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ISO Tank Container Operation Safety

ATCO General Meeting Shanghai November 2016

Yi Yang

Dow Pacific TS&S

Issue Date: Nov 4th , 2016

Disclaimer This document is intended for DOW ISO tank operation safety introduction at

ATCO Shanghai General Meeting on Nov 16th 2016 . Dow has provided for the

compilation of the information in this document as a part of an effort by its

employees to collect and share their experience and expertise in the areas of

environment, health and safety. The contributors to this document believe the

information provided is accurate, and they have provided this information in good

faith. However, no warranty, express or implied, is given by Dow. When used by

other than Dow employees, or other than in Dow facilities, those who use this

document should use their independent judgment in evaluating information

contained herein, and assume the risk for using the information provided in this

document. The user is solely responsible for compliance with applicable

governmental requirements.

2

Course Outline

3

• Introduction

•Standards, Regulations, Convention Overview

•Structural design and safety features

•Fittings design and safety features

Design and Safety Features

•Operational work flow introduction Operating Work

Flow

•Selection • Acceptance • Inspection & Test

•Maintenance & Cleaning •In Service

Operating Safety

• In Conclusion

•Reference Materials Post Training

ISO Tank Overview Tank: a portable tank (including a tank-container), a road tank vehicle, a rail tank wagon

or a receptacle with a capacity of not less than 450 l to contain solids, liquids, or liquefied

gases.

Portable Tank: portable containment designs to carry all sorts of bulk liquids, powders,

granules and liquefied gases which come in various sizes and can be carried as a discrete

cargo transport (or loading) units (CTU) or carried within another container.

ISO Tank: portable tank meets ISO standards and other International conventions &

regulations which can be shipped via multi-modal methods in container ship cells, container

road chassis or container rail cars.

4

Road Tank Vehicle

Rail Tank Wagon

Tank

Portable Tank

Swap Tank SSL IBC ISO Tank

ISO Tank Overview ISO tank typical standards, regulations and international conventions

− ISO 688: freight containers -- Classification, dimensions and ratings

− ISO 1496: freight containers -- Specifications and testing

− ISO 6346: freight containers -- Coding, identification, marking

− IMDG Code: Portable tank construction, testing,

− Other regulations are also applied optional to enable international ships,

including USDOT, UIC, ADR, RID, RDN, AAR, TC, etc. All regulations adopt

ISO and IMDG code concepts, the confliction is less.

5

More than 410,000 ISO tank containers are in operation in the whole world till end of

2013. And approximately 5-10% increase every year!

ISO Tank Overview • ISO tank has same dimensions as GP (general purpose) container according to

ISO 688 with 8’ wide, 8’6” high and different length (10’,20’,30’, 40’, 45’).

• ISO tank have different designed types to carry all sorts of bulk liquids,

powders, granules and liquefied gases with 9,000 to 27,000 liter capacity.

• ISO tank is designed for different dangerous goods transportation.

6

More than 95% of all

ISO tanks built are

20ft long.

14,500 Liter 20’ Liquid ISO

Tank – T11

10’ Liquid ISO Tank – T11

Pressurized Liquefied Gases

ISO Tank – T50

Refrigerated Liquefied Gases

ISO Tank – T75

multiple-element gas

containers (MEGCs) Tank

ISO Tank Overview ISO tank has proper design and fittings for safe operation and transport.

A bird’s eye view of typical liquid ISO tank below.

7

Design and Safety Features Structural

There are three structural types, Frame Tank, Beam Tank and Collar Tank

8

Either type of ISO tank meets structural design safety. The stronger frame

protection (like full frame tank with top rails), the heavier in tare weight,

the less payload of product.

Frame Tank The barrel load is supported in a structural frame. The barrel itself offers no strength to the tank container

Beam Tank The barrel is supported by the end frames. The barrel is integral in the strength of the overall tank container

Collar Tank The barrel is supported by the end frames. Collar type SLL is welded to the barrel end dome and end frames.

Design and Safety Features Tank Shell

• Tank shell is manufactured from either stainless steel or carbon steel.

• The shell thickness and pressure rating of the vessel is determined by the

regulatory codes applied to it.

• The shell thickness is 3-10mm in reference steel from T1 to T23 ISO tank.

• The shell vessel must pass minimum test pressure by tank T code. Minimum

test pressure is 1.5 times of Maximum Allowable Working Pressure (MAWP).

Vessel is NOT designed for negative pressure and NOT sustain vacuum.

9

A reference steel is used, because

different types of steel have

different mechanical properties

and strengths. A thin stainless

steel, can have the same

‘strength’ as a thicker mild steel.

For example, the most popular

used T11 tank requires 6mm

thickness in reference steel,

Usage of 316 stainless steel can

reduce the thickness to 4.2mm

with the equivalent strength.

Plate cut and rolled into

cylinder Tank ready to set in frame

Design and Safety Features Heating

There are two types of heating system, Steam Heating and Electrical Heating.

Heating system heats or cools transported product through temperature transfer

mediates (water, steam or electrical thermal elements). Heating increases

(decrease) fluidity of product for easy loading/unloading. All means of heating will

be enclosed by insulation and cladding.

10

Steam Heating has same MAWP as vessel, Do NOT heat steam over pressure! AT11

tank has 4bar MAWP which equals to 151℃. The designed max temp is 130 ℃ usually.

Please always engage business Product Steward, Material Handling Technical

Center to determine heating method and process. For example, monomer allows water

heating only.

Water Steam Electrical

Temperature 0-100℃

Lowest heat transfer ratio

Temperature 100-151℃

Medium heat transfer ratio

Temperature >150℃

Highest heat transfer ratio

http://ischain.intranet.dow.com/WorkProcess/TechCenter/Organization.asp


Design and Safety Features Insulation & Cladding

• Insulation is wrapped all around the shell, in order to maintain the product

temperature. The main insulation types are Rockwool and Glass wool. The

thickness of insulation is variable, typically 50-100mm. Thickness of insulation is

one of the factors to impact payload capacity.

• Insulated tank is covered with either a GPR (Glass Reinforced Plastic),

stainless steel or an aluminum cladding jacket to protect any material in contact

with shell and insulation. Cladding should always be sealed and repaired to

prevent the ingress of sea water and other corrosive materials.

11

Rockwool insulation over

aluminum foil barrel

Rockwool insulation over

aluminum foil barrel The cladding / insulation

material is not designed to

withstand a person

standing on it!

Design and Safety Features Man Lid(Manhole, Hatch)

• Opening on top of tank with width no less than 500mm in diameter for

Inspection, Cleaning, Top loading(unloading) operation purpose. Normally located

in central of manlid spill box on top of ISO tank.

• Various types of gasket e.g. PTFE or rubber are used to seal the manlid.

Tanktyt is a Fort Vale gasket of PTFE covering a nitrile rubber core for Nitrogen

blanket or pressurized cargo ‘Gas tight’ purpose.

12

Standard 500mm, 8 point swing bolt manlid.

For Liquid ISO tank typically. Flanged bolt down manlid 20 points.

For pressurized liquified gas ISO tank typically.

Design and Safety Features Pressure Relief Valves(PRV) - Liquid

• PRV’s or SRV’s (Safety Relief Valves) are designed to prevent

an explosion by relieving excess pressure which may build up in a tank for a variety of reasons, or

excess pressure both positive and negative, and to provide vacuum-relief in case partial vacuum conditions arise in the shell. The vacuum relief ensures that the tanks will not implode due to low pressure.

• Each PRV inlet shall be situated on top of the shell in a position as near the longitudinal and transverse centre of the shell.

• At least one PRV is required, additional PRV is required provisionally.

• PRV shall set a nominal pressure start to discharge 110% of MAWP normally.

13

Flanged 2½” PRV (4.4bar) Screwed 2½” PRV (4.4bar) Gas Relief Valve

Design and Safety Features Frangible disc & Pressure gauge

• Frangible discs (bursting discs) are fitted to provide

protection to PRV from the corrosive effect of the substances and/or their vapors being

carried, or any other kind of malfunction caused by the cargo

a guarantee that toxic vapors will only be released in extreme conditions

additional security for higher hazard cargoes. Indicate pressure below setting.

• A pressure gauge or suitable tell-tale indicator shall be provided between the

frangible disc and the pressure relief device. The gauge should be read “Zero”.

14

PRV with Frangible

disc and Pressure Gauge Fire retarding gauze (flame trap)

is also one of PRV ancillary fitted

for flammable products per

regulations to stops a fire entering

a tank to ignite the cargo. Usually

on Vacuum SRV.

Design and Safety Features Airline (Vapor) Valve

Usually located in the Rear Spill Box on top of ISO tank.

As a tank vent valve to balance pressure between the inside and outside.

As a connection for a pressure discharge utilizing either air or an inert gas.

As a vapor return line in a ‘closed loop’ filling or discharge system to prevent the cargo

fumes from escaping to the atmosphere.

There are two main types of airline valve: the ball valve and the butterfly valve

which can vary in size and termination (threaded or flanged)

15

Remote control airline valve

is one of safety features to

avoid working at height

1 ½”BSP Ball Valve

2” Flanged Butterfly Valve

2”BSP Butterfly Valve

Design and Safety Features Top Discharge Valve & Siphon Tube

Top discharge valve is usually located in the Rear

Spill Box on top of ISO tank.

Use for cargo top loading/unloading.

Mandatory when regulations prohibit opening below

liquid level of tank

3” butterfly valve flange type are the most popular

used type in the market, while ball valve also can be

used on small capacity tanks if no space compliance

issue.

Siphon Tube is a vertical pipe, typically 2-3” in

diameter which extend from top of shell to close to

the bottom. Siphon tube is used for

Top unloading for all cargos

Top loading for highly flammable liquid to avoid

static electricity generation caused by liquid splashing

during loading

16

3” Flanged Top Discharge Butterfly

Valve Fitted next to a 1 ½” BSP Airline

Siphon Tube looks

like internally

Design and Safety Features Spill Box, Drain Tube, Walkway & Handrail

• All above items can be normally found within Spill Box

on top of ISO tank to retain any spills from loading and

unloading process. Centre Spillbox and Rear Spillbox.

• Drain Tube is generally surface mounted on container,

assists with the drainage of rainwater, melt water from

snow, ice and any spilt in the spill box during loading.

• Walkway is usually perforated aluminum plate for access

and operate on top of ISO tank. Walkway and supporting

structure are lightweight and only designed to support two

persons. Walkway configurations vary from very small

length to full coverage. Full Walkway is recommended for

increasing stringent working at height restrictions.

• Collapsible Handrail is optional fitted that fold down

within ISO dimensions. It should NOT be a safe means of

Working at Height, but merely as guide to edge of the

vehicle or ISO tank and driver moving forward on it.

17

Drain Tube

Spill box

Handrail

Walkway

Design and Safety Features Top view of ISO Tank

18

PRV

Manlid

Airline

Full

Walkway

Provision

Outlets

Frame

Design and Safety Features Bottom Discharge

• Bottom Discharge is located at rear of ISO tank.

• Except T1, T3 and T6 ISO tank, all ISO tanks allowed bottom discharge must be

at least three serially mounted and mutually independent shut off devices fitted

within the bottom valve assembly.

Foot Valve or Internal Valve

Secondary Valve

Threaded Cap or Blind Flange Termination

19

Design and Safety Features Foot Valve (Internal Valve)

• Foot valve (internal valve) is designed to stay intact and contain the cargo inside

the tank even if main valve body is damaged or impacted.

• Three types of Foot Valve typically, High Lift (Marsden), Clean Flow and

Univalve.

20

Design and Safety Features Foot Valve (Internal Valve)

• Foot valve must be fitted with remote operating device for remote shut off in

case of emergency.

• (internal valve) is designed to stay intact and contain the cargo inside the tank

even if main valve body is damaged or impacted.

21

• Fusible links are generally fitted to tank containers

carrying certain flammable liquids into the US. This

link is designed to break if higher temperatures

associated with a fire. The spring will then pull the

foot valve close remotely. It is Not mandatory for

other countries.

Design and Safety Features Secondary Valve

• Secondary valves are usually a 3” flanged butterfly valve.

• Ball valve can also be used, but on large capacity tanks they are too large to

stay within the ISO dimensions of the frame.

22

Design and Safety Features Threaded Cap or Blind Flange Termination

• A valve termination is what the hose used to empty or fill the tank connects to.

• Threaded valve terminations are BSP, NPT, RJT, ACME. The ‘Male’ thread on

the ISO tank, must match the ‘Female’ thread on the customers hose.

• Bind Flanged valve terminations are either ANSI or DIN. Flanges are bolted

together with customer hose. No “Male”, “Female” differentiation.

• 3” BSP with cap is the most common in the industry. NPT is more common in

the US.

23

3”BSP Male

Termination

3”BSP Female

Cap

Design and Safety Features Thermometer

• At least one thermometer is mounted on the cladding at

the rear of the tank.

• Thermometers are usually surface mounted measuring

the temperature of the external shell. For special cargo’s

the thermometer probe can extend into the cargo via a

thermowell.

24

Ladder

• Ladder built into end of end frame of ISO tank. Some

of which can be clearly discernable as a ladder, while

others may appear as a climbing frame

• It is regulatory requirements that a warning decal

must be marked to indicate overhead hazards and

power cables when access to top of ISO tank.

24

Ladder should only be used when suitable steps or an access

platform adjacent to the tank container is not available as

emergency!

Design and Safety Features Heating Termination

Steam heating system has Steam Outlet and Steam Inlet

at rear of ISO tank, 1” BSP treaded cap usually.

25

Earthing Connection

Cargo which is flammable or susceptible to ignition from

static electricity, must be capable of being electrically

earthed during operations. A designed Earthing

Connection point at rear of ISO tank should be

connected to a suitable ground point.

25

Documentation Box

A Documentation Box is usually attached with frame of

ISO tank for documents accompany with transport, such

as MSDS, Tremcard, etc. as optional.

Design and Safety Features Data Plate

Data plate is regulatory required to be fitted to the

ISO tank, normally located at rear of ISO tank. Data

includes

Tank type and serial number

Name of Owner

Name of Serial number of Manufacturer

Capacity, T/W, MPGW, Stacking Weight

MAWP, Test pressure

Material Specifications

Connections

Regulatory approvals

Date of Initial, last and next

2.5y or 5y test

26 26

Design and Safety Features Rear view of ISO Tank

27 27

Design and Safety Features Other optional safety fittings • Baffle (Surge Plate) is required if payload between

20-80% of vessel volume if vessel total volume is

greater than 7,500liter to reduce the free flow of liquid

as the container is moving during transport. Normally,

baffle area should be greater than 40% of cross

sectional area of ISO tank.

• Compartment is set by one or more watertight

bulkheads welded across the shell’s cross section.

Each of compartment is capable of carrying a different

cargo or same cargo in each compartment less than

7,500liter to meet payload regulatory requirement.

• Other discretionary fittings

Large number of fittings may be fitted in addition to the

mandatory fittings. These include level indicators,

low/high level alarms, electric operating systems,

hydraulic operating systems, etc.

28 28

Transverse baffle

Full diameter baffle

Baffle tank adds

additional weight and is

more difficult to clean

Compartment is not

widely used since need to

meet compatibility rules

and difficult to clean

Design and Safety Features Decals & Markings

• Under ISO6346 all tank containers that are international intermodal loading units

must carry:

three letter owner identification code

an equipment identifier “U” – presenting all shipping modes.

a unique serial number consisting of six Arabic numerals

a check digit based on ISO 6346 calculation rule

• 22T6 is an ISO6346 size and type code to identify the type of freight container.

2 – Container length is 20 feet

2 – Container height is 8’6” and width 8’.

T6 – Tank container up to 6 bar pressure From 2013, to avoid confusion with UN Portable

tank instructions, the ‘T6’ will change to ‘K2’. 22K2 will become the most common code.

29 29

Container Serial number Equipment Identification

doe

Owner code Check Digit

Container code

Design and Safety Features Decals & Markings

• ISO tank also complies with other international conventions and region(country)

regulation, decals and markings must be in place accordingly

30 30

RID / ADR – approved for European Rail and Road.

AAR 600 – approved for America Rail

UN PORTABLE TANK – UN of transport is met

TC IMPACT APPROVED - has been impact tested

according to Transport Canada (TC) regulations

‘IC 70’ - meets ISO 1496 and UIC 592-2

(International Union of Railway), 70 is the UK.

Super Heavy Triangle - Maximum Gross Weight

>30480kg and < 34000kg according to UIC

2.6m 8’6” - Height decal at least 8’ (2438mm) high.

24cbm / 4 Bar MAWP – Liquid Capacity and

Maximum Allowable Working Pressure

L4BN - ADR code for EU domestic transport

T11 – UN portable tank code

Coffee Break

31 31

ISO Tank Operation Work Flow • Besides technical design and fittings, process control also enable layers

protection on ISO tank operation safety.

• Selection, Acceptance, In-service, Cleaning, Inspection & Test,

Maintenance are main sub-processes in a routine ISO tank operation cycle.

32 32

Selection Acceptance In service

Cleaning Inspection &

Test Maintenance

ISO tank could be owned

by Carriers or Shippers via

leasing or purchasing.

COC means Carrier Owned

Container.

SOC means Shipper Owned

Container.

COC and SOC has same

operation work flow but

different accountability of

sub-process.

• Shipper are recommended to maintain Safe Handling Guides for all Dangerous

Goods transported in bulk, including product properties, industrial hygiene, PPE,

(un)loading, ER, transport equipment specifications ( shell, piping, valve, lining,

gaskets, previous cargoes…).

ISO Tank Operating Safety Selection

Several factors need to be considered to select ISO tank, besides business safe

handling guides:

• Tank type determination – T code and Tank special provision (TP) could

be found in IMDG Dangerous Goods List according to cargo hazardous

classification, it will determine shell thickness, minimum test pressure, bottom

opening allowance, etc…

• Tank Size determination – determine tank size per degree of filling and

order size

• Compatibility check – cargo reactivity check against previous (last) cargo,

adjacent cargo, transport equipment cargo contact with ( shell, pipe, gasket…).

• Fittings check – validate specific product and source/customer needs to

determine fitting devices, such as type and size of connections, siphon tube,

insulation thickness, heating system, baffle, pressure gauge…

33 33

Fitting requirements really depend on product handling requirements by

business and operational requirements from sources and customers.

Sometime, modification to existing ISO tank is necessary, and it takes time

and cost.

ISO Tank Operating Safety Selection - ISO tank type determination

Step 1 – find out UN number and Packaging group code in product MSDS

section 14th

34 34

Step 2 – determine Tank T code (13) and Special provision (14) from IMDG

Dangerous Goods List


Step 3 – review T code requirements from IMDG Portable Tank Instructions

(4.2.5.2.6)

35 35


Step 4 – determine offered ISO tank type whether can be met.

36 36

•Tank T code has NO

any permission

rationale related to

number sequence of T

Code!

This table describes the

permission rule among

different T code tanks.

•For this example, T11

is also permitted to

carry cargo under T7.

Special provision TP2

means not filling over

95% of tank capacity .

ISO Tank Operating Safety Selection – Tank size determination

Tank owner can offer various size of liquid ISO tanks from 9,000-27,000 liters

normally. Minimum and Maximum filling ratio below must be complied with under

waterway and Road/Rail in most of countries.

• Unless Baffle or Compartment less than 7,500liter is utilized, or liquids

having viscosity greater than 2,680 mm2/s at 20 ℃ without heating, ISO tank

shall not be filled more than 20% but less than 80% of capacity for transport.

• ISO tank shall not be filled in excess of maximum degree of filling specified

in next slide.

37 37

Max Degree

of filling

ISO Tank Operating Safety Selection – Tank size determination

• Formula 1 - Maximum degree of filling for liquid of Not Regulated and

General other than specified in formula 2

Degree of filling = 97% / 1 + α (tr – tf)

• Formula 2 - Maximum degree of filling for liquids of – class 6.1 and 8 (packing groups I and II) and liquid vapor pressure more than 1.75 bar

@ 65 ℃,

– marine pollutant

Degree of filling = 95% / 1 + α (tr – tf)

tf = temperature of the liquid during filling (in℃)

tr = maximum temperature of the liquid during transport (in℃)

α = coefficient of cubical expansion of the liquid

38 38

ISO Tank Operating Safety Compatibility Check – Previous (last) & adjacent cargo

Cargo to be loaded may react with previous cargo or cargo in adjacent

compartment by either substance mixture or temperature impact potentially, even

the equipment is stated clean and ready to serve. It may damage the product and

equipments, or cause severe reactive incident in the worst situation. Compatibility

check is important step to prevent reactive incident.

Several ways to determine the compatibility of previous & adjacent cargo

• Coast Guard Chart

• CRW (Chemical Reactive Worksheet)

• Birdwell Chart

• HM-183

• EPA Chart

• MSDS section 10th – Stability and Reactivity, there is an Incompatible

Materials list prohibited .

39 39

ISO Tank Operating Safety Compatibility Check – Transport equipments

Cargo to be loaded is possible to react / corrode vessel shell, pipes, internal

lining, valves, seals, gaskets, damages the equipments and causes safety

incident also, if it is incompatible.

Several ways to determine compatibility against transport equipments

• IMDG Tank Special Provisions (TP) regarding to compatibility limitation to

containment material and lubricant

• MSDS Section 7th – Handling & Storage, it will advice containment material

limitation.

• MSDS section 10th – Stability and Reactivity, there is an Incompatible

Materials list prohibited for material contact with

40 40

ISO Tank Operating Safety Acceptance

After ISO tank selection, it is recommended to check ISO tank On-Hire Condition

to make sure ready in service.

• Last valid Periodic Inspection Report

• On-Hire Survey Report

• Cleanliness Certificate

ISO tank should be rejected if any failure identified during On Hire Condition

check process. Re-inspection or re-test shall be carried out after reparation,

maintenance or re-cleaning completion.

.

41 41

•This practice is normally applied to ISO tank Off-Hire

process also, to align with return acceptance from tank

owners.

•On hire survey and cleaning survey must be carried

AFTER tank modification per customer requests.

ISO Tank Operating Safety Inspection & Test

Initial, Midway (2.5-year) , Full Period (5-year) inspection & test must be carried

out according to IMDG, ADR, RID, CSC regulations.

Examination items below:

42 42

Initial Midway (2.5-year)

Full Period (5-year)

Design characteristics √

Internal √ √ √

External √ √ √

Fittings √ √ √

Pressure test √ √

•Initial inspection report is usually provided by tank

manufacturer. Midway and Full period inspection report is

usually provided by tank owner, which is conducted by an

independent 3rd

party surveyor.

•Filled tank inspection is allowed to exceed the last

periodic inspection expiration date with in three months

•ACC (Acceptable Container Condition) rule might be

utilized by tank owners and users


On-Hire Survey Report, Cleanliness Certificate are commonly used as industrial

practice between tank owners and tank users for hand over.

ACC (Acceptable Container Condition) Manual, developed by ITCO

(International Tank Container Organization), is popularly used as industrial

guidance for operation safety purpose.

43 43

http://www.itco.be/download.php?id=acc4dec2010


• Fair Ware and Tear is defined in ACC manual, which is the age-related

deterioration of the container or any of its component parts while being properly

maintained and used for its intended purpose. Cost of Fair Ware & Tear is under

tank owners.

• Any deterioration resulting from improper use, improper maintenance or lack of

maintenance is not 'Fair Wear and Tear.‘

• Replacement of leaking or contaminated seals and gaskets is a normal operating

requirement and is not 'Fair Wear and Tear.‘

• Cleanliness Certificate is a must to be carried out to prove the specific ISO

tank is Clean, Dry and Odor Free.

44 44

•There is no clear specification of Cleanliness under IMDG, CSC. ACC manual

provides guidance on cleanliness acceptance conditions on Interior, Exterior and

Foreign Marks.

•Cleanliness Certificate is issued by individual 3rd

party surveyors. In some

circumstances, Cleanliness Certificate could include additional inspection

requirements from tank users, such as

Concentration of specific substance

Blanked pressure (Nitrogen, Air)

Cleaning process supervision…

ISO Tank Operating Safety Maintenance & Cleaning

• ISO tank Maintenance and Cleaning are performed at Tank Cleaning

Stations, which are usually granted by Tank owners and 3rd party surveyors.

Tank users could also involve Tank Cleaning Stations nomination per customer

special provisions.

• Other ISO tank operation activities also can be performed at Tank Cleaning

Stations, such as heating, modification…

45 45

• Considering the reality of

developing market, DOW

encourages tank cleaning service

providers to implement cardinal

rules mentioned in next slides as

fundamental elements in the

assessment (self or independent).

Cardinal Rules for Tank Cleaning

Legal Compliance

1. The assessed company and its employees shall obtain all applicable

licenses, permits, certificates, assessment reports per regulatory

requirements and in current valid period, which include but not limit to

• Business license;

• Environment assessment report;

• Pollution discharge permit (if applicable);

• Fire acceptance report;

• Special work certificate, e.g. crane/boiler operator (if applicable);

2. The assessed company shall have all obligatory insurances and keep

in valid period, which include but not limit to

• Publicity insurance

• Employer liability insurance

• Pollution liability insurance (if applicable)

46


Management System

1. Organization chart shall show individuals' roles and link to

responsibilities of the work carried. The company shall have formally

designated a Safety & Health Manager, an Environmental Manager, a

Security Manager and a Quality Manager. The roles can be part-time

or full time depending on company size.

2. Policies and procedures are being executed effectively with traceable

records in reasonable retention period.

47


Management System (cont.)

3. The company shall have effective policies or procedures, including;

• Chemical hazardous awareness, identification and risk analysis;

• Personal Protection Equipment usage policy or procedure;

• Specific product cleaning or heating procedures and agreed by customers

prior to operation;

• Task based work safety procedure, e.g. work at height, confined space,

hot work (if applicable);

• Container hand-over and inspection procedures;

• Waste treatment procedures;

• Comprehensive Emergency Response Plan with drill test at least

annually;

• Training program covering policies and procedures above by roles or by

tasks

48


Hardware Design and Usage

1. The site shall have proper security hardware ( i.e. fences, supervised

barriers, CCTV, gate registration ) to control accessibility.

2. The working and storage area shall have liquid tight ground and

proper containment to prevent pollution to earth, rivers or vegetation.

3. Explosive proof equipment, lightening protection and grounding

system must be used in electric classified area.

4. Ventilation system must be in place in cleaning workshop if exposure

limits reached.

49


Hardware Design and Usage (cont.)

5. A waste collection, recycling, treatment and dispose system shall be

in place and controlled effectively within permitted quota limits.

6. Critical equipment and spare parts shall be installed, operated in

sound and serviceable condition, mandatory inspection and

calibration shall be in place, including but not limit to

• Firefighting system;

• Energy resources;

• Repair workshops;

• Cleaning workshops;

• Waste treatment system;

• Container storage area.

50


Operation Safety and Quality

1. Last cargo must be checked against Material Safety Data Sheet and

confirm with customers on reactive compatibility prior to operation.

2. Site Personal Protection Equipment and other safe ground rules shall

be always followed.

3. Container hand-over inspection shall follow ACC (Acceptable

Container Condition) Manual.

4. Unless customer specified otherwise, tank in-service acceptance

condition shall be granted by 3rd party well known surveyor

companies, including but not limit to

• On Hire Survey Report;

• Cleanliness Certificate to ensure Clean, Dry and Odor Free

51


Operation Safety and Quality (Cont.)

5. Work at height shall be restricted in area with fence securing or

personal life arrest system.

6. Confined Space entry ground rules must be followed: – Only authorized person;

– Test Oxygen (19.5-23.5%) before and during entry;

– Test flammable gas < 10% of Low Explosive Limits if applicable;

– Test toxic gas < Exposure Limits if applicable;

– All required PPE shall be properly worn according to hazards identification;

– Whole attendance to monitor by standby person;

– Rescue Plan is available.

7. Energy resources usage shall be properly locked or Isolated to

prevent person exposure to hazardous conditions.

52


Operation Safety and Quality (Cont.)

8. Unless customer specified otherwise, tank maintenance and

periodic test shall be conducted in a mutual agreed cleaning

station by well known 3rd party survey companies and tank

owners.

9. Pharmaceutical or food or feed grade tank shall be cleaned in an

isolated cleaning bays with dedicated equipment and qualified

utilities.

53

ISO Tank Operating Safety In Service

ISO tank under tank users’ custody for operation after hand over from tank

owners is In Service status. There are operation safety guidance regarding to

specific individual In Service steps need to be considered below generally:

Lifting

Stacking &Stowage

Carrying

Loading & Unloading

Sealing

Placard, UN mark, PSN

54 54

ISO Tank Operating Safety In Service - Lifting

• Lifting equipments shall meet proper design standard fit for lift, such as crane,

super stacker, large forklift, etc.

• Risk assessment must be conducted prior to lifting operation, depends on

equipment lifting weight/height limitation, handling area limitation, and other

surrounding factors. Driver must be trained accordingly.

• General safety rules:

ISO tank without forklift pocket is prohibited to be lifted by forklift

End frame attachments should not be used to lift ISO tank

Use of side frames for all loaded tank lifting is prohibited

ISO Tank may be lifted by slings but the lifting equipment should

be of such design that there is a vertical force at the corner fittings

55 55

ISO Tank Operating Safety In Service – Stacking & Stowage

• ISO tank storage terminals should develop effective emergency response plan

All life saving and fire fighting equipment should be kept in good order and periodically

inspected and their inspection recorded

Appropriate containment should be effective as part of emergency response plan in case

of leakage.

• ISO tank must be stowed and segregated according to IMDG stowage &

segregation principles and other relevant regulations.

• A stacking plan should be developed based on risk assessment criteria below

General stacking consideration – see next slide in details

Ground surface – sustainable weight limitation

Surroundings – distance from buildings, pedestrians, allowable room to maneuver

Local weather conditions – effects of strong wind

Stacking equipment – equipment handling weight and height limitation

Other considerations – Accessibility, Stability, Visibility, Human factors…

56 DOW RESTRICTED 56

Empty ISO tanks containing dangerous residuals and have not been cleaned must be

declared as EMPTY UNCLEANED or RESIDUE LAST CONTAINED under the provisions of

the IMDG Code

ISO Tank Operating Safety In Service – Stacking & Stowage

General stacking consideration:

• Allowable Stacking Weight – Most ISO tanks are built

withstand up to superimposed load of 192,000 kg. However the

Allowable Stacking Weight of specific ISO tank can be found in

Data Plate.

• Stacking on ships - shall be carried out in accordance with

instruction in ship’s “Cargo Securing Manual”.

• Stacking on the ground

all containers should be stacked with the corner fittings aligned within

tolerance (25mm laterally and 38mm longitudinally)

No greater than 3 container height for laden Non DG ISO tank

container.

No greater than 2 container height for laden DG ISO tank

container.

57 57

ISO Tank Operating Safety In Service – Carrying

The chassis carrying ISO tank shall have special attentions besides general

chassis inspection criteria:

• Frames of ISO tank not exceeds chassis fleet all dimensions to prevent ISO

tank damage by collision. Additional length to prevent rear collision is

recommended.

• Twist locks and Supporting legs must be well functioned and inspected

properly to carry the super heavy tank

• Low centre of gravity design is recommended to minimize surging degree

58 58

ISO Tank Operating Safety In Service – Loading & Unloading

Several pre-cautions suggest to be considered for (un)loading operations

specific for ISO tank:

• Personal Protection Equipment

• Working at Height

• (Un)Loading Scheme

• Coupling and Hoses

Other safety considerations, like Roles & Responsibilities, Emergency

Response Plan, BBS, SQAS, SULID, etc…are general, not specific safety

precautions for ISO tank loading and unloading operations.

Please refer to details in CEFIC (The European Chemical Industry Council)

Best Practices

59 59

http://www.cefic.org/Industry-support/Transport--logistics/Best-Practice-Guidelines1/

ISO Tank Operating Safety Loading & Unloading – Personal Protection Equipment(PPE)

As last barrier of defense to protect the driver against risks during (un)loading

activities, PPE is required for site access, and in most of countries, it already

became regulatory requirements.

PPE requirements shall be based on task risk analysis. ISO tank (un)loading

operation has more complicated activities and higher injury severity risks, LSP

shall build up basic concept of PPE and follow site PPE instruction strictly.

Main behavioral expectations:

• Correct use specific PPE

• Follow site instruction

• Respect of capacities and limitations

• Proper inspection and disposal

• Proper maintenance and storage

60 60

ISO Tank Operating Safety Loading & Unloading – Personal Protection Equipment(PPE)

PPE usage chapter recommendations of CEFIC.

Note: This chapter covers only general PPE requirements. For specific products (e.g. class 8 or 6.1) and/or for specific

chemical plant environments, additional specific PPE may be required in accordance with risk assessments.

61 61

ISO Tank Operating Safety Loading & Unloading – Working at Height

Working at height is regulatory requirements in most of countries. Definition may

be vary by country. Working at top of ISO tank on land (>8.6 feet) or on chassis

(>14 feet) is definitely Working at Height.

Main working at height principles are

• Try to avoid by alternative solutions

• Risk assessment by tasks

• LSP follow site instructions

62 62

If there are no appropriate tools

available and a safe working

environment is not guaranteed, the

driver must stop the activity and

contact his management!


63 63

Options Safety Provisions Example

Fence Securing (Fixed gantry, mobile gantry, mobile step ladder)

•Barrier at least 1.1m height with at least one intermediate rail all side of working area. •No empty space between barrier and edge of ISO tank •No space between ladder and tank •Gantry and ladder in good condition •Not carry hoses and rings once climbing ladder •Avoid long distance walk on walkway

Personal life arrest systems

•Include safety harnesses in PPE list •Well trained personnel •Life system above user •Life system in good condition •Ware properly •Supervision all time •Restricted working condition •Not carry hoses and rings once climbing ladder

Tank Truck must be secured to prevent movable during loading &

unloading operation ALL THE TIME! including engine power off,

auto-brakes, wheel chocks, warning plates, keeping key, etc…


As mentioned, ISO tank rear ladder is ONLY for temporary or emergency uses.

There are limited hand holds available for climber to grip. Climb off is more

dangerous since climber can not see the steps and in awkward position.

Some principles on climbing ISO tank rear ladder

• Slowly and carefully

• Do not carry anything in your hands

• Two hands, one foot or two feet , one hand in contact

with the ladder at all times (3 points rule)

• Supervision at all times

64 64

More working at height recommendations, please refer

to DOW Elevated Work Standard , but not mandatory to

LSPs.

http://ehs.intranet.dow.com/library/standards/0605_Falls/default.asp

ISO Tank Operating Safety Loading & Unloading – (Un)Loading Scheme

Loading Schemes

L1 • Top loading through open manhole

L2 • Top loading through dome with cone and with vapor recovery

L3 • Top loading with dip tube and with vapor recovery

L4 • Top loading with dip tube and with inert gas blanketing

L5 • Bottom loading with open manhole

L6 • Bottom loading with closed manhole and with vapor recovery

L7 • Bottom loading with closed manhole and with blanketing

Unloading Schemes

U1 • Bottom unloading by pump with open manhole

U2 • Bottom unloading by gravity with open manhole

U3 • Bottom unloading by compressed air or inert gas

U4 • Bottom unloading by pump with closed manhole and with intake of air

U5 • Bottom unloading by gravity with closed manhole and with vapor return

U6 • Bottom unloading by pump with closed manhole and with vapor return

U7 • Bottom unloading by pump with closed manhole and with inert gas

U8 • Top unloading by pump with closed manhole and with vapor return

65 65

Improper (un)loading

scheme handling may

cause severe incident!


66 66


67 67


68 68


69 69


70 70


71 71


.

72 72


73 73


74 74


76 76


77 77


78 78


79 79


80 80


Except PPE and Working at Height, other main risks of different scheme



General precautions recommended by CEFIC



Specific precautions by scheme recommended by CEFIC



This is a comprehensive scheme determination chapter based on product

hazardous categories risk assessment and precautions recommended by CEFIC.

84 84

ISO Tank Operating Safety Loading & Unloading – Coupling and Hoses

Coupling and hoses are main parts of connection between ISO tank and site tank. Proper

coupling and hoses design, operation is very important to (un)loading site and LSP driver.

The driver is responsible for making the connections to the vehicle, whilst the site operator

is responsible for making the connections to the storage tank. Coordination and

cooperation between the driver and operator is of vital importance to avoid incidents

There is vary type of couplings, the mainly used types are, BSP, Flange and Kamlok

Other types of coupling like Tankwagen, Guilemin, KNZ, DDC (Dry Disconnect

Couplings) do exist, but are not widely used for liquid chemicals in Asia Pacific region.

85 85

BSP Flange Kamlok

British Standard Pipe, Standard parallel threaded pipes with same outside diameter throughout, tightened against a gasket

DIN 80 PN 10 for ISO tank. the internal diameter is 80mm. a gasket is to be placed in between. no male or female part

coupling is tightened against a gasket. The male part (without the arms) is usually part of the tank container


86 86

Coupling Advantages Disadvantages Condition of Use

BSP •fairly common, mostly on ISO-tanks •the coupling can be tightened fairly easy •strong connection allowing more couplings in series.

•At least 6 full turns are necessary, not a ‘Quick connect coupling’. •thread is vulnerable and can not be fixed nor replaced.

•The use of Teflon tape or other materials in the threads is entirely useless. The coupling is made over the gasket

Flange •common, easy to use •the coupling can be tightened fairly easy. •strong connection allowing more couplings in series. •nut and bolt is independent and easily replaced

•Additional time to align holes and tighten nuts, not a ‘Quick connect coupling’. •Tighten bolts and nuts and gasket replacement each time has behavioral issues

•Can be used under any condition •ANSI and DIN has some alterations by bolt-holes modification. a single adaptor DIN – ANSI is preferred

Kamlok •‘Quick connect coupling’

•kept in place by friction, the arms need to be secured. •Seal/gasket easily damage •not desirable for high pressure (un)loading

•Easy, not very reliable, •for specific non-dangerous goods only •Non pressurized (un)loading only


In conclusion the safest and strongest coupling is the Flange coupling.

ISO tank bottom discharge – Foot valve, Butterfly valve and 3” BSP with CAP

are mounted together by flange to make it • Complied with regulations

• Easy to repair & replace individually

• Strong and safe

• Shortest length accommodate within ISO dimension

• Common used in the industry

• Able to add connection adapter to fit for (un)loading site coupling

87 87

1

2

3

However, this design still has disadvantages,

like invisible of the cleanliness, residual

remains between valves easily. Therefore it is

important to close /open bottom valves in

sequence by Foot valve, Butterfly valve,

Cap always during (un)loading even after

drained or blown


There are less chances to request LSPs to carry hoses for (un)loading

connection. This shall try to avoid because it needs extended responsibilities to

LSPs on hose management like connection, maintenance, whilst reduces

payload.

General principals are:

• Annual testing and visual inspection

• Proper material made of and design to resist pressure, temperature and

compatible with product

• Proper marking, indicating

• Proper working, cleaning, inspection, maintenance instruction

88 88

ISO Tank Operating Safety Sealing

ISO tank shall be sealed per sealing requirements under each transportation

mode.

89 89

• A 1/8” diameter wire cable seal is recommended to be

affixed to any container opening i.e. manlid, bottom outlet.

• Cable seals fulfilling the ISO IS 17712 specification must be

used.

• Seal must be applied at shipping origin.

• Each shipping points shall document their requirements for

the selection and application of container seals.

• All pensonnel who prepare shipments on behalf of shipper

shall be trained on the proper selection/ application/

documentation of seals as applicable to the materials/

shipping containers handled at that facility.

ISO Tank Operating Safety Placard, UN marks, Proper Shipping Name (PSN)

Placard, UN marks, PSN ( can be found in MSDS section 14th) shall be affixed to

exterior surface of ISO tank according to applicable transport regulations.

90 90

Here is the general highlights of IMDG placard, UN marks, PSN principles:

• Previous placards, marks and signs shall be removed

• Placard must be clearly displayed each side

• Placard size no less than 250mm, with a line same color as symbol 12.5mm inside the edge

• Proper Shipping Name shall be durably marked on at least both sides

• UN number marks shall be displayed in black digits not less than 65mm high, either

against white background in the lower half of each primary placard, or

on orange rectangular panel not less than 120mm high, 300mm wide, adjacent to placard

3082

3082

Environmentally Hazardous

Substance, Liquid, N.O.S (1,2-

Benzisothiazol-3(2H)-one)

Environmentally Hazardous

Substance, Liquid, N.O.S (1,2-

Benzisothiazol-3(2H)-one)

Or

In Conclusion

91 91

ISO tank is one of the safest means of transport for

chemicals as long as related regulations and guidelines

have been strictly followed!

Location: China

ISO tank was hit by

another collapsed ISO

tank from 3rd stacking

high in Typhoon season.

No cargo leakage

Location: Japan

A container was exploded

besides ISO tank.

Insulation and cladding

were seriously damaged.

No cargo leakage

Location: Taiwan

A severe fire incident at

terminal. After fire, all

insulation and cladding

of ISO tank were burn

out. No cargo leakage

Reference Materials

92 92

• DOW Supply Chain Material Handling Technical Center

• IMDG code – International Marine Dangerous Goods code

• ISO – International Standard Organization

• CEFIC – Transport & Logistics of The European Chemical

Industry Council

• ITCO – International Tank Container Organization

Also thanks for ISO tank training materials shared from ISO

tank owners (EUROTAINER, EXSIF, DAELIM)!


http://www.iso.org/iso/home.htm

http://www.cefic.org/Industry-support/Transport--logistics

http://www.cefic.org/Industry-support/Transport--logistics

http://www.itco.be/

FAQ

93 93

Further Questions?

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