NSG Logistics, LLC
Environmental, Health, & Safety
Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 1 of 11
Scope
This safety program is site-specific to and applies to NSG Cleburne (also known as “NSG”,
“employer” or “the company”) rail operations and all affected employees whose duties may
require working on, under, or between rolling equipment, which may include, but not limited to
the safe loading or unloading of non-pressure general-service tank cars, pneumatic cars, and/or
covered hopper bottom rail cars.
Purpose
This program is intended to assist and provide NSG Cleburne employees with the safe operating
practices of NSG, applicable state or federal regulations, and industry best safe practices for
working on, under, or between rolling equipment. This program will also outline the
recommended methods and industry best safe practices for the safe loading and unloading nonpressure general-service tank cars of non-hazardous liquids and dry bulk materials from covered
hopper bottom rail cars and pneumatic cars.
This set of safe operating practices will serve as general guidelines to help keep employees safe
and prevent any incidents and/or non-accident releases (NARs). Product that is released in an
NAR or unsafe practices can potentially be significant:




Potential injuries or illnesses because of unsafe practices.
Loss of customer product.
Contamination of product.
Environmental impact.
This program is comprised of the following:



Recommended and current industry best safe practices and related NSG Cleburne safety
rules for working on, under, or between rolling equipment when handling general-service
tank cars. Rolling equipment includes locomotives, railroad cars, and one or more
locomotives coupled to one or more cars per federal regulation 49 CFR § 218.5.
Recommended and current industry best safe practices for proper securement of generalservice tank cars, covered hopper bottom rail cars, or pneumatic cars; including, but not
limited to Association of American Railroads Pamphlet 34 – Recommended Methods
for the Safe Loading and Unloading of Non-Pressure (General-Service) and Pressure
Tank Cars.
Recommended and industry best safe practices and state or federal regulations applicable
to the handling and loading and unloading of general-service tank cars, covered hopper
bottom cars, and pneumatic cars.
Section 1: General Safety Rules
NSG Logistics, LLC
Environmental, Health, & Safety











Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 2 of 11
Understand and comply with all applicable NSG safety rules, applicable state or federal
regulations, and industry best safe practices.
Job safety briefing shall be conducted with all individuals involved in the task before
work begins and if the work process or work group changes. A briefing must consist of
the following:
o Consider existing and potential hazards that could potentially be involved because
of weather, scope of work, tools, and equipment.
o Identify applicable personal protective equipment (PPE) requirements.
o Review electronic device restrictions. (e.g., ear buds, cell phone, etc.)
o Assign responsibility.
o Explain group and/or individual assignments, while considering abilities and
experience.
o Be aware of other work groups (e.g., contractors) and equipment in the work area.
o Identify track or job location.
o Verify all employees involved have a clear understanding of the instructions and
assignments. Clear communication is critical!
For Complex Jobs: brief only in portions and conduct additional briefing(s) as the job
progresses.
PPE shall be used where conditions of the job require or in accordance with applicable
regulations or direction from the terminal manager or safety department. PPE is to be
properly maintained, worn, and not to be altered.
Wear clothing that allows the person to perform duties safely and efficiently.
Electronic devices are prohibited from use when:
o In a red zone or work location where safety sensitive duties are being performed.
Red Zone is defined as: anytime an employee is working within an area where
there is the potential to be struck by moving equipment, when required to work
on, under, or between equipment.
o Operating any equipment.
o Anyone is assisting in preparation of a train, engine, or rolling equipment for
movement.
Inspect and use the proper tools and equipment required to perform the work in a safe and
efficient manner. This includes maintaining tools and equipment in accordance with
manufacturer’s instruction and design.
When using bars, levers, or tools, brace yourself and be alert to slippage or unexpected
movement. Place hands, feet, and body positioning safely to prevent injury.
Employees are empowered to work safely and are responsible for personal safety and
accountable for their behavior.
Employees shall correct or protect any unsafe condition or practice and report the
terminal manager or direct supervisor.
Always maintain situational awareness.
NSG Logistics, LLC
Environmental, Health, & Safety





Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 3 of 11
Work within the limits of physical capabilities; excessive force shall not be used to
accomplish tasks.
Employees shall not place hands, fingers, feet, legs, or any part of their body in a position
where there is a potential for being struck by, caught-in-between, pinched, or crushed.
Non-rail crew members are required adhere to any instructions given by the conductor(s)
prior to and during any rail car movement.
If duties require
Expect movement at any time, on any track, in either direction. Do not rely on hearing
the approach of a train or rolling equipment.
Section 2: Working On, Under, or Between Rolling Equipment
Always be alert and take proper precautions when working near, on, or under rolling equipment
(rolling stock). All employees involved in the task shall clearly communicate any potential
hazards and be alert to train movement from either direction or at any time.
Employees shall take the following precautions when near passing trains or equipment:





Move away from the track to avoid being struck by rolling equipment.
Stand clear of all tracks when trains are approaching or passing in either direction.
Employees shall not rely on others for notification of an approaching train, engine, or
other equipment unless that person’s duties include providing warnings.
Do not stand on one track while trains or equipment are passing on an adjacent track.
Do not stand next to or between equipment while a train, engine, or other equipment are
passing on an adjacent track.
When assigned duties require standing, walking, or working between or near tracks, keep a
careful lookout in both directions for trains, locomotives, cars, or other moving equipment.






Expect movement at any time, on, any track, in either direction.
Do not rely on hearing the approach of a train or equipment.
Terminal managers, direct supervisors, others in charge shall require employees to be
alert, watchful, and to keep out of danger.
Employees shall not stand, sit, walk fouling of or walk between rails of any track unless
required by assigned duties.
Stop before fouling or crossing track(s) and look in both directions, ensure no movement
is closely approaching, and look for conditions that could interfere with footing.
When walking near or crossing tracks; walk straight across tracks, avoid conditions that
could interfere with footing, and step over rails, frogs, switches, guardrails, etc.
NSG Logistics, LLC
Environmental, Health, & Safety
Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 4 of 11
Sufficient Distance:
 Unless authorized, employees must not cross or step foul of tracks closely or behind
moving equipment.
 Only go around the end of equipment if there is at least 25 feet between the employee and
equipment.
 Only go between two cuts of standing equipment (rail cars) if there is at least 50 feet of
separation.
 When there is no known movement to occur and sufficient distance is maintained to
avoid injury, employees may go between or around the equipment.
Safety Appliances:
 Employees shall visually inspect safety appliances on rolling equipment for defects such
as loose, damaged, or missing hand holds, ladders, grab irons, sill steps, or crossover
platforms.
 Do not use defective safety appliances. Warn others and report any defects to the terminal
manager or direct supervisor.
 Do not get on equipment that is not equipped with safety devices.
 Do not get on or off equipment except when required in the performance of duty, and
only when it can be done safely.
The following precautions must be taken when getting on or off and while on standing
equipment:
Always use the provided safety appliances (steps, ladders, and hand holds). Be aware of
and take necessary precautions to prevent injury from the buildup of snow, ice, water,
mud, grease, and oil on footwear, all sill steps, platforms, and side ladders.
 Keep hands free of all objects that may hinder a secure handhold and always maintain a
secure grip on handholds on engines platforms or appliances on rolling equipment and be
prepared for sudden movement.
 When getting on and off standing equipment, always face the equipment and use the side
ladder or steps, maintaining three-point contact and feet securely placed.
 Pause at the bottom step maintaining 4-point contact and observe surface conditions of
the ground and activity in the area before getting off.
 Guard against injury by looking out for unsafe footing, obstructions, or equipment
moving on other tracks, perform a 180 degree look before stepping off equipment.
 When getting off, retain a grip with both hands on the hand hold until both feet are firmly
placed on the ground or other support and pause with four-point contact before releasing
your grip on the hand hold.
Crossing through or fouling equipment:
 Do not get on, cross through, crawl, sit, or lie under cars, unless duties require. When
duties require, assure that all movement has stopped, and protection has been provided
and no movement will occur.
NSG Logistics, LLC
Environmental, Health, & Safety
Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 5 of 11
Crossing through standing equipment:
 When duties require crossing through a standing train or cut of cars, proper protection
against movement must be provided.
 Employees shall choose equipment carefully, using cars with ends equipped with a
crossover platform and hand holds, when available.
 Keep hands free of objects that may hinder a secure handhold.
 Be prepared for unexpected movement, maintaining a three-point contact while walking
across the end of the car.
 When placing feet, do not place feet on knuckles, uncoupling lever, drawbar assembly or
any cushioning drawbar device.
Red Zone Protection
Establishing Protection Before Crossing Through or Fouling Equipment:
A train, engine, or rail crew member must establish Red Zone Protection before:
 Performing work where there is potential to be struck by moving equipment.
 Crossing through or fouling equipment coupled to or on the same track as an engine
occupied by an engineer or other occupied motive equipment.
Establishing Red Zone Protection
Red Zone Protection will be established by the engineer or primary operator (conductor) via
through agreed hand signals or radio communication. Actions required before entering the Red
Zone:
 Allow movement to stop and slack to adjust
 Employees may not enter Red Zone until the primary operator (conductor) has verified it
is safe to do so.
 Before initiating movement, the conductor who established the Red Zone Protection must
ensure all employees in the loading and unloading are clear of the Red Zone by hand
signals or radio communication.
Unexpected Movement: When duties require moving around, inside, or on equipment, anticipate
and protect yourself from sudden stops, starts, slack action, or other movements and:
 Be adequately braced.
 Maintain a firm hand hold.
Hand Brake: Before operating hand brake inspect for defects. Use good body mechanics to
prevent strains, sprains, etc. Maintain firm footing and hand hold to prevent slipping, falling, or
injuries.
While operating hand brakes employees must not:
 Use end ladders to go up or down the car.
NSG Logistics, LLC
Environmental, Health, & Safety
Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 6 of 11
 Brace any part of body against another car.
 Place feet in wheel or on a hand brake lever or pawl.
 Place thumb inside wheel when applying or releasing wheel type brake.
 Apply or release brake from ground while car is in motion.
 Use unapproved material or device to apply or release brake.
 Place both hands on brake wheel.
The following hand brakes must be operated from a position on the equipment:
 End-mounted brake.
 Horizontal wheel (staff) hand brake.
Releasing Hand Brake: Use caution when releasing hand brake. Obtain help when necessary and
avoid being struck by the brake when the pawl is released. Avoid having clothing or hand caught
in spinning brake wheel.
Difficult or Defective Hand Brake: If hand brake is difficult to operate, defective or damaged, do
not attempt to operate it. Report the defective brake to the terminal manager.
*Note: Only certified rail crew members are authorized to release hand brakes on railcars.
Wheel Chock: Use wheel chock where required. When placing or removing wheel chocks, keep
body outside rail or place from outside the rails to avoid pinch points.
Blue Signal Protection of Workmen
This rule outlines the requirements for protecting NSG employees who are working on, under, or
under rolling equipment. Because certain tasks, but not limited to the NSG employees to work
on, under, or between rolling equipment (e.g., loading and unloading general-service tank cars
and/or covered hopper cars), workmen are exposed to potential injury from moving equipment.
As used in this rule, the following definitions apply:
Rolling Equipment: Engines, cars, and one or more engines coupled to one or more cars.
Blue Signal: During the day, a clearly distinguishable blue flag or light, and at night, a blue light.
The blue light may be steady or flashing.
Switch Providing Direct Access: A switch that is used by rolling equipment could permit the
rolling equipment to couple to the equipment being protected.
Blue Signal Signifies
A blue signal signifies that employees that are near, on, under, or between rolling equipment and
requires that:
NSG Logistics, LLC
Environmental, Health, & Safety
Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 7 of 11
 Rolling equipment must not be coupled to or moved, except as provided
Cars Being Loaded or Unloaded: Personnel who may load or unload cars are responsible to:
 Remove and clear work areas of all tools and equipment, which may include but not
limited to, platforms, boards, tank car couplings and connections, conveyors, loading or
unloading spouts, similar appliances or connections, vehicles and other obstructions or
equipment.
 Ensure car doors and/or valves on cars are closed.
 Make sure persons in, on, or about cars have vacated cars before allowing switching.
Preventing Uneven Loads:
 When loading or unloading cars, take precautions to prevent the load from becoming
unevenly distributed which may cause the car to overturn or derail.
 Do not handle cars with improper or uneven loads if the load could shift or fall or the car
could derail or overturn.
Section 3: Unloading a Tank Car
To ensure the safe operations prior to tank car loading or unloading and proper securement of the
general service tank car, the following safety precautions shall be taken prior to loading or
unloading:









Set up blue signal protection for workers, commonly known as blue flag. The blue flag is
to signify that workers are on, under, or between rolling equipment. If the car can be
approached from either direction, be sure to put up a blue flag at both ends.
Prevent entry into the track by lining the switch away from workers that will be working
on, under, or between rolling equipment.
Check the handbrakes to ensure they’ve been applied. Do not assume that someone else
has tied them.
Chock wheels in both directions.
Inspect the rail car safety appliances to ensure none are broken, loose, or missing, which
include:
o steps
o grab irons
o ladders
o crossover platforms
Look for missing or loose bolts
Check all piping, valves, fittings, and gaskets, including those not used, for leaking
product.
Ensure proper tools and equipment are for loading and unloading operations and in
proper working condition.
All loading/unloading inspections should be properly documented through a checklist or
similar method.
NSG Logistics, LLC
Environmental, Health, & Safety


Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 8 of 11
The loading/unloading area should have adequate lighting and be free of obstacles or
unnecessary equipment. A clear path of travel free from obstruction shall be maintained
in the event of unexpected movement.
During the loading/unloading process, cars shall be attended by trained personnel or
monitored by an approved monitoring system. DO NOT ALLOW the loading/unloading
operation to stand unattended or unmonitored while connections are attached to the car.
If necessary to discontinue operations for a period of time, all valves shall be closed, all
connections removed and the car must be prepared as if ready for transportation.
However, operations can be discontinued on an attended or monitored car by closing the
valves on the car and closing valves at the facility without disconnecting hoses.
General Service Tank Cars are used to transport liquids or flowable solids. The valves and
fittings on most general service tank cars are visible on the top. General service fittings typically
include:
 Bottom outlet valves (BOV)
 Internal or external heater coil systems
 Top valves and fittings
 Top operated bottom outlets
 Manways
 Pressure relief devices, including safety valves and safety vents
Bottom outlets can be operated either from the top or bottom of the tank car. Both types of
bottom outlets shall be checked to make sure they operate properly and are not leaking prior to
loading or unloading. During unloading, the tank car must be vented by use of either a closed
system or to the atmosphere.
Section 4: Before Unloading a Tank Car





General procedures in Section 3 should be followed.
All fittings and seals shall be examined before removing them for evidence of tampering.
Verify that fittings and valves are closed before removing plugs, caps, and flanges.
Any dirt or debris should be removed from the fittings before opening them.
If the tank car is a general service tank car, relieve tank pressure by one or more of the
following methods:
o Slowly opening the vent valve.
o Carefully open the fill hole cover or hinged manway cover. If using the manway
cover for pressure relief, use caution when loosing bolts. The bolt(s) by the handle
are the safety bolt(s). Loosen the safety bolt(s) by one or two turns at a time, and
then loosen the remaining bolts.
NSG Logistics, LLC
Environmental, Health, & Safety
Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 9 of 11
Unloading





When unloading through the bottom outlet, with the manway open, take care to prevent
contamination of the product (e.g., high winds causing particulates to spread) or, in the
case of flammable materials, or other sources of ignition.
Verify that the bottom valve is closed before loosening bottom outlet plug or cap.
Be prepared to collect any materials trapped in the bottom outlet leg upon loosening of
the cap/plug assembly. Slowly loosen the outlet cap. If more than 2 – 3 quarts are
collected in the containment system, there is potential leakage of bottom outlet valve. Do
not remove the cap completely, if the valve continues to leak tighten the cap/plug
assembly. Immediately inform the terminal manager or direct superior of the leaking
condition and request what action to take.
Before opening the unloading valves, securely attach the transfer system and perform a
leakage test, if possible.
If a non-pressure tank car is being unloaded by pumping through the bottom outlet valve
(BOV) or top-mounted liquid valve, a means of preventing vacuum (which may cause a
collapse of the tank) must be provided. Relieve all pressure used to unload the car.
After Unloading a Tank Car





Verify that all valves are closed.
Verify that ally unloading connections are removed.
Secure all fittings, valves, and openings in the appropriate manner. (All plugs and outlet
caps must be secured with a suitable tool. Use non-sparking tools per company
procedures when required.) Exceptions: Thermometer and magnetic gauging device
covers with o-rings are to be hand tight, not tool tight.
If the manway was opened during the operation, inspect the manway gasket for damage,
deterioration, and proper alignment. Tighten the manway bolts using the appropriate star
pattern and torque values per company procedures.
Visually inspect the car to verify that no obvious defects are present.
NSG Logistics, LLC
Environmental, Health, & Safety
Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 10 of 11
Section 5: Covered Hopper Rail Car
Covered hopper rail cars unloaded through gravity fed hopper bottom doors with sliding gates
opened and closed by self-locking/unlocking knuckles.










Set up blue signal protection for workers, commonly known as blue flag. The blue flag is
to signify that workers are on, under, or between rolling equipment. If the car can be
approached from either direction, be sure to put up a blue flag at both ends.
Prevent entry into the track by lining the switch away from workers that will be working
on, under, or between rolling equipment.
Check the handbrakes to ensure they’ve been applied. Do not assume that someone else
has tied them.
As an industry best practice, it is recommended that wheels be chock in both directions
due to potential load shift during unloading process. Wheels chocked can help reduce
slack and movement during unloading process.
Inspect the rail car safety appliances to ensure none are broken, loose, or missing, which
include:
o steps
o grab irons
o ladders
o crossover platforms
Look for missing or loose bolts
Ensure proper tools and equipment are for loading and unloading operations and in
proper working condition.
All food grade product loading/unloading inspections should be properly documented
through any applicable or required checklist or similar method.
The loading/unloading area should have adequate lighting and be free of obstacles or
unnecessary equipment.
When using bars, levers, or tools, brace yourself and be alert to slippage or unexpected
movement. Place hands, feet, and body positioning safely to prevent injury.
*Note: Defective hopper sliding gates/doors and knuckles should be reported immediately to
terminal manager.



Operate rail car unloading equipment in accordance with manufacturer’s instruction and
design (e.g., pneumatic rail car vibrators).
Remove wheel chocks, tools, and equipment prior to movement of rail cars.
Keep all tools and equipment in an orderly fashion and clear path of travel in unloading
area.
NSG Logistics, LLC
Environmental, Health, & Safety


Initial Issue Date
Revision Date:
Revision No.
General Rail Safety
Preparation: EHS
Doc No:
Next Review Date:
Authority: EHS
Issuing Dept: NSG Management
Page:
General Rail
5/01/2023
Initial Version
0
5/01/2024
Page 11 of 11
When duties require occupying the roof of a covered hopper rail car (rolling stock), must
do so only with proper authority from terminal manager, proper training, conditions
permit, and equipment has been safely secured to prevent any movement. When
occupying the roof of a hopper car it is a requirement to walk only on the running boards
affixed to the top of the rail car, running boards are considered safety appliances.
Employees shall not jump or attempt to crossover from one rail car to another when
occupying the roof, a rail car.