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DEF Handling Design Loading and Installation Experts
SafeRack takes worker safety very seriously and offers a full range of products and equipment designed specifically to reduce the risks associated with DEF transportation while improving loading and unloading throughput.
Operator and Environmental Safety – SafeRack has been providing safe, reliable platforms, handrails, and gangway solutions to the chemical industry for many years. From multifaceted fall prevention retrofits to new builds, SafeRack’s priorities are operator and environmental safety while still focusing on creating an efficient and productive solution that allows a significant return on investment.View Full Text
Typical DEF Loading Platform
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Below are some of the loading and unloading solutions for illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs.
DEF Loading Arms
DEF is typically loaded into railcars via chemical hoses or loading arms.
The current best loading practice is to use a 3″ chemical hose or a carbon steel loading arm with quick-acting coupling, often in the form of Hammer Unions with stabber pipe. The chemical hose or loading arm will have a top inlet with a control valve to ensure that it is self-draining after use and is supported along the length of a mechanical loading arm to improve handling; this is known as a by-pass arm. You can install one liquid and one vapor arm, or mount both the liquid and vapor hoses on one by-pass arm.
Break-away couplings can be fitted near the inlet of the hose for additional safety in the event of a premature departure.
Loading Gangways and Safety Cages
A wider access gangway (36″- 48″ is preferable) as it helps improve access and egress to and from the vessel. In addition, a wider gangway will reduce the risk of the operator’s PPE getting caught, torn or damaged, and will improve productivity and safety. Powered gangway solutions are also an option, with both hydraulic and pneumatic solutions being commonly used.
Each gangway will be fitted with a two-rail safety cage for the railcar crash box. This will be a centered 6’x8’ safety cage to sit directly over the cashbox. This will provide a safe, secure work environment for your operator when connected to their breathing apparatus
GX SELF-ADJUSTING STAIR (SAS) GANGWAY
SafeRack’s NEW GX SAS gangways uses Retractalok power-assist technology allowing operators to raise or lower effortlessly, light as a feather to lift, solid as a rock. Tested in the most critical applications, this revolutionary new gangway outperforms all others. Available in multiple lengths and widths. Learn More
DEF Eye Wash/Drench Showers
ANSI guidelines state that an Eye Wash/Drench Showers need to be located 10 seconds or 55’ (16.8m) from contaminants or hazardous materials.
Eyewash stations need to be on the same horizontal plane with no obstructions.
Therefore, we would propose the installation of a standard combination Drench Shower/Eyewash Unit, which will save limited space and fit easily into any work environment.
DEF Spill Containment
Spill containment pans will be provided at the point of loading operations and is an essential piece of equipment in overall site safety and environmental protection
While not highly flammable, high airborne concentrations can be ignited and pose a significant fire and explosion hazard, especially in confined spaces. Steel containers or vessels of ammonia may also explode when subject to excessive heat or high temperatures. Industry best practice includes the grounding of all vessels prior to starting the (un)loading process.
- Ground controllers — ensure true grounding before product flow is permitted
- Explosion-proof enclosures — meet or exceed UL, CSA and Ex requirements
Safety Gates DEF Loading Applications
Safety Gates will be installed at the top of stairs and any other openings to ensure operator safety at all times.
YellowGate Safety Gates
SafeRack’s line of industrial safety gates is the most flexible product on the market with the ability span openings between 16” and 36” and is field adjustable with nothing more than a wrench. Learn More
DEF Loading Platform Options
- Lighting – Lighting both over and under the platform will be provided. For overcast days or second shift, lighting is essential for improved safety and improved productivity.
- Platform & Canopies – Full platform canopies reduce exposure to the elements and improve the safe and productive loading operation from the operator’s perspective.
- Operator Shelter – Depending on your site requirements, consideration should be given to the requirement of an operator or guard building on the loading platform. This can be customized to meet specific site requirements
- Wheel Chocks – Railcar Wheel Chocks provide fast blocking of all types of railcars and meet OSHA regulations to safely prevent railroad cars from moving during loading or unloading operations. This is a requirement by the Department of Homeland Security
Personal Protective Equipment PPE Requirements
Eye/Face Protection: Wear chemical safety goggles. A face shield (with safety goggles) may also be necessary.
Skin Protection: Wear chemical protective clothing e.g. gloves, aprons, boots. Coveralls or long sleeve shirts and pants in some operations. Wear a chemical protective, full-body encapsulating suit, and self-contained breathing apparatus (SCBA). Suitable materials include butyl rubber, neoprene rubber, Viton®, Viton®/butyl rubber, Barrier® – PE/PA/PE, Silver Shield® – PE/EVAL/PE, Trellchem® HPS, Trellchem® VPS, Saranex®™, Tychem® BR/LV, Tychem® Responder® CSM, Tychem® TK. The following materials should NOT be used: natural rubber, polyvinyl chloride. Recommendations are NOT valid for very thin neoprene rubber gloves (0.3 mm or less).
Respiratory Protection: Up to 5 ppm:
(APF = 10) Any chemical cartridge respirator with cartridge(s) providing protection against chlorine*; or Any supplied-air respirator*.
*Reported to cause eye irritation or damage; may require eye protection.
APF = Assigned Protection Factor
Recommendations apply only to National Institute for Occupational Safety and Health (NIOSH) approved respirators. Refer to the NIOSH pocket guide to chemical hazards for more information.
Use local exhaust ventilation and enclosure, if necessary, to control the amount in the air. Consider using a corrosion-resistant exhaust ventilation system separate from other ventilation systems. It may be necessary to use stringent control measures such as process enclosure to prevent product release into the workplace. Use backup controls (e.g. double mechanical pump seals) to prevent the release of this material due to equipment failure. * For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs
We recommend that you also refer to the Chlorine Institute, found at chlorineinstitute.org. The Chlorine Institute (CI) was founded in 1924 and is a technical trade association of companies involved in the safe production, distribution and use of chlorine, sodium and potassium hydroxides and sodium hypochlorite, the distribution and use of hydrogen chloride and the distribution of vinyl chloride monomer.
Things to know about Diesel Exhaust Fluid (DEF)
DEF, also known as AUS 32, is mixture of (typically) 2/3 deionized water and 1/3 urea… The hot exhaust gas and DEF then enter the catalytic converter where the urea from the DEF and the exhaust gas react with a variety of metallic compounds to convert dangerous nitrogen dioxide and monoxide into harmless nitrogen and water.
Diesel engines can be run with a lean burn air-to-fuel ratio (overstoichiometric ratio), to ensure the full combustion of soot and to prevent their exhausting unburnt fuel. The excess air necessarily leads to generation of NOx, which are harmful pollutants, from the nitrogen in the air. SCR is used to reduce the amount of NOx released into the atmosphere. DEF from a separate tank is injected into the exhaust pipeline. Within the SCR catalyst, the NOx are reduced by the ammonia into water and nitrogen, which are both less polluting. The water and nitrogen are then released into the atmosphere through the exhaust.
Bulk volumes of DEF are often transported by railcar or truck and can be stored in polyethylene containers, fiberglass reinforced plastic (FRP), and steel tanks. DEF is also often transported and stored in IBC or intermediate bulk containers.
Diesel Exhaust Fluid (DEF) is clear and is safe the handle and non-toxic. In fact, of all the fluids used in a truck, such as diesel, engine oil, brake fluid, and antifreeze, DEF is the least hazardous. DEF does sometimes have a slight ammonia smell (similar to home cleaning agents), but these are not harmful.
It can corrode some metals and must be stored and transported carefully. It is recommended that DEF be stored in a cool, dry, and well-ventilated area that is out of direct sunlight.
Diesel exhaust fluid is offered to consumers through a variety of quantities ranging from containers for single or repeated small usage, up to bulk carriers for consumers requiring a large amount of DEF.
Personal Protective Equipment: Wearing protective clothing is not necessary when handling DEF, however, it can stain clothes. If you do spill any DEF on your clothing, rinse it off with water.
Spill Containment: Small amounts of DEF can be washed away with water or wiped up. If left to dry it will turn into white crystals. These can be washed away with water. As when transferring any bulk chemical, industrial spill containment solutions are needed.
Fumes: Inhalation is not expected under normal conditions, However, when pumping Diesel Exhaust Fluid (DEF) in a closed area or in bulk, it is possible that inhalation of ammonia fumes from DEF might occur. If inhales, it’s recommended to get fresh air. I physician should be consulted for prolonged exposure or symptoms, such as irritation to nose or throat.
Selective Catalytic Reduction – SCR reduces levels of NOx (oxides of nitrogen emitted from engine exhaust), a major contributor to pollution. SCR is a process and technology that treats exhaust. Small quantities of diesel exhaust fluid (DEF) are injected into the exhaust. The DEF vaporizes and decomposes to form ammonia and carbon dioxide. The ammonia (NH3) with the SCR catalyst, converts the harmful nitrogen oxide (NOx) into harmless nitrogen (N2) and water (H2O).
Customer Reviews4 5Very positive group of people in sales and customer service.By Jim Burch from GenOn on5 5SafeRack came to our facility not only to measure, but also took the time to discuss the operation of the product.By Lance Barrow from Brenntag on4 5Product installation was spot on.By George Sajenko from I.P.S.C Company, Inc. on5 5Travis and the rest of the SafeRack support staff were always one step aheadBy Bryan Eggleston from Lafarge on4 5As usual, just what I wanted and expected.By Jason Boaz from Darling Ingredients Inc. on4 5It was such an easy process.By Geoff Powers from Diamond Pet Food on
Is your plant or facility compliant with ANSI, OSHA, and local safety codes? We can help!
EMERGENCY EYEWASHES / SHOWER EQUIPMENT AND THE ANSI/ISEA Z358.1 – 2014 STANDARD
Following eye contact, you must start washing with water immediately to prevent permanent damage. In the event of skin contact, you must start washing with water immediately to prevent slow-healing chemical burns.
Are you aware that ANSI guidelines state that Eye Wash/Drench Showers need to be located 10 seconds or 55′ from contaminates or hazardous materials and located on the same horizontal plane, with no obstructions? If bottom loading/unloading, an additional shower should be located at grade as well. SafeRack provides the above equipment plus much more needed to keep employees safe and expedite bulk chemical loading and unloading.
OSHA Regulation Experts – Does your existing chemical safety equipment or chemical loading systems meet OSHA’s latest requirements? SafeRack’s professional technical sales consultants are available to meet with your team to make recommendations to keep your facility in front of OSHA’s ever-changing country and region-specific standards and regulations, including lifeline and trolley beam fall arrest systems, metal stairs, and access platforms.
The SafeRack approach is a collaborative one. Let’s call it The SafeRack Way. We have, over many years amassed a great deal of experience and understanding of the safety aspects involved in loading road tankers and railcars, as well as the behavioral habits of the operators.
With the best intentions in the world, if a system is designed that is inconvenient or difficult to operate, it becomes the operator’s mission to bypass, abuse, and generally defeat that system. This could result in the (un)loading procedure being far more dangerous than no system at all.
To avoid this, SafeRack has developed industry-leading safe access solutions, seamlessly integrating loading arms and ancillary 3rd party equipment to be user friendly with the operation of loading becoming cleaner, more automated, and far safer.
Experts In Chemical Loading
North America’s largest loading terminal
World-leading designer, manufacturer, and installer of truck and railcar loading platforms
As one of the primary railcar loading points, Hardisty is one of the major crude oil hubs in North America and a major origination point of pipelines that export to the United States. SCS was asked to supply and construct a SafeRack crude oil loadout terminal spanning nearly half a mile. The USD Hardisty terminal can load up to two 120-railcar unit trains per day and consists of a fixed loading rack with 62 railcar loading positions enclosed, separate control, operator and mechanical buildings, as well as a unit train staging area and loop tracks capable of holding multiple unit trains simultaneously. SCS also supplied and installed boom-supported loading arms with supply and vapor management systems.
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Located in South Carolina
Located in South Carolina
Located in South Carolina
Located in South Carolina
Located in South Carolina