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SafeRack takes worker safety very seriously and offers a full range of products and equipment designed specifically to reduce the risks associated with Methylene Diphenyl Diisocyanate 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 MDI 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.
MDI Loading Arms
MDI is transported either by truck, rail, or ISO and “tight fill” loaded or unloaded using a loading arm or chemical hoses w/ dry disconnect fittings.
The current best loading practice is to use a 3″ chemical hose or a carbon steel loading arm with quick-acting coupling. The hose or 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.
MDI 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 use 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
MDI 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
MDI 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
MDI is highly flammable, and industry best practice includes the grounding of all vessels before starting the (un)loading process.
- Vehicle grounding and bonding — ensure true grounding before product flow is permitted
- Explosion-proof enclosures — meet or exceed UL, CSA and Ex requirements
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
- 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
Exposure to MDI can cause asthma, lung damage, and in severe cases, fatal reactions. OSHA Permissible Exposure Limit (PEL) @ 0.02 parts per million
Best practice loading/unloading include: wearing chemical-resistant clothing, gloves, splash goggles at all times to protect eyes and skin. Additional respiratory projection may be required when working with MDI. Since the operators are regulated to wearing a restrictive chemical suit, SafeRack recommends the use of a wider gangway and a MAX Rack for more ergonomic access and egress.
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 MDI*; 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 a 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
Methylene Diphenyl Diisocyanate 101
Things to know about Methylene Diphenyl Diisocyanate (MDI)
(MDI) is a chemical used in the production of polyurethanes for many applications. MDI is used primarily in the production of rigid polyurethane foams used for home insulation, such as spray foam sealants, adhesives, coatings, and many other industrial applications.
Due to its relatively high flash point and autoignition temperature, MDI doesn’t catch fire or burn easily, but it’s very dangerous if inhaled and therefore highly regulated in the workplace
Petrochemicals are made from either petroleum or natural gas feedstock. A wide variety of petrochemicals are created/produced depending on the process.
- Aromatics – Aromatics are hydrocarbons that consist exclusively of the elements carbon and hydrogen. Common Aromatics are Benzene, Toluene, and Xylenes. Often used for creating Dyes, synthetic detergents, fibers, and plastics.The catalytic reforming of naphtha produces aromatics, which include benzene, toluene, and xylene. Together they are referred to as BTX and are predominantly obtained from petroleum refineries by the extraction from the reformate produced in catalytic reformers using naphtha obtained from petroleum refineries.
- Olefins – The most reactive class of hydrocarbons tend to crack. Common Olefins are Ethylene, Propylene, and Butadiene. Often used for creating plastics, and synthetic rubber. Chemical plants produce olefins by steam cracking of natural gas liquids like ethane and propane. Olefins include ethene, propene, and butadiene. Ethylene and propylene are chief sources of both plastic products and industrial chemicals. Butadiene is mainly used in the production of synthetic rubber.
- Synthesis gas (SynGas) – A mixture comprising of carbon monoxide, carbon dioxide, and hydrogen. Common Synthesis Gas is Ammonia and Methanol. Often used for creating Fertilizers and explosives. Synthesis gas is a mixture of carbon monoxide and hydrogen used to make ammonia and methanol. Ammonia is used to make the fertilizer urea, and methanol is used as a solvent and chemical intermediate. Steam crackers are not to be confused with steam reforming plants used to produce hydrogen and ammonia.
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.
Experts In Chemical Loading
- Aluminum Sulfate
- Ammonium Nitrate
- DEF (Diesel Exhaust Fluid)
- Dodecylbenzene Sulfonic Acid
- Ethyl Chloride
- Ferrous Chloride
- Hydrochloric Acid
- Hydrogen Peroxide
- Methyl Ethyl Ketone
- Molten Sulphur
- Nitric Acid
- Renewable Diesel
- Sodium Hypochlorite
- Sulfuric Acid
- Sulfur Dioxide
- Titanium Tetrachloride
- UAN (Urea Ammonium Nitrate)
- Vinyl Chloride
- Specialty Chemical
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