Tank Car & Tank Truck Loading

Tank Car & Tank Truck Loading


  1. Care must be taken when removing plugs or caps on connection to tank cars manholes. Shut-off valves may be leaking or may not be closed tightly.
  2. All loading connections must be tight and purpose of each valve must be understood before beginning loading or unloading tank cars or tank trucks.
  3. If a leaking safety relief valve is discovered, it should be reported immediately to the supervisor in charge.
  4. When working around a relief valve, care must be tank not to place one’s head or face over the valve.
  5. Avoid skin contact with LP gas evaporates rapidly causing freezing. Treatment for injury from contact with LP gas is similar to that for burns.
  6. A constant check must be maintained on tanks, hose, valves, lines and other loading equipment to detect and prevent tanks.
  7. Dome cover gaskets must be in good condition and place when dome covers are closed on gasoline and general purpose tank cars.
  8. Employees, train crews and truck drivers, are to use only flashlights or electric lanterns approved for use in hazardous atmospheres, around loading racks. The use of open lights is prohibited.
  9. Empty tanks that have contained LP gas or gasoline are more hazardous from a fire or explosion standpoint than tanks that are full or under pressure. Sparks and flames must be kept away from all tanks.
  10. Loading spouts for gasoline must be placed against the bottom of the tank and be secured with the hold-down chain. This will minimize turbulence of the liquid and generation of static electricity in the loading stream.
  11. Adequate fire fighting equipment must be available at the LP gas or gasoline loading rack and in the loading area. Loading rack employees shall be instructed in the proper use of the equipment and what to do in case of fire.
  12. Loading operations must be discontinued during electrical storms.
  13. All swing joints on racks must turn freely at all times to avoid the kicking of loading hose. Flexible arm loading joints such as “ Chicksan” joints shall be moved only the way they are constructed.
  14. An employee must be in attendance at all times when tank cars or trucks are being loaded or unloaded except at truck loading racks where diver loading is authorized and wen authorized driver is in attendance.
  15. Smoking, open lights, or fires are not permitted within 150 feet of loading and/or unloading areas.
  16. Where H²S may be present, an approved H²S monitor is be available as well as SCBA


Tank Cars

  1. If the loading section of the track is insulated, to minimize the flow of stray currents, tank cars must be spotted on the insulated part of truck only. In no case is a tank car permitted to rest partly on insulated and partly on uninstalled track during loading or unloading operations.
  2. Tank car dome should be spotted as near to walkway in carrying loading Jose to tank.
  3. While cars are on sidetrack for loading or unloading, the tank car brakes must be set and the wheels at both ends of the string shall be blocked on the rails.
  4. Automobiles and trucks must be kept at a safe distance from loading rack  while cars are being loading.
  5. Regulation blue flag “STOP” signs must be placed one car length or more from the end of the loading rack before loading or repairing operations are started and shall remain until loading or repair is complete.
  6. Jumping from loading rack to tank cars to car is hazardous and is prohibited.
  7. Before receiving product, the tank car must be thoroughly checked for any exterior damage and to see that all Department of Transportation (DOT ) markings are legible. Safety relief valve should especially be noted. Its setting will immediately determine the service for which the car is intended. Inspect all packing nuts around valve stems and gauge tube to see if additional packing is required.
  8. Tank cars found in bad order in any way must be reported to the supervisor in charge and not be loaded until repairs have been  made.
  9. A “TANK CAR CONNECTED” sign, as covered by DOT rules, must be installed at the active end or ends of the siding while the tank car is connected.
  10. The bonding cable must be in proper contact with the tank shell before loading. Note: Tanks Must be grounded.
  11. Prior to loading LPG product, a vent line must be provided to vent pressure from tank car.
  12. Any leaks discovered during loading must be repaired or reported to the supervisor in charge immediately. Loading must be discontinued until the leak is repaired.
  13. The maximum permitted filling density of LPG tank cars must not be exceeded under circumstances.
  14. Before breaking out loading hose on LPG cars, the rack loading valves and tank car valves must be closed and the pressure vented from the hose. The vent valve shall be closed immediately after hose pressure is released to avoid a “ kick-back” of pressure from some other venting source.
  15. When loading has been completed, the loading hose is to be hooked to the loading rack out of the way. The bonding cable is to be put back in its proper place.
  16. Loading cars are to be inspected thoroughly for leaks before being approved for shipment.
  17. A tank car must not be sealed and shipped if it is leaking. The supervisor in charge must be immediately notified when such conditions are found.
  18. When no leaks are found and all connections to the tank car have been removed, raise and secure the walkway and remove the rail blocks and “TANK CAR CONNECTED” sign.
  19. Loading cars must be labeled with the placard as designated be the DOT.
  20. Employees must keep away when tank cars are being coupled or uncoupled.
  21. Any undue rough handing of tank cars on Company property whether loading or not, must be reported immediately to the supervisor in charge.


Tank Trucks

  1. Product loading lines and valves should be color-coded to aid in identifying the product to be loading.
  2. A traffic pattern should be established at each loading rack and reasonable precautions shall be taken so that incoming or outgoing trucks will not drive into a loading area contaminated with flammable vapors.
  3. The loader is to refuse to load any tank truck which is leaking or is in an unsafe condition. If there is any doubt about the condition of the truck, the supervisor in charge must be advised immediately and his approval secured before the truck is loaded.
  4. The loader is not to load any truck if the driver is obviously under the influence of drugs or alcohol, or for any reason appears unable to operate his truck safely. The supervisor in charge must be notified immediately of such condition.
  5. After the truck has been moved to loading position, the engine must be stopped. Ignition ,lights, radio, and heater fan shall be turned off and shall not be turned on again unless authorized by the loader. No switch on the truck shall be turned on or off during loading operations.
  6. The driver and any riders must leave the truck cab and shall not return to the cab unless authorized by the loader or loading is completed and truck is ready to leave.
  7. Place chocks or blocks at front and back of rear wheels of tank truck or trailer before making any loading connections.
  8. A bonding cable must be attached to tank, making sure that good metal to metal contact is obtained.Note: Tanks mist be grounded.
  9. No mechanical repairs or adjustments are be made to the truck while spotted at the loading rack.
  10. Only approved coupling are to be used for attaching the loading line to the truck.
  11. It is recommended that loose hose ends be secured when not in use to prevent the hose from flying around, should wrong valve be opened.
  12. The maximum permitted filling density is not to be circumstances.
  13. After the truck is fully loaded, loading valves must be closed and the loading pump shut down.
  14. The loading line must then be evacuated by venting into the vapor return line.
  15. The loading and vapor lines must then by disconnected, and after a few minutes delay, the bonding cable shall detached.
  16. The tank truck must then be rechecked to be sure it is not overloaded.
  17. Tank openings must then be sealed, if required.
  18. Necessary papers are to be completed, chock blocks removed, and the truck driver authorized to leave the loading area.
  19. Where diver-attended loading is authorized, authorized driver will be responsible for performing the above loading operation. Any violations of instruction, detected be a company employee, shall be reported to his supervisor as soon as possible.

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