Tank Car Specialist

Tank Car SpecialistTraining Support Package

November 2014

Module 13: Transfers

Tank Car Specialist

Introduction

The type of transfer discussed in this module is a field transfer performed at a derailment site or in a less than ideal setting. Derailments do not always allow this. The techniques, procedures, and equipment described should be considered as recommendations. Because each situation is unique, it may be safer or more practical to deviate from these recommendations.

Tank Car Specialist

Enabling Learning Objectives13-1 Identify reasons for field transfers. 13-2 Identify the risks involved and other considerations for

field transfers. 13-3 Identify procedures for transfer of a liquid product from

and to low-pressure tank cars.  13-4 Identify procedures for transfer of a liquefied gas

product from and to pressure tank cars. 13-5 Participants will demonstrate their proficiency in

properly completing these transfers.

Tank Car Specialist

Reasons for Transfer• Container damage prevents movement• Container is not accepted at the shipping

or receiving location• Site conditions are not favorable for

continued transport• Location of container• Overloaded container

Tank Car Specialist

Risks of Field Transfer

• Loss of product• Contamination• Proper transfer equipment or trained

personnel are not available

Tank Car Specialist

Considerations• Ensure components are compatible

– Receiving container– Pumps– Fittings– Hoses

• Reaction / deterioration• Product contamination

– Cleaned container– Cleaned transfer equipment

Tank Car Specialist

Considerations• Container of sufficient capacity

– Specification Plate– Data plate– Tank specification

• Material of construction– Liners

• Pressures• Multiple receiving vessels

– Isolation valves

Tank Car Specialist

Safety Considerations

• Secure the area to prevent entry, including track and roads in the area

• Establish monitoring for exposures• Set the brakes on all equipment and

stabilize tank cars• Grounding and bonding of containers

Tank Car Specialist

Types of Transfers• Open

– Vapors vent to atmosphere• Closed

– Vapors through containers• Scrub

– Vapors processed through medium• Pressure differential• Gravity

Tank Car Specialist

Liquid Transfer• Prepare equipment list• General service tank car eduction lines,

manways, or bottom outlets fittings are generally available and accessible

• If the car is upright or on its side – At less than 90 degrees from vertical off load

about 1/2 the contents using pressure– Structural damage or holes pumping may be

required

Tank Car Specialist

Safety Considerations

• Ensure gas used is inert/compatible for a pressure transfer.

• Do not overpressure! Use only enough pressure to get product to move.

• Note: The liquid pump does not increase the pressure.

Tank Car Specialist

Preferred Conditions• Tank not exposed to fire or contents have

cooled sufficiently• Tank car position that will allow the transfer• Required fittings and/or bottom outlet

accessible and operable• Trained/experienced personnel available

Tank Car Specialist

Safety Precautions

• Secondary containment• Secure manways and protective

housing lids• Fire protection• Place blue flags, if required

Tank Car Specialist

Safety Precautions

• Clean and wrap all pipe threads with pipe joint tape.

• Clean all hose connections before joining.• Use an emergency shutoff system.• Emergency shutoff valve is designed to be

operated from a remote location. • Back flow check valve is designed to

prevent back flow in a hose.

Tank Car Specialist

Safety Precautions• Small pressure differential may allow some leakage

in the reverse direction.• Use the appropriate personal protective equipment.• If the product is flammable or combustible

− Control ignition sources within 150 feet of operations:• Do not permit smoking on site• Electrical equipment that is intrinsically safe• Shut off any internal combustion engines

• A liquid transfer using a liquid pump may be considered an open system.

• NFPA 77 and OSHA 1910.106 require grounding and bonding.

Tank Car Specialist

Liquid Transfer• Determine the capacity of the damaged tank car. • Determine the internal pressure in the damaged tank

car.• Obtain a compatible receiving tank.• Check the receiving tank for damage.• Inspect receiving tank for proper specification and

sufficient capacity• Verify that any residue in the receiving tank is

compatible• Note: The receiving tank pressure

Tank Car Specialist

Liquid Transfer• Prepare a checklist of all equipment to perform the

transfer.• Prepare a plan for setup, implementation, and

shutdown of the liquid transfer operation:− Diagram the location and orientation of the cars involved.− Diagram the location and orientation of equipment, gauges,

hoses, and connections to be used in the liquid transfer.− Prepare a checklist of the procedures:

• Setup• Implementation• Shutdown

− Prepare a site safety plan.

Tank Car Specialist

Tools• Two each, 12-, 24- and 36-inch adjustable pipe wrenches• Spanner or "J" wrench and dead blow hammer• Pair of pliers• Monitoring equipment - Oxygen meter (optional), Explosimeter, etc.• Paint scraper• Wire brush• Four rolls of pipe joint tape• Roll of duct tape• Two spray bottles containing leak detector or a solution of dishwashing

soap• 25-foot-long rope• Copper grounding rods• Grounding cables with pressure point clamps• Tool Caddy• Ladder

Tank Car Specialist

Transfer Pump

Tank Car Specialist

Block Valve w/Purge

Tank Car Specialist

OutletBlock Valve w/Purge

Tank Car Specialist

Vapor OutletBlock Valve w/Purge

Tank Car Specialist

Pressure Gauge

Tank Car Specialist

Damaged Tank Car Receiving Tank Car

4

2

3

4

2

31

Liquid flow

Liquid valve outlet assembly

Liquid valve inlet assembly

Vapor valve inlet assembly Vapor valve

outlet assemblyPressure gauge

Pressure gauge

Vapor flow

Liquid pump

Liquid Pump

Liquid

Vapor

1 Liquid valve2 Vapor valve 4 Gauging device3 Sample line

Liquid Transfer

Emergency Remote Shut-off

Emergency Remote Shut-off

Tank Car Specialist

Safety Briefings• Prior to set up, Prior to flow of product,• Before breakdown:• Hold a safety briefing and discuss:

− The person in charge − The properties of the product(s) and cautions

involved with them− Signals for emergency shutdown − Evacuation routes, etc.– Decon standby

Tank Car Specialist

Gas Transfers• Liquid pump and vapor compressor • Vapor compressor reduces the time• Gas transfer appropriate for:

− Mechanical damage− Safe re-railing− Tank car overloaded− Damage to valves and fittings− Extensive damage to the tank car 

Tank Car Specialist

Plan Transfer Additional for Gas Transfer

• Using a pressure gauge determine the internal pressure

• Note- Receiving tank used to unload the pressure must be reduced if not 10-15 psi less than damaged tank

• Make a list of all equipment and obtain equipment

Tank Car Specialist

Liquid Valve Inlet Assembly

Tank Car Specialist

Liquid Valve Outlet Assembly

Tank Car Specialist

Vapor Outlet Assembly

Tank Car Specialist

Vapor Inlet Assembly

Tank Car Specialist

Compressor and Pump

11

5544

2233

6611 11

5544

2233

6611

LiquidLiquid

VaporVapor

1 Liquid valve 4 Thermometer well2 Vapor valve 5 Gauging device3 Sample line 6 Pressure relief valve

1 Liquid valve 4 Thermometer well2 Vapor valve 5 Gauging device3 Sample line 6 Pressure relief valve

Damaged Tank Car Receiving Tank Car

Gas Transfer

Liquid valve outlet assembly

Liquid valve outlet assembly

Pressure Gauge

Vapor valve inlet assembly

OutletInlet

Pressure Gauge

Vapor valve outlet assembly

Liquid valve inlet assembly

InletOutlet

Vapor Compressor

Liquid pump

Compressed vapor flow

Liquid flow

Vapor flow

Tank Car Specialist

Damaged Tank Car Receiving Tank Car

1

54

23

61 1

54

23

61

Liquid flow

Liquid valve outlet assembly

Liquid valve inlet assembly

Vapor valve inlet assembly Vapor valve

outlet assemblyPressure

gauge

Pressure gauge

Vapor flowCompressed vapor flow Vaporcompressor

Vapor Compressor

Liquid

Vapor

1 Liquid valve 4 Thermometer well2 Vapor valve 5 Gauging device3 Sample line 6 Pressure relief valve

Gas Transfer

Tank Car Specialist

Damaged Tank Car Receiving Tank Car

1

54

23

61 1

54

23

61

Liquid flow

Pressure gauge

Pressure gauge

From inertgas source

To vapor flare,vent pipe, or

vapor treatmentsystem

Compressed or Inert Gas

Vapor valve inlet assembly

Vaporvalve outletassembly

Liquidvalve outlet assembly

Liquid valve inlet assembly

Liquid

Vapor

1 Liquid valve 4 Thermometer well2 Vapor valve 5 Gauging device3 Sample line 6 Pressure relief valve

Tank Car Specialist

Safety Briefings• Prior to set up, Prior to flow of product,• Before brake down• Hold a safety briefing and discuss:

− The person in charge − The properties of the product(s) and cautions

involved with them− Signals for emergency shutdown − Evacuation routes, etc.– Decon standby

Tank Car Specialist

ConclusionParticipants were given information to allow them to:• Identify causes for field transfers.• Identify the risks involved and other

considerations for field transfers.• Identify procedures for transfer of a liquid

product from and to low-pressure tank cars. • Identify procedures for transfer of a liquefied

gas product from and to pressure tank cars.• Demonstrate proficiency in properly

completing the various transfers listed above.