10 TRANSPORTATION: FACILITIES AND PROCEDURES
10.4 DRUM AND INTERMEDIATE BULK CONTAINER FILLING AND ISO TANK CONTAINER LOADING
10.4.1 General
If aviation product is to be supplied in drums, Intermediate Bulk Containers (IBC) or ISO tank containers, the requirements of 10.4.1 to 10.4.3 shall be applied.
To meet these requirements, locations where drums or IBCs are filled or ISO tank containers are loaded shall have documented procedures and systems in place to ensure quality (as well as health, safety and environmental) considerations are adequately managed. These should include:
− Procedures for the inspection of new and used drums, IBCs and ISO tank containers, including defined rejection criteria.
− Systems to ensure adequate control of any drum or IBC flushing, cleaning and waste disposal.
− Procedures to ensure drum or IBC filling or ISO tank container loading is carried out safely, including consideration of manual handling requirements, bonding, fire hazards and spill hazards.
− Procedures for the storage and release of product in drums or IBCs and ISO tank containers.
− Recognition of any statutory requirements applicable to drum and IBC filling and ISO tank container loading operations.
10.4.2 Drums and IBCs
Drums are typically of 210 litres (55 USG) capacity, and of a design to protect against mechanical damage to the lining. Drums should comply with ISO/ANSI MH2a or ISO 15750-2. IBCs are rigid reusable containers up to 1 500 litres (396 USG) capacity. Drums and IBCs can be used either for international transportation by sea, rail or road or for use as temporary storage.
10.4.2.1 Materials of construction
Drums used for storage of aviation fuel shall be manufactured from steel. They shall be lined with a suitable lacquer or lining meeting EI 1541.
Under no circumstances shall internally galvanised drums or plastic drums be used.
Any material used for the sealing/seaming of the bottom and top of drums shall be compatible with aviation fuel.
Any sealing material used in the manufacture of drum closures and bungs shall be compatible with aviation fuel.
IBCs used for storage of aviation fuel shall be manufactured from stainless steel or aluminium. Under no circumstances shall internally galvanised IBCs or plastic IBCs be used.
10.4.2.2 Filling equipment
The filling system for each grade of product shall be fully segregated to provide complete protection against cross-contamination. The product grade name and colour code shall be clearly displayed on all filling equipment, tanks, pipelines, etc. (in accordance with EI 1542).
Since aviation fuel in drums or IBCs will normally be supplied directly to aircraft (and may not be filtered during fuelling), filling equipment for Avgas or jet fuel shall include a filtration system as used for into-plane filtration, i.e:
− A filter monitor meeting EI 1583, 6th edition, or
− A filter/water separator meeting EI 1581, 5th edition,
− or for Avgas only, a microfilter meeting EI 1590, 2nd edition.
NOTE: filter monitors shall not be used with jet fuels containing FSII.
Filling shall be accomplished in such a way as to avoid "splash" filling, for example by use of a stand pipe. The drum or IBC shall be bonded to the filling equipment and/or grounded through the rollers or through a dedicated grounding strap beneath the drum or IBC being filled.
10.4.2.3 Quality control
Provided that product is available for Release as defined in chapter 8, then no further testing is required before filling begins.
Every empty drum or IBC (including those that are new) shall be examined internally before filling to ensure that it is in a satisfactory condition, i.e. clean and free from rust, water, manufacturing oils or other contaminants and, for drums, free from lining defects.
Before filling, drums shall be colour coded (in accordance with EI 1542) and, for drums and IBCs, clearly marked with the grade of fuel, specification to which the aviation fuel was manufactured, batch number, filling date, date of retest (if applicable), quantity, filling location and 'leaded fuel' statement if applicable.
After filling, a Control Check shall be carried out on a representative number of drums or IBCs. The drums or IBCs chosen shall include the first and last one filled, and the first and last ones when there is a change in fuel batch. Drums or IBCs shall be sealed immediately after filling with grade-marked tab seals.
All consignments of drums or IBCs released shall be covered by a Release Certificate.
10.2.2.4 Re-Use of drums or IBCs
A drum or IBC may be re-used provided that:
− In the past it has only been used for the grade of aviation fuel with which it is to be re-filled.
− The interior is inspected, rinsed and found to be satisfactory. Only the grade of fuel with which it is to be filled shall be used for rinsing and the fuel downgraded to non-aviation use afterwards.
− For a lined drum, the lining is free of any damage, cracking, flaking etc.
− A record of inspection is maintained.
− All labelling is updated.
− Whenever an aviation fuel drum or IBC is to be filled with a non-aviation product, the old grade marking and colour identification shall be completely obliterated before refilling.
10.4.2.5 Storage
Whenever possible, the use of well-ventilated buildings is recommended for storage.
Storage outside of buildings is acceptable, provided that a means of protection against environmental exposure (precipitation, sunlight) is provided.
DRAFT EI/JIG 1530 FOR STAKEHOLDER REVIEW. Copyright © EI & JIG 2012 EI12/059 Please submit any comments to [email protected] by 4 January 2013
Drums should be stored horizontally with bungs below the liquid level. The bottom drums shall be held in position (e.g. by wedges) to prevent collapse of stacks. Where this is not possible, drums may be stored upright (typically on pallets) provided that they are stored under cover, or stored with drum top covers for not more than 3 months (before release).
IBCS should be stored upright (typically on pallets) and under cover.
Consignments should be stored in separate batches to facilitate periodic inspection, and issued in rotation according to filling date, preferably first in – first out.
Drums and IBCs shall be inspected for leakage after filling, initial storage and monthly thereafter. Markings shall be checked and renewed as necessary to maintain clear identity of the information listed in 10.4.2.3.
Batches remaining in stock twelve months after the filling date, and at six monthly intervals thereafter, shall be sampled and the product subjected to a Periodic Test.
10.4.2.6 Sampling and testing
If a batch of packaged stock requires a Periodic Test, the number of containers to be sampled, and the actual number of Composite Samples required for laboratory testing shall be in accordance with Table 16.
Table 16 - Number of sampl es to be drawn and analysed
Number of drums/IBCs Number of samples taken Number of composite samples analysed
1-3 All 1
4-64 4 2
65-125 5 3
126-216 6 3
217-343 7 3
344-512 8 3
513-729 9 3
730-1000 10 4
1001-1331 11 4
As an example, if there are 250 containers in a batch, samples will be drawn from 7 containers at random. Of these 7 samples, three random (but identifiable) samples should be mixed to form one Composite Sample, two others mixed to make another sample, and the remaining two to make a third sample, thus giving a total of THREE Composite Samples to be actually analysed, as indicated in the table.
Where the results of testing are unsatisfactory, the batch shall be quarantined and the issue investigated .
10.4.3 ISO Tank Contain ers 10.4.3.1 Definition
This section details the use of ISO IMO Type 1 tank containers in the capacity range of 20m3 to 50 m3. They can be used either for international transportation by sea, rail or road or for use as temporary storage.
10.4.3.2 Materials of construction and design
ISO tank containers used for storage and transportation of aviation fuel should be manufactured from stainless steel, aluminium or carbon steel. Carbon steel ISO tank containers should be lined with a suitable lacquer or lining meeting EI 1541.
The ISO tank container should have a drain line and suitable valves to facilitate the drawing of samples and drainage of water, and to facilitate cleaning.
All top tank access chamber and dip point covers shall be sealed completely against the ingress of water and/or dirt. Filling should preferably be via bottom loading.
10.4.3.3 Loading facilities
The supply tank and filling system for each grade of product shall be fully grade segregated to provide complete protection against cross-contamination. The product grade name and colour code should be clearly displayed on all tanks, pipelines etc.
ISO tank container filling equipment for Avgas and jet fuel shall be fitted with a filter. This shall be:
− A filter monitor meeting EI 1583, 6th edition; or
− A filter/water separator meeting EI 1581, 5th edition;
− or for avgas only a 5 micron microfilter meeting EI 1590, 2nd edition.
NOTE: filter monitors shall not be used with jet fuels containing FSII.
Loading connections should be fitted with couplings of a size and type chosen to give the maximum practical degree of grade security.
10.4.3.4 Change of grade
ISO tank containers are used to carry a wide range of cargoes/grades of petroleum, and non-petroleum products. They are rarely dedicated for use for one specific grade, or product group/type, and for this reason there is the risk of cross-contamination from previous cargoes unless stringent control measures are implemented. ISO tank containers shall be either:
− drained (and deemed acceptable for use) (Procedure A in Table 17), or
− drained, gas-freed and cleaned, typically by a specialist contractor, (and deemed acceptable for use) (Procedure B in Table 17), or
− rejected as unacceptable following assessment by a specialist.
When changing from one grade to another, procedures A or B from Table 17 shall be applied to ensure that there can be no product contamination from any residues of the last grade carried.
DRAFT EI/JIG 1530 FOR STAKEHOLDER REVIEW. Copyright © EI & JIG 2012 EI12/059 Please submit any comments to [email protected] by 4 January 2013
Table 17 - Requirements for ISO tank container grade changes
Previous Product Carried Grade to be loaded
Jet fuels Avgas
Avgas A A
Motor gasoline (leaded or unleaded) A A
Kerosine A A
Jet fuels A A
Gas Oil or diesel including ultra-low sulphur diesel and biodiesel containing up to 15% FAME
B B
Black oils, other chemicals, lubricating oils, vegetable oils and biodiesel containing greater than 15% FAME
* *
A: The ISO tank container shall be drained completely until no liquid remains (drainings to be downgraded to non-aviation use). The ISO tank container shall be internally inspected through the tank access chamber to ascertain that it is clean and dry. If sludge or dirt is present, it shall be cleaned out.
The intention of procedure A is to allow Product Quality Inspectors to be satisfied that the next grade can be loaded safely and delivered in an uncontaminated condition. If the ISO tank container cannot be left in a suitable condition for filling by using procedure A, then it shall be gas freed and thoroughly cleaned. Detergents or cleaning chemicals shall not be used.
In circumstances where procedure A is not permitted due to automatic loading and/or vapour recovery systems, then local procedures which meet these additional requirements shall be developed.
B: The ISO tank container to be gas-freed and subjected to cleaning following specialist advice. Detergents or cleaning chemicals shall not be used.
*Specialist advice is required on a case by case basis. Issues to consider include surfactancy, water solubility, presence of trace metals, presence of additives, presence of nitrogen-containing components, whether it is a hydrocarbon. This assessment will either conclude that specialist cleaning is required, or that the ISO tank container is to be rejected as not suitable.
After any cleaning is carried out, a cleaning certificate should be prepared and be available for review prior to loading.
10.4.3.5 Quality assurance
Provided that product is available for Release as defined in chapter 8, then no further testing is required before loading begins.
The cleaning certificate, if applicable, should be reviewed.
The ISO tank container shall be inspected to ensure that it is clean and free of water before loading. To avoid working at height, this may be done by checking the low points and draining any traces of water or particulates.
On completion of loading the ISO tank container shall be checked by the fuel supplier for the presence of free water and any found shall be removed.
After filling, ISO tank containers shall be clearly marked with the grade of fuel.
Before dispatch, all ISO tank container openings shall be secured and sealed by the fuel supplier.
All ISO tank containers released shall be covered by a Release Certificate.
DRAFT EI/JIG 1530 FOR STAKEHOLDER REVIEW. Copyright © EI & JIG 2012 EI12/059 Please submit any comments to [email protected] by 4 January 2013