Design, Construction, Operation, Maintenance, and Inspection of Terminal & Tank Facilities

API STANDARD 2610 SECOND EDITION, MAY 2005

Design, Construction, Operation, Maintenance, and Inspection of Terminal & Tank Facilities

Downstream Segment

API STANDARD 2610 SECOND EDITION, MAY 2005

SPECIAL NOTES

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Copyright © 2005 American Petroleum Institute

FOREWORD

This standard was developed to guide the management of terminals and tanks in a manner that protects the environment and the safety of workers and the public. This standard is intended for petroleum terminal and tank facilities associated with marketing, refining, pipe- line, and other similar facilities. This standard may be used as a resource and management guide by those responsible for such facilities and by those working on their behalf. This stan- dard is a compilation of industry knowledge, information, and management practices for all relevant aspects of terminal and tank operations aggregated into an overview document com- prising best practices. In instances where greater detail or additional information may be helpful or needed, this standard references other API publications or similar industry guides and standards. It is intended to be consistent with, but is not a substitute for, any applicable local, state, or federal regulations.

The requirements of this standard represent minimum requirements applicable to all facil- ities within the scope of this document. Some provisions in this standard, as indicated by the use of the word shall, are mandatory and have to be followed to meet the intent of this stan- dard. Some provisions are recommended, as denoted by the word should, but are not manda- tory. These provisions will need to be considered based on site-specific factors. Still other provisions are optional, as denoted by the word may. Typically, these will be given where a range of good options exists.

To foster greater awareness and assist the industry in addressing environmental, health, and safety concerns, the API has undertaken the development of this single document aggre- gating the various standards, specifications, and recommended practices on the design, con- struction, operation, inspection, and maintenance of petroleum terminals and tanks. API also has significant research underway to assist members in addressing issues of groundwater protection and remediation of soil contamination. This research includes the evaluation of improved leak detection technology and the evaluation of better methods to detect and reme- diate groundwater and soil contamination.

API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict.

Suggested revisions are invited and should be submitted to API, Standards Department, 1220 L Street, NW, Washington, D.C. 20005, standards@api.org.

iii

1. Overview 8

2. Site Selection 8

3. Spacing Requirements 9

1. POLLUTION PREVENTION AND WASTE MANAGEMENT 10

   1. Applicability 10

   2. Waste Management Hierarchy 10

   3. Pollution Prevention 11

   4. Waste Management Practices 13

2. SAFE OPERATIONS OF TERMINALS & TANKS 14

   1. General 14

   2. Hazard Identification 14

   3. Operating Procedures 14

   4. Safe Work Practices 14

   5. Emergency Response and Control Procedures 14

   6. Management of Change 15

   7. Training 15

   8. Pre-Startup Safety and Operational Inspection 15

   9. Incident Investigation 15

   10. Contractor Safety 16

1. TANKS 20

   1. Aboveground Petroleum Storage Tanks 20

   2. Operations, Inspections, Maintenance, and Repair for Aboveground Tanks . . . 23

   3. Fiberglass Aboveground Storage Tanks 24

   4. Underground Tanks and Piping 24

      v

   5. Underground Storage Tank Vapor Emissions 24

2. DIKES AND BERMS 24

   1. Overview 24

   2. Dikes 24

   3. Berms 26

1. LOADING, UNLOADING AND PRODUCT TRANSFER FACILITIES 30

   1. Scope 30

   2. General Design 30

   3. Truck Loading/Unloading 31

   4. Rail Tank Car Loading and Unloading 33

   5. Marine Loading/Unloading 34

   6. Aviation Loading/Unloading 35

   7. Vapor Control 35

   8. Oxygenate Blending 37

   9. Emergency Shutdown Systems and Procedures 37

   10. Product Testing 37

   11. Communication 37

   12. Measurements 37

   13. Valves, Lines, Loading Arms, and Hose Product Identification 38

   14. Release Prevention System in Loading/Unloading Areas 38

   15. Maintenance/Testing 38

   16. Auxiliary Systems 38

2. CORROSION CONTROL 38

   1. Scope 38

   2. Protective Coatings 38

   3. Internal Tank Lining 41

   4. Cathodic Protection 42

3. STRUCTURES, UTILITIES, AND YARD 43

   1. Structures 43

   2. Utilities 44

   3. Yard 49

4. REMOVALS AND DECOMMISSIONING OF FACILITY 51

   1. General 51

   2. Site Control and Protection 53

   3. Preparations 53

   4. Execution 53

   5. Site Assessment and Remediation 53

   6. Closeout and Cleanup 53

Figures

1. Typical Electric Service and Distribution System Terminals and Bulk Plants . . . 45

2. Segregated Waste Stream in a Typical Terminal 47

3. Tank Truck Loading Yard Layout without Garage 50

4. Tank Truck Loading Yard Layout with Garage 51

5. Yard Dimensions for Trucks (See Table Above) 52

Design, Construction, Operation, Maintenance, and Inspection of Terminal & Tank Facilities

1. General

   1. SCOPE AND PURPOSE

      This standard covers the design, construction, operation, inspection, and maintenance of petroleum terminal and tank facilities associated with marketing, refining, pipeline, and other similar activities as stipulated in 1.1.1 through 1.1.7. This standard covers the issues of site selection and spacing, pollu- tion prevention and waste management, safe operation, fire prevention and protection, tanks, dikes and berms, mechanical systems, product transfer, corrosion protection, structures, utili- ties and yard, and removals and decommissioning.

      The purpose of this standard is to consolidate a wide base of current industry experience, knowledge, information, and management practices into a cohesive standard comprising a range of best practices.

      Mandatory requirements in this standard are designated by the word “shall” or “must.” Recommendations are designated by the use of the word “should.” Optional items are desig- nated by the word “may” (refer to Section 3). This standard incorporates by reference a number of other standards and recommended practices. The distinctions between mandatory, recommended, and optional provisions in the referenced doc- uments are not changed by the nature of their reference in this standard.

      The values stated for this standard are in U.S. Customary units with the International System of units (SI) provided in parentheses.

      The petroleum industry is engaged in the manufacture, storage, transportation, blending, and distribution of crude oil and refined products. Individual terminal facilities and plants may perform one or more of these functions. These facilities represent diverse operations ranging from small distribution facilities (e.g., bulk plants and warehouses), to large storage and distribution facilities (e.g., pipeline and marine terminals and wholesale plants), and large integrated facilities (e.g., petroleum refineries, and grease production, oil blending and packaging plants). The specific application of this standard within those various types of operations is itemized in 1.1.1 through 1.1.7.

      
      

      1. Petroleum Terminals

         Petroleum terminals may include tank farms, loading and unloading areas, pipeline manifolds, storage areas, ware- houses, docks, garages, laboratories, and office buildings. Products may be received and distributed by pipeline, marine transport, rail, or truck. Bulk quantities of refined products are stored in aboveground tanks for distribution in smaller quantities to industrial customers, to commercial consumers,

         and to retail and wholesale marketing facilities. Petroleum terminals may also store petroleum products in consumer packaging, bulk containers, inside tanks and drums.

         
         

      2. Pipeline Tankage Facilities

         Pipeline tankage facilities consist of tanks and tank farms used to receive petroleum (crude oil and refined products) from pipelines, trucks, railcars, or marine facilities and to pro- vide surge relief from pipeline operations (see Office of Pipe- line Safety, Research and Special Programs Administration regulation 49 CFR Part 195 and the U.S. Coast Guard regula- tion 33 CFR Parts 154 and 156).

         
         

      3. Refinery Facilities

         Provisions for loading and unloading areas, docks, blend- ing and packaging facilities, warehouses, and some refinery tankage facilities are included in this standard. Refinery tank- age covered by this standard does not include those above- ground tanks or groups of tanks as defined in 1.2.c (e.g., process tanks).

         Examples of covered refinery tankage include tanks that are used to accomplish the following:

         1. Receive incoming crude oil.

         2. Store intermediate products or components outside of the refinery process units.

         3. Store finished products for shipment by truck, marine transport, rail, or pipeline.

         Examples of refinery tankage and other equipment specifi- cally excluded are as follows:

         1. Tanks and equipment that are integral to refinery process equipment.

         2. Refinery tanks and other equipment located within the bat- tery limits of process units.

         3. Process equipment located outside the process unit battery limits.

         4. Tanks that contain materials, such as additives, used in refinery processes or utility systems.

         
         

      4. Bulk Plants

Although bulk plants typically handle smaller quantities of product, operations and facilities at these plants are similar to those at petroleum terminals. Bulk plants typically receive and distribute product by truck, although some are serviced by rail, marine transport, or pipeline. Bulk plants may also store an inventory of petroleum products in consumer pack- aging, bulk containers, inside tanks and drums.

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