Transcript 3.5.7 CETP Instructor PowerPoint Template

3.5.7
Loading a Bobtail
Following the proper procedures for filling
bobtails is essential to a safe and efficient
loading operation .
In this module you will learn to identify:
1. Attendance requirements during the loading
process
2. Safety procedures during the loading process
3. Steps for propane transfer using the plant pump
to fill the bobtail
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 1
Loading Attendance Requirements
U.S. Department of Transportation regulations require
that qualified persons be “in attendance” throughout the
process of loading a cargo tank motor vehicle.
The person who is responsible for loading the cargo tank is also
responsible for ensuring that it is so attended.
A person is “qualified” if he/she
• has been made aware of the nature of the hazardous
material
• has been instructed on the procedures to be followed in
emergencies
• is authorized to move the cargo tank
• has the means to do so .
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 1
Loading Attendance Requirements
Identifying Safety Procedures During the Loading Process— in
addition to the regulatory requirements, the person performing
cargo tank loading operations should be:
• In a position to monitor the filling of the cargo tank
• Alert for any abnormal operating condition or emergency
• Aware of the activities of other persons in or near the
transfer area
• In a location that allows for quick response to abnormal
operating conditions or activation of emergency
shutdown systems, and rapid evacuation from the area
should the need arise.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 1
Loading Attendance Requirements
Proper and safe procedures prior to the filling operation include:
a) Before moving the vehicle to the loading bulkhead, check
for any obstacles that might create an unsafe condition.
b) Remove the chock blocks from the wheels and store them
temporarily on the vehicle.
c) Check the PTO to ensure it is disengaged.
d) After starting the engine, ensure all instrumentation
indicates normal operation.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 2
Loading Attendance Requirements
Proper and safe procedures prior to the filling operation include:
e) Position the bobtail at the loading bulkhead in a way that
maximizes the shearing effect of the hoses and piping
should a pull-away occur. The fill connection on the cargo
tank should be at least 10 feet from the nearest bulk storage
container.
f)
Engage the parking brake and turn off the engine.
g) Place chock blocks in front and behind a rear wheel to
prevent movement.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 2
Using the Plant Pump to Fill the Bobtail
Step 1:
Position the bobtail.
Step 2:
Set the liquid level gauges on the bobtail.
• Determine the maximum permitted filling level by
obtaining the specific gravity of your propane from
shipping papers and observing the liquid propane
temperature on the thermometer located either in the
bobtail, or in the propane storage container at the plant.
• When a storage container is filled by volume, the
filling operation is stopped when the volume of the
liquid inside the container reaches a certain percent of
the container's water capacity. This is determined by a
fixed maximum liquid level gauge, which extends inside
the container and measures the level of the liquid.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 2
Using the Plant Pump to Fill the Bobtail
Fixed Maximum Liquid Level Gauge
Figure 1. Fixed Maximum Liquid Level Gauge
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 3
Using the Plant Pump to Fill the Bobtail
Variable Liquid Level Gauges
Figure 2. Rotary Gauge
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 3
Using the Plant Pump to Fill the Bobtail
• Temperature and specific gravity are essential when using
a rotary gauge. The temperature of the propane can be
determined from the thermometer installed in the supply
container. The specific gravity can be obtained from the
plant receiving records. If the specific gravity information is
not available, use 0.508 as the specific gravity for propane.
• When rotary gauges are set, they operate the same as
fixed liquid level gauges. During the filling operation,
propane vapor vents through the dip tube and bleeder valve
into the atmosphere. When the liquid in the cargo tank
reaches the bottom of the dip tube, a steady stream of white
mist sprays out of the bleeder valve, indicating the maximum
permitted filling level has been reached.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 4
Using the Plant Pump to Fill the Bobtail
Figure 3. Rotary Gauge Face
If the specific gravity of
the propane liquid is
0.508 and its
temperature is 60°, by
setting the indicator arm
so that it crosses the set
point, the maximum
filling level of 88% is
indicated.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 5
Using the Plant Pump to Fill the Bobtail
The float gauge consists
of a float in the container
that moves up and down
with the liquid.
The filling operation is
stopped when the
pointer indicates it has
reached the set point on
the gauge face.
Figure 4. Cargo Tank Float Gauge Face
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 5 & 6
Using the Plant Pump to Fill the Bobtail
Step 3:
Connect the Fill and Vapor Equalizing Hoses.
• To maintain pump efficiency when transferring liquid
between bulk storage tanks and cargo tanks the use of
the vapor equalizing hose is recommended.
• Before making the connection, make sure all sources
of ignition within 25 feet of the transfer point are
removed. Internal combustion engines within 15 feet of
the point of transfer must be shut down while transfer
operations are in progress, with exceptions as listed in
NFPA 58.
• Carefully inspect the liquid and vapor transfer hose
assemblies, using the rejection criteria. If any defect is
found, discontinue the loading operation, notify your
supervisor and do not resume loading until the defect
has been eliminated.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 6
Using the Plant Pump to Fill the Bobtail
Step 3:
Connect the Fill and Vapor Equalizing Hoses.
• Connect the liquid plant hose-end valve to the fill valve
on the bobtail.
Once the connector is hand-tight, turn the connector an
additional ¼ to 1/8 turn using a spanner wrench, tapping
the handle of the spanner wrench with the palm of a
gloved-hand.
•If leakage exists, close the hose end valve and
disconnect the ACME adapter after the connection has
bled down and is de-pressurized. Examine the condition
of the O-ring or flat gasket in the filler adapter and
replace as needed.
3.5.7 Student Book  © 2004 Propane Education & Research Council
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Using the Plant Pump to Fill the Bobtail
Figure 5a.
Excessive Thread
Wear
Figure 5 b. New ACME Thread Profile &
Worn ACME Thread Profile
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 7
Using the Plant Pump to Fill the Bobtail
Step 4:
Sniff Test to Verify Propane Odorization.
• DOT regulations and NFPA 58 require that propane be
odorized prior to transportation to the bulk plant. As a
verification of odorization, vent a small quantity of liquid
through a #54 vent. Close the vent and sniff immediately
after the liquid vaporizes.
• If you cannot smell propane odorant – DO NOT LOAD
THE Bobtail. Contact your supervisor immediately after
disconnecting and securing the transfer hoses in their
storage racks. TELL OTHERS IN THE AREA NOT TO
LOAD UNTIL APPROVED BY THE FACILITY MANAGER
OR SUPERVISOR .
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 7 & 8
Using the Plant Pump to Fill the Bobtail
Step 5:
Fill the Bobtail.
• A qualified person must be present at the transfer point
to handle emergencies and monitor the condition of the
transfer system at all times while hoses are connected.
• Ensure all liquid and vapor valves are fully open in the
transfer piping between the plant storage containers and
the bulkhead and on the cargo tank.
• Start the plant transfer pump. Listen for any unusual
pump noise.
• Continue the transfer process until a steady white mist
fog is first emitted from the gauge vent valve, then
immediately shut down the pump, close the ESVs and the
hose end valves.
3.5.7 Student Book  © 2004 Propane Education & Research Council
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Using the Plant Pump to Fill the Bobtail
Step 5:
Fill the Bobtail.
• If a leak or fire develops and it is safe to do so, close all
ESVs immediately and stop the pump by moving quickly
to a remote emergency shutdown station and activating
the emergency shutdown control.
Stay away from the transfer area so long as leaking gas
or fire is present. Warn others in the bulk plant.
AVOID BECOMING TRAPPED OR ALLOWING OTHERS
TO BECOME TRAPPED WITHIN FENCED AREAS WHERE
LEAKING GAS IS PRESENT.
3.5.7 Student Book  © 2004 Propane Education & Research Council
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Using the Plant Pump to Fill the Bobtail
Step 6:
Disconnect the Transfer Hoses and Prepare
the Bobtail for Travel.
If for any reason the transfer operation is interrupted, or the
attendant must leave the area, the pump must be shutdown
and transfer hoses disconnected. DO NOT leave transfer
hoses connected to a Bobtail while unattended by a
qualified person.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Page 9
Time to See If You Got the Key Points of
This Module…
• Complete the Review on page 10 & 11.
• See if you are ready for the Certification
Exam by checking off the
performance criteria on page 12 &
13.
3.5.7 Student Book  © 2004 Propane Education & Research Council
Pages 10 - 13