Sulfuric Acid Railcar Unloading Checklist

• Site conducted

  Select

• Conducted on

  Date

• Prepared by

• Railcar Number

• Bulk Material

  Acid

  Caustic

• THIS SECTION IS TO BE COMPLETED BEFORE UNLOADING THE CHLORATE RAILCAR

• IP Unloading Employee:

• Complete the before loading and after loading sections by selecting yes once the item is complete.

• In the event of leakage, complete Section 3 and distribute as indicated.

• This checklist is designed to supplement facility loading/unloading procedures. All loading and unloading of materials shall be done in accordance with specific facility procedures!!

Procedures at Loading/Unloading Site

• QO ensures correct placard for acid (1830) is on car

  Yes

  No

  N/A

• QO puts blue caution flag in place. (White letters - blue background)

  Yes

  No

  N/A

• QO sets derailer

  Yes

  No

  N/A

• QO chocks wheel and sets brake

  Yes

  No

  N/A

• QO checks safety shower and eye wash

  Yes

  No

  N/A

• QO checks safety structure of car for defects (Grab irons, steps, handrails, platforms). If defects exist, are immediate repairs required for safe unloading? If yes, discontinue unloading and notify Shift Team Leader immediately.

  Yes

  No

  N/A

• QO checks if car is equipped with coupler vertical restraint system (double shelf couplers).

  Yes

  No

  N/A

• QO checks D.O.T. specification number for legibility. Make sure test dates have not expired (including safety valve)

  Yes

  No

  N/A

• QO call QME to prepare car for unloading. QO can also prepare the car

  Yes

  No

  N/A

• QO ensures air & acid header valves on the other station are closed

  Yes

  No

  N/A

• QO or QME will check car for pressure by slowly removing air plug on car before removing acid plug on car

  Yes

  No

  N/A

• QO or QME slowly removes acid plug on car

  Yes

  No

  N/A

• QO or QME installs piping on acid outlet and air inlet on car

  Yes

  No

  N/A

• QO insures air is only on car planned to be unloaded

  Yes

  No

  N/A

• QO inspects flexible acid unloading hose and air hose for good repair. If ok, connect hoses to car; if not, have QME replace defective hose

  Yes

  No

  N/A

• QO opens acid header valve

  Yes

  No

  N/A

• QO opens air valve in piping located on car

  Yes

  No

  N/A

• QO records car numbers on Chem Prep Report

  Yes

  No

  N/A

• Loader/Unloader Name

• Loader/Unloader Signature

  Sign

• Date

  Date

After Loading/Unloading

• QO ensures the car is empty by the tank level rise ~9ft. ; if unsure, further troubleshooting is needed and completed

  Yes

  No

  N/A

• QO closes acid header valve

  Yes

  No

  N/A

• QO closes air header valve, bleeds air pressure off of car

  Yes

  No

  N/A

• QO calls QME to prepare car for shipment. QO can also prepare car for shipment

  Yes

  No

  N/A

• QO disconnects air hose from car

  Yes

  No

  N/A

• QO disconnects acid unloading hose from car

  Yes

  No

  N/A

• QO or QME removes Safety Vent cover and inspects frangible disc for corrosion or damage

  Yes

  No

  N/A

• QO or QME closes manhole cover and cross torques all bolts to 150 ft/lbs

  Yes

  No

  N/A

• Picture of closed manhole cover

  Media

• QO or QME removes air and acid piping from car

  Yes

  No

  N/A

• QO or QME closes and tightens the unloading pipe cap using a wrench or T-bar to ensure it is tool tight

  Yes

  No

  N/A

• QO or QME closes and tightens the air valve plug using a wrench or T-bar to ensure it is tool tight

  Yes

  No

  N/A

• Picture of unloading pipe cap and air closed air valve plug

  Media

• QO or QME checks the piping, valves, fittings and gaskets for corrosion, damage or any unsafe condition

  Yes

  No

  N/A

• QME and/or QO visually check car for any missing or loose bolts, nuts or elements that make the car unsafe for shipment

  Yes

  No

  N/A

• QO raises gangway to the upmost position and secures manual latches

  Yes

  No

  N/A

• Picture of raised gangway

  Media

• QO checks D.O.T. specification number for legibility. Make sure test dates have not expired (including safety valve)

  Yes

  No

  N/A

• QO ensures car is secure for transport. Visually inspect external tank shell for abrasion, corrosion, cracks, dents, distortions, defects in welds or any other condition that would make the tank car unsafe for transportation

  Yes

  No

  N/A

• QO visually checks coupler vertical restrainT

  Yes

  No

  N/A

• QO ensures car is hosed and cleaned off

  Yes

  No

  N/A

• QO ensures four (4) placards remain as if car is fully loaded

  Yes

  No

  N/A

• QO removes wheel chock

  Yes

  No

  N/A

• QO completes "Chemical Car Shipping Form"

  Yes

  No

  N/A

• QO has the STL or another Operations Resource review all paperwork and sign the checklist.

  Yes

  No

  N/A

• Loader/Unloader Name

• Loader/Unloader Signature

  Sign

• Date

  Date

• All forms must be turned in to the Area Leader or representative and transported to the designated DOT representative onsite to perform official release in the railcar database. Forms will be filed for future reference. If there is ANY leakage, car damage, or other service problems, file a copy of this form with EHS and notify the Shift Team Leader

Leakage or Car Damage

• Describe Car Damage

• Explain Leakage

• After Loader/Unloader Name

  Select

• After Loader/Unloader Signature

  Sign

• Date

  Date

• Verifier Name

  Select

• Verifier Signature

  Sign

• Date

  Date

• All forms must be turned in to the Area Leader or representative and transported to the designated DOT representative onsite to perform official release in the railcar database. Forms will be filed for future reference. If there is ANY leakage, car damage, or other service problems, file a copy of this form with the Facility Safety Manager and send an additional copy to: Distribution Operations, Tower II, Room 460 Memphis (or fax to 9017637295)

• THIS SECTION FOR FRONT LINE LEADER (FLL) ONLY

Railcar Audit Inspection Form

• Unloading/Loading Paperwork Properly signed

  Yes

  No

  N/A

• Comments

• Dome Bolts Tight

  Yes

  No

  N/A

• Comments

• Valves Closed

  Yes

  No

  N/A

• Comments

• Plugs In Place

  Yes

  No

  N/A

• Comments

• Placards on all 4 sides

  Yes

  No

  N/A

• Comments

• Placards legible

  Yes

  No

  N/A

• Comments

• Car is clean

  Yes

  No

  N/A

• Comments

• Car markings legible

  Yes

  No

  N/A

• Comments

• Car ready to be released

  Yes

  No

  N/A

• Comments

• **Note: After audit is complete, chemical unloader to remove the blue flag, chokes, derailer, and verify that the catwalk to the cars, if applicable, are in the upright position.**

• Auditor

  Select

• Auditor Signature

  Sign

• Date

  Date

Ready to Release

• Car Ready to be moved from the spot

  Yes

  No

  N/A

• CALL IN THE RAILCAR TO THE CHEMICAL RELEASE VOICEMAIL AND VERIFY NAME, DATE/TIME, CHEMICAL, AND RIALCAR NUMBER

• Derailer Remover Name

  Select

• Derailer Remover Signature

  Sign

• Date

  Date

• Misc. Comments