Product Quality in Light Product Storage and Handling Operations API RECOMMENDED PRACTICE 1640 FIRST EDITION, AUGUST 2013 Copyright American Petroleum Institute Provided by IHS under license with API[.]
Scope and Purpose
This recommended practice (RP) offers essential guidance on the minimum equipment standards and operational procedures for the receipt, storage, blending, and delivery of non-aviation light products, including their blend components and additives, at distribution and intermediate storage terminals It also encompasses related operations involving pipeline, marine vessels (such as barges or ships), and road and rail transport.
This publication offers recommended practices instead of strict guidelines Users should recognize that unusual or abnormal circumstances may affect the applicability of these practices, and in such cases, it is essential to seek specialist advice.
This publication aims to support individuals engaged in fuel handling at distribution and intermediate storage facilities While API has taken steps to ensure the accuracy and reliability of the information provided, it does not offer any guarantees or warranties regarding the content and disclaims any liability for losses or damages arising from its use, as well as for any conflicts with local or regional laws or regulations.
This RP outlines the essential equipment standards and operational procedures for the receipt, storage, and blending of light products such as gasoline, kerosene, diesel, and heating oil, along with their blend components like ethanol, biodiesel, and butane It applies to distribution and storage terminals, as well as the shipment of light products through pipelines, marine vessels (barges or ships), and road and rail transport.
This RP offers essential guidelines for the design, construction, operation, and maintenance of terminals dedicated to the storage and distribution of light products, with a primary focus on safeguarding product quality.
This document references various standards and recommended practices, maintaining the distinction between mandatory, recommended, and optional provisions as outlined in the referenced materials.
The values stated in this RP are International Units (SI); US Customary (USC) units are in parentheses.
Non-Applicability
This document is not intended to cover fuels addressed in other applicable documents (i.e aviation fuels) covered under API 1595.
This RP does not cover intermediate or residual fuels (i.e bunker fuels, #4 oils and #6 oils).
This standard's design and construction provisions are primarily aimed at new facilities For existing facilities, equipment, or structures, a careful evaluation is necessary to determine the applicability of these provisions, especially for those under construction or installed prior to this publication This evaluation should take into account site-specific conditions, risk tolerance, existing installation circumstances, and the overall benefits of implementing the required design and construction standards.
This standard references various standards, codes, publications, and specifications For dated references, only the specified edition is applicable, while for undated references, the most recent edition of the document, including any addenda, is relevant.
API Manual of Petroleum Measurement Standards Chapter 3.3, Ethanol Density and Volume Correction Factor Tables
API Manual of Petroleum Measurement Standards Chapter 8.1, Manual Sampling of Petroleum and Petroleum Products
API Manual of Petroleum Measurement Standards Chapter 11.1 Physical Properties Data Section—Temperature and
Pressure Volume Correction Factors for Generalized Crude Oils, Refined Products, and Lubrication Oils
API Bulletin 939-E, Identification, Repair, and Mitigation of Cracking of Steel Equipment in Fuel Ethanol Service API Recommended Practice 652, Linings of Aboveground Petroleum Storage Tank Bottoms
API Recommended Practice 1626, Storing and Handling Ethanol and Gasoline-ethanol Blends at Distribution
API Recommended Practice 2003, Protection Against Ignitions Arising Out of Static, Lightning, and Stray Currents API Standard 653, Tank Inspection, Repair, Alteration, and Reconstruction
API Standard 2610, Design, Construction, Operation, Maintenance, and Inspection of Terminal and Tank Facilities ASTM D1835 1 , Standard Specification for Liquefied Petroleum (LP) Gases
ASTM D3244, Standard Practice for Utilization of Test Data to Determine Conformance with Specifications.
ASTM D4057, Standard Practice for Manual Sampling of Petroleum and Petroleum Products
ASTM D4362, Standard Specification for Propane Thermophysical Property Tables.
ASTM D4650, Standard Specification for Normal Butane Thermophysical Property Tables
ASTM D4806, Standard Specification for Denatured Fuel Ethanol for Blending with Gasolines for Use as Automotive Spark-Ignition Engine Fuel.
ASTM D6751, Standard Specification for Biodiesel Fuel Blend Stock (B100) for Middle Distillate Fuels
ASTM Manual 47, Fuel and Fuel System Microbiology: Fundamentals, Diagnosis, and Contamination Control CONCAWE 2 , Guidelines for handling and blending biodiesel
ISO 4259 3 , Petroleum Products - Determination and Application of Precision Data in Relation to Methods of Test
Title 40 Code of Federal Regulations 5
1 ASTM International, 100 Barr Harbor Drive, West Conshohocken, Pennsylvania 19428, www.astm.org.
2 CONCAWE, Boulevard du Souverain 165, B-1160 BRUSSELS, Belgium, www.concawe.be.
3 International Organization for Standardization, 1, ch de la Voie-Creuse, Case postale 56, CH-1211, Geneva 20, Switzerland, www.iso.org.
4 Energy Institute, 61 New Cavendish Street London W1G 7AR, UK, www.energyinst.org.
5 The Code of Federal Regulations is available from the U.S Government Printing Office, Washington, DC 20402.
For the purposes of this document, the following definitions apply:
A fuel comprised of mono-alkyl esters of long chain fatty acids derived from vegetable oils or animal fats, designated B100, and meeting the requirements of ASTM D 6751
Biodiesel is a renewable fuel designed for diesel engines, derived from agricultural co-products and byproducts like soybean oil and other natural oils As an advanced biofuel, it must adhere to the stringent quality standards set by ASTM D 6751 This versatile fuel can be blended with petroleum diesel in any proportion.
A blend of biodiesel fuel meeting ASTM D 6751 with petroleum-based diesel fuel, designated BXX, where XX represents the volume percentage of biodiesel fuel in the blend.
To ensure quality, the entire tank must be certified before product release, allowing for analysis and corrections since the product does not move directly into conveyance This process involves batch mixing components either inline or within the tank, along with online analytical control of the blend.
The document that contains the test results and declarations that comprise the certification of the product Also called the certificate of quality in some locations.
The product declaration must accurately and completely reflect compliance with regulatory, contractual, and company policy requirements, ensuring traceability to a specific batch or volume of the product.
Corrective actions are improvements to an organization's processes taken to eliminate causes of non-conformities or other undesirable situations.
A pipeline that is only used to handle one grade of fuel
Refers to dedicated hardware, vessels and/or facilities such as pipelines, piping, tankage, and filters that are used to handle only one grade of fuel or component
3.9 fit for purpose/fit for use
Meet or exceed equipment requirements and reasonable consumer needs.
A batch that may be mixed with one or more batches of product of the same grade and specification.
Having an affinity for water; readily absorbing or dissolving in water
A volume of petroleum product generated in a pipeline between two adjacent volumes of non-identical petroleum product that consists of a mixture of the two adjacent products.
The act of creating a positive physical separation or barrier between products or components.
A tank that is actively receiving and/or delivering product.
Used to describe an aspect of the product quality, a subset of the “total” specification for the product For example:
%vol Benzene is one parameter of a motor gasoline specification Octane is another.
Piping systems, including pipes, valves, and manifolds, are essential for transferring products between tanks and various conveyances such as pipelines, ships, barges, and tank trucks These systems are designed with specific characteristics to ensure efficient and safe product movement.
— the tankage and piping are under the control of one site,
The volume of each batch exceeds the volume of the piping, which allows for the expectation of a maximum of one interface within the piping at any given time This definition applies to pipelines that accommodate more than one interface.
A pipeline is essentially a lengthy tube composed of one or more conduit sections, designed to link various installations such as terminals, refineries, and docks for the transportation of light products and other fluids.
— The tankage, piping and pipeline are under the control of more than one site.
— The volume of the pipeline is large (can expect more than one interface in the pipeline at any time).
Procedures are documented work instructions that include scope, defined responsibility, task, frequency and reference standards.
Refers to the shipment of a product to various locations or customers.
Refers to either the movement of product from one conveyance or vessel to another, or change of title or custody.
A product waiver is an official release that acknowledges the acceptance of business and customer risks associated with a product that does not meet specified standards These waivers are restricted by factors such as time, parameters, volume, and geographical location.
Unplanned variations in product quality, including customer complaints, product waivers, and quality incidents, do not align with the expectations outlined in this RP.
An incident occurs when a product fails to meet specifications, is not fit for use, does not comply with regulations, or violates company policy, and has crossed a defined boundary, such as a site boundary or a point of custody transfer, whether between an entity and a third party or among internal business units.
RHD is a fuel made entirely from hydrotreated biomass feedstocks, compliant with EPA registration requirements under Section 211 of the Clean Air Act and the ASTM D975 specification Importantly, RHD does not include any fatty acid esters.
Risk is the combination of the consequence and probability of failure mode scenarios.
A running (live) tank is defined as any tank that is receiving and delivering product simultaneously (see Live Tank).
To collect a sample, lower the closed sampling device to the outlet suction level, ensuring it remains above free water Open the sampler and raise it at a consistent rate, aiming for a fill level between 70% and 85% upon withdrawal Alternatively, samples can be taken from all levels using specially designed samplers that fill as they descend through the product.
A bottom sample refers to a spot sample taken from the lowest point of a tank, container, or line The term can have different interpretations, so it is essential to specify the exact sampling location, such as 15 cm (6 in.) from the bottom, to ensure clarity and accuracy.
A spot sample of free water taken from beneath the petroleum contained in a ship or barge compartment or a storage tank.
A sample is collected from the lowest accessible point in a tank, usually taken directly from the floor or datum plate of the shore tank or the bottom of the vessel compartment.
General
Guidance can be found in API 2610 for the following procedures:
— health and safety permit to work system;
— maintaining the integrity of fuel tanks and systems.
Management Responsibility and Accountability
Effective management of storage and distribution terminals is crucial for ensuring that facility design and operations meet industry standards and comply with relevant health, safety, environmental protection, and security regulations.
Storage and distribution terminals must have their operating procedures documented in a manual or accessible format for staff reference It is advisable to integrate adherence to these procedures within a quality assurance system, as detailed below.
Effective management at every level must establish a system for the prompt detection and resolution of changes or disruptions in production, supply chain, or product usage that could lead to quality concerns.
Quality Assurance System
To avoid significant commercial, consumer, and regulatory repercussions, it is crucial for organizations to implement an effective quality assurance system that guarantees the delivery of correct, fit-for-use, and on-specification products.
— expectations are communicated to all personnel who can have an impact on product quality;
— products are designed and specified to both comply with applicable regulations and be fit for purpose;
— product quality performance is evaluated and the degree to which expectations and customer requirements are met is assessed;
— clear objectives are set that demonstrate leadership and promote commitment to improving product quality performance through active and visible participation;
— employees at all levels accept responsibility for effective product quality controls, and early identification of potential customer problems;
— suppliers and contractors that can impact product quality are involved in maintaining and improving product quality performance;
— there are seamless and visible product quality improvement work processes;
To ensure the safe and uncontaminated delivery of light products throughout the supply chain and to the point of custody transfer, it is essential to provide and maintain appropriate facilities and equipment.
— there is an auditable documentary record demonstrating the correct handling, storage, blending and delivery of product at the intermediate and distribution terminal
The company will appoint individuals to oversee quality assurance for each terminal, with responsibilities tailored to the specific operations of each unit Detailed records will be maintained for these individuals, documenting their experience and training.
Each site will have a designated product quality manager responsible for the effective functioning of the quality assurance system Typically, at intermediate storage and distribution terminals, this role is fulfilled by the terminal manager, supervisor, or operations manager in larger facilities.
The Site Product Quality Manager shall be accountable for:
— implementation of correct quality control procedures;
— release of product only of satisfactory quality; and
— training of all staff at the site who are designated as Product Quality Inspectors
All personnel involved in essential quality assurance tasks must receive comprehensive training and be appointed as Product Quality Inspectors, typically fulfilled by terminal operators These responsibilities can be executed either on-site or remotely and encompass a range of activities.
— checking that the documentation on incoming consignments is correct and that it corresponds to the transport or container concerned;
— visually inspecting and conducting control checks and on-line sampling from pipelines and dock lines on incoming and outgoing material, including checking seals on vehicles (if present);
— product receipt into storage and post receipt testing;
— loading of material on marine vessels, road or rail transports, containers and pipelines; and
— maintaining appropriate records of inventory, quality, and equipment checks.
Training
Understanding the impact of lapses in quality control procedures is crucial for operations personnel It is essential that all staff are thoroughly trained to perform planned quality control tasks and effectively address any unforeseen events that may compromise product quality.
Common elements of a training program shall ensure that:
— training requirements for each job position are identified;
— individual needs are assessed against the identified job requirements;
— there is a documented training plan to close the identified training gaps;
— training programs linked to operating procedures are implemented according to the plan and regularly updated;
— evaluation of the competency of the individual after training is completed;
— testing and evaluation methodologies are used to document effectiveness of training programs (materials, methods and content) and counter any weaknesses by improving the programs;
— individual needs are assessed at specified intervals and refresher training carried out as needed;
— training records are kept for all identified individuals; and
Change management procedures are established to identify modifications in tasks, job scope, or individual responsibilities, ensuring that any required additional training is recognized and effectively implemented.
Risk Assessments
Receipt, storage and delivery operations shall be risk assessed to determine the frequency and depth of oversight testing The Risk Assessment should consider:
— any previous Product Quality audit, assessment or review of the facility;
— any history of incidents at the facility or with product from the facility;
— the terminal procedures for receipt testing (abbreviated testing) and additive reconciliation;
— if blending operations are performed;
— if the operation using pipelines is discharging to working tanks (live to the rack); and
— contract volume and service of products (i.e consider the business impact if the product is not fit for service).
Changes that may affect product quality must be accompanied by procedures to ensure that testing or other validation methods are implemented These changes encompass a variety of factors.
— hardware and software changes, and
— basic logistic changes (i.e product source changes, receipt or delivery mode changes and tank change of service).
Incident Management
It is the goal of incident management to:
— identify events where there is a deviation from the expected product quality;
— manage or mitigate the impact;
— learn from the incident; and
— share what has been learned to prevent future incidents.
There shall be written procedures for the management of:
— regulatory inquiries or violations; and
— other events which can impact product quality.
A designated responsible party or group, along with a communication plan, is essential for managing product quality incidents, including out-of-hours backups The primary objective of the initial response is to verify the incident, assess its scope, and mitigate any further impact.
Once the incident is verified, the concerned and affected parties shall be notified as soon as possible so additional mitigation steps may be taken.
An assessment of the incident shall be carried out and management shall be notified A Product Quality Incident Investigation shall be initiated with an investigation owner.
There shall be documented procedures for product quality complaints and incidents that ensure timely and regular stakeholder communication.
There shall be documented procedures in place and followed to ensure that all incidents are recorded and investigated in a timely manner.
The investigation shall address the failure mode(s), contributing factors, root causes and corrective actions.
The investigation will lead to corrective actions targeting each failure mode, contributing factor, and root cause Each action will specify responsible personnel, implementation timelines, and methods for verifying sustainability and effectiveness.
For ongoing learning, summaries of Product Quality investigations, including an assessment of the business impact, shall be circulated according to predetermined guidelines.
General
Adhering to key practices in the design, construction, and commissioning of facilities for the storage, handling, and transport of fuels, components, and additives is crucial for maintaining product quality.
5.1.1 Segregation of Fuels and Components
All facilities for fuel and component handling must be segregated by product and grade, unless there is a monitoring and control system in place This system should be designed to detect and appropriately downgrade product interfaces, as outlined in sections 5.3 and 9.2.
The construction materials for pipework, vessels, and tanks used in the storage and handling of light products must adhere to relevant API standards, industry specifications, and recommended practices.
The choice of construction materials and equipment components is an important factor, particularly when new or novel blend components are being introduced.
Particular attention should be paid to issues (i.e elastomer compatibility, sulfate deposition, pitting, corrosion and stress fractures) associated with the use of some biofuels
Changes in fuel composition have been shown to cause some seal material degradation
Some dyes have corrosive components that may result in accelerated corrosion in dye storage tanks
According to API 1626, it is essential to assess the design and compatibility of all components that will interact with gasoline-ethanol blends before handling, storing, and dispensing them Key properties to consider include the potential for stress corrosion cracking in steel structures, vapor flammability, vapor pressure, the hydrophilic nature of ethanol, and its differential solvency effects on polymeric materials, such as swelling, extraction, permeation, and embrittlement Additionally, the water tolerance of ethanol blends must be evaluated When introducing a new blend, it is crucial to analyze these properties at every stage of the supply chain to ensure product quality and safe handling and storage.
Ethanol exhibits higher electrical conductivity and oxygen content compared to gasoline and other hydrocarbon fuels, which allows it to absorb water effectively When water is suspended in gasoline-ethanol blends, it creates an oxygen-rich environment that promotes galvanic corrosion and rusting These conditions can lead to significant corrosion and metal loss in components that typically remain unaffected by gasoline.
Ethanol can corrode certain soft metals such as zinc, brass, copper, lead, and aluminum, potentially leading to component failure and compromised fuel quality Additionally, seals, gaskets, and elastomers not designed for ethanol blends may lose integrity, resulting in leaks It is essential to confirm the compatibility of any components with ethanol by consulting the manufacturer before use.
Existing supply and distribution systems for hydrocarbon-only diesel fuels are generally suitable for biodiesel blends However, it is essential to assess the need for hardware modifications across the supply chain, taking into account potential material incompatibilities and the heightened risk of deposit formation Key considerations should include the compatibility of materials and the impact on system performance.
— dedicated lines may be needed for imports and exports (at terminals) in order to avoid water and other contamination;
— gaskets should be compatible with B100 including those fitted in flanges and swivel joints;
— lagged or heat traced pipelines may be appropriate depending on the ambient temperatures and the cold flow properties of the diesel blend; and
— the design of product filters should be considered as well as the frequency of change out.
Biodiesel (B100) differs chemically from traditional fuel hydrocarbons, which can lead to compatibility issues within the fuel distribution system Certain materials may swell or degrade when exposed to biodiesel over time, potentially causing fuel degradation due to their chemical properties.
Biodiesel can cause degradation of certain hoses, gaskets, seals, elastomers, glues, and plastics with prolonged exposure It is particularly unsuitable for storing B100 in polyethylene and polypropylene containers, as these plastics may become permeable over time Materials such as natural or nitrile rubber, polypropylene, polyvinyl, and plasticized PVC tubing are especially vulnerable In contrast, polytetrafluoroethylene, fluoroelastomers, synthetic rubber, and Nylon are resistant to biodiesel and are recommended for replacing incompatible materials in equipment.
Tanks intended for diesel fuel storage are generally suitable for B100 storage as well Recommended materials for these storage tanks include aluminum, steel, fluorinated polyethylene, fluorinated polypropylene, polytetrafluoroethylene, and various fiberglass products.
Brass, bronze, copper, lead, tin, and zinc can accelerate the oxidation of biodiesel, leading to the formation of insoluble gels and salts To prevent this issue, it is essential to avoid using lead solders, zinc linings, copper pipes, brass regulators, and copper fittings Instead, equipment should be replaced with materials such as stainless steel, carbon steel, or aluminum for better compatibility with biodiesel.
Table 3 outlines materials recommended for use and those to avoid when handling biodiesel (B100) While this list is not exhaustive, it is crucial that the material quality aligns with the specific application It is advisable to consult B100 product suppliers and equipment vendors for the latest information on material compatibility in bio-component applications.
Diesel fuels with low biodiesel concentrations, specifically at 10% v/v or lower, generally have minimal impact on fuel distribution system materials, though nitrile rubbers may show some sensitivity Despite this, it is advisable to avoid certain metals listed in Table 3 to reduce the risk of metal pick-up, even in diesel fuel blends.
6 This section used by permission from the CONCAWE Guidelines for handling and blending Biodiesel.
Tankage
To ensure effective operations, the number and size of tanks must be adequate for settling, testing, cleaning, and maintenance needs Additionally, it is essential to consider the reliability of supply, batch volumes, and delivery frequency.
All new vertical tanks or existing tanks having new bottoms installed should have at least the floor and first (bottom)
According to API 652, the internal coating of walls should extend 3 feet and be in white or light colors to facilitate inspection Additionally, all new horizontal and small vertical tanks, with a capacity of 30,000 U.S gallons or less, must have internal coatings applied throughout.
Tank fittings are essential for enabling access and conducting critical operations during both static and dynamic processes They ensure the safe movement of air, products, and personnel, thereby maintaining operational integrity and product quality However, improper installation and maintenance can lead to contamination and degradation of product quality To mitigate these risks, all vents must be equipped with screens or designed to prevent the entry of contaminants.
Table 3—Material Compatibilities with Biodiesel (B100)
Polytetrafluoroethylene Chloroprene Fluoroelastomer Natural rubber
Hypalon Styrene-Butadiene rubber Butadiene rubber
All tanks must include a low point sump with a drain line and valve for effective removal of water and sediment Excessive water accumulation in product tanks is prohibited, and tanks should be designed to facilitate efficient water draw Sufficient manholes must be installed for gas-freeing, inspection, and cleaning, along with provisions for representative sampling according to ASTM D4057 and API MPMS Ch 8.1 Fill connections and gauge openings should have tightly fitting covers to prevent contamination and evaporation Additionally, each tank must have separate inlet and outlet piping to ensure that dispensed products originate from the tank, not from untested incoming lines Finally, all tanks should be clearly labeled for easy identification of the stored product.
Ethanol, whether in its pure form, as fuel ethanol, or in gasoline-ethanol blends, can be stored in terminals using fixed roof tanks or tanks with internal floating roofs A key factor in the storage of ethanol is ensuring it does not come into contact with water.
External floating roof tanks are exposed to environmental conditions, which allows precipitation to seep past the roof seals and contaminate the stored product Additionally, rainwater can enter the tank through a faulty roof drain Consequently, the use of external floating roof tanks is not advisable for storing ethanol or ethanol blends.
Ethanol is hygroscopic, meaning it readily absorbs water and forms a uniform solution with it, which can lead to contamination in gasoline-ethanol storage tanks Unlike gasoline, which is hydrophobic and has low water solubility, the addition of ethanol increases the overall solubility of water in ethanol-gasoline blends Understanding the impact of water on these blends and how to detect it is essential for ensuring better fuel quality.
Water can enter storage tanks through unintended openings in the tank shell or roof, especially during rain or snow External floating roofs are particularly vulnerable to water ingress during bad weather Additionally, temperature fluctuations and high humidity can lead to condensation forming on the inner surfaces of tanks above the internal floating roof If enough condensation accumulates, it can drain past the floating roof seals into the stored liquid product.
Stress corrosion cracking occurs in susceptible metals or tough thermoplastics due to the combined effects of tensile stress and exposure to corrosive environments Ethanol can create such corrosive conditions, making it essential to consider this factor in the design and construction of storage vessels.
It is recommended that API 1626 and API 939-E be referenced when preparing an operation for ethanol service.
Biodiesel (B100) must be stored at temperatures at least 6 °C above its cloud point, and above-ground storage tanks should be insulated or equipped with heating systems to protect against climate variations The heating system should be designed to avoid hotspots and limit the biodiesel's exposure to high temperatures Additionally, incorporating agitation is essential, as slow agitation can prevent the accumulation of precipitates at the tank bottom and assist in redissolving any that may form in the fuel.
Product Receipt System Design
This section refers to product receipts from pipelines, marine vessels, rail cars and trucks.
Where product is supplied to a terminal via an external source, the product receipt system shall maintain the quality of the products being transferred
The following shall be considered:
— Interface pressures and change of pressure ratings for components (i.e filtration equipment)
— Facilities to collect product discharged from pressure relief systems, cloudy fuel arising from pipeline pigging and other product quality issues
— Information systems to provide the following:
— volume of fuel received during a transfer,
— Other measures and information as appropriate and relevant to product quality.
Pipework within Storage and Distribution Terminals
5.4.1 Segregation of Fuels and Components
In the facility product system, it is essential to keep each type and grade of fuel separate, with the exception of specific pipework used for mixed cargo discharge from coastal and inland vessels, as well as for receipts from multi-product pipelines or systems designed for blending products and components.
To ensure product quality control, it is essential to implement positive segregation of lines In multi-tank storage terminals, both the inlet and outlet lines connected to each tank must be equipped with appropriate fittings.
— a valve arrangement designed to isolate product and prevent bypass via pressure build up either by temperature changes within isolated sections of pipe or due to static head pressure;
— a removable distance piece (pipe spool and blind flanges); or
— a spade or spectacle blind; and
— double block and bleed valves where appropriate
Piping configuration and the flow profile that allows contaminants to accumulate shall incorporate means for drainage at low points
When designing or modifying a site, the use of recirculation piping or mixing nozzles should be considered Among other advantages, recirculation piping allows:
— product being pumped from the storage tank through a filtration train (if available);
— product being pumped through a fuel additive system to meet customer requirements; and
— mixing for homogeneity and seasonal conversion.
Recirculation piping should be designed with appropriate controls to ensure tank bottom water and sediment are not carried out with the product during delivery
All piping and valves in receipt and loading systems must be distinctly labeled It is essential to display the product name, utilize color coding, and indicate flow directional arrows at all connection points, as well as on both sides of any sections where the pipework is not visible.
Component and Fuel Blending Systems
Fuel blending systems must be engineered to automatically mix fuel grades or components at specified concentrations Additionally, the control systems should be capable of halting the blending process and refraining from issuing a Bill of Lading if any components fall outside the defined blend tolerances.
Accurate measurement of blend components and finished product volumes is essential for compliance with regulatory standards Fuel ethanol and gasoline meters can be precisely calibrated due to their consistent properties Temperature variations affecting volume can be adjusted using temperature coefficient of expansion tables, with each component having its specific expansion table as outlined in API MPMS Ch 11.1.
The accuracy of a meter is influenced by the location of the blend point When the smaller blend stock is added just before the delivery meter, there may not be enough distance for proper mixing, leading to inconsistent stream characteristics and inaccurate volume measurements To enhance measurement accuracy, it is recommended that the blend point be positioned at least 6 feet upstream of the delivery meter.
Road and Rail Transport Loading and Unloading
Bottom loading and unloading of road and rail transports is the preferred method of product transfer
Top loading and unloading should only be performed under cover to avoid weather hazards and the associated product contamination
— The use of drop tube or stingers for unloading should be avoided to reduce risk of the following:
— excessive sediment buildup on the bottom of the vessel;
— excessive remaining onboard (ROB) quantities of products; and
Filtration
Filtration systems are essential for preventing contamination from particulates and foreign materials They can be installed on various transportation methods, including trucks, rail, pipelines, and marine vessels, allowing for sampling both before and after the filtration process.
Where filtration exists, the system(s):
— shall be sized consistent with the expected flow rate and product type;
— may include two or more vessels to allow for bypassing a single vessel without interruption to operations;
— shall have a differential pressure monitoring system or equivalent to ensure system integrity;
— shall include air eliminators to reduce risk of internal fire or explosion that may affect filter integrity and product quality;
— shall be fitted with a pressure or thermal relief valve where flow is redirected such that product quality is preserved;
— shall include low-point drain ports to monitor and evacuate water from the vessel;
— may include a water defense system that would shut down flow or trigger an alarm when unacceptable water levels are detected; and
— shall ensure a minimum of 95 % efficiency for media sizes that are consistent with internal specifications, customer and regulatory requirements.
NOTE The use of filtration systems may increase the buildup of static electricity within the product Refer to API 2003 for specific guidelines.
6 General Operating, Maintenance, Inspection and Test Requirements
Planned Maintenance, Inspection, and Testing
A system of planned maintenance, inspection, and testing shall be established and records kept for all product quality activities.
Filtration Equipment
All strainers, filtration, and water separation equipment shall be checked and maintained regularly (see Section 7).
All service filter vessels must document the dates of their last inspection and the last element change It is advisable to display these dates directly on the vessel's body or on an attached information plate.
All service filter vessels must display filter element and vessel bolt torque data either directly on the vessel's body or on an attached information plate If this data is not present on the vessel, it must be documented and maintained on-site.
Tank Movement Indicators (Level Alarms)
Indicators shall be tested at least annually to ensure all components of the system are functioning correctly.
Tank Vents
Annual inspections of all tank vents are essential Any damaged or corroded mesh screens must be replaced promptly Additionally, for pressure and vacuum vents, it is crucial to verify that the pressure weights meet the tank's design pressure rating.
Tank Inspections and Cleaning
When a tank is decommissioned, it must be inspected for cleanliness, and thorough cleaning is required if microbial growth or sediment buildup exceeds 1/5 of the tank's bottom surface Additionally, prompt inspections should be conducted if there are signs of poor fuel quality downstream, such as short filter lifespans, sediment in the finished product, discolored water drainage, or slimy deposits.
Inspection for internal mechanical condition shall be carried out in accordance with local regulatory requirements or per API 653.
Regular inspections are essential to mitigate the risk of contamination from foreign compounds like water, sediment, and rust, as well as to prevent operational failures in storage and handling Internal tank surfaces must be visually inspected for sediment, bacterial growth, and surfactant contaminants, along with an evaluation of the lining's condition to determine if cleaning is required Additionally, the external condition of the tank and its fittings should be thoroughly inspected, with necessary repairs or servicing performed Utilizing checklists will ensure a comprehensive inspection, focusing on critical areas of concern.
— tank base and foundation (e.g for evidence of tank settlement or water “wash-out” damage);
— vent valves, mesh screens, gauge hatches and gauging systems;
— tank-side valves drain lines, sampling systems;
— tank floor leak detection; and
Tank grounding is essential for ensuring safety and preventing electrical hazards A comprehensive internal mechanical condition inspection is crucial for assessing the structural integrity of the tank To maintain product quality, this inspection should encompass various critical aspects, including but not limited to the tank's overall condition and functionality.
— gauge tube and stilling well,
— tank floor low point, and
A report will be created and made accessible for on-site inspection Photographs must be taken to record the tank's internal condition, and all relevant documents should be updated to accurately represent the current state of the tank.
For effective cleaning, it is advisable to use simple flushing techniques and mopping The use of chemicals or cleaning materials is prohibited unless they have been pre-approved, as they may contaminate the fuels stored in the tanks.
Inspection records for the tank must be maintained and accessible for reference, detailing the types and quantities of contaminants such as dirt, rust, sediment, and water.
The dates of the most recent inspection and cleaning shall be stenciled on the tank shell or otherwise documented and stored at the facility.
Piping Systems
Guidance for piping systems can be found in API 2610.
7 Strainer and Filtration Equipment Management
Strainers
Mesh strainers must be drained, opened, and inspected a minimum of twice a year, with inspections spaced at least 180 days apart Additionally, strainers that protect pumps and valves should undergo inspection at least once a year.
Filters
A visual inspection for water and sediment must be conducted on a sample taken from the filter drain while the filter is under pressure This inspection should occur weekly, with the frequency increased as needed to prevent issues.
Draining must persist until all free water and sediment are eliminated, ensuring no visible signs remain It is essential to document the amounts of water and sediment, along with any observable microbiological growth during the sump draining process.
Daily monitoring of differential pressure is essential during manned operations to prevent exceeding the maximum limit, which can be done either manually or through electronic systems Additionally, it is important to record the differential pressure weekly at the maximum achievable flow and to create a graph that illustrates these readings, adjusted to reflect the maximum flow conditions.
The filter used in direct-reading differential pressure gauges shall be checked and replaced as needed whenever filter vessels are inspected or filter element replaced.
All filter vessels shall be opened at annual intervals and inspected internally for the following:
— proper fitting of elements, which shall include confirmation of torque settings; and
— inspection for proper operation of the vessel air eliminator and thermal relief system.
During inspection of the filter vessel, attention shall be paid to:
— any gelatinous or “slimy” contaminants or sludge;
— any “leopard spotting”, indicating the presence of microbiological growth;
— the condition of seals, gaskets, “O” rings and the torque on element securing bolts;
— the condition of ancillary equipment (i.e air eliminators and pressure relief valves);
— any elements showing signs of mechanical damage;
— any signs of electrical static discharge.
A record shall be maintained of the results of the inspection and any repairs performed.
7.2.4 Electronic and Mechanical Water Defense System Check
All electronic and mechanical Water Defense Systems shall be checked annually for proper operation.
Element Change Criteria
These shall be replaced if:
— the differential pressure reaches the maximum limit set by the manufacturer;
— element failure is indicated by a sudden drop in differential pressure;
— samples from the downstream side of the filter contain significant quantities of particulate.
7.3.2 Filter and Water Separators: Coalescer Elements
— if the differential pressure exceeds manufacturers recommended maximum limit;
— if element failure is indicated by a sudden drop in differential pressure;
— if samples from the downstream side of the filter contain significant quantities of particulate; and
— after a maximum of three years in service.
7.3.3 Filter and Water Separator Elements
Polytetrafluoroethylene (PTFE) coated screens and synthetic separator elements can remain in use indefinitely if they meet the manufacturer's water-repellent test criteria In contrast, paper separators should be replaced whenever the coalescer elements in the vessels are changed.
Filter Vessel Change Out Procedure
The filter vessel change out procedure shall address the following:
— a filter element change out shall only be performed by trained staff using manufacturer’s recommended procedures and tools;
— all filtration vessel change out work shall be risk assessed, completely isolated and a work permit issued before starting inspection or maintenance work;
— the lid of the vessel securing bolts shall be torqued in place to the manufacturer’s recommended settings;
To reduce the risk of fire and explosion, it is essential to fill all filter vessels slowly and with care During the filling process, ensure that all air is bled off from the unit.
— filling shall be supervised throughout by a trained operator After filling, all joints and gaskets shall be carefully examined for signs of leakage.
General
Sampling must be conducted by skilled and trained individuals following well-defined procedures and using suitable equipment to guarantee that the collected sample accurately represents the original material.
Samples for certification testing, which require results to be reported to customers, regulators, or to support claims, must be collected following the procedures specified in the test method or by recognized industry standards.
— API MPMS Ch 8.1/ASTM D4057, Standard Practice for Manual Sampling of Petroleum and Petroleum Products;
— API MPMS Ch 8.2/ASTM D4177, Standard Practice for Automatic Sampling of Petroleum and Petroleum Products;
— ASTM D1265, Standard Practice for Sampling Liquefied Petroleum (LP) Gases, Manual Method; and
— ASTM D5842, Standard Practice for Sampling and Handling of Fuels for Volatility Measurement.
NOTE Specific sample types are defined in Section 3.
When conducting in-house confirmation to ensure there is no unacceptable contamination, it is essential to adhere to standard industry practices However, alternative methods that effectively guarantee the samples accurately represent the product being tested may also be utilized.
Sampling—Basic Requirements
Before sampling, ensure that all sampling equipment, including ropes and containers, is clean and free from contaminants For light petroleum products, it is advisable to rinse the container with the product before sampling Sample containers must not contain any substances that could influence the test results However, this rinsing practice should be avoided if it would compromise the sample's intended purpose or if it contradicts the nature of the material being sampled, such as in the case of drain samples for water and dirt content.
All metal sampling gear as well as ropes or cords shall be constructed from non-spark generating materials
Sample containers should conform to the requirements listed in Table 4
The operator carrying out the sampling shall wear clean gloves impervious to finished fuels, components, and additives to prevent contamination of the sample
Sampling points shall be designed to prevent the intrusion of water, dirt and other foreign material
Precautions must be implemented to preserve the integrity of the sample and protect it from contamination due to adverse weather conditions and environmental factors.
Sample containers shall be securely closed immediately after the sample has been taken
Samples must accurately represent the material being tested For tank samples, they should be collected from a gauge hatch or another appropriate opening that allows unrestricted access to the liquid bulk, or from a properly designed piped sampling system.
Representative tank samples cannot be collected using solid gauge tubes, which are commonly found on various external and some internal floating roof tanks The solid boundary created by these tubes restricts the free flow of liquid, rendering samples taken from them ineffective for accurately assessing the properties of the stored product.
If it is suspected that a sample or set of samples is not fully representative, a further sample or set of samples shall be taken.
Samples shall be free from dirt and water except in the case of samples specifically taken to determine the presence of such contaminants
No sample container shall be completely filled with liquid The ullage space required for certain samples and testing can be found in ASTM D4057 or API MPMS Ch 8.1.
All samples taken must be documented, with sample containers clearly labeled for easy identification and sealed right after collection Relevant information should be included on the label or accompanying documentation as necessary.
— Sample Source (i.e Tank No., Pipeline Batch No., Vessel name and compartment),
— Sample Type (i.e composite, line), and
When samples are required from levels in a tank or bulk container, the order of sampling shall be from the top downwards
Samples of materials that could be affected by light shall be stored in a dark place
When sampling gasoline or gasoline blend components, particularly in high ambient temperatures, it is crucial to handle the sample with care immediately after collection and during transport Inspect the container thoroughly for leaks to prevent the loss of light ends through the cap sealing material.
To ensure the integrity of samples, they must be shielded from direct sunlight and stored in a cool environment to prevent the degradation of light ends and minimize oxidation Whenever feasible, samples should be collected directly into the designated container without transferring them from one sampler to another.
Testing
Testing procedures shall be established to provide confidence that product has not been contaminated.
Sample Retains
Retaining samples is essential for investigating complaints, disputes, or incidents, as these samples are tested to determine the actual product quality and identify any causes of failure within the supply chain Ensuring traceability of batches allows for a focused investigation on the specific samples related to the product in question.
Retained samples play a crucial role in ensuring safety and managing liability, as they are essential for assessing the impact of Product Quality events and determining the need for product recalls.
Retained samples are essential at various stages of the supply chain, including the refinery's finished product tank, pipeline entry, loading docks, and terminal tanks These samples must be collected and stored for a duration that meets internal company policies, customer needs, and regulatory standards The minimum retention period outlined in Table 4 should be extended as needed, depending on how long the product stays within the supply chain.
Table 4 defines the minimum sample size, storage container type and retention time that should be followed. (Continued)
Table 4—Minimum Sample Size, Storage Container Type and Retention Time Sample Type Sample Location Container Size Container Type Retention Time a
Line sample during receipt 1-Quart Glass Until tank is approved for release
Vessel composite prior to discharge 1-Gallon Glass c , Epoxy-lined container or Metal Can b
(or until next receipt if longer than 30 days)
Line sample during discharge 1-Quart Glass Until tank is approved for release
Line sample during loading 1-Quart Glass Retain only if test results indicate off-spec product
Tank composite post-receipt 1-Gallon Glass c , Epoxy-lined container or Metal Can b
30 days (or until next receipt if longer than 30 days)
General
To maintain regulatory compliance and enhance customer satisfaction, it is essential to prevent fuel contamination beyond permissible limits, which can lead to off-specification or unsuitable products Adhering to the following guidelines is crucial in avoiding such contamination.
Product Segregation
Product segregation is necessary to ensure product quality
Segregation involves implementing measures to ensure that tanks are completely isolated to maintain product quality Each tank's inlet and outlet, along with any potential piping connections to different product grades, must be equipped with appropriate fittings.
— double block and bleed valve arrangement (either using single DBB valve or using two valves with a drain arrangement in a pipe spool between them);
100) representative sample Tank composite post-receipt 1-Quart Glass, Epoxy-lined container or Metal Can b
(or until next receipt if longer than 30 days)
Vessel composite after loading 1-Gallon Glass, Epoxy-lined container or Metal
Additive Tank Car 1-Quart Glass 60 days
(or until tank car is empty)
Monthly Tank Composite 1-Quart Glass 30 days
Additive Tank Truck 1-Quart Glass
(or until next receipt if longer than 6 months)
Additive Tank Bottoms 1-Quart Glass
Only retain products if test results show they are off-spec due to poor appearance In cases of product quality disputes, retention times should be extended Soldered metal cans are unsuitable for Fuel Ethanol or ULSD samples due to the risk of sulfur contamination Amber glass bottles should be used when appropriate.
Table 4—Minimum Sample Size, Storage Container Type and Retention Time (Continued)Sample Type Sample Location Container Size Container Type Retention Time a
Dedication involves the use of specific tankage, piping, valves, and filters exclusively for one grade of fuel, serving as a method of segregation This approach is the most efficient way to guarantee product isolation.
To ensure that the product remains uncontaminated and free from unacceptable inter-product mixing, a comprehensive risk assessment must be documented This assessment should encompass various critical elements, including but not limited to specific risk factors and mitigation strategies.
— type of segregation (i.e blank, single valve, double block valve, double block and bleed valve, and valve interlocks);
— potential to exceed maximum design pressure differential across valves;
— potential for contaminant ingress, such as:
— vapor recovery unit return streams;
— water brought in with product;
— timing of valve opening and closing;
— contamination due to lubricating of valve plugs; and
— contamination resulting from mechanical work, startup or shutdown;
— contamination due to product from static lines or static vessels.
Table 5 shall be used as guidance when evaluating the risks of co-mingling products.
Additives
Product additives are intended to be in the finished product for:
— protection and performance of distribution and user equipment
Finished product additives play a crucial role in enhancing product performance and include a variety of components such as detergents, multi-functional additive packages, ignition improvers, lubricity improvers, anti-valve recession additives, flow improvers, conductivity improvers, dyes, markers, and anti-oxidants/corrosion inhibitors.
Additive systems should be integrated into product lines to comply with regulatory and contractual performance and safety standards However, it is crucial to prevent unchecked entry of additives into the product system To avoid over-additization, safeguards must be implemented to ensure that additives are not introduced during shutdown periods.
Product and Component Inventory Variations
Inventory variations can signal potential contamination during receipt, storage, and loading processes Any unexplained inventory change exceeding 0.25% must be thoroughly investigated to confirm that no contamination has compromised the product's quality.
Possible causes of unintended product movement may include, but are not limited to:
— improper valve closure from conveyance after receipt completion;
— tank-to-tank movement due to pump or static head pressure;
— line-to-line movement due to failed check valves during loading; and
— improper tank lineups or blend component setups.
Settling
When unacceptable levels of water or sediment are detected during product receipt, it is essential to implement measures that allow the tank to "settle" before release During this settling period, the tank must be properly isolated and clearly marked.
— Distillates One hour per foot depth of fuel from the suction or outlet or 24 hours (whichever is less)
— Gasoline Five minutes per foot depth of fuel from the suction or outlet
Table 5—Potential Effects of Cross Contamination of Products
Gasoline Base Jet Fuel (Wide-cut) 2, 3 1 1 1 1, 6
Residual or Heavy Distillate Fuels 2, 3, 4, 5 2, 4, 5 2, 6 2, 5, 6
In operations requiring rapid product turnaround, such as "live to the rack" processes, it is crucial to implement special measures to prevent the delivery of tank bottoms, including water, sediment, dirt, and rust, with the product The procedures may differ depending on the tank bottom design, as cone down tank bottoms are less likely to introduce contaminants during delivery.
When using externally controlled mixers, such as paddle mixers and recirculation pumps, to achieve uniformity in the tank, settling times should commence only after the mixers are turned off.