1. Tank Car Specialist Training Support Package November 2014 Module 13: Transfers

2. 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.

3. Tank Car Specialist Enabling Learning Objectives 13-1 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.

4. 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

5. Tank Car Specialist Risks of Field Transfer Loss of product Contamination Proper transfer equipment or trained personnel are not available

6. Tank Car Specialist Considerations Ensure components are compatible –Receiving container –Pumps –Fittings –Hoses Reaction / deterioration Product contamination –Cleaned container –Cleaned transfer equipment

7. Tank Car Specialist Considerations Container of sufficient capacity –Specification Plate –Data plate –Tank specification Material of construction –Liners Pressures Multiple receiving vessels –Isolation valves

8. 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

9. Tank Car Specialist Types of Transfers Open –Vapors vent to atmosphere Closed –Vapors through containers Scrub –Vapors processed through medium Pressure differential Gravity

10. 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

11. 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.

12. 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

13. Tank Car Specialist Safety Precautions Secondary containment Secure manways and protective housing lids Fire protection Place blue flags, if required

14. 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.

15. 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.

16. 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

17. 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.

18. 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

19. Tank Car Specialist Transfer Pump

20. Tank Car Specialist Block Valve w/Purge

21. Tank Car Specialist Outlet Block Valve w/Purge

22. Tank Car Specialist Vapor Outlet Block Valve w/Purge

23. Tank Car Specialist Pressure Gauge

24. Tank Car Specialist Damaged Tank CarReceiving Tank Car 4 2 3 4 2 3 1 Liquid flow Liquid valve outlet assembly Liquid valve inlet assembly Vapor valve inlet assembly Vapor valve outlet assembly Pressuregauge Pressuregauge Vapor flow Liquid pump Liquid Pump Liquid Vapor 1 Liquid valve 2 Vapor valve4 Gauging device 3 Sample line Liquid Transfer Emergency Remote Shut-off

25. 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

26. 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

27. 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

28. Tank Car Specialist Liquid Valve Inlet Assembly

29. Tank Car Specialist Liquid Valve Outlet Assembly

30. Tank Car Specialist Vapor Outlet Assembly

31. Tank Car Specialist Vapor Inlet Assembly

32. Tank Car Specialist Compressor and Pump 11 55 44 22 33 66 11 11 55 44 22 33 66 11 LiquidLiquid VaporVapor 1 Liquid valve4 Thermometer well 2 Vapor valve5 Gauging device 3 Sample line6 Pressure relief valve 1 Liquid valve4 Thermometer well 2 Vapor valve5 Gauging device 3 Sample line6 Pressure relief valve Damaged Tank CarReceiving Tank Car Gas Transfer Liquid valve outlet assembly Pressure Gauge Vapor valve inlet assembly OutletInlet Pressure Gauge Vapor valve outlet assembly Liquid valve inlet assembly Inlet Outlet Vapor Compressor Liquid pump Compressed vapor flow Liquid flow Vapor flow

33. Tank Car Specialist Damaged Tank Car Receiving Tank Car 1 5 4 2 3 6 1 1 5 4 2 3 6 1 Liquid flow Liquid valve outlet assembly Liquid valve inlet assembly Vapor valve inlet assembly Vapor valve outlet assembly Pressuregauge Pressuregauge Vapor flow Compressed vapor flow Vaporcompressor Vapor Compressor Liquid Vapor 1 Liquid valve4 Thermometer well 2 Vapor valve5 Gauging device 3 Sample line6 Pressure relief valve Gas Transfer

34. Tank Car Specialist Damaged Tank Car Receiving Tank Car 1 5 4 2 3 6 11 5 4 2 3 6 1 Liquid flow Pressuregauge Pressuregauge From inert gas source To vapor flare, vent pipe, or vapor treatment system Compressed or Inert Gas Vapor valve inlet assembly Vapor valve outlet assembly Liquid valve outlet assembly Liquid valve inlet assembly Liquid Vapor 1 Liquid valve4 Thermometer well 2 Vapor valve5 Gauging device 3 Sample line6 Pressure relief valve

35. 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

36. Tank Car Specialist Conclusion Participants 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.