Itco Repair Procedure
Itco Repair Procedure
Itco Repair Procedure
Contents
Page
Introduction
Definitions
1. Cleanliness
2. Frame
3. Walkway and Ladder
4. Paintwork
5. Insulation and Cladding
6. Manway Assembly
7. Safety Relief Valves
8. Top Valves
9. Pressure Vessel (Tank Shell or Barrel)
10. Bottom Valves
11. Heating
12. Miscellaneous
13. Test
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6
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19
23
24
25
27
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ITCO Secretariat
c/o Freson
Korteveld 3
3090 Overijse
Belgium
freson@itco.be - administrator@itco.be
Tel: +32 2 783 2270
Fax : +32 2 783 2271
Mob : + 32 475 79 81 94
web : www.itco.be or www.tankcontainer.org
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Introduction
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Definitions
Acceptable and Not acceptable Conditions
The condition guide which follows lists the component parts of a tank container
and describes what is acceptable and what is not acceptable according to the
standards agreed by the ITCO.
NOT Acceptable Condition
Is damage which affects the safety, structural integrity, cargo-carrying capability,
the ISO dimensions of the tank container or where repairs are improper or not in
compliance with the applicable regulations:
THIS TYPE OF DAMAGE MUST BE REPAIRED
Acceptable Condition
Is minor damage or fair wear and tear which does not affect any of the above
conditions:
NO REPAIR IS REQUIRED
'FairWearandTear'istheagerelateddeteriorationofthecontaineroranyofits
component parts while being properly maintained and used for its intended
purpose.Anydeteriorationresultingfromimproperuse,impropermaintenance
orlackofmaintenanceisnot'FairWearandTear.'
Replacementofleakingorcontaminatedsealsandgasketsisanormaloperating
requirementandisnot'FairWearandTear.'
NOTES:
I
Some tank containers may be fitted with equipment which does not
conform to the make and specification stated in the text. Where there is
doubt as to the suitability of this equipment please refer to the owner.
II
III
The drawings included in this manual are not applicable to all types of tank
containers.
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Cleanliness
1.1 Interior
NOT Acceptable Condition
Previous cargo, contamination or odour.
Discolouration or transferable stain which can be removed by the manual
application of a plastic abrasive pad and/or solvent.
Corrosion, pitting, grinding or gouges. (See Section 9).
Missing or improper Cleanliness Certificate.
_______________________________________________________________
Acceptable Condition
Abrasion or scratches to finer than 120 grit polish equivalent.
NOTE:
When the tank is received into depot for off-hire the depot must be in possession
of a valid certificate of cleanliness stating the proper shipping name and U.N.
number of the last cargo carried in the tank.
The Cleanliness Certificate must have the date of inspection later than the last
cargo or any internal work or internal cleaning.
For man entry it is the responsibility of the depot supervisor to ensure that the tank
container is safe to enter. This may require an inspection for gas contamination or
low oxygen. (Gas Free Certificate).
Tank containers are accepted for delivery into depot for off-hire only when
accompanied by a Cleanliness Certificate. Tanks containers without valid
documentation must be considered unsafe and should not be inspected. A
Cleanliness Certificate issued by an independent surveyor is required for all tanks
redelivered for off-hire. (See Appendix A).
1.2 Exterior
NOT Acceptable Condition
Previous cargo, contamination or odour.
Oil, grease deposits.
Road dirt reducing legibility of tank markings.
_____________________________________________________________________
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Acceptable Condition
Road dirt. (Except as stated above).
NOTE :
The valve and manlid spillage trays must be clean and free of cargo spillage. Check
areas of overspill for damage to paint and cladding and inspect drain tubes for
blockage.
1. 3 Foreign Markings
NOT Acceptable Condition
Hazard warning labels or cargo labels.
Non-standard labels or misleading marks.
Remnants of labels.
Insecure label holders.
__________________________________________________________________________
AcceptableCondition
Serviceable non-standard label holders.
Glue residue
2Frame
2.1CornerPosts
NOT Acceptable Condition
Cuts or holes or gouges.
Cracks or splits in welds or parent metal.
Improper repairs..
Dents or distortions of a formed or folded edge or face greater than 15 mm
(0.6 inch) in depth irrespective of length of deformation.
Dents greater than 10 mm (0.4 inch) and less than 15 mm (0.6 inch) in
depth in excess of two per post.
Dents greater than 10 mm (0.4 inch) extending over a length greater than
300 mm (12 inch).
Twisted or bent or over-plated beyond the requirements of ISO.
Corrosion affecting the structural strength of the member.
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_________________________________________________________________________
Acceptable Condition
Dents or distortions not exceeding 15 mm (0.6 inch) in depth except as qualified
above
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Acceptable Condition
Dents not exceeding 25 mm (1 inch).
Dents in bottom face of bottom rails which do not affect any formed edge.
2. 3 Ancillary Bracing
Improper repairs.
Dents and distortions greater than 25 mm (1 inch).
Twisted or bent outwards beyond the limits of the ISO corner dimensions.
Severe corrosion.
_____________________________________________________________________________
Acceptable Condition
Dents and distortions less than 25 mm (1 inch).
Acceptable Condition
Dents and distortions less than 25 mm (1 inch).
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Acceptable Condition
Distortions smaller than 50 mm (2 inch) measured over not less than l m
length and not affecting safety.
Dents up to 25 mm (1 inch) and not affecting safety.
Cuts not affecting safety.
4 Paintwork
NOT Acceptable Condition
Paint removed by spillage of cargo.
Paint removed by improper handling.
Corrosion or paint abrasion equal to, or more severe than, Euro Standard
Re4.
____________________________________________________________________________
Acceptable Condition
Superficial corrosion.
Light discoloration.
Light scuffs and scratches.
Note :
Paint damage and resulting corrosion must be repaired as part of routine
maintenance.
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INSULATIOCLADDING
5.1 Insulation
NOT Acceptable Condition
Missing insulation material.
Saturation by water or cargo.
Improper repairs.
Deterioration by heat (burnt or baked).
5. 2 Cladding
NOT Acceptable Condition
Cuts, holes, cracks or splits penetrating the cladding thickness and allowing
moisture ingress.
Gaps in cladding and patch joints allowing moisture ingress.
Deterioration by heat (burnt or baked).
Insecure cladding or retaining straps.
Surface damage or staining of cladding due to cargo contamination.
Corrosion or pitting allowing moisture ingress
Improper repairs.
Distorted outwards beyond the limits of the ISO corner fittings.
Dents greater than 25 mm (1 inch).
_____________________________________________________________________________
Acceptable Condition
Distortion not affecting security nor allowing moisture ingress except as
stated above.
Abrasion.
Full belly GRP patch on existing aluminium cladding
NOTE:
I.
In all cases of damage to the cladding the tank shell, heating tubes and
electrical components must also be checked.
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II.
The following criteria will apply when assessing the type and extent of
repair required. Use self colour polyester in-fill or overlay riveted patches
(minimum 2 mm (0.08 inch) thick G.R.P. for G.R.P. cladding-minimum and
0.9 mm (18 s.w.g.) Alum Alloy for Alum Alloy cladding in the same colour).
Minimum patch size 150 x 150 mm (6 inch x 6 inch).
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6ManwayAssembly
6.1ManlidandSwingboltAssemblies
NOT Acceptable Condition
Leaks.
Missing, insecure, seized or non-operational parts.
Dents or distortion greater than 6mm (0.25 inch) or affecting proper sealing
of the manlid.
Cracks.
Missing Customs sealing ring.
Pitting, corrosion or contamination.
Improper repairs.
.................................................................................................................................................................
Acceptable Condition
Non-standard hand nuts which are similar design and similar material.
6. 2 Manlid Seal
NOT Acceptable Condition
Cuts, cracks or distortion affecting sealing.
Contamination.
Square butt joint.
Missing.
.................................................................................................................................................................
Acceptable Condition
Minor surface degradation (ozone or chemical) which does not contain
contamination and does not affect sealing.
Note :
The following criteria will apply when assessing the type and extent of repair
required : Seals fitted must be to owners specification. Solid seals may be
cleaned.
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Note :
Dipsticks may or may not be standard. When in doubt refer to the owner.
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7SafetyRelief Valves
7.1 Pressure Only or Pressure Vacuum Valves
NOT Acceptable Condition
Contamination or corrosion.
Missing parts.
Distortion, damaged or worn threads affecting correct operation or security.
Leaks or incorrect pressure setting.
Missing or defective Customs sealing ring.
Improper repairs, seals or gaskets.
.................................................................................................................................................................
Acceptable Condition
Missing dust plug.
PTFE or CF gaskets.
Note :
Flame arrestors are not necessary on non-hazardous tanks or on Pressure Only
Valves.
8 Top Valves
Acceptable Condition
SWR or PTFE airline cap seals.
Caps of non-corrodible material.
Note :
If no valve is fitted, airline screw cap seals must be of the full face type.
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*RefertonotesunderFairwearandtear
9PressureVessel
Sharp indentations, creases or dents causing the elastic limit of the material to be
exceeded resulting in permanent deformation.
Dents greater than 6 mm (0.25 inch) to the top third of the tank shell.
Dents greater than 10 mm (0.4 inch) to the bottom two thirds of the tank shell.
Vacuum ring distortions greater than 15 mm or 50% of the thickness , whichever is
smaller
AcceptableCondition
Gradual distortions measured over the length between exterior stiffeners of less
than 10 mm (0.4 inch) in bottom two thirds or less than 6 mm (0.25 inch) in top
third of tank shell.
Light abrasions or scratches to 120 grit polish equivalent or finer.
Superficial pitting with no resulting contamination traps see type A hereafter
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Note
Mandatory hydrostatic retesting is required after all welded repairs to the tank shell
10 Bottom Valves
10.1 Foot Valve
NOT Acceptable Condition
Leaks.
Contamination or corrosion.
Damage or distortion affecting correct operation or sealing.
Improper repairs, seals or gaskets.
Customs sealing ring missing.
Incompatible Material*.
* Refer to notes under Fair Wear and Tear
Note
Foot valve to tank flange gaskets must be PTFE envelope CF
Note :
Where renewal is necessary bolts should be stainless steel. Replacement gaskets
should be PTFE envelope CF or solid PTFE.
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BottomOutletValve
Item Description
Item Description
PTFE/CFvalvetotankgasket
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VitonORing
Bayonetcap
12
PTFEORing2off
Spring
13
Stuffingclamp
Pressureplate
14
CapscrewM63off
FortyteORing
15
Operatinghandle
ClampPlate
16
ScrewM6
ScrewM6PTFE3off
17
Washer
PTFE/CFvalvetoballvalvegasket
18
Crankblockassembly
PTFEspindlebush
19
Sleeve
10
Spindle
20
Body
Acceptable Condition
SWR seals.
Note
Replacement caps must be secured by a chain.
Butterfly Valve Top and Bottom Outlet and Vapour Return Valve
Item Description
Item Description
HandleLever
13
GlandPlateWasher
HandlePin
14
GlandPlateNut
HandleScrew
15
GlandORing
HandleSpring
16
FlangedBody
GlandPlateScrews
17
GlandPlateWasher
Handle
18
GlandPlateNut
GlandPlate
19
FixedPivot
GlandPin
20
BottomBearing
GlandRing
21
ClosingPlate
10
GlandORing
22
MainSeal
11
Shaft
23
LocatingRing
12
GlandRing
24
SealPlate
11Heating
11.1 Steam Tube and Cap
NOT Acceptable Condition
Leaks.
Damaged screwed fittings.
Missing dust caps.
Missing chain or cable.
Distortions greater than 50% of the steam tube depth
Note :
In all cases of damage the steam tubes must be pressure tested. Defective steam traps
should be removed, replacement is not required.
11.2 Thermometer
NOT Acceptable Condition
Not operating correctly.
Broken facia or dial.
Missing or insecure.
Improperly fitted.
..................................................................................................................................................
Acceptable Condition
Condensation which does not prevent legibility.
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Note
All parts must be well-maintained and fully-operational. An electric function test is
required at off-hire and on-hire for every electric heated tank.
12Miscellaneous
12.1 Decals and Data Plates
NOT Acceptable Condition
Insecure.
Missing or illegible plates.
Missing, illegible, obscured or partly missing decals and logos.
Twisted or bent beyond limits of ISO.
_____________________________________________________________________
AcceptableCondition
Scuffs.
Dents except as stated above.
Note :
All plates and decals required by applicable regulations must be in place. Refer to
owner for details of the data plates and decals to be fitted.
Acceptable Condition
Non-standard type.
Splits or tears.
Cargo residues, dirt, sundry waste.
Blocked, damaged, missing drain tubes.
13Test
13.1AirLeakageTest
The tank must be pressurized with air to 1 bar (15 p.s.i.g.) and all fittings and
flanges checked with liquid soap at off-hire.
Leak checks to 1.0 bar (15 p.s.i.g.) are required to all tanks as part of the completed
repair inspection.
Where tanks are stored in depot for periods greater than six months from the time
of the completed repair inspection, a repeat leak test is required prior to delivery.
13.2HydraulicTest(afterrepair)
Mandatory retesting is required after all welded repairs to the shell of hazardous
tanks (see applicable regulations.).
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APPENDIX A
ITCO FORMAT
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CLEANLINESS CERTIFICATE
TANK CONTAINER CLEANLINESS SURVEY REPORT
(Certificate invalid if not fully completed)
Survey Company Name and Address
.................................................................................................
...................................................................................................................................................................
Tank Container Serial No ........................................................................................................................
Inspection Date ............................................................... Inspection Time ...........................................
Inspection Location ...................................................................................................................................
Cleaning Co .................................................. Cleaning Procedure ............................................................
Last Cargo Carried.................................................................................... UN No ...................................
(Statement of last Cargo was provided by ................................................................................................ )
EXTERIOR
Frame, tank and walkways free of contamination and cargo
Manlid and valve compartments free of contamination and cargo
Serial numbers and statutory markings legible
Cargo labels removed
Yes
No
Yes
Yes
Yes
No
No
No
INTERIOR
Entry made into tank by surveyor
Free from odour
Clean and free from all cargo and contamination
Free from corrosion or pitting (if no, report details below)
Dry
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
REMARKS: .............................................................................................................................................
...................................................................................................................................................................
...................................................................................................................................................................
A thorough visual examination has been carried out and the interior of the tank, valves and fittings are
free of contamination, previous cargo and odour. The tank is clean and dry.
ITCOFORMAT
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INTERNALINSPECTIONREPORT
TANKSERIALNO.
Location:
InspectedBy:
LASTPRODUCT:
Ref.No.:
Date:
OrderNo.:
Front
Rear
Name(Print)
SignedDate
The seals and gaskets below are listed for guidance only. Many other materials exist
which may be used as seals for standard cargoes or specified to obtain compatibility
with special cargoes.
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