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AS 2809.5––2001

Australian Standard™

Road tank vehicles for dangerous goods

Part 5: Tankers for bitumen-basedproducts

AS 2809.5

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This Australian Standard was prepared by Committee ME-057, Road Tanker forHazardous Liquids and Gases. It was approved on behalf of the Council ofStandards Australia on 14 August 2001 and published on 8 October 2001.

The following interests are represented on Committee ME-057:Australasian Fire Authorities CouncilAustralian Chamber of Commerce and IndustryAustralian Gas AssociationAustralian Industrial Gas Manufacturers AssociationAustralian Industry GroupAustralian Institute of PetroleumAustralian Liquefied Petroleum Gas AssociationAustralian Valve Manufacturers AssociationCommercial Vehicle Industry Association of AustraliaDepartment for Administration and Information Services, S.A.Department of Defence (Australia)Environment Protection Authority of N.S.W.Queensland TransportVictorian WorkCover AuthorityWorkCover New South Wales

Keeping Standards up-to-dateStandards are living documents which reflect progress in science, technology andsystems. To maintain their currency, all Standards are periodically reviewed, andnew editions are published. Between editions, amendments may be issued.Standards may also be withdrawn. It is important that readers assure themselvesthey are using a current Standard, which should include any amendments whichmay have been published since the Standard was purchased.Detailed information about Standards can be found by visiting the StandardsAustralia web site at www.standards.com.au and looking up the relevant Standardin the on-line catalogue.Alternatively, the printed Catalogue provides information current at 1 January eachyear, and the monthly magazine, The Australian Standard, has a full listing ofrevisions and amendments published each month.We also welcome suggestions for improvement in our Standards, and especiallyencourage readers to notify us immediately of any apparent inaccuracies orambiguities. Contact us via email at mail@standards.com.au, or write to the ChiefExecutive, Standards Australia International Ltd, GPO Box 5420, Sydney,NSW 2001.

This Standard was issued in draft form for comment as DR 00034.

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AS 2809.5––2001

Australian Standard™

Road tank vehicles for dangerous goods

Part 5: Tankers for bitumen-basedproducts

Originated as AS 2809.5––1990.Second edition 2001.

COPYRIGHT© Standards Australia InternationalAll rights are reserved. No part of this work may be reproduced or copied in any form or by anymeans, electronic or mechanical, including photocopying, without the written permission of thepublisher.Published by Standards Australia International LtdGPO Box 5420, Sydney, NSW 2001, AustraliaISBN 0 7337 4119 3

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AS 2809.5––2001 2

PREFACEThis Standard was prepared by the Standards Australia Committee ME-057, Road Tankersfor Hazardous Liquids and Gases to supersede AS 2809.5 — 1990.

While certain grades of bitumen-based products are flammable liquids, and AS 2809.2,Road tank vehicles for dangerous goods, Part 2: Tankers for flammable liquids, wasintended to cover all types of flammable liquids, there are certain peculiarities of bitumenthat necessitated special treatment, not the least of these being the complex and variablemethod of operation of the industry.

In field and operational matters, it is recommended that reference be made to the proceduralguidelines in the ‘Austroads Bitumen Sealing Safety Guide’.

Amongst other aspects requiring special consideration are the tank design requirements,which differ substantially from other flammable liquids tankers. Bulkheads are not used,and the options for construction material are fewer, so the table of shell thickness has beensimplified. It seems possible to simplify it further as more thought is given to the specialcase of bitumen. A complex relationship between longitudinal and circumferential stiffenershas been dropped.

A new appendix has been added in this revision to expand the details of burners andcontrols. These details would cover the necessary safety issues should permission be givenby the appropriate authority to allow heating in transit.

The term ‘normative’ has been used in this Standard to define the application of theappendix to which it applies. A ‘normative’ appendix is an integral part of a Standard.

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AS 2809.5––20013

CONTENTS

Page

SECTION 1 SCOPE AND GENERAL1.1 SCOPE......................................................................................................................... 41.2 APPLICATION ........................................................................................................... 41.3 NEW DESIGNS AND INNOVATIONS ..................................................................... 41.4 INTERPRETATIONS.................................................................................................. 41.5 REFERENCED DOCUMENTS................................................................................... 41.6 DEFINITIONS............................................................................................................. 61.7 VEHICLE REQUIREMENTS ..................................................................................... 6

SECTION 2 TANKS, ACCESSORIES AND COMPONENTS2.1 MATERIALS............................................................................................................... 72.2 TANK DESIGN AND CONSTRUCTION .................................................................. 72.3 MANHOLES, VALVES AND VENTS ..................................................................... 112.4 FILLING/DIPPING PROVISIONS ........................................................................... 122.5 PIPEWORK AND PIPE FITTINGS .......................................................................... 122.6 PUMPS...................................................................................................................... 142.7 IDENTIFICATION (TANK AND ANCILLIARIES) ................................................ 152.8 VEHICLE CABLING AND ELECTRICAL EQUIPMENT ...................................... 152.9 TESTING................................................................................................................... 172.10 IDENTIFICATION.................................................................................................... 18

SECTION 3 TANK TESTING AND MAINTENANCE PROCEDURES3.1 GENERAL PRECAUTIONS..................................................................................... 193.2 ENTRY INTO TANK................................................................................................ 193.3 GAS-FREEING OPERATIONS ................................................................................ 193.4 TANK REPAIRS OR MODIFICATION ................................................................... 193.5 REGULAR TESTING AND MAINTENANCE ........................................................ 20

APPENDIX A BURNERS AND CONTROLS FOR TANKERS CARRYING BITUMENBASED PRODUCTS ....................................................................................21

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STANDARDS AUSTRALIA

Australian StandardRoad tank vehicles for dangerous goods

Part 5: Tankers for bitumen-based products

S E C T I O N 1 S C O P E A N D G E N E R A L

1.1 SCOPEThis Standard specifies requirements for the design and construction of tankers for thetransport of bitumen-based products including bitumen sprayers. It is complementary toAS 2809.1.

1.2 APPLICATIONTankers for the transport of bitumen-based products shall comply with Parts 1 and 5 of thisStandard. Where any requirement of Part 5 differs from a similar requirement in Part 1,Part 5 shall take precedence.

1.3 NEW DESIGNS AND INNOVATIONSAny novel materials, designs, methods of assembly, procedures etc, which do not complywith specific requirements of this Standard, or are not mentioned in it, but which giveequivalent results to those specified, are not necessarily prohibited. The Standards AustraliaCommittee ME-057, Road Tankers for Hazardous Liquids and Gases can act in an advisorycapacity concerning equivalent suitability, but the specific approval remains the prerogativeof the relevant Authority.

1.4 INTERPRETATIONSQuestions concerning the meaning, application, or effect of any part of this Standard maybe referred to the Committee ME-057, Road Tankers for Hazardous Liquids and Gases forexplanation. The authority of the Committee is limited to matters of interpretation and itwill not adjudicate in disputes.

1.5 REFERENCED DOCUMENTSThe following documents are referred to in this Standard:

AS1160 Bituminous emulsions for construction and maintenance of pavements

1210 Pressure vessels

1375 Industrial fuel-fired appliances (known as the SAA Industrial Fuel-firedAppliances Code)

1449 Wrought alloy steels—Stainless and heat-resisting steel plate, sheet and strip

1657 Fixed platforms, walkways, stairways and ladders—Design, construction andinstallation

1853 Automatic oil and gas burners–– Mechanical draughtLice

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AS1940 The storage and handling of flammable and combustible liquids

2008 Residual bitumen for pavements

2157 Cutback bitumen

2380 Electrical equipment for explosive atmospheres––Explosion-protectiontechniques

2380.9 Part 9: Type of protection––Non-sparking

2430 Classification of hazardous areas2430.1 Part 1: Explosive gas atmospheres

2470 Steel cylinders for compressed gases—Welded three piece construction withlongitudinal joint—11 kg to 150 kg

2475 Threaded hose connection fittings for bituminous materials

2809 Road tank vehicles for dangerous goods2809.1 Part 1: General requirements2809.2 Part 2: Tankers for flammable liquids

2865 Safe working in a confined space

3814 Industrial and commercial gas-fired applicances

4100 Steel structures

D26 Tube fittings with Dryseal American standard taper pipe and unified threadsfor automotive and industrial use

AS/NZS1020 The control of undesirable static electricity

1425 LP Gas fuel systems for vehicle engines

1554 Structural steel welding1554.1 Part 1: Welding of steel structures1554.5 Part 5: Welding for steel structures subject to high levels of fatigue loading

1596 Storage and handling of LP Gas

1869 Hose and hose assemblies for liquefied petroleum gases (LP Gas), naturalgas and town gas

2053 Conduits and fittings for electrical installations2053.1 Part 1: General requirements2053.2 Part 2: Rigid plain conduits, and fittings of insulating material2053.7 Part 7: Rigid metal conduits, and fittings

3509 LP gas fuel vessels for automotive use

3678 Structural steel—Hot-rolled plates, floorplates and slabs

3679 Structural steel3679.1 Part 1: Hot-rolled bars and sections

BS6862.1 Specification for cables for vehicles—Cables with copper conductors

UL21 Standard for safety LP Gas hose

AIPCP13 Manual of petroleum measurement standards

ADR Australian Design Rules for Motor Vehicles and TrailersLice

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1.6 DEFINITIONSFor the purpose of this Standard, the definitions given in AS 2809.1 apply.

1.7 VEHICLE REQUIREMENTS1.7.1 Spillage hazardsThe appropriate requirements of AS 2809.1 and the following requirements shall apply:

(a) Any portion of an engine or exhaust system which, by reason of its location, can bereached by spillage from above, whether the tanker is parked or moving, or which iswithin 1 m of a liquid-carrying component of the pumping system, shall be protectedfrom such spillage by a metal shield.

(b) The distance between the shield and any hot part of the engine or exhaust shall be notless than 50 mm.

(c) The distance between the shield and any cargo-carrying component shall be not lessthan 75 mm.

(d) The shield for a vertical exhaust pipe shall extend as nearly as practicable to the fullheight of the pipe, but not lower than the top of the cabin, and shall be sealed to itliquid-tight at the top. The shield shall be at least 100 mm larger in diameter than theexhaust pipe. Any openings or perforations for ventilation shall be located on the sideremote from the tank.

1.7.2 Propulsion engine exhaustThe engine exhaust system shall comply with the appropriate requirement of AS 2809.1 andthe following requirements:

(a) The exhaust system shall not run beneath a tank unless shielded, see Clause 1.7.1.

(b) The exhaust shall discharge behind the cabin and forward of the tank, at a level notlower than the top of the cabin and at least 1 m from the tank opening, or on the right-hand side of the vehicle, sideways and forward of the front wheels, or not more than150 mm behind the front wheels.

NOTE: Other authorities may require special exhaust arrangements to suit their defined area ofoperation, such as airports.

1.7.3 Auxiliary engines, intake and exhaust terminationsThe intake and exhaust of an auxiliary engine shall not terminate at a level lower than thetop of the cabin, nor in a hazardous zone as described in AS 2809.2.

For portable or trailer units, the terminations shall be above the tank top and at least 2 mfrom any opening into the tank.

1.7.4 Rear impact protectionFor sprayers only, the rear work platform, spray piping system and other fittings may betaken into account in assessing the need for a rear bumper. For tankers other than bitumensprayers, see AS 2809.1.

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S E C T I O N 2 T A N K S , A C C E S S O R I E S A N DC O M P O N E N T S

2.1 MATERIALS2.1.1 StandardsMaterials used in the construction of tanks shall be not less than the grades specified inAS 1449, AS/NZS 3678 and AS/NZS 3679.1.

2.1.2 SuitabilityMaterials shall be suitable for the conditions of use, and in particular shall be compatiblewith adjacent materials and with the cargo.

2.2 TANK DESIGN AND CONSTRUCTION2.2.1 Design criteriaThe tank and its supports and connections shall be designed in accordance with AS 4100, asappropriate, with the following qualifications:

(a) The design load for the tank and its attachments shall be not less than twice the totalmass of the tank, its accessories, and its cargo. The mass of the cargo shall becalculated from its actual density or 1000 kg/m3, whichever is the greater, and themaximum safe filling level.

(b) Loadings caused by the weight of equipment, the reactions at supports, and thermalgradients shall be taken into account.

(c) The thickness of the shell, heads, bulkheads and baffles shall be not less than thatspecified in Table 2.1.

NOTE: The thicknesses for tank heads may be reduced to equal the shell thickness provided that acalculation for head thickness carried out in accordance with AS 1210 indicates that it is safe todo so.

2.2.2 Stiffening of heads and bafflesHeads and baffles shall be stiffened, either by dishing or by another approved method.

2.2.3 Circumferential reinforcementThe tank shall be reinforced circumferentially by stiffeners or baffles (or in anycombination) in accordance with the following requirements:

(a) Reinforcements shall be located so that the maximum unreinforced length (L) shallnot exceed that specified for the particular shell thickness in Table 2.1.

(b) The reinforcements shall be located within 25 mm of points where the longitudinalalignment of shell sheets changes direction by more than 10 degrees, unless otherwisereinforced sufficiently to keep stresses within the specified limits.

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8

© S

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TABLE 2.1MINIMUM PLATE THICKNESS

DESIGN MAXIMUM DENSITY 1000 kg/m3

Minimum nominal thickness, mmShell Heads and

bulkheadsBaffles Heads and

bulkheadsBaffles

Tank details Unreinforced length of shell*, m Largecompartment

circulartanks

Non-circulartanks

Non-circulartanks

Largecompartment

circulartanks

Largecompartment

circulartanks

Rated capacityper metre oftank lengh

Maximumshell radius

<0.9 (L1) >0.9 ≤≤≤≤1.4 (L2) >1.4 ≤≤≤≤2.7 (L3) LCS HSLASS

LSC HSLASS

LCS HSLASS

LCS HSLASS

LCS HSLASS

L mLCS HSLA

SSLCS HSLA

SSLCS HSL

SS

≤1400>1400 ≤2100>2100 ≤2700

>2700

2.32.32.32.3

2.02.42.83.0

1.82.02.42.8

2.42.83.03.5

2.02.42.83.0

2.83.03.54.0

2.42.83.53.5

5555

5555

4444

6666

5555

* Distance between heads, bulkheads, baffles or ring stiffeners.LEGEND:LCS = low carbon steelHSLA = high strength low alloy steelSS = austenitic stainless steel

Licensed to Australian Asphalt Pavement Association on 25 Feb 2002. Single user licence only. Storage, distribution or use on network prohibited.

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(c) Ring stiffeners shall be continuous, and shall have a section modulus about theneutral axis of the ring section parallel to the shell not less than that determined fromthe following equation:

Z = KbL

where

Z = section modulus, in millimetres cubed

K = 0.0069 for all steels

b = tank width or diameter, in millimetres

L = ring spacing, i.e. the maximum distance from the midpoint of theunsupported shell on one side of the ring stiffener to the midpoint of theunsupported shell on the opposite side of the ring stiffener, in millimetres

Where a ring stiffener is welded to the shell in accordance with Item (d) below, themaximum portion of the shell which can be used as part of the ring for computing thesection modulus shall be as described in Table 2.2.

(d) The welding which attached stiffening members shall be not less than 50 percent ofthe total circumference, and no unwelded length of the joint shall exceed 40 times theshell thickness.

TABLE 2.2PARTS OF SHELL IN RING STIFFENER

Number of circumferential ringstiffener to tank shell welds

Distance between parallelcircumferential ring stiffener to

shell welds

Maximum shell section credit

1 — 20t

2 Not over 20t s + 20t

2 Over 20t 40t

LEGEND:t = Shell thicknesss = Distance between parallel circumferential ring stiffener to shell welds

2.2.4 Access through bafflesEach baffle shall have a manhole-sized opening where no other means exists for gainingaccess to tank space on both sides of the baffle. Openings through which heater tubes andother internal pipework can pass without attachment to the baffles shall have enoughclearance to permit deflection of the tubes without contact.

2.2.5 Distribution of loadsThe loads from supports should be taken on stiffening members and should be distributed aswidely as possible through pads, gussets, and the like.

2.2.6 Roll-over protectionWhere any component is of such a design, or is located in such a way, that it is vulnerableto damage in a roll over, the tank shall be provided with roll-over protection which shallcomply with the following requirements as appropriate:

(a) The protection shall consist of one of the following:

(i) A guard in the form of inverted U-coamings, the thickness of which shall be notless than the appropriate value given in Table 2.3.Li

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(ii) Guards or domes as provided in Items (b), (c) and (d) below.NOTE: For demountable tanks where the capacity does not exceed 2500 L, a verticalmetal strip not less than 4.5 mm thick surrounding the fittings may be used.

(iii) The locating of the component, or fittings, within the body of the tank.

(iv) The design of the component itself to provide sufficient inherent resistance todamage to obviate the need for further protection.

(b) Any guard, dome, or coaming shall project at least 25 mm above the top of the fittingwhich it protects.

(c) Any guards or domes not specifically defined in Item (a) above shall be designed andinstalled to withstand without failure a load of twice the mass of the loaded tank, inany direction. The calculation of strength shall be based on the ultimate strength ofthe material.NOTES: 1 If two or more guards are provided, the load may be proportioned between them.2 These design loads may be considered independently.

(d) The material of a guard shall be compatible with that of the tank shell.

(e) Any air space enclosed inside a coaming, guard or dome, shall have openings topermit draining and purging before repair. Where the enclosed space is used totransfer vapour, the openings shall be plugged.

(f) A tank which exceeds 2500 L capacity shall incorporate drains to prevent liquid fromcollecting on top of the tank. Drains shall discharge to a safe place.

TABLE 2.3THICKNESS OF MATERIAL FOR U-COAMINGS

Thickness, mmType of tank

LCS HSLA/SS

Large-compartmentNon-circular-compartment

53

52.5

LEGEND:LCS = Low carbon steelHSLA = High strength low alloy steelSS = Austenitic stainless steel

2.2.7 Component attachmentThe attachment of auxiliary components and accessories should be to the subframe orskirting wherever practicable. Where attachment to the tank shell is unavoidable, thefollowing requirements shall apply:

(a) The design of the component or its method of attachment shall be such that thecomponent will break before damage is caused to the shell.

(b) Where the attachment is to a mounting pad welded to the tank, the followingrequirements apply:

(i) The mounting pad shall be no thicker than the shell at that point, and shallextend at least 25 mm beyond the perimeter of the component attachment, andshall be shaped so as to avoid stress concentrations at sharp corners.Li

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(ii) The means of attachment shall not create pockets which could initiatecorrosion. The welding of mounting and reinforcing pads to the tank shall becontinuous unless a gap for drainage is provided at the bottom. All pads shallbe formed to closely follow the tank contour at the point of attachment.

2.2.8 WeldingWelding for structural joints or the attachment of accessories, mounting pads and the likeshall comply with AS/NZS 1554.1 and AS/NZS 1554.5. Butt welds in the shell shall be fullpenetration. Welding consumables shall be suitable for the material being welded and forany conditions due to the cargo, in particular the possibility of stress-corrosion cracking.

2.2.9 Fire tube designFire tube systems for tank heating shall be designed so that either the tube or a flame tubeinsert is readily removable for replacement or service. Where pipework passes through, oris attached to tank shells or baffles, appropriate reinforcing shall be provided. Suchreinforcement shall not exceed the thickness of the tank shell, and shall follow the contoursof the tank at the point of attachment. Return passes shall be as low as practicable.

NOTE: AS 1375 gives design guidance for combustion systems.

2.3 MANHOLES, VALVES AND VENTS2.3.1 GeneralEvery tank opening except a vent shall be provided with an effective means of closure inaccordance with one of the requirements of this Clause (2.3), as appropriate.

2.3.2 ManholesTanks with a capacity below 5000 litres shall be accessible through at least one manhole,not smaller than 300 mm × 400 mm and fitted with a cover capable of passing the tankpressure test (see Clause 2.9.1). Where the manhole cover incorporates a hatch, it shall alsocomply with the requirements for hatch assemblies (see AS 2809.2). Manhole coamingsshall extend no further than 50 mm into tank vapour space. Tanks with a capacity of5000 litres and above shall be provided with a manhole. The manhole shall be a minimumof 400 mm diameter and may be located on the rear head of the tank or within a recess orshroud on top of the tank.

2.3.3 ValvesEach opening in a tank below the safe fill level shall be provided with a shut-off valvesuitable for service at the piping design temperatures and pressures. Such valves shall belocated as close to the tank shell as practicable, and be positioned so as to minimizeaccidental damage.

2.3.4 Sampling valvesSampling valves, and caps, where fitted shall comply with AS 1160, AS 2008 and AS 2157as appropriate. Sampling valves shall be situated in a convenient location for sampling anda permanent platform attached to the tanker to support the sampling container during filling.

Material used in the manufacture of valves and sampling cocks shall be compatible with thematerial of the tank, and the product being transported, and shall be suitable for themaximum service temperature.

2.3.5 Vents and venting systemsEach tank shall be provided with a normal vent and an emergency vent. The normal ventshall have sufficient capacity for normal loading and emptying, and the volume changesassociated with heating, circulation, and the like. The normal vent shall be designed so thatin the event of a roll over at least half the liquid contents remain in the tank.Li

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The emergency vent shall be capable of relieving a boil-over during filling. An open fillinghatch may be taken into account for this purpose.

NOTE: Figure 2.1 illustrates a typical free vent. The vent pipe passes from the top through thebottom of the tank, where it discharges. The clearance between the open top of the vent pipe andthe coverplate on the housing equals the vent area of the pipe. Removal of the vent coverplatewill allow regular maintenance/cleaning of vent openings in the tank shell and the base of thevent pipe. The height of the vent pipe above the tank shell is designed to cope with product slopduring vehicle braking.The design will retain all the cargo without spillage in a roll over of 180 degrees, but will allow avariable amount of spillage at lesser angles, the maximum being half the cargo at 90 degrees.

2.3.6 Loading and unloading protectionA tank which is intended to be loaded or unloaded with the hatch covers closed, shall beprovided with enough liquid-venting capacity to discharge the whole of the liquid deliveryrate of the pump, and with enough air inflow capacity to match the liquid withdrawal rate.

NOTE: The free vent design illustrated in Figure 2.1 will provide adequately for the usual rate ofpumping.

2.4 FILLING/DIPPING PROVISIONS2.4.1 LoadingTankers shall be designed to be filled either through open hatches (at refineries and majorbulk depots) using an overhead filling nozzle or by means of the tanker pump andcirculating pipework (at intermediate or site storages).

2.4.2 DipstickAny dipstick indicating system shall comply with the following requirements:

(a) The full indication on the dipstick shall allow an ullage space of at least 5%.

(b) A dipstick shall measure from a point of contact at the top of the tank. Any dipstickwhich measures by contacting the bottom of the tank shall be provided with a durablestriker pad of thickness not less than that of the tank shell or 5 mm, whichever is thegreater, attached firmly to the tank bottom below the dip opening.

(c) A dipstick shall be provided with a stayed vertical guide.

(d) A clear indication on the dipstick shall show a level of product that will allow thefuel-fired burner to operate safely.

2.5 PIPEWORK AND PIPE FITTINGS2.5.1 Strength of pipingPiping and associated fittings shall be designed for the pressure to which they may besubjected in service, and shall be designed and supported to allow for expansion,contraction, and vibration. Unrestrained slipjoints shall not be used for this purpose. Valvesor fittings directly attached to the tank that support attached pipework shall be capable ofsupporting the loadings. External piping shall be located so that it is protected from damagethat could occur in the normal operation of the tanker.

2.5.2 Circulating pipeworkWhere recirculation pipework discharges into the vapour space, the velocity of dischargeinto the vapour space shall not exceed 5 m/s, the atomization or spraying of product intovapour spaces or onto heater tubes or hot surfaces shall be minimized, and all productdischarged into a tank shall be discharged in a downward direction.

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DIMENSIONS IN MILLIMETRES

FIGURE 2.1 TYPICAL TANK VENT

2.5.3 Hoses and hose couplingsHoses shall be capable of withstanding both pressure and suction operation at temperaturesup to 230°C. Hose connections shall comply with AS 2475.

NOTE: Detailed information concerning bitumen hoses may be obtained from Code of Practicefor Bitumen Transfer Hoses issued by the Australian Asphalt Pavement Association, Melbourne,Victoria.

2.5.4 Access ladders/walkwaysAccess ladders shall be provided for safe access from the tank walkway to ground level.Access ladders/walkways shall comply with AS 1657.

2.5.5 Flushing systemFlushing liquid (such as high flash point kerosene or distillate) may be kept on a sprayer ina container of less than 250 L capacity. The formation of spray in the vapour space shall beavoided. The container shall be vented in such a manner as to avoid the presence ofpotentially combustible vapour in the vicinity of an ignition source. These flushing tanksshall be designed and mounted to the appropriate ADR rules for side mounted fuel tanks.Each flushing tank shall be fitted with an outlet valve, with an appropriate removablesecured sealed cap. The flushing system shall be so designed to prevent accidentaldischarge of flushing fluid into the bulk product tank compartments.

NOTE: Equipment and ancillaries required to enable the full immersion of spray bars are notrequired to meet the Australian Design Rules.

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2.6 PUMPS2.6.1 SuitabilityA pump intended for handling the product shall be suitable for use with the product and forthe required pressures, flow rates, and temperatures. A sprayer pump shall be of anon-pulsating type.

2.6.2 Pressure regulationA pumping system shall be provided with automatic means to ensure that the designpressure of any component within the system will not be exceeded.

2.6.3 Pump-driving enginesA compression engine or a new spark ignition engine may be used for propulsion. Thepropulsion engine of the road tank vehicle and or an auxiliary engine may be used as thepump engine. The engine shall be provided with a shutdown system which shall be easilyidentified and complies with the following:

(a) An approved manually operated strangler shall be fitted to the air intake (see Note 1).

(b) There shall be provision to isolate the field circuit of a generator, or of an alternatorunless it is of a non-sparking (brushless) type (see Note 2).

(c) The air intake shall comply with Clause 1.7.3.NOTES: 1 A strangler may take the form of a valve which closes the air intake passage to the engine. In

such a case, account must be taken of the effects of vacuum on the intake piping and of otherpassages (such as sump breather pipes) through which air may pass to the air intake of theengine. A fire extinguisher of not less than 2.7 kg filled with the appropriate extinguishantmay be used as a strangler provided that the extinguisher is a 100 percent discharge type andis arranged to discharge into the air intake close to the intake manifold.

2 The isolation function may be provided either by a separate switch or by the battery-isolatingswitch. If a separate switch is used, a warning light to indicate whether the switch is open isdesirable, as a reminder to resume charging after pumping is finished. However, the use of abattery-isolating switch will have the effect that no electrical equipment of any sort will befunctional during pumping. This is something which is not otherwise required or necessary,and may be undesirable or impracticable in certain cases.

It is important that the resumption of battery charging is not overlooked, and it may bedesirable to interlock the isolating arrangement with the starting or engagement controls forthe pump.

2.6.4 Protection of auxiliary enginesAuxiliary engines shall be located or shielded so as to comply with Clause 1.7 and shall beat the remote end of the vehicle from the spraybar.

2.6.5 Location of controlsPower driven pumps shall be provided with controls which shall comply with the followingrequirements:

(a) Controls shall be clearly marked, easily accessible, and located in a position remotefrom the pump.

(b) A strangler-operating device or an emergency stop for the engine or motor shall beprovided. All such devices shall be clearly identified and easily accessible.

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2.7 IDENTIFICATION (TANK AND ANCILLIARIES)2.7.1 GeneralAll emergency equipment and valves on the tanker shall be clearly labelled as to theirfunction.

2.7.2 IdentificationAn identification plate bearing the following information shall be provided on each tank:

(a) The tank manufacturer's name.

(b) The tank design approval/registration number as issued by the authority withjurisdiction.

(c) The number of this Standard, i.e. AS 2809.5.

(d) The serial number of the tank.

(e) Date of manufacture.

(f) Date of manufacturer’s test.

(g) Design pressure, in kilopascals.

(h) Head material (grade, and thickness in millimetres).

(i) Shell material (grade, and thickness in millimetres).

(j) Tank capacity (litres) by compartments (front to rear).

(k) Maximum liquid load, in kilograms.

The plate shall be made of a metal which is compatible with the material of the tank and isnot subject to corrosion. It shall be permanently fixed to the tank or attached structure. Itshould be located on the non-driver side of the tank, near the front, in a place readilyaccessible for inspection. The information shall be stamped, embossed, or applied by othersuitable means, into the material of the plate in characters at least 5 mm high. The plateshall not be painted over or obscured in any fashion.

The tank serial number shall also be stamped on a substantial part of the tank structure inletters at least 10 mm high.

2.7.3 Burner operation proceduresSigns shall be provided adjacent to burner equipment to indicate —

(a) normal start up and shutdown procedures;

(b) restarting procedures after flame-failure shutdown; and

(c) minimum safe product level while using the burner.

2.8 VEHICLE CABLING AND ELECTRICAL EQUIPMENT2.8.1 ApplicationThe requirements of this Clause 2.8 shall apply when the cargo is flammable or the tanker isto operate in hazardous areas.

Cables shall comply with BS 6862.1, and shall be installed in accordance with theAustralian Design Rules for Motor Vehicles and Trailers.

Cabling to the rear of the cab shall have protection complying with Clause 2.8.7.

Cabling to intrinsically safe equipment can be protected by means other than conduit.

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2.8.2 Protection of wiringCables outside and to the rear of the cabin shall be protected in accordance withAS/NZS 2053, Parts 1, 2 and 7, or AS D26 (flared fittings), or by an alternative meanshaving at least equivalent effectiveness. When a tank trailer is being towed by a vehiclewhich is not a road tank vehicle or which is a road tank vehicle for classes of dangerousgoods which are not flammable, the requirements of this Clause apply to the tank traileronly unless the tanker is to operate in hazardous areas.Cables shall be securely fastened and located, such that all wiring and fittings areadequately protected against vibration, impact, abrasion and any other types of mechanicaland thermal stresses (see AS 2809.2 for some acceptable methods of cable protection). Allcircuits, with the exception of the main battery supply, the starter and alternator circuits,shall be protected by an appropriate fuse or other circuit breaker. The fuse shall be mountedin the cab or in a junction box complying with Clause 2.8.7 and shall be of a non-sparkingtype as described in AS 2380.9.

2.8.3 BatteryThe battery shall have a substantial and well secured acid resistant cover, electricallyinsulated on the side adjacent to the batter terminals.

2.8.4 Battery-isolation switchA battery isolation switch shall be provided for use in an emergency only. In such a case, itis necessary to isolate the battery. Reconnection should only be made when the hazard hasbeen removed. The means of operating the isolating switch shall be located on the driver’sside and to the immediate rear outside of the cabin, in such a position that is clearly visibleand easily accessible to a person outside the vehicle, and shall be clearly labelled. Thebattery isolation switch shall have fully enclosed contacts and be weather-proof.

NOTES:1 The switch should only be turned on, (supplying power) or turned off (no power), when the

hazard has been removed.2 Where an engine is fitted with an alternator, and the battery is isolated before the engine is

stopped, damage to the alternator is likely unless its field coils have been first disconnected.

2.8.5 Vehicle rollover devicePurpose-built road tank vehicles designed to carry dangerous goods in bulk shall be fittedwith a rollover device which automatically shuts down the engine and all power sources inthe case of a rollover, by activating the battery isolation switch. The device shall not beactivated at less than 45° to the vertical. The rollover device is only required to be fitted onthe prime mover of a combination or on rigid chassis vehicles.

2.8.6 Hazardous locationsAny electrical equipment activated during cargo transfer and is located within a hazardousarea (see AS 2430.1) shall be suitable for use in such an area. The following hazardousareas shall be deemed to exist during the whole period of cargo transfer and for 5 minthereafter:(a) Within 500 mm of any point of product release shall be as Class 1, Zone 1.(b) Rear of the cabin and 8 metres radially from any uncapped valve or transfer

connection from ground level to a height of 500 mm shall be Zone 2.NOTES: 1 500 mm allows the use of rear lights in bumper bars on vehicles with rear-mounted hose reels.

It also allows the removal of the limitation concerning the vertical exhaust outlet from beingin range of a manhole or vent. 500 mm also removes the limitation of side clearance lightsmounted on the barrel being in range of valves or drop hoses. It also allows cable running onthe opposite chassis rail to avoid the Zone 1 area.

2 All zoning is for the transfer plus five minutes only.

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2.8.7 Cabling to hazardous areas of Zone 2Cabling to the tanker rear of the cabin shall be deemed to be suitable for temporary use inZone 2 if it complies with the following:

(a) Conduit and fittings shall have weatherproof level of protection. Where equivalentprotected cabling is used instead of conduit, sealing glands shall be used.

(b) Junction boxes for electrical cable other than intrinsically safe cabling shall beweatherproof and use threaded gland or bonded entries.

(c) If proprietary equipment such as transmission temperature probes does not readilyallow the use of proprietary connectors the hazard shall be assessed and an equivalenttechnique employed.

NOTE: Also refer to Clause 2.8.2.

2.8.8 Cabling to hazardous areas of Zone 1Cabling shall be suitable, or in conduit suitable, for Zone 1, together with any associatedglands and junction boxes.

2.8.9 Sparking equipmentAny sparking equipment such as relays or switches with make and break contacts mounted500 mm or greater from the rear of the cabin or in a hazardous location as defined inClause 2.8.6 shall be suitable for use in Zone 1.

Switches installed in the electronic flame supervision are exempted from this requirement.

2.8.10 Electrical bondingThe electrical resistance between the tank and the tanker chassis, prime mover chassis, ortrailer undercarriage, and between the tank and the connection of the tanker pipework to thedelivery hose, shall not exceed 10 Ω.

2.8.11 Earthing pointAt least one non-corrodible bare metal lug shall be welded to an integral part of the tank foruse as an earthing point, unless the tanker incorporates an earth wire reel system the lugshall be in a position convenient for the operator but shall not be within the space enclosedby the coaming, and shall be as far away as practicable from points where flammablevapour could emerge. Additional lugs may be placed at convenient points. The filling orloading connection for a tank larger than 8 kL shall be provided with a facility for attachingthe bond or static wire of a tanker in accordance with AS/NZS 1020.

2.9 TESTING2.9.1 Tanks initial test and after any repairA tank or an individual tank compartment shall not leak, distort, or show evidence ofimpending failure when filled with water, the temperature of which does not exceed 30°C,and hydrostatically pressurized to 30 kPa for small-compartment tanks and non-circulartanks, or 45 kPa for large-compartment circular tanks and the pressure maintained withoutleaks for 10 minutes. Each compartment shall be tested individually with adjacentcompartments empty and at atmospheric pressure. Relief devices which could prevent thetest pressure being reached shall be made inoperative during testing.

The vapour-recovery transfer system shall not leak when subjected to a pressure of 30 kPaand the pressure maintained without leaks for 10 minutes.

2.9.2 Hatch assembly initial testA hatch assembly shall pass the test described in AS 2809.2.

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2.9.3 Piping initial test and after any repairPiping systems shall be tested in accordance with the following:

(a) A piping system subject to pumping pressure shall be tested to a pressure 1.5 timesthe maximum working pressure or 200 kPa whichever is the greater.

(b) Valves, manifolds, piping and fittings which can be subjected to surge pressures dueto the closure of some valve in the system, shall be tested to 1600 kPa.

All tests designated in Items (a) and (b) shall have the test pressure maintained for10 minutes without any leakage occurring.

All other and auxiliary equipment shall be tested to the appropriate Standard or themanufacturer’s requirements, whichever has the safest outcome.

2.9.4 RecordsA record of all tests performed on the tanker, or its associated equipment, shall be kept fornot less than three years.

2.10 IDENTIFICATIONAn identification plate bearing the information required by the Australian Design Rules forMotor Vehicles and Trailers shall be provided on each tanker, together with the following:

(a) The tank design approval number as issued by the Statutory Authority.

(b) The number of this Australian Standard, i.e. AS 2809.5.

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S E C T I O N 3 T A N K T E S T I N G A N DM A I N T E N A N C E P R O C E D U R E S

3.1 GENERAL PRECAUTIONSTanker servicing and repair which can be conducted on a scheduled basis at pre-arrangedtimes shall be carried out in workshops in which the staff have had prior training in theprecautions and emergency procedures required for tankers for flammable liquids. Where,because of breakdown at a remote location, a workshop without such trained staff is used,the owner’s representative shall instruct the workshop staff of the nature of the cargo andthe precautions to be taken. In all circumstances the conditions given in AS 2809.2 and thefollowing requirements shall apply:(a) The tank shall be gauged to determine that it is not filled beyond the maximum filling

level. Any overfilled condition shall be corrected.(b) No hot work shall be conducted either indoors or outdoors on the tank or on any

component that has contained liquid or vapour unless the tank and the component aregas-free and a work permit has been issued.

(c) The vehicle shall not be parked near a source of heat of sufficient intensity to riskcausing a discharge from the vents due to heating of the cargo.

(d) For hot work to be carried out on parts of the vehicle when the tank is not gas-free thefollowing shall apply:(i) The surroundings shall be checked and shown to be gas-free for the whole

period of the risk.(ii) Fire-extinguishers shall be deployed in the area.(iii) A fire hose or hose reel, shall be in reach.

(e) Extreme caution shall be observed when a degassing procedure is being undertaken.(f) Extreme caution shall be observed when pressure testing tank and components. See

Clause 2.9.

3.2 ENTRY INTO TANKWhere it is necessary that personnel enter a tank, a work permit shall be issued prior tocommencing, and the requirements of AS 2865 shall apply.

NOTE: Examples of typical work permits are illustrated in AS 1940, AS 2865, and AIP CP13.

3.3 GAS-FREEING OPERATIONSGas-freeing operations shall be conducted, either in the open air or under a specificallydesigned shelter, with no ignition sources in a hazardous area all as complying withAS 2430.1.

3.4 TANK REPAIRS OR MODIFICATIONWhere a tank is repaired or modified, the following requirements shall apply:

(a) The tank and its appurtenances shall be tested in accordance with Clause 2.9 before itis approved for re-use.NOTE: Where a tank is ruptured as the result of an accident, it may be rebuilt and replated toits original design.

(b) If the basic tank design is changed, or there is a change in the basic structure, thedesign shall be re-assessed and re-approved to current Standards.

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3.5 REGULAR TESTING AND MAINTENANCE3.5.1 HatchesAt intervals not exceeding two and a half years, the pressure-tightness of every hatch shallbe tested at 25 kPa, either on the tank with the pressure-vacuum vents blanked off, or afterremoval from the tank, i.e. as a bench test. Where equipment is bench-tested, no furthertests are required when reinstalled on the tank.

3.5.2 VentsAt intervals not exceeding one year, vents shall be removed and completely dismantled andcleaned. The vent shall be assembled, inspected and checked to ensure free passage.

3.5.3 Product heating systemAt intervals not less than 3 months, the product heating system shall be inspected, testedand checked that it operates within the original manufacturer’s specification.

3.5.4 Precautions necessary prior to workWork shall proceed only if the following conditions apply:

(a) It has been established that there is no leakage of cargo.

(b) All valves are shut (P/V vents excepted), and all outlets including hoses are cappedshut.

(c) No hatches will be opened, and no vents, valves, or piping will be removed.

(d) No ignition source will exist within the hazardous zone defined in Figure 3.

(e) The ventilation rate for the area is at least four air changes per hour.

3.5.5 Safe work procedureWork shall proceed only under the conditions specified in Clause 3.5.4 Items (a) to (e)above and there is no ignition source existing within 15 m of the tanker.

FIGURE 3 HAZARDOUS ZONE FOR P/V VENT

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APPENDIX A

BURNERS AND CONTROLS FOR TANKERS CARRYING BITUMENBASED PRODUCTS

(Normative)

A1 GENERALThis Appendix specifies requirements for burner types and controls suitable for use ontankers carrying bitumen based products.

A2 LIQUEFIED PETROLEUM GAS (LP Gas) SUPPLYA2.1 Installation of fuel vesselsLP Gas on the tanker shall either be in cylinders or vessels. Cylinders shall comply withAS 2470 with cylinders sizes of 45 kg, 90 kg and 190 kg water capacity being therecommended sizes.

Vessels for LP Gas shall comply with AS/NZS 3509, carbon steel vessels which aremanufactured up to 500 kg water capacity, whilst stainless steel vessels are limited to200 kg water capacity.

The whole installation, either with cylinders or vessels, shall comply with AS/NZS 1425.

A2.2 Interconnecting pipework between gas storage and burnerThe interconnecting pipework between gas storage and the burner shall comply in allrespects with AS/NZS 1596. The use of copper pipework and fittings on these installationsis prohibited. Flexible connections between the gas storage cylinders or vessel to the fixedpipework and from the fixed pipework to the burner is permitted, provide these two flexibleconnections shall each be limited to one and a half metres in length. Flexible connectionsshall comply with AS/NZS 1869 or UL 21.

A3 BURNERSA3.1 Burners typesBurners shall either be those requiring mechanical draft or natural draft atmosphericburners.

Burner requiring mechanical draft shall be considered as automatic burners and shallcomply in all respects with AS 1853.

Burners designed for natural draught and are considered as an atmospheric burner, shallcomply with the necessary aspects of AS 1375 as appropriate.

A3.2 Manual ignition systemBurners requiring natural draught and manual ignition shall be installed and arranged sothat the operator can simultaneously operate the fuel valve, initiate ignition, and alsoobserve the flame in safety. A flame failure device to initiate the operation of a shut-offvalve or valves fitted in the fuel line shall be installed. This device shall comply withappropriate requirements given in AS 3814.

A3.3 Electronic ignitionWhere an electronic ignition system is installed, the burner start sequence shall be initiatedby a start switch fitted as close as practical to the burner.

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During the firing sequence, the operator shall remain in attendance to ensure pilot flameestablishment and subsequently main flame establishment.

Upon main flame establishment, the operator shall then follow the normal companyprocedures for bitumen-based product use.

In the event of an abnormal shutdown, the burner is to sequence to a safe lockout condition.

The burner controls shall be so arranged that a restart is not possible until the cause of theabnormal shutdown is located, corrected and made safe for a restart.

An over-temperature device shall be fitted to operate within the product. The device to havea preset limit and when activated, it shall shutdown the burner to the lockout condition.

A3.4 Burner operationThe tanker owner shall initiate and ensure that the operator undertakes sufficient training toenable the whole of the operating tasks required to be carried out in a safe and reliablemanner. The tanker owner to ensure that instructions and procedural aids are available tothe operator, that at all times the owner shall ensure that the operator follows the latest safeprocedures. For further information, see Clauses 3.5.3 and 3.5.4. Care shall be taken toensure the fire tubes are always beneath the lowest level of the product, with sufficientallowance being made for any inclines that may be met during transit.

A3.5 Heating in transit systemsUse of heating in transit systems is currently prohibited by the majority of State andTerritory regulatory authorities. Any owner of plant wishing to operate such a system shallapply for permission to do so from the relevant authority in the State or Territory ofoperation. The use of a heating system whilst in transit shall only apply to residual bitumen.For residual bitumen details, see AS 2008.

Owners receiving permission to operate such a system shall comply with the followingadditional safety conditions and controls:

(a) System status indicators shall comprise the following:

(i) System in operation (main flame established).

(ii) System lockout (abnormal condition).

(iii) System lockout (sensor activated).

(iv) Product temperature indicator (digital or analog).

These indicators shall be situated in the driving cab in easily readable positions.NOTE: Indicators described in Items (a)(i), (ii) and (iii) may be LEDs or low voltage bulbs incolours to be decided by the owner.

(b) Driving cab controls—Shutdown switch to shutdown heating system shall be situatedin an easily accessible position reachable from the driver’s seat.

The heating in transit system shall not be capable of being initiated from the drivingcab.

(c) Other controls —the following apply:

(i) In the event of an abnormal shutdown, the burner shall be placed in a safestand-by condition ready to restart when permitted to do so, or in the lockoutcondition appropriate to the situation.

(ii) An indication of abnormal shutdown cause, such as a fuel or electrical fault.

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A3.6 Heating in transit system sensorsRoad tankers which have a burner or burners and intend to fire the burner or burners whilstthe tanker is normally mobile, shall comply with Clauses A3.1 and A3.5, and shall be fittedwith impact sensors installed in positions detailed as follows:

(a) Two sensors fitted adjacent to the front bumper bar, whilst four (two high, two low)sensors fitted to the rear bumper bar and further four fitted, two for any side impact,and two at high level on the front of the tank. These side impact sensors shall befitted as close to the fuel storage as is practical. Impact on any sensor shall lockoutthe heating system to a safe condition. The burner shall not be capable of a restartuntil the system is made safe.

(b) A plan and rear elevation of a prime mover and tank with the sensor positions isshown in Figure A1.

FIGURE A1 DIAGRAMMATIC VIEW OF SENSOR LOCATIONS

Care shall also be undertaken to ensure the fire tubes are always beneath the lowest level ofthe product, with sufficient allowance being made for anticipated inclines.

A3.7 Roll over protection for burner systemIn the event of a tanker roll-over, the burner system shall have a device or devices whichwhen activated will shut down the burner system and make it safe immediately. Theactivating device shall operate when it is at or above 45° to the vertical.

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Standards AustraliaStandards Australia is an independent company, limited by guarantee, which prepares and publishesmost of the voluntary technical and commercial standards used in Australia. These standards aredeveloped through an open process of consultation and consensus, in which all interested parties areinvited to participate. Through a Memorandum of Understanding with the Commonwealth government,Standards Australia is recognized as Australia’s peak national standards body.

Australian StandardsAustralian Standards are prepared by committees of experts from industry, governments, consumersand other relevant sectors. The requirements or recommendations contained in published Standards area consensus of the views of representative interests and also take account of comments received fromother sources. They reflect the latest scientific and industry experience. Australian Standards are keptunder continuous review after publication and are updated regularly to take account of changingtechnology.

International InvolvementStandards Australia is responsible for ensuring that the Australian viewpoint is considered in theformulation of international Standards and that the latest international experience is incorporated innational Standards. This role is vital in assisting local industry to compete in international markets.Standards Australia represents Australia at both ISO (The International Organizationfor Standardization) and the International Electrotechnical Commission (IEC).

Electronic StandardsAll Australian Standards are available in electronic editions, either downloaded individually from our Website, or via on-line and CD ROM subscription services. For more information phone 1300 65 46 46 orvisit us at

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