/Middle/Lower/Bottom) taken and checked as per requirements?

h

iii. Is composite sample sent for batch formation tests?

i Is the product released only after the Lab confirmed that the product meets specification?

11 TANKER LOADING/DESPATCH

a Is a certificate obtained from the Master/surveyor confirming that the tanks are clean, dry and fit to carry the product?

b Is a valid test report for the product to be loaded available?

c During transfer, are samples checked as per Manual and records maintained?

d For Naphtha, are the required tests done after loading up to one meter?

e After completion of loading, are the samples drawn from tanker tanks and distributed as per Manual requirements?

f Is Storage of retention samples standardized? Check for leaks / seal / label condition


Locations

INDUSTRY


SR. NO.


BRANDED FUELS 12 BRANDED FUELS : MS & HSD

a Check whether receipts of additive consignments are accompanied with supplier’s agreed technical specifications.

b Are samples of additives drawn barrel wise and tested for density and recorded in comparison with parent density and whether variation is within tolerance limit?

c Check availability of lab test reports of the additives from stock points. Are additive barrels serially numbered & system of FIFO maintained?

d Check daily stock logbook for additives and check whether the same is reviewed by Location-in-Charge.

e Check the correctness of the system of doping the desired doses of additive in MS / HSD. Whether proper mixing and homogeneity with fuel is ensured

f Check daily retention composite sample of branded MS / HSD drawn from first TT filled and check whether retained properly for 30 days

g Check whether dedicated TTs with locking arrangement are used for despatch of branded fuels.

h

On addition of additive in every supply, is the product visually monitored for appearance, color, water, sediments & density and its records maintained? Check whether challans for branded MS / HSD carry a certification from TLF Officer that requisite doses of additive has been added.

i Check records of lab test report (including RON) of quality monitoring of branded fuel monthly.

j Check 2 hourly density records in delivery challan of TTs for branded fuels.

k Are additives barrels stored under covered area? l Are MSDS of additives available?


Locations

INDUSTRY


SR. NO.


ETHANOL DOPED MOTOR GASOLINE

13 RECEIPT OF ETHANOL

a Check whether receipt of Ethanol is in dedicated tank trucks and there is no scope of ingress of water into the compartments during transportation.

b Whether Specific Gravity at 15 deg C of Ethanol received at location is within +/- 0.0005 of the despatching location. Is record maintained?

c Check whether consignment of denatured Ethanol is accompanied with quality certificate as per IS 15464 which conforms to the tender requirement.

d

Check records of tests carried out on top & bottom sample of each compartment of the TTs carrying Ethanol on receipt at location and whether the composite samples are tested for appearance, colour, density, ethanol content & hydrocarbon contamination checks before decantation into storage tank.

e Check the 30 days retention samples of Ethanol (1X 1 liter composite) drawn from the TTs for seals /labels/leakages if any.

f Check whether the special Nitrile / Neoprene rubber hoses are used for unloading operation of Ethanol and its quality & capping arrangement.

g Check the 80 mesh strainers provided before pump/tank inlet as the case may be.

h Check the batch control logbook and check whether records are maintained as per Appendix 13 of IQCM.

14 STORAGE & HANDLING OF ETHANOL

a Check colour coding of Ethanol Facilities

b

Check the condition of silica gel in the silica gel trap provided in the vent pipe of the storage tank. Whether regular fortnightly condition of silica gel checked & record maintained?

c Check the storage tanks and allied facilities for Ethanol for positive segregation.

d Check the storage tank openings/pipeline fittings for air tightness.

e Check presence of any water in Ethanol tanks by drawing tank bottom samples.

f Check records of monthly monitoring tests carried out in lab for Ethanol.

g Check the records of 30 days retention samples of Ethanol drawn from storage tanks


Locations

INDUSTRY


SR. NO.


15 DOPING OF ETHANOL IN MS

a Check the correctness of the system used for on-line doping of Ethanol in MS to ensure correct dosage.

b Check the 80-mesh filter provided on the delivery side of the storage tank of Ethanol.

c

Check quality monitoring records of Ethanol doped MS samples drawn from TLF Line before commencement of loading in each shift, whenever there is a switchover of tank and regular hourly samples check for ethanol content during loading & Monthly Monitoring.

d Check 30 days retention samples of Ethanol doped MS

drawn from TLF as per IQCM requirements.

16 FIELD TEST FACILITIES

a Check availability of hydrometers / alcholometer / thermometers / glass cylinders / specific gravity conversion charts.

b Whether location is having master alcohol meter with the calibration certificate

c Confirm whether in use alcohol meter is verified with the master alcohol meter

d Check availability of adequate A-Class 100 ml graduated glass cylinders with stopper, 10 ml graduated pipette ( for alcohol content)

17 TTs FOR TRANSPORTATION OF ETHANOL DOPED MS

a

Are dedicated TTs being used for transportation of EBMS? If not, whether adequate precautions for up gradation of TTs are taken as per IQCM & checked for cleanliness & dryness before putting into service.

18 GENERAL:

a Housekeeping – Comment on the conditions of hoses, manner in which the hoses have been kept, appearance of tank farm, T/W siding, T/T loading shed, etc.

b Remarks on any QC activity witnessed during inspection. c As per Location In-charge are there any impediments in

carrying out the manualised QC procedures?

e Any suggestions for improvement.

f In the opinion of the Location In-Charge are the officers & staff adequate to carry out all the required QC checks.

g Status of compliance report/corrective action taken on the last QC inspection.

19 COMPLIANCE :

a What is the status of compliance to the last QC Inspection?

b Suggestions:


Storage Locations

INDUSTRY


SR. NO.


20 Any other observations related to QC aspects

Inspecting

Officer Officer present during

inspection Location in-charge

Name

Designation

Signature

APPENDIX – 18

AREAS OF RESPONSIBILITY FOR MAINTAINING THE QUALITY OF

PRODUCTS

SUBJECT PAGE NO.

Trunk Pipe Line transfer, Refinery to Marketing tap off point

1 & 2

Local Pipe Line transfer, Refinery to Marketing Company

2

Local Pipe Line transfer, Marketing company to Marketing Company

2

Tanker loading directly by Refinery 2 Tanker loading by other Marketing Company

3

Tanker Discharge 3 Tank Wagon/Tank Truck Operations

3

Appendix 18 Areas of Responsibility for Maintaining Quality of Product

INDUSTRY

QUALITY CONTROL MANUAL Areas of Responsibility

Page No. 1 of 3

AREAS OF RESPONSIBILITY FOR MAINTAINING THE QUALITY OF PRODUCTS

I Trunk pipeline transfers from Refinery to Tap off point of Marketing Company:

1 Refinery shall provide the test report(s) confirming that, the product in the tank(s) from which transfer is proposed meets specification, to the Marketing Company and Pipeline Division.

2 Refinery before each transfer will, in the presence of Pipeline Division & Marketing Company, take separately an upper, middle and lower sample, composite them, and preserve in sealed containers. Second set of this retention sample should be made available to the Marketing Company and Pipeline Division.

3 The Pipeline Division will be responsible for adhering to the procedures to maintain the quality of this product while pumping the product (Clauses 3.3 & 5.2) from the refinery pump discharge manifold to the Marketing Company Tank(s).

4 At Tap Off Points, Pipelines Division and Marketing Company representative shall sample the tank(s) nominated to receive the product and the samples retained.

5 The tank(s) shall then be handed over to the Pipeline Division for completing the transfer in accordance with the QC Procedures (Clauses 3.3 & 5.2).

6 At refinery pump discharge manifold and the receipt tank inlet, the Pipeline Division will draw the initial, middle and final sample before switch over of the tank checked as per Test ‘A’ (Appendix 2), sealed and retained. The Marketing Company reserves the right to be present, while these samples are drawn.

7 The Marketing Company reserves the right to inspect the Inland Pipeline Transfer Log Book, associate with sampling during transfer, investigation for quality failures during pumping, and after completion of transfer.

8 At locations where the tank is not handed over to the Pipelines Division, sampling will be done as mentioned at `4' above, and the receiving location will be responsible for the procedures inside their Terminals (Clause 3.3) and informing the Pipeline Division if there is a quality failure during pumping.

9 Samples and documents shall be retained as per Appendix 2A.

10 Product will be released from the Marketing Company tanks in accordance with the laid down procedure (Clause 3.2.10).


INDUSTRY


Page No. 2 of 3

II Local pipeline transfer from Refinery to Marketing Company:

1 The Clauses at I.1 & I.2 shall be followed.

2 At Refinery pump discharge manifold, the Refinery will draw the initial, middle and final samples and retain them separately (Appendix 2A). The Refinery will also follow the procedure for transfer of product by pipeline (Clauses 3.3 & 5.2). The Marketing Co. reserves the right to be present during sampling and to inspect the records of transfer.

3 Marketing Company will take a sample from the nominated receipt tank(s). The Refinery reserves the right to be present while sampling.

4 At the point where the Marketing Company's Tap off starts, an initial, middle and final sample shall be drawn by the Marketing Company, subjected to Test ‘A’ (Appendix 2) sealed and retained. The Refinery reserves the right to be associated with this exercise.

5 A sample from the Pipeline as close to the inlet of receiving tank should be drawn and Test ‘A’ (Appendix-2) carried out. This sample should be sealed and retained.

6 The Marketing Company will be responsible for informing the Refinery if there is any quality failure during transfer.

7 All documents and samples shall be retained as per Appendix 2A

III Local pipeline transfer from Marketing Company To Marketing Co. Clauses 1 to 7 as in II above are applicable.

IV Tanker Operations:

a) Tanker loading directly by a Refinery-

1 Clauses I.1, I.2 & II.2 shall be followed.

2 The Marketing Company will ensure fitness of tanker tanks to load the product.

3 At jetty end and tanker end, the Marketing Company will be responsible for the quality procedures (Clause 5.1.6).

4 The initial, middle and final sample from the tanker manifold will be drawn by the Marketing Company in the presence of the ship's representative, subjected to Test ‘A’ (Appendix 2), sealed and retained (Appendix 2A).

5 On completion of loading, quality formalities (Clause 5.1.7) shall be completed by Marketing Company.

6 Refinery shall hand over test report(s) of each shore tank(s) used for loading the tanker and the shore tank(s) sample to the Marketing Company for onward transmission/submission to the ship

7 At load port ship's composite samples shall be drawn by cargo owner/ ship’s representative/ Marketing Company and surveyor and signed/sealed (Appendix 2A). Sets of these samples should be available with the ship for disport.


INDUSTRY


Page No. 3 of 3

b) Tanker Loading directly by the other Marketing Companies Clauses 1 to 7 as in IV above are applicable.

c) Tanker Discharge:

1 The Charterer of the tanker will be responsible for implementing the procedure (section 3) at the tanker and jetty end.

2 Subsequent receiving location of Marketing Company shall, after complying with all the clauses in Section 3, excepting Clause 3.2.2, accept the product for discharge.

3 When one Marketing Company transfers the product during tanker discharge, to another Marketing Company, then the Quality Control responsibilities are :

- The first Marketing Company will ensure compliance of Clauses 3.1, 3.2.2, 3.2.3 & 3.2.4 and maintaining relevant records.

- The second Marketing Company will take over the quality responsibility from their tap off point, draw initial, middle and final samples during pumping and adhere to the quality procedures (Clauses 3.2.6 to 3.2.10).

4 In case of Other Marketing Company charter/ Other Marketing Cos' products, the joint sampling should be done at disport. The representatives of the oil companies should sign the test reports.

5 In the event of disputed test results of first samples, the repeat samples should be jointly drawn by cargo owner (loading co.), Surveyor and the receiving company from individual tanker tanks. The test reports should be jointly signed by the Oil companies.

6 In case of failure of product, individual tanks samples should be tested jointly for batch formation by representative of cargo owner, ship’s representative and receiving company in presence of Surveyor for investigation and cargo disposal. These test reports prepared after testing of repeat samples should be jointly signed by the involved oil companies.

V) Tank Wagon/Tank Truck Operations: The entire responsibility of product going off-spec in the tank wagon at any stage is of the Marketing

Company having sole agency for distribution of the product of that Refinery or the loading Company (in case of Terminals, unless it can be proved that the product was off-spec in the refinery tank itself or went off-spec at various stages of refinery pipeline manifolds including the loading points, in that case, the responsibility of off-spec product in the wagon will be of refinery end).

APPENDIX 19

PRODUCT ACCEPTANCE

LIMITS EX REFINERIES / PIPE LINES / IMPORTS

Appendix 19 Product Acceptance Limits for Refineries/Pipelines/Imports

INDUSTRY

QUALITY CONTROL MANUAL Product Acceptance Limits Page No. 1 of 4

PRODUCT ACCEPTANCE LIMITS EX REFINERIES / PIPE LINES / IMPORTS **

Table 1 Manufacturing Specifications for Rail / Road / Dedicated Pipeline

SR NO CHARACTERISTIC BIS MANF SPCFCN

MS BS – II

i) Density, Kg/M3 710 - 770 711 - 768

ii) RON, min 88.0 88.5

iii) Distillation

Recovery at 70 deg C, % Vol 10 - 45 11 - 38

Recovery at 100 deg C % Vol 40 - 70 41 - 70

Recovery at 180 deg C % Vol min 90 91

FBP deg C max 215 200

iv) Benzene, % Vol max 3.0 2.7

v) Total Sulphur, ppm max 500 480

vi) RVP, kPa 35 - 60 38 - 58

MS BS- III

i) Density, Kg/M3 720 - 775 721 - 773

ii) RON, min 91.0 91.5

iii) Distillation

Recovery at 70 deg C, % Vol 10 - 45 11 - 38

Recovery at 100 deg C % Vol 40 - 70 41 - 70

Recovery at 150 deg C % Vol min 75 76

FBP deg C max 210 200

iv) Benzene, % Vol max 1.0 0.90


vi) RVP, kPa max 60 58

HSD BS-II

i) Cetane Index min 46.0/43.0 46.5/43.5

ii) Distillation

Recovery at 370 deg C, % Vol min 95.0 95.5

iii) Flash Point, deg C min 35.0 37.0

iv) Total Sulphur, ppm max 500 480

v) Lubricity, microns, max 460 420

vi) Particulate Matter, mg/kg max NA 24

HSD BS-III

i) Cetane Index min 46.0 46.5

ii) Cetane Number min 51 51

iii) Distillation

Recovery at 360 deg C, % Vol min 95.0 95.5

iv) Flash Point, deg C min 35.0 37.0


vi) Lubricity, microns, max 460 420

vii) Oxidation Stability, gm/m3 max 25 22


INDUSTRY

QUALITY CONTROL MANUAL Product Acceptance Limits Page No 2 of 4

Table 2 Manufacturing Specifications for Multi-Product Pipeline **

[A]

MS BS – III [Pipeline Product Sequence: SKO – MS BS III – SKO]

A For SKO : Sulphur Max 1000 ppm, FBP < 280 oC

FBP Max

oC

RON Min

Sulphur ppm

Other Properties

190 92 / 91.6* 135 As per Rail / Road Manufacturing Specifications

* For MJPL only, whenever Motor Gasoline with RON 91.6 is pumped, the interface may be warranted for reprocessing

B For SKO: Sulphur Max 2000 ppm, FBP < 280

oC

FBP Max

oC

RON Min

Sulphur ppm

Other Properties

190 92 / 91.6* 125 As per Rail / Road Manufacturing Specifications

* For MJPL only, whenever Motor Gasoline with RON 91.6 is pumped, the interface may be warranted for reprocessing

MS BS – II [Pipeline Product Sequence: SKO – MS BS II – SKO]

A For SKO: Sulphur Max 1000 ppm, FBP < 280 oC

FBP Max

oC

RON Min

Sulphur ppm

Other Properties

195 89 470 As per Rail / Road Manufacturing Specifications B For SKO: Sulphur Max 2000 ppm, FBP < 280

oC

FBP Max

oC

RON Min

Sulphur ppm

Other Properties

195 89 450 As per Rail / Road Manufacturing Specifications


INDUSTRY


[B]

HSD BS – III [Pipeline Product Sequence: SKO – HSD BS III – SKO]

A For SKO : Sulphur Max 1000 ppm, FBP < 280 oC, Cetane No. 35 Min

Cetane Number Min

Sulphur ppm

Other Properties

51.4 320 As per Rail / Road Manufacturing Specifications B For SKO: Sulphur Max 2000 ppm, FBP < 280

oC, Cetane No 35 Min

Cetane Number Min

Sulphur ppm

Other Properties

51.4 300

As per Rail / Road Manufacturing Specifications

HSD BS – II [Pipeline Product Sequence : SKO – HSD BS II – SKO]

A For SKO: Sulphur Max 1000 ppm, FBP < 280 oC, Cetane No. 35 Min

Cetane Number Min

Sulphur ppm

Other Properties

48.4 470 As per Rail / Road Manufacturing Specifications B For SKO: Sulphur Max 2000 ppm, FBP < 280

oC, Cetane No 35 Min

Cetane Number Min

Sulphur ppm

Other Properties

48.4 450 As per Rail / Road Manufacturing Specifications [C]

MS BS – III / HSD BS – III BS III product specification will be equivalent to Rail / Road transportation

** The above figures are directional. Refer Section 2, Clause 2.1.


INDUSTRY


Note 1: Where ever the interface quantity increases the above limits, the same will be bypassed/ isolated and subject to correction /reprocessing. Note 2: Acceptance of any deviation in above requirement is to be approved by Operations Head of the Refinery Head Quarter.

Note 3: SKO Flash Point should be 38

oC minimum for all types of Multi Product pipeline dispatches. For Rail / Road /

Dedicated pipeline dispatches from refinery, the Flash Point should be 38oC minimum

Note 4: Naphtha: Used as Feed Stock for Fertilizers Non Volatile matter (NVM) by (P: 64) test method should not be more than 5 mg/100 ml. Note 5:

Wherever specific deviations are required, the manufacturing specification need to be worked out considering the technique adopted for interface management on transportation through multi-grade pipeline i.e. by mechanical/gas/chemical pig and also taking into account length of pipeline, gradient of pipeline, batch length interruptions & accuracy of sharp interface cutting or by isolation at receiving end and subsequently reprocessing or absorption with the bulk product. Note 6: Wherever fuels are blended with ethanol, bio-diesel etc. the manufacturing specification shall be controlled in accordance with the requirement as mentioned in respective manuals.

Note 7: When transfers take place through a multi-product pipeline Kinematic Viscosity for all HSD grades shall be (minimum) 0.2 cSt higher than the prevailing lower specification limit.

APPENDIX 20

GLOSSARY OF

TERMS

Appendix 20 Glossary of terms

INDUSTRY

QUALITY CONTROL MANUAL Glossary Page No. 1 of 2

GLOSSARY OF TERMS

1. REFINERY GOOD CONDITION

All products, after manufacture, are tested and certified by the refinery that it meets the required specifications. The QC System and procedures are outlined to maintain the products in the Refinery Good Condition by keeping the ingress of all extraneous matters (dust, dirt, water etc.) to the barest minimum and also to take immediate corrective action whenever such foreign matters are detected.

2. SAFETY AND OPERATIONS MANUAL

Each organisation has outlined the manner in which safe operations are to be carried out, in the respective manuals. These manuals also have to be followed whenever implementing the Non-Aviation Quality Control Manual.

3. MULTIPRODUCT PIPELINE A common line used for transferring different grades of petroleum products. 4. DEDICATED PIPELINE

A totally segregated pipeline with no cross over connections, flange connections or any other connection with any other pipeline, used by an organisation to transfer a single grade of petroleum product from their refinery to their storage tank for distribution, e.g. the pipeline from :

a) HPC Vishaka Refinery to HPC Vishakha Terminal b) HPC Refinery Bombay to HPC Mahul Storage tanks

c) IOC Mathura Refinery to IOC Mathura Installation

d) IOC Mathura Refinery to HPC Mathura Installation

e) IOC Koyali Refinery to HPC Nandesari Installation

5. LOCAL DEDICATED PIPELINES:

A totally segregated pipeline with no cross over connections, flange connections or any other connections with any other product used by an organisation to transfer a single grade of Petroleum product from their locations to other Oil Company’s locations separated by boundary/short distance.

6. UNCONNECTED TANK WAGONS:

A tank-wagon on which the paste-on label is not available, the Quality Control Release Certificate is not available, sick tank wagons transhipped by the Railways without supervision by Marketing Organisation etc.

7. SAMPLING AIDS (IS-1447)

a) Weighted sampling can : Metal sampling apparatus of such weight as to sink readily in the product to be sampled. The

apparatus shall be provided with means to permit filling at any desired level and shall have attached a non-sparking chain or cord. Metal used to weigh the apparatus shall be fitted externally at the bottom or contained in an oil tight false bottom since irregularities in the metal may retain material which will contaminate the sample if the weight is fitted in the interior.

b) Sampling cage

A metal holder or cage suitably constructed to hold the appropriate bottles or cans. The combined apparatus shall be of such weight as to sink readily in the product to be sampled and provision shall be made to permit the bottle or can at any desired level.

c) Sampling thief

This is a metal sampling apparatus with an opening at the bottom and is actuated when the apparatus comes to rest on the tank bottom.

d) Sampling Facility

Fitted on the pipeline by opening of which the pipeline contents can be drawn out.

8) BONE DRY There should not be even traces of the previous product. 9) OMC – OIL MARKETING COMPANIES

1) M/s. Indian Oil Corporation Limited 2) M/s. Bharat Petroleum Corporation Limited 3) M/s. Hindustan Petroleum corporation Limited

10) INTERFACE

In pipeline context, interface is a mixture of two compatible products. It is assumed that interface contains equal percentage of both the products.

==== END ===

Appendix 20 Glossary of terms

INDUSTRY QUALITY CONTROL MANUAL Glossary Page No. 2 of 2

Branded Fuels: Colour coding

45 -50 mm thick and 300 mm long

Branded MS 100mm

300mm

Speed ##

50mm centre band

## = 88 or 91

Speed 97

10mm bands

5mm gap

100 mm

300 mm

Branded HSD BSII / III 45 -50 mm thick and 300 mm long

Hi Speed HSD

Gaps proportionate

100 mm

300 mm

Branded MS / HSD Euro IV 45 -50 mm thick and 300 mm long

Hi Speed HSD BS IV

Speed

10 mm bands

5 mm gap 50 mm centre

band

Gaps proportionate

BS IV

IQCM 2009

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