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Although no two HCl Loading solutions will be identical, the product itself determines much of the critical design criteria that will ensure that optimum safety and productivity can work together in harmony.
In the United States, HCl is typically a “tight-fill” (closed-loop) loading operation and is loaded into trucks or rail cars via chemical hoses or by-pass arms. HCl, if not handled properly can be fatal and Personal Protective Equipment (PPE) is required. Additionally, because operators are on top of the vehicles during the loading process, fall prevention is essential, not only for safety but increases throughput.
HCl is typically transported in 20,800-gallon non-insulated rubber lined tank cars. Rail cars have a typical overall length of ~44′, with 6’x6′ centered or off-set crash boxes. When transporting HCl over the road, smaller barrel (diameter) acid trailers are typically used. Since acid is heavier than water these trailers often carry the same weight as a comparable tank truckView Full Text
Typical Hydrochloric Acid Loading Platform
Typically, as a starting point, we will need to know answers to these questions for your project
- The Railcar connection locations need flexibility – Do you know what the breadbasket connections look like?
- What do your tank car “crash-box” openings look like? Are they centered to the bread basket or off-set?
- Are you using liquid and vapor arms/hose as two separate devices or a single piggyback arm?
- Is the loading station indoors or outdoors?
- Is the loading area temperature controlled?
- How many railcars are you (un)loading day/week/month?
- How many spots? Single or Double-sided spur?
- Where are you shipping to or receiving products from?
In addition, we undertake a detailed site survey to check and clarify all dimensions and other salient issues.
HCl Loading Arms
HCl is typically loaded into railcars via chemical hoses or by-pass arms.
The current best loading practice is to use a 3″ PTFE lined chemical hose, with quick-acting coupling, often in the form of Hammer Unions with stabber pipe. The PTFE lined hose 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.
In addition to PTFE, Rubber, Ethylene-propylene and Viton are common gasket or seal materials for HCl applications.
Break-away couplings can be fitted near the inlet of the hose for additional safety in the event of a drive-off
Although some sites use PTFE lined loading arms, our experience has been that these can be cost-prohibitive to maintain and challenging to keep a leak-tight seal across each arm section.
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’x6’ 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
Hydrochloric Acid 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.
Hydrochloric Acid 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. Since HCl is highly corrosive and will attach most common metals SafeRack recommends either a polyethylene or composite track pan.
Grounding for Hydrochloric Acid Loading
HCl is highly reactive and will attac most common metals, and in the process will release hydrogen. If allowed to concentrate, the hydrogen can create a flammable mixture that could lead to a fire or explosion. Therefore, industry best practice includes the grounding of all vessels before 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 for Hydrochloric Acid Application
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
Hydrochloric Acid Loading 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.
Respiratory Protection: Up to 5 ppm
* For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs
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MAJOR HCI PRODUCERS WHERE WE HAVE SUCCESSFULLY EXECUTED HCI LOADING PROJECTS
Hydrochloric Acid 101
Things to know about Hydrochloric Acid
Chemical formula: HCl
Appearance: Clear and slightly yellow liquid
Physical State: Liquid
Hydrochloric acid is a strong corrosive acid that’s formed by dissolving hydrogen chloride in water. Also referred to as Hydrogen chloride and Muriatic acid. HCI has many uses and it is used in the production of chlorides, fertilizers, dyes, textiles, rubber, and pharma. HCI is an inorganic liquid that’s clear to slightly yellowish in color and reacts negatively with strong alkalis. HCI is typically shipped at a strength of 32 to 36%, with the balance being water.
Concentrated forms of HCI release acidic mists that are also dangerous; seek immediate medical assistance if exposed. SafeRack further recommends adding a fan to the platform to help dissipate fumes or mist
OSHA Permissible Exposure Limit (PEL) @ .05 parts per million. At 50 parts per million
it’s considered “Immediately Dangerous to Life and Health”
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.
From Scope Development to Installation and Training – SafeRack understands how proper training prolongs the life of your equipment, reduces long-term maintenance costs, and protects the safety of employees. From installation and commissioning through to long-term preventative maintenance programs, our Aftermarket Team offers a full menu of training options that can be tailored to suit your site needs.
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