D - Annual Sprayer Checklist

Are the brake linings going to last the season?

What is the condition and available adjustment of the clutch?

Service. When is the next service due? If it fulls between July and December, get it done in June as this will eliminate down time during the season.

Zero Harm. Check and rectify any Zero Harm requirements to Downer standards.

Mechanical Check. Conduct a full mechanical check with E2 process.

Mechanical Cleaning. Conduct cleaning of radiator and intercooler.

Damage. Check and rectify damage.

Safety. Check and replenish and date tag the first aid kit and environmental spill kit.

COF. Carry out a pre COF check and obtain a new COF

Valet. Check and valet the cab interior to Downer Standards.

Does the tank placarding comply with the requirements of section A5.2 of Appendix 5?

Are the tank placards (hazchem etc) Clean and legible?

Has the design, construction, modification and commissioning been carried out under the direct supervision of a suitably qualified and experienced person?

Do records of all commissioning tests exist?

If records of all commissioning tests exist, have they been signed off?

Does the tank design and construction comply with Appendix 12?

Are pipe connections sized and placed so that liquids enter in a downwards direction with a minimum of splashing? ie a drop pipe.

TRI ANNUAL ONLY - Where circulation is used for blending, is the returned liquid dispersed throughout the tank? eg by a pipe along the floor of the tank with exit holes along its length.<br>

TRI ANNUAL ONLY - Is piping sized so that inlet velocities comply with the table in clause 5.5.1 (c)?

Are all valves suitable for the products, temperatures and pressures that they will be subjected to?

Are all tank valves located as close as practicable to the tank shell, and positioned so that accidental damage through impact or tank rollover is minimised?

Are all valves located so they can be operated without risk of the operator contacting hot surfaces?<br>

Are all valves located so that the operator has unimpeded escape if a malfunction occurs?<br>

Are all valves clearly labelled?<br>

Are all valves opening and closing fully?<br>

Are all valves open to atmosphere lockable? This includes small air bleed valves when these are positioned between the tank and the connection point valves.<br>

Does the pump have pressure control? Describe operation.<br>

Is a regular schedule of inspection for pump pressure relief valves in place and occurring?<br>

Record the maximum pressure setting for the pump. How did you measure this?<br>

Is the pump reversible?

Record the maximum pressure setting in the reverse direction. How did you measure this?

Are all engines and exhaust systems protected from spillage from above by a metal shield?<br>

TRI ANNUAL - Are all engines and exhaust systems protected by a metal shield if they are within 1 metre of a liquid carrying component of a pumping system?

TRI ANNUAL - Are all exhaust systems underneath a tank shielded?<br>

TRI ANNUAL - Is the shield greater than 50mm from the exhaust system?<br>

TRI ANNUAL - Are all parts of the exhaust system greater than 0.5 metres of a vapour source?<br>

TRI ANNUAL - Are all engine exhausts directed away from, and terminate no closer than 1.5 metres, from any vapour source?<br>

Are there any components that would result in a hole greater than 320 mm² (20mm in diameter) if damaged during a roll-over? eg manhole, valves, pipes, vents, dipstick openings etc.<br>

Are these adequately protected from damage? See 5.7 for acceptable options.<br>

Are all components attached to the tank shell mounted on doubler plates? If a component is attached directly to the tank shell the design shall ensure that the component will fail before the tank is ruptured.<br>

Do the doubler plates comply with the requirements of 5.8 (b)?<br>

Tri - Annual Does the manhole comply with the size requirements of clause 5.9.1? Record the diameter.<br>

Tri - Annual Is the hinge for the manhole cover located at the front?<br>

Tri - Annual If the manhole is the emergency vent, does the latch mechanism ensure that the manhole cover remains sealed during normal use and during a roll-over, yet allow the cover to blow open in the event of a tank explosion?<br>

Tri - Annual If the manhole is the emergency vent, is it restrained just past the vertical position so that it will reclose if blown open by a tank explosion?<br>

Tri - Annual Is the manhole cover adequately attached to the tank to ensure that the cover will not part company in the event of a tank explosion?<br>

Tri - Annual Is any water that may collect around the manhole drained away?<br>

Tri - Annual Is any condensate that drips from the manhole collected and drained away? It must not drip onto the cladding where it may contaminate the insulation.<br>

Tri - Annual Are drainage pipes for water or condensate straight to enable inspection and cleaning?<br>

Tri - Annual Is the manhole fitted with a grate or basket so that no objects or people could fall into the tank when the manhole is open?<br>

Tri - Annual If bolted access hatches are installed, are these all greater than 500mm in diameter? Record the diameter.<br>

Tri - Annual Is it possible to access all tank compartments without passing through more than two baffles? If this is not the case then additional access hatches are required.<br>

Tri - Annual If tank compartment access openings are provided in baffles, are these all greater than 500mm in diameter? Record the diameter.<br>

Tri - Annual Is the tank free venting? ie an open vent.<br>

Tri - Annual Is the vent design such that in the event of a roll-over half the liquid contents will remain in the tank?<br>

Tri - Annual Does the free vent design prevent rainwater or foreign matter entering the tank?<br>

Tri - Annual Does the free vent design and construction enable regular inspection and cleaning?<br>

Tri - Annual Is the free vent a minimum of 50 NB ? Record the internal diameter of the free vent.<br>

Tri - Annual Is any condensate that drips from the vent collected?<br>

Tri - Annual Is the top of the collecting container lower than the free vent outlet?<br>

Tri - Annual Is the manhole coaming inside the tank vented (front and rear) at the highest point?<br>

Tri - Annual Is there an emergency vent? Provide description.<br>

Are there two independent temperature indicators?<br>

Is at least one of these independent temperature indicators below the minimum safe heating level?<br>

Are all temperature measuring sensors installed in fixed blind pockets?<br>

Is all electrical cabling securely fastened, located and adequately protected against vibration, impact, abrasion or any other mechanical or thermal stress?<br>

Is all electrical cabling that is exposed to vapour release during spraying operations protected from, or suitable for, exposure to hydrocarbon solvents?<br>

Are all electrical circuits (except the main battery, starter and alternator circuits) protected by appropriate fusing or circuit breakers?<br>

Are the batteries fitted with an accessible and labelled isolating switch?<br>

Is electrical cabling that passes through any hazardous zone (ie within 500mm radius of any vapour source) continuous with no connections or joints?<br>

Are all electrical devices located outside the hazardous zones (ie further than 500mm radius from any vapour source)?<br>

If there are any electrical devices located within the hazardous zone, do these comply with clause 5.11.3?<br>

Is there a Certificate of Compliance for electrical systems above 32 VAC?<br>

Is there an electrical WOF, less than 12 months old, for all systems above 32 VAC?<br>

Is there a residual current device (RCD) on any external 230 volt single phase supply lead?<br>

Is there a residual current device (RCD) on any generator output?<br>

Do electrical leads have current certification to AS/NZS 3760:2003 (6 monthly)?<br>

Is the electrical resistance between the tank structure, associated pipework, loadout gantry and road tankwagon less than 10 ohms?<br>

Is there at least one labelled non-corrodible bare metal lug installed for use as an earth bonding point during loading?<br>

Is the electrical resistance between any conductive parts of the vehicle and ground less than 1 megaohm?<br>

Electrical insulation resistance between current carrying conductors and ground connections shall exceed 1 megohm, with the exception of element insulation resistance of MIMS (mineral insulated metal sheathed) elements. These must have an individual insulation resistance of greater than 0.01 megohms as tested with a 500 volt insulation tester.<br>

Does the tank have multiple separate compartments?<br>

If so, does each compartment comply with all the requirements of this code? A separate checklist should be used for each compartment.<br>

Is the dipstick clearly marked in at least 1000 litre increments?<br>

Is the dipstick clearly marked with the maximum hot working level? Record this.<br>

Is the dipstick clearly marked with the minimum safe heating level(s)? Record this. <br>

Is the dipstick clearly marked with the tank identification number?<br>

Is the dipstick made of non-ferrous material?<br>

Is the dipstick positioned so that dip error is minimised when the tank is on sloping ground? The RNZ E/2 requires dipsticks to be within 400mm of the tank centre.<br>

Is the dipstick top hung so that it does not contact the tank floor?<br>

Does the dipstick include a reference point so that wear can be checked and corrected?<br>

Is the dipstick provided with a guide to hold it in a vertical position?<br>

Are all parts of fuel and flushing tanks positioned further than 1 metre horizontally from a vertical line through the burner?<br>

TRI ANNUAL - Is there a labelled shut off valve at the outlet of the burner fuel supply tank?<br>

Do all pipe connections to fuel and flushing tanks enter from the top of the tank via drop pipes?<br>

Was the tank shell sandblasted and painted with high temperature paint prior to being insulated?<br>

Is tank clad so that spillage and rainwater cannot enter insulation material?<br>

Are heating tubes isolated from the insulation material by an air space of at least 10mm?<br>

Is there a tank cold start heating procedure?<br>

Does the stated minimum safe heating level ensure that every part of the heat transfer surface inside the tank is covered with at least 200mm of binder?<br>

Is the electric element rating less than 12.5 kilowatts per square metre of external tube surface?<br>

Is the flame tube surface temperature limited to less than 350 0C?<br>

If yes, how is this achieved?<br>

Is the flame tube fitted with a removable liner?<br>

Is burner tube free of carbon build up<br>

Is the flame tube liner easily removed for servicing?<br>

Is the flame tube inlet more than 1.5m away (via the vapour path) from any hatch, vent, overflow pipe exit or other vapour source?<br>

Is the flame tube flue exit more than 1.5m away (via the vapour path) from any hatch, vent, overflow pipe exit or other vapour source?<br>

<br>Are burner exhaust flues not in direct contact with tank shell?<br>

TRI ANNUAL - Does the manual (attended) heating procedure include a requirement for the operator to ensure that a minimum of 200mm of product covers the highest point of the heating tube surface before heating?

Does the manual (attended) heating procedure include a requirement for the operator to not heat the product above the desired temperature?<br>

Does the manual (attended) heating procedure include a requirement for the operator to turn off the heating before changing the product level in the tank?<br>

Does the manual (attended) heating procedure include a requirement for the operator to turn off the heating 15 minutes before the heating tubes are exposed to the vapour space in the tank?<br>

Does the manual (attended) heating system have a permanent "Do not operate heating unattended" notice displayed adjacent to the heater?<br>

Does the automatic (unattended) heating system have two temperature sensors placed above the uppermost heating surface and below the low level heating switch?<br>

Does the automatic (unattended) heating system have two independent (primary and secondary) temperature control systems?<br>

Does the secondary temperature controller turn off the heating and not allow it to restart without a manual reset operation?<br>

Does the automatic (unattended) heating system have two independent methods to stop the heating (usually achieved with two contactors or relays in series)?<br>

Does the automatic (unattended) heating system have a low level switch that turns off the heating if 200mm or less of the product covers the uppermost point of the heating surface?<br>

Does the low level switch turn off the heating and not allow it to restart without a manual reset operation?<br>

Is there visual indication that heating has been selected for the tank?<br>

Does a procedure exist for the routine checking of the temperature control systems and the level switches?<br>

Does a procedure exist for the routine calibration of the temperature control systems?<br>

Are all electrical devices installed under the cladding suitable for the temperatures encountered?<br>

Is all wiring installed under the cladding suitable for the temperatures encountered?<br>

Does the automatic (unattended) heating system have a permanent notice displayed at the heater controls stating that the heating system is suitable for unattended operation?<br>

Are all burners equipped with flame out safety interlocks?<br>

Are the temperature control systems fail safe? ie lock the heating off in the event of a temperature sensor open or short circuiting.<br>

TRI ANNUAL - Are flame and element heating tubes protected from hammering where they pass through baffles?<br>

Are granular material (eg crumbed rubber) containers metallic and earthed to the tank structure?<br>

Is granular material (eg crumbed rubber) conveyed to the tank by an earthed metallic pipe or chute?<br>

Does the procedure for the addition of granular material (eg crumbed rubber) to a tank require the operator to wear PPE if adding material directly into the manhole?<br>

Is there one 9kg dry powder fire extinguisher fitted?<br>

Is the colour coding correct? Old extinguishers are white, new ones are red with a white band.<br>

Is there one 9 litre AFFF aqueous foam fire extinguisher fitted?<br>

Is the colour coding correct? Old extinguishers are blue, new ones are red with a blue band.<br>

Is there one dry powder or AFFF extinguisher in the tankwagon truck cab?<br>

Are the fire extinguishers mounted in a readily accessible position with quick release brackets (or boxes) and away from burners? Can the extinguisher be extracted from its location and readied for use within 10 seconds?<br>

Are the mounting brackets and catches sufficient to withstand the prolonged vibration of a road vehicle?<br>

Are the extinguishers protected by clear plastic replaceable covers or in boxes?<br>

Are the extinguishers being maintained in accordance with NZS 4503:2005? Inspection 6 monthly and pressure test and recharge 5 yearly.<br>

Is there one 9 litre first aid pressurised water supply?<br>

Is the colour coding correct? Old extinguishers are polished stainless steel, new ones are green.<br>

Is the 9 litre first aid pressurised water supply fitted with a fine mist spray nozzle?<br>

Is it clearly labelled for first aid use only?<br>

Are there clear operating instructions?<br>

Is the first aid water supply mounted in a readily accessible position with quick release brackets (or boxes) and away from burners? Can it be extracted from its location and readied for use within 10 seconds?<br>

Does the tanker have a "Mobile Bitumen Tanker Engineer's Certificate"? Attach copy.<br>

Is the tank labelled as required by clause 15.18.2?<br>

Are external inspections of exposed parts of tank walls and fittings to detect leaks, and other possible defects, carried out on a routine basis?<br>

Are intervals between full internal inspections of tank walls, floor, roofs and internal fittings specified in company procedures?<br>

Is a regular schedule for inspection of tank vents in place and occurring?<br>

Is a regular schedule for inspection of float (level) switches in place and occurring?<br>

Is a regular schedule for inspection of tank manhole and vent water and condensate drains in place and occurring?<br>

If the tank has been modified or repaired, is there a "Mobile Bitumen Tanker Engineer's Certificate" that states that the modification or repair complies with this code? Attach copy.<br>

Is the tankwagon provided with a rear bumper to protect the tank, pipe and fittings in the event of a rear end collision? Excludes sprayers.<br>

Is the bumper attached to the subframe of the tank or to the chassis of the vehicle? It must not be attached directly to the tank.<br>

Is under-run protection required?<br>

Is under-run protection fitted?<br>

If the tanker is a semi-trailer, are the fifth wheel requirements specified?<br>

Do all bitumen and emulsion transfer hoses have current certification?<br>

Do all bitumen and emulsion handlance (and other small diameter) hoses have current certification?<br>

Is the Transfer hose in good condition? (no weeping,fraid braiding, missing or chipped seals or damage/ missing camlock parts or locking mechanisim)<br>

Do all bitumen and emulsion spraybar supply hoses have current certification?<br>

Are all Camlock style couplings fitted with a mechanism to stop the unintentional opening of the lever arms?<br>

Is a First Aid and Burns kit available? (should be restocked before leaving the yard).<br>

Is a system in place to check First Aid and Burns kits contents? ie replenishment of used and expired items.<br>

Is a burns card readily accessible? (should be kept in the cab at all times)<br>

Is there a comprehensive operating and maintenance manual? For details see appendix 13.<br>

Does the manual contain schematic diagrams showing the layout of pipework, pumps, valves etc?<br>

Does the manual contain operating procedures for product transfer, heating, clearing blockages etc?<br>

Are the dangerous goods documents (Dangerous Goods Declaration, Emergency Procedure Guide, Bitumen Burns Card) carried in a clearly marked secure folder inside the driver's door, or in a prominent position on a trailer.<br>

Is there a "Danger Water" tag for attaching to the vehicle key ring in the cab?<br>

Is there a reversible "Danger Water" label attached to the tank?<br>

Has a tank inspection for carbon been carried out to determine if water blasting is necessary (inspection must be done in each baffled compartment not just the hatch area)<br>

Are the linings going to last the season. If no, replace. This will help to elininamte down time during the season<br>

When is the next service due? If it fulls between July and December, get it done in June as this will eliminate down time during the season..<br>

A full Mechanical check should be carried out as part of the E2 process.<br>

Check and rectify and report any damage repairs carried out.<br>

Check and rectify any Zero Harm requirements to Downer standards.<br>

Check and replenish and date tag the first aid kit and environmental spill kit.<br>

Carry out a pre COF check and obtain a new COF<br>

The tank should be inspected internally and water blasted if required.<br>

The burner should be serviced and the burner liner and tube should be inspected for damage, warping and cabon build up.<br>