Manual sampling of no pressurised tanks

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Human DevelopmenConsultants Ltd.

Training Module

Manually Sample

Non-PressurizedTanks



Manually Sample

Non-Pressur ized Tanks

December, 2003

Human Development Consultants Ltd.

© HDC Human Development Consultants Ltd.

All rights reserved . No part of this publication may be copied, reproduced, stored in a computer orretrieval system, published, distributed, or transmitted in any form or by any means whatsoever, including

without limitation by mechanical means, photo copying, recording, digital or electronic media, the Internet,or otherwise, without the express prior written permission of HDC Human Development Consultants Ltd.(HDC). HDC grants to the purchaser of a Single User License (as defined in the agreement with suchpurchaser) a limited license to store the electronic file(s) on one computer only and to make a singlepaper copy of this publication. HDC grants to the purchaser of a Site License (as defined in theagreement with such purchaser) a limited license to store the electronic file(s) on one local area networkserver accessible by individual users' computers at one site or location only and to make paper copies ofthis publication for a company’s employees at the same site or location only. Each site or location mustpurchase a separate Site License for employees at that site. HDC grants the purchaser of a CorporateLicense (as defined in the agreement with such purchaser) a limited license to store the electronic file(s)on its intranet and on computers at company sites or locations and to make paper copies for any or allemployees. Nothing in the foregoing restricts, amends or abrogates the provisions of the agreementbetween HDC and the purchaser of the applicable license. Any copying or use other than pursuant tosuch a license is illegal. For further information, please consult the applicable license agreement.

This publication is designed to provide general information regarding the subject matter covered. Carehas been taken to ensure the accuracy of the information and that the instructions contained in thispublication are clear and reflect sound practice. The user understands that HDC is not providingengineering services. The user understands that any procedures (task steps) that are published orreferenced may have to be modified to comply with specific equipment, work conditions, companystandards, company policies and practices, legislation, and user qualifications. HDC does not make anyrepresentations, guarantees, or warranties of any kind whatsoever with respect to the content hereof andthe results to be achieved by implementing the procedures (task steps) herein. To the maximum extentpermitted by applicable law, in no event shall HDC be liable for any damages whatsoever (includingwithout limitation, direct or indirect damages for personal injury, damages to the environment, damages tobusiness property, loss of business profit, or any other pecuniary loss). The use of the information andprocedures (task steps) herein is undertaken at the sole risk of the user.

ISBN 1-55338-038-X

Canadian Cataloguing in Publication Data

1. Petroleum—Sampling. I. HDC Human Development ConsultantsTP692.5.M25 2003 665.5’028’7 C2003-905958-8

This training kit consists of the following parts:

♦ Training Module and Self-Check♦ Knowledge Check and Answer Key♦

Blank Answer Sheet

♦ Performance Check ♦ Job Aid

Published by HDC Human Development Consultants Ltd.

Published in Canada

HDC Human Development Consultants Ltd.

Website: www.hdc.ca

E-mail: [email protected]

Phone: (780) 463-3909



Manually Sample

Non-Pressurized Tanks

Human DevelopmentConsultants Ltd.

ContentsTraining Objectives 1

1 Introduction 1

2 Samples 3

2.1 Spot and Composite Samples 3

2.2 Sampling Levels 4x

3 Sampling Equipment 7

3.1 Samplers (Primary Sample Receiver) 8

3.2 Drop Cords and Trip Cords 14

3.3 Sample Containers (Secondary Sample Receiver) 15

3.4 Sampler and Sample Container Closures 15

4 Sample Accuracy 16

4.1 Uncontaminated Sample 16

4.2 Representative Sample 17

4.3 Sample for Laboratory Analysis 19

4.4 Properly Labeled Sample 19

4.5 Correct Sample Handling and Shipping 20

5 Safety 21

5.1 Physical Hazards 21

5.2 Chemical Hazards 22

5.3 Safety before Climbing to the Roof 24

5.4 Safety while Sampling 24

5.5 Sampling Tanks with Floating Roofs 25

December, 2003 Page i of ii



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Contents (continued)

6

Sampling Procedures 26

6.1 Spot Sample Procedure: Core Thief Sampler 26

6.2 Spot Sample Procedure: Bacon Bomb Sampler 28

6.3 Spot Sample Procedure: Cage and Bottle Sampler 29

6.4 Spot Sample Procedure: Weighted Beaker Sampler 30

6.5 Running Sample Procedure: Cage and Bottle Sampler 31

6.6 Bottom Sample Procedure: Core Thief Sampler 32

7 Self-Check 33

8 Self-Check Answer Key 37

December, 2003 Page ii of ii



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Training

Objectives

Upon completion of this training kit, you will be able to:

Describe the purpose and importance of manually

sampling non-pressurized tanks

Describe types of samples

Describe tank sampling equipment

Describe tank sampling accuracy

Describe tank sampling safety hazards and precautions

Sample tanks

1 IntroductionIn the oil and gas industry, well emulsions, fuel, field chemicals,

by-products from gas processing, and refined petroleumproducts are stored and transported in non-pressurized tanks.

Non-pressurized tanks include storage tanks at well sites,

batteries, plants, and terminals, and also rail tank cars, tanker

trucks, and ship and barge tanks.

Products in a tank are sampled and analyzed to determine the

product’s chemical and physical properties, such as density

(API gravity), water content, and contaminants. These

properties are used in the determination of standard volumes

and prices.

To take a sample, an operator lowers a sampler on a cord from

the gauge hatch at the top of the tank until the sampler is at the

desired level in the tank. At the desired level, the operator

remotely trips the sampler to allow the sampler to fill and then

pulls the sampler back up. The operator carefully transfers the

sample from the sampler to a sample container, closes the

container, and affixes a label to the container. Depending on

the analyses required, the operator analyzes the sample

immediately, takes the sample to a local laboratory, or sends

the sample to a central laboratory.

Tanks are sampled in accordance with the standard practice

published by:

American Petroleum Institute (API): Manual of Petroleum

Measurement Standards, Chapter 8—Sampling; 8.1—

Manual Sampling of Petroleum and Petroleum Products;

8.3—Mixing and Handling of Liquid Samples of Petroleum

and Petroleum Products

December, 2003 Page 1 of 37



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American Society for Testing and Materials (ASTM):

D 4057-95 (2000)—Standard Practice for Manual Sampling

of Petroleum and Petroleum Products

International Organization for Standardization (ISO):Petroleum Liquids – Manual Sampling (ISO 3170)

Contents of this Training Kit

This training kit describes how to safely and reliably take

manual samples of liquid petroleum products and free water

from non-pressurized tanks. The kit focuses on methods for

sampling:

crude petroleum

liquid hydrocarbons with Reid Vapor Pressure (RVP) below

101.32 kilopascals (kPa) (14.7 pounds per square inch

absolute—psia)

NOTE

Reid Vapor Pressure is the pressure of a liquid when it is

heated to a temperature of 37.8°C (100°F) in a sealed Reid test

chamber. A product’s RVP is a measure of the product’s

volatility: the higher the RVP, the more volatile the product.

This kit is aimed primarily at pipeline terminal/field operators

who are responsible for manually sampling storage tanks, rail

tank cars, tank trucks, and ship and barge tanks. The kitdescribes:

different types of sample

manual sampling equipment

practices which ensure sample accuracy

manual sampling safety issues

procedures for manually obtaining a sample of liquid

hydrocarbons from storage tanks, rail tank cars, tank trucks,

and ship and barge tanks.

This training kit does not include procedures for:

manual sampling of tank residues, lumpy solids, greases, or

asphaltic materials

manual sampling of pipelines

automatic sampling of tanks or pipelines

sampling fuels for determining the fuel’s volatility

sampling products with Reid Vapor Pressure above 101.32

kPa (14.7 psia)




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This kit is one of a series of two HDC training kits related to

storage tanks. The other kit is Manually Gauge Non-

Pressurized Above-Ground Tanks.

NOTE

This kit provides instruction on tank sampling equipment and its

application. The kit does not endorse or promote any specific

model, manufacturer, or supplier.

2 SamplesThis section describes spot and composite samples and the

levels in the tank at which samples are taken.

2.1 Spot and Composite Samples

Types of sample include:

spot sample—a sample taken at a specific location in a

tank

composite sample—a sample obtained by combining spot

samples in defined proportions so that the sample is

representative of the product in the tank:

– for upright cylindrical tanks, spot samples are taken at

the levels indicated in the following table and blended in

equal proportions. (Sampling levels are described in thenext section.)

Composite Sample: Vertical Cylindrical Tanks

Required SamplesTank Capacity Product Height

upper middle lower

larger than 160 m3 (1000 bbls)

> 4.5 m (>15 ft.)

larger than 160 m3 (1000 bbls)

3 – 4.5 m(10 – 15 ft.)

up to and including

160 m3 (1000 bbls)




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– for horizontal cylindrical tanks, such as rail tank cars

and tank trucks, samples are taken and blended at the

levels and proportions indicated in the following table.

Figure 1 illustrates this concept.

Composite Sample: Horizontal Cylindrical Tanks

Sampling Level

(percentage of diameter

above the bottom)

Composite Sample

(proportional parts

out of 10)

Liquid Depth

(percentage of

diameter)

upper middle lower upper middle lower

100 80 50 20 3 4 390* 75 50 20 3 4 3

80 70 50 20 2 5 3

70 50 20 6 460* 50 20 5 5

50 40 20 4 6

40* 20 10

30 15 10

20 10 1010 5 10

*Refer to Figure 1.

For tankers or vessels with compartments, take at least one

sample from each compartment. When a composite sample of

the different compartments is required, the volume of sample

from each compartment making up the composite sample

should be in the same proportion as the volume of product in

each compartment. For example, one compartment of a tanker

truck is 100% full and the other compartment is only 60% full.

The composite sample would contain 10 parts from the first

compartment and 6 parts from the second compartment.

2.2 Sampling Levels

Samples are taken from the gauge (thief) hatch at the top of thetank.

NOTE

Samples are not taken from valves near the bottom of the tank.

Such samples are usually not representative of the product in

the tank. Also, with infrequent use, the valve may fail when

opened and tank contents may be spilled.




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50 %

3

3

4

25 %20% level

50% level

75% level 75 %

100%

0%

Tank 90% full

5

5

20% level

50% level

Tank 60% full

10

20% level

Tank 40% full

50 %

25 %

75 %

100%

0%

50 %

25 %

75 %

100%

0%

Figure 1—Sampling Levels and Composite Samples for Horizontal Cylindrical Tanks



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water & sediment

outlet (suction level)sample

lower 1/3

middle 1/3

lower sample(middle of lower 1/3)

middle sample(middle of middle 1/3)

upper sample(middle of upper 1/3)

(1/6 from top surface)

top sample150 mm (6 in)below surface

bottom sample

upper 1/3

Figure 2—Sampling Levels

The following sampling levels are illustrated in Figure 2:

top sample—a spot sample taken 150 mm (6 in.) below thetop surface of the liquid.

upper sample—a spot sample taken from the middle of the

upper one-third of the product in the tank (i.e., one-sixth of

the depth of liquid below the top surface), excluding any

free water or sediment at the bottom of the tank.

middle sample—a spot sample taken from the middle of

the middle one-third of the product in the tank (i.e., one-half

of the depth of liquid below the top surface), excluding any


lower sample—a spot sample taken from the middle of thelower one-third of the product in the tank (i.e., five-sixths of

the depth of liquid below the top surface), excluding any


outlet (suction-level) sample—a spot sample taken at the

tank outlet. The opening of the sampler is level with the

bottom of the outlet.

Gauge (Thief) Hatch

Small cover located onthe top of the tank. Thegauge hatch allowsoperators to look insidethe tank and to gauge andsample the tank.



Manually Sample



bottom sample—a spot sample taken from the material at

or close to the bottom of the tank. Bottom sample locations

must be specified (e.g., “150 mm [6 in.] from the bottom”).

bottom water sample—a spot sample of the layer of freewater located below the petroleum in the tank

all-levels sample—a sample obtained with a sampler

which is filled to between 70 and 85% while the sampler

passes through the total liquid height in either a downward

or an upward direction:

– an empty, stoppered sampler is lowered to the bottom of

the tank (or just above the free water level). At the

bottom, the stopper is removed remotely and the

unstoppered sampler is raised to the surface at a rate

that allows the sampler to fill between 70 and 85 percent.

– an empty, unstoppered sampler is lowered to the bottom

of the tank (or just above the free water level) at a rate

that allows the sampler to fill between 70 and 85

percent. At the bottom, the stopper is inserted remotely

and the stoppered sampler is raised to the surface.

running sample—a sample obtained with a sampler which

is slowly filled while the sampler passes through the total

liquid height in both downward and upward directions. An

empty sampler, stoppered with a perforated stopper, is

lowered to the bottom of the liquid in the tank and raised to

the surface at a uniform rate that allows the sampler to fillbetween 70 and 85 percent.

3 Sampling EquipmentSampling equipment includes:

samplers (primary sample receiver)drop cords and trip cordssample containers (secondary sample receiver)closures

sample carriers

3.1 Samplers (Primary Sample Receiver)

Several different types of samplers have been designed for

manually sampling petroleum tanks.




Manually Sample



The type of sampler to use depends on the type of product and

the type of sample required. Before selecting a sampler,

consider the following:

Samplers must be resistant to the solvent action of theproduct and cleaning agents used to clean the sampler after

use.

Plastic samplers and bottles:

– are acceptable for sampling and storing gas oil, diesel

oil, fuel oil, and lubricating oil

– should not be used to store crude oil, gasoline, aviation

jet fuel, kerosene, and white spirit

NOTE

Conventional polyethylene (i.e., non-linear polyethylene)

containers must not be used because the polyethylene may

contaminate the petroleum sample.

Samplers and sample containers must be made of a non-sparking material.

The sample taken must be suitable for the analyses that willbe performed on the sample:

– Samplers must be large enough to contain the requiredsample. If the sampler is used as both primary andsecondary receiver (i.e., if the sample will not betransferred from the sampler to a sample container),samplers must have room for thermal expansion

(approximately 10 to 15%). – Samples may lose light ends (i.e., volatile gases) during

transfer from a primary sampler to a secondary samplecontainer. When analyses of density or composition arerequired, samples should be left in the primary sampleruntil the moment of analysis (providing the primarysampler can be adequately sealed). When takingcomposite samples for density analysis, you will needenough samplers to take the required samples and holdthe samples until the analyses are performed.

Light EndsThe lighter molecules in ahydrocarbon mixture.Light ends have a lowerboiling point and tend tovaporize readily.

– If the sample needs to be mixed before analysis,consider how suitable the sampler is for mixing. Forexample, if a sample of crude oil has stratified in thesampler before arriving at the laboratory, the sampler/sample may need to be placed on a mixer and mixedbefore analysis. In this case, the sampler must be ableto fit on the mixer and withstand the mixing action.




Manually Sample




This section describes:

the four common types of sampler:

– core thief

– Bacon bomb – cage and bottle

– weighted beaker

samplers used for:

– all-levels and running samples

– bottom samples

Core Thief Sampler

Core thief samplers (thiefs) (Figure 3) are used to take spot

samples and bottom samples in storage tanks, rail tank cars,

tank trucks, and ship and barge tanks.

Core thiefs have the following features: a transparent glass or plastic (or metal) barrel with top and

bottom spring-loaded closures

a gauge for determining the height of sediment and water in

the barrel

a mechanical device and trip cord for tripping the valve

closure mechanism. The operator uses the trip cord to

remotely open/close the valve.

Figure 3—Two Core ThiefSamplers(Courtesy of W. L. Walker Co., Inc.)



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low clearance: able to take a sample within 15 to 25 mm

(1/2 to 1 in.) of the tank bottom

sufficient weight so that the thief can sink in the product

removable extension rods (from 75 to 460 mm) (3 to 18 in.)for sampling at specific heights above the tank bottom

Samples taken in core thiefs usually have to be transferred to a

sample container so that the thief can be reused.

Bacon Bomb Sampler

Bacon bomb samplers (Figure 4) are used to take bottom

samples and spot samples in storage tanks, rail tank cars, tank

trucks, and in ship and barge tanks.

Figure 4—Two Bacon Bombs(Courtesy of Koehler InstrumentCompany, Inc.)

Bacon bombs have the following features:

a chrome-plated brass or stainless steel barrel

an internal plunger-type valve:

– The plunger opens automatically when the sampler

strikes the tank bottom and closes when the sampler is

raised.

– If the plunger is fitted with a trip cord, the operator can

remotely open and close the plunger by lifting and

releasing the trip cord.




Manually Sample




low clearance: able to take a sample within 15 to 25 mm

(1/2 to 1 in.) of the tank bottom

sufficient weight so that the bomb can sink in the product

removable extension rods (from 75 to 460 mm) (3 to 18 in.)for sampling at specific heights above the tank bottom

Samples taken in Bacon bombs usually have to be transferred

to a sample container so that the Bacon bomb can be reused.

Cage and Bottle Sampler

Cage and bottle samplers (also known as weighted bottle

samplers) (Figure 5) are used for taking spot samples,

all-levels, and running samples, and for taking samples of

volatile products in storage tanks, rail tank cars, tank trucks,and ship and barge tanks.

Cage and bottle samplers have the following features:

a brass, stainless steel, or plastic frame or cage fitted with a

litre or half litre (quart or pint) clear or amber glass bottle

a stopper connected to the cage by a rod (as in Figure 5), a

cord, or a chain. During sampling, the operator removes the

stopper by sharply jerking the drop cord.

sufficient weight so that the sampler can sink in the product

Figure 5—Cage and Bottle Sampler(Courtesy of HERMetic, Inc.)



Manually Sample



Samples taken in cage and bottle samplers do not have to be

transferred to a sample container. Bottles can be removed from

the cage, wiped off, stoppered, and transported to the lab. In

this way, volatile light ends are not lost through evaporationduring the transfer. For this reason, cage and bottle samplers

are preferred for sampling volatile products.

Weighted Beaker Samplers

Weighted beaker samplers (also known as weighted can

samplers) (Figure 6) are used for taking spot samples, all levels

samples, and running average samples in storage tanks, rail

tank cars, tank trucks, and ship and barge tanks.

Figure 6—Weighted BeakerSampler(Courtesy of Koehler InstrumentCompany, Inc.)




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Weighted beaker samplers have the following features:

made of stainless steel, copper, or brass attached to a lead

base

equipped with a stopper tied to the beaker. Duringsampling, the operator removes the stopper by sharply

jerking the drop cord.

sufficient weight so that the sampler can sink in the product

After the sampler has been raised to the surface, the sample

must be transferred to a sample container so that the weighted

beaker can be reused.

The flux used during the soldering manufacture of can

samplers must be thoroughly removed before the sampler can

be used. Some fluxes are difficult to remove and may

contaminate the sample for certain analyses. Check with your

vendor and laboratory to determine the suitability of the

sampler.

Samplers Used for All-Levels and Running Samples

Cage and bottle samplers and weighted beaker samplers

can be used to take all-levels samples and running samples.

Bottles and beakers can be fitted with closures that have small

openings, allowing restrictive filling. When the sampler is

lowered to the bottom of the tank and raised at a uniform rate,

liquid flows into the restrictive opening. The product viscosity,

density, and tank height dictate the size of the opening

required. When the opening size and sampling speed are

correct, a pocket of air remains when the sampler is removed

from the tank. If there is no pocket of air, the sampler filled

before the complete run was completed and the sample may

not be representative of the product at all levels. Even when

filled correctly (i.e., 70 to 85% full), the sample is not

necessarily representative, depending on operator skill and

tank dimensions.

Bacon bomb samplers can be equipped with a needle valve

at the top of the bomb. When the sampler is lowered to the

bottom of the tank at a uniform rate, liquid flows into the lower

end of the sampler only at the rate the air is displaced through

the needle valve at the top.




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Because you cannot see into the sampler, it is not possible to

determine if the sampler is correctly filled (i.e., if there is a

pocket of air).

Samplers Used for Bottom Samples

Core thief samplers and Bacon bomb samplers are used for

bottom sampling. Both types allow a sample to be taken from

very close (15 to 25 mm; 1/2 to 1 in.) to the bottom.

The core thief sampler is open while being lowered to the tank

bottom: product flows through the sampler. When the sampler

strikes the bottom (or when the operator remotely trips the

mechanism), the valves close, trapping bottom product.

The Bacon bomb sampler is closed while being lowered to the

tank bottom. When the sampler strikes the bottom, the valve

opens, admitting product into the bottom and expelling air from

the top. When the sampler starts moving upward, the valve

closes and traps bottom product.

3.2 Drop Cords and Trip Cords

Drop cords or chains (also known as sample lines or lowering

cords) are used to lower the sampler into the product. Trip

cords (also known as plunger lines or valve cords) are used totrip the valve mechanism on core thief and Bacon bomb

samplers.

Cords and chains should be spark resistant (i.e., unable to

carry a static electrical charge—a source of ignition). For this

reason, cords are usually made of vegetable fibers such as

cotton or sisal; man-made fiber content should be limited.

Chains are usually made of nickel-plated brass or stainless

steel.

Before taking samples, the operator measures and marks the

required sample levels on the cord or chain. Cords are

available with brass ferrules spaced at 300, 400, or 450 mm

(12, 16, or 18 in.) intervals from the bottom of the sampler.




Manually Sample



3.3 Sample Containers (Secondary Sample Receiver)

Sample containers (secondary sample receivers) are normally

clear or amber glass or metal bottles with an adequate stopper.

Bottles normally range between 0.25 and 5 litres (1 cup to

1 gallon); they must be large enough to hold the required

sample with sufficient space for expansion and mixing

(10 to 15%).

As with samplers:

sample containers must be resistant to the solvent action of

the product and cleaning agent

conventional polyethylene (i.e., non-linear polyethylene)

containers must not be used

sample containers must be made of a non-sparking material

Sample containers must have a tight stopper to prevent the

escape of volatile light ends.

On metal bottles, the flux used during the soldering

manufacture must be thoroughly removed before the bottle can

be used. Some fluxes are difficult to remove and may

contaminate the sample for certain analyses. Check with your

vendor and laboratory to determine the suitability of the metal

bottle.

3.4 Sampler and Sample Container Closures

Closures for samplers and sample containers are corks, inert

plastic stoppers, ground glass stoppers, and plastic or metal

screw-caps.

Corks should be clean, intact, and free from crumbling or loose

bits. Corks:

should only be used for one type of product to prevent

cross-contamination between different types of productshould not be used for volatile liquids, because the vapor

can diffuse into the cork and contaminate other samples




Manually Sample



Wrapping the cork in clean aluminum foil before insertion into

the container prevents the sample from contacting and

contaminating the cork. Wrapping any stopper with aluminum

foil protects highly refined products from moisture and dust.Containers with screw caps are used for samples that will be

tested for density or composition. Screw caps must provide a

vapor-tight seal. Caps should be fitted with a liner made of cork

or other oil-resistant material. Cork liners must be replaced

each time the screw cap is used to prevent cross-contamination

between samples.

Rubber stoppers should not be used because the rubber may

be degraded by the product.

4 Sample AccuracySamples must be taken and handled properly to ensure the

sample which arrives at the laboratory is representative of the

product in the tank. If sampling techniques are not correct, the

sample—and subsequent analyses—may not be accurate.

Inaccurate test results can mean lost revenue for your

company. Sampling must therefore be carefully carried out.

Ensure that:

the sampler and sample container are free of contaminants

the sample is representative of the product (i.e., has the

same composition as the product)

the sample is suitable for the required laboratory test

the sample is correctly labeled

the sample is correctly handled and transported

4.1 Uncontaminated Sample

Cleanliness is an important part of proper sampling: any

contaminants (such as water, dirt, cleaning solvent, soap, lint)

introduced into the sample will produce inaccurate test results. All sampling equipment must be clean before a sample is

taken.




Manually Sample

Non-Pressur ized TanksHuman Development Consultants Ltd.

Cleaning Procedure

After the sample has been removed, reusable samplers and

sample containers should be cleaned thoroughly with cleaning

solvent to remove all traces of product and sediment.

WARNING

Read the material safety data sheet (MSDS) for the cleaning

solvent. Use the personal protective equipment recommended

in the MSDS when working with the solvent. Discard the

solvent in accordance with your company’s hazardous waste

procedures.

Cleaning with solvent is followed by a wash in a strong soap

solution to remove all traces of solvent, a thorough rinse with

tap water, and a final rinse with distilled water. The containersmust be air dried, either with clean, warm pressurized air or in a

hot dust-free cabinet. As soon as the containers are dry, they

must be stoppered and stored in a clean cabinet.

Gauge (Thief) Hatch

Dirt and grime may be present around the tank’s gauge hatch.

Operators should ensure that the gauge hatch and the area

End of Sample A full licensed copy of this kit includes:

• Training Module and Self-Check

• Knowledge Check and Answer Key

• Blank Answer Sheet

• Performance Check

• Job Aid

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Manual sampling of no pressurised tanks

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