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GPG RAILCAR LOADS/UNLOADS IPT > IPT > Flashcards

IPT Flashcards

1
Q

Name 3 administrative controls with fall prevention as it relates to Rail Cars?

A

Use of Carbis Rack, 3 points of control, Re-spotting Rail Car to minimize gaps, use of procedure, placing load funnel immediately upon opening manway, limiting time exposed to fall hazards, staying centered while on rail car, maintain good footing and avoid squatting on balls of feet.

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2
Q

What are 3 LEO’s that are performed when loading/unloading a Railcar?

A

Removing plugs on rail car, removing caps from load hoses, opening manway on rail car

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3
Q

Where must fouling markers be placed?

A

13ft, before roadways and bumpers.

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4
Q

What must be checked before any work can take place at a loading spot? If an issue is found what must be done before work can take place ?

A

R/c load schedule, tank levels, sump levels, r/c # , product (tags) derail, blue flag, blue light, chocks, inspection dates, r/c damage/ obscene graffiti, hand brake, safety showers, lot #, requested quantity/ verify tank is released.
If issue is found, escalate to tier 4/TA.

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5
Q

What is the purpose of a blue flag?

A

To warn that derail is on track and let switch crew know that work is being preformed behind blue flag.

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6
Q

What is the purpose of a blue light ?

A

To warn watco that derail is in track and work is being preformed behind flag/ derail.
Blue light is a second warning signal used in tandem / w blue flag. The light is easier to see during bad weather .

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7
Q

What is the purpose of a derail?

A

To protect workers working behind derail/flag, to prevent cars from being moved during loading/unloading and to protect from a possible runaway car.

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8
Q

What is the Minimum Railroad Corridor Clearances?

A

11 feet by 22.6 feet

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9
Q

What are the requirements while working behind a permanent derail?

A

It must be engaged when loading/unloading and must be red tagged for contractors

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10
Q

What is the minimum distance parked equipment and personnel adjacent to railroad tracks be to maintain a safe distance?

A

10 feet

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11
Q

DOT regulated materials requires _____ during the loading of Railcars?

A

Active Attendance

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12
Q

Is loading allowed at a spot that does not have a high-level switch as a shutoff device for secondary overfill protection?

A

Yes, with 100% attendance

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13
Q

What is an Explosimeter used for?

A

Used to monitor air and detect LEL’s/Ignitable atmosphere

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14
Q

List all the common cardinal rules associated with Rail.

A

Always attach ground clamps, to approved locations during loading/unloading of flammable liquids/combustible dusts.

Always provide rail clearance markings at all crossings and fouling points and store rail cars inside clearance markers.

Always store rail tank car manway gaskets in a flat position i.e. on a shelf.

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15
Q

Why do we attach ground cables to rail?

A

To discharge static safely to ground

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16
Q

What is the proper placement of chocks and why is it important?

A

Touching the wheels on both sides and it’s to prevent unwanted movement

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17
Q

How do you properly store manway gaskets?

A

Flat, on a shelf, and not hanging.

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18
Q

Describe ALWAYS de-pressure equipment and piping prior to opening. What EHS standard applies to this cardinal rule?

A

LEO
LINE OF FIRE
Staying out of line of fire, slowly remove bull plug while wiggling to release stored pressure and open bleed to de-pressure lines/equipment

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19
Q

Why do you ALWAYS allow for thermal expansion when blocking in liquid filled systems?

A

THERMAL EXPANSION.
It can expand and build pressure causing gasket failures, equipment damage, exposures, injuries, psce’s.

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20
Q

What chemicals specific to GPG would be a concern for thermal expansion? And in what situation?

A

All products in the tanks that we blow back to.

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21
Q

What precautions are taken for these chemicals that thermal expand?

A

Clear lines with nitrogen and blow back to tank.

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22
Q

Why do you ALWAYS provide vent relief or pressure source when unloading a railcar?

A

To prevent vacuum collapse.

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23
Q

What precautions are taken to prevent vacuum collapse of a tank or shipping container ?

A

Supply nitrogen though vent valve on railcar. Supplied pressure though vent/vapor valve.

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24
Q

Why do you ALWAYS perform visual inspection and leak check on hoses prior to use?

A

It prevents use of damaged or faulty equipment that could cause a psce.

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25
Q

How are hoses checked prior to use?

A

Check gaskets, look for kinks, holes, damaged dog ears, abrasions, etc.
Apply leak detector fluid to hose connections while hose is pressured up with nitrogen.

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26
Q

Why do you never over-pressure a storage tank by allowing excessive gas to flow into the tank?

A

To prevent damage to the tank/prv, and prevent a release of product.

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27
Q

How does a tank car loading/unloading create over-pressure in a storage tank?

A

If railcar runs empty and nitrogen runs unchecked to tank. Forgetting to turn off nitrogen after blowback to tank.

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28
Q

Where must ground clamps be installed on the rail car?

A

On one of the four body bolsters and/or grounding lugs.

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29
Q

What is the common term used for surge pressure events?

A

Line hammer/Hammer Effect

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30
Q

In case of any SIS trip, what is the correct action to take?

A

If work doesn’t shutdown automatically then shutdown manually and escalate, follow SSIS procedures.

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31
Q

What are 3 potential protection layers on the control system for any LOPA scenario?

A

Process Design, Control Systems, Operator Response, PPE

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32
Q

What is the SSIS (Safety System Impairment Standard) used for?

A

To prevent unintentional impairment of a safety instrumented system.

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33
Q

If any alarm becomes active and is latched, what does that mean and why is it used?

A

Alarm becomes active if measurement is greater than the set point & stays active until the measurement is less than the latch.

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34
Q

Where do we vent vapors (unit tank, unit vent system, or SL tank or SL vent system)?

A

Vent rail car to atmosphere with muffler.

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35
Q

Describe the load/unload spots studied by LOPA?

A

MA and EDA / ?All spots?

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36
Q

What is the SSIS (Safety System Impairment Standard) used for?

A

Manages safety equipment in and out of service such as mechanical, electrical, or process control.

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37
Q

What is a DO/DI mismatch on a block valve or a pump motor?

A

Block valve must be lined out for distribution, pump must be in auto, not manual or off.
If pump is not in correct switch position it will not read DI from process and turn on.

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38
Q

When are vapor balancing systems used for loading or unloading hazardous products?

A

On MA.

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39
Q

What helps avoid flammable mixtures in the vapor line (inverted or diluted)?

A

A closed loop system and dedicated lines to MA.

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40
Q

How is the vapor emission system monitored and controlled?

A

Compressor shuts off at 80%.
MA closed loop system, monitored with gas detector and auto shut down.

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41
Q

What is the PPE used when loading a tank car USP/DPG vs. EPH/PPH?

A

DPG/USP - Block minimum, Mono-Goggles, Nitrile Gloves.
PPH/EPH - Slicker Suit, Face Shield, Neoprene Gloves, Rubber Boots.

42
Q

List the potential hazards associated with loading a tank car and working in that area.

A

PSCE, Loud Noise, Overfill railcar, pinch points, ergonomics/strains, slips, trips, falls, overpressure railcar, exposures.

43
Q

What precautions do you use to avoid hazards from happening?

A

Admin controls/procedure use, line of fire, proper ppe, eyes on task/path, proper ergonomics, carbis rack, RAD tool use/proper tools, knowing the safe operating limits.

44
Q

What equipment is in place to prevent unintentional movement of rail cars?

A

Wheel chocks, hand brake, blue flag, blue light, derail.

45
Q

Is the loading operations controlled by scale, meter, or overfill device?

A

Flow meter, high level probe, mod 5.

46
Q

Does a secondary device automatically stop the loading in the event of scale or meter failure? What is the name of this device?

A

Yes.
High Level Probe.

47
Q

If the primary device fails, how would the load be completed.

A

With 100% attendance.

48
Q

Do you load rail cars from the top or bottom?

A

Top.

49
Q

Do you unload rail cars from the top or bottom?

A

BOTH.
MA - Top
OLOA - Bottom

50
Q

How do you properly ground/earth before loading or unloading when loading or unloading flammables.

A

On the grounding lug and/or body bolster.

51
Q

Is there an interlock system to prevent loading or unloading if the grounding/earthing is electrically discontinuous?

A

No.

52
Q

Where are the emergency stops located?

A

Loads - At the bottom of each stairway.
Unloads - 1 on ground level and 1 on the upper level.
1 in truck rack for MA

53
Q

What procedures are in place to prevent vacuum collapse during unloading operations per LPP8.1 3OM13, and clearing operations per logistics cardinal rules?

A

Nitrogen, open domes, open vent lines.
OLOA/EDA PROCEDURES.

54
Q

What chemicals use dry disconnect couplings?

A

Drumming products from railcars.

55
Q

Are hoses capped or blind flanged when not in use?

A

Capped.

56
Q

When is there a need to install a fitting or spool piece to connect the hose?

A

To alter or extend a fitting

57
Q

Is secondary containment volume equal to 110% of the largest container loaded/unloaded available?

A

Yes.

58
Q

How is liquid managed (rainwater or small spills)?

A

By 1312 sump which is sampled for TOC’s and pumped out after lab results are called in to process control room.

59
Q

Are there any admin restrictions on managing the sump?

A

Yes. Must communicate with process to pump the sump and report the sample results.

60
Q

Describe what is activated when an ESD is pushed.

A

Automatic closure of ABV and an alarm is sent to process control room.

61
Q

When you start your H-33 Checklist what important information must you write down before proceeding? List these items.

A

Railcar number, product, spot number, track number, date, tank number, tank starting level, amount to load, batch number.

62
Q

Besides the H-33, what other items do you need before loading?

A

Procedure, ppe, bulk tags, seals, tools, radio, Lims, Sample bottles, load schedule.

63
Q

After derailing the track, installing the blue flag and chocks, an inspection is done on the tank car. What are the items you are checking?

A

Inspection dates, hand brake, inspect for damage, check compression springs and shoes, railing and ladders, rail car number and stenciling, spotting position, internal/external valves, obscene or obstructive graffiti.

64
Q

What procedure do you follow if during the inspection of the tank car you find a discrepancy?

A

Current procedure being used.
Escalate to tier 4 or TA.

65
Q

Can samples be shipped with the transportation (MOT)?

A

No, all samples are given to the lab.

66
Q

If you see a pump in the wrong position, what do you do?

A

Confirm pump is in wrong position, communicate with process and return pump switch to correct position.

67
Q

Describe what can happen when a pump is left in the wrong position?

A

Dead heading, cavitation, psce, DI/DO mismatch, exposures, equipment damage, gasket/seal failure, injuries.

68
Q

Pump operating positions (Auto, Manual, and Off) are very important. For every thank that is used for rail car loading, tell what position the pump control is in Before, During, and After “Blow Back” procedures.

A

D-3009 (AEEA) - AUTO
D-3008 (V-2000) - ON,AUTO,OFF
D-3006 (MDEA) - AUTO
D-1214 (TPG) - OFF,AUTO,OFF
D-22 (LB-250) - OFF,AUTO,OFF
D-3002 (DPG) - OFF,AUTO,OFF
D-3001/4001 (PGUSP) - OFF,AUTO,OFF
D-3201A (EPH) - AUTO
D-2012/2015 (PPH) - AUTO

69
Q

How is a tank lined up for blowback?

A

Shut off pump, isolate the pump from blowback, open distribution and open recycle line to blowback. Close distribution and open pump discharge mbv to line up to recycle and return pump switch to correct position.

70
Q

Why do we blow back certain products?

A

Thermal expansion and to keep them from freezing in the lines.

71
Q

Certain products need to be blown back through the distribution line , recycle line , and into the tank when loading is complete. What are those products and their tank numbers?

A

AEEA D-3009
V-2000 D-3008
MDEA D-3006
TPG D-1214
LB-250 D-22

72
Q

What is the procedure for lining the tank up for distribution?

A

Verify tank has been released, verify valve positions, turn on pump, open distribution valve, throttle back recycle.

73
Q

What are the tank #’s and names of products that are loaded into rail cars?

A

D-3001/4001 - PGUSP/PGI
D-3002 - DPG
D-3006 - MDEA (GASSPEC)
D-3008 - V2000
D-3009 - AEEA
D-1214 - TPG
D-22 - LB250
D-2012/2015 - PPH
D-3201A - EPH

74
Q

What containment exists for a spill from a rail car?

A

The ditch under the load spots that drains to 1312 sump.

75
Q

What are the reportable quantities for any spills of material being loaded into rail cars?

A

Any amount is to be reported to tier 4/TA.

76
Q

Describe the correct procedure to secure a railcar.

A

Teflon all bull plugs, confirm internal/external, loading/vent valves are all closed, ensure manway is tight and dome lid is closed, install all seals and bulk/product tags, remove fall protection and raise carbis rack, wash off r/c.

77
Q

Who is responsible for securing a railcar?

A

Operator who signs H-33.

78
Q

When is “Active in Attendance” required while loading a rail car?

A

Every load. 100% attendance is required during last 10klbs of load and when no secondary overfill protection is being used.

79
Q

When the tank car has been loaded and sealed, what are the steps you take to complete the job?

A

Wash off r/c, secure carbis rack, tie down load hose, pull wheel chocks, line out tank, turn off blue light, remove derail and lower blue flags, complete paperwork.

80
Q

Who should you call if a spill occurs?

A

IRL

81
Q

List the special loading requirements for all food grade loads. What are your sample points on food grade loads?

A

Must be clean shaven, R/C arrives sealed, dedicated fittings, closed dome load, sample point at internal/external valve, heel must be sampled before loading, final sample must be in 16oz bottle, R/C must be sealed with return seals when loaded.

82
Q

What items on the H-33 are you responsible for completing?

A

R/C info/date section, All steps on H-33 that apply to current task, if steps don’t apply they should be marked N/A, no steps should be left blank.
Loading/unloading sections, prep, before, during, after, blue flag/light/derail etc.

83
Q

How must Camlock dog ears be secured when in use?

A

In locked position with a one-plus strap.

84
Q

Name some reasons why you should not load a rail car.

A

Wrong R/C #, expired test dates, not enough product in tank, damage to r/c, missing fittings, internal valve damaged or leaking by, obscene graffiti.

85
Q

What is the maximum gross weight allowable on a tank car?

A

263K/286K Jumbo R/C

86
Q

How do you check the tank car for pressure? When do you do this?

A

Staying out of the line of fire, remove bull plug on vent valve per procedure, install muffler, slowly open vent valve to release pressure. Performed before loading/installing fittings, and before draining heel.

87
Q

The three products unloaded at the unload rack are EDA, MA, and OLOA 200. What is the specific PPE used for each of those products?

A

OLOA - Regular PPE w/Nitrile gloves during LEO
MA/EDA - Regular PPE for non LEO,
FF-Respirator, slicker suit, rubber boots, neoprene gloves for LEO’s

88
Q

What are the potential hazards that could occur when unloading these products?

A

Chemical Exposures, PSCE/Title 5, Ergonomic strain, overfilling tanks, heat stress, injuries.

89
Q

What must be done to all bull plugs even if not used before the MOT leaves?

A

Teflon wrapped and tool tight.

90
Q

How can you prevent these potential hazards from becoming real hazards?

A

Verifying tank levels before unloading, staying out of line of fire, wearing proper PPE, inspecting all gaskets and equipment before use, proper ergonomics, proper tools for the job, limiting time exposed to hazards and heat stress, follow procedure, know safe operating limits for task.

91
Q

When do you put on your slicker suit?

A

Before LEO during connecting/disconnecting, during leak check, and until all open lines are secured.

92
Q

When the unloading is complete, what are the final tasks you accomplish to finish the job?

A

Secure all openings/verify all valves are in proper position, secure carbis rack, secure hoses, remove chocks, remove ground cables, dispose of PPE, remove derail, lower flag, shut off blue light, circulate and sample 1312 sump, complete all paperwork and H-33.

93
Q

For the following products listed below be able to list: Tank, ISO, or Railcar in regards to origin of product and be able to list all the destinations of each product.
MA
OLOA 200
EDA

A

MA-From R/C to D-2A/2B
OLOA-Frome R/C to D-1254
EDA-From R/C to D-870/871

94
Q

In the tank car unload area there is a covered garbage can marked “Non-Hazardous Waste”. What can be discarded there?

A

Household trash.

95
Q

You are scheduled to offload an MA R/C. The level in the MA storage tanks D-2A/2B are 40% and 41%. Would you offload the R/C now?

A

No, only offload once the levels are less than 35%.

96
Q

You are scheduled to offload an EDA R/C into tanks D-870/871. The levels read 46%. Can you unload the R/C?

A

No, only offload once the levels are less than 35%.

97
Q

What is the requirements around 19” gaps and how do we mitigate the hazard?

A

Required to follow TEEW policy guidelines, and use administrative controls.

98
Q

If the sign becomes tattered and illegible on any labeled containers, who is responsible for replacing it?

A

The operator.

99
Q

Explain the sump sampling procedure.
What must be done?
How long does it take to generally get back the sample results?
Who do you call to have it pumped? Who can give you the go ahead to unload before the sump is pumped?

A

When sump is at 50% or higher after offloading MA.
1 hour and 30 mins.
Process, permission is needed and sample results must be provided.

100
Q

How often do you take a job procedure with you when unloading these products?

A

100% of the time.

GPG RAILCAR LOADS/UNLOADS IPT (2 decks)

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