bulk Carbon Dioxide Delivery - Login - The Linde Group Del pump TRO-19-08.pdf · Pre-Delivery Steps and Dynamic Risk Assessment 6 ... DEL-04-54-RNA Bulk Carbon Dioxide Delivery 3.2

Author: Guy Dalton Quality Reviewer: Dennis Woods and Craig Messing Approver: Guy Dalton DEL-04-54-RNA Bulk Carbon Dioxide Delivery 3.2 June 2013 Copyright © The Linde Group – Distributed by a locally registered Linde company Page 1 of 21 Uncontrolled Copy - do not use after date of printing

Bulk Carbon Dioxide Delivery

Purpose 1 Scope 1 Driver Testing and Certification 1 Terms and Definitions 2 Hazards of Carbon Dioxide 3 Pre-Unloading Considerations 5 Liquid Carbon Dioxide Trailer Delivery Procedures 6

Pre-Delivery Steps and Dynamic Risk Assessment 6 Connect and Fill the Customer Tank 9 Pump Shutdown and Disconnect 16

Forms and Attachments 18 Document Information 19

About this Document 19 Change History 20

Learning and Assessment Guide 21

Attachments: PowerPoint: CO2 Unloading Procedure

Purpose

Purpose

This document provides guidelines and procedures for safe delivery and unloading of bulk liquid Carbon Dioxide (CO2) trailers at customer locations in Linde Region North America. For bulk liquid CO2 loading procedures, see CO2-20-08 : RNA Bulk CO2 Product Trailer Loading.

Scope

Scope

This document applies to all personnel associated with unloading bulk liquid CO2 at Linde North America customer locations.

Driver Testing and Certification

Driver requirements

Drivers are required to:

• View the CO2 Unloading training video and the CO2 Hazards and Definitions video

• Pass the theory test for this chapter in Traccess

• Pass the practical certification for CO2 product delivery under the supervision of a trained and certified driver trainer. See the Practical Assessment Guide for CO2 Delivery (see attachment in DEL-01-52-RNA).

DEL-04-54-RNA Bulk Carbon Dioxide Delivery 3.2 June 2013

Certification

Driver recertification is required annually on both the Traccess theory and practical tests for CO2 product delivery.

Terms and Definitions

Document terms

For purposes of this document, the following definitions apply.

Term Definition

Blowdown valve A manual valve used to depressurize liquid and vapor pipes and hoses.

Customer tanks Storage vessel at customer sites that meets all regulatory agency requirements for bulk liquid CO2 storage and are free of defects that may cause an incident or injury.

Crossover line and valve

A piping and valve designed to allow the purging of liquid carbon dioxide from piping and hoses using available trailer vapor. See the picture below.

FRAC The term FRAC refers to the grade of product delivered to the gas and oil industry that is used for well stimulation. Due to the risk of contamination of non-FRAC grade product, dedicated FRAC trailers are used and special procedures employed when Non-FRAC trailers are used in FRAC service.

Liquid carbon dioxide Carbon dioxide (CO2) can exist as a liquid only at pressures between 60.4 psig and 1055.9 psig (416 kPa and 7280 kPa) and temperatures between -69.9°F and 87.9°F (-56.6°C and 31.1°C).

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Neutral Ergonomic Body Position

Lower back in, chest out, neck straight, upper arms at the side, wrists straight, work positioned in front of the body at or just below waist height.

Maintaining a neutral ergonomic body position to the maximum extent possible when operating hoses, valves and other equipment used in the liquid CO2 delivery process reduces the chance of being injured.

Purging The procedure for displacing air, moisture, and other foreign materials by using carbon dioxide vapor or liquid.

Sublimation The process of changing from solid phase directly to the gas phase without passing through the liquid phase. Dry ice "sublimes" into a vapor without first changing into a liquid at atmospheric pressure.

Trailer Transport vessels that comply with U.S. Department of Transportation (DOT) specifications MC-330 and MC-331. In Canada, transport vessels are defined as highway tanks under specification TC-331.

Triple point The temperature and pressure at which a material exists simultaneously as a solid, liquid, and gas, which is -69.9°F (-56.6°C) and 60.4 psig (416 kPa), for carbon dioxide.

Hazards of Carbon Dioxide

Oxygen Deficient Atmosphere

Carbon dioxide in its gaseous state is colorless, odorless, and not easily detected in the atmosphere at ambient temperature. Gaseous carbon dioxide is 1.5 times heavier than air, and therefore it will be found in greater concentrations at low elevations or in enclosed areas.

When positioning the tractor/trailer at the customer tank for a delivery, position the trailer away from the customer station taking advantage of the 20 foot fill hoses to allow as much room as possible between the trailer and the customer station/tank. This practice allows ample space for any CO2 liquid and vapor to disperse that is vented during the fill process.

Carbon Dioxide must never be vented in an enclosed area due to the risk of over-exposure and the potential for an oxygen deficient atmosphere. An oxygen deficient atmosphere will result in asphyxiation and death!



Low Temperature

At temperatures below -34°F (liquid CO2 pressure at 150 psig) some materials used in CO2 piping and storage systems, e.g., carbon steel, may become brittle and fail if stressed by the low temperature of liquid CO2 or dry ice (-109°F or -78.3°C). Maintain trailer pressure above 150 psig at all times!

Liquid CO2 in customer tanks and piping must not be allowed to fall below 200 psig (-20°F) as a working minimum pressure.

Failure to maintain adequate liquid CO2 pressure could result in a catastrophic failure of storage vessels, piping or hoses and result in an uncontrolled release of CO2 that could cause serious injury or death and property damage.

Impact/Rapture Hazard from Dry Ice

Liquid carbon dioxide in a hose or pipe flows like water. However, when the pressure is reduced below 60.4 psig, the CO2 liquid can quickly change to a mixture of vapor and solid carbon dioxide (dry ice). Solid carbon dioxide, when formed in a pipe or hose, may create a dry ice plug and prevent depressurization and create a safety hazard.

To prevent dry ice formation and blockage, liquid carbon dioxide must be purged from the hose or pipe before reducing the pressure below 60.4 psig. This can be done by continually supplying carbon dioxide vapor to the hose or piping system to maintain the pressure of the liquid above the triple point until liquid is purged. Use the rear trailer cross over valve to keep pressure on the liquid hose until all liquid CO2 is purged. Conversely, use the rear trailer cross over valve to pressurize hoses and piping with CO2 vapor before admitting liquid to prevent the formation of dry ice.

See Pump Shutdown and Disconnect (page 16) if a dry ice blockage occurs in the liquid product delivery hose.

See DEL-04-50 : Bulk Filling and Delivery Hazards and Safety for more information relating to the hazards of transporting and delivering bulk liquid products.

Flexible rubber product transfer hoses that have contained dry ice may be damaged. This can lead to failure of the hose with the potential for serious injury and/or property damage. Any product delivery hose that has contained dry ice must be inspected for damage before continued use. Contact your manager or supervisor for further instructions. Refer to Maintenance Bulletin FY03-12 dated Sept. 12, 2003, which is available from Linde Fleet Maintenance.

The pressure behind or within a dry ice plug may increase as the CO2 sublimes until the plug is forcibly ejected or until the hose or pipe ruptures. Dry ice may be ejected from an open end of a hose or pipe with enough force to cause serious injury, both from the impact of a dry ice plug or the sudden whip of the hose.



Personal Protective Equipment (PPE)

The following PPE is required for bulk liquid CO2 delivery operations:

• 100% cotton clothing and a long-sleeved shirt

• Hard hat

• Safety glasses with side shields

• Face shield worn in the "down" position whenever working with CO2 hoses and equipment

• Safety boots with leather uppers

• Hearing protection (ear plugs or ear muffs)

• Insulated leather mechanic or palm style gloves

• Traction aid footwear in icy, snowy or slippery conditions

• Cold and wet weather clothing as needed for rain, snow cold and wind

For details, see IMS-27-04 : PPE Requirements for Linde RNA.

Note: Reflective vests must be available in the cab for use by Linde drivers and are required to be worn at a minimum whenever near vehicle road traffic or construction equipment. Individual Linde locations may also require that reflective vests be worn in some or all areas of the facility according to local policy.

Failure to wear required personal protective equipment can result in serious injury.

Pre-Unloading Considerations

Tank First Fill

A Customer Engineering Services (CES) service technician must be present and supervise the first fill of any carbon dioxide tank.

• Containers placed in carbon dioxide service containing air or other gases must be adequately purged to ensure product purity.

• Since trailer CO2 vapor is used to pressurize the customer tank, do not allow the trailer pressure to decrease below 150 psig (-34°F). See Low Temperature.

Note: For more information, see DEL-04-50 : Bulk Filling and Delivery Hazards and Safety.

• Due to the amount of CO2 vapor needed for large customer tanks, more than 1 trailer may be required to pressurize tanks larger than 24 tons.

• Partially full trailers with higher pressure are best for vapor pressurization.

• After filling, monitor the customer's tank pressure for an excessive pressure rise caused by an incomplete cooling of the tank.

• Beware of vented carbon dioxide vapor that may accumulate in low areas or confined areas adjacent to the customer tank. For details, see Oxygen Deficient Atmosphere.

• Do not use CO2 liquid in lieu of CO2 vapor during any first fill procedure. This practice can cause internal shock to the vessel wall and could cause formation of dry ice, catastrophic failure of the inner vessel, or both. For details, see Low Temperature.



Cross Contamination

The delivery practice in the bulk liquid carbon dioxide industry is to use a two-hose fill system, one for vapor return and one for pumped liquid. The nature of the two-hose system makes it possible for contaminants from the receiving container to return to the trailer through the vapor return line and, in rare cases, through the liquid line in low-pressure differential situations. Liquid may also return to the delivering trailer if the storage container is over filled to the point that liquid returns through the vapor line.

In some cases it is not possible to return vapor from the receiving container or is not desirable to return vapor due to purity concerns. In these cases, see DEL-04-55 : CO2 Single Hose Product Delivery Procedures for additional instructions.

USP Trailer Unloading

Follow the procedures described in USP Trailer Unloading at a Customer Location (in CO2-22-06) when delivering USP product to a customer.

FRAC Delivery Procedures

See Tagging a FRAC Carbon Dioxide Trailer (in DEL-04-150) when using a NON-DEDICATED FRAC trailer to deliver carbon dioxide to a FRAC customer.

Note: Dedicated FRAC trailers are exempt from this policy.

Liquid Carbon Dioxide Trailer Delivery Procedures

Pre-Delivery Steps and Dynamic Risk Assessment


Step Action

1 When arriving at the customer site, park the tractor/trailer in a safe place. Activate tractor/trailer parking brakes and hazard warning lights.

2 Exit the cab using safe exit procedures.

For further information, see DEL-02-10 : Safe Entry and Exit of a Commercial Vehicle Cab.

2.1 Check mirrors for approaching vehicle traffic before opening the door.

2.2 Look to make sure that there are no hazards such as potholes or uneven surfaces when climbing down the steps of the cab to the ground.

2.3 Face the cab when exiting or entering the tractor.

2.4 Keep at least one hand on a grab handle at all times.

2.5 Keep 3 points of contact (2 hands and 1 foot or 2 feet and 1 hand) in contact with the steps and grab handles at all times.

2.6 Do not hold anything in your hands.

2.7 Do not jump down the steps.

Failure to follow safe tractor cab exit and entry procedures can cause slips, trips and falls that result in serious injury.




Step Action

3 Conduct a risk assessment of the delivery area (Get Out And Look).

For further information, see TRO-18-08 : Dynamic Risk Assessment.

3.1 Physically inspect the delivery work area for any hazards that could cause an incident or an injury during the delivery process.

3.2 Correct any minor hazards that can easily be corrected without risk of injury.

3.3 Contact the customer or the National Operations Center (NOC) for hazards that must be corrected by the customer.

3.4 Be aware of slip and trip hazards that cannot be eliminated due to wet, icy or slippery conditions, hazards hidden under snow, etc. Use foot traction aids as needed.

Hazards that cannot be eliminated or managed to an acceptable level of risk must be corrected before the delivery can proceed. If unsafe conditions cannot be corrected, contact your supervisor immediately for further instructions. DO NOT attempt to deliver in unsafe conditions!

4 Inspect the customer tank and determine the tank approach.

4.1 All containers and transfer equipment must be in good repair, meet all regulatory tests and qualifications, and be free of defects that may cause an accident or injury. The vessels must be in carbon dioxide service and at normal operating pressures. If unusual conditions are noted, contact the NOC or your supervisor for instructions and observe appropriate caution before attempting any product transfer.

4.2 Check the customer tank markings for the correct product labels and placards and National Board markings.

4.3 Check the customer tank pressure and level gauges to ensure the customer tank needs product. Ensure the pressure is within normal operating ranges and is more than 200 psig.

Note: If the pressure is below 200 psig, DO NOT FILL. Contact the National Operations Center (NOC) or your supervisor for instructions.

4.4 If safe conditions required for the delivery are confirmed, determine if the tractor/trailer can be driven forward into position to connect the delivery hoses. Driving the tractor/trailer forward into position to the customer station is almost always preferred.

4.5 If it is necessary to back into position, place cones to establish a safe backing lane and to mark the final stopping point. See the DEL-02-14 : Linde Cone Policy.

5 Maneuver the tractor/trailer into position at the customer station.

5.1 Re-enter the cab of the tractor using safe entry procedures.

5.2 Position the trailer at the customer station.

When positioning the tractor/trailer at the customer tank for a delivery, drivers must position the trailer away from the customer station, taking advantage of the 20 foot fill hoses to allow as much room as possible between the trailer and the customer station/tank. This practice allows ample space for any CO2 liquid and vapor to disperse that could be vented during the fill process. See Oxygen Deficient Atmosphere.


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Step Action

6 Engage the PTO only for Hydraulic pumps units used for non-beverage customers, who do not require delays for product testing, when the connection and purge procedure can be started without delay.

6.1 With the tractor engine at idle, engage the clutch and slowly put the transmission in gear.

6.2 Engage the PTO switch.

6.3 Take the transmission out of gear and slowly release the clutch pedal.

6.4 Listen for any unusual noise. If the system appears normal, increase the engine RPM to the preset position (usually between 800 to 1,200 RPM).

6.5 Exit the cab using safe exit procedures.

Note: For customers where trailer product sampling is required or for any customer where excess waiting time is necessary, shut down the tractor engine to minimize fuel consumption. Restart the engine and follow the steps outlined above prior to connecting the product transfer hoses to the customer tank.

7 Place cones around the vehicle.

For further information, see the DEL-02-14 : Linde Cone Policy.

7.1 Place cones on the front and rear corners of the tractor/trailer to establish a safe zone around the vehicle.

7.2 Set wheel chocks if required by the customer.



Step Action

8 Stretch and warm up.

Cold, stiff muscles are especially prone to injury. By stretching and warming up, and using proper ergonomic body positioning, the risk of injury from handling hoses and operating tank and trailer valves can be significantly reduced.

Failure to stretch and warm up before beginning the delivery procedure increases the chance of being injured when handling hoses and operating valves and equipment.

Connect and Fill the Customer Tank


Step Action

1 Open the rear trailer access door. Verify that the rear trailer liquid and vapor valves are fully closed. Open the liquid and vapor blow down valves on the trailer to ensure that no pressure exists behind the dust caps.

2 Verify that the customer station vapor and liquid valves are closed. Open the liquid and vapor blow down valves on the customer station to ensure that no pressure exists behind dust caps.

Note: Dust caps are vented on CO2 systems; however, the potential for pressure still exists between valves and dust caps on the trailer and customer station. Before removing dust caps, relieve any pressure by opening the blow down valves.

Always stand to the side when removing or replacing dust caps and hose plugs.

If pressure builds within the hose or system piping due to dry ice or valve leak by, the cap or plug can be ejected under force and cause a serious injury.




Step Action

3 Remove the dust caps and plugs from the following:

• Trailer vapor and liquid connections

• Product transfer hose ends

• Customer station vapor and liquid fill connections

Note: For single hose delivery only: If the customer tank vapor will not be recirculated back to the trailer, leave the rear trailer vapor connection dust cap on and lightly tightened in place. Follow the rest of the unloading procedure using only the liquid hose connection instructions. For additional instructions, see DEL-04-55 : CO2 Single Hose Product Delivery Procedures.

4 Inspect the product transfer hoses and report damage or wear. Do not use damaged or worn hoses. Inspect all connections for cleanliness. Wipe if necessary with a clean, dry cloth.

5 Connect the liquid and vapor product delivery hose ends to the trailer.

5.1 Open the trailer hose tube doors. While using a neutral ergonomic body position, connect the liquid and vapor product hoses to the trailer connections while leaving the other end of the hoses in the hose tubes. Attach the safety restraints (whip checks) to the hoses and the trailer. Snug the hose nuts by hand using a light force.

5.2 Place the CO2 wrench on the hose nut and lightly strike the wrench using a 21 oz. dead blow hammer to tighten the nut. Make sure that your hand and fingers are positioned where they will not be struck by the hammer. See the photo below.

Note: Do not use the hammer to operate valves or attempt to free a dry ice block in a hose or pipe. Use the hammer to tap the CO2 hose nut wrench tight or loose instead of using the palm of your hand.

Do not "slap" the wrench with the palm of your hand to tighten the hose nut! This practice can cause injury.




Step Action

6 Connect the liquid and vapor product delivery hose ends to the customer station.

6.1 Using a neutral ergonomic body position, remove the unconnected end of the liquid and vapor hoses from the hose tubes, remove the hose plugs and connect the hoses to the customer station fill connections. Attach the safety restraints (whip checks) to the customer station. Snug the hose nuts by hand using a light force.

If… Then…

If no secure connection point is available at the customer station for the safety restraints,

Complete the Linde Driver Report/Customer Equipment Write-Up (see attachment in DEL-04-53-RNA) so the discrepancy can be corrected.

If the customer station's fill connections are located above shoulder height (about 60 inches) or below knee height (about 18 inches),

Complete the Linde Driver Report/Customer Equipment Write-Up (see attachment in DEL-04-53-RNA) so that the connections can be relocated by Customer Engineering Services (CES) to a better ergonomic position.

6.2 Place the CO2 wrench on the hose nut and lightly strike the wrench using a 21 oz. dead blow hammer to tighten the nut. Make sure that your hand and fingers are positioned where they will not be struck by the hammer.

Do not "slap" the wrench with the palm of your hand to tighten the hose nut! This practice can cause injury.

7 Close the liquid and vapor blowdown valves on the customer station and on the trailer.

8 Slowly open the vapor belly valve on the trailer.

Use a neutral ergonomic body position and use only as much force as needed to move the valve handle. Do not "jerk" the valve handle to operate the valve.

If any trailer valve is too difficult to operate without risking injury, submit a Linde DVIR (see attachment in DEL-02-09-RNA) so the issue can be corrected. See DEL-02-09 : Pre and Post-Trip Vehicle Inspections.

Always make sure that both hoses are securely connected with whip checks before opening any trailer belly valve!




Step Action

9A If the trailer IS equipped with a belly vapor crossover valve, take the following steps to ensure that the trailer liquid piping is pressurized with trailer vapor:

9A.1 Open the trailer belly vapor crossover valve. See the photo below.

9A.2 Keep the trailer belly crossover valve open until the pump pressure gauge and the tank pressure gauge are about equal.

9A.3 Close the trailer belly vapor crossover valve.

9B If the trailer IS NOT equipped with a belly vapor crossover valve, take the following steps to ensure that the trailer liquid piping is pressurized with trailer vapour. The liquid hose must be connected and blowdowns must be closed!

9B.1 Make sure both liquid belly valves on the trailer are fully closed.

9B.2 Open the rear trailer liquid valve.

9B.3 Open the rear trailer vapor crossover valve (This step pressurizes the liquid piping and liquid product hose with trailer vapor pressure).

9B.4 Keep the rear trailer crossover valve open until the pump pressure gauge and the tank pressure gauge are about equal.

9B.5 Close the rear trailer liquid valve.

9B.6 Close the rear trailer vapor crossover valve.




Step Action

10 Slowly open the unloading liquid belly valve on the trailer (pump inlet valve).

Use a neutral body position and use only as much force as needed to move the valve handle. Do not "jerk" the valve handle to operate the valve. The photo below demonstrates the best method of positioning your body to operate the belly valves.

If the valve is too difficult to safely operate, submit a Linde DVIR (see attachment in DEL-02-09-RNA) so the issue can be corrected. See DEL-02-09 : Pre and Post-Trip Vehicle Inspections.

Use a neutral ergonomic body position and limit the amount of force used to operate the valve to the absolute minimum. To the extent possible, avoid bending, stooping, reaching, jerking and using excessive force to open the trailer liquid belly valve as this practice can cause a serious injury!

11 Open the rear trailer vapor valve.

12 Open the customer station vapor blowdown valve and purge the hose with trailer vapor. Purge only as long as needed to remove air from the hose.

13 Close the customer station vapor blowdown valve after purging the vapor hose.




Step Action

14 Reduce the customer tank pressure.

14.1 Slowly begin to open the customer station vapor valve and return vapor to the trailer.

Note: if there is a concern that the trailer safety relief valve will lift due to a high customer tank pressure, this step may be delayed until just before starting the liquid transfer pump. Some trailers may have a lower operating pressure (270 psig approximately) than some customer tanks (300 psig approximately) and may require manual venting the customer tank.

14.2 Monitor the trailer pressure while the customer tank pressure equalizes with the trailer pressure. Adjust the customer station vapor valve, if needed, to maintain the trailer pressure below the trailer safety relief valve setting.

14.3 If the customer tank vapor will not be recirculated back to the trailer, use the customer tank vent valve to lower the customer tank pressure. Maintain the customer tank pressure above the minimum operating pressure of 200 psig at all times during the delivery! Notify the customer if the tank must be vented below normal operating pressure.

Do not allow the customer tank pressure to fall below the minimum operating pressure and in no case below 200 psig.

15 Open the rear trailer vapor crossover valve.

16 Open the customer station liquid blowdown valve to purge the hose. Purge only as long as necessary to remove air from the hose.

17 Close the customer station liquid blowdown valve after the liquid hose is adequately purged.

18 Close the rear trailer vapor crossover valve.

19 Open the rear trailer liquid valve.

20 Open the customer station liquid blow down valve once again to cool down the trailer transfer pump. Allow the blowdown valve to remain open until liquid CO2 appears.

21 Close the customer station liquid blowdown valve after liquid CO2 appears.

Ensure that the customer station blowdown valves are vented to a safe location and are not directed at the driver or into an enclosed area such as inside the tank enclosure or "doghouse." If the customer tank connection blowndowns need to be relocated, submit a Linde Driver Report/Customer Equipment Write-Up (see attachment in DEL-04-53-RNA) so that the deficiency can be corrected.

22 Open the customer station liquid valve.

23 As a safeguard, slightly (1/4 turn) open the customer station vapor blowdown valve during the fill process in case the customer tank liquid gauge fails to work properly. Liquid will vent from the vapor hose blowdown valve if the customer tank is full, in which case, immediately shut down the fill.

Do not use the trailer vapor blowdown valve as a means to detect if the customer tank is full. If the customer station is not equipped with a blowdown valve, complete a Linde Driver Report/Customer Equipment Write-Up (see attachment in DEL-04-53-RNA) so the discrepancy can be corrected.

Where the customer CO2 tank is filled from a long extended fill connection, using the customer station vapor blowdown valve as a means to determine when the tank is full may result in significant overfilling of the tank. All liquid in the customer station vapor piping must be thoroughly purged with vapor pressure from the customer tank to ensure that a vapor space is left in the tank after the fill.




Step Action

24 Inspect for leaks.

Prior to starting the trailer pump, observe all hose connections for leaks. NEVER try to stop a leak when hoses are pressurized. Depressurize the hose(s) and piping and retighten the connections if needed.

25 Turn the product meter on and zero, if applicable.

26 If the product meter is inoperable:

If… Then…

If there is a scale at the customer location, Weigh the vehicle both prior and after making the delivery and note the weights on the customer delivery ticket.

If there is not a scale at the customer location, Note the trailer liquid level gauge and the customer tanks levels both before and after delivery.

27 Start the trailer transfer pump and commence the fill.

27.1 Ensure the transfer pump is cooled down and flooded with CO2 liquid before starting the pump.

27.2 Hydraulic Pumps: Engage the hydraulic control valve to the full open position to start the pumping procedure.

27.3 Auxiliary Pumps: Start the auxiliary pump engine and allow a short idle and warm up time. Engage the clutch to start the pump and throttle the engine to the proper speed for unloading.

27.4 Check the customer's liquid level gauge to ensure product is being transferred into the tank.

27.5 Check the customer's tank pressure.

27.6 Check the hydraulic drum unit or auxiliary pump engine and connections for any leaks. Immediately stop the pump if any leaks are detected. Use spill clean up supplies and immediately report any spill of oil.

Note: If needed, return to the truck cab, start the engine and engage the PTO system as described earlier in this procedure. The truck engine is not needed for units equipped with an auxiliary pump.

27.7 Ground Pumps: If the customer location is equipped with a ground pump, follow the posted instructions. If instructions are not posted, notify your supervisor or manager. Ground pump operating instructions must be posted at the customer location.

28 Monitor the customer's tank fill.

Remain with the trailer and the customer's tank during the fill procedure and observe the liquid level and pressure gauges on the customer tank. The customer's tank fill is complete when:

• The tank liquid level gauge reaches the "full" mark.

• CO2 liquid appears at the customer's tank vapor blowdown valve.

• The trailer is empty.

Note: To prevent damage, never run the CO2 pump dry. If the trailer empties before the customer tank is full, there will be a distinct change in the sound of the pump, and the pump pressure gauge will drop to approximately the same pressure as the trailer (approximately 270 psig). The pump must be stopped at this point.


Pump Shutdown and Disconnect


Step Action

1 After the customer tank fill is complete, stop the trailer transfer pump, shutdown and blowdown hoses.

1.1 Disengage the hydraulic control valve to stop the pumping process (hydraulic pumps only).

1.2 Disengage the pump clutch and slow the pump engine to an idle speed to allow a cool down during the hose blowdown and disconnecting process (auxiliary pumps only).

1.3 Record the product meter reading and turn off the meter (if applicable).

1.4 Close the trailer rear liquid and vapor valves.

1.5 Close the customer tank liquid and vapor valves.

1.6 Open the trailer rear vapor crossover valve.

1.7 Open the customer station liquid and vapor blow down valves to depressurize the vapor hose and to start draining liquid from the liquid hose.

Note: If CO2 liquid has overfilled from the customer tank into the vapor hose, ensure that a vapor space is left in the customer tank by opening the customer vapor valve (first). Then "crack" open the trailer vapor blowdown. When liquid is no longer present, close the customer station vapor valve.

2 Allow the rear vapor crossover valve and the trailer vapor belly valve to remain open until all CO2 liquid has been purged from the delivery hose. Never drain liquid CO2 from a hose without using the vapor crossover valve or dry ice will form in the hose and create a safety hazard.

2.1 Be aware that normal CO2 depressurization is a slow steady process ending with a slight whistling sound from the blowdown valves. Any sudden stop in depressurization may indicate a dry-ice plug has formed.

2.2 Cycle the rear vapor crossover valve to open and close several times to ensure all CO2 liquid and pressure has been removed from the hoses and customer connection.

2.3 Make sure that the rear vapor crossover valve is closed before proceeding to the next step.

2.4 If a dry ice blockage is suspected in the liquid product delivery hose:

• Ensure that the trailer loading and unloading liquid belly valves are closed.

• Ensure that the customer station liquid and vapor loading valves are both closed.

• Ensure that all blowdown valves are closed on the trailer and the customer station.

• Ensure that the vapor and liquid hoses are securely connected to the trailer and the customer station.

• Ensure that the trailer vapor belly valve is open.

• Ensure that the rear trailer crossover valve is open.

• Allow at least 10 minutes for the CO2 dry ice block in the hose to change back to CO2 liquid or vapor while under pressure.

• Slowly open the customer tank liquid blow down valve while leaving the rear trailer crossover valve open.

• If a steady flow of vapor is present, the dry ice plug has been cleared.

• If no vapor pressure is present, or only present for a moment, close the blowdown valve and allow another 10 minutes for the dry ice to turn back into vapor or liquid before opening the customer station liquid blow down valve again.



Step Action

Dry ice may be ejected from an open end of a hose or pipe with enough force to cause serious injury, both from the impact of a dry-ice plug or the sudden whip of the hose. The pressure behind or within a plug may increase as the dry ice sublimes until the plug is forcibly ejected or until the hose or pipe ruptures.

3 Slowly close the unloading liquid belly valve on the trailer (pump inlet valve).

Use a neutral body position and use only as much force as needed to move the valve handle. Do not "jerk" the valve handle to operate the valve!

Note: The piping between the unloading liquid belly valve and the rear trailer liquid valve does not have to be depressurized.

4 Disengage the PTO: Hydraulic Pumps Only

Return to the tractor, re-enter the cab using safe entry procedures and slow the engine to idle, engage the clutch, disengage the PTO switch, release the clutch, and turn off the tractor engine.

Shut off the auxiliary pump engine for Auxiliary pumps only.

5 Slowly close the trailer vapor belly valve.

Note: The piping between the unloading liquid belly valve and the rear trailer liquid valve does not have to be depressurized.

6 Disconnect the liquid hose.

6.1 After the hoses are clear of CO2 liquid and depressurized, leave the customer tank blowdown valves open and open the trailer rear blowdown valves until the hoses are disconnected to ensure no pressure or liquid is trapped in the hoses.

6.2 Use the 21 oz. dead blow hammer and CO2 hose nut wrench to lightly tap the liquid hose nuts loose.

6.3 Disconnect the liquid hose nuts from the trailer and the customer station.

6.4 Remove the safety restraints (whip checks) only after the hose is disconnected and there is no evidence of pressure or dry ice.

6.5 Close the liquid blowdown valve on the customer station.

6.6 Replace the dust cap on the customer station.

6.7 Install the hose plugs, place the liquid hose in the hose storage tube, and secure the hose tube door.

6.8 Install the dust cap on the trailer liquid connection.

6.9 Close the liquid blowdown valve on the trailer.

Always stand to the side when removing or replacing dust caps and hose plugs.

If pressure builds within the hose or the system piping due to dry ice, the cap or plug can be ejected under force and cause severe injury.

7 Disconnect the vapor hose.

7.1 Use the 21 oz. dead blow hammer and CO2 hose nut wrench to lightly tap the vapor hose nuts loose.

7.2 Disconnect the vapor hose nuts from the trailer and the customer station.

7.3 Remove the safety restraints (whip checks) only after the hose is disconnected and there is no evidence of pressure or dry ice.

7.4 Replace the dust cap on the customer station.




Step Action

7.5 Close the vapor blowdown valve on the customer station.

7.6 Install the hose plugs and place the vapor hose in the hose storage tube. Secure the hose tube door.

7.7 Install the dust cap on the trailer vapor connection.

7.8 Close the vapor blowdown valve on the trailer.

Failure to properly secure the trailer hose storage tube door can cause the hose to fall out onto the road when operating the vehicle. This practice can represent a potentially serious driving hazard to the public!

8 Vent the trailer after delivery only if necessary to provide a 25-50 psi "cushion" below the trailer safety valve setting.

9 Close and secure the access doors on the trailer. If needed, close and secure the customer station doors.

10 Store and secure equipment.

10.1 Collect and store safety cones.

10.2 Store and secure all tools and wheel chocks, if used.

11 Complete a walk-around safety inspection of the customer station and transport equipment.

11.1 Double check the trailer and customer station valve position and tank pressure. Check for leaks or other abnormal conditions.

Note: If any customer tank problems were found during the delivery, fill out the Linde Driver Report/Customer Equipment Write-Up (see attachment in DEL-04-53-RNA) and turn the form into your supervisor.

11.2 Do not leave any trash. Always leave the customer premises clean.

12 Have the delivery note signed, if needed.

13 Update the electronic on-board recorder.

14 Obey all customer traffic requirements and slowly exit the customer facility.

Forms and Attachments

Forms

The following forms are included in this document:

• DEL-01-52-RNA: Practical Assessment Guide for CO2 Delivery (see attachment in DEL-01-52-RNA)

• DEL-02-09-RNA: Linde DVIR (see attachment in DEL-02-09-RNA)

• DEL-04-53-RNA: Linde Driver Report/Customer Equipment Write-Up (see attachment in DEL-04-53-RNA)

PowerPoint Presentation

A PowerPoint presentation has been developed for this document:

• PowerPoint: CO2 Unloading Procedure (see attachment)



Document Information

About this Document

Version Date Author Quality Reviewer Approver

3.2 June 2013 Guy Dalton

Fleet Compliance and Safety Manager

Craig Messing

SHEQ HPO Manager

Dennis Woods

Lead Fleet Trainer

Guy Dalton


3.1 June 2013 Guy Dalton


Craig Messing

SHEQ HPO Manager

Dennis Woods

Lead Fleet Trainer

Guy Dalton


3.0 May 2013 Craig Messing

SHEQ HPO Manager

Dennis Woods

Lead Fleet Trainer

Guy Dalton


2.4 April 2012 Dennis Woods Lead Fleet Trainer

Dennis Woods Lead Fleet Trainer

Guy Dalton, Head of Transport

Safety/Compliance

2.3 November 2008 Dennis Woods, Transportation ToE

Leader, Gases America

Brian Ledwon, IMSS Technical Writer

Dennis Woods, Transportation ToE


2.2 June 2008 Dennis Woods, Transportation ToE


Brian Ledwon, IMSS Technical Writer



2.1 October 2007 Dennis Woods, Transportation ToE


Fred Moudy, National Fleet Trainer




2.0 July 2007 Dennis Woods, Transportation ToE


Joe McWilliams, National Driver Trainer

Review Team

Gary Brooks, Driver Trainer - Lima, OH

Dale Bowen, Driver Trainer - Chester, VA

Dale Parks, CES Trainer - Butler, PA

Ron Hans, CES Field Technician - Butler, PA

John Smith, Engineer - Murray Hill, NJ

Bill Jensen, Rehab Shop Manager - Chattanooga,

TN



1.0 June 2003 Lori Lay, IMSS Technical Writer

Redirect to CO2-22-09-RNA

Change History

Version Description of Change

3.2 Corrected the practical assessment link, which is now in DEL-01-52-RNA.

Corrected the Linde Driver Report/Customer Equipment Write-Up which is now in DEL-04-53-RNA

Deleted the obsolete link: DEL-04-51-RNA.

3.1 Connect and Fill the Customer Tank section: Added step 24 regarding alternative means of measuring product delivered

3.0 Changed document title from "CO2 Product Filling and Delivery" to "Bulk Carbon Dioxide Delivery".

Rewrote entire document per current practice.

Updated the Traccess test and submitted document for retesting.

Added a Practical Assessment.

Updated the Attachment: PowerPoint: CO2 Unloading Procedure

Deleted the Forms:

• Scale Ticket

• Railcar Batch/Lot Tag

2.4 Converted from TRO-19-08-GAM to DEL-04-54-RNA. Updated to LiMSSv13.

Made changes to content to update procedures.

Updated links to converted DEL documents.

Removed the following:

• Delivery Note

• Manual Delivery Note

• Bill of Lading


2.3 Added information about handling ice blockages.

2.2 Updates to Liquid Carbon Dioxide Trailer Delivery (Unloading Procedures).

2.1 • Updates to Liquid Carbon Dioxide Trailer Delivery (Unloading Procedures).

• Updates to PowerPoint: CO2 Unloading Procedure (see attachment).

2.0 CO2 Product Filling and Delivery (DEL-04-54-RNA) document created and no longer redirects to CO2-22-09-RNA.

1.0 Redirect to CO2-22-09-RNA

Learning and Assessment Guide

DEL-04-54-RNA : Bulk Carbon Dioxide Delivery

Prerequisites

As a result of training in the content of this document you will be able to:

Learning method:

Assessment method:

Reference:

Use the terms and definitions applicable to CO2 product filling and delivery.

Self Study and Coaching

Multiple Choice Test and On-the-

Job Training

Terms and Definitions (page 2)

Identify the special hazards involved. Self Study and Coaching


Job Training

Hazards of Carbon Dioxide (page 3)

Apply the special handling procedures when delivering CO2.

Self Study and Coaching


Job Training


(page 6)

Identify the types of valves used. Self Study and Coaching


Job Training


(page 6)

Apply the liquid CO2 unloading procedures. Self Study and Coaching


Job Training


(page 6)

Identify and complete the forms for CO2 delivery Self Study and Coaching


Job Training

Forms and Attachments (page 18)

Assessment Complete Sign Date

Learner: Assessor:

Other references

Practical Assessment Guide for CO2 Delivery (see attachment in DEL-01-52-RNA)

Documents

bulk Carbon Dioxide Delivery - Login - The Linde Group Del pump TRO-19-08.pdf · Pre-Delivery Steps and Dynamic Risk Assessment 6 ... DEL-04-54-RNA Bulk Carbon Dioxide Delivery 3.2