4.2.2 Student Book © 2004 Propane Education & Research CouncilPage 1 4.2.2 Preparing ASME Tanks for Transportation & Installation To safely and properly

4.2.2 Student Book © 2004 Propane Education & Research Council Page 1

4.2.2

Preparing ASME Tanks for Transportation &

Installation

To safely and properly install ASME tanks, qualified propane personnel must understand and know how to verify ASME tank condition, load, transport, and unload at the customer’s site.

In this module you will learn to:(1) Identify DOT regulations pertaining to transporting ASME

tanks (2) Verify ASME tank conditions(3) Identify procedures for loading, transporting, and unloading an

ASME tank using a tank setting trailer (4) Identify procedures for loading, transporting, and unloading an

ASME tank using a marketer-operated truck-mounted crane


U.S. DOT Regulations Pertaining To Evacuating ASME Tanks

1. Each container must be constructed in compliance with the requirements of the ASME code

2. Each container must be equipped with safety devices in compliance with the requirements for safety devices on containers as specified in NFPA pamphlet no. 58

4. …Containers shall not be shipped when charged with liquefied petroleum gas to more than 5 percent of their water capacity.

5. Storage containers of less than 1,042 pounds water capacity (125 gallons) may be shipped when charged with liquefied petroleum gas in

compliance with DOT filling density.

The DOT regulatory reference for load securement inspection is found in 49 CFR § 392.9.


Verifying ASME Tank Condition

Read, understand, and apply any company policies and procedures for maintaining ASME tanks and other containers used for customer propane storage.

Particular attention should be given to company-specific standards that stipulate requirements for condition of container coating, customer information decals, sealing of container valves when not in service, and inspection of container valves, fittings, regulators, and other container appurtenances.



The following items (as a minimum) should be checked on each tank transported from the bulk plant to a customer location: • Check for leaks at all tank welds and fittings

Figure 1. Checking for Leaks on AG/UG Tank



The following items (as a minimum) should be checked on each tank transported from the bulk plant to a customer location:

• Check for leaks at all tank welds and fittings

• Verify that any tank over 125 gallons water capacity contains 5% or less propane in liquid form.

Figure 2. Liquid Level Must Be 5% or Less

If Tank Is Larger Than 125 Gallons



The following items (as a minimum) should be checked on each tank transported from the bulk plant to a customer location:

• Check for leaks at all tank welds and fittings

• Verify that any tank over 125 gallons water capacity contains 5% or less propane in liquid form.

• Check the condition of the tank coating

Figure 3a. Underground

Tank Coating

Figure 3b. Aboveground Tank Coating



• Check the condition of each tank valve and fitting.

Weather caps

Plug is sealed on liquid withdrawal valve

Tank is properly purged of air



Figure 4a. Relief Valve

Figure 4c. Vapor Equalizing Valve

Figure 4b. Filler Valve

Figure 4d. Liquid Withdrawal Valve



Figure 5. Underground Tank Data Plate

• Verify that the tank is properly marked and labeled for transportation. ASME data plate markings or ASME certification stampings in the tank head or shell must be readable.



Figure 6. Flammable Gas Shipping Label

• If the tank contains propane, it must have proper shipping labels or placards—one on each side for tanks with water capacities less than 1,000 gallons. If the water capacity is 1,000 gallons or more, flammable gas labels or placards are required on each end and both sides.



• Check the condition of the tank’s lifting lugs and supports.

After the condition of the ASME tank has been determined to be satisfactory, the tank and any required installation materials should be readied for loading. Secure installation items such as masonry foundation blocks on the delivery vehicle; they are considered cargo under DOT regulations.


Inspecting and Maintaining the Tank-Setting Trailer

Read and follow manufacturer’s instructions for inspecting, maintaining, and operating tank setting trailers. Always be sure to comply with any applicable company-specific procedures.

Figure 8. Components of a Typical Tank Setting Trailer



Read and follow manufacturer’s instructions for inspecting, maintaining, and operating tank setting trailers. Always be sure to comply with any applicable company-specific procedures.

Tank Setting Trailer Components – designs vary in the following ways:

• type of lifting mechanism

• method for activating braking systems

• method for securing the tank support cross-members (called “bunks”, in their tank transporting and empty traveling configurations)



On electric/hydraulic brake systems, the electrical current flows when the towing vehicle’s brake lights are activated. Proper operation of the brake lights is critical to the operation of the trailer braking system, along with proper electrical connection to the towing vehicle.

On coupler-activated hydraulic systems, proper lubrication and movement of the trailer tongue-mounted hydraulic cylinder levers is critical to proper braking system operation.

Braking Systems



Figure 8. Components of a Typical Tank Setting Trailer



Pre-Trip Inspection – If the trailer is towed on public roadways a pre-trip inspection is required by DOT regulations.

Pre-use inspection items on tank trailers should, as a minimum, include:

• Hydraulic Systems

• Electrical System

• Mechanical Components

• Mounting Hardware

• Brake Master Cylinder Reservoir

• Lights

• Reflectors

• Tongue & Tow Coupling

• Tongue Jack

• Bunks

• Safety Breakaway Mechanism

• Safety Chains

• Rims and Tires

• Placard Holder



Post-Trip Inspection

A towed tank trailer used to transport ASME tanks is a commercial motor vehicle (CMV) under U.S. Department of Transportation regulations.

Before the vehicle is operated on a public roadway, the driver must complete a pre-trip inspection, including a review of the previous Driver Vehicle Inspection Report (DVIR).

At the end of the day, or when use of the CMV is finished for the day, a post-trip inspection and a DVIR must be completed. The towing vehicle as well as the trailer must be included in the CMV pre-trip and post-trip inspections and DVIR.

4.2.2 Student Book © 2004 Propane Education & Research Council Pages 8 & 9


Basic Trailer Maintenance – The best source for guidance for trailer maintenance is the manufacturer owner’s manual.

General maintenance items include:

Trailer Tires Check for proper inflation and condition, loss of flexibility, dry rot, and becoming out-of-round.

Brake Pads and Drum

Check condition as part of the scheduled maintenance program for the complete braking system.

Storage Battery (if used)

Check for terminal corrosion, proper electrolyte levels, and periodically recharge



Hydraulic System

Check for leaks and defects

Hitch and Tongue Jack

Lubricate as specified by the manufacturer. If a defect is found in the hitch, it should be repaired or replaced without delay.

Lifting Cables and Slings

Inspect for defects or damage and make sure there is adequate lubrication applied to extend the cable life.



Protective Rubber Coatings

Check coatings to electrical wiring insulation, hydraulic hoses, and tires.

Corrosion Protection

Metal primers and coatings should be applied to prepared metal surfaces when the original finish is lost or damaged.

Lifting Cables and Slings

Inspect for defects or damage and make sure there is adequate lubrication applied to extend the cable life.


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Figure 2. LP-Gas Placard(Either Hazard Class 2 or Division 2.1 may be used.)

Loading, Unloading & Transporting Tanks

Vehicle Placards – If the weight of the tank and LP-gas exceed 1,001 pounds, the vehicle must be placarded on the front, back and both sides with placards.



Tank Labels – Tanks having water capacities less than 1,000 gallon must be labeled on two sides.

Figure 3. (4 x 4) Flammable Gas Shipping Label

3.9 incheseach side

solid lineinner border0.2 to 0.25 in .from ed eg

h a z a r d c l a s s0 . 2 5 t o 0 . 5 i n .h i g h

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Tank Labels

During transportation, ASME tanks that contain propane must be labeled using either flammable gas shipping labels or placards. Flammable gas shipping labels or placards must be placed on two sides of tanks with less than 1,000 gallons capacity during transportation in addition to the four placards required for the vehicle. Tanks with 1,000 gallon capacity and larger must have labels or placards placed on both sides and both ends.



Securing the Tank – Straps or chains should be secured in at least two locations, one on either side of the tank dome or the valves, if the dome is removed.

Figure 4. 1,000 Gallon Water Capacity ASME Tank Being Prepared for Transportation

4.2.2 Student Book © 2004 Propane Education & Research Council Pages 11 &12


Loading the Tank

Figure 5. Positioning the Trailer Tank for Loading

Figure 7. Securing the Bunks to

the Trailer Frame

4.2.2 Student Book © 2004 Propane Education & Research Council Pages 11 &12


Loading the Tank

Follow manufacturer instructions for installing the bunks and be sure that they are secured as directed. If lock pins or clips are required, be sure that they are in place. If the bunk shows any defect such as a broken weld, or if it is bent so that it does not fit properly, do not continue the loading operation until the bunk is repaired or replaced.



Loading the Tank

Figure 8. Lowering Tank Onto Bunks

Figure 9. Securing the Tank with Cargo Straps


Requirements & Precautions for Tank Installation

Tank Installation

When tanks are installed at customer locations, propane personnel should consider the following factors before driving on the customer’s property or unloading the tank.

1. Is the soil around the installation location sufficiently dry to support the towing vehicle and trailer ?

2. Are all underground facilities marked ?

3. Does the tank installation location meet NFPA 58 code, and can it be serviced ?



Precautions

1. DO NOT use a tank trailer that has any mechanical or structural defect.

2. Be sure that the towing hitch is rated to carry the load & in sound condition.

3. Be sure safety chains and breakaway connections are properly secured to the towing vehicle.

4. Check the tongue jack and dolly to be sure that it is locked in the transport position.

5. Be sure that the trailer hitch is secured and locked on the towing vehicle’s towing hitch before lifting the tank.



Precautions

6. Check the condition of the trailer’s lifting equipment before attaching or lifting a tank.

7. Do not lift a tank by its lifting lugs if it contains more than 5% liquid propane.

8. Avoid placing hands, arms, or any body part beneath a suspended tank.

9. Be sure that tank bunks are secured according to manufacturer’s instructions before lowering the tank.

10. Secure the tank with at least two suitable securing devices



Precautions

11. Be sure that the trailer tongue weight does not overload the towing vehicle hitch. If too much weight is carried on the rear axle of the towing vehicle, it can cause loss of steering control, fishtailing, or unstable braking.

12. Secure any loose tools, slings or chains in a toolbox on the trailer or towing vehicle before transporting the tank, or after setting a tank and returning to the bulk plant.

13. Be sure that bunks are secured and locked onto the trailer according to manufacturer instructions before leaving the tank installation location.


Moving an ASME Tank Using a Truck-Mounted Crane

Pre-Job Planning

Before the tank is lifted, transported, and placed in its new location, pre-job planning that includes everyone who will be involved should establish the following objectives:

1. Develop a detailed tank loading or unloading plan along with a description for each person’s responsibilities in the operation.

2. Equipment operators must be assigned and the means used for communicating and coordinating each step of the job established.

3. The locations of trucks and other equipment used should ensure that crane lifts, swings, and other movements are smooth and clear of people and property.


Moving an ASME Tank Using a Truck-Mounted Crane Pre-Job Planning

4. Truck drivers and equipment operating personnel should do a “walk through” before trucks or cranes are brought onto the site. Special care should be given to ensuring proper support for vehicles, avoiding buried structures and overhangs, and slopes or terrain hazards that could lead to truck or crane overturn.

5. Safety guidelines should be reviewed with emphasis allowing no one beneath a tank during lifts, swings, or positioning.

6. Any special tank handling requirements should be outlined with clear instructions for each person who has a responsibility in performing a related task


Coordinating Truck-Mounted Crane Operations

Figure 15. Positioning the Crane Truck

Where two or more employees are involved pre-job planning, assignment of individual responsibilities, & agreed clear communication methods are imperative to protect people and property.



Operating the Truck-Mounted Crane

Truck-crane operators should read and follow the manufacturer’s instructions for inspecting, maintaining and operating the crane.

They should know the crane’s maximum lifting capacity, and how the crane boom angle and positions affect the crane’s load capacity and stability.




Fundamental principles of crane operations:

1. A crane is basically a large lever. Considering the basic forces at work on lever-type devices, the operator should understand the following:

a) A crane’s maximum lifting capacity is available when the boom (the lever) is as close to vertical as possible.

b) The crane’s most stable lifting configuration is when the boom is as close to vertical as possible, and outriggers distribute the weight of the crane and its load over a wide area.





2. As the crane’s boom is lowered from vertical, its lifting capacity is reduced.

3. As the boom angle is moved toward horizontal, it produces a center-of-gravity shift away from the center of the crane’s undercarriage (vehicle chassis on self-propelled cranes) toward the side of the vehicle where the boom is pointed. If the crane’s counterweights and the load-bearing area for the crane (outriggers and soil) do not exceed the force imposed by the load, the instability may result in crane overturn or collapse.





4. For safety and stability, cranes must be leveled and properly supported before any rigging, lifting, or load positioning is started.

5. The crane’s lifting and operating characteristics are also affected by the mechanical condition of all its components.

6. Watch for overhead electric wires, overhead utilities and any other overhead hazard.



Figure 2a. Set the Parking Brakes Figure 2b. Place Chock Blocks

The crane truck should be located on level ground so that the ASME tank can be lifted and positioned within safe working limits of the crane. The vehicle parking brakes should be set, and chock blocks placed in front of and behind the vehicle’s rear wheels.



Figure 3. Setting Outriggers and Leveling the Crane

Next, the crane outriggers should be fully extended and locked into position. Crane outriggers (where provided by the manufacturer) are used to prevent damage to the truck chassis and maintain stability.



Figure 4a. Inspect the Lifting Hook

Before lifting the tank, the crane should be given a brief but thorough visual inspection. Special attention must be directed to the lifting hook and swivel to be sure that it is not damaged, and that locking pins or set screws are present to secure the hook and swivel.

Figure 4b. Inspect the Sling



Figure 4a. Inspect the Lifting Hook

If the tank contains more than 5% liquid, the tank’s lifting lugs or “eyes” should not be used. Instead a ‘basket lift” should be made using slings or chains with adequate load ratings.

Figure 4b. Inspect the Sling


Inspecting Lifting Chains and Slings

OSHA regulations on slings are found in 29 CFR §1910.184. Regulations on truck-crane operations are found in 29 CFR §1910.180

OSHA guidelines include:

1. The operator must exercise intelligence, care and common sense when selecting and using slings.

2. Slings must be selected in accordance with their intended use, based upon the size and type of load.

3. All slings must be visually inspected before use to ensure their effectiveness.



OSHA guidelines include:

4. When inspecting alloy steel chain slings, pay special attention to any stretching, wear in excess of allowances made by the manufacturer, and nicks and gouges. These signs indicate that the sling may be unsafe and they must be removed from service.

5. When inspecting wire rope slings, if ten randomly distributed wires in one lay [twisted wire bundle; “lay” describes the direction the wires and strands are twisted during the construction of the wire rope] are broken, or if five wires in one strand of a rope lay are damaged, the sling must not be used. Wire rope slings must also be removed from service if the inspection reveals any of the following conditions:



Wire-rope sling rejection criteria:

a) Damaged end fittings

b) Excessive corrosion

c) Localized wear

d) A one-third reduction in outer wire diameter

e) Distortion, kinking, bird caging, or other structural damage to the wire rope



6. When inspecting fabric rope or web slings, the sling must be removed from service if any of the following defects exist:

a) Acid or caustic burns

b) Melting or charring of any part of the surface

c) Snags, punctures, tears, or cuts

d) Broken or worn stitches

e) Wear or elongation exceeding the amount recommended by the manufacturer

f) Distortion of the fittings


Rigging Lifting Slings

Slings used should have load ratings well in excess of the weight of the tank and its contents. Operators must always bear in mind that if slings are not arranged to lift vertically as shown in the illustration on the left of Figure 5, the load capacity of the sling decreases as the sling angle moves from vertical to horizontal.

M axim um S ling LoadCapacity Availab le w ithS lings in Vertica l Position

Figure 5. The Effect of Sling Angle on Sling Lifting Capacity


Rigging Lifting Slings

After the arrangement and selection of lifting slings is determined, operating personnel should coordinate the attachment of the slings, tank lift, and travel. At NO time should operating personnel stand or walk beneath the lifted tank.

Figure 6a. Using a Chain Sling to Lift Tank

Figure 6b. Staying Clear of the Lift

4.2.2 Student Book © 2004 Propane Education & Research Council Pages 21 - 27

Time to See If You Got the Key Points of This Module…

• Complete the Review on pages 21-24.

• See if you are ready for the Certification Exam by checking off the performance criteria on pages 25 - 27.

Documents

4.2.2 Student Book © 2004 Propane Education & Research CouncilPage 1 4.2.2 Preparing ASME Tanks for Transportation & Installation To safely and properly