Leaflet No.4

XYZ Engineering Services Design & Construction of Dynamic Superstructures REF: SAB-033/2003

REV: 00 PAGE 1 of 1 [email protected]

SUBJECT: MINIMUM REQUIREMENTS FOR ROAD TANK VEHICLES

ONE LEAFLET

Minimum Requirements for road tank vehicles

Draft Requirements

DOC. NUMBER SAS- 004/ 2010 RELEASE DATE 01 JUNE 2010 RELEASE STATUS DRAFT - One fleet team

1‐GENERAL

The following technical specifications are intended to improve the standardization; the general safety and the quality of the products handled on behave of JPRC. The specification is written for NEW rigid tank trucks or tractors to be coupled with a tank semi trailer and articulated vehicles with a maximum gross vehicle weight as allowed in The Hashemite Kingdom of Jordan traffic rules, for which they are designed and to carry petroleum products, as motor spirits and automotive diesel (ADR Class 3, number 3b, 31c, 41c and 71). Road vehicles -- Mechanical couplings between tractors and semi-trailers -- Part 2: Interchangeability between low-coupling tractors and high-volume semi-trailers ISO 1726-2:2007 specifies dimensions to ensure interchangeability between a low coupling height tractor vehicle and a coupled high-volume semi-trailer, the two together constituting a high-volume articulated vehicle. It specifies certain interchangeability dimensions, including those of the optimized gooseneck contour, as well as operating dimensions related to angle values. The specifications are primarily intended to permit semi-trailers to be coupled with two-axle tractors. However, three-axle tractors are not excluded, provided they are in compliance with the requirements of ISO 1726-2:2007. Maximum Gross vehicle weight: (Jordanian Traffic Rules/ Ministry of Public works & housing-Jordan) Rigid truck equipped with two axles : 18 ton on the road Rigid truck equipped with one steering and two rear axles: 24 ton on the road Tractor + semi-trailer (road trains with min. 5 axles) : 40 ton on the road Tractor + semi-trailer (road trains with min. 6 axles) : 51 ton on the road Tractor + semi-trailer (road trains with min. 7 axles) : 55 ton on the road

The truck, chassis and superstructures, tanks and there equipment should comply with the existing National and international regulations, CATEGORY O4

* For road vehicles carrying dangerous goods, ADR 2011 ADR: European agreement concerning the international carriage of dangerous goods by road.



Edition: January 2011 ref.: UN - ECE/TRANS/115 - - ISBN 92-1-139055-9

2‐TRUCK ‐ TRACTOR CHASSIS

Truck or tractor chassis must have a local type approval, and sufficient original factory service must be available in the area were the vehicle will operate. The vehicle must minimum be equipped with: 2.1 Low type “Day cabin”. 2.2 Diesel engine according the EURO 2 emission criteria. Min. 6 kW/ton. If utilized in flat country area. Min. 7 kW/ton. if utilized in slightly hilly country. More than 8 kW/ton in mountain areas. (Consumption figures to be specified according to DIN specs.) 2.3 The Noise level at Full power shall not be more than 89 Dba in the cabin at the driver’s seat. 2.4 Fully synchronized gear box min. 6 speed range change of sufficient performance. It will in conjunction with the final drive give a governed road speed of 90 Km/h and capable of 30% grad ability performance when fully loaded. (Half or fully automated gear box will be considered if separately quoted for) 2.5 Deferential lock on driving axel(s). 2.6 If tractor: - 4 x 2 type axle configuration. ( if allowed for the local maximum Gross Vehicle Weight ) - Fifth wheel (GF) to couple with standard 2" king pin, at a height of not more than 1250 mm above ground, but as low as possible, for the tractor giving sufficient clearance for the semi-trailers during road travel. If truck : - Several axel configurations are possible, 4 x 2, 6 x 2, 6 x 4, 8 x 2, 8 x 4. Depending upon the local circumstances preference must be given to 6 x 2 with eventually a assisted steering axles at the rear ( front axle of the rear bogie.) - All connectors for Air and electricity supply to the semi trailer shall be mounted on a separate chassis easy accessible for connection and disconnection behind the cabin. 2.7 Air suspension with suitable shock absorbers is preferred for all axles; it is normal practice for all tucks with a GVW over 20 T. For larger vehicles it is required to have air-suspension on the driving ( rear ) axle and on all running axles, ( Parabolic springs are eventually accepted for the steering axle ). Anti roll bars to be fitted only if required to give a better (proven) ride performance. 2.8 Brakes : According to the latest EEC-, and locale regulations including; “Preferable” disc brakes with ABS or EPS Minimum requirements : Full air dual system spring brake parking A.B.S. on all axles Air Dryer Automatic slack adjusters Automatic load dependable brake adjusting Asbestos free brake lining to be mounted



2.9 A continues service brake system ( endurance braking system ) need to be provided in accordance with Marginal 220.522 & 220.535 of the ADR regulation, which performance is sufficient to reduce the speed of a fully loaded truck ( 40 ton tractor and trailer ) in accordance with the requirements the ECE regulation No 13 and ADR. The retarded, exhaust- or Jacobs brake shall be fitted so, as when activated the brake lights will operate.

2.10 A speed limiter will be installed set at the maximum national speed limit for the type of truck in which it will operate or 90km/h whatever is the lowest. 2.11 Electrical installation of 24V with master switch and remote knock off button located in the cabin. The Battery box shall have an acid resistant insulated cover. 2.12 Fuel tank with a minimum capacity of one day’s driving range. For smaller rigid trucks this is approx. 100liters Up to 250 liters for a tractor - semi trailer combination. 2.13 Fully integrated power steering to give a turning circle kerb to kerb as short as possible but not greater

than 15 m.

2.14 Air bags if available but Seat with 3 point seat integrated safety belts are a mandatory requirement to be installed on all seats having an independent suspension.

3‐ADDITIONAL EQUIPMENT FOR TRACTORS & RIGID TRUCKS 3.1 Tachogaph according the International and local legislation. (The Tachograph must continue even

when the master switch is in the OFF position.) 3.2 2 front, 1 rear fog lamp(s) 3.3 Mirrors as described SABRA standard “Minimum Requirement for Mirrors on tractors/trucks”. 2 rear mirrors, one at each side, Normal + wide angle vision 1 Kerb finding mirror Front bumper visibility mirror (for flat nose cabins ) 3.4 Engine and gearbox compartment (between cabin and fifth wheel for semi trailers and from cabin until the end of the gearbox for rigid trucks) to be covered with an easy detachable Aluminum anti slip cover plate. 3.5 If the exhaust is mounded behind the driver’s cabin, it should be covered by a metal plate, protecting product to drip on the hot pipe. Exhaust pipes mounted with the outlet at the top of the truck are forbidden. 3.6 Tow hooks (front and rear) and tow bar. 3.7 ADR requested equipment (Orange indication lamps, ADR plate, maintenance equipment etc.)

3.8 All wheels should be of the single rim type. This applies also for trailers and semi trailers. 3.8 All wheels to be equipped with clear pass mudguards this applies also for trailers and semi trailers. 3.9 1 Fire extinguisher 6kg ABC powder mounted adequately protected against dirt and spraying water at the driver’s site, this is extra to the legal required extinguisher in the driver’s cabin.

4‐TANKS ON RIGID TRUCKS AND SEMI‐TRAILERS



4.1 General

The specification is written for tanks which shall carry light petroleum products, as motor spirits and

automotive diesel (ADR Class 3, number 3b, 31c, 41c and 71). The tanks should comply with the existing National and international regulations, * For road vehicles in general, * For road vehicles carrying dangerous goods, * Any other national or international legislation which might be applicable on this equipment while

travelling on the road or during loading and discharge:

- EU directive 94/63/EC dd. 20.12.94 (Vapor recovery directive) - ADR

- CEN 296 - Etc. (this is a non limitative list).

4.2 Tank shell

4.2.1 Tank Shell

The tank shell should be made of a light metal steel or aluminum.( If ALU is used the Barrel and all structural elements3 as welded construction etc. will be made out of aluminum alloy AlMg4,5Mn W28 cold rolled complying with DIN 1725 ( AD merkblatt W6-1 / TRB 100 ADW 6-1) or by SABRA accepted equivalent ALU). The construction must be done according to the highest possible standards, taking into account the requirements of ADR. The tank should have the lowest possible centre of gravity which for box-shape tanks should not exceed 2.2m in loaded condition, and for circular tanks not more than 2.35m.

4.2.2 Tank shape

The tank shape is free to be chosen, box or circular, but the total carrying capacity and overall stability of the tank is very important to SABRA. A static tilt angle in loaded condition of 25° must be possible.



4.2.3 Tank mounting

The tank should be mounted in such a way that in any possible loading situation, all compartments can be completely drained if the truck is parked under an angle of max. 4° in any direction. The maximum volume left in a compartment and its drain pipes is 100 ml. (excluding the volumes in eventual measuring systems).

4.2.4 Supplementary requirements

Inside each compartment with ullage of more than 4.500 liter one additional baffle plate is required. All baffle plates- and participation-plate in double-S-form (In accordance with THESEUS study) with a thickness of min. 3 mm and the same material as the tank shell. End-plates of the tank in front and at the rear will be made as double-wall-end-plates with a minimum thickness of 4 mm. in accordance to Marginal 10220 (1) of ADR.

4.2.5 Deflector / Static electricity

The liquid input when bottom loading a vehicle tank compartment should be effectively controlled, e.g. by means of foot valve design or a baffle, to minimize turbulence from the jetting or spraying of product and thereby undue generation of static electricity. The maximum distance between any point in a tank compartment and the nearest conductor, tank shell, partition or baffle plate should not exceed 0.8m. This is to reduce the maximum static energy possibly build up at the surface of the liquid during loading. All conductive parts of the mounted equipment possibly in contact with the product should be bonded the tank shell with a resistance of less than 10 ohm.



4.2.6 Manholes / Inspection cover

Each compartment will have an opening for inspection. Whether quick operable manholes (fill cover) or bolted inspection covers will be fitted, will depend on the operational area for that specific vehicle, however both need to be designed so that they are mounted internal to the tank shell.

All manholes will be of the self latching type with double locking mechanism.

5‐LOADING REQUIRMENTS

5.1 TOP LOADING

If designed for top loading a suitable access ladder at the rear of the tank with wide anti slip stairs will be provided. The top of the tank will be equipped with foldable hand rail protection against people falling of the tank; the handrail can be operated from ground level or from the rear ladder. Suitable protection for the tank top equipment (pneumatics / electrics etc.) must be installed.

5.2 BOTTOM LOADING

If the tank loading installation must be of the bottom loading type, The requirements are according to annex IV of the EU directive 94/63/EC dd. and the requirements in the draft CEN document with regards to “Operating conditions “(issued by CEN/TC296WG4) Each compartment must be equipped with an incorporated high level/overspill detection system according the Draft CEN standard 296007 (latest version)

Local or national industry practice may change. An approved overspill detection system needs to be in place for all vehicles equipped for bottom loading

The bottom loading couplings should be 4" API and installed on the off side of the road tank vehicle in accordance with ANNEX IV of the EU Directive 94/63/EC and the above mentioned code of practice. The couplers should be adequately protected to prevent unauthorized tampering.

Bottom loading coupling location The road tank vehicle couplings should be installed within an envelope as mentioned in ANNEX IV but taking in to account the optimum ergonomically height for easy coupling and uncoupling of 4" hoses by the drivers.



5.3 Piping

The design of the road tank vehicle piping system, including any components between the bottom loading coupling and the compartment foot valves, should be suitable for at least 500 kPa working pressure and should not leak at 2 times working pressure. The piping system shall be capable of withstanding 1,500 kPa and "shock" loading conditions, such as may occur if the foot valve is closed against flowing product in an emergency situation. Note :

(i) It shall be the responsibility of SABRA to ensure that the equipment is correctly designed and installed to withstand the maximum operating pressures stated in the specification, and in those situations where truck-mounted overfill systems are fitted, the surge (i.e. shock pressures) which can occur on operation. It is brought to the SABRA attention that devices, such as air eliminators, when fitted with floats, are liable to damage at pressures greater than 600 kPa. SABRA is advised to consult with the manufacturer of his equipment. Any component which does not meet these requirements, e.g. a lower rated unloading system, should be isolated from the bottom loading system. (ii) The design of the truck metering and pumping system must be capable of withstanding a filling pressure of 600 kPa during loading (i.e. working pressure), with parts of the piping manifold and truck equipment not able to withstand this pressure isolated during the filling of the truck. Quick closing on board truck valves shall not be operated during loading, due to the very high surge pressures which can be generated at 2,500 L/min. since the pressure generated during closing can greatly exceed 600 kPa.

5.4 Foot valve

Foot valve (normally pneumatic actuated or mechanically) shall have a closing characteristic which minimize surge pressure generated under maximum product flowing conditions. The (ND 100) valve fitted shall have a closure time against pump pressure of not less than 2.3 seconds, and not greater than 4 seconds.

5.5 Vapor venting (for bottom loading tanks with vapor recovery )

The vapor manifold vents installed should be of sufficient capacity to prevent damage to the vehicle tank from vapor pressure, at the maximum loading rate. They must be opened in sequence with the foot valves and by the same operating control. (the foot valve may not be opened without the vent valve is being opened before ). The pressure/vacuum valves fitted to the tank to permit it to 'Breathe' under normal operating conditions, should be designed to limit the internal tank compartment pressure in static conditions to + 12 kPa +/- 5 and - 2 kPa +/- 5.

5.6 Vapor recovery



5.6.1 General

The design of the vapor recovery system should permit complete drainage by gravity of any liquid accumulating in the system. The design should also permit easy gas freeing of the tank for repair. The vapor collection manifold should have a minimum area equivalent in cross section to a ND 100 pipe, terminating in a ND 100 vapor recovery coupling. The connection from each compartment to the manifold should have a minimum area equivalent in cross section to a ND 75 pipe. (ND 65 if no detonation or flame arresters need to be installed) The vapor collection manifold may be either a separate pipe or the roll-over coming and the vapor vents should adequately seal it to prevent product entering the manifold during conveyance. A common manifold is adequate for vapor recovery when transporting mixed loads of motor spirit and automotive gas oils.

5.6.2 Vapor recovery coupling

The vapor recovery coupling should be in accordance with the national industry standard. Provisions must be made to allow the easy installation of a ND 100 coupler / valve as required by the EU Directive 96/35/CE ANNEX IV. The road tank vehicle vapour recovery coupling should be allocated as required by EU directive 96/35/CE ANNEX IV and the above mentioned code of practice.

5.6.3 Vapor recovery system protection

Any vapor recovery equipment installed on the top of the tank should be protected from damage in the event of overturning of the vehicle. This may preferably be achieved by enclosing it within the contour of the tank shell, or by a rigid coming welded to the tank shell.



Or to use the roll bars protection in the top of the tank via top walkway as shown.

ROLLBARS ALONG ITS TOP



5.6.4 Vapor recovery hose

To avoid confusion, the vapor recovery hose should be BLACK in color.

5.7 Liquid venting

The tank venting system should be of sufficient capacity to prevent damage to the vehicle tank liquid pressure at the maximum loading rate in an overfill condition.

5.8 Overfill protection 1. Overfill Protection system will be min. of a 5-wire optical system, according the draft CEN standard CEN: 296007,( unless the local industry standard is requiring another type ). 2. A high level cut-off probe approved compatible with the used monitor and certified to CENELEC E.E.x i.a., Group 11 EN50039 i.a. for use in petroleum products, should be installed in each compartment of the vehicle. 3. The vehicle high level cut-off system wiring should be both physically and electrically isolated from other vehicle circuits by the use if dedicated conduits and junction boxes. 4. Where a vehicle earth proving connection, i.e. gantry earth connection to vehicle chassis, is to be included in the system then, an resistance of 10 ohms is the preferred value (maximum 100 ohms). 5. Under normal loading conditions the high level cut-off system is required to operate infrequently; therefore physical check for each probe should be made to ensure reliability prior to the commissioning of any tank. 6. The high level cut-off probes should be adjusted to allow a rest flow of min. 150 liters after the system has given the shut down signal.

5.9 Safety interlocks To prevent spillage and/or other hazards, effective means should be provided in the form of interlocks to prevent the vehicle being moved (by applying the trailer brakes or ignition circuit cut down) until all foot valves, and vents are closed and all loading hoses, vapor hose,



earthling and overfill protection cables are disconnected. If the coupling valve levers are fixed, they should be locked in position and immobilized before the vehicle can move.

5.10 Bottom loading a vehicle when vapor recovery is not taking place. Where a vapor recovery system is not available at a loading or discharge stand, the road vehicle's vapor recovery system must vent to atmosphere when loading to prevent pressurization of the tank and it's vapor recovery system. This venting must be realized by a valve opened on each compartment or in the vapor recovery line, this valve will be opened in sequence with the foot valves.

6‐DISCHARGE INSTALLATION

6.1 General Several discharge installations are possible depending upon the final application of the tanker. These discharge installations shall be chosen carefully. Attachment 1 gives limited a number of options. A detailed list and description of the equipment’s, such as meters and pumps have to be agreed purchase or lease.

6.2 Tank equipped with measuring installation(s)5 : The measuring installation(s) will be accessible from the kerb site of the truck. If motor spirits and diesel oil will be transported on the same truck than two systems will be mounted if

designed with conventional volume metric displacement6

meters. One installation will be designed for motor spirit (A1 product ) the other for middle distillates ( A3 product ). Provisions must be taken to retrofit temperature compensation if not required. The middle distillate installation may be alternatively equipped with a pump, to be able to discharge in gravity , pumped direct or trough a hose reel The measuring installations will comply with the existing legislation on Weights and Measures and will be approved by the competed authority before the tanker will be commissioned.

6.3 Vapor recovery system A single vapor recovery system for both motor spirit and middle distillate (AI & AIII products) equipped with a pressure - vacuum relief valve is sufficient. The system should allow the connection of NW 100 hose for vapors balancing at the kerb side of the truck.



If legislation requires, a hose connection security system for the vapors recovery hose must be provided.

7‐SUSPENTION FOR SEMI‐TRAILERS AND TRAILERS All axles shall have air suspension and ABS fitted; type ELECTRONICALLY-CONTROLLED-AIR-SUSPENSION (ECAS), including - Constantly leveled height of vehicle independent of load - steering of lift axle - Start-driving-aid laden - Exact steering of brakes in laden condition of vehicle by using pressure of air suspension body as steering pressure - demonetizing of air usage during driving - Indifferent levels of driving can automatically be adjusted to a constant situation (level)

8‐SAFETY EQUIPMENT

8.1 Rear Under running Protection:

1 adequate under run bar fitted to the rear end over the whole width of the tanker in accordance with EC requirements (EEC directives 79/490 and 81/333) taking in to account the recommendations of Theseus. Under run bar is connected to the boogie sub frame.

An under running protection at the rear side of the truck must be installed according to the EU and GGVS (German) regulations. A Theseus approved system will consider.

8.2 Pedestrian protection Near and off side under run protection (pedestrian protection) according the EC regulations and the customer minimum requirements as in attachment. Side grade (Cyclist) protection shall be installed at the sides of the tanker were no cabinets or other parts of the body work are providing a flat surface. The maximum gap between the body parts and / or the cyclist protection will be 0.3m. The side grades will have a flat surface of at least 0.2m height.

8.3 Chassis and axles



Same rules as for tractor/rigid trucks 8.4 Miscellaneous

Each wheel will have Clear Pass mudguards fitted. All couplers, hose stowage and pumping cabinets must be protected against dripping, by adequate collectors to retain the product provided with a drain valve. Adequate landing legs to support fully loaded tank semitrailers must be installed to enable disconnection from the tractor. 4 Earthling pins (2 at both side of the tank) and a cable reel Earthling connection at the discharge side. Trailers and semi trailers will have one extra Fire extinguishers 6kg ABC powder.

9‐DOCUMENTATION Operating and maintenance instructions in driver’s languish and maintenance supervisor. Technical checklist for daily- weekly and monthly inspections. Full maintenance and service requirements Maximum height indication to install at the dash board of the truck. Pipe diagram of the loading/discharge- and vapour recovery installation to be installed in the pumping cabinet.

10‐PAINTING AND LIVERY

10.1 Neutral livery: Only to be used for trucks which are on spot hire. Tank (and cabin) should be painted white. Chassis side protections and pumping cabinet black. A removable identifier shall be placed at both sides of the tank and to the rear as described in 10.2 Full END-USER Livery: To be used for all own and contracted trucks. Painting to be done according specification in the “Standard for END-USER truck livery “

11‐RECEPTION AND TESTING

Compartments must be adequately measured in volume. Compartments and piping systems should be tightness tested according to ADR requirements. Tank and vapour return system should be tested on vapour tightness. All equipment must be tested on its functionality in real operation. The measuring installations (if present) must be adjusted as close as possible to 0.0, but with a maximum tolerance of +0.1/-0.2%. An official approval certificate will be provided. "ADR" approval certificate. A loading plan for the maximum axle weights with products having a specific density of 0.725 and 0.845 and there possible combinations. Operating and maintenance instructions. Checklist for day- and monthly inspections to be supplied by the manufacturer.



Attachment 1 : Truck Menu (Types of Trucks) Attachment 2 : Minimum requirement for rear‐view mirrors

Attachment I

Truck Menu (Types of Trucks with allowable payloads/axles)

5 axles 47 Ton

6 axles 51 Ton



7 axles 55 Ton

8 axles 60 Ton

Attachment II

Minimum requirement for rear‐view mirrors Minimum Requirement for Mirrors on tractors/trucks



References

** ADR 2009 updated to ADR2011 starting from 01.07.2011 ** EN 12972, 2007, Tanks for transport of dangerous goods‐Testing, inspection and marking of metallic tanks. ** EN 13094, 2008, Tanks for the transport of dangerous goods, metallic tanks with a working pressure not exceeding 0.5 bar – Design & Construction. ** COMMENTS TO FEDERAL DOCKET RSPA‐99‐5921 ** FUTURE CONFIGURATION OF TANK VEHICLES HAULING FLAMMABLE LIQUIDS IN MICHIGAN ** Rollover Stability of Partially Filled Heavy‐Duty Elliptical Tankers Using Trammel Pendulums to Simulate Fluid Sloshing ** AN ASSESSMENT OF TANK TRUCK ROLL STABILITY ** NON‐LIENER DYNAMIC ANALYSIS FOR TRAILERS ** THE INSTITUTE OF PETROLEUM, PETROLEUM ROAD TANKER DESIGN AND CONSTRUCTION ** Rollover of Heavy Commercial Vehicles ** CARGO TANK ROLLOVER FORCE VERIFICATION ** Ministry of Public works & housing‐Jordan ** ISO 1726‐2:2007 All references copied on the attached CD‐ROM with this STD.

Leaflet No.4

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