1. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 1 Unloading propane railcars requires well-trained and qualified persons. They must be knowledgeable in handling hazardous materials and understand the bulk plant and its procedures. In this module you will learn to identify: 1.Regulatory requirements relating to railcar unloading 2.Safety precautions related to the transfer of propane from railcars 3.Positioning the railcar/spotting procedures 4.and check the valves and fittings used in unloading the railcar 5.Procedures for unloading the railcar 6.Unloading and releasing procedures 3.6.5 Unloading Propane Railcars Using the Plant Compressor

2. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 1 Identify regulatory requirements relating to railcar unloading The transportation of hazardous materials is regulated under Title 49 of the Code of Federal Regulations (CFR). The Department of Transportation (DOT) defines hazardous materials as “materials which pose an unreasonable risk to health and safety or property when transported in commerce.” DOT regulations require employers to train and test every employee directly involved in the transportation of hazardous materials. This requirement also includes personnel who inspect, load or unload pressurized railcars used in LP-gas transportation.

3. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 1 & 2 Identify regulatory requirements relating to railcar unloading Some specific regulations that are pertinent include: 49 CFR §173.31, Qualifications, Maintenance, and Use of Railcars 49 CFR, Part 172, Subparts H Training, and I Security Plans 49 CFR, Part 174, Carriage By Rail, Subparts A, B and C 49 CFR Part 179, Specifications for Railcars and §179.7 Quality Assurance Program 49 CFR §180.509, Requirements for Inspection and Test of Specification Railcars

4. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 1 & 2 Identify regulatory requirements relating to railcar unloading Other regulations or standards adopted by reference that may apply Include : AAR, Manual of Standards and Recommended Practices, M-1002, Appendix C, Railcar Marking Requirements AAR, Field Manual Rules, 70, 88, 89, and 90 CGSB 43.147-97 Abbreviations: AAR — Association of American Railroads CGSB — Canadian General Standards Board

5. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 2 Identifying Safety Precautions Related to the Transfer of Propane From Railcars The following are precautions that apply : Remove all sources of ignition from the transfer area before beginning the railcar unloading operation. A minimum 18 pound B:C fire extinguisher must be accessible to and within the work area of the unloading operator. NFPA 10 states an extinguisher must be “conspicuously located where they will be readily accessible and immediately available, preferably along normal paths of travel including exits from areas.” Wear heavy vinyl gloves, eye protection, and other appropriate personal protective equipment (PPE) during the entire unloading operation. Never drag a hose connector or hose-end valve across the ground, railcar walkway or riser platform.

6. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 2 Identifying Safety Precautions Related to the Transfer of Propane From Railcars The following are precautions that apply : Never carry a valve by the handwheel or operating lever. Always carry it by the valve body with the outlet pointed away from the body. Never leave the transfer operation unattended. If you must leave the area for any reason except an emergency, always stop the compressor, close all valves, and disconnect and stow all transfer hoses. Be sure of the following conditions railcar wheels are chocked railcar brakes are set derail is set to the derailing position railcar and spur entrance(s) are flagged rail car is inspected product identity and quality is verified before making hose connections

7. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 3 Identifying Safety Precautions Related to the Transfer of Propane From Railcars The following are precautions that apply : If a leak or fire occurs during the transfer operation, close the plant emergency shutoff valves (ESVs) from a remote emergency shutdown station, and shut down the compressor immediately. Do not unload a railcar with obvious mechanical defects or damage. Do not stand or place any body part directly above the slip tube (gauge rod) when using it—internal pressure may force the rod upward with considerable force and cause severe injury.

8. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 3 Identifying Safety Precautions Related to the Transfer of Propane From Railcars CAUTION: Use extreme care when working around the railcar sampling valve, outage gauge and relief valve. Comply with all applicable company safety and operating procedures for railcar unloading and be thoroughly familiar with emergency plans and equipment.

9. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 4 Identifying Positioning the Railcar and Spotting Procedures Inspect the Tank Car: Attach the bill of lading to the clipboard and walk completely around the tank car. Check the tank and head shields for fresh dents or gouges, and structural damage. If significant damage is found or leaks of any kind, notify the supervisor at once. Check the tank to be sure it is marked PROPANE or LIQUEFIED PETROLEUM GAS. {3.6.5.7} And carries FLAMMABLE GAS placards in holders on each side and at each end. Check the tank car identification of serial number to make sure it matches the number shown on the bill of lading.

10. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 4 Identifying Positioning the Railcar and Spotting Procedures Inspect the Tank Car: Check the deign information on the tank to be sure it shows one of the approved DOT design codes for tank cars. The markings are usually stenciled onto the tank immediately beneath the identification number, but occasionally they may be found stamped into the metal at the centers of the tank heads. In either case, they should specify one of the following DOT design codes: 105A-, 112A-, 112J-, 112T-, or 114A-. If the tank car is improperly marked or the tank identification number does not match the one shown on the bill of lading, notify the supervisor at once. Climb the unloading riser and lower the platform to gain access to the dome and tank car openings. Caution: Be sure the platform is properly seated and secured before crossing over to the tank car. Exercise caution when climbing or working on the riser, especially in wet or icy weather.

11. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 4 Identifying Positioning the Railcar and Spotting Procedures Inspect the Tank Car: Examine the seal on the dome lid carefully for evidence of tampering. If the seal has been broken or tampered with in any way, notify the supervisor. Otherwise, clip the seal, attach it to the clipboard along with the bill of lading, and open the dome. Caution: Before opening dome, be sure that all sources of ignition have been removed from the area. Also, avoid creating sparks when opening or working in the dome. If one of the fittings is leaking, the dome may be filled with propane vapor.

12. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 4 Identifying Positioning the Railcar and Spotting Procedures Inspect the Tank Car: Inspect the valving inside the dome carefully for leaks, damage, and missing parts. Be sure all fittings are tightly plugged and that valves, operators, and gauges are free from damage that would create a hazard during unloading. NOTE: If there is evidence of a leak inside the dome, locate the source and correct if possible. Generally, leaks from valve openings can be stopped by fully closing the valve. Leaks from the packing on the slip tube gauge or on valve operators can be corrected by tightening the packing nut with an adjustable wrench. All other leaks-from the relief valve, the flanges of liquid or vapor valves, or any other source that communicates directly with the inside of the tank- should be reported the supervisor immediately and noted on the “bad order” tag enclosed in the dome. Never attempt to unload a tank car if it has a leak that cannot be corrected.

13. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 5 Identifying Positioning the Railcar and Spotting Procedures Inspect the Tank Car Inspect the safety appliances such as hand brakes, running boards, and handrails Caution: Keep eyes, face and other parts of the body away from the relief valve opening when working in the dome.

14. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 5 & 6 Identifying Positioning the Railcar and Spotting Procedures Gauge and Test the Contents of the Tank Car In order to “sniff” test and gauge the contents of the tank car: Conduct a “sniff” test on the propane by quickly opening and closing the sampling valve to vent a small amount of liquid to the atmosphere. If the presence of odorant cannot be detected or if large amounts of water appear at the valve opening during the sniff test, notify the supervisor before continuing the operation. Check for leaks around the plug on the thermometer well, then remove the plug with a wrench. Caution: If propane begins to escape around the plug threads, retighten the plug and fill out a “bad order” tag. DO NOT REMOVE THE PLUG.

15. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 5 & 6 Identifying Positioning the Railcar and Spotting Procedures Gauge and Test the Contents of the Tank Car In order to “sniff” test and gauge the contents of the tank car: Check the fluid level in the thermometer well. If necessary, “top up” the well with antifreeze or light oil (Do not use water). Then carefully lower a glass-tube thermometer in the well for at least ten minutes, then withdraw it just far enough to read the scale. Record the reading and repeat the process to check the accuracy of the first reading. Record the final result on the bill of lading or the company unloading form. Replace and retighten the thermometer well plug.

16. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 6 Identifying Positioning the Railcar and Spotting Procedures Gauge and Test the Contents of the Tank Car In order to “sniff” test and gauge the contents of the tank car: Carefully remove the threaded cover from the slip gauge assembly If possible, correct leaks by fully closing the bleeder valve on the gauge and/or tightening the packing nut at the bottom of the slip tube with a wrench. If the leak continues, notify the supervisor Caution: If propane begins to escape around the threads or the cover binds as it is unscrewed, do not remove it the rest of the way unless the leak can be controlled for sure when the cover is fully removed.

17. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 6 Identifying Positioning the Railcar and Spotting Procedures Gauge and Test the Contents of the Tank Car In order to “sniff” test and gauge the contents of the tank car: Push down firmly on the slip tube and release the locking bar. Then, slowly release the brake and allow the slip tube to rise two to three feet. Re-engage the brake. Never use any tools to pry or pull up the slip tube. If the slip tube is difficult to release, apply a small amount of light oil to the tube and twist the tube from side to side as it is raised. If it continues to stick, loosen the packing nut until the slip tube moves freely. Caution: All slip tubes are under high pressure and can cause serious injuries if allowed to shoot out suddenly or unexpectedly. Keep a firm grip on the gauge at all times and assume a position so that head and body are well away from the gauge.

18. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 6 & 7 Identifying Positioning the Railcar and Spotting Procedures Gauge and Test the Contents of the Tank Car In order to “sniff” test and gauge the contents of the tank car: Open the bleeder valve slowly until a mist of propane liquid (i.e., white mist) vents from the valve. Continue raising the slip tube until the vapor vents from the bleeder valve. Then slowly lower the tube again until liquid just begins to vent from the bleeder valve. At this point, the bottom of the slip tube is in contact with the surface of the liquid in the tank car. Apply the slip tube brake and read the outage on the slip tube directly opposite the pointer. Repeat the measurement at least twice to be sure it is correct. Record the final reading on the bill of lading or the company unloading form. Convert the slip tube reading to gallons, using the strapping table for the tank car. Subtract the outage in gallons from the water capacity of the tank car and record the result on the company unloading form.

19. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 6 & 7 Identifying Positioning the Railcar and Spotting Procedures Gauge and Test the Contents of the Tank Car In order to “sniff” test and gauge the contents of the tank car: Correct the tank car gallonage for temperature and specific gravity by multiplying it by the appropriate volume correction factor. The correction factor can be obtained from the company unloading forms or a chart attached to the strapping table. Compare the result to the gallonage recorded on the bill of lading. Follow company procedures for reporting discrepancies. Close the bleeder valve on the slip tube tightly, lower the gauge, and lock it into place. Replace the gauge assembly cover. Once these tests and inspections are complete and you are assured there are no leaks or tank car damage that would cause the car to be rejected, the preparation to unload can continue.

20. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 7 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Figure 1. The Manway Cover

21. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 8 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Figure 2. Alternate Railcar Valves and Fittings Arrangement

22. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 8 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Figure 3. Side View and Top View of Valves and Fittings Courtesy union railcar and BP

23. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 9 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Figure 4. Cut-Away View of Manway And Tank Interior The railcar fittings in Figures 2 and 3 are further explained in the cut-away view to the right (Figure 4.). This illustration shows how the various valves and fittings interact with the interior of the cargo tank.

24. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 10 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Liquid and Vapor Connections The outlets of the two liquid valves face the ends of the railcar Thermometer Well Sampling Valve The sampling valve is a small manual shutoff valve attached to a long open tube that leads to the bottom of the railcar. It is used to test the contents of the railcar for odorization, the presence of water or other impurities, and, in rare cases, to measure the specific gravity of the propane. It can also be used during the unloading operation to determine whether any propane liquid remains in the bottom of the tank

25. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 10 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Figure 5. Slip Tube Gauge Slip Tube Gauge Most railcars are equipped with a slip tube gauge (Figure 5), which is used to measure the contents of the railcar. The slip tube gauge is similar to a fixed maximum liquid level gauge. However, the dip tube is not fixed, but can be moved up and down in the gauge housing to

26. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 10 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Pressure Relief Valves Never tamper with it and never work directly over it Unloading Risers To gain access to the top openings in railcars, most plants use an unloading riser (also known as a tower).

27. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 11 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Identifying Procedures for Unloading the Railcar Gauge Contents of Railcar A series of graduated markings on the slip tube indicates the distance in inches and feet from the top of the tank to the surface of the liquid. This is commonly referred to as the "outage" of the railcar. Figure 6. Portion of a Railcar Outage Table

28. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 12 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Determine the Maximum Amount of Propane That can be Transferred to the Plant Bulk Storage Tanks To determine the amount of propane each plant tank will hold safely: Gauge the contents of the plant storage tank with the rotary or float gauge installed in the tank head. Record the reading on the company form or on a worksheet. Using the temperature and specific gravity of the propane in the railcar, determine the maximum permitted filling level for the plant tank(s). Record the result on the worksheet. Subtract the gauge reading from the maximum permitted filling level.

29. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 12 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Determine the Maximum Amount of Propane That can be Transferred to the Plant Bulk Storage Tanks To determine the amount of propane each plant tank will hold safely: Calculate the maximum amount of propane that can be added to the storage tank by multiplying the difference between the two numbers by the water capacity of the tank in gallons. If, for example, the gauge on a 30,000 gallon storage tank shows that it is 40% full and its maximum permitted filling density at the present temperature is 85%, 45% X 30,000 or 13,500 gallons can safely be added to the tank. If there is more propane in the railcar than the plant tank(s) will hold safely, notify your supervisor.

30. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 12 & 13 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Connect Liquid and Vapor Hoses Between the Railcar and the Unloading Riser To gain access to the top openings in railcars, most plants use an unloading riser, also known as a tower. (Figure 7) Figure 7. Railcar Riser with Emergency Shutoff Valves

31. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 13 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Figure 8a. Stub Connected to Vapor Valve Figure 8b. Connecting Hose to Stub in Liquid Valve Connect Liquid and Vapor Hoses Between the Railcar and the Unloading Riser During unloading operations, a railcar unloading nipple (also known as a “stub”)—essentially a straight section of schedule 80 threaded piping—is inserted through the holes in the side of the dome and screwed into the valve outlets after the valve shipping plugs are removed. (Figure 8.)

32. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 14 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Connect Liquid and Vapor Hoses Between the Railcar and the Unloading Riser In order to complete this step: Check the manual shutoff valves on the railcar liquid and vapor connections to make sure they are fully closed. Then carefully remove the plugs Install unloading stubs or ESVs in the liquid and vapor valves. Thread the stubs or ESVs into the valve opening until they are handtight. Then tighten them with the appropriate wrench until they are securely seated. Once installed, open the ESVs in accordance with company procedures. Caution:Propane may vent around the plug threads for a short time. Wear heavy vinyl safety gloves throughout the operation and keep face and other parts of the body away from the valve opening. If propane continues to vent around the plug threads, the manual shutoff valve may be faulty. Retighten the plug and notify the supervisor. If the chains on the plugs are broken or missing, store the plugs in a safe place.

33. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 14 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Connect Liquid and Vapor Hoses Between the Railcar and the Unloading Riser In order to complete this step: Remove the dust caps from the connectors on the riser hoses. Check the connectors to be sure they are clean. Check the O-rings on the ESV or unloading stub to be sure they are in good condition. If necessary, clean the connectors with a rag and replace worn, flattened, or damaged O-rings. Connect the hoses to the railcar stubs or ESVs by spinning on the ACME connectors until they are handtight. As the connectors are tightened, move the hose or hose-end valve up and down slightly to prevent the thread from seizing. When each connection is handtight, tighten it an additional 1/8 turn with a hook spanner. NEVER POUND ON THE CONNECTOR WITH A WRENCH OR OTHER DEVICE.

34. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 14 & 15 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Connect Liquid and Vapor Hoses Between the Railcar and the Unloading Riser In order to complete this step: Check the ESVs at the riser by opening and closing them according to plant test procedures. Be sure the remote operators are working properly and that all fusible links are intact. If the ESVs will not operate properly, do not continue the transfer operation. If possible, correct the problem. Otherwise, notify your supervisor. Check each connection for leaks by opening and closing the manual shutoff valve at the railcar to charge the connection with propane. Note: If using ESV's instead of unloading stubs, open the ESV to charge and test the hose connection. If there are any connection leaks, close all valves and retighten the connection. If the leak continues, notify your supervisor.

35. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 15 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Unload the Railcar A qualified person must be present during the entire transfer operation to handle emergencies and monitor the condition of the transfer system. If leaving the area, find someone as a replacement who has a working knowledge of the transfer equipment and plant emergency procedures. Otherwise, shut down the operation until returning. If a leak or fire develops at any time during the operation, close all ESV's immediately and stop the compressor. Then follow company procedures to handle the problem. Be alert throughout the operation for signs of erratic compressor operation. If a problem develops, shut down the operation and correct it before continuing.

36. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 15 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Unload the Railcar An excess-flow valve in an eduction valve or the plant tank may stick or freeze shut. As a result, it will not reopen when the pressure is equalized across the valve. If this happens during unloading operations, reopen the valve by applying compressor discharge pressure to the stuck excess-flow valve. If the excess-flow valve is in a vapor connection, it is reopened simply by reversing the four-way valve and restarting the compressor

37. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 16 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar To unload the railcar : Open the vapor valves at the riser. Then, open all valves in the liquid line, starting at the manual shutoff valves on the railcar and working toward the plant storage tank(s). Allow as much liquid as possible to drift between the two tanks, then open the remaining valves in the vapor line. Check to be sure the four-way valve and the plant valves have been set so the compressor will remove vapor from the plant storage tank and discharge it into the railcar. Figures 10 and 11 illustrate the compressor 4-way valve and piping positions for unloading in a typical bulk plant. Your plant piping may be different. Be sure you verify the proper valve positions and operating procedures for your plant. Note: Open valves slowly to prevent excess-flow valves from slugging

38. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 16 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Figure 9. Compressor and Bulk Plant Connections and Valves Figure 10. 4-Way Valve Positions 4-Way ValveValve AValve BValve C Position OneOpen Close Figure 11. Operation of Valves for Cargo tank Unloading

39. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 16 & 17 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar To unload the railcar : Start the compressor and check the pressure gauges for excessively high exhaust or excessively low intake pressure. If either occurs, stop the compressor and correct the problem before continuing. Check the sight glass or flow indicator to make sure liquid is flowing through the system. When the plant storage tank reaches its maximum permitted filling level or the railcar is empty, close all valves in the liquid line and stop the compressor.

40. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 16 & 17 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar To unload the railcar : Reverse the four-way valve and adjust the plant piping manifold so the compressor will withdraw vapor from the railcar and force it through the liquid space of the plant storage tank. (Figures 12b and 12c.) Restart the compressor and check the pressure gauges for excessively high discharge or excessively low intake pressure. If either occurs, shut down the compressor and correct the problem before continuing. At the end of the vapor recovery operation, close all valves in the vapor line and shut down the compressor. Some plants shut down the compressor when the discharge pressure rises to four times the intake pressure. Others stop vapor recovery operations when the intake pressure drops to 50 psi in the summer or 30 psi in the winter. Under some conditions plants will also shut down their compressors, if the intake pressure drops less than 10 psi during 15 minutes of operations. Check with your supervisor for the proper guidelines to follow

41. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 17 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Figure 12a. Compressor and Bulk Plant Connections and Valves Figure 12b. 4-Way Valve Positions 4-Way ValveValve AValve BValve C Position TwoCloseOpen Figure 12c. Operation of Valves for Cargo Tank Vapor Recovery Note: Monitor the liquid gauges on the plant storage tank(s) carefully to prevent overfilling

42. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 18 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Open the sample valve. If vapor is released, the railcar is totally unloaded. If liquid escapes, it may not be fully unloaded. Resume unloading operations until the railcar is totally un- loaded. Close all railcar discharge valves, ESVs and transfer hose-end valves. Vent the propane trapped between valves, stubs and hose couplings. When the connections are fully de- pressurized, disconnect the transfer hoses. Remove the railcar unloading nipples, or “stubs”, that are screwed into the railcar valve outlets To finish the operation and prepare the railcar for return: Figure 13. Checking the Sample Valve

43. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 18 & 19 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Replace all railcar valves openings and tighten as appropriate. (Figures 14 and 15) To finish the operation and prepare the railcar for return: Figure 14a. Preparing Plug Threads Figure 14b. Installing Plug in Slip Tube Gauge Figure 15. Tightening Plug in Discharge Valve

44. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 19 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Replace and secure all covers over fittings. (Figure 16) Check to be sure there is no liquid left in the railcar by partially opening the sampling valve Bleed down and disconnect the hoses at the riser. Replace all dust caps and store the hoses Remove the unloading stubs or ESVs from the railcar, and replace the plugs in the liquid and vapor valve openings To finish the operation and prepare the railcar for return: Figure 16. Replacing Fitting Cover Caution: Never disconnect any hose until the propane trapped in the connection has been safely bled off.

45. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 20 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar If any railcar defects were found during the unloading operation, complete the “Bad Order Tag” (Figure 17) and attach it to one of the liquid education valves. Lower the dome cover and secure it appropriately. Stow all transfer hoses and fittings and raise the unloading riser platform to its stored position Identifying Unloading and Releasing Procedures: NOTE: The same defect(s) must be reported in the Railcar Return Form. Figure 17. “Bad Order Tag”

46. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 20 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Identifying Unloading and Releasing Procedures: Remove and store the warning signs, chock blocks and reset the derail (when used) from the derailing position. (Figure 18) Figure 18a. Removing ChocksFigure 18b. Stowing Warning Sign and Resetting Derail NOTE: DO NOT release the hand brake on the railcar. This will be done by railroad personnel when the railcar is picked up.

47. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 21 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar Verify that all placards are in good shape and in place. (Figure 19) Take an extra look around the railcar and unloading site to make sure everything is safe and secure. Complete the Railcar Return Instructions Form and deliver the form to the rail carrier representative. Identifying Unloading and Releasing Procedures: Figure 19. Replacing Damaged Placard CAUTION: Whether loaded or unloaded, a railcar is hazardous. Unless it has been thoroughly purged and cleaned, there is no such thing as an empty railcar. Even un-loaded to the maximum extent possible, it still contains propane. Therefore, whether a propane railcar is loaded or unloaded, all safety and hazardous materials handling regulations must be observed.

48. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 22 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar The Railcar Return Instruction Form must be prepared, signed and presented to the rail carrier representative for their signature before the railcar is released. Figure 20. Sample Railcar Return Instructions Form

49. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 22 & 23 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar While completing the Railcar Return Instructions Form, the propane marketer’s representative should : Verify the date entry when the company was notified of the railcar’s arrival, when it was received on the siding, and when unloading was completed. On the Company Copy of the railcar return form, enter the date when the car was removed from the siding. Retain it in company records. List in the remarks section any defect(s) that were present when the car was received Determine if any defect(s) occurred or was discovered during the time the railcar was on the siding and being unloaded. If so, describe it in the remarks section and attach a copy to the “Bad Order Tag”.

50. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPage 22 & 23 Identifying and Checking the Valves and Fittings Used in Unloading the Railcar While completing the Railcar Return Instructions Form, the propane marketer’s representative should : Verify other information preprinted on the form, sign and date it. Deliver the Railcar Return Instructions Form personally, or by electronic means to the railroad agent, for their signature and date. {3.6.5.31} Sometimes a bulk plant employee will notify the railroad company representative by telephone or fax, and hold the form for signature until the rail car is picked up. From the time the railcar return form is used to notify the railroad company agent that the car is ready to be picked up, until the time it is actually removed from the siding, the propane marketer must provide a safe and secure environment for the railcar. Comply with any company-specific procedures for releasing a rail car after unloading. Be sure you know and follow all company rules for handling railcars.

51. 3.6.5 Student Book © 2004 Propane Education & Research CouncilPages 24 - 30 Time to See If You Got the Key Points of This Module… Complete the Review on page 24 - 27. See if you are ready for the Certification Exam by checking off the performance criteria on page 28 - 30.