IN DUSTRY MA-1`'T LiAL ONOPERATION

Q ICJ A L I rI-' r

AFTY

ONANHYDRO LTS

ETHANOLFOR

A 1_1 TOM.OTI'\7- F LJ L _

N OV*M.3 E,R, 2 004

INDUSTRY MANUAL ON OPERATIONS, QUALITY & SAFETY ON ANHYDROU SETHANOL FOR USE IN AUTOMOTIVE FUE L

An Industry group under the convenor ship of DGM(QC), IOC Ltd worked collectively t obring out Industry Manual On Operations, Quality & Safety on Anhydrous Ethanol fo ruse in Automotive Fuel . As a part of this exercise, various meetings with the Industrymembers were undertaken . The group also visited the distilleries and obtained the suppor tfrom respective R&D Centre .

Experience gained during the pilot project and feed back from the field was also considere dwhile preparing this document . Interaction and liaisoning with BIS was also maintained t obring out relevant specification and test methods .

The group has deliberated in great detail and has drawn up this manual containing in th efollowing pages, to be implemented by all Oil Industry .

Sr .No .

Name Designation Signature

1 . Shri .P.D.Bahukhandi .(Convenor)

DGM(QC) ,Indian Oil Corporation Limited .Head Office Mumba i

2 . Dr.PVSL .Narasimham Senior Manager(QC )Bharat Petroleum Corporation Limite dSewri, Mumbai

3 . Shri .D .Roy Senior Manager(QC )Hindustan Petroleum Corporation LimitedHead Quarters, Mumba i

4 . Shri .K.Hariharan Manager(Ops)IBP Co. LimitedHead Office, Mumbai

2

Foreword ,

Ethanol is a high octane product which is used for doping with Motor Gasoline . It is derive dfrom molasses and other renewable resources . It is an oxygen-enhancing additive tha thelps Motor Gasoline burn cleaner, thus reducing air pollution due to lesser harmfu lemissions such as carbon monoxide . It also results in reduction in the use of crude oil, anon-renewable resource and in dependence on import of petroleum products thereb ysaving valuable foreign exchange for the country . Ethanol doped Motor Gasoline isbecoming a worldwide practice and is mainly used in countries like, U .S.A., Brazil, Mexico ,Australia, New Zealand, etc . Ethanol Doped Motor Gasoline is widely accepted as Moto rVehicle Fuel .

Bureau of Indian Standards specification for Motor Gasoline, IS 2796 :2000 permits thedoping of Ethanol to the extent of 5% v/v max . in Motor Gasoline .

Ministry of Petroleum & Natural Gas vide its Gazette Notification Extraordinary Part I -Sec.1, under Sr . No. 230 & resolution No. P-45018/28/2000-CC dated 3rd September 200 2mandated sale of only 5% ethanol doped Motor Gasoline w.e .f. 1st January 2003 . in thenotified States and Union Territories . However, due to non availability of adequat eethanol/price differential, the dates of implementation as well as mandate is amended fro mtime to time .

While practising the laid down procedures, various laws / statutory requirements pertainin gto the handling, storage, dispensing, purchase, sale, safety etc . need to be adhered to. Al lpractices as being followed in handling Class `A' Petroleum Products are required to b eadhered to while handling Ethanol and Ethanol Doped Motor Gasoline .

BIS has come up with specification IS 15464:2004 for Anhydrous Ethanol for use i nAutomotive Fuel .

The Manual provides guidelines based on proven practices developed in this field . Safe andenvironmentally acceptable working procedures and simple tests to assess quality in th efield are furnished in this Manual . In near future, even if the vehicles are required t ooperate on Motor Gasoline having more than 5% v/v of ethanol, the basic practices o fhandling Ethanol and Ethanol Doped Motor Gasoline will remain the same .

3

Section 1 5Introduction

Section 2 6Terminology

Section 3 8Salient Features of Ethano l

Section 4 9Quality of Ethano l

Section 5 1 1Receipt of Ethano l

Section 6 1 3Storage and Handling of Ethano l

Section 7 1 5Colour Coding for Ethano l

Section 8 1 6Quality Monitoring for Ethano l

Section 9 1 7Doping of Ethanol in Motor Gasoline and Quality Control Check s

Section 10 1 9Tank Trucks for Transportation of Ethanol Doped Motor Gasolin e

Section 11 20Handling of Ethanol Doped Motor Gasoline at Retail Outlets

Section 12 22Safety

Section 13 25Additional Precautions

4

Appendix 26

Reference 27

Appendix : 1 28

Appendix :2 33Typical Line Diagram of Ethanol Automatic filing facility at Locatio n

Appendix 3 34Typical Line. Diagram of Ethanol Facility at Locatio n

Appendix 4 35Frequently Asked Questions

I

5

Industry Manual on Operations, Section. 1 Introductio nQuality Control & Safety for Ethanol Clause No. 1 Page No. 1 / IDoped Motor Gasoline

PROPERTIES, RECEIPT, STORAGE, DOPING & DELIVERY AT DEPOT PREMISES /RETAIL OUTLETS

1 .

Introduction :

1 .1 Ethanol is an agricultural based product, mainly a by-product of sugar industries i nour country, available in sugar belt areas . Presently Bureau of Indian Standard sunder specification IS 2796 : 2000 recommends addition of ethanol in Moto rGasoline up to 5 % vol . Max.

One of the main motives for use of ethanol in Motor Gasoline is to improve ai rquality. By switching to these new fuels, the fleet owners are leading the way toenergy security and cleaner air . Motor gasoline with ethanol is well suited fo rreplacing gasoline in light duty vehicles making fuel more environmentally friendly .

There is a difference in polarity between Ethanol and Motor Gasoline . Doping o fethanol can be unstable particularly if water is present at low temperatures, resultin gin the separation of two phases, one rich in Ethanol and the other rich i nhydrocarbons . This property of Ethanol makes it mandatory to ensure water-fre estorage and distribution system for Ethanol doped Motor Gasoline . In short, sinceEthanol is readily miscible in water, all ethanol and Ethanol doped Motor Gasolin edistribution and storage systems shall be kept "dry" .

1 .2

The procedures outlined in this manual are only the minimum requirements in orde rto ensure quality of ethanol as well as ethanol-doped fuel .

6

Industry Manual on Operations, Section. 2 TerminologyQuality Control & Safety for Ethano lDoped Motor Gasoline Clause No. 2.1 to 2 .5 Page No. 1 / 2

2 .

Terminology

2 .1

Ethanol :

Ethanol is the pure chemical, otherwise known as hydroxyethane, corresponding t othe constitution CH 3CH 2OH and molecular formula C 2 H5OH .

2 .2

Ethyl Alcohol (Absolute Alcohol) :

Ethyl alcohol (Absolute alcohol) is a Clear, Colourless and homogenous liquid ,consisting essentially of ethanol admixed with not more than 0 .5% by vol . of water .

2.3

Anhydrous Ethanol :

Anhydrous ethanol is essentially ethyl alcohol, which is denatured and is meant fo ruse as fuel in automobile engines . The IS 15464: 2004 prescribes requirements ,methods of sampling and test for anhydrous ethanol, which is used either as such o rmore usually in admixture with petrol and diesel as a fuel for automobile engines .

2.4

Denaturant :

Denaturant is a substance completely miscible in ethyl alcohol and of suc hcharacter that while its addition makes the material or any aqueous dilution of i tunpleasant and unwholesome for potable purposes, its presence does not rende ranhydrous ethanol, either as such or doped with petrol or diesel, unsuitable for usein automobile engines .

The denaturant to be admixed with ethyl alcohol and the proportion in which it is t obe used shall be as prescribed by law from time to time .

2.5

Prohibited Denaturants :

Specific mention must be made of some materials that have extremely advers eeffects on fuel stability, automotive engines and fuel systems . These materials shal lnot be used as denaturants, for anhydrous ethanol for use in automobile fuels ,under any circumstances . They are as follows : Methanol Pyrroles, Turpentine ,Ketones and Tars (high molecular weight pyrolysis products of fossil and non-fossi lvegetable matter) . Unless a denaturant, such as a higher aliphatic alcohol or ether ,is known to have no adverse effect on gasoline-ethanol mixture or on automotiv eengines or fuel systems, it shall not be used .

7

Industry Manual`on Operations, Section. 2 Terminolog yQuality Control & Safety for Ethano lDoped Motor Gasoline Clause No. 2 .6 to 2 .9 Page No. 2 / 2

2.6

Motor Gasoline :

A volatile mixture of liquid hydrocarbons, generally containing a small amount o fadditives, suitable for use as a fuel in spark ignition and internal combustion enginesconforming current BIS specification IS : 2796 and or as per the requirement of theGazette notification issued by Govt. of India from time to time and or guidelin eissued by MOP & NG regulatory authorities from time to time.

2 .7

Ethanol Doped Motor Gasoline :

A fuel consisting primarily of Motor Gasoline doped with 5% vol ./vol . of denature danhydrous Ethanol for fuel conforming to Motor Gasoline Specification .

2.8

Oxygenate :

An oxygen containing ash-less, organic compound such as an alcohol or ether ,which may be used as a fuel or fuel supplement .

2.9

Denatured anhydrous Ethanol for fuel :

Denatured anhydrous Ethanol for fuel is made unfit for use as beverage by th eaddition of denaturants as per IS 15464 for Anhydrous Ethanol for use i nAutomotive Fuel Specification . In the following sections wherever the term Ethano lis used it refers to denatured anhydrous Ethanol for fuel .

8

Industry Manual on Operations, Section. 3 Salient Features ofQuality Control & Safety for Ethanol EthanolDoped Motor Gasoline Clause No. 3.1 to 3 .6 Page No . 1 / 1

3 .

Salient features of Ethanol :

3.1 Ethanol is completely soluble in water, which presents potential problems fo rstorage and handling. However, Ethanol will not be significantly degraded by smal lamount of clean water, though water addition dilutes its value as a fuel .

3 .2 A higher conductivity suggests that Ethanol will dissipate static charges that build u pwhen pumping fuel during fuel transfers faster than Motor Gasoline . This givesEthanol a theoretical safety advantage over Motor Gasoline, as static electrica lcharges generated will be dissipated more quickly .

3.3

Viscosity of Ethanol is higher than that of Motor Gasoline . However, it does notpose any problem in handling in cold weather.

3.4 The auto-ignition temperature of Ethanol is significantly higher than that of Moto rGasoline . This makes Ethanol less susceptible to ignition when spilled on ho tsurfaces such as Engine Exhaust Manifolds .

3.5

The lower flammable limit of Ethanol is higher than Motor Gasoline . This is anotheradvantage over Motor Gasoline .

3.6

Pure Ethanol burns with a flame that is not clearly visible in bright sunlight .However, Ethanol doped Motor Gasoline flame is visible .

9

Industry Manual on Operations, Section. 4 Quality Of Ethano lQuality Control & Safety for Ethanol Clause No . 4.1 to 4 .2 Page No. 1 / 2Doped Motor Gasoline

4.

Quality of Ethanol :

4 .1

Bureau of Indian Standards under Alcohols and Allied Products Sectional Committe ePCD 10/T-29 C has approved IS 1546 4

"Anhydrous Ethanol for use in Automotive Fuel" .

The present characteristics requirement of Ethanol for Motor Gasoline is worked ou tbased on the domestic quality of Ethanol available, its specification and experienc eon application in its end-use as Ethanol Doped Motor Gasoline through the Pilo tProjects /Field experience .

4.2

Specification of Ethanol :

The Anhydrous Ethanol to be used for doping with Motor Gasoline should conformto IS 15464 Specification . The Manufacturer should also ensure that a denaturant i sadded at their premise before the product is dispatched to the Oil Companies . TheManufacturing Specification is mentioned in table 1 (under Section 4) as under .

Description :

The material shall be a Clear, Colourless and homogenous liquid, free fro msuspended matters and consisting essentially of Anhydrous Ethanol . The materia lshall also comply with the requirements given below Table 1 .

1 0

Industry Manual on Operations, Section. 4 Quality Of Ethano lQuality Control & Safety for Ethanol Table No . 1 & Clause Page No . 2 / 2Doped Motor Gasoline 4.3.2

Table No . 1

Sr .No

Characteristics IS 15464 Method of Test Refer IS15464 (Annex)

01 Relative Density at 15.6/15 .6°C, Max . 0 .7961 ** A02 Ethanol content % by Volume at

15.6/15 .6°C, Min . (excludingdenaturant)

99 .5 ** B

03 Miscibility with water Miscible C04 Alkalinity Nil D05 Acidity (as CH3COOH) mg/I, Max . 30 D06 Residue on evaporation, percent b y

mass Max .0.005 E

07 Aldehyde content as CH3 (CHO )mg/I, Max

60 F

08 Copper mg/kg, Max 0.1 G,09 Conductivity, pS/m, Max 300 H10 Methyl alcohol, mg/litre, Max. 300 J11 Appearance Clear and

Bright **Visua l

Note :** With a view to ensure ethanol quality by the time it is received at the location, Industry' srequirement is more stringent in respect of ethanol content 99 .6% vol . and consequentl y0 .7956 density at 15.6 deg . C, and appearance Clear & Bright and free from suspende dmatter .

4 .3

Denaturants :

4.3.1 The denaturant to be added with Ethanol and the proportion in which it is to be use dshall be as per prescribed excise regulation from time to time conforming to th eautomotive fuel requirements . Denaturants may be considered as a part of Ethano land component of the fuel . These denaturants should not have detrimental effect onspecification and stability of Motor Gasoline .

4.3.2 The following are some of the Prohibited denaturants as per Clause 2 .5 for Ethano lcannot be used i .e.' Pyrroles, Methanol, Turpentine, Ketones, Tar, Organo-metalli ccompounds .

The Anhydrous Ethanol must contain any of the denaturants in suitable dosage a sper IS : 4117 in line with IS-15464 .

The denaturants should be pre mixed at ethanol manufacturer end beforetransporting the Ethanol to oil company premises .

1 1

In this manual wherever "Ethanol" is mentioned means "Denatured Ethanol" only .

Industry Manual on Operations, Section. 5 Receipt Of Ethano lQuality Control & Safety for Ethanol Clause No. 5.1 to 5 .6 Page No. 1 / 2Doped Motor Gasoline

5 .

Receipt of Ethanol :

5.1

Receipt of Ethanol :

5 .1 .1 Ethanol shall be received at depots in dedicated tank trucks . All care shall be take nto prevent ingress of water into the compartments during transportation .

5 .1 .2 The fittings in tank trucks used for transportation of Ethanol to receiving location sshall be the same as used for storage and handling of Class 'A' Petroleum products .

5 .1 .3 The consignment of Ethanol must carry Quality Certificate as per IS 15464Specification covering the specification as per table No . 1 with foot note unde rSection 4 . This Quality Certificate should also contain the Batch number and thename of the denaturant used along with its dosage .

5 .2

On arrival, one litre top and bottom sample from each compartment of the tank truc kshall be drawn after the line content is drained off .

5.3 These samples should be tested for visual appearance and Specific Gravity (SG) a t15.6°C / 15 .6°C . For conversion of SG from ambient temperature to 15 .6°C /15 .6°C, separate charts as per IS 2302 - Table 1 & Table 2 as well as IS 321 -Appendix B are to be used . The SG should be within + 0 .0005 of the despatchSpecific Gravity . A composite sample should be made from these samples for futuretests . (Relative Density at 15.6°C / 15.6°C of IS 15464 as mentioned in Table 1 ofSection 4 is same as Specific Gravity in Air 15.6°C / 15 .6°C of IS 321, Table I, Ite m(ii)) .

Alternative to the above ASTM D4052 method for Density and Relative Density o fLiquids by Digital Density Meter may be used for measurement of specific gravity ,however, the method under IS 15464 :2004 will be the referee method .

5.4

The above composite sample should be tested for the following characteristics :

Appearanceii. Colour (Visual )iii. Ethanol Content % Vol . IS- 2302iv. Hydrocarbon contamination checks (Refer clause 5 .7) .

Specific gravity at 15 .6°C/15 .6°C for computing quantity can be calculated from th epercentage of Ethanol content using the table 1 and 2 of IS 2302 and table I, ite m(ii) in Appendix B of IS 321 .

12

5 .5

For determining Ethanol Content IS 2302 Tables for Alcoholometry by hydrometermethod should be used .

5.6 Specific gravity can be derived by using the Ethanol Content and the Appendix B o fIS 321 . The specification, however, includes option to determine specific gravity bythe method given in IS 321 .

Industry Manual on Operations, Section. 5 Receipt Of Ethano lQuality Control & Safety for Ethano lDoped Motor Gasoline

Clause No. 5 .7 to5.12

Page No. 2 / 2

5.7 To ensure that there is no contamination of hydrocarbon with Ethanol, take 50 ml o fwater in 100 ml clean graduated stoppered glass cylinder (A class), put 50 ml o fEthanol at the top of it . Stopper the cylinder and shake thoroughly for 15 sec . Setaside the cylinder . Observe that water is fully soluble with Ethanol and no layer i sformed . This ensures no contamination of hydrocarbons with Ethanol .

5 .8 One litre composite sample of Ethanol from the tank truck should be drawn, sealed ,labelled and jointly signed by the driver/authorised representative of the transporte rand the receiving Officer of the Oil Company. These samples shall be retained for aperiod of 30 days. Only Glass or Stainless Steel sample containers should be used .Aluminium containers should not be used for storing Ethanol samples .

5.9 Product can be decanted into the tank, after matching the quality certificate of theconsignment of the supplier with that of the requirement of the characteristics a smentioned in table no . 1 of Section 4 as well as physical verification carried out asper clause 5 .3 and 5 .4 .

5 .10 The unloading operations shall be carried out through special Nitrile rubber or an yother compatible hoses . Ethanol being hygroscopic in nature, utmost precautio nneeds to be taken to ensure that there is no ingress of water or humidity . Both theends of the hoses after use shall be capped . 80 mesh strainers (material asspecified in Section: 6) shall be provided before the pump / tank inlet as the casemay be. All safety precautions shall be taken as that for Class `A' product .

5 .11 Appropriate recommended dosage of Metal Deactivator and Corrosion Inhibitor shal lbe added during the decantation of Ethanol from tank truck into the storage tank, s oas to ensure homogeneity of additives with ethanol in the storage tank . A separateOperations and Inventory logbook shall be maintained for the additive .

5.12 The location shall maintain a Batch-Control Logbook tank-wise for receipt of Ethano lin the storage tank as per the following format

Batch Control Log Book Location :Despatch Details Receipt Detail s

Sr.No .

Supplier's Name Date

o fDespatch

BatchNo .

Test ReportNo .

Date

ofReceipt

Batch No . Sig n

1 3

Industry Manual on Operations, Section. 6 Storage and HandlingQuality Control & Safety for Ethanol Of Ethano lDoped Motor Gasoline Clause No. 6.1 to Page No . 1 / 2

6.11

6 .

Storage and Handling of Ethanol :

6 .1 Material recommendations : The compatibility of Ethanol/Ethanol Doped Moto rGasoline with material coming in contact while handling means not only thatequipment made from material will not deteriorate but also that the quality of Ethano las well as Ethanol Doped Motor Gasoline in contact with the material will no tdegrade. The supplier/contractor will ensure in this regard . It is recommended tha tintegrity of all materials coming in to contact with the fuel will be verified with `Soa ktesting' as per standard engineering practice .

6 .2

Nozzles, fittings, connectors, piping, pump and impellers may be of best suitabl ematerial compatible with Ethanol as recommended for the storage tanks .

6.3 Zinc, Brass, Lead, Copper and Aluminium are some of the sensitive material sknown to be degraded while contact with Ethanol . Lead based solders are als oincompatible with Ethanol . Avoid using them.

6.4

Un-plated Steel, Stainless Steel, Black Iron and Bronze have shown acceptabl eresistance to corrosion by Ethanol .

6 .5 Non-metallic materials that degrade when in contact with Ethanol include Natura lRubber, Polyurethane, Cork gasket material, Leather, Polyester – bounde dFibreglass laminate, Polyvinyl Chlorides, Polyamides and Methyl and Methacrylat ePlastics .

6.6 Non-metallic materials that have been successfully used with fuel Ethanol includ eBuna-N, Neoprene rubber, Polyethylene, Nylon, Polypropylene, Nitrile, Glass, Vito nand Teflon .

6.7 Ethanol can be stored in above ground or underground tank(s) . Factors like the siz eof the tank, the space available, requirements for stationary evaporative emission sand Safety aspects will determine which type of tank is best for use .

6 .8

Epicoating is not recommended for the tanks proposed for storage of Ethanol .

14

6.9 Epicoating recommended in storage tank for general hydrocarbons may not b ecompatible for system handling Ethanol / Ethanol Doped Motor Gasoline and it ma ybe ensured before any application or use .

6.10 Ethanol falls under the same handling and storage requirements as Motor Gasolinewithin the provision of applicable norms .

6.11 Tank should be constructed of low carbon, cold finished steel and butt-welded . Donot use any plated material tank .

Industry Manual on Operations, Section. 6 Storage and HandlingQuality Control & Safety for Ethanol Of Ethano lDoped Motor Gasoline Clause No. 6.12 to Page No . 2 / 2

6.17

6.12 The storage tanks and allied facilities for Ethanol shall be positively segregated . The.existing Class `A' product storage tank fitted with Pressure Vacuum Valve (P Vvalve) can be used for storing Ethanol after thorough cleaning . The tank shall beabsolutely free from water at all times .

6 .13 Ethanol storage tanks shall be cleaned once in two years or more frequentl ydepending on the need . Tank cleaning certificate shall be maintained as perAppendix – A of IQCM . Date of tank cleaning and due date of next tank cleaningshall be painted on the manhole cover . For Under Ground Tanks, the details of tan kcleaning shall be displayed on a suitable display card .

6 .14 All level samples after receipt of first parcel in a newly commissioned tank / afte rtank cleaning shall be sent to laboratory for necessary Test (Clause No . 9 .2.2) . Theproduct from the tank shall be released only if the Laboratory confirms that th eproduct meets specification requirement in respect of the tests carried out .

6 .15 As Ethanol is hygroscopic and will absorb moisture from the air, Silica Gel trap mus tbe provided in the vent pipe of the tank to prevent ingress of moisture into the tank .Regular check on the Colour of silica gel shall be maintained (Blue Colour) and shal lneed immediate replacement on showing signs of saturation by way of change o fcolour. Say, Silica gel turns from blue to pink after it absorbs moisture .

6 .16 The silica gel can also be reactivated on heating in an air oven for about one hour a t110°C, till it again turns blue . Then it will become ready for re-use .

6.17 Other storage tank openings / pipeline fittings shall be airtight and the threade dconnections if any shall be tightened with the help of Teflon paste or Teflon tapes .Bolted connections shall have gaskets of Teflon .

1 5

Industry Manual on Operations, Section. 7 Colour Coding forQuality Control & Safety for Ethanol EthanolDoped Motor Gasoline Clause No . 7 .1 Page No. 1 / 1

7 .

Colour Coding for Ethanol :

7.1 The colour band for Ethanol on the pipeline shall be Purple (ISC No . 796) . Theprocedure for Colour Coding shall be in accordance with Clause 4 .3.3 of IndustryQuality Control Manual for Non Aviation Products (IQCM) .

16

Industry Manual on Operations, Section. 8 Quality Monitoring forQuality Control & Safety for Ethanol EthanolDoped Motor Gasoline Clause No. 8 .1 Page No. 1 / 1

8 .

Quality Monitoring for Ethanol :

8 .1 One litre composite sample of Ethanol from the storage tank(s) shall be collected i nStainless Steel or Glass container for Monitoring Tests and send to the neares tLaboratory once in a month . A counter sample is to be retained at location till la btest are obtained .

These samples shall be tested for all characteristics as per clause 9 .2.2.(i) .

1 7

Industry Manual on Operations, Section. 9 Doping of Ethanol in Moto rQuality Control & Safety for Gasoline and Quality Contro lEthanol Doped Motor Gasoline Checks

Clause No . 9.1 to Page No . 1 / 29 .1 .3

9 .

Doping of Ethanol in Motor Gasoline and Quality Control Checks :

9 .1

At Depot / Installation / Terminal :

9 .1 .1 It is necessary that adequate care be taken to ensure the correct dosage in onlin edoping of Ethanol with in Motor Gasoline. Ethanol is to be doped in Moto rGasoline with the concentration of 5% v/v .

9 .1 .2 Manufacturing specification of Motor Gasoline to be kept at Refinery end such tha tthe end product from Marketing after doping 5% v/v Ethanol into Motor Gasolin eremains within specification IS 2796 .

9 .1 .3 Procedure for Doping Anhydrous Ethanol in Motor Gasoline :

To ensure uniform doping of Ethanol with Motor Gasoline, on line doping o fEthanol shall be carried out through a closed system, with proper interlocks, whil emaintaining efficacy of mixing Ethanol in the right proportion of 5% v/v as pe rspecification .

The quantity of Ethanol to be doped into the Motor Gasoline is worked out fo reach compartment of the tank truck on the basis of 5% vol . of Ethanol in MotorGasoline. Doping shall be carried out by synchronising with the total delivery o fdesired 5% vol . of Ethanol with Motor Gasoline in that compartment . This can b everified by test method given in Appendix- 1

An 80-mesh filter shall be provided on the delivery side of Ethanol storage tank i .e .between pump and TLF Gantry point .

Typical line diagram of Ethanol facility at storage locations is given as Appendix- 2/ 3 .

1 8

Industry Manual on Operations, Section . 9 Doping of Ethanol in MotorQuality Control & Safety for Gasoline and Quality Contro lEthanol Doped Motor Gasoline Checks

Clause No . 9 .1 .4 Page No. 2 / 2to 9 .2.2

9.1 .4 The following QC checks are recommended for the doping :

a. All samples shall be drawn, tested and retained as per the procedure laid downin IQCM.

A sample of Ethanol Doped Motor Gasoline shall be drawn in each shift an dwhenever there is a switch over of Motor Gasoline / Ethanol tank on an hourl ybasis. The sample should be tested for Appearance, Density at 15°C an dAlcohol content .

Determination of Ethanol content in Ethanol Doped Motor Gasoline is to b ecarried out as per procedure outlined in Appendix 1 .

b. In case Ethanol content of Motor Gasoline exceeds / less than the permissibl elevel of 5%, corrective steps are to be taken immediately .

c. Retention of the Ethanol Doped Motor Gasoline sample from TLF shall b efollowed as per IQCM requirements (before commencement of loading in eac hshift and whenever there is a switchover of Motor Gasoline / Ethanol tank) .

9.2

Test / Facilities required for Ethanol testing :

9 .2.1 At Depot / Installation :

Facilities required for the field test of Anhydrous Ethanol Content :

• Hydrometers/Alcoholometers (IS :3608 Part 2 : 1987) ,• Thermometers ,• Glass Cylinders ,• 100 ml graduated glass cylinder (A class) with stopper .

1 9

Specific gravity at 15 .6°C/15 .6°C for computing quantity can be calculated from th epercentage of Ethanol content using the table 1 and 2 of IS 2302 : 1989 and table Iof item (ii) in Appendix B of IS 321 :1964 .

9.2.2 At QC Labs :

i) As per full specification test of Ethanol other than Copper content an dmethyl alcohol content (Batch Formation test) However, colour of ethano lmay be slightly vary due to addition of special additive like, Meta ldeactivator and corrosion inhibitors .

ii) Contamination / suspected adulteration or deviation in ethanol may b everified by carrying out full specification test as per Table .l of section 4 .2 .

Industry Manual on Operations, Section. 10 Tank Trucks for Transportatio nQuality Control & Safety for of Ethanol Doped Moto rEthanol Doped Motor Gasoline Gasoline

Clause No. 10 .1 Page No. 1 / 1to 10.3

10 .

Tank Trucks for Transportation of Ethanol Doped Motor Gasoline :

10.1 The tank trucks can be upgraded for the purpose as specified in IQCM for handlin gnon-aviation products and inspect from inside for cleanliness and dry out an yaccumulated water or product before loading Ethanol Doped Motor Gasoline .

10.2 The tank truck fit for transportation of Motor Gasoline shall be used for Ethano ldoped Motor Gasoline . Adequate care shall be taken to ensure that the tank truckfittings are absolutely airtight and no ingress of water or air is allowed .

10.3 The Epicoating applied in tank trucks for transportation of Petroleum products ma ynot be compatible with Ethanol Doped Motor Gasoline . The compatibility needs tobe ensured before use of such tank trucks

20

Industry Manual on Operations, Section. 11 Handling of Ethanol Dope dQuality Control & Safety for Motor Gasoline at Retail OutletsEthanol Doped Motor Gasoline Clause No . 11 .1 Page No. 1 / 2

to 11 .2 .2

11 .

Handling of Ethanol Doped Motor Gasoline at Retail Outlets :

11 .1

Underground Tanks, dispensers and fitting s

11 .1 .1 Storage tank shall be suitable for Class "A" product and openings / pipeline fitting sshall be airtight and the threaded connections if any shall be tightened with the hel pof Teflon tapes. Bolted connections shall be provided with proper gaskets . Storagetanks shall be thoroughly cleaned ; ensuring absence of any trace of water beforecommissioning on Ethanol doped Motor Gasoline . Fill cap and dip cap fittings shal lbe watertight and have suitable gaskets / packing to prevent entry of moisture .

The fill / dip caps shall be raised sufficiently high above the ground level . In casethese are situated in chambers, the chambers shall be constructed in a manner s oas to avoid entry of water into the tank and the caps positioned sufficiently abov ethe bottom of the chamber. The presence of any water in the underground tan kshall be checked by using water-finding paste everyday . During the rainy seasonthe water shall be promptly removed from the tank .

11 .1 .2 Ethanol being hygroscopic in nature, utmost precaution needs to be taken t oensure that there is no ingress of water or moisture in the storage tanks . Suitabl esilica gel trap shall be fitted in the vent of the tank storing Ethanol Doped Moto rGasoline at Retail Outlet to prevent ingress of moisture . Regular check on th ecolour of silica gel shall be maintained and it should be immediately replaced on it schange . The colour of silica gel turns from Blue to pink after absorbing moisture .

11 .1 .3 Sampling procedures at the Retail Outlets would be the same as mentioned in th eIndustry Marketing Discipline Guidelines .

11 .1 .4 Dispensing Units are typically manufactured with Steel, Cast Iron, Aluminium ,Brass, Bronze and sometimes Stainless Steel components . "Ethanol doped MotorGasoline" should not pose problem with any of these metals . Normal dispensin ghoses can be used for "Ethanol doped Motor Gasoline" .

2 1

11 .2

Receipt of Ethanol Doped Motor Gasoline :

11 .2 .1 The procedure will remain same as is being followed for un-doped Motor Gasoline . .

11 .2.2 During rainy seasons, wherever the canopy is available, the tank lorry shall b echecked under the canopy, to avoid ingress of water . Tarpaulin cover shall be use dduring tank lorry discharge . The dip cap of underground tanks shall be kept close dduring tank lorry unloading operation .

Industry Manual on Operations, Section . 11 Handling of Ethanol Dope dQuality Control & Safety for Motor Gasoline at Retail OutletsEthanol Doped Motor Gasoline Clause No . 11 .3 Page No. 2 / 2

to 11 .4

11 .3

Colour coding for dispensing pumps for Ethanol Doped Motor Gasoline :

The colour coding for the dispensing pumps used for Ethanol Doped Motor Gasolin eremains same as that of un-doped Motor Gasoline .

11 .4

Fire fighting system :

The most accepted system is Dry Chemical Powder (DCP), which works a seffectively on Ethanol fire as being used for Motor Gasoline fire . The personnelshould be informed about the properties of Ethanol doped MS and safe practice sfor operating, fuelling etc .

All staff in the Retail Outlets must be trained in handling any emergencies .

22

Industry Manual on Operations, Section. 12 SafetyQuality Control & Safety fo rEthanol Doped Motor Gasoline

Clause No . 12 . 1to 12.6

Page No. 1 / 3

12 .

Safety :

12 .1 Ethanol comes under Class 'A' and hence all safety precautions need to be taken a srequired for Class `A' product . Ethanol is a flammable liquid with a flash point of13°C. It requires fire-fighting facilities like, Alcohol Type Concentrate Foam (ATC) o rCO2/Dry Chemical Powder (DCP) extinguishers .

12 .2 Earthing and bonding procedure shall be followed as being done for other Class 'A 'products .

12.3 Ethanol material safety data sheet :

• Chemical formula C2H 5OH• Mol . Wt . 46.07• Appearance and odour Clear, Colourless, volatile liquid with a n

ethereal odour• Octane(R+M)/2 98-100• RON/MON 108 .6/89 . 7• Lower heating value BTUs/lb .

: 11,500• Reid Vapour pressure (psi) 2 .3• Ignition Point :

a) Fuel in air percentage 3-1 9b) Temperature (approx . °C) 455

• Specific Gravity 15 .6° / 15 .6°C 0.7936• Boiling point °C 78• Solubility in water @ 21°C%vol 100• Flame visibility poor• LEL / UEL

:4.3/1 9• Flash Point °C

13 .0• Cubical expansion Lt ./kl/°C

1 .12

12 .4 Extinguishing media :

23

Carbon-di-oxide, Dry Chemical Powder & water for small fires and Polar Solven tFoam for large fires .

12 .5 Special fire fighting procedures :

Use necessary protective equipment & breathing apparatus as would normally b eused when fighting fires where there may be danger of breathing hazardou sproducts of combustion .

12 .6 Unusual fire and explosion hazards :

Flammable li q uidIndustry Manual on Operations, Section . 12 SafetyQuality Control & Safety fo rEthanol Doped Motor Gasoline

Clause No . 12 . 7to 12.15

Page No. 2 / 3

12.7 Stability :

Stable

12 .8 Conditions to avoid in normal use (incompatibility, material to avoid) :

May react vigorously with oxidizing materia l

12.9 Hazardous decomposition or by- products

Combustion may produce COX, NOX and reactive hydrocarbons. Hazardouspolymerisation will not occur .

12.10 Health hazards :

Roots of entry inhalation / skin / ingestio n

12 .11 Acute and chronic health hazards :

May cause mucus membrane irritation, unconsciousness, respiratory failures an ddeath .

12.12 Toxicity :

Moderate

12 .13 Signs and symptoms of exposures :

May cause dizziness, loss of balance and co-ordinatio n

12 .14 Emergency and safety procedures :

If swallowed, induce vomiting . If inhaled, remove person to fresh air . Give artificia lrespiration if breathing has stopped and call a physician .

24

If splashed in eyes or on skin, flush immediately with copious amounts of water .

12 .15 Precautions for safe handling and use :

In case spilled, released out, then eliminate all sources of ignition . Small spill sshould be flushed with large quantities of water . Large spills should be collected fo rwaste disposal .

Industry Manual on Operations, Section . 12 SafetyQuality Control & Safety forEthanol Doped Motor Gasoline

Clause No. 12.1 6to 12 .20

Page No. 3 / 3

12.16 Waste disposal methods :

Do not allow entering sewers where vapours may become ignited . Incinerate underthe law. Explore for resale to supplier .

12 .17 Precautions to be taken in handling and storage :

• Keep away from heat, sparks and open flames ;• Keep containers closed ;• Use with adequate ventilation ;• Use explosion proof electrical equipment an d• Non-sparking tools .

12.18 Protective Controlled measures :

Air supplied mask to be used for a high concentration as a respiratory precaution .Use protective rubber gloves and goggles for eyes . Eye bath and Safety shower isrecommended as outer protective equipment .

12 .19 Salient features :

Carcinogenic compounds are not present in pure Ethanol .

12.20 Environmental impact of Ethanol Doped Motor Gasoline :

• Ethanol Doped Motor Gasoline vehicle reduces most of the exhaust emissions .• Compared with Motor Gasoline vehicle, . the Ethanol Doped Motor Gasolin e

vehicle produces lower hydrocarbon, carbon monoxide and carbon dioxid eemissions .

• At operating temperature, the catalytic converter in an Ethanol Doped Moto rGasoline vehicle is very efficient at breaking down aldehydes in to less harmfu lchemicals .

25

Industry Manual on Operations, Section. 13 Additional PrecautionsQuality Control & Safety for Ethanol Clause No . Page No .Doped Motor Gasoline 13.1 1

13 .

Additional Precautions :

13.1 Additional Precautions and First Aid

Don'ts First Aid measures1 Prolonged

exposure

to

hig hconcentration should be avoided

Move person to an open area . Give artificia lrespiration in case of breathing problem . Getmedical attention .

2 Ingestion/swallowing

should

beavoided

Induce vomiting immediately as directed b ymedical practitioner .

3 Skin contact should be avoided toprevent

absorption

of

toxiccompound into body .

Immediately flush skin with plenty of wate rfor

at

least

15

minutes .

Remove

al lcontaminated clothing and shoes . Wash &clean clothing & shoes before reuse .

4 Splashes and eye contact shouldbe avoided .

Immediately flush eyes with plenty of clea nrunning water for at least 15 minutes, movinglower and upper eye lids occasionally .

5 In

case

of

spill

do

not

usecombustive

materials

such

assawdust etc .

Do not flush tosewage

system .

Remove

al lsources

of

ignition

throughappropriate protective equipment .

Collect liquid in appropriate container o rabsorb with inert material like vermiculate ,dry sand, earth .

26

Industry Manual on Operations, Appendix Backup SupportQuality Control & Safety for Ethano lDoped Motor Gasoline

Clause No .1 — 4

Page No .1

APPENDI X

1 .

Test Method for Determination of Ethanol (Alcohol) Content i nA). Ethanol (received by Tank Truck) :B). Ethanol doped Motor Gasoline - Water Extractio nC). Ethanol doped Motor Gasoline - Water Extraction (Short Method)

2 .

Typical line diagram of Ethanol Automatic filling Facility at location .

3 .

. Typical line diagram of Ethanol Facility at location (in general )

4 .

Frequently asked Questions

27

Industry Manual on Operations, Reference ReferenceQuality Control & Safety for EthanolDoped Motor Gasoline

Clause No .1 – 7

Page No .1

REFERENC E

1.

Anhydrous Ethanol for use in Automotive Fuel . specification IS 15464 :2004

2.

Tables for Alcoholometry by Hydrometer Method : IS: 2302 .

3.

Relation between Proof Strength, Specific Gravity & % of Alcohol by Weight &Volume. IS: 321, Appendix B' .

4.

Specification for Glass Alcoholometers with Thermometer : IS: 3608 (Part II )

5.

Test method Ref Rectified Spirit IS 32 3

6.

Alcohol Denaturants IS 411 7

7.

Water Content – IS : 2362

8.

Specification for Absolute Alcohol : IS : 321 (Grade-2 )

28

Industry Manual on Operations, Appendix 1 Test Method for Determinatio nQuality Control & Safety for of Ethanol ContentEthanol Doped Motor Gasoline Procedures Page No .

A toB.3.d 1/5

Test Method for Determination of Ethanol Conten t

A. In Ethanol (received by T/L) :

For determining the percentage of Ethanol content table 1 and table 2 of IS 2302 :1989 should be used .

B. In Ethanol doped Motor Gasoline :

Method for Determination of ethanol content in 5% ethanol doped MotorGasoline by using Water - A Field Tes t

1 . Scope :This method covers the determination of ethanol content in ethanol doped Moto rGasoline as field test at supply point, Retail Outlet etc, by using water . This metho dprovides a test of on line ethanol doped gasoline for ethanol content by % b yvolume. The method can suitably be used for quality monitoring of ethanol dope dgasoline for ethanol content in down stream . In case of dispute the sample may b esubjected to a method ASTMD 4815 as referred in BIS IS 2796 Amendment 3,forMotor Gasolin e

2 . Reference :a. Motor Gasoline - Specification IS 279 6b. Anhydrous ethanol for use in automotive fuel IS 1546 4

3 . Definitions :

a. Ethanol / Denatured Ethanol : Ethanol is the pure chemical, otherwis eknown as hydroxy-ethane, corresponding to the constitution CH 3CH2OH andmolecular formula : C2H 5OH . Nominally anhydrous ethanol made unfit fo rbeverage use by the addition of noxious or toxic materials (denaturants) an dsame is used as ethanol for the purpose of this test method .

29

b. Motor Gasoline : A volatile mixture of liquid hydrocarbon, generall ycontaining a small amount of additives, suitable for use as a fuel in sparkignition and internal combustion engines conforming to IS : 2796 .

c. Ethanol Doped Motor Gasoline : A fuel consisting primarily of MotorGasoline doped with 5% vol ./vol . of denatured anhydrous Ethanol for fue lconforming to IS :2796 .

d. Water : Water is preferred for extraction procedure, but potable water may b eused .

Industry Manual on Operations, Appendix 1 Test Method for Determinatio nQuality Control & Safety for of Ethanol ContentEthanol Doped Motor Gasoline Procedures Page No .

B.4toB.6 2/5

4. Outline of the test method :30 ml of water is added to 100 ml of ethanol doped Motor Gasoline taken in 100 m lgraduated stoppered cylinder. The mixture is shaken vigorously for about 3 0seconds and cylinder is set aside for five minutes to observe the separation o faqueous layer. Increase in the volume of aqueous layer over and above 30 m lindicates the presence of extractable ethanol in the ethanol doped motor gasolin esample tested . The exact quantity of ethanol is then worked out referring th eobservation to the calibration plot made on exact quantity of ethanol vis-a-vi sextracted from 100 ml of various known concentration of Motor Gasoline vis-a-vi sextraction through 30 ml of water. Whenever there is change in the source o fgasoline, the calibration chart is to be re-plotted .

5. Significance and use :The test method is employed to check the percentage of ethanol in ethanol dope dMotor Gasoline, as ethanol is having more affinity for mixing with water . Theaddition of water in ethanol doped Motor Gasoline extracts the ethanol present i nthe ethanol doped Motor Gasoline in to aqueous phase . The increase in the waterlevel indicates the quantity of ethanol in Ethanol Doped Motor Gasoline .

6. Apparatus:a. 100 ml glass Stopper cylinder with l ml graduation (Class 'A' Certificate)b. 10mI or 25 ml and 5 ml glass pipette, (Class 'A' Certificate )c. Water

30

Industry Manual on Operations, Appendix 1 Test Method for DeterminationQuality Control & Safety for of Ethanol ContentEthanol Doped Motor Gasoline Procedures Page No .

B .7 to B.8 .g 3 / 5

7. Calibration on known ethanol content in ethanol doped Motor Gasoline and it sextraction .

a. Prepare twelve . number of synthetic ethanol doped Motor Gasoline with th econcentration of 1 to 12 ml of ethanol concentration by percentage volume .

b. Take each 100 ml sample in 100 ml graduated stoppered glass cylinde ralong with one blank Motor Gasoline (without ethanol) .

c. Shake the stopper cylinder vigorously for at least for 30 seconds .d. Loosen the stopper of glass cylinder to release the vapour pressure in th e

cylinder but do not remove the stopper .e. Tighten the stopper and allow the stopper cylinder to sit undisturbed a t

ambient temperature upright on the levelled surface for a period of at leas tfive minutes to allow the water-ethanol mixture to settle to the bottom .

f. If separation of two layers is not complete lightly tap the cylinder t oencourage the complete separation .

g. Record the level of aqueous layer in glass cylinder by reading th emeasurement at the lowest part of the meniscus .

h. Presence of Ethanol % in ethanol doped Motor Gasoline =Volume of aqueous layer observed in graduated cylinder – 30 ml (wate radded during testing) .

i. Plot a graph on various values obtained in "h" as ordinates vis-a-viscorresponding synthetic lab-blend as per "a" as abscissa including that of theobservation made on the blank .

8 . Procedure :

a. Take 100 ml sample of ethanol-doped gasoline under test in 100 m lgraduated stoppered glass cylinder (Thoroughly cleaned and dried) .

b. Add precisely 30 ml water to the sample taken in the glass cylinder .c. Shake the stopper cylinder vigorously for at least 30 seconds .d. Loosen the stopper of glass cylinder to release the vapour pressure in th e

cylinder but do not remove the stopper .e. Tighten the stopper and allow the stopper cylinder to sit undisturbed at

ambient temperature upright on the levelled surface for a period of at leas tfive minutes to allow the water-ethanol mixture to settle to the bottom .

f. If separation of two layers is not complete lightly tap the cylinder t oencourage the complete separation .

3 1

Record the level of aqueous layer in glass cylinder by reading th emeasurement at the lowest part of the meniscus .

g. Presence of Ethanol % in ethanol doped Motor Gasoline =Volume of aqueous layer observed in graduated cylinder – 30 ml (wate radded during testing

Industry Manual on Operations, Appendix 1 Test Method for DeterminationQuality Control & Safety for of Ethanol ContentEthanol Doped Motor Gasoline Procedures Page No .

9to 11 4/5 .

9 . Calculation :a) Observation made under 8 .(g), is to be put on the abscissa and th e

corresponding concentration of ethanol is to be obtained from the ordinate .b) Whenever there is a change in source of Motor Gasoline, for better results, i t

is recommended to re-plot the graph as mentioned in the paragraph 7 (i )

10 . ReportReport the fully corrected results to the nearest 0 .5 ml as the ethanol water mixtureand report after deducting 30 ml (water added during testing), as percentage o fethanol content available in the given ethanol doped Motor Gasoline sample .

11 . Precision and bias :In the absence of calibration plot the value observed in aqueous phase can becalculated to the nearest percentage volume as per the under mentioned precisio nlevels .

Based on the field tests, it was observed that a maximum of 4 .6 ml (average) ofethanol content is extracted in to the aqueous phase as against 5 ml ethanol adde din ethanol doped Motor Gasoline .

The Standard Deviation of the test results indicates ± 0 .24% .

Considering the precision of the graduated glass cylinder, the maximum possibl emeasurement can be 4 .5% Volume with standard deviation of ± 0 .5% .

Percentage

Repeatability

5 % v/v

0 .5ml (Approximately)

Bias: No justifiable . values of reproducibility, bias for this test method can be state das the test at best detects the presence of ethanol in ethanol doped Motor Gasolin eand test can be recommended as a field test method .

.O R

32

Industry Manual on Operations, Appendix 1 Test Method for Determinatio nQuality Control & Safety for of Ethanol ContentEthanol Doped Motor Gasoline Procedures Page No .

C 5/5

C.

Water Extraction Method (Short) :

This is a simple test and it can be used to determine the amount of Ethanol presen tin gasoline qualitatively as well as semi-qualitatively. The test is based on simpleprinciple of "water extraction" of Ethanol doped Motor Gasoline .

A 100 millilitres (ml) graduated stoppered glass cylinder (A class) is used for th etest . Place 100 ml of the Ethanol doped Motor Gasoline sample in the graduate dcylinder (thoroughly cleaned and dried) . Add precisely' 30 ml of distilled water intothe cylinder . Stopper the cylinder and shake thoroughly for at least one minute . Setaside the cylinder for about five minutes . If no Ethanol i s. present, the 10-m1 of wate rwill settle to the bottom of the cylinder . If Ethanol is present, it will dissolve withwater and come along with water in the water layer thereby increasing the volume ofbottom quantity of water to greater than 30 ml .

Subtract 30 ml from total volume of water plus ethanol content at the bottom an dreport the remainder as percentage of Ethanol in the Ethanol doped Motor Gasoline .

Equipment require d

1.

100 ml graduated stoppered cylinder with graduation interval of 1 .0 ml (Aclass with works certificate )

2.

10 ml Pipette (A class )3.

Distilled water

33

Industry Manual on Operations, Appendix 2 Typical Line Diagram of EthanolQuality Control & Safety for automatic filing facility at Locatio nEthanol Doped Motor Gasoline Procedures Page No .

1/1

EXISTING TL FPUMP HOUSE

NEW FACILITY EXISTING TL FGANTRY

SAFE AREA

ELECTRONIC PUMP AUTO STROK ECONTROLLER PANEL.

ROOMI WITCH HOUEK*STING NEC

3" PO METER 'AWTH PULSE TXMETERING PUMP WITH AUTOSTROKE ACTUATOR

PRESSURE VACCUM RELIEFVALVE (PERV)Y—TYPE STRAINER

LBGTSID4—20MA SIGNAL

JI.RFL PULSE WINWATER SEPERATO R

I')G= 1■1

PERFOPAIED--T A

AIR DRIE RTRAY P- 1

p¢-*MNNCMETFR

EXISTING ETHANOL STORAGE TAN K(UNDER GROUND / ABOVE GROUND)

MIXER

REF, P & ID NO. 1002 FOR

CHECK VALVE

PIPEUNE REDUCER

FLOW INDICATING TX .

FLOW STRAIDNTNIR

LOCOING Pi.1

x(011 GATE VALVE

I6I BALL VALVELOADING P M

NOTES: -

1. EXISTING FACILITIES (TO BE USED) A PROCESS PARAMETERS ARE TO BECHEMED AT ST E

0. BLENDING OF OX ANHYDROUS ETHANOL IN MS 15 TO BE ACHIEVED BYMEASURING MS FLOW THROUGH METER (PTT) & PUMPING PROPORTIONA LETHANOL BY USING MEWING PUMP P—1 .

3. MAXIMUM WATER CONTENT ALLOWED IN ETHANOL IS 0.2X,4. EXISTING MS TANK IS TO BE MADE MOISTURE FREE FOR STORING ETHANO L5. ONLY GALL VALVES/PLUG VALVES HAMNO SOFT PARTS / SEALS SUITABL E

FOR ETHANCL SHALL BE USED?.B. TURBINE FLOW METER . FLOW RATE AS PER SITE.7. O. PD PUMP (P—1) SHALL HAVE DISCNAACE PRESSURE AS 1,25 TIMES ER

THE MAX. PRESSURE IN MS HEADER .i. PO METERING PUMP — FLOW RATE RANGE (MIN ./MAX .) SHALL BE IR K

OF TURBINE FLOW METER FLOW RATE (1,11N ./MAX )B . WATER SEPARATOR — C0RLO :MR TYPE — FLOW RATE RANGE 1 .25 TIMES OF

PD PUMP RANCE (MIN./MAX.) & MAX. DIFF. PRESSURE IS 1kg/an2c.

BHARAT PETROLEUM CORPN. LTD .

SVBIIEI

MAIMEDYLBANOR SOWID500

PAM (TYPICAL) : BLENDING OP ZEHINOL IIIMOIRE SPORT UT MCI FOR INBTALEATICNB

au :

un:vm w . wvnuem .

I rra® w

E&P/1001

LORDING PT.3

I MOISTURE TRAP WTI SILICA GEL

34

Industry Manual on Operations, Appendix 3 Typical Line Diagram of Ethano lQuality Control & Safety for Ethanol Facility at Locatio nDoped Motor Gasoline Line Diagram Page No .

1/1

JfleOLJ

1A RA'r

OF ETNAN *

{} tLrr

+r-

[5Ej)01" . . .

S?:/

--r

'MS Lime. Artf.F

S} twist,. P44N,19 LK_

1j .t€tA$ xnou 1itL T iLPE

•d

3J))

W

Mh.4nT

t1Q1 e.4Pt'Hal[ 4

n3

EFMf

vER•r

I JtiII L

rGA L* .

YN13'P'

;a*w7E.R+JR2'aPJn+1 (F DWI J4*Gg Ke :iusln 03.4 der y:FW ".y 3IAt*s IL' Mlif Itu Id se zZuvil AL yW, 4J*Yr,'1$

k) *JSt rlh ;1 J IJ'.D MI'c[*

Mr...,Re nt n

"s •3*a TEtre

- a e

'TANK

0e.PtSOTettggO.4 iRI3buJ

35

Industry Manual on Operations, Appendix 4 Frequently AskedQuality Control & Safety for Ethanol QuestionsDoped Motor Gasoline Question No . Page No.

1to5 1/3

1. What is Fuel Ethanol or Gasohol or Ethanol for Motor Gasoline ?

Ethanol for Gasoline, also known as Fuel Ethanol or Gasohol, is a high octane, wate rfree denatured Ethanol, produced from the fermentation of sugar or molasses o rgrains or other renewable agricultural and agro forestry feedstock. It is used fo rdoping with a concentration ranging from 5% – 10 % in Motor Gasoline, which i spresently recommended up to 5% only as per BIS specification for motor gasoline I S– 2796 : 2000

2. What is Ethanol Doped Motor Gasoline or Ethanol doped Petrol?

When fuel Ethanol is doped in Motor Gasoline, it is named Ethanol doped Moto rGasoline or Ethanol Doped Petrol . This is primarily used for two stroke and four strok evehicles and is conforming to Motor Gasoline specifications IS -2796 : 2000 .

3. What are the advantages of using Ethanol Doped Petrol?

Fuel Ethanol is a renewable agro product and with Motor Gasoline it gives a cleaner ,environment friendly fuel .

It adds to clean engine while burning . It lowers net Carbon-di-oxide emission . I tlessens the dependency on imported light crude oil .

Use of Ethanol Doped Motor Gasoline expands market opportunity for farmers an deconomic opportunities for rural India .

4. How does the use of Ethanol Doped Motor Gasoline benefit the environment ?

• The emissions produced by burning Ethanol are less reactive with sunlight tha nwith those produced by burning Motor Gasoline . Thus results in lower potentia lfor forming the damaging Ozone .

• The use of Ethanol Doped Motor Gasoline can reduce the net emission o fgreenhouse gases .

• Oxygenated Gasoline such as Ethanol Doped Motor Gasoline lowers the level o fCarbon monoxide gas emission by promoting the more complete combustion o fthe fuel .

5.

Is the Ethanol production energy efficient ?

36

Ethanol contains about 22,400 BTUs pre litre (high heating value) . The energycontent however may not be as important as the energy replaced due to the highe rcombustion efficiency of Ethanol and its octane credit . Ethanol can replace 26, 57 5BTU of Gasoline .

Industry Manual on Operations, Appendix 4 Frequently AskedQuality Control & Safety for Ethanol QuestionsDoped Motor Gasoline Question No . Page No .

6to 11 2/3

6. How will the use of Ethanol Doped Motor Gasoline affect the vehicles ?

Almost all manufacturers approve the use of Ethanol Doped Motor Gasoline an dsome even recommend it for environmental reasons . Ethanol helps to clean out th efuel injection system and may add in the maintenance of cleaner engine .

All alcohols have the ability to absorb water and therefore condensation in the fue lsystem is absorbed. Ethanol will not burn engine valves . As such ethanol burns coole rthan gasoline. In fact, high-powered racing engines use pure Ethanol for that reason .

Ethanol can loosen contaminants and residues that have been deposited by previousgasoline fills . These can collect in the fuel filter . This problem has happene doccasionally in older cars, and can easily be corrected by changing fuel filters .

7.

Is it safe to handle Ethanol Doped Petrol ?

Material safety data sheet reveals that the properties of Ethanol Doped Moto rGasoline are substantially the same as conventional Motor Gasoline .

8.

Do ethanol brands need special handling of storage ?

Only in special circumstances . The water accumulated in the storage tank needs tobe pumped out . It is wise to check the presence of water and drain the tank i fnecessary .

9. Is water contamination in Ethanol Doped Motor Gasoline a big problem ?

No, it's not . The vast majority of installations abroad handling Ethanol Doped Moto rGasoline have never experienced any water contamination in their product .

10. How do you know if there is water in a storage tank of ethanol doped gasoline ?

Water is heavier, if present, will settle to the bottom of the storage tank . Ethano labsorbs the small amounts of water and will not affect performance while in use .

11. If water is not traceable then what prevents from watering down of the Ethano lDoped Petrol ?

Ethanol Doped Motor Gasoline can not absorb unlimited amount of water . Theamount of water dissolved depends on total volume, percentage of Ethanol ,

37

temperature of the product . It would be almost impossible to water down the Ethano lDoped Petrol .

Industry Manual on Operations, Appendix 4 Frequently AskedQuality Control & Safety for Ethanol QuestionsDoped Motor Gasoline Question No . Page No .

12-17 3 / 3

12. How does water get into the storage tank?

Ground water may seep through the cracks in old storage tanks . It may also get int othe tank through rains, or snow, due to cracks / poorly / improperly fitted caps on fil lpipes or improper vent .

13. If Ethanol absorbs water, how can there be water contamination in Ethano lDoped Petrol ?

Ethanol Doped Motor Gasoline can absorb a certain amount of water . The higher th etemperature the greater amount of water the mixture will hold till it attains saturation . I fsaturated mixture drops in either temperature or percentage of Ethanol, the water wil lstart to precipitate and settle at the bottom of the tank . This water will be mixed wit hethanol. The Gasoline mixture at the top will still be saturated . This is what is referre dto as phase separation .

14. What happens if people buy phase separated gasoline?

If phase separation occurs in a storage tank then delivery may have Gasoline wate rEthanol or Gasoline Ethanol or water Ethanol depending on the degree of separation ,and the height of the water Ethanol in relation to the discharged pipe leading from th etank to the dispenser.

15. Will everyone who buys phase–separated gasoline experience problems i nvehicles?

Fortunately, no. Very few people usually experience problems . Many people buying awater-saturated product will still have some unsaturated gasoline / ethanol mixtures i ntheir tanks . The vehicle tanks are often warmer than bulk storage underground tanks .

16. How does the water from the phase separated mixture is removed ?

The best way to correct the water problem in an ethanol gasoline tank is to remov ethe ethanol / water mixture from the bottom of the tank and tank may be topped upwith a fresh mixture of ethanol and gasoline to bring down the saturation . This wastemust be disposed off according to the environmental regulations .

17. What to do if water contamination is observed in vehicle fuel tank ?

Drain out the water. This problem can be addressed properly keeping the fuel tank ful lin the winter months and ensuring that the fuel tank cap is tight .

********************** *

3 8