CTM 9.5	Chemical Tanker Manual CTM Cargo Loading Operations	Doc No.: CTM 9.5 Revision: 01 Date: 15 Oct 2024 Issued by: DPA Approved by: MD

1. APPLICATION

This document applies to all Chemical Tankers managed by the Company.

2. PURPOSE

The purpose of this document is to provide guidelines and instructions for the safe and efficient cargo loading operations for chemical tankers.

3. CARGO LOADING PLAN

3.1 Basic Information

The Chief Officer shall prepare a Cargo Operation plan which provides a detailed sequence of cargo and ballast operations. It shall cover the following:

• Quantity and grade of each parcel
• Density, temperature and other relevant properties
• A plan of the distribution lines and pumps to be used
• Transfer rates and maximum allowable pressures
• Cargo pollution category
• Flammability and toxicity (including antidotes if applicable)
• Fire protection including fire-fighting agent
• Miscibility
• Critical stages of the operation
• Notice of rate change
• Venting requirements
• Stability and stress information
• Drafts and trims
• Ballast operations
• Emergency stop procedures
• Action to be taken in the event of a spill
• Protective equipment requirements
• Hazards of the particular cargoes

Additionally, as required or applicable, the following may be included:

• Inhibitor requirements
• Inerting and padding
• Cargo viscosity
• Cargo melting point
• Cooling
• Tank coating material compatibility
• Precautions against static generation
• Control of cargo heating systems
• Line clearing
• Under keel clearance limitations
• Bunkering
• Special precautions required for the particular operation

3.2 Loading Methods

The Cargo Operation plan shall clearly specify:

• Manifold/line to be used
• Connecting method for jumping hoses or spool pieces
• The caution when connecting the manifold pipe of each tank with a common line by using spool pieces, that:
  • Person in charge shall ensure removal of the spool piece for each tank, and that
  • A blank flange must be fitted instead

3.3 Loading Directly from Deck

When cargo is loaded directly from the deck by using a hose (loading overall), the Cargo Operation plan should show clearly:

• Schematic indication of the procedure of attaching a fitting to a butterworth hole
• Connecting method of a hose
• Preparation prior to loading
• Checks during loading
• Clearing operations after loading
• Jobs allotted to the relevant crewmembers at each stage

3.4 Involvement of Engine Department

The Chief Officer shall discuss relevant items of the Cargo Operation plan with the Engine Department, which shall include the following:

• When and how ballast pumps are used
• Steam arrangements required for checking heating coils for leaks prior to loading, cargo heating, etc.
• Check the compressor’s air charge for air blow
• Stress and Stability with regard to Bunker tanks distribution
• If bunkering is scheduled, planning both operations so as not to interfere with one another

4. PRIOR LOADING

4.1 Cleanliness of tanks and associated equipment prior to loading

The Chief Officer shall consider the following when verifying cleanliness/readiness of the cargo system prior to loading:

• Cargo pipes are enclosed and thus almost preclude visual checks from outside. Accordingly, he must be confident of the cleaning procedure and check their cleanliness visually as far as possible.
• Cleaning water trapped in the line has been removed by air blow or draining.
• After tank cleaning, cargo line strainers have been removed to clean their elements.
• When open, cleanliness of relevant pipes connected thereto have been checked.
• Cargo valves have been drained by removing their bottom plugs, as applicable.
• Spool pieces, spectacle flanges, reducers are removed to check the cleanliness from inside.

Note:

• Reducers are generally attached to cargo pipes at the manifold for connecting cargo hoses. If dirty, they may give an unfavourable impression that the entire piping systems are stained.
• The terminal usually arranges connecting hoses from the shore to the manifold. Arrange for checking the cleanliness of the hose from inside.

4.2 Inspection of tanks prior to loading

The Chief Officer shall arrange for the following to be ready:

• Approved flashlights, shoe covers, and cotton gloves
• Facilities to remove possible tank sweat or foreign substances in the piping system such as bucket, cotton rags, or sponge
• Manpower for the above and have them report on the outcome

The Chief Officer shall ensure:

• In case of heated cargo, heating coils are steamed in advance.
• When air blow of the loading line is required, condensed oily water in the air tank is drained.

Inspection

The Chief Officer shall:

• Accompany the surveyors and inspect each nominated tank.
• Confirm that the tanks are empty, dry, and in a fit condition to receive the nominated cargo.
• Record the time for tank inspection in the statement of facts.

Note:

• If inspections have been carried out prior to berthing due to terminal instructions or as otherwise decided by Master or Charterer, perform a final check of the tanks just before berthing.
• Ensure a copy of the surveyor’s certificate of inspection/fitness is provided to the vessel.

Note:

• In addition, complete COMPANY Form E25 Tank Inspection Report

4.3 Other actions and tests to be carried out prior to loading

Heating/Steam Line

The Chief Officer shall:

• In case of non-heated cargo, ensure a blank flange is inserted in the heating line of the relevant tanks.
• In case of heat-sensitive cargo, positively blank the heating line for the concerned tank.
• Ensure heating coils are blown through and the contents examined for contamination.

Vapour Return

The Chief Officer shall ensure:

• Whenever vapour is required to be returned ashore:
  • The vent line of the cargo tanks is connected to the vapour return manifold.

Note:

• This can be done by either connecting a spool piece or by removing the blank of the vent line (subject to the design of vessel).
• When the vapour return line is not required by the terminal:
  • The cargo venting system is disconnected from the vapour return manifold.

  Note:

  • This can be done by either removing the spool piece or by inserting a blank.
  • The tanks are vented via the high-velocity vent valves.

Air Hoses

The Chief Officer shall ensure:

• The air hoses are prepared ready for use at the connecting position.

Coution:

• Before connecting shore hoses to vessel’s cargo line, ensure the relevant loading line is air-blown and drained completely.
• Such air is free from lubricating oil, water, and other impurities.

Loading Manifolds

The Chief Officer must plan the following to make the loading manifolds ready:

• Place identification tags for the various grades to be loaded at the respective manifolds to aid hose connection.
• Open vessel's lines as required except the manifold valve.
• On completion of tank inspection and hose connections, and when all preloading precautions have been taken.

4.4 Line-up of cargo tanks and lines

For cargo quality control and to prevent contamination, the Chief Officer shall ensure the following is checked:

• Cargo piping system is properly set to the relevant cargo tank.
• All drains & openings of pumps and lines are closed.
• Spool pieces and spectacle flanges are properly fitted in position.
• After spool pieces have been disconnected, the relevant flanges are covered with blank flanges using proper flange packing.
• Blank flanges are fitted to unused and uncovered flanges on the cargo line.
• Tightness of such spectacle or blank flanges as set in position, by air pressure.

5. LOADING

5.1 Start of loading operation

The Chief Officer shall:

• Ensure the vessel's manifold valve is not opened until the responsible person from the terminal informs the vessel that the shore is ready to commence.
• Ensure samples are taken from the manifold as far as possible prior to the flow of cargo into the tank.
• Start loading at a slow rate.
• Check all tanks, including empty ones, to ensure that:
  • cargo is entering the correct tanks properly and that
  • there is no leakage from the lines, into pump rooms, cofferdam, or onto the sea.
• Ensure regular checks are made thereafter to confirm cargo system is free of leaks until completion of the entire operation.
• When all checks have been made and the operation is found to be in order, take the following into account prior to increasing the loading rate gradually to the agreed maximum:
  • Working pressure of ship’s lines and hoses being used.
  • Capacity of vapours or vent lines.
  • Capacity and the required ullage in cargo tanks.
  • Nature of Cargo.
  • Generation and accumulation of electrostatic charge (See CTM 9.3, 9.2, Static Electricity Precautions).

5.2 Control of flow

When loading two or more tanks simultaneously with the same grade of cargo, the flow of cargo to tanks must be controlled by the:

• Tank delivery valve, or
• Manifold valves of specific tanks, whichever is applicable (unless loading overall).

Such valves must not be closed completely or rapidly unless another tank is open to receive the flow.

Tanks where loading has been completed shall be isolated from others by two (2) valves segregation.

5.3 Progress of loading

The OOW shall:

• Take periodical measurements of ullage and temperature.
• Calculate the loaded quantity and the loading rate.
• Estimate the time of completion of loading.

Note:

• Record above in COMPANY CHEM 04 – Hourly Monitoring Record

Coution:

• If there is a substantial discrepancy in loading rates from those calculated at the previous periodical measurement or the loading plan, the OOW shall enquire about the reasons for same from the responsible person on the shore/barge and inform the Chief Officer and Master accordingly.
• Keep periodical contact with the shore or barge representative.
• Maintain contact with crew members in charge of the deck watch to:
  • Keep them informed of the progress of cargo handling operations.
  • Ascertain that the cargo watch is kept in a proper manner.
  • Confirm walkie-talkies are functioning properly.

5.4 Topping off procedures

The Chief Officer/OOW shall consider the following points during “topping off”:

• Comply with all arrangements as agreed with the terminal in the pre-loading conference.
• Reduce the number of valves to be closed during "topping-off" to a minimum.
• Verify Communications - both internal & external to be in order.
• Reduce the loading rate to a safe level.

Note:

• This will require a request to the shore to reduce the rate and shall take into account time required to affect such reduction.

Coution:

• Do not use Ship tank valves to reduce the rate as this can lead to pressure surges or excessive pressure in the system.
• UTI/MMC to be used only for cargoes where Open/restricted gauging is permitted as per IBC chapter 17.

Note:

• Remote gauges may only be used for cross-reference. Sighting ports may also be used effectively in addition to UTI/MMC ullage gauges.
• Keep the vessel upright as far as possible.
• Check tanks not being loaded frequently for any change in level.
• Stagger final stages of tank filling to ensure that only one tank is being "topped-off" at any one time.
• Shut master valves after "topping-off" individual tanks, where possible, to provide two-valve separation.
• Always keep one tank in each grade slack as a "dump tank".

Note:

• If a valve failure or major leak is experienced, so that a tank being "topped-off" cannot be closed off, the availability of a "dump tank" will provide space to divert the flow during an emergency reduction in rate or complete stoppage.
  The "dump tank" is by nature the final tank to be loaded.
• On completion of loading the cargo, the flow must be stopped on shore and not by shutting the vessel’s valves. All the vessel’s valves must be shut thereafter.

6. LOADING OVERALL AND SPLASH FILLING

6.1 Loading overall

There may be specific port or terminal regulations relating to loading from the top.

Non-volatile petroleum having a temperature lower than its flashpoint minus 10ºC may be loaded from the top in the following circumstances:

• If the tank concerned is gas-free, provided no contamination by volatile petroleum can occur.
• If prior agreement is reached between the Master and the terminal representative.
• The free end of the hose should be lashed inside the tank coaming to prevent movement.
• Ballast or slops must not be loaded or transferred from the top into a tank which contains a flammable gas mixture.
• All flange connections shall be well made up and have suitable gaskets.
• Vegetable oil cargoes may not be loaded from top owing to possible oxidization of cargo during free fall causing deterioration in quality.

6.2 Splash filling

Splash filling of vegetable oil cargoes is undesirable owing to possible oxidization of cargo during free fall causing deterioration in quality.

If permitted by the Marine Department, ensure the following:

• The tank to be loaded is gas-free.
• The free end of the hose is securely lashed inside the tank, to prevent the tank structure or coating from being damaged by its movements.
• All flange connections are well made up and have suitable gaskets.

7. LINE FLUSHING

The Chief Officer shall:

• Consult the Surveyors to confirm:
  • Method and necessary time for line flushing.
  • Cargo quantity for flushing.
  • Whether Ship Stop or Shore Stop.
• To prevent flushing cargo from entering irrelevant tanks by erroneous operation, ensure that the following is conveyed to all crew members:
  • Tank numbers to be flushed.
  • Sequence of operations.
  • Valve handling.
  • Other important matters as necessary.

Note:

• Ensure the instructions are passed on both verbally and by posting such instructions in the Cargo Control Room.
• Arrange appropriate allocation of crew members and means of communication between the deck and the control room.

8. AFTER COMPLETION OF LOADING

The Chief Officer shall supervise the following on completion of loading:

• All cargo lines are drained empty of the product and thereafter all cargo valves are to be shut.
• Cargo hoses and arms are cleared as agreed, and only disconnected from the manifold after:
  • They have been drained of the cargo residues.
  • Relieved of pressure.
• Tank and Butterworth hatches, ullage, and sighting ports are closed and secured.
• P/V valves and vent lines are checked to confirm that they are clear.

9. REFERENCED FORMS AND CHECKLISTS

• CHEM-01 - Cargo Operation Plan
• E25 - Tank Inspection Report
• CHEM-04 - Hourly Monitoring Record