Identifying Equipment & Procedures Used on Propane Transports 2.3.1 Most of the propane used by residential, commercial and industrial customers is transported to bulk plants or directly to large customer accounts by tractor-trailer transports. In this module, you will learn to: Identify applications and features of propane transports Maintain and operate pumps and associated circuits on transports Identify functions of emergency discharge control systems and safety features of transports Identify U.S. DOT cargo tank labeling and markings   2.3.1 Student Book  © 2004 Propane Education & Research Council Page 1

Features of Propane Transports In U.S. Department of Transportation regulations in some cases use the term “transport” to refer to any bulk cargo tank motor vehicle, regardless of its size or configuration. DOT regulations also call bulk delivery vehicles cargo tank motor vehicles (CTMVs). In the propane industry, transports are understood to mean tractor/trailer combination vehicles that have semi-trailers that are cargo tanks. “Metered delivery service” means an unloading operation conducted at a metered flow rate of 100 gallons per minute or less through an attached delivery hose with a nominal inside diameter of 1.25 inches or less. The majority of propane transports are not equipped with liquid meters and small diameter delivery hoses, and are not used in metered delivery service. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 1

Features of Propane Transports Regardless of their size, application, or devices used to control their operation, all transports have basic features and equipment in common. Figure 1. Cargo Tank Motor Vehicle 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 2

Features of Propane Transports Cargo Tank Figure 2. Typical Features of Transport Cargo Tanks 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 2

Features of Propane Transports Data Plate Name Plate May be combined in a single data plate. Specification Plate Figure 3. Cargo Tank Data Plates 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 3

Features of Propane Transports Data Plate Figure 4. MC 331 Cargo Tank Data Plate 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 3

Features of Propane Transports Cargo tanks have the following openings for connections: Liquid level gauges Temperature well Pressure gauge Cargo tank fill and equalizing connections Cargo tank withdrawal connection Pressure relief valve(s) 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 3

Features of Propane Transports Rotary Gauge Figure 5a. Rotary Gauge 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 4

Features of Propane Transports Rotary Gauge Figure 5b. Cross Sectional View of Rotary Gauge 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 4

Features of Propane Transports Rotary Gauge Figure 6. Rotary Gauge Face 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 5

Features of Propane Transports Float Gauge Figure 7a. Float Gauge Figure 7b. Cargo Tank 50% Liquid Filled 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 5

Figure 8b. Cross Sectional View in Cargo Tank Features of Propane Transports Fixed Liquid Level Gauges Figure 8a. Fixed Liquid Level Gauge Outage Figure 8b. Cross Sectional View in Cargo Tank 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 6

Features of Propane Transports Thermometer & Pressure Gauge Fixed maximum liquid level gauges installed in pressure cargo tanks are used each time the tank is filled. The pressure gauge and thermometer are used to check the load of gas in the cargo tank, while the thermometer and scales on the liquid level gauge are used to determine the maximum permitted filling level. One method of checking the accuracy of rotary and float gauges is to fill the cargo tank with propane until a white mist vents out of the fixed maximum liquid level gauge. The rotary and float gauges should indicate the same percentage of tank volume as indicated by the fixed maximum liquid level gauge if you have a liquid temperature near 40° F. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 6

Figure 9. Fixed Maximum Liquid Level Gauge Features of Propane Transports Fixed Liquid Level Gauges Figure 9. Fixed Maximum Liquid Level Gauge 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 7

Figure 10. Temperature Well Features of Propane Transports Temperature Well & Thermometer Figure 10. Temperature Well Figure 11. Dial Indicating Temperature Gauge 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 8

Figure 12. Thermometer, Pressure Gauge And Fixed Liquid Level Gauges Features of Propane Transports Temperature Well & Thermometer Figure 12. Thermometer, Pressure Gauge And Fixed Liquid Level Gauges 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 9

Features of Propane Transports Loading, Unloading and Vapor Equalizing Connections The fill and equalizing connections in propane cargo tanks vary according to their applications for metered or un-metered delivery service. The vapor equalizing connections always contain a riser inside the tank that extends to the vapor space in the cargo tank. The fill connection in most cargo tanks connects to a riser used to "spray fill" the tank. When piping is installed, even though the fill connection and the connected bypass piping will contain liquid propane, the opening at the outside of the cargo tank must be permanently labeled either “VAPOR” or “Spray-Fill” because the piping ultimately communicates with the vapor space of the cargo tank due to the spray fill feature. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 10

Features of Propane Transports Loading, Unloading and Vapor Equalizing Connections Figure 13. Schematic Drawing of Transport Cargo Tank Loading, Unloading and Vapor Equalizing Connections 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 11

Figure 14a. Bottom-Center Loading & Unloading Valve Connections Features of Propane Transports Loading, Unloading and Vapor Equalizing Connections Figure 14b. Rear Loading & Unloading Valve Connections Figure 14a. Bottom-Center Loading & Unloading Valve Connections 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 11

Figure 15. Internal Valves Withdrawal Connection Figure 15. Internal Valves 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 11

Withdrawal Connection Figure 15a. Valve Closed (Position A) Position A: When the operating lever is in the closed position, tank pressure (liquid or vapor) holds the main and pilot valves in the closed position. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 12

Figure 15b. Bleed Open, Excess Flow Valve Closed Withdrawal Connection Figure 15b. Bleed Open, Excess Flow Valve Closed (Position B) Position B: When the operating lever is moved to the open position, the cam moves the valve stem upward, opening the pilot valve orifice. Tank pressure bleeds through the pilot orifice and begins to build up downstream pressure. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 13

Withdrawal Connection Figure 15c. Valve Open (Position C) Position C: As downstream pressure equalizes with tank pressure, the excess flow spring opens the main valve. The system is ready for transfer operations with the main valve acting as an excess flow valve. Releasing the operating lever to the closed position instantly closes both the main valve and the pilot valve (Position A). 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 13

Figure 16. Cable Installation Withdrawal Connection Figure 16. Cable Installation 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 14

Figure 17. Pump Pressure Operated Internal Valve (Flanged) Withdrawal Connection Figure 17. Pump Pressure Operated Internal Valve (Flanged) 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 15

Figure 18. Three-Way Valve Withdrawal Connection Figure 18. Three-Way Valve 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 15

Relief Valves Figure 19c. Open Figure 19b. Closed Figure 19a. Internal 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 16

Figure 20. Relief Valve Caps and Covers Relief Valves Figure 20. Relief Valve Caps and Covers Relief valves are removed and independently tested as part of the cargo tank 5-year pressure test performed by a U.S. DOT Registered Inspector. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 16

PTOs & Pumps Figure 22a. Tractor PTO Output Shaft Figure 22b. Connecting “Jack Shaft” Between Tractor and Trailer 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 17

PTOs & Pumps PTO SHAFT HAZARD WARNING: DO NOT attempt to connect or adjust the PTO shaft section between the tractor and trailer with the engine running. NEVER place any body part, clothing, hair, or hand-held object (within 3 feet of) a rotating PTO shaft. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 17

PTOs & Pumps Figure 23. In-Cab Pneumatic PTO Control 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 18

PTOs & Pumps Figure 24. Sliding Vane LP-Gas Pump 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 18

PTOs & Pumps Figure 24. Sliding Vane LP-Gas Pump 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 18

PTOs & Pumps Never allow the pump to run dry. Liquid LP-gas is the lubrication and cooling material that protects the pump from premature wear and failure. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 19

Auxiliary Pump Inlet Figure 25. Auxiliary Pump Inlet 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 20

Liquid Meters Most transports are not equipped with a liquid meter. CTMVs in metered delivery service, however, have a liquid meter installed in the pump discharge line to account for the correct number of gallons delivered to customers. To ensure accurate inventory records, deliveries of propane to bulk plants and industrial customers are adjusted so the invoice displays the volume of gas at 60° F. Figure 26. State Weights & Measures Registration Decal on Meter Register 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 22

Transfer Hoses Vapor Equalizing Hose – Typically attached to the plant transfer bulkhead, but on CTMVs in metered delivery service, may be carried on the transport Use of the vapor equalizing hose prevents or minimizes the following: excessive pump cavitation excessive pressure build up in the customer storage containers venting of relief valves on customer storage containers in hot weather or on ASME tanks that fill to the liquid space 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 22

Transfer Hoses Delivery Hose Assembly (Liquid) – One of the most frequent causes of early failure of delivery hoses is damage from abrasion caused by vibrations of the hose. When this condition is detected, there are two important steps to be taken at once. The hose must be inspected more frequently and the cause of the vibration should be determined and corrected. If wear is so extensive as to expose the hose reinforcing fabric, the hose cannot be used until it is repaired and pressure tested or replaced with a new hose. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 22

Emergency Discharge Control Systems U.S. DOT regulations require the installation of either off-truck remote emergency discharge control systems or passive shutdown systems. MC 330, MC 331, and non-specification cargo tank motor vehicles …. must be retrofitted with required emergency discharge control equipment at their first scheduled pressure test after July 1, 2001. All required retrofits must be complete by July 1, 2006. There are three types of emergency discharge control systems used on transports: Manually actuated systems Off-truck remotely actuated systems Passive shutdown systems 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 24

Emergency Discharge Control Systems Manually Actuated Systems Figure 27b. Emergency Shutdown Station—Rear Deck Location Figure 27a. Emergency Shutdown Station—Front Trailer Location 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 25

Emergency Discharge Control Systems Off-Truck Remotely Actuated System Figure 28. Example of Off-Truck RF Device 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 25

Emergency Discharge Control Systems Passive Emergency Shutdown System – Passive emergency shutdown systems are systems that can stop the flow of product and stop the vehicle engine without human action within 20 seconds in the event of a complete delivery hose separation. Figure 29a. Passive Shutdown System Control Box Figure 29b. Discharge Line Sensor 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 26

Figure 30. Undercarriage Interlock Gate Open for Loading Pull-away Prevention Devices Safety Air Brake Interlocks – The purpose of the interlocks is to prevent accidents such as moving the vehicle from a loading or unloading bulkhead with the PTO engaged or the hoses connected. Figure 30. Undercarriage Interlock Gate Open for Loading 2.3.1 Student Book  © 2004 Propane Education & Research Council Pages 26 & 27

Cargo Tank Labeling & Marking U.S.Department of Transportation regulations require specific cargo tank markings, including: Hazard Class Placards Product Shipping Labels Cargo Tank Inspection and Test Markings Quench Tempered or Non-Quench Tempered Markings Placards and shipping labels (Figures 31 and 32) are required on the front, back and both sides. 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 27

Cargo Tank Labeling & Marking Figure 31. Propane Shipping Label and Placard with LP-gas Identification Number 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 28

Figure 32. Hazard Class Placards Cargo Tank Labeling & Marking *Some states may require decals stating, "WE STOP AT RAILROAD CROSSINGS," to be placed on the rear of the vehicle. Figure 32. Hazard Class Placards 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 28

Cargo Tank Test and Inspections Cargo Tank Labeling & Marking Tests & Inspections – The month and year of the latest required annual cargo tank inspections and the test and inspections required every five years must be shown near the cargo tank data plate. All commercial motor vehicles must also pass an annual vehicle inspection. Documentation of the annual mechanical inspection may be in the form of a decal. Cargo Tank Test and Inspections Annual Inspections 5-Year Test and Inspection External visual inspection (V inspection), and Leak inspection (K inspection). Hydrostatic pressure test (P test), and Internal inspection (I inspection) 2.3.1 Student Book  © 2004 Propane Education & Research Council Page 28

Time to See If You Got the Key Points of This Module… Complete the Review on page 29. See if you are ready for the Certification Exam by checking off the performance criteria on page 30. 2.3.1 Student Book  © 2004 Propane Education & Research Council Pages 29 & 30