OISD-STD-225

First Edition August 2007

Amended Edition October 2010

STORAGE, HANDLING AND DISPENSING

AT
PETROLEUM RETAIL OUTLETS

PREPARED BY
FUNCTIONAL COMMITTEE

OIL INDUSTRY SAFETY DIRECTORATE

7th FLOOR, NEW DELHI HOUSE
27, BARAKHAMBA ROAD,
NEW DELHI-110001

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 NOTE

OISD publications are prepared for use in the oil and gas industry under Ministry of
Petroleum & Natural Gas. These are the property of Ministry of Petroleum & Natural
Gas and shall not be reproduced or copied and loaned or exhibited to others without
written consent from OISD.

Though every effort has been made to assure the accuracy and reliability of the data
contained in these documents, OISD hereby disclaims any liability or responsibility for
loss or damage resulting from their use.

These documents are intended to supplement rather than replace the prevailing
statutory requirements.
 FOREWORD

The Oil Industry in India is more than 100 years old. As such, a variety of
practices have been in vogue because of collaboration/ association with different
foreign companies and governments. Standardisation in design philosophies, operating
and maintenance practices was hardly in existence at a national level in early days.
This coupled with feed back from some serious accidents that occurred in oil & gas
industry, the Ministry of Petroleum & Natural Gas in 1986 constituted a Safety Council
assisted by the Oil Industry Safety Directorate (OISD) for formulating and implementing
a series of self regulatory measures aimed at removing obsolescence, standardising
and upgrading the existing standards to ensure standardisation and safer operations.

Accordingly, OISD constituted a number of functional committees comprising of experts

nominated from the industry to draw up standards and guidelines on various subjects.

Retail Outlets are the principal installations for refueling of MS/HSD for automotive use.
The safety of these installations is of paramount concern keeping in view the
associated hazards of petroleum products handled, vehicles and public. Accidents at
Petroleum Retail Outlets in the recent past, emphasized the need for the industry to
review the existing design, operation and maintenance practices in Petroleum Retail
Outlets. Therefore, a need was felt to frame a standard for safe storage, handling of
Petroleum Products at Retail Outlet.

This document was prepared based on the accumulated experience and knowledge of
industry members, and various national and international codes and practices.

This document will be reviewed periodically for improvements based on the new
experiences and better understanding. Suggestions may be addressed to :

The Coordinator,
Committee on “Retail Outlet”
Oil Industry Safety Directorate,
7th floor, New Delhi House,
27, Barakhamba Road,
New Delhi – 110001.
 FUNCTIONAL COMMITTEE MEMBERS

NAME ORGANISATION
LEADER

Shri Ashoke Datta IBP Co. Ltd., Mumbai

MEMBERS

Shri R.C. Kaul Petroleum & Explosives Safety Organisation,

Nagpur.

Shri Vivek Srivastava, Reliance Industries Ltd., Mumbai

Shri A.K. Goel Bharat Petroleum Corporation Ltd., Mumbai
Shri Milind Pawar Shell India Marketing Ltd., Bangalore
Shri R. Murali Hindustan Petroleum Corporation Ltd., Mumbai
Shri M. Shailendra Indian Oil Corporation Ltd., Mumbai
Shri V. Jagdish UL India Ltd. Bangalore
Shri S.C. Gupta Oil Industry Safety Directorate, New Delhi
MEMBER COORDINATOR

Shri A. Mishra Oil Industry Safety Directorate, New Delhi

 CONTENTS
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S.NO. DESCRIPTION PAGE No.
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1.0 INTRODUCTION
2.0 SCOPE
3.0 DEFINITIONS
4.0 STATUTORY REQUIREMENTS
5.0 LAYOUT & FACILITIES

6.0 ELECTRICAL POWER DISTRIBUTION SYSTEM

7.0 OPERATING PROCEDURES

8.0 INSPECTION

9.0 MAINTENANCE

10.0 SAFETY EQUIPMENT

11.0 EMERGENCY PLAN AND PROCEDURE

12.0 TRAINING

13.0 CUSTOMER SAFETY & AWARENESS

14.0 REFERENCES

------------------------------------------------------------------------------------------------------------

ANNEXURES

I Checklist for Daily Inspection

II Checklist for Electrical Audit
III Checklist for Safety Audit
IV Format for Work Permit
V Stock Receipt & Tanker Discharge Process
 “STORAGE, HANDLING AND DISPENSING
AT
PETROLEUM RETAIL OUTLETS”

1.0 INTRODUCTION

Motor Spirit (MS) / High Speed Diesel (HSD) are widely used as automotive
fuels. There has been high growth in consumption of these products
commensurate with the increase in number of vehicles. Accordingly,
number of retail outlets for dispensing of MS/ HSD have gone up in the
country. In recent times, petroleum retail outlets have witnessed addition of
alternate fuels (namely LPG, CNG) and various other formats not connected
to petroleum fuels.

Accordingly, a need was felt to frame guidelines on safety of these

Petroleum Retail Outlets as safety at these installations is one of the
important considerations in view of the hazards associated with handling of
these products, operating conditions such as pressure, storage of other
flammable materials etc.

2.0 SCOPE

This standard lays down the minimum requirements in design, operation,

inspection, maintenance, training, consumer safety at Petroleum Retail
Outlets (PRO).

It does not cover the certification or fitness requirements of vehicles using

MS / HSD.

This Standard does not deal with provision of CNG and LPG dispensing
facilities for automotive use in the same station which are covered in
OISD-STD-179 and OISD-STD-210 respectively.

3.0 DEFINITIONS

Authorised Person : A person trained and assigned to carry out a

specific job by the owner or marketing company.

Capacity : The maximum volume of water that can be stored in a

vessel/container at 15 oC at atmospheric pressure.
 Competent Person : A person recognised by the concerned Statutory
Authority for the purpose in respect of which the competency is required.

C-Store: C-Store means the area in which non-fuel goods / consumables

are sold.

Dispenser : The equipment provided in the retail outlet for delivering MS/
HSD to the Auto Fuel Tank of motor vehicles / approved receptacles.

Emergency shut off : A shut off to cut off power supply as well as
product supply which in an emergency, operates automatically or can be
operated remotely.

Fill Point : The point of inlet pipe connection of a bulk storage tank for
MS/ HSD where hose is connected for filling the products into the tank.

Vent Pipe : The pipe fitted on an underground tank in Petroleum Retail

Outlets for breathing.

Petroleum Retail Outlet : The area provided with facilities and specially
designed for storage and dispensing to the fuel tanks of motor vehicles
and any other approved receptacles.

Pressure Vacuum Valve: A pressure and vacuum relief device used to

limit the maximum pressure and vacuum that can exist in storage tank and
vessel.

Tank Truck / Tank Lorry / POL Tank Lorry: A truck mounted with a
properly designed and approved tank for transportation of MS / HSD in
bulk to the dispensing stations.

Petroleum & Explosives Safety Organisation (PESO): The statutory

body for licensing the retail outlet under Petroleum Rules, 2002.

4.0 STATUTORY REQUIREMENTS

Petroleum Retail Outlets are covered under Petroleum Rules, 2002 and
require licence from PESO The site layout and construction of the retail
outlet requires to be approved by PESO.

In addition to above, approval from other applicable Statutory Bodies and

local authorities shall be obtained.
5.0 LAYOUT & FACILITIES

5.1 General

i. The space chosen for a petroleum retail outlet shall be sufficiently

spacious to allow it to be designed to minimize the risk from the petroleum
fuels to any person likely to be at or near the retail station.

ii. The layout should ensure unobstructed movement of all vehicles together
with adequate provision for entry and exit of Tank trucks.

iii. Location of the facilities, equipment , entrance, exit & paving shall be
arranged in a such manner to avoid the risk of any collision amongst the
motor vehicles.

iv. There should be unobstructed view of the operating and dispensing areas
from the salesroom.

v. Access for mobile fire fighting equipment to all the Retail Outlet facilities
shall be ensured.

vi. The location of tanks, filling and vent pipes, dispensing equipment and
road tanker decanting area as well as on site buildings shall be designed
to provide for satisfactory means of escape for persons in the event of fire
or other incident.

vii. The hazardous areas shall be protected from sources of ignition.

viii. The items to be sold from a Convenience Store (C-Store) in a retail outlet
shall be decided keeping in view hazards associated with the items being
stocked and sold. Open flame appliances shall not be used in PRO.

ix. Provision for car parking shall be made in PRO with C-Store @ one slot
distinctly marked for each 25 sq. metre of C- Store area.

x. Separate pathways outside dispensing area shall be provided for

movement of customers for C-Store.

xi. Hazardous area classification shall be done in line with OISD-STD-113

and IS : 5571.
5.2 Storage Tanks

i. Petroleum shall be stored only in underground tanks in single / double

walled [membrane] and its installation shall be outside any building.

ii. These shall be placed in an earthen or masonry or concrete pit and shall
be packed with sand/earth/gravel without leaving any space between the
tank and concrete/masonry wall. Alternatively, tank shall be installed in
earth pit in a manner that no part of the tank is less than 1.5 metre from
any point of the marked boundary.

iii. No part of the space over the buried tanks shall be used for any purpose
other than installing equipment specifically meant for the withdrawal/
monitoring of contents of the tank.

5.2.1 Material of construction

Following materials shall be used for underground storage tanks.

Steel tanks : Carbon steel as per IS: 2062 or equivalent

Design Code IS: 10987: 1992 for petroleum products
or equivalent

GRP Tank : ASTM D4021, conforming to UL 1316 or equivalent,

5.2.2 Tank Installation

i. The underground tanks shall be either installed in the dedicated tank

farm area “Away from Driveway (Remote Tank Farm)” or under the
driveway with an appropriate reinforced concrete slab above the tank
(“Under Driveway”).

ii. All tanks shall be pneumatic or hydro tested as per the design code or
operating pressure, whichever is higher, before boxing up of the tanks.

iii. Steel tanks shall be suitably protected against corrosion.

iv. Design shall provide adequate protection against buoyancy for the
Tanks installed.

v. Installation of GRP / ERP tanks shall follow the manufacturer’s

recommendations.
5.2.2.1 Tanks installed under driveway

i. Underground tanks shall be installed under concrete slab or alternate

pavement material. Design consideration shall take care of loading
either through masonry pit walls or back fill material and burying depth of
tanks.

ii. Man way covers (metallic / GRP) shall be designed for the intended
vehicle load and to prevent water ingress during rain and also ensure
safety of tank fittings.

iii. RCC slab for the tank pit to be designed for the intended vehicle load.

5.2.2.2 Tanks installed away from driveway

i. Underground tanks preferably to be installed in a masonry pit to ensure

product retention within the pit in the event of any leakage or overflow.
ii. Installation of GRP / FRP tanks shall follow the manufacturer's
recommendation.
iii. Man ways sump shall be covered adequately in order to avoid ingress of
rain water and also to ensure safety of tank fittings.

5.3 Fill points

i. The fill points for the tank/tanks, whether off set or direct fill shall be
located in such a manner so that any spillage of petroleum and its
subsequent ignition does not pose any immediate threat to members of
the public or fore court or delivery staff.
ii. Fill points shall be located in the open air such that any flammable
concentrations of vapours resulting from normal filling operations or
spillage does not reach potentially ignition sources, or accumulates in
either building or out door locations so as to pose a danger.
iii. The fill points shall maintain a minimum safety distance of 3 mtrs. all round
including property boundary or any other structure where a source of
ignition is likely to be present. This distance of 3 m may be reduced if a
fire – resistant wall is constructed, e.g. of brick or concrete, which is at
least 2 m high and extends sideway or parallel to the boundary. If the wall
is a part of a building which houses a sensitive population, such as a
school, hospital or residential dwelling, this distance should be increased
to 12 m.
iv. Fill pipes shall have minimum 1:200 slope towards the storage tank to
ensure easy flow due to gravity and also to avoid any product retention
with in the fill pipe.
 v. Fill pipe shall be carried down nearly to the bottom of the tank to prevent
fire hazard due to generation of static charge arising out of free fall of
product.
vi. Proper identification of fill points for various types of fuels shall be
provided to avoid wrong decantation.
vii. An “earthing bus” shall be provided in the close vicinity of fill points.
viii. Hose connections shall be properly tightened using screwed / cam lock
couplings.
ix. Fill pipe caps shall be made of softer material like brass or aluminium.
x. Fill cap shall have a proper locking system and key shall be kept under the
custody of the authorized person.
xi. Fill points shall be so located that the tank lorry when under decantation is
in drive out position.

5.4 Pipelines

i. Pipelines from tanks to dispensing points and vent pipes shall be routed
below the ground surface. It shall not be under a building or other
features which prevent access to the pipelines after installation. Fuel
Pipes should be sloped towards Underground Storage Tank.
ii. In case of pressurised system, entire piping system including the
appurtenances shall wherever possible be constructed with welded joints
and where necessary with flanged joints. The number of flanged joints
shall be kept down to a minimum.
iii. Piping shall run as directly as practical from one point to another and with
as few restrictions such as elbows and bends as conditions will permit.
iv. Provision shall be made in the piping including connection to the bulk
storage vessel to compensate for expansion, contraction, jarring and
vibration
v. Each pipe line shall be hydro tested as per design code. Alternatively, it
shall be hydro tested at 1.5 times the design pressure maintaining at least
for a period of 30 minutes.
vi. Pipe lines shall be earthed and to maintain electrical continuity suitable
“Jumpers” to be provided at the flanged joints to ensure dissipation of
static charge developed due to product flow in pipe line. The resistance
value between each joint shall not exceed 1 ohm.
vii. The pipelines shall be protected against corrosion by suitable coating
strapping and where necessary by cathodic protection.
5.4.1 Material of Construction or equivalent (being finalized)
i. Material specifications for metallic piping & fittings shall conform to IS-
1978 or equivalent.

ii. Material specifications for non metallic piping and fittings shall conform to
UL 971, EN 14125 or equivalent.

5.5 Vent pipes

i. Each tank shall be provided with independent vent pipe(s) of adequate

capacity unless vapour recovery system is installed.
ii. Vent point shall never be located under any shade /cover.
iii. Open ended vent pipes shall extend to a height greater than the maximum
liquid level of a road tanker likely to deliver petroleum to the underground
tanks and shall not be less than 4 mtrs. In case of venting above the
canopy, the vent pipes shall be terminated 1.5 mtrs above it.
iv. The vent pipe opening shall also observe minimum 4 mtr. clearance in the
horizontal plane from all structures.
v. The vent pipe shall be protected against damage by inadvertent collision
with vehicles.
vi. The outlet (opening) of the vent pipe shall be covered with two layers of
non corrosive metal wire mesh having not less than 11 meshes per square
centimeter and a rain cap or bend downwards.
vii. Vent pipe shall be gradually sloped towards the tank to avoid chocking of
vent pipe due to any water ingress or due to product in the event of tank
overflow.
viii. The vertical portion of the vent pipe shall not be provided with any
intermediate thread joint.

5.6 Dispensing equipment

i. Dispensers shall be located In the open space where they will be

adequately ventilated.
ii. The dispensers shall maintain a minimum distance of 6 mtrs. from any
above-ground structure / property boundary.
iii. The dispenser shall be installed on a firm foundation and protected
against physical damage from vehicles.
iv. A shear valve to be provided in dispensers in a pressurised system.
v. The length of the hose connected to the dispenser shall be kept minimum
keeping in view the operational requirement and shall not in any case
exceed 4 m.
vi. Breakaway coupling shall be installed in Dispensing Hose / nozzle,
vii. The dispensing hose shall be electrically and mechanically continuous and
earthed. Necessary provisions shall be available in Dispenser to earth the
receptacles other than fuel tank of vehicles while dispensing.
viii. Installation of any Electronic Peripheral device shall be done at a 1200mm
above the base level of the dispensing unit.

5.7 Decantation locations

i. The road tanker delivery locations for unloading into storage tanks shall be
in the open, away from the sales building, dispensing activities and
emergency escape routes.
ii. The hose used shall conform to OISD-STD-135.
iii. Hose length shall not be more than 5.5 m.
iv. The location chosen shall allow the road tanker to gain access without the
need to reverse on to the site.
v. The discharge area also needs to be substantially leveled but should also
incorporate drainage arrangements to intercept largest possible likely
spillage.

5.8 Sales room

i. Any building or room intended to serve as a control point for a retail outlet
shall preferably be so located that an attendant in the sales room can see
the forecourt and the dispensing area clearly.

5.9 Canopy

i. The canopy, if provided, for weather protection shall not adversely effect
the ventilation or access to the equipment.
ii. Canopy heights installed at fuel fore court shall have at least 300mm
clearance from the maximum permitted height recommended by Central
Motor Vehicle Rules for the vehicles to be fuelled.
iii. Wind and seismic load for the canopy design shall be considered as per
IS: 875 and IS:1893 respectively.
iv. Canopy structure shall be properly earthed as per IS :3043.
6.0 Electrical Power Distribution System

The following elements / components shall be considered in designing the

Electrical Power Distribution system in a Retail Outlet.

• Total electrical load for the entire Retail Outlet

• Availability, Suitability & Reliability of the State Electricity Board (SEB)
grid.
• Fault (KA) rating of the SEB Feeder
• Load to be fed from back-up DG power
• Load which need stabilized and/or Uninterrupted Power Supply (UPS)
supply to function smoothly
• Rated load of the connected & future equipment

The list of reference Standards / Codes is covered under Chapter 14.

For downstream distribution on the LT side, a suitable LT Power

Distribution Panel (PDP) shall be designed to feed the various types of
loads in PRO safely from a centralized location.

6.1 Elements of Protection

a. Protection shall be provided to guard against sudden failures viz. neutral

disconnection and against overload, short-circuit & earth fault.
b. The motors shall be protected against short circuit and overload.
c. Protection shall be provided for variation in voltage, frequency and phase
unbalance.

6.2 Backup Power Supply

The following shall be considered to arrive at the capacity of the Diesel

Generator (DG) set, if provided.

• “Critical” lighting fixtures are fed with DG supply.

• The DG rating shall be sufficient enough to sustain the starting power
requirements of the connected motors without disturbing normal
operation of the other loads.

6.2.1 The Retail Outlet operating after sunset, emergency lighting with battery
backup shall be provided near the DG set, dispenser, sales room and
electrical room.
6.3 Layout & Installation

i. For HT supply, the substation shall mainly consist of lightning arrestor,

HT fuse, transformer, SEB metering cubicle.

(a) Retail Outlets with an outdoor type of HT/LT substation, a DP

structure surrounded with barbed wire fence, entry gate shall be
provided outside the licensed area. Alternatively, a Packaged Sub
Station shall be provided.

ii. The Power Distribution Panel, Automatic Voltage Stabiliser, UPS shall
be installed with following clear spaces for ease of safe operation &
maintenance activities:

In front of the equipment - 1000 mm.

Behind the equipment - > 750 mm. (if approach is required)
- < 200 mm (if approach is not required)
At sides - > 750 mm. Between equipments
- < 200 mm. (if approach is not required)

iii. Electrical room shall be provided with proper ventilation to extract the
heat generated in the power distribution equipments.

iv. All electrical equipment shall be as per IS : 5572 in line hazardous area
classification.

v. Cable entry shall be through gland plate either at top or bottom. Further
spare holes, if any, in the gland plates shall be blocked.

vi. Cables shall be neatly dressed, clamped and tag marked to easily
identify the feeder and device it connects.

vii. The cable entry holes on the building wall in cable trench or overhead
shall be sealed to prevent entry of water.

viii. For underground laying under different conditions of terrain the methods
may be as follows:-

(a) For direct burial within PRO, top of the topmost layer of cable shall
be laid at a minimum depth 600 mm from surface of ground, each
subsequent layer at the bottom shall maintain a minimum vertical
clearance of 150 mm.

(b) For road crossings, cables shall be routed at a minimum depth of

600mm from surface and thru’ pipe. The pipe may be of GI or steel
reinforced hume pipe or HDPE pipe.
6.4 Earthing System

The earthing system shall be designed as per IS 3043 and following

procedures shall be followed:-

i. All metallic structure, pipe fittings and enclosures of electrical

equipments shall be connected to earth.

ii. Equipment rated up to 230 V, 1-phase supply, the enclosure shall

be grounded at least one point.

iii. Equipment rated above 400 V, 3-phase supply, the enclosure shall
be grounded at least at two separate points.

iv. Two nos. earth pits shall be provided for each of transformer / DG
set neutral earthing, equipment earthing.

v. All earthing pits except DG neutral and instrument / IT earthing

shall be connected through grid (s).

vi. In lightning prone areas, a risk assessment shall be carried out for
need of lightning protection and guidelines given in IS 2309 shall be
followed.

6.5 Emergency Stop System

i. Emergency stop system shall be provided to cut off the power supply to all
metering pumps/ dispensing equipment and associated equipment, other
than certified intrinsically safe equipment at PDP and in / on Sales
Building. On actuating any of these push buttons, electrical power supply
to entire PRO shall be isolated instantaneously.

ii. The push button shall be of red colour, mushroom type, marked and a key
to open.

6.6 Illumination System

Following Minimum illumination level (lux) shall be maintained in various

areas of the PRO for safety and visibility.

Area LUX
Approach Area 50
Under the canopy 150
Customer Care Room 100
Electrical Room 100
 The design shall ensure that illumination is glare-free for customers driving
in vehicle in a Retail outlet.

7.0 OPERATING PROCEDURES

7.1 General

i. Operating personnel of retail outlet shall possess adequate knowledge

and experience of handling MS/ HSD to ensure functioning of the station
in a safe and efficient manner.

ii. During unloading of the product from the tank truck to the bulk storage
vessels, the tank truck shall be parked in the space marked for the
purpose.

iii. Operation of dispensing fuel to motor vehicles shall be suspended during

the period of unloading of fuel from tank truck to the storage tanks.

iv. All operations at Retail Outlet shall be suspended during the period of
evacuation of the storage tank for maintenance and testing.

v. MS/ HSD shall not be filled in the fuel tank of motor vehicle while the
engine of the vehicle is running.

vi. The operating procedures shall be displayed at relevant locations for the
unloading of tank truck.

vii. Dos and Don’ts shall be prominently displayed in Retail Outlet. (Please
refer item no. 13)

viii. Action in the event of emergency shall be clearly established and

understood by all concerned and displayed prominently.

ix. The following are the critical activities ;

a. Decantation
b. Management of the Forecourt / Fuelling area
c. Sampling
7.2 Decantation of Tank Lorries

On receipt of Tank lorry from the supply point, Dealer or his authorized
representatives shall check seals, match the numbers with the supply point
documents, number of compartments and quantity/ product contained
therein. The unloading operations shall be done in presence of the
authorised person at Retail Outlet & Tank Truck Crew.

The procedure for stock receipt and tank lorry discharge is given in
annexure – V.

After decanting the product into the tank, at least 50 liters of product
should be dispensed through the pump before taking sample from the
pump nozzle for ascertaining the density of the product in the storage tank
after receipt. The density at 150C thus ascertained should be recorded in
the density register.

7.3 Forecourt Management

i. Guide the vehicle to the position at the designated area of the retail outlet
facing the direction of exit.

ii. Do not leave the vehicle unattended during refueling operation.

iii. Ensure that sources of ignition, such as pilot lights, electrical ignition
devices, electrical appliances/ gadgets, and engines located on the
vehicle being refueled are turned off before dispensing of fuel to a vehicle.

iv. Delivery Sales Person must show zero setting to the motorist before
commencing delivery.

v. Deliver product to customer as required .

vi. After completion of delivery, remove nozzle and place it on the Pump boot.

vii. Position the next vehicle and repeat all steps as above.

viii. At the end of the day’s work, ensure that valves are closed, hoses are
properly stowed and electrical equipment is switched off.

ix. Always guide all vehicles entering into the retail outlets to designated area
for refueling.

x. Important operational activities shall be logged and records of such

activities highlighting receipt, inventory, level, pressure, temperature,
equipment running etc shall be maintained.
 xi. A two-wheeler shall be re-fueled only after the Riders have dismounted.

7.4 Sampling

i. The samples shall be taken in approved containers duly earthed/ bonded

in line with the industry guidelines.

ii. The samples shall be stored at designated approved place.

iii. Total storage of samples shall not exceed 30 litre for Class A product.

iv. The samples shall not be poured back directly to the storage tank.

v. The samples shall be collected in a separate receptacle for each product

and transfer to storage tank through a container fitted with hose. The retail
outlet operations shall be suspended during this transfer.

8.0 INSPECTION

i. A well designed system of periodic inspection of all facilities of retail outlet

shall be formulated to maintain it in safe operable condition all the time.

ii. Safety audit of the retail outlet shall be undertaken & certificate of fitness
declaring integrity with respect to equipment, facilities, operations & safety
procedures shall be accordingly issued. Check list for inspection is
enclosed as Annexure -III.

iii. All recommendations of the safety audit/ inspections shall be complied in a

time bound manner and records maintained thereof.

iv. The system of permit to work shall be established for non-routine works
with and such works shall be undertaken with full knowledge and approval
by authorised person.

v. Equipment appurtenances, protection devices associated with the

dispensing unit as incorporated in the design and approved by PESO shall
be tested, maintained, repaired and replaced as recommended by the
manufacturer.

vi. Checklist shall cover conformity with the design intention, operating and
maintenance procedures, preventive measure & protection systems and
safety practices.

vii. The earthing resistance shall be checked at least once a year and records
maintained thereof.
8.1 SAFETY INSPECTIONS / AUDIT

The safety inspections / audit of Petroleum Retail Outlet shall be carried

out as given below:

TYPE FREQUENCY AGENCY

Safety Inspection Daily Operating personnel

Safety Audit Once in 6 months Company authorised Person
/ Agency
Electrical Audit Once a year Company authorised Person
/ Agency

The typical checklist for these inspections/ audits are enclosed as

Annexure-I, Annexure-II and Annexure-III which shall be used as a
guideline to develop comprehensive checklists to check compliance and
also proper system to liquidate the non complied points with target dates.

9.0 MAINTENANCE

9.1 GENERAL

i. A comprehensive maintenance system of all facilities of retail outlet shall

be formulated to maintain it in safe operable condition all the time.

ii. Preventive maintenance schedules shall be drawn for all equipment in

accordance with manufacturer’s recommendations and established
mandatory / recommendatory standards. Records of all preventive
maintenance undertaken shall be maintained and updated from time-to-
time.

iii. All repairs, non routine maintenance work shall be carried out after
issuance of work permit as per the procedure and format enclosed as
annexure - IV. The format need to filled in duplicate.

iv. The work permit shall be issued by company authorized person or dealer
or manager at the retail outlet as per the class of activities detailed in item
(v) & (vi) given below.
 v. The following typical activities involving maintenance of Operational area
& office requires work permits which can be issued by dealer/ manager at
the retail outlet or company authorized person. The dealer/company
authorized person will issue the permit to contractor or his authorized
person for carrying out the assigned work after ensuring compliance with
laid down conditions.

a. All activities capable of producing a spark inside a hazardous area.

b. Access into a building / canopy roof.
c. Access into a building canopy cavity.
d. Concrete cutting in the hazardous zone.
e. Electrical switch Board work.
f. Excavation including Forecourts.
g. Forecourt surface repair.
h. Water Removal from Under Ground Tank.
i. Operation of all electrical and electronic instruments inside hazardous
areas, unless certified intrinsically safe.
j. Promotional activities on forecourts.
k. Signage, including canopy signage / lighting not covered by long term,
routine maintenance contract.
l. Setting up of temporary equipment including product recovery
equipment. E.g. Compressor, water blasting equipment etc.

vi. The following needs work permits which shall be issued by company
authorized person. The company representative or authorised person will
issue the permit to dealer or his representative who in turn will issue the
same to contractor for carrying out the assigned work after ensuring
compliance with laid down conditions

a. Repair / rework / cleaning on the tanks and pipelinework

b. Tank Removal / Decommissioning.
c. Non-routine maintenance / replacement / major electrical work within
hazardous area.
d. Oxygen Deficiency / Inert gas Entry.
e. Pneumatic / Hydrostatic pressure testing.
f. Oil interceptor cleaning – where entry into the interceptor is required.
g. Hot work including but not limited to welding / grinding / gas cutting.
h. Demolition / revamping.

10.0 SAFETY EQUIPMENT

i. Each dispensing unit shall be covered by at least 2 nos. ISI marked 10 kg

DCP Fire Extinguishers placed at a safe location within 3m radius.
ii. Minimum 1 no. 4.5 kg CO2 fire extinguisher conforming to IS :2878 shall
be available in each electrical meter room.
 iii. Minimum 4 nos. sand buckets filled with dry sand should be available at
the premises.
iv. All employees working in the premises must be conversant with the safe
handling of petroleum products and first hand knowledge of the fire
fighting & emergency handling.
v. Insulated pliers, screw driver, non-sparking tools , flameproof torch shall
be available in the premises.
vi. All periodic tests shall be carried out by competent / authorised persons,
as applicable and records shall be maintained.
vii. Fire extinguishers are to be periodically tested
and maintained as per OISD-STD-142.

viii. The fire extinguishers are to be checked as per the following schedule:

• Visual check of the extinguisher : Daily

• Condition of DCP, Hose, Nozzle and safety clip : Every month
• Weight checking of CO2 Cartridge : Every Quarter
• Performance Testing & DCP Extinguisher : Every Year
• Pressure Testing of Extinguisher : Every Three years

11.0 EMERGENCY PLAN AND PROCEDURE

i. Each Retail Outlet shall be provided with at least 2 points for emergency
shutdown.

ii. The Operating Company having control over the Retail Outlet shall draw
an operational emergency plan keeping in view the following:

a) Major failure of fittings resulting in spillage

b) Accidents or other emergencies, which can affect the Retail
outlet
c) Electrical Emergencies
d) Civil emergencies
e) Any other risk arising from the existence or operation of the
Retail Outlet

The above emergency plan shall be disseminated amongst all personnel

involved and ensured that they understand their roles and responsibilities
in the event of an emergency.

iii. The in-charge of the Retail Outlet shall maintain close liaison with Fire
Service, Police, District Authorities and marketing company.
iv. Important telephone numbers for emergency use shall be displayed
prominently in the Retail Outlet.

v. Means of communication shall be always at the disposal of the In charge

of the Retail Outlet.

vi. Emergency Action Plan should be tested with mock drill at least once a
year.

vii. First Aid Kit shall contain items to handle possible emergencies as per
State Factories Rules.

viii. Shock treatment chart written in bilingual & local languages. RO

attendants shall be given training on how to treat an electrocuted person
before help from a doctor is available.

12.0 TRAINING

The objective of training is to provide good understanding of all the facets

of operations at the Retail Outlet. Training shall ensure that the jobs are
performed in accordance with the laid down procedures and practices.

i. Each oil company shall develop training module of their own which should
include inter-alia of the following :

a) Hazardous characteristics of product handled.

b) Familiarisation with operational procedures & practices.
c) Hands on experience on operation of equipment.
d) Knowledge of emergency and manual shut down systems
e) Immediate and effective isolation of any spill
f) Safety features and accident prevention.
g) Fire fighting facilities, its upkeep and operation.
h) Evacuation and safe egress of the vehicles in an emergency.
i) Housekeeping
j) Decantation
k) First aid
l) Dos & Don’ts
m) Emergency plan./drills

Additionally, people shall be trained for specific job / activity.

ii. Proper records for the training and refresher courses shall be maintained.

13.0 CUSTOMER SAFETY & AWARENESS

13.1 Display of important information :

At Retail Outlet, the particulars of licence, emergency telephone nos. of

local fire service, police, marketing company and emergency instructions
shall be conspicuously displayed.

i. Caution boards shall be displayed near the dispenser for customer

awareness as below :

a. Stop the engine before refueling

b. No smoking
c. Non-use of Mobile phone

13.2 DOs & DON’Ts

DOs

i. Switch off the mobile phone.

ii. Switch off the engine before commencement of refueling .

iii. Ensure a 10 kg DCP Fire Extinguisher is available near the Dispenser.

iv. In case of any spill / fire observed, press the “EMERGENCY STOP ”
button on the Dispenser.

DON’Ts

i. Do not start the engine / drive away the vehicle till the filling nozzle has
been disconnected from the filler cap of the vehicle.

ii. Do not refuel the vehicle during the period MS/HSD is being decanted
the tank.
iii.
Do not Smoke
iv.
Do not use naked flame

14 REFERENCES

ix. Petroleum Rules – 2002

x. Marketing Discipline Guidelines
xi. IS 2062 :1999 : Steel for General Structural Purpose
 xii. IS 1239 : Part 1 : 2004, and IS 1239 : Part 2 : 1992, Steel Tubes and
Other Wrought Steel Fittings.
xiii. IS-5572 : Hazardous Area Classification
xiv. IS 10987 : 1992 : Code of Practice for Design, Fabrication, Testing and
Installation of Underground / Above ground Horizontal Cylindrical Storage
Tanks for Petroleum Products.
xv. IS 2309 : 1989 : Code of Practice for the Protection of Building and Allied
Structures Against Lighting
xvi. IS 3043 : 1987 : Code of Practice for Earthing
xvii. UL 1316 : Glass-Fiber-Reinforced Plastic Underground Storage Tanks for
Petroleum Products, Alcohols, and Alcohol-Gasoline Mixtures.
xviii. UL 971 : Nonmetallic Underground Piping for Flammable Liquids
xix. EN 14125 : 2004 : Thermoplastic and Flexible Metal Pipe Work for
Underground Installation at Petrol Filling Station
xx. OISD-STD-113: Classification of Area for electrical installations at
Hydrocarbon processing and handling facilities
xxi. OISD-STD-142: Inspection of fire fighting equipments and systems
xxii. OISD-STD-135: Inspection of loading and unloading hoses for petroleum
products
xxiii. IS-1978 : Indian Standard Specification for Line Pipe (Second Revision)
xxiv. UL 87- Power Operated Dispensing Device for Petroleum Product or
Relevant Standards
xxv. UL 79- Power Operated Pumps for Petroleum Dispensing Products or
Relevant Standards
 Annexure - I

Daily Check List

Date: Time:
Sr.No Particulars Remarks
(To be carried out by individual DSM on rotational basis)
1. All the Dispensing Units externally & internally clean. In the sand below Y/N
Dispensing units there is no Spillage of product and inflammable waste.
2. All the piping connections of Dispensing units & tank farm are leak free Y/N
& there is no sweating in the joints
3 Wire mesh in the product vent is not choked with foreign matter. Y/N
4. Fire Extinguishers are in place and are valid for use as on date. Y/N
5. Road & pathways are clear of any obstructions. Y/N
6 Safety signs are in place. (No smoking, Mobile Phone Switch Off) Y/N
7 Tank farm is clean and free of dry vegetation. Y/N
8 The sand in the fire bucket is dry and without any lumps. Y/N
9 All the light fixtures at the periphery, canopy and the sales room are in Y/N
working condition.
10 No employee of the Retail Outlet is in an intoxicated state Y/N
11 Daily briefing [Dos and Don’ts] on Safety before starting of shift has Y/N
been carried out
12 General House Keeping is good. Y/N

13 There are no electrical faults observed in the entire Retail Outlet. Y/N
14 Any other unsafe condition Y/N
 Annexure –II

System Document for Electrical Safety Audit

Sl.No. Item Observation Action Needed

A. Deviation from laid down procedure
1. Deviation from Statutory Immediate
Requirements as laid down attention needed to
in Indian Electricity Rules, rectify the issue &
Petroleum Rules, OISD comply with
Standards, viz. Statutory
requirements
1.1 Equipments enclosure mis- Equipment with
match with corresponding appropriate
zone of application enclosure, to be
installed.
1.2 Clearances not maintained as Minimum
per guideline clearance to be
ensured.
1.3 Material not as per Replaced with IS
respective Indian Standards approved
materials.
1.4 Inappropriate illumination Modify to meet the
levels recommendation.
B. Insulation, Grounding & Lightning Protection
2. Grounding & Lightning Protection Systems are not as per
IS-3043 & IS -2309
2.1 Electrical equipments are not Earth connection
earthed as per the to be provided as
recommendation per
recommendation.
2.2 Neutral point of Transformer Neutral points
and DG Set are not earthed. have to be
grounded as per
recommendation.
2.3 The Lightning/Surge Lightning/Surge
Arrestors are in not in place Arrestor to be
and/or not connected to properly placed &
earth. connected

2.4 Earth Resistance High Salt & water to be

added to earth pit
to reduce earth
resistance.
2.5 Insulation Resistance Low, Damage portion of
less than 1 Mega Ohm insulation to be
repaired, insulation
resistance to be
increased beyond 1
Mega Ohm.
2.6 All panel doors are not Missing flexible
earthed with flexible braided earth links to be
connection put at the earliest.
2.7 The Electrical Room is not Room to be
clean, and there is water cleaned, water
accumulation inside the wiped out, all
room/cable trenches holes for water
entry, to be
blocked.
C. Protection & Metering System
3 Protection System is not operating
3.1 Emergency Push Button Push button to be
jammed replaced, safety
checked by
simulation
3.2 Under-voltage, over-voltage, Relay to be
Phase Unbalance Protection properly set &
not working fault condition to
be simulated to
check & ensure
healthiness of the
Protection System.

3.3 Neutral Snap, Phase failure

Protection not working
3.4 Meters not Meter, its C.T. &
indicating/recording P.T., as required,
properly to be replaced
immediately.

D. Loose connection & overheating

4.1 Loose connection in cable Termination to be
termination tightened properly
4.2 Equipments running in Load must be
overload condition, heating restricted within
& burning smell the Design Limits,
Loose connection,
if any, shall be set
right.
E. Safety
5.1 Non-functioning of Lighting Lighting fixtures
fixtures, especially in the and its associated
strategic zones viz. near the circuits to be
Dispenser, Tank Farm Area, checked &
Front & Rear of Sales rectified for
Room, Electrical Room illuminating the
zones.
5.2 Safety equipment, viz. To be put at their
Insulating mats conforming designated places
to IS:15652:2006 having ISI immediately and
mark, CO2 Fire Extinguisher, persons trained on
Shock Treatment Chart, the Shock
Flameproof Torch are not in Treatment
their designated places Procedure.
5.3 Repairing work being Immediately work
carried out without any authorization
authorized Work-permit procedure to be
implemented
5.4 Components material used Standard good
are of poor sub-standard quality
quality components to be
used
5.5 Labels/Tag- Missing
marking/ferruling on Labels/Tag-
equipments, cables, feeders, marks/ferrules to
cable cores are missing be put as per
drawing.
5.6 Drawing/Documents not Drawing
available in panels /documents to be
kept in the
dedicated pockets
in panels
F. Repair & Maintenance
6.1 Dirt & Dust accumulation Dirt & dust
inside panel cleaned
periodically.
6.2 Spare holes in Electrical Spare holes to be
Panel blocked.
 ANNEXURE- III

Safety Audit Checklist

Sl.No. Item Observation Recommendation

1 Statutory Requirements

1.1 Is CCOE License & Drawing

at the site available?

1.1.1 Validity and date of renewal

1.2 Does the drawing correctly

reflect existing facilities?

1.3 Are safety message like Tel.

No., Police, Fire Brigade,
Hospital and No Smoking,
T/L under decantation and
explosive licence No.
displayed?

1.4 Is extract of explosives rules

exhibited?

1.5 Are 2 Nos. of DCP type (10

Kg_ fire extinguishers per
outlet /pump (as applicable)
provided?

1.5.1 Last. Date of charging.

1.6 Are fire buckets (9 ltr.

Capacity) having round
bottom (max 10 nos.) and
cover contain dry sand?

1.7 Last date of W&M

verifications.

2 General

2.1 Are the good housekeeping

practices (e.g. provision of
dustbin, garbage disposal /
cotton waste disposal,
cleaning of drainage) being
observed?

3 Tanks
3.1 Is the dip rod floating?

3.2 Are the fill pipe threads

correspond to the standard
size 75 mm diameter as
carried by tank lorries calling
at the site?

3.3 Is the vent pipe located as

per the approved drawing?

3.4 Is the wire gauge of the vent

cap :

(a) Missing ?

(b) Clogged ?

3.5 Is the manhole chamber free

of :

(a) Rubbish (i.e. cotton

waste / rags etc.)

(b) Oil Spillage

3.6 Are tank curb walls / pipe

railings in good condition?

3.7 Are lorry discharge points

distinctively painted as per
our standard?

3.8 Are the following securely

closed :

(a) Lorry discharge points?

(b) Dip pipe?

3.9 Are sank buckets and fire

extinguishers positioned near
the T/L during T/L
unloading?

3.10 Is bonding wire connected

while decanting the
tanklorry?
4 Pumps

4.1 Are the pumps :

(a) Clean?

(b) Leaky?

4.2 Are the electric motors

properly earthened?

(a) Located as per the

drawing?

(b) Easily accessible?

4.3 Is there any loose wiring in

the pump?

4.4 Are flameproof boxes closed

properly?

4.5 Is dry sand filled in the gap

below pump in pump
pedestal?

5 Building & other facilities

5.1 Are any other flammable

materials like LPG cylinders,
cardboard cartons etc., are
stored in the generator
room?

5.2 Whether generator room

properly ventilated, clean
and dry?

6 Electrical

6.1 Is the electrical system as

per our standard?

6.2 Is there any loose wiring in

the switch board?

6.3 Is the earthing provided as

per new standards?

6.4 Are the light fixture in good

condition?

6.5 Are the cables with FLP

glands fitted to pumps?
6.6 Are all the equipments a
labeled?

6.7 Are all the cable / wire

terminations tightened?

6.8 Is there any dirt or dust

inside the electrical panels?

6.9 Are all spare cable entry

holes in all electrical panels
blocked?

6.10 All panel doors are earthed

with flexible braided
connection?

6.11 Are all electrical equipments

earthed as per
recommendations?

6.12 Are Neutral point of

transformer and DG set
earthed?

6.13 The lightning / surge

arrestors are in place and in
working condition and are
connected to earth?

6.14 Is the insulation resistance of

each feeder is more than 1
Mega Ohm?

6.15 Is the voltage between the

neutral and earth limited to
3V?

6.16 Is the electrical room

maintained clean, free from
water accumulation?

6.17 Is there any undue heating in

any parts of any equipment?

6.18 Is the shock treatment chart

is available in electrical room
and all concerned persons
are trained on the treatment
procedures?
7 Tank Lorry

7.1 Is the earth wire connected

properly during decantation?

7.2 Is fire extinguisher available?

7.3 Is the fire extinguisher kept

accessible?

7.4 Is PCVO crew aware of fire

fighting methods?

7.5 Is dip pipe kept closed while

decanting?
 ANNEXURE- IV

WORK PERMIT

(NAME OF COMPANY) (LOCATION)

Sl.No.______________

DATE AM / PM DATE AM / PM

VALID FROM__________________________
UPTO___________________________

PERMISSION IS GRANTED TO
SECTION/CONTRACTOR___________________________________________

NAME___________________________________________________________

NATURE OF WORK
___________________________________________________________

LOCATION OF WORK
___________________________________________________________

THE FOLLOWING ITEMS SHALL BE CHECKED BEFORE ISSUING THE

PERMIT
(Please put tick [ ] mark in the appropriate box)
-----------------------------------------------------------------------------------------------------------
S.No. Item Done Not Required
------------------------------------------------------------------------------------------------------------

1. Equipment / Work Area inspected [ ] [ ]

2. Surrounding area checked,cleaned [ ] [ ]

and covered

3. Equipment electrically isolated [ ] [ ]

and tagged

4. Running water hose / Portable [ ] [ ]

extinguisher provided
5. Equipment blinded/disconnected / [ ] [ ]
closed / isolated / wedge opened

6. Equipment properly drained / [ ] [ ]

depressurised

7. Equipment water flushed [ ] [ ]

8. Equipment properly steamed / [ ] [ ]

purged

9. Pyrophoric Iron removed / kept wet [ ] [ ]

10. Proper ventilation and [ ] [ ]

lighting provided

11. Gas test done , found [ ] [ ]

gas free

13. Standby personnel provided [ ] [ ]

from
-------------------------------------------------------------------------------- ---------------------------

SPECIAL INSTRUCTIONS

1. Following personal protective equipment are required (check all items

required) :

Safety Helmet / Gloves / Goggles / Safety Shoes / Boiler Suit/ Welding

Suit / Dust Respirator / Face Shield / Fresh Air Mask/Apron / Lifeline /
Safety Belt / Airline /Film Badges.

2. In case of fire alarm, all work must be stopped. All personnel must leave
work site and proceed to designated areas.

3. Remarks on toxic/hazardous chemicals, if

any:___________________________________________________
___________________________________________________________
___________________________________________________________

4. Alternate means of escape available/provided/not required.

5. This permit must be available at work site at all times.

6. Additional items, if
any:_____________________________________________________________
___________________________________________________________

Name and_____________________ Name and ______________________

Signature of Receiver__________ Signature of Issuer____________

Name and_____________________ Name and ______________________

Signature of Receiver__________ Signature of Issuer____________

Permit Extended upto Signatures

Additional precautions
--------------------------- required, if any -------------------------------------
Date Time Issuer Receiver
------------------------------------------------------------------------------------------------------------

________________________________________________________________

______________________________________________________________

________________________________________________________________

________________________________________________________________

________________________________________________________________

AM / PM DATE
WORK COMPLETED/STOPPED/AREA CLEARED AT
_____________________

By___________________ By__________________________
Signature Signature

_____________________ __________________________
(Name of Issuer) (Name of Receiver)

(PLEASE RETURN PERMIT TO ISSUER)

 Annexure -V

Stock Receipt : Procedures

Steps Details Points to note

1 Bring tank dip • Operator should get spillage kit gloves, oil
equipment to finding paste and water finding paste to the
Discharge area Discharge area.
2 Ensure no ignition • There should not be any mobile phones or
within the area any other sources of ignition within the tank
dip area
3 Put on spill kit gloves • The operator and Supervisor should put on
the spillage kit gloves to protect their hands
and skin
4 Master Valve opened • Ensure that the master valve is in open
position
5 Pull out dip stick • Pull out the dip stick from the tank
• Find the Dip Level mark on the dip stick that
corresponds with the Compartment capacity
6 Apply the oil and • Apply oil finding Paste onto the Dip Level
water finding paste fuel mark on the dip stick
• Apply water finding paste onto the bottom 1
cm on the dip stock
7 Insert the dipstick • Insert the dip stick back into the tank slowly
back into the tank until it reaches the base of the compartment
• Let go of the dip stick
8 Check for the highest • Pull out the dip stick
wet marking on the oil
• Ensure that the oil finding paste mark is wet
finding paste & Check
till the Dip Level indicating that compartment
for water using the
is filled till capacity
water finding paste
• Verify the color of water finding paste. In
case there is change of color indicating
presence of water, alert the supervisor
9 Obtain density reading • With hydrometer and thermometer, obtain
the density reading of the fuel sample
• Use the density table to convert the tank fuel
density reading to the equivalent of fuel
density at 15 degrees C
10 Check density • Record equivalent of fuel density from each
variance compartment at 15 degrees C in density
 register
• Check variance between density of supplied
product and observed density in density
table (at 15 degrees C)
• If the variance between density of supplied
product and observed density and the
compartment fuel density ia above
acceptable limits report to the person in
charge
11 Replace equipment • Replace the safety cones/any equipment for
and wash hands isolating,water finding paste, Gasoline
Gauging Paste and the spillage kit gloves
• After the tank dip, clean your hands with
soap and return to regular duty

B. Tank Lorry Discharge Process

Procedures
Steps Details Points to note
1 Check current • Before the tanker discharge, perform a tank dip procedure to
fuel balance in find out the balance of fuel in UGT.
UGT through
• Perform tank dip only for the tanks containing the type of
tank dip
fuel to be discharged. For example, if the tanker is to
discharge Main grade ULP, it is not necessary to do a tank
dip for Premium Grade MS or HSD tanks.
• Measure balance in tank as per the tank dip reading
• Record pre-discharge tank dip reading, tank capacity and
ullage (difference between tank capacity and tank dip
reading) in the Records
2 Wave tanker • When the tanker arrives at the station, forecourt supervisor
into should wave it into the designated discharge area
designated
• The designated Discharge area should be on a fairly level
position
ground & clearly demarcated.
• Ensure that tanker is parked properly in the designated
discharge area and that the engine is switched off.
• Tanker parking brakes and gear must be engaged at all
times.
• Ensure that there are no sources of ignition within 20m of
the tanker (Sources of ignition would include cigarette,
naked flames and hand phone)
• Fire extinguisher should be easily accessible in the event of
an emergency and positioned upwind before discharging.
 • Ensure that the stand containing the Fire Buckets is easily
accessible, has min 3 sand buckets with protective cover &
is filled up to 75 % capacity with clean dry sand.
3 Check • Take the delivery order (D.O.) from tanker driver
D.O/Invoice,
• Check that the station name, address, date, time, vehicle
CCOE license
number of tanker on the D.O is correct.
& Tank Truck
Calibration • Match all relevant details on the D.O. with the order.
Certificate • Check CCOE License is valid
• Check Tank Truck Calibration certificate is valid & details
confirm to all fittings & measuring instruments/marks.
4 Check fittings • Dome covers and Master Valve box are properly welded
on Tank Truck
• Seal numbers on the Tank Hatch covers and Discharge
& Discharge
valves the same as those indicated in the DO/ Invoice
Hose
• Seals are intact and not tampered nor broken or covered
with any solution.
• Dip rod checked for vehicle no and W&M seal.
• Dip rod checked for actual length
• The lorry compartments filled up to the oil level on the dip
rod.
• No attempt should be made to pour back any product in the
Tanker manhole.
• Discharge Hose of tanker should confirm to OISD-STD-135
• Ensure only Hoses with approved quality, brading &
electrical continuity are used.

5 Connect Earth • Is the earth reel on the lorry connected to the Earthing Boss
reel near the receiving tank/fill point (This must be done before
opening any fill/discharge point or connection).
• Ensure that the ends of the crocodile clip are not rusted
• Ensure that the Earth reel doesn’t have any breaks/joints
• Ensure that the crocodile clip ends are properly connected
and are not loose
6 Fill in details • Fill in the date, time, name and amount of fuel to be
of Fuel discharged, tank into which fuel to be discharged
Discharge
• Enter the tank balance prior to fuel discharge (from tank dip
reading)

7 Perform • Measure the quantity of fuel in the tanker (for each grade)
tanker dip & by doing tanker dip
 check quantity • Record the tanker dip reading
of fuel
• The total volume of fuel to be discharged from tanker must
delivered
not exceed 90% ullage (Ullage = Maximum Available
Capacity for Fuel Discharge, i.e., Total Capacity of Tank
LESS Quantity of Fuel already present in tank).
• It is important to obtain an accurate reading of the current
balance in the tank to ensure that the 90% ullage is not
exceeded.
8 Perform • Take density reading of the tanker fuel for each grade
density check
on tanker fuel
9 Check seal on • Check that the seal on the tanker is intact before accepting
tanker & fill the load.
and dip points
• Do NOT break seal
• If there is insufficient ullage to accept the load of fuel or
• Inspect fill and dip points during tank dip and prior to fuel
discharge to ensure that there are no loose fittings at fill &
dip points of underground storage tanks.
10 Retailer /Shift • Retailer to authorize fuel discharge by signing on the D.O.
Mgr to
• Fuel discharge hose must be connected to the correct
authorize
underground tank before discharge.
discharge
• The hose connections must be in good order and have no
leakages during product discharging. Check that there are
no loose fittings at fill & dip points of underground storage
tanks
• Ensure that master valve is opened during tanker discharge.
• Inform the driver on the correct compartment to discharge
the fuel. It is CRUCIAL that there are no mistakes in
discharge. Different fuels MUST not be mixed.
• Ensure that tanker driver must be present during the entire
discharge process. Similarly, station representative must
also be present throughout entire process.
11 Milk residual • Tanker driver should rapidly open and shut the valve
fuel controlling fuel flow to 'milk' the remaining fuel from the
tanker.
• After that, pour the fuel thus obtained back into the
respective tanks.
• Apply fuel finding paste to the end of the tanker dipstick and
insert into each tanker compartment to ensure that no un-
discharged fuel remains inside the tanker
• Petrol must be drained into an aluminum container which
 shall be bonded/earthed.

12 Lock filling • After entire process is complete, ensure that filling point is
point locked and that all tank inlets are properly capped.
13 Acknowledge • Retailer should sign and put station stamp on D.O as
delivery acknowledgement of receipt of fuel.
• Ensure that head office copy of the D.O is properly signed
and stamped before returning it to the tank driver.
• Station copy of D.O to be retained for updating of records.
14 Check new • Perform another tank dip to check on new balance.
fuel balance
• Record the new tank balance

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