3.6.5
Unloading Propane Railcars Using the Plant
Compressor
Unloading propane railcars requires well-trained
and qualified persons. They must be
knowledgeable in handling hazardous materials and
understand the bulk plant and its procedures.
In this module you will learn to identify:
1. Regulatory requirements relating to railcar unloading
2. Safety precautions related to the transfer of propane
from railcars
3. Positioning the railcar/spotting procedures
4. and check the valves and fittings used in unloading
the railcar
5. Procedures for unloading the railcar
6. Unloading and releasing procedures
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 1
Identify regulatory requirements relating to railcar unloading
The transportation of hazardous materials is
regulated under Title 49 of the Code of Federal
Regulations (CFR).
The Department of
Transportation (DOT) defines hazardous materials
as “materials which pose an unreasonable risk to
health and safety or property when transported in
commerce.”
DOT regulations require employers to train and test every employee
directly involved in the transportation of hazardous materials. This
requirement also includes personnel who inspect, load or unload
pressurized railcars used in LP-gas transportation.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 1
Identify regulatory requirements relating to railcar unloading
Some specific regulations that are pertinent include:
•
•
•
•
•
49 CFR §173.31, Qualifications, Maintenance, and Use of Railcars
49 CFR, Part 172, Subparts H Training, and I Security Plans
49 CFR, Part 174, Carriage By Rail, Subparts A, B and C
49 CFR Part 179, Specifications for Railcars and §179.7 Quality
Assurance Program
49 CFR §180.509, Requirements for Inspection and Test of Specification
Railcars
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 1 & 2
Identify regulatory requirements relating to railcar unloading
Other regulations or standards adopted by reference that may apply
Include:
• AAR, Manual of Standards and Recommended Practices, M-1002,
Appendix C, Railcar Marking Requirements
• AAR, Field Manual Rules, 70, 88, 89, and 90
• CGSB 43.147-97
• Abbreviations:
•
•
AAR — Association of American Railroads
CGSB — Canadian General Standards Board
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 1 & 2
Identifying Safety Precautions Related to the Transfer of
Propane From Railcars
The following are precautions that apply:
•
•
•
•
Remove all sources of ignition from the transfer area before beginning the railcar
unloading operation.
A minimum 18 pound B:C fire extinguisher must be accessible to and within the
work area of the unloading operator. NFPA 10 states an extinguisher must be
“conspicuously located where they will be readily accessible and immediately
available, preferably along normal paths of travel including exits from areas.”
Wear heavy vinyl gloves, eye protection, and other appropriate personal
protective equipment (PPE) during the entire unloading operation.
Never drag a hose connector or hose-end valve across the ground, railcar
walkway or riser platform.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 2
Identifying Safety Precautions Related to the Transfer of
Propane From Railcars
The following are precautions that apply:
•
•
•
Never carry a valve by the handwheel or operating lever. Always carry it by the
valve body with the outlet pointed away from the body.
Never leave the transfer operation unattended. If you must leave the area for
any reason except an emergency, always stop the compressor, close all valves,
and disconnect and stow all transfer hoses.
Be sure of the following conditions
• railcar wheels are chocked
• railcar brakes are set
• derail is set to the derailing position
• railcar and spur entrance(s) are flagged
• rail car is inspected
• product identity and quality is verified before making hose connections
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 2
Identifying Safety Precautions Related to the Transfer of
Propane From Railcars
The following are precautions that apply:
•
•
•
If a leak or fire occurs during the transfer operation, close the plant emergency
shutoff valves (ESVs) from a remote emergency shutdown station, and shut
down the compressor immediately.
Do not unload a railcar with obvious mechanical defects or damage.
Do not stand or place any body part directly above the slip tube (gauge rod)
when using it—internal pressure may force the rod upward with considerable
force and cause severe injury.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 3
Identifying Safety Precautions Related to the Transfer of
Propane From Railcars
CAUTION: Use extreme care when working around the
railcar sampling valve, outage gauge and relief valve.
Comply with all applicable company safety and
operating procedures for railcar unloading and be
thoroughly familiar with emergency plans and
equipment.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 3
Identifying Positioning the Railcar and Spotting Procedures
Inspect the Tank Car:
•
•
•
Attach the bill of lading to the clipboard and walk completely around the tank car.
Check the tank and head shields for fresh dents or gouges, and structural
damage. If significant damage is found or leaks of any kind, notify the
supervisor at once.
Check the tank to be sure it is marked PROPANE or LIQUEFIED PETROLEUM
GAS. {3.6.5.7} And carries FLAMMABLE GAS placards in holders on each side
and at each end.
Check the tank car identification of serial number to make sure it matches the
number shown on the bill of lading.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 4
Identifying Positioning the Railcar and Spotting Procedures
Inspect the Tank Car:
•
•
Check the deign information on the tank to be sure it shows one of the approved
DOT design codes for tank cars. The markings are usually stenciled onto the
tank immediately beneath the identification number, but occasionally they may
be found stamped into the metal at the centers of the tank heads. In either
case, they should specify one of the following DOT design codes: 105A-, 112A-,
112J-, 112T-, or 114A-. If the tank car is improperly marked or the tank
identification number does not match the one shown on the bill of lading, notify
the supervisor at once.
Climb the unloading riser and lower the platform to gain access to the dome and
tank car openings.
Caution:
Be sure the platform is properly seated and secured before crossing over to the tank car.
Exercise caution when climbing or working on the riser, especially in wet or icy weather.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 4
Identifying Positioning the Railcar and Spotting Procedures
Inspect the Tank Car:
•
Examine the seal on the dome lid carefully for evidence of tampering. If the seal
has been broken or tampered with in any way, notify the supervisor. Otherwise,
clip the seal, attach it to the clipboard along with the bill of lading, and open the
dome.
Caution:
Before opening dome, be sure that all sources of ignition have been removed from the
area. Also, avoid creating sparks when opening or working in the dome. If one of the
fittings is leaking, the dome may be filled with propane vapor.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 4
Identifying Positioning the Railcar and Spotting Procedures
Inspect the Tank Car:
•
Inspect the valving inside the dome carefully for leaks, damage, and missing
parts. Be sure all fittings are tightly plugged and that valves, operators, and
gauges are free from damage that would create a hazard during unloading.
NOTE:
If there is evidence of a leak inside the dome, locate the source and correct if possible.
Generally, leaks from valve openings can be stopped by fully closing the valve. Leaks
from the packing on the slip tube gauge or on valve operators can be corrected by
tightening the packing nut with an adjustable wrench. All other leaks-from the relief
valve, the flanges of liquid or vapor valves, or any other source that communicates
directly with the inside of the tank- should be reported the supervisor immediately and
noted on the “bad order” tag enclosed in the dome. Never attempt to unload a tank car if
it has a leak that cannot be corrected.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 4
Identifying Positioning the Railcar and Spotting Procedures
Inspect the Tank Car
•
Inspect the safety appliances such as hand brakes, running boards, and
handrails
Caution:
Keep eyes, face and other parts of the body away from the relief valve opening when
working in the dome.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 5
Identifying Positioning the Railcar and Spotting Procedures
Gauge and Test the Contents of the Tank Car
In order to “sniff” test and gauge the contents of the tank car:
•
•
Conduct a “sniff” test on the propane by quickly opening and closing the sampling valve to
vent a small amount of liquid to the atmosphere. If the presence of odorant cannot be
detected or if large amounts of water appear at the valve opening during the sniff test, notify
the supervisor before continuing the operation.
Check for leaks around the plug on the thermometer well, then remove the plug with a
wrench.
Caution:
If propane begins to escape around the plug threads, retighten the plug and fill out a “bad
order” tag. DO NOT REMOVE THE PLUG.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 5 & 6
Identifying Positioning the Railcar and Spotting Procedures
Gauge and Test the Contents of the Tank Car
In order to “sniff” test and gauge the contents of the tank car:
•
•
•
Check the fluid level in the thermometer well. If necessary, “top up” the well with
antifreeze or light oil (Do not use water). Then carefully lower a glass-tube
thermometer in the well for at least ten minutes, then withdraw it just far enough
to read the scale.
Record the reading and repeat the process to check the accuracy of the first
reading. Record the final result on the bill of lading or the company unloading
form.
Replace and retighten the thermometer well plug.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 5 & 6
Identifying Positioning the Railcar and Spotting Procedures
Gauge and Test the Contents of the Tank Car
In order to “sniff” test and gauge the contents of the tank car:
•
Carefully remove the threaded cover from the slip gauge assembly
Caution:
If propane begins to escape around the threads or the cover binds as it is unscrewed, do
not remove it the rest of the way unless the leak can be controlled for sure when the cover
is fully removed.
•
If possible, correct leaks by fully closing the bleeder valve on the gauge and/or
tightening the packing nut at the bottom of the slip tube with a wrench. If the
leak continues, notify the supervisor
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 6
Identifying Positioning the Railcar and Spotting Procedures
Gauge and Test the Contents of the Tank Car
In order to “sniff” test and gauge the contents of the tank car:
•
Push down firmly on the slip tube and release the locking bar. Then, slowly
release the brake and allow the slip tube to rise two to three feet. Re-engage
the brake. Never use any tools to pry or pull up the slip tube. If the slip tube is
difficult to release, apply a small amount of light oil to the tube and twist the tube
from side to side as it is raised. If it continues to stick, loosen the packing nut
until the slip tube moves freely.
Caution:
All slip tubes are under high pressure and can cause serious injuries if allowed to shoot
out suddenly or unexpectedly. Keep a firm grip on the gauge at all times and assume a
position so that head and body are well away from the gauge.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 6
Identifying Positioning the Railcar and Spotting Procedures
Gauge and Test the Contents of the Tank Car
In order to “sniff” test and gauge the contents of the tank car:
•
•
Open the bleeder valve slowly until a mist of propane liquid (i.e., white mist)
vents from the valve. Continue raising the slip tube until the vapor vents from
the bleeder valve. Then slowly lower the tube again until liquid just begins to
vent from the bleeder valve. At this point, the bottom of the slip tube is in
contact with the surface of the liquid in the tank car. Apply the slip tube brake
and read the outage on the slip tube directly opposite the pointer. Repeat the
measurement at least twice to be sure it is correct. Record the final reading on
the bill of lading or the company unloading form.
Convert the slip tube reading to gallons, using the strapping table for the tank
car. Subtract the outage in gallons from the water capacity of the tank car and
record the result on the company unloading form.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 6 & 7
Identifying Positioning the Railcar and Spotting Procedures
Gauge and Test the Contents of the Tank Car
In order to “sniff” test and gauge the contents of the tank car:
•
•
•
•
Correct the tank car gallonage for temperature and specific gravity by multiplying
it by the appropriate volume correction factor. The correction factor can be
obtained from the company unloading forms or a chart attached to the strapping
table.
Compare the result to the gallonage recorded on the bill of lading. Follow
company procedures for reporting discrepancies.
Close the bleeder valve on the slip tube tightly, lower the gauge, and lock it into
place. Replace the gauge assembly cover.
Once these tests and inspections are complete and you are assured there are
no leaks or tank car damage that would cause the car to be rejected, the
preparation to unload can continue.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 6 & 7
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Figure 1. The Manway Cover
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 7
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Figure 2. Alternate Railcar Valves and Fittings Arrangement
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 8
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Courtesy union railcar and BP
Figure 3. Side View and Top View of Valves and Fittings
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 8
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
The railcar fittings in Figures 2
and 3 are further explained in
the cut-away view to the right
(Figure 4.). This illustration
shows how the various valves
and fittings interact with the
interior of the cargo tank.
Figure 4. Cut-Away View of Manway
And Tank Interior
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 9
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
•
Liquid and Vapor Connections
•
•
•
The outlets of the two liquid valves face the ends of the railcar
Thermometer Well
Sampling Valve
•
The sampling valve is a small manual shutoff valve attached to a long open
tube that leads to the bottom of the railcar. It is used to test the contents of
the railcar for odorization, the presence of water or other impurities, and, in
rare cases, to measure the specific gravity of the propane. It can also be
used during the unloading operation to determine whether any propane
liquid remains in the bottom of the tank
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 10
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Slip Tube Gauge
•
Most railcars are equipped with
a slip tube gauge (Figure 5),
which is used to measure the
contents of the railcar. The slip
tube gauge is similar to a fixed
maximum liquid level gauge.
However, the dip tube is not
fixed, but can be moved up and
down in the gauge housing to
Figure 5. Slip Tube Gauge
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 10
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
•
Pressure Relief Valves
•
•
Never tamper with it and never work directly over it
Unloading Risers
•
To gain access to the top openings in railcars, most plants use an
unloading riser (also known as a tower).
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 10
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Identifying Procedures for Unloading the Railcar
•
Gauge Contents of Railcar
• A series of graduated markings on the slip tube indicates the distance in
inches and feet from the top of the tank to the surface of the liquid. This is
commonly referred to as the "outage" of the railcar.
Figure 6. Portion of a Railcar Outage Table
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 11
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Determine the Maximum Amount of Propane That can be
Transferred to the Plant Bulk Storage Tanks
To determine the amount of propane each plant tank will hold safely:
•
•
•
Gauge the contents of the plant storage tank with the rotary or float gauge
installed in the tank head. Record the reading on the company form or on a
worksheet.
Using the temperature and specific gravity of the propane in the railcar,
determine the maximum permitted filling level for the plant tank(s). Record the
result on the worksheet.
Subtract the gauge reading from the maximum permitted filling level.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 12
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Determine the Maximum Amount of Propane That can be
Transferred to the Plant Bulk Storage Tanks
To determine the amount of propane each plant tank will hold safely:
•
•
Calculate the maximum amount of propane that can be added to the storage
tank by multiplying the difference between the two numbers by the water
capacity of the tank in gallons. If, for example, the gauge on a 30,000 gallon
storage tank shows that it is 40% full and its maximum permitted filling density at
the present temperature is 85%, 45% X 30,000 or 13,500 gallons can safely be
added to the tank.
If there is more propane in the railcar than the plant tank(s) will hold safely, notify
your supervisor.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 12
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Connect Liquid and Vapor Hoses Between the Railcar and the
Unloading Riser
•
To gain access to the top openings in railcars, most plants use an unloading
riser, also known as a tower. (Figure 7)
Vapor
Valve
Figure 7. Railcar Riser with Emergency Shutoff Valves
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 12 & 13
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Connect Liquid and Vapor Hoses Between the Railcar and the
Unloading Riser
•During unloading operations, a railcar unloading nipple (also known as a
“stub”)—essentially a straight section of schedule 80 threaded piping—is
inserted through the holes in the side of the dome and screwed into the valve
outlets after the valve shipping plugs are removed. (Figure 8.)
Figure 8a. Stub Connected to
Vapor Valve
Figure 8b. Connecting Hose to
Stub in Liquid Valve
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 13
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Connect Liquid and Vapor Hoses Between the Railcar and the
Unloading Riser
In order to complete this step:
•Check the manual shutoff valves on the railcar liquid and vapor connections to
make sure they are fully closed. Then carefully remove the plugs
Caution:
Propane may vent around the plug threads for a short time. Wear heavy
vinyl safety gloves throughout the operation and keep face and other parts of the body
away from the valve opening. If propane continues to vent around the plug threads, the
manual shutoff valve may be faulty. Retighten the plug and notify the supervisor. If the
chains on the plugs are broken or missing, store the plugs in a safe place.
•Install unloading stubs or ESVs in the liquid and vapor valves. Thread the stubs
or ESVs into the valve opening until they are handtight. Then tighten them with the
appropriate wrench until they are securely seated. Once installed, open the ESVs
in accordance with company procedures.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 14
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Connect Liquid and Vapor Hoses Between the Railcar and the
Unloading Riser
In order to complete this step:
•Remove the dust caps from the connectors on the riser hoses. Check the
connectors to be sure they are clean. Check the O-rings on the ESV or unloading
stub to be sure they are in good condition. If necessary, clean the connectors with
a rag and replace worn, flattened, or damaged O-rings.
•Connect the hoses to the railcar stubs or ESVs by spinning on the ACME
connectors until they are handtight. As the connectors are tightened, move the
hose or hose-end valve up and down slightly to prevent the thread from seizing.
When each connection is handtight, tighten it an additional 1/8 turn with a hook
spanner. NEVER POUND ON THE CONNECTOR WITH A WRENCH OR OTHER
DEVICE.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 14
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Connect Liquid and Vapor Hoses Between the Railcar and the
Unloading Riser
In order to complete this step:
•Check the ESVs at the riser by opening and closing them according to plant test
procedures. Be sure the remote operators are working properly and that all fusible
links are intact. If the ESVs will not operate properly, do not continue the transfer
operation. If possible, correct the problem. Otherwise, notify your supervisor.
•Check each connection for leaks by opening and closing the manual shutoff valve
at the railcar to charge the connection with propane.
Note:
If using ESV's instead of unloading stubs, open the ESV to charge and test the hose
connection. If there are any connection leaks, close all valves and retighten the
connection. If the leak continues, notify your supervisor.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 14 & 15
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Unload the Railcar
•A qualified person must be present during the entire transfer operation to handle
emergencies and monitor the condition of the transfer system. If leaving the area,
find someone as a replacement who has a working knowledge of the transfer
equipment and plant emergency procedures. Otherwise, shut down the operation
until returning.
•If a leak or fire develops at any time during the operation, close all ESV's
immediately and stop the compressor. Then follow company procedures to handle
the problem. Be alert throughout the operation for signs of erratic compressor
operation. If a problem develops, shut down the operation and correct it before
continuing.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 15
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Unload the Railcar
•An excess-flow valve in an eduction valve or the plant tank may stick or freeze
shut. As a result, it will not reopen when the pressure is equalized across the
valve. If this happens during unloading operations, reopen the valve by applying
compressor discharge pressure to the stuck excess-flow valve.
• If the excess-flow valve is in a vapor connection, it is reopened simply by
reversing the four-way valve and restarting the compressor
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 15
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
To unload the railcar:
•
Open the vapor valves at the riser. Then, open all valves in the liquid line,
starting at the manual shutoff valves on the railcar and working toward the plant
storage tank(s). Allow as much liquid as possible to drift between the two tanks,
then open the remaining valves in the vapor line.
Note:
Open valves slowly to prevent excess-flow valves from slugging
•
Check to be sure the four-way valve and the plant valves have been set so the
compressor will remove vapor from the plant storage tank and discharge it into
the railcar. Figures 10 and 11 illustrate the compressor 4-way valve and piping
positions for unloading in a typical bulk plant. Your plant piping may be different.
Be sure you verify the proper valve positions and operating procedures for your
plant.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 16
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Figure 10. 4-Way Valve Positions
Figure 9. Compressor and Bulk Plant
Connections and Valves
4-Way Valve
Valve A
Valve B
Valve C
Position One
Open
Open
Close
Figure 11. Operation of Valves for Cargo tank Unloading
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 16
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
To unload the railcar:
•
•
Start the compressor and check the pressure gauges for excessively high
exhaust or excessively low intake pressure. If either occurs, stop the
compressor and correct the problem before continuing. Check the sight glass or
flow indicator to make sure liquid is flowing through the system.
When the plant storage tank reaches its maximum permitted filling level or the
railcar is empty, close all valves in the liquid line and stop the compressor.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 16 & 17
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
To unload the railcar:
•
•
Reverse the four-way valve and adjust the plant piping manifold so the
compressor will withdraw vapor from the railcar and force it through the liquid
space of the plant storage tank. (Figures 12b and 12c.) Restart the compressor
and check the pressure gauges for excessively high discharge or excessively
low intake pressure. If either occurs, shut down the compressor and correct the
problem before continuing.
At the end of the vapor recovery operation, close all valves in the vapor line and
shut down the compressor. Some plants shut down the compressor when the
discharge pressure rises to four times the intake pressure. Others stop vapor
recovery operations when the intake pressure drops to 50 psi in the summer or
30 psi in the winter. Under some conditions plants will also shut down their
compressors, if the intake pressure drops less than 10 psi during 15 minutes of
operations. Check with your supervisor for the proper guidelines to follow
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 16 & 17
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Figure 12a. Compressor and Bulk
Plant Connections and Valves
Figure 12b. 4-Way Valve Positions
4-Way Valve
Valve A
Valve B
Valve C
Position Two
Close
Open
Open
Figure 12c. Operation of Valves for Cargo Tank Vapor Recovery
Note: Monitor the liquid gauges on the plant storage tank(s) carefully to prevent overfilling
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 17
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
To finish the operation and prepare the railcar for return:
•
•
•
•
Open the sample valve. If vapor is
released, the railcar is totally
unloaded. If liquid escapes, it may not
be fully unloaded. Resume unloading
operations until the railcar is totally unloaded.
Close all railcar discharge valves,
ESVs and transfer hose-end valves.
Vent the propane trapped between
valves, stubs and hose couplings.
When the connections are fully depressurized, disconnect the transfer
hoses.
Remove the railcar unloading nipples,
or “stubs”, that are screwed into the
railcar valve outlets
Figure 13. Checking the Sample Valve
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 18
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
To finish the operation and prepare the railcar for return:
•
Replace all railcar valves openings and tighten as appropriate. (Figures 14
and 15)
Figure 14a. Preparing Plug
Threads
Figure 14b. Installing Plug in
Slip Tube Gauge
Figure 15. Tightening Plug in
Discharge Valve
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 18 & 19
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
To finish the operation and prepare the railcar for return:
•
•
•
Replace and secure all covers over
fittings. (Figure 16)
Check to be sure there is no liquid
left in the railcar by partially opening
the sampling valve
Bleed down and disconnect the
hoses at the riser. Replace all dust
caps and store the hoses
Caution: Never disconnect any hose
until the propane trapped in the
connection has been safely bled off.
•
Figure 16. Replacing Fitting Cover
Remove the unloading stubs or
ESVs from the railcar, and replace
the plugs in the liquid and vapor
valve openings
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 19
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Identifying Unloading and Releasing Procedures:
•
If any railcar defects were found
during the unloading operation,
complete the “Bad Order Tag”
(Figure 17) and attach it to one of
the liquid education valves.
NOTE: The same defect(s) must be
reported in the Railcar Return Form.
•
•
Lower the dome cover and secure it
appropriately.
Stow all transfer hoses and fittings
and raise the unloading riser
platform to its stored position
Figure 17. “Bad Order Tag”
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 20
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Identifying Unloading and Releasing Procedures:
•
Remove and store the warning signs, chock blocks and reset the derail (when
used) from the derailing position. (Figure 18)
Figure 18a. Removing Chocks
Figure 18b. Stowing Warning
Sign and Resetting Derail
NOTE: DO NOT release the hand brake on the railcar. This will be done by railroad
personnel when the railcar is picked up.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 20
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
Identifying Unloading and Releasing Procedures:
•
Verify that all placards are in good
shape and in place. (Figure 19)
•
Take an extra look around the railcar
and unloading site to make sure
everything is safe and secure.
•
Complete the Railcar Return
Instructions Form and deliver the form
to the rail carrier representative.
Figure 19. Replacing Damaged
Placard
CAUTION: Whether loaded or unloaded, a railcar is hazardous. Unless it has
been thoroughly purged and cleaned, there is no such thing as an empty railcar.
Even un-loaded to the maximum extent possible, it still contains propane.
Therefore, whether a propane railcar is loaded or unloaded, all safety and
hazardous materials handling regulations must be observed.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 21
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
The Railcar Return Instruction
Form must be prepared, signed
and presented to the rail carrier
representative for their signature
before the railcar is released.
Figure 20. Sample Railcar Return Instructions Form
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 22
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
While completing the Railcar Return Instructions Form, the propane
marketer’s representative should:
•
•
•
•
Verify the date entry when the company was notified of the railcar’s arrival, when
it was received on the siding, and when unloading was completed.
On the Company Copy of the railcar return form, enter the date when the car
was removed from the siding. Retain it in company records.
List in the remarks section any defect(s) that were present when the car was
received
Determine if any defect(s) occurred or was discovered during the time the railcar
was on the siding and being unloaded. If so, describe it in the remarks section
and attach a copy to the “Bad Order Tag”.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 22 & 23
Identifying and Checking the Valves and Fittings Used in
Unloading the Railcar
While completing the Railcar Return Instructions Form, the propane
marketer’s representative should:
•
•
•
Verify other information preprinted on the form, sign and date it.
Deliver the Railcar Return Instructions Form personally, or by electronic means
to the railroad agent, for their signature and date. {3.6.5.31} Sometimes a bulk
plant employee will notify the railroad company representative by telephone or
fax, and hold the form for signature until the rail car is picked up.
From the time the railcar return form is used to notify the railroad company
agent that the car is ready to be picked up, until the time it is actually removed
from the siding, the propane marketer must provide a safe and secure
environment for the railcar.
Comply with any company-specific procedures for releasing a
rail car after unloading. Be sure you know and follow all
company rules for handling railcars.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Page 22 & 23
Time to See If You Got the Key Points of
This Module…
• Complete the Review on page 24 - 27.
• See if you are ready for the Certification
Exam by checking off the
performance criteria on page 28 30.
3.6.5 Student Book  © 2004 Propane Education & Research Council
Pages 24 - 30