Information
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Conducted on
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Personnel
Purpose
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The purpose of this procedure is to provide specific railcar unloading instructions. Following these procedures consistently will ensure safe railcar unloading and prevent damage to railcars.
Scope
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These procedures apply to all Bin Complex Operators tasked with unloading PD rail cars.
Standard Operating Procedures
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1). Review Positive Release form issued by QA listing the railcar number and designated hopper(s) to be unloaded.
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Railcar number
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Designated Hoppers
- Hopper B
- Hopper BC
- Hopper AC
- Hopper A
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Are multiple hoppers designated to be unloaded?
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Pick Hopper that is being unloaded.
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2). Bring railcar onto Track 3 and spot-up to unloading system.
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Date/time railcar placed onto track 3, beginning unloading.
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Name/signature of employee(s) assigned to unloading.
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3). Remove discharge line cap and hook up vacuum unload hose.
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Add photos verifying removal of caps.
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4). Remove positive pressure line cap and hook up positive pressure blower hose.
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Open all air inlet valves to each hopper and close blower side valve on discharge side of positive pressure line.
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5). Open lids on designated hopper on top of railcar and remove bonnets.
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6). Ensure plastic screens are in place on hatches to prevent contamination.
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Add photos verifying open lids/screens in place.
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7). Verify lines are set to desired bin indicator for unloading.
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Open discharge valve on desired hopper.
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8). Start positive pressure blower on Track 3's panel.
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Date/Time beginning hopper unload.
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Start unload system on DCS in bin complex control room.
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9). Proceed to bin tops to ensure product is going to the selected bin.
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10). Periodically check hopper to ensure product is being removed. Hopper unloads shouldn't take more than 2 hours.
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11). Verify hopper is completely empty.
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Blow out any residual product from hopper and unload tubes.
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Add photo showing empty hopper(s).
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12). Close discharge valves and replace caps (ensure caps are tight).
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Add photo after caps are replaced.
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13). Replace bonnets and close lids.
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Add photos of closed lids.
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Add date/time hopper unload was completed.
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If car is a rejected car, take to elevator to be cleaned and inspected. If car is being unloaded due to out of spec product, take car to designated track to be reloaded.
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Add SOP for each hopper being unloaded.
Hoppers
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Pick Hopper that is being unloaded.
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2). Bring railcar onto Track 3 and spot-up to unloading system.
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Date/time railcar placed onto track 3, beginning unloading.
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Name/signature of employee(s) assigned to unloading.
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3). Remove both caps from unloading system/tube (front and back)
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Add photos verifying removal of caps.
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4). Open discharge valves on bottom of hopper.
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5). Open both lids on designated hopper on top of railcar and remove bonnets.
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6). Ensure plastic screens are in place on hatches to prevent contamination.
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Add photos verifying open lids/screens in place.
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7). Verify lines are set to desired bin indicator for unloading.
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8). Start unload system (select rail unload icon for correct screen).
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Date/Time beginning hopper unload.
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9). Proceed to bin tops to ensure product is going to the selected bin.
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10). Periodically check hopper to ensure product is being removed. Hopper unloads shouldn't take more than 2 hours.
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11). Verify hopper is completely empty.
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Blow out any residual product from hopper and unload tubes.
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Add photo showing empty hopper(s).
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12). Close discharge valves and replace caps (ensure caps are tight).
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Add photo after caps are replaced.
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13). Replace bonnets and close lids.
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Add photos of closed lids.
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Add date/time hopper unload was completed.
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2). Bring railcar onto Track 3 and spot-up to unloading system.
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14). Once car is completed, take car to track 4 for reloading.
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Enter date/time car unloading was completed.
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Operator completing unload of railcar.
