initial osha & dot training module 5 loading and unloading

INITIAL OSHA & DOT TRAINING

MODULE 5

Loading and Unloading


Module 5 - Loading and Unloading Introduction

This module will cover DOT regulations for loading and unloading bobtails, transports, and railcars. Your company is required to provide hands-on training for your specific job function.

Procedures for loading and unloading were developed to maintainhigh safety standards, minimize damage or loss, and establish consistent routines. All propane drivers must be trained to followthese procedures. Following proper loading and unloading procedures ensures the security and integrity of your vehicle, and reduces the chance of an accident or product release.

After completing this module, you will be able to:

Explain the general requirements for propane shipments. List attendance requirements when you are transporting hazardous materials. Discuss how and when to inspect hoses and discharge equipment. Identify the markings on a cargo tank to determine when testing and re-testing is

required. Describe the specifics of loading and unloading railcars.

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LESSON 1

General Requirements

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LESSON 1


General Requirements Introduction

Every propane company conducts its day-to-day business differently. However, there are government regulations and accepted industry practices that must be followed to ensure safety during all stages of transport.

Specific scenarios and job functions will be discussedlater in this module. This lesson concentrates on general safety requirements applicable to all drivers and transfer personnel.

After completing this lesson, you will be able to:

Identify the procedures to prevent vehicle movement. Identify common methods for controlling ignition sources. Explain how to detect the presence of an odorant.

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LESSON 1


Preventing Vehicle Movement

It is important to ensure that your vehicle does not move during loading or unloading. Unexpected movement during these operations can create a safety hazard. For bobtails and transport trucks, set the parking brakes and place chock blocks in the front and back of the rear wheel assembly.

You are also required to set the brakes and block the wheels when unloading railcars. When railcars are on rail sidings for loading or unloading, you must block and place special notification signs at both ends of the track. Additionally, a set of derailers must be placed on or in the track.

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LESSON 1


Controlling Ignition Sources

Combustion requires three elements: fuel (in this case, propane), oxygen (air), and an ignition source, such as a spark, flame, or static electricity. Since flammable gas and air are already present in the loading and unloading area, you must eliminate any nearby ignition sources.

Keep ignition sources at least 25 feet away from any placarded vehicle carrying hazardous materials. Common ignition sources include:

Pilot burner flames Match flames Cigarette lighter flames Sparks from a vehicle’s engine Light switches and thermostats Lit cigarettes Cell phones or other portable electronic devices

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LESSON 1


Controlling Ignition Sources, cont.

In addition, you must take every precaution to avoid producing a spark. Use only nonsparking tools made of materials such as brass or aluminum to tighten connections and perform maintenance procedures.

NOTE: Smoking of any kind is never allowed when working near propane.

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LESSON 1


Purpose of Odorant

Because odor is one of the primary safety measures for detecting the presence of propane, all initial shipments into a plant must be checked for the presence of an odorant following the guidelines of National Fire Prevention Association (NFPA) 58, the Liquefied Petroleum Gas Code.

Although other odorants may be used, the most common is ethyl mercaptan, which is added at the rate of at least one pound per 10,000 gallons of propane.

The smell of ethyl mercaptan is quite strong and is often compared to that of rotten eggs. This helps ensure any unintended propane release can be detected quickly, both at the plant and at customer locations.

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LESSON 1


Purpose of Odorant, cont.

Effective odorization:

Enables you to detect leaks before gas concentrations in the air reach a flammable level.

Reduces gas loss through early detection and repair of leaking pipes, fittings, and storage container fixtures.

Refer to your company policy to see if odorant checks are required when loading or unloading. If an odorant is not detected during these checks, immediately stop all transfer operations and contact your supervisor. You should notify other drivers, as they may also have unodorized products on board their vehicles.

Never deliver a product to a customer if your load is not properly odorized.

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LESSON 1


Determining Presence of Odorant

The most common way to check for an odorant is by performing a basic sniff test. Vent a small quantity of propane through the vent valve on the plant liquid hose, and sniff the area immediately after the liquid vaporizes.

If you can smell a propane odorant, proceed with the loading operation.

If you cannot smell a propane odorant or you smell anything unusual, stop loading the cargo tank, contact your supervisor immediately, and tell others in the area not to load until your supervisor indicates it is safe to do so.

On very rare occasions, propane is not required to be odorized. Some very sophisticated industrial heating processes, as well as certain aerosol propellants, are examples of products that may use unodorized propane.

Please refer to your company policy regarding the handling of un-odorized propane.

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CHECK FOR UNDERSTANDING

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LESSON 2

Attendance Requirements

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LESSON 2


Attendance Requirements Introduction

A qualified person must be in attendance at all times when loading or unloading propane. A person is considered “qualified” if he or she is aware of the nature of the hazardous material, has been instructed on emergency procedures, and is authorized and able to move the cargo tank. This lesson describes attendance requirements for tasks you are likely to perform. Refer to your company policy for any additional requirements.


Discuss bobtail attendance requirements. Discuss transport attendance requirements.

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LESSON 2


Bobtail Attendance Requirements

A bobtail in metered delivery service must be attended by a qualified person at all times while being loaded and unloaded. If a bobtail is unattended, it must be shut down and disconnected.

During loading and unloading, the qualified attendant must:

Remain within 150 feet of the cargo tank. Remain within 25 feet of the delivery hose. Have an unobstructed view of the cargo tank and

delivery hose, except when necessary to use controls or monitor the receiving container.

If an unobstructed view is not possible, observe both the cargo tank and the receiving container at least once every five minutes when the internal self-closing stop valve is open.

Always refer to your company policy for any additional attendance requirements.

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LESSON 2


Bobtail Emergency Shutoff Requirements

In the event of an emergency during loading or unloading, all bobtails must be equipped with a means of immediately shutting down the transfer of propane. This includes an off-truck remote to control the self-closing stop valve, and shut off motor and auxiliary power equipment. This remote must function reliably at a minimum of 150 feet.

Once the transfer has been remotely shut down, the internal self-closing stop valves can be reopened only manually. The remote shutoff device must not be capable of opening these valves and reinitiating transfer.

DOT requires that off-truck remotes be tested within 18 hours of the first delivery. Drivers may test from a line-of-sight distance of 150 feet to visually verify that the internal valve has closed. This test should be completed at the plant prior to operating the vehicle on the highway. Trucks that fail this test must not be driven until repaired.

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LESSON 2


Bobtail Emergency Shut-Off Requirements, cont.

Bobtails in metered delivery service with a capacity greater than 3,500 gallons must be equipped with an off-truck remote shutdown capability, and, for obstructed-view deliveries, either a transmitter/query system or passive shutdown capability.

When a query system is used, it verifies that the qualified attendant is present at least once every five minutes. If the attendant is not present, the system will automatically close the internal, self-closing stop valve and shut off all motor and auxiliary power equipment.

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LESSON 2


Transport Attendance Requirements

Like bobtails, transport trucks must be attended by a qualified person at all times during loading and unloading operations. The person responsible for loading the cargo tank is also responsible for ensuring that it is attended.

Most transports are designed to be in nonmetered service, so their requirements for attendance are a little different.

When loading or unloading a non-metered transport, the qualified attendant must:

Remain within 25 feet of the cargo tank when the internal, self-closing stop valve is open.

Have an unobstructed view of the cargo tank and delivery hose, except when necessary to activate controls or monitor the receiving container.

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LESSON 2


Transport Attendance Requirements, cont.

If an unobstructed view is not possible, observe both the cargo tank and the receiving container at least once every five minutes when the internal, self-closing stop valve is open.

A transport in nonmetered delivery service must also have Passive Emergency Shut-Down Capability. This means, the transport must be able to shut off the flow of propane within 20 seconds of an unintentional release caused by a complete separation of a liquid delivery hose without human intervention.

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LEARNING ACTIVITY

Loading and Unloading Requirements

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LESSON 3

Inspections

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LESSON 3


Inspections Introduction

Inspections are a critical part of maintaining safety while loading and unloading. This lesson introduces what to look for when performing common inspections for different vehicles used in the industry. More details are provided later in this course.

After completing this lesson, you will be able to identify the basic inspection requirements for:

Vehicles Cylinders Hoses

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LESSON 3


Vehicle Inspection Overview

DOT requires that you inspect Commercial Motor Vehicles (CMV) before and after each trip to make sure the vehicle is operating properly. This helps prevent accidents and serious incidents during all stages of transport.

Always check the following before and after a trip:

Service brakes, including trailer brake connections.

Parking (hand) brake. Steering wheel and column. Lights and reflectors. Tires. Horn. Windshield wipers. Rear-view mirrors. Coupling devices. Emergency equipment

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LESSON 3


Cylinder Inspection Overview

Before filling or transporting cylinders, make sure the cylinder is in good working condition by performing a quick visual inspection.

Look for:

Damage, including dents, bulges or cracks. Excessive rust or pitting. Condition of the cylinder foot ring and cylinder

collar or valve cover. The date the cylinder was manufactured or

last recertified. and the Readability of cylinder markings.

Details on cylinder inspection are covered later in this course.

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LESSON 3


Hose Inspection Overview

Hoses used during the loading and unloading process should be examined before and after each use. Any hose that is in an unsafe condition must be removed from service.

When examining hoses, look for:

Cracking. Large cuts or abrasions. Soft spots. Bulges. Blisters. Exposed fabric. Damaged fittings. Defects.

Hose inspection is discussed in greater detail later in this course.

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LESSON 4

Cargo Tank Requirements

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LESSON 4


Cargo Tank Requirements Introduction

Before bobtail and transport tanks are allowed into service, they must be tested for structural integrity and leakage. The date of these tests, and other specifications about the tanks and how they were built, must be marked clearly at various places around the vehicle.


Explain the importance of manufacturing and emergency shutoff markings.

Identify the requirements for cargo tank testing markings.

Explain the importance of cargo tank data plates.

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LESSON 4


Manufacturing and Emergency Shutoff Markings

Bobtail and transport tanks are manufactured to the specifications of the American Society of Mechanical Engineers (ASME) and DOT and have specific DOT code numbers. Every cargo tank used for the transportation of propane must conform to the specifications in Title 49 CFR §178.

If a cargo tank is not built according to DOT standards, it is called a “non-specification cargo tank.” This information can be found near the data plate.

In some states, a non-specification ASME cargo tank of 3,500 gallons or less may be allowed to transport propane if it meets all of the requirements of the regulations. However, DOT does not approve these tanks for interstate commerce, and they may not cross that state’s borders for delivery. Refer to your company policy and state authority to determine which type of vehicle you are allowed to use when delivering propane

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LESSON 4


Manufacturing and Emergency Shutoff Markings, cont.

All MC330 and MC331 cargo tanks must be visibly marked with QT or NQT in letters 2 inches or taller, near the specification plate. “QT” (Quenched and Tempered) means the steel was heated and quickly cooled to harden during the manufacturing process. “NQT” (Non-Quenched and Tempered) steel was not manufactured in this way.

Each on-vehicle, manually activated remote shutoff device must be marked “Emergency Shutoff.” The letters must be at least 3/4 inch tall, in a color that contrasts with its background, and located in an area immediately adjacent to the means of closure.

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LESSON 4


Cargo Tank Testing Requirements and Markings

A cargo tank may not be filled or transported if the required tests or inspections have not been completed by their due dates. Cargo tank inspection and test markings must be shown near the data plate. The month and year of the latest required tests and inspections are included.

The following lists required inspections, their markings, and how often they are to be performed:

External Visual Inspection (V): Annually. Leakage Test (K): Annually. Pressure Test (P): Every five years. Internal Visual Inspection (I): Every five

years. Only applicable if the tank is equipped with a manhole.

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LESSON 4


Cargo Tank Testing Requirements and Markings, cont.

For example, a cargo tank with a marking of “V,K 08/09,” tells the driver that before September 2010 (one year) the tank must have another visual inspection (V) and leak test (K) completed. A cargo tank with a marking of P, 08/09, tells the driver that on or before September 2014 (five years) the tank must have a pressure test (P) performed. Since this tank is not equipped with a manhole, an internal visual inspection (I) is not required.

A cargo tank may require requalification sooner if it is damaged or subjected to physical abuse, excessive corrosion, or heat. Cargo tanks that have been exposed to fire must be removed from service immediately.

The person performing the test or inspection must be registered with DOT and meet the requirements found in Title 49 CFR.

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LESSON 4


Cargo Tank Data Plate

DOT requires a data plate displaying information about cargo tank specifications and how it was manufactured.

Tank repair shops, DOT authorities, and company personnel need to obtain information from the plate, so it must be maintained in legible condition. A cargo tank that does nothave a data plate cannot be used.

Although there is much more information included on a data plate, the most critical information for a driver to be able to identify is:

The tank manufacturer’s name. The serial number. The DOT specification number. The vessel material specification number. The water capacity in pounds and gallons. The original test date. The design working pressure of the tank.

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LESSON 4


Cargo Tank Data Plate

The plate must be marked plainly, in characters at least 3/8 inch high. Cargo tanks certified after October 1, 2004, may have required markings combined on a single plate in characters at least 3/16 inch high.

Data plates must be attached to the cargo tank in an accessible, yet protected location. Every cargo tank must have a data plate permanently affixed to the left side near the front of the tank. Tanks built before July 1, 1985, may have the data plate located on the right.

Some cargo tanks will have two data plates, an ASME plate and a DOT plate.

Data plates are welded around the entire perimeter. Missing, loose, or damaged data plates should be reported immediately to your supervisor.

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LESSON 5

Dot Railcar Requirements

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LESSON 5


DOT Railcar Requirements Introduction

Just as cargo tanks have specific marking and inspection requirements, railcars must comply with DOT regulations to ensure safety during loading and unloading. Due to the size of the tank and mode of transport, railcar tanks have additional requirements and procedures for transfer operations.

When you have finished this lesson, you will be able to:

List identification requirements specific to railcar tanks.

Describe safety requirements for loading and unloading railcars.

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LESSON 5


Railcar Identification Requirements Overview

DOT requires the following identification information for railroad tank cars:

Stenciled tank markings: Unlike cargo tanks and IM portable tanks, railcars do not have a data plate. Instead, DOT design specifications and other information are stenciled directly on the heads and sides of the tank.

Hazard class placards: Railcars must be placarded with the hazard class name and number on the front, back, and both sides.

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LESSON 5


Railcar Identification Requirements Overview, cont.

Product shipping name: Railcars must be marked clearly with the shipping name on the front, back, and both sides.

Railcars are rarely owned by propane companies, and therefore, DOT does not require propane employees to inspect, service, or repair them. However, employees are required to check the general appearance and condition of the tank, tank valves, and tank markings to ensure that it is safe for loading and unloading.

In this section, we will discuss requirements for safety during railcar transfer operations.

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LESSON 5


DOT Railcar Requirements

DOT has additional requirements for railcar or transport truck transfer points and operations. When unloading from a railcar, remember:

The tank car siding must be relatively level. A “Tank Car Connected” sign must be installed at the

active end or ends of the siding while the tank car is connected.

Transfer points must be separated from storage tanks, other vehicles, and ignition sources.

A means of remote closing must be located close to the point where the liquid piping and hose are connected to prevent uncontrolled discharge, such as a backflow check valve, excess-flow valve or a shutoff valve.

While cars are on the sidetrack for loading or unloading, the wheels at both ends must be blocked on the rails.

Derailers must be used while the railcar is parked.

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LESSON 5


Railcar Safety Requirements

When loading and unloading a railcar, remember these points:

DOT requires connections to be attached securely before any discharge valves are opened and removed immediately after the operation is completed.

The car must be attended during transfer operations and while connected to the loading device.

If you must stop the transfer for any reason, all connections must be disconnected. Valves must first be tightly closed, and the closures of all other openings secure.

After the transfer operation is complete, tighten all valves using a bar, wrench, or other suitable nonsparking tool.

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LESSON 5


Railcar Safety Requirements, cont.

Railroad defect cards may not be removed.

All tools used must be kept free of oil, dirt, and grit. Carefully inspect the outlet of the safety-relief valve for debris,

corrosion, or damage that could prevent it from operating as designed.

After transfer operations are complete, inspect the tank car for any condition that would make it unsafe for transportation.

Check for the following:

Abrasion, corrosion, cracks, dents, distortions, and defects in welds.

Corrosion or damage to piping, valves, fittings, and gaskets. Make sure the valves are operating properly, and that there are no leaks.

Any bolts, nuts, or other elements that may be missing or loose. If any defects or damage are found, contact the railroad

immediately.

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MODULE 5 QUIZ

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initial osha & dot training module 5 loading and unloading

Documents

specifics of loading

proper loading

dot regulations

common ignition sources

handson training

lesson concentrates

nearby ignition sources

vehicle movement