User Manual for TATA Fuel Tanker Application on LPT 2516 as per CCOE G

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18 KL Fuel Tanker on LPT 2516 / 48

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Contents
1) Introduction 5
2) Controls & Equipments 6
2.1) Emergency Shut off
2.2) Gate Valve
2.3) Dust Cap for Gate Valve
2.4) Gravity Discharge Hose
2.5) Manhole Assembly
2.6) Pressure Vacuum Valve
2.7) Emergency Vent
2.8) Fusible Link
2.9) Remote Control Emergency Shut off Valve
2.10) Grounding Plate
2.11) Abloy Locking system
2.12) Cutoff switch
2.13) Spark Arrestor
3) Features 13
3.1) Right Hand Side View
3.2) Left Hand Side View
3.2) Rear View
4) Procedure for Loading a Top Loading Tanker 16
5) Procedure for Unloading Top Loading Tanker 17

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6) Do’s & Don’ts / Precautions 18
7) Service Schedule for Tanker 20
8) Additional Information 21
8.1) Technical Specifications
8.2) Offer Drawing
8.3) General Tank / safety Requirements from different Oil companies:

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1) Introduction:
We are pleased to inform you about the introduction of 18 KL Fuel Tanker on LPT 2516 / 48. LPT 2516 is suitable for long
distance transportation with reliability. Salient features of chassis:
• CUMMINS 6BTAA 5.9,160 -20
• 6 speed gear box.
• SQR 109, Bogie Axle.
• Semi elliptical leaf spring at front and rear antiroll bar at front axle only
• Cab Full Forward
• Dual circuit full air S-cam brake
• Anti-lock Braking System
The Fuel Tanker has been provided with the standardized aggregates complying with CCOE.
To ensure the better accessibility and to provide quick and satisfying service while repairing and maintenance, proper
service schedule and service cutouts where ever required have been provided.
At the end, we say that this Fuel Tanker is meticulously designed to take care of vehicle transportation needs.
Note:
• The pictures shown in this manual are for illustration purpose only.

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2) Controls & Equipments
2.1 Emergency Shut off Valve: It is fitted at the bottom of the sump at each compartment. These valves are being
used for unloading. At the time of loading these are closed. This valve is operated manually through lever
connected with wire rope.
2.2 Gate Valve: It is an outlet point to unload the product. It is connected with Emergency Shut off Valve through a
pipe line. Gravity discharge hose is connected to the gate valve
Note: Gate valves need to be in closed position during loading.
Spring
Lever Link
Brass Spring Seat
MS Cover
Flange bolted underneath the Tank
Flange
Bolted to
the Pipeline
CCOE
approved
supplier details
Hand
Operated
Wheel Gate Valves – Separate
for each compartment

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2.3 Dust cap for Gate valve: It acts as the protective Cover for the Gate valves. It is made up of aluminum, for the
reason of non corrosion and easy handling.
2.4 Gravity Discharge Hose: Gravity discharge hose is designed according to the petroleum standards. 3”flexible
hose with 3” gunmetal swivel nut on both ends.
Dust Cap – Having internal
threads. Screwed onto external
threads on Gate Valve
Flexible Gravity discharge hose
Gun Metal Swivel nut. One end is
fitted to the Gate Valve and other
to the receiver

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2.5 Manhole Assembly: All compartments of petroleum tank are equipped with manhole openings, large enough
for a man to pass through. All these openings are covered by a lid. It consists of fill pipe, dip pipe, pressure
vacuum valve & Emergency vent. It consists of fill pipe to fill the product, dip pipe to check the quantity level
Fuel pipe: This portion remains
inside the tank
Dip Pipe for
inserting dip
stick

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2.6 Pressure Vacuum Valve: For compartment breathing i.e. to prevent the development of pressure and Vacuum,
while the product is being drained off, inside the compartment.
2.7 Emergency Vent: The role of emergency vent is to release the smoke and fire (pressurized gas).the
emergency vent is designed in such a way to release pressurized gas and fire at time of emergency.
End Remain
Outside the
Tank. Fitted
on Manhole
cover
End goes inside the
tank. Fitted on the
Manhole cover
Assembly of Pressure
Vacuum Valve
Lead
Outer Ring
Top Cover

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2.8 Fusible Link: It acts as a fuse, linking the emergency shut off valve and Remote Control Emergency Shut
off Valve Operation lever. At the time of fire accident the fuse link will be de-linked due to heat and the entire
valves will be automatically closed.
2.9 Remote Control Emergency Shut off Valve Operation: It is mounted on the remote control emergency shut
off valve operation box. Each compartment is fixed with a shut off valve and the same is connected with the
Wire Rope to the lever
Remote Controlled
Emergency Shut off valve
lever
Wire rope – connected to
Emergency shut off valve via
fusible link
Lead
Insert
Ends fitted to the
connecting wire
Fusible Link

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2.10 Grounding Plate: It is used to ground the track while loading and unloading. Crocodile clip is connected to the
grounding plate while loading unloading grounding plate is primarily services as ear thing.
2.11 Abloy Locking System: Abloy locking system designed in such away that all manhole domes at single
operation and also its lock remote control emergency shut off valve operation box.
Anti Skid Cat Walk
Abloy Locking
Manhole cover

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2.12 Battery Cut off switch: To disconnect entire electrical circuit in the vehicle while loading and unloading the
product this switch serves the purpose.
Caution: Cut off the battery while loading and unloading.
2.13 Spark Arrestor: It is fitted at the end of exhaust pipe in order to prevent the sparks if any to come out and pose
a safety threat.
Spark
Arrestor
Aluminum Fins
inside the Spark
Arrestor

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3) Features:
3.1 Left Hand Side View:
3.2 Right Hand Side View:
Spark Arrestor
FUPD
Valve Box – Stainless
Steel
HPCL Logo
Hazardous Goods
Instruction from HPCL
in compliance to
CCOE

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3.3 Rear View:
SS Mudguard
Z-Section Long
Member
HPCL Sticker
10 Kg Fire
Extinguisher
D-Shape Shell
U-Bolt Mounting
Display Board

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Rear Bumper
Lever Box – In order to
operate emergency shut
off valve
Rear Dished End
Ladder
SS Number Plate
HPCL Logo
Hazardous Goods instruction
Sticker as per CCOE
RUPD

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4) Procedure for Loading the Top Loading Tanker:
1. Park Tank truck in the loading bay
2. Switch off the Engine.
3. Ground the truck.
4. All the compartment Gate Valves close condition
5. Close the Dust Caps from the Gate valve
6. Remote Control Emergency Shut Off Valve lever is close
condition
7. Insert and secure the top loading arm in the manhole of the
compartment to be loaded
8. Start the loading operation.
9. After the completion of loading operation, remove the loading
arm and close the manhole cover
10. Repeat steps 7to 9 for remaining compartment to be
loaded.
11. Remove the grounding. The Loading Operation is complete.
PRODUCT OUT
PRODUCT
IN
VAPOUR OUT
TOP LOADINGTOP LOADING
Man hole plate
Delivery valve

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5) Procedure for Unloading the Top Loading Tanker
1. Park Tank truck in the unloading bay.
2. Switch the off Engine.
3. Ground the truck.
4. Open the lever box.
5. Remove the Dust Caps from the Gate valve.
6. Connect the Gravity Discharge hose to the Gate valve of the compartment to be unloaded.
7. Pull the Remote Control Emergency Shut Off Valve lever corresponding compartment to be unloaded.
8. Open the Gate valve
9. After completion of the unloading operation of the compartment, close the Gate valve.
10. Disconnect the Gravity Discharge hose from the gate valve.
11. Repeat the steps from 5 to10 for remaining compartments to be unloaded.
12. Replace the dust caps on the Gate valve.
13. Close the lever box.
14. Remove the grounding. The Unloading Operation is complete.

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6) DO’S & DON’T’S / Precautions:
Ø Loading and Unloading of Fluid:
a) Do not unload the material in areas other than the place approved by the authorized agencies.
b) The Engine of the vehicle should be switched OFF before loading and Unloading of the product. Battery
should be disconnected from the electrical system through Battery Cut off Switch.
c) Do not park the vehicle carrying Petroleum product on a public road or in any congested area or at place 10
meters of any source of Fire.
d) Do not drive the tank with Lube oil, if the Tank walls, Valves are leaking. Attend to the leakage before
loading the vehicle.
e) During loading the tank, Filling pipe and the chassis of the tank vehicle should be efficiently grounded.
f) Dip rod if lowered into the tank before loading of the tank should not be completely raised above the liquid
level during or within one minute of the completion of such loading.
Ø Prevention of Static Charge Generation:
a) No tanker or compartment of the tank vehicle which has last carried petroleum class A product shall be filled
with petroleum of any other class if the interior has any floating non-conducting loose objects or water.
b) No tanker should be Splash Loaded.
c) No tank vehicle shell be loaded unless the vehicle’s wheels have been secured by efficient brakes.
d) Tank compartment which carried petroleum class A should not be filled with petroleum of other class unless
the compartment has been completely drained of residual oil and its discharge faucet and emergency valve
have been closed firmly.
Ø Maintenance, Periodic Inspection & Testing:
Adequate care should be taken to prevent any ignition source that May arise while maintenance / repair is being
carried out on a Tanker.
Caution: DON’T DO ANY WELDING ON TANKER UNLESS ANY PART OF THE TANKER IS FREE
FLAMMABLE LIQUID OR VAPOUR.
a) Every compartment and all piping Hoses should be emptied of liquid contents.
b) All shut off valve should be closed and all outlet or inlet connections should be capped.

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c) Any residue in the compartment, Hose, Pipe should be removed
d) No repair should be done unless
1. Tank is purged free of Dangerous goods.
2. Inspected and tested in such a manner sufficient to ensure that the tank is free from dangerous
goods.
e) Inspected and tested in such a manner sufficient to ensure that the tank is free from dangerous goods.

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7) Service Schedule for Tank
SI.NO Description Frequency Action
2 Check for proper functioning of emergency shout off
valve by operating the hand lever.
Daily
3
Check the tightness of the ‘U’ bolt.
Every 3000Kms Tighten the ‘U’ bolt
4
Check rubber gaskets in the Manhole and in the
Emergency shut off valve
Daily Replace the gaskets,
If damaged
5 Compartment Flushing When required to carry
different product
Use Soap/Caustic solution to
flush the compartment
6
Manhole Locking bolts Tightness. Daily Tighten the bolt, if it is loose

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8) Additional Information:
8.1 Technical Specification:
Parameter 18 Kl on LPT 2516
Model LPT 2516 / 48
Type 18 Kl on LPT 2516
Chassis Details
Engine Cummins 6BT 5.9
Clutch Single Plate Dry Friction Type, Clutch Lining Dia: 352mm,
Transmission TATA G 600
Electrical System 24 V DC
Cabin Sleeper tilt Cab
Wheel & Tyres
10 X 20, 16 PR - Rib
7.5 X20 Wheel Rim
Wheelbase,mm 4800
Max. Width,mm 2440
Track width front 1964
Track width rear 1814
Front Overhang,mm 1338.5
Tank Capacity 20000 L + 3% ullage
External Dimensions:
Length 6400
Width 2350
Height 1750
Specification Sheet for 18 KL Fuel Tankers

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Shell:
Shape : D Shape
Material: Fe 410
Thickness:3.15 mm
No. of Compartments: 4
No. of Manholes: 4
Compartment Capacity:
C1– 5000; C2 – 5000; C3 – 5000;C4 – 5000 .
Fitments:
1) Fire Extinguisher: 10 kg DCP – One no.
2) Battery box provision: Inside cabin (Below cabin incase of Tilt
Cab)
3) Hose Carrier: 150 mm Mild Steel Pipe – One no. per vehicle
4) Hose pipe :One no. composite hose with end coupling
5) Rear Bumper: Steel Structure (Heavy Duty)
6) Mud Guard:Stainless steel Sheet with M.S. Brackets
7) Ladder: On rear side of Tanker
8) Catwalk: Steel structure
9) Marking on the Body: As per CMVR Regulations
10) Dip Rod: One no. per Vehicle. (Aluminium / Brass)
11) Spark arrestor:As per Petroleum Rules 2002 Rule No 63 and
77 (ENESAR Make – CCOE Approved)
12) Battery Cut off switch:Heavy duty with Double pole wiring.
13) SUPD : As per CMVR Regulations
14) Security Locking System: As per Petroleum Company Rules
Body

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Integration Type
Mounted with Chassis main frame
using Z shape runners with U Bolts
Safety Fittings CCOE Approved - NSR make
Painting
Inside: No Coating/Epoxy Coating (Optional)
Outside: Epoxy Primer Coating and two coats of Polyeurethin
Paint

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8.2 Schematics:

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8.3) General Tank / safety Requirements from different Oil companies:
S.No Descriptions BPCL IOCL HPCL
1. Spark arrester as per Petroleum
rules
Applicable Applicable Applicable
2. Battery cut off switch as per
Petroleum rules
Applicable Applicable Applicable
3. Battery provision as per Petroleum
rules
Applicable Applicable Applicable
4. Wiring through Conduit pipe
Counseled
Applicable Applicable Applicable
5. Double pole wiring as per
Petroleum rules
Applicable Applicable Applicable
6. Earth plate Applicable Applicable Applicable
7. Discharge hose electrically
continuous
Applicable (Gun
metal end fitting)
Applicable (Cam
lock type
Aluminum end
fitting.)
Applicable (Gun
metal end fitting)
8. Fire extinguisher on cabin & tank 2kg - C 10kg - T 2kg – C 10kg - T 10kg - C 10kg - T
9. Distance between tank & cabin
(min 150mm required)
Applicable Applicable Applicable
10. Cabin use only M.S or Non
flammable material
Applicable Applicable Applicable
11. Fuel Tank Guard Applicable Applicable Applicable
12. Master valves as per Petroleum
rules
Applicable Applicable Applicable
13. Fusible links as per Petroleum
rules
Applicable Applicable Applicable
14. Shear section on discharge pipe
line
Applicable Applicable Applicable

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15. Dome covers As per BPCL type
dome cover.
As per IOCL type
dome cover.
As per HPCL type
dome cover.
16. Fill pipe to be covered with brass
mesh
Applicable Applicable Not applicable
17. Dip Rod pipe to be covered with
brass mesh
Applicable Applicable Applicable
18. Dip Rod (Gauge) Applicable Applicable Applicable
19. Pressure vacuum valve as per
Petroleum rules
Applicable Applicable Applicable
20. Emergency Vent as per Petroleum
rules
Applicable Applicable Applicable
21. Hydrostatic pressure of not less
than 0.316 kg/cm2.
Applicable Applicable Applicable
22. locking for dome Abloy locking Abloy locking Not Applicable
23. Advertisement Board Not applicable Not applicable Applicable
24. Valve sleeve assembly (For
locking Delivery Valve)
Not Applicable Not Applicable Applicable