www.safetyontheweb.com
HMT
Bulk
Loading/Unloading
www.safetyontheweb.com
Introduction
If you load or unload hazardous materials in
bulk containers, it is your responsibility to
follow the correct procedures. Incidents
involving hazardous materials can lead to
serious injury, property and environmental
damage, and even death.
www.safetyontheweb.com
Introduction
Department of Transportation statistics show
that 97 percent of all hazardous material
incidents involve tank cars and tank trucks.
And surveys show that up to 50 percent of all
vehicles are placarded incorrectly.
www.safetyontheweb.com
Identifications & Markings
Bulk Packaging is packaging other
than a vessel or barge that hazardous
materials are loaded onto which has a
maximum capacity greater than 119
gallons, has a maximum net mass
greater than 882 pounds, or has a water
capacity greater than 1,000 pounds.
www.safetyontheweb.com
Identifications & Markings
This includes railroad tank cars, tank
trucks, and portable tanks that meet the
criteria just mentioned. All bulk
containers must have the correct
placards and markings according to the
requirements in Title 49 of the Code of
Federal Regulations.
www.safetyontheweb.com
Identifications & Markings
Railroad Tank Cars
Proper Shipping Name
Reporting Marks
Tank Car Classification
Safety Valve & Tank Test Information
DOT Hazard Warning Placarding
www.safetyontheweb.com
Identifications & Markings
Tank Trucks
Shipper’s Name and Location
DOT Hazard Warning Placarding
UN or NA Identification Number
www.safetyontheweb.com
Identifications & Markings
Railroad tank cars can be divided into
two groups:
Pressurized Tank Cars
General Purpose Tank Cars
www.safetyontheweb.com
Identifications & Markings
A general purpose or non-pressurized
tank car is cylindrical in shape with
convex (curves or bulges outward)
heads.
www.safetyontheweb.com
Identifications & Markings
Loading devices and equipment are
found in the platform area on the top of
the tank car.
www.safetyontheweb.com
Identifications & Markings
In addition, bottom outlet valves for
unloading are at the center of the car,
and heater coil outlets sometimes
protrude from underneath the tank.
www.safetyontheweb.com
Identifications & Markings
Pressure tank cars are also
cylindrically shaped with convex
heads. Pressurized tank cars are
always loaded from the top. The
loading devices and fittings are
located in one housing on the top
center of the tank cars.
www.safetyontheweb.com
Loading & Unloading
As a person who loads and unloads bulk
shipments of hazardous material, there are
two reasons why it is important that you
follow the proper procedures and
safeguards:
www.safetyontheweb.com
Loading & Unloading
1. To ensure your safety and health.
2. To reduce the odds of a release
occurring during transport.
www.safetyontheweb.com
Loading & Unloading
It is also important that you are familiar
with the material you work with.
www.safetyontheweb.com
Loading & Unloading
Though Material Safety Data Sheets do not
necessarily provide specific DOT
information, they are a valuable source for
finding out the physical characteristics and
hazards of a material, the recommended
Personal Protective Equipment to be worn,
and other safety precautions.
www.safetyontheweb.com
Loading & Unloading
There are specific requirements that must
be followed when loading and unloading
tank trucks or portable tanks into or onto
trucks.
www.safetyontheweb.com
Loading & Unloading
When loading or unloading a bulk package
on a truck, whether the tank is portable or
cargo, the vehicle’s engine must be shut
off, the parking brake set, and the wheels
chocked.
www.safetyontheweb.com
Loading & Unloading
Because of the possible buildup of static
electricity, the vehicle must also be
grounded.
www.safetyontheweb.com
Loading & Unloading
The responsible person must verify that the
driver understands the potential hazards of
the material, is wearing the proper Personal
Protective Equipment, and knows the
proper procedures to follow in case of an
emergency.
www.safetyontheweb.com
Loading & Unloading
The driver must have a clear view of the
vehicle and remain within 25 feet of the
truck during the loading or unloading
process.
www.safetyontheweb.com
Loading & Unloading
Before loading or unloading, the person
performing the function must inspect the
tank to make sure all fittings, valves, and
safety relief devices are in proper condition
for safe transportation.
www.safetyontheweb.com
Loading & Unloading
Loading and unloading both pressure and
general purpose tank cars requires the
same thorough checklist as tank trucks.
Before the process begins, blue flags are
positioned with one of the two following
warnings:
www.safetyontheweb.com
Loading & Unloading
STOP, TANK CAR CONNECTED
or
STOP, MEN AT WORK
www.safetyontheweb.com
Loading & Unloading
The wheels are then chocked, and the hand
brake is set.
www.safetyontheweb.com
Loading & Unloading
Because of the potential for static
electricity buildup, the tank car is
grounded.
www.safetyontheweb.com
Loading & Unloading
On general purpose tank cars equipped
with secondary outlet valves, the plugs
must be removed, and the top and bottom
valves opened during loading. Internal
heating coil caps must also be removed
during loading.
www.safetyontheweb.com
Loading & Unloading
If loading, check the tank car’s interior for
cleanliness, and to verify that the previous
contents are compatible with the material
being loaded.
www.safetyontheweb.com
Loading & Unloading
Make sure all valves and fittings are in
their proper setting, and all loading or
unloading connections are properly
attached. If corrective actions are needed
to the tank car before loading or
unloading, notify the switching office or
terminal manager.
www.safetyontheweb.com
Loading & Unloading
After loading and before shipment or
unloading and release, disconnect the
appropriate lines or hoses. If loading,
check to make sure the required outage has
been left to allow for expansion, or that the
tank is empty if you have been unloading.
www.safetyontheweb.com
Loading & Unloading
Make sure you properly seal the dome
cover and uniformly cross-tighten all
securing nuts. All valves must also be
securely closed.
www.safetyontheweb.com
Loading & Unloading
Check to be sure that all valve caps and
plugs are in place and have been tightened
with a wrench. All protective housings and
covers must also be in place, closed, and
wrench tight.
www.safetyontheweb.com
Loading & Unloading
On general purpose tank cars, make sure
the bottom outlet valve gasket is in good
condition. Tighten the bottom outlet
valve cap with a wrench that has a
minimum 36-inch handle.
www.safetyontheweb.com
Loading & Unloading
The plug in the bottom outlet valve should
be wrench tight. Make sure all secondary
outlet valves and plugs are tight.
www.safetyontheweb.com
Loading & Unloading
Check the tank car for any signs of leakage
or spills, and make sure the correct
placards are in place.
www.safetyontheweb.com
Loading & Unloading
If loading, check the marks to see that the
load limit has not been exceeded and the
OSHA hazard warning is in place.
www.safetyontheweb.com
Loading & Unloading
The person loading or unloading must be
able to rapidly halt cargo transfer during
the process if the material is hazardous.
www.safetyontheweb.com
Placarding
After all final checks, once the tank cars,
portable tanks, and tank trucks have been
loaded or unloaded, but before their
shipment, they must be placarded according
to 49 CFR Part 172.504.
www.safetyontheweb.com
Placarding
Placards inform emergency response
personnel of the hazard class and associated
dangers of the material being transported.
www.safetyontheweb.com
Placarding
The regulations require specific placards for
each of the nine hazard classes, as well as
specific placards for those hazard classes
that are further separated into divisions.
www.safetyontheweb.com
Placarding
Most bulk transport containers require four
placards, one on each side and each end.
www.safetyontheweb.com
Placarding
As a general rule of thumb, placards must
be visible on all four sides of a bulk
packaging and at least three inches away
from any other markings.
www.safetyontheweb.com
Placarding
If a portable container holds more than 119
gallons, but less than 1,000 gallons, the tank
may be placarded on two opposite ends.
www.safetyontheweb.com
Placarding
Sometimes a material will have a primary
and a secondary, or subsidiary, hazard. In
these cases, placards showing both hazards
must be displayed, but the secondary hazard
class placard must have the hazard class
number removed or obliterated.
www.safetyontheweb.com
Summary
Loading and unloading hazardous materials
is a serious responsibility. Be familiar with
and respect the hazards associated with the
material you load or unload.
www.safetyontheweb.com
Summary
Follow all procedures and safe work practices,
including proper selection of tools and
Personal Protective Equipment.
www.safetyontheweb.com
Summary
Make sure you double check that all valves,
fittings, caps, seals, and closures are properly
secured, whether you used them or not.
www.safetyontheweb.com
Summary
Check the placards before releasing the bulk
container.
www.safetyontheweb.com
Summary
Knowing and following the proper procedures
can ensure safe transportation of bulk
shipments.
www.safetyontheweb.com
Summit Training Source,
Inc.
Contact us at:
1-800-842-0466
or at
[email protected]
www.safetyontheweb.com