If you have followed me for years, you know I love to use the International Fire Code over outdated OSHA standards. For me, it is ALL about safety and not compliance; luckily, I have many clients who take the same approach, and we have made some serious improvements to a hazardous process. Here is a lock at what the IFC states about Bulk Transfer and Process Transfer Operations (5706.5).
I have highlighted some parts that are better DEFINED and QUANTIFIED than what we will find in 1910.106(f)(3). For example, the IFC DEFINES and QUANTIFIES the chocks that must be used to secure the vehicle…
Not less than two chock blocks not less than 5 inches by 5 inches by 12 inches (127 mm by 127 mm by 305 mm) in size and dished to fit the contour of the tires shall be used during transfer operations of tank vehicles.
The IFC is full of other improvements to help manage the catastrophic risks associated with these bulk transfers.
5706.5 Bulk transfer and process transfer operations.
Bulk transfer and process transfer operations shall be approved and be in accordance with Sections 5706.5.1 through 5706.5.4.5.
5706.5.1.1 LOCATION
Bulk transfer and process transfer operations shall be conducted in approved locations.
Tank cars shall be unloaded ONLY on private sidings or railroad-siding facilities equipped for transferring flammable or combustible liquids.
Tank vehicles and tank cars engaged in bulk transfer or process transfer operations shall be separated from
-
- buildings,
- above-ground tanks,
- combustible materials,
- lot lines,
- public streets, public alleys, or public ways
by a distance of
-
- 25 feet (7620 mm) for CLASS I LIQUIDS and
- 15 feet (4572 mm) for Class II and IIIA liquids
measured from the nearest loading or unloading valve on the tank vehicle or tank car.
Exception: Buildings for pumps and shelters for personnel supporting transfer operations shall not be required to be separated from tank vehicles and tank cars engaged in bulk transfer or process transfer operations.
5706.5.1.2 WEATHER PROTECTION CANOPIES
Where weather protection canopies are provided, they shall be constructed in accordance with Section 5004.13.
Weather protection canopies shall NOT be located
-
- within 15 feet (4572 mm) of a building or combustible material or
- within 25 feet (7620 mm) of building openings, lot lines, public streets, public alleys, or public ways
5706.5.1.3 VENTILATION
Ventilation shall be provided to prevent accumulation of vapors in accordance with Section 5705.3.7.5.1.
5706.5.1.4 SOURCES OF IGNITION
Sources of ignition shall be controlled or eliminated in accordance with Section 5003.7.
5706.5.1.5 SPILL CONTROL AND SECONDARY CONTAINMENT
Areas where transfer operations are located shall be provided with spill control and secondary containment in accordance with Section 5703.4.
The spill control and secondary containment system shall have a design capacity capable of containing the capacity of the largest tank compartment located in the area where transfer operations are conducted.
Containment of the rainfall volume specified in Section 5004.2.2.6 is NOT required.
5706.5.1.6 FIRE PROTECTION
Fire protection shall be in accordance with Section 5703.2.
5706.5.1.7 STATIC PROTECTION
Static protection shall be provided to prevent the accumulation of static charges during transfer operations.
Bonding facilities shall be provided during the transfer
-
- through open domes where Class I liquids are transferred or
- where Class II and III liquids are transferred into tank vehicles or tank cars that could contain vapors from previous cargoes of Class I liquids.
Protection shall consist of a METALLIC BOND WIRE PERMANENTLY ELECTRICALLY CONNECTED TO THE FILL STEM.
The fill pipe assembly shall form a continuous electrically conductive path downstream from the point of bonding. The free end of such bond wire shall be provided with a clamp or equivalent device for convenient attachment to a metallic part in electrical contact with the cargo tank of the tank vehicle or tank car.
For tank vehicles, protection shall consist of a flexible bond wire of adequate strength for the intended service and the electrical resistance shall NOT exceed 1 megohm.
For tank cars, bonding shall be provided where the resistance of a tank car to ground through the rails is 25 ohms or greater.
Such bonding connection shall be fastened to the vehicle, car, or tank BEFORE DOME COVERS ARE RAISED AND SHALL REMAIN IN PLACE UNTIL FILLING IS COMPLETE AND ALL DOME COVERS HAVE BEEN CLOSED AND SECURED.
Exceptions:
1. Where vehicles and cars are loaded exclusively with products not having a static-accumulating tendency, such as asphalt, cutback asphalt, most crude oils, residual oils and water-miscible liquids.
2. Where Class I liquids are not handled at the transfer facility and the tank vehicles are used exclusively for Class II and III liquids.
3. Where vehicles and cars are loaded or unloaded through closed top or bottom connections whether the hose is conductive or nonconductive.
Filling through open domes into the tanks of tank vehicles or tank cars that contain vapor-air mixtures within the flammable range, or where the liquid being filled can form such a mixture, SHALL BE BY MEANS OF A DOWNSPOUT THAT EXTENDS TO NEAR THE BOTTOM OF THE TANK.
5706.5.1.8 STRAY CURRENT PROTECTION
Tank car loading facilities where Class I, II, or IIIA liquids are transferred through open domes shall be protected against stray currents by permanently bonding the pipe to not less than one rail and to the transfer apparatus.
Multiple pipes entering the transfer areas shall be PERMANENTLY electrically bonded together.
In areas where excessive stray currents are known to exist, all pipes entering the transfer area shall be provided with insulating sections to isolate electrically the transfer apparatus from the pipelines.
5706.5.1.9 TOP LOADING
When top loading a tank vehicle with Class I and II liquids without vapor control, valves used for the final control of flow shall be of the SELF-CLOSING TYPE and shall be MANUALLY HELD OPEN except where automatic means are provided for shutting off the flow when the tank is full.
Where used, automatic shutoff systems shall be provided with a manual shutoff valve located at a safe distance from the loading nozzle to stop the flow if the automatic system fails.
When top loading a tank vehicle with vapor control, flow control shall be in accordance with Section 5706.5.1.10.
Self-closing valves shall NOT be tied or locked in the OPEN position.
5706.5.1.10 BOTTOM LOADING
When bottom loading a tank vehicle or tank car with or without vapor control, a POSITIVE MEANS SHALL BE PROVIDED FOR LOADING A PREDETERMINED QUANTITY OF LIQUID, together with an AUTOMATIC SECONDARY SHUTOFF CONTROL TO PREVENT OVERFILL.
The connecting components between the transfer equipment and the tank vehicle or tank car required to operate the secondary control shall be functionally compatible.
5706.5.1.10.1 Dry disconnect coupling
When bottom loading a tank vehicle, the coupling between the liquid loading hose or pipe and the truck piping shall be a dry disconnect coupling.
SAFTENG NOTE: Dry disconnect couplings are designed for the quick and spill-free connection and disconnection of hoses and pipelines.
5706.5.1.10.2 Venting
When bottom loading a tank vehicle or tank car that is equipped for vapor control and vapor control is not used, the tank shall be vented to the atmosphere to prevent pressurization of the tank. Such venting shall be at a height equal to or greater than the top of the cargo tank.
5706.5.1.10.3 Vapor-tight connection. Connections to the plant vapor control system shall be designed to prevent the escape of vapor to the atmosphere when not connected to a tank vehicle or tank car.
5706.5.1.10.4 Vapor-processing equipment
Vapor-processing equipment shall be separated from above-ground tanks, warehouses, other plant buildings, transfer facilities or nearest lot line of adjoining property that can be built on by a distance of NOT LESS THAN 25 FEET (7620 mm).
Vapor-processing equipment shall be protected from physical damage by remote location, guard rails, curbs or fencing.
5706.5.1.11 SWITCH LOADING
Tank vehicles or tank cars that have previously contained Class I liquids shall NOT be loaded with Class II or III liquids until such vehicles and all piping, pumps, hoses, and meters connected thereto have been completely drained and flushed.
5706.5.1.12 LOADING RACKS
Where provided, loading racks, stairways or platforms shall be CONSTRUCTED OF NONCOMBUSTIBLE MATERIALS.
Buildings for pumps or for shelter of loading personnel are allowed to be part of the loading rack.
Wiring and electrical equipment located within 25 feet (7620 mm) of any portion of the loading rack shall be in accordance with Section 5703.1.1.
5706.5.1.13 TRANSFER APPARATUS
Bulk and process transfer apparatus shall be of an approved type.
5706.5.1.14 INSIDE BUILDINGS
Tank vehicles and tank cars shall NOT BE LOCATED INSIDE A BUILDING WHILE TRANSFERRING CLASS I, II, OR IIIA LIQUIDS unless approved by the fire code official.
Exception: Tank vehicles are allowed under weather protection canopies
5706.5.1.15 TANK VEHICLE AND TANK CAR CERTIFICATION
Certification shall be maintained for tank vehicles and tank cars in accordance with DOT 49 CFR Parts 100–185.
5706.5.1.16 TANK VEHICLE AND TANK CAR STABILITY
Tank vehicles and tank cars shall be STABILIZED AGAINST MOVEMENT DURING LOADING AND UNLOADING in accordance with Sections 5706.5.1.16.1 through 5706.5.1.16.3.
5706.5.1.16.1 Tank vehicles
When the vehicle is parked for loading or unloading, the cargo trailer portion of the tank vehicle shall be secured in a manner that will prevent unintentional movement.
5706.5.1.16.2 Chock blocks
NOT LESS THAN TWO CHOCK BLOCKS NOT LESS THAN 5 INCHES BY 5 INCHES BY 12 INCHES (127 MM BY 127 MM BY 305 MM) IN SIZE AND DISHED TO FIT THE CONTOUR OF THE TIRES SHALL BE USED DURING TRANSFER OPERATIONS OF TANK VEHICLES.
5706.5.1.16.3 Tank cars
BRAKES SHALL BE SET AND THE WHEELS SHALL BE BLOCKED to prevent rolling.
5706.5.1.17 MONITORING
Transfer operations shall be monitored by an approved monitoring system or by an attendant. Where monitoring is by an attendant, the operator or other competent person shall be present at all times.
5706.5.1.18 SECURITY
Transfer operations shall be surrounded by a noncombustible fence not less than 5 feet (1524 mm) in height.
Tank vehicles and tank cars shall not be loaded or unloaded unless such vehicles are entirely within the fenced area.
Exceptions:
1. Motor fuel-dispensing facilities complying with Chapter 23.
2. Installations where adequate public safety exists because of isolation, natural barriers or other factors as determined appropriate by the fire code official.
3. Facilities or properties that are entirely enclosed or protected from entry.