Safety must be top of mind when designing a loading system to transport hazardous materials like caustic chemicals or unrefined petroleum products. Falls, improper vapor management, insecure coupling attachment, unintended breakaways, and static shocks all pose substantial risks to workers when operating loading systems. Using the correct components in a bottom-feed loading system reduces the risks associated with hazardous fluid transfer.
Fall Protection & Prevention
Slips, trips, and falls are the most common causes of workplace injuries in the United States. Top-feed systems require workers on tanks to maneuver the system into place with OSHA-compliant fall arrest or prevention systems. Using a bottom-feed loading system allows staff at the loading bay to work at ground level, reducing the severity of any injuries that could occur.
Vapor Management
Depending on the media being pumped, vapor leaks can be the source of hazardous fume inhalation or an ignition source. There are two components to proper vapor management: reducing excess aeration and preventing fumes from leaking out of the loading system. Unlike top-feed loading systems, bottom-feed systems connect at the bottom of the tank, creating less turbulence inside the tank and decreasing the chance for aeration to occur through splashback. Additionally, there are options for bottom-feed systems to recover displaced vapor, increasing output in the system. Having secure coupling attachments wherever necessary in the system will prevent vapor leakage and hazardous spills.
Breakaway Safeguards
In a loading system, the connections between the hoses and loading arms are at the biggest risk of spills through unexpected pull-away events. Utilizing couplers with breakaway technology will shut off hazardous fluids from spilling after a hose detaches from the loading system, increasing operator safety and preventing spills. However, to maximize the lifespan of these couplings, it is recommended to ensure they are not dropped.
Shock Prevention
Static electricity poses a serious risk in industrial environments, especially when handling explosive materials. Factors such as friction, contact, separation, and rapid temperature changes can increase the likelihood of these charges. In manufacturing settings, filling, spraying, pouring, mixing, flowing, and even walking can contribute to the buildup of electricity.
Diffusing static electricity before it becomes an ignition source is typically done in one of two ways: grounding and bonding. Grounding uses a conductive material like copper, steel, or a specialty grounding rod to draw the static electricity to the ground, eliminating the charge altogether. Bonding uses a conductive wire to attach two or more conductive materials, equalizing- but not eliminating- static discharge from the attached sources to prevent a spark. Pairing a bottom-feed loading system with grounding equipment eliminates the buildup of static electricity.
OPW Bottom-Feed Loading System Solutions
OPW Engineered Systems specializes in the design of bulk loading systems for hazardous chemical transfer. Each loading arm they manufacture is highly engineered to the application at hand to ensure maximum efficiency and worker safety for each loading station they work with. Their A-Frame loading arms eliminate the need for excess, cumbersome hoses and allow for easy mobility when in use.
In addition to their loading arms, OPW offers direct-pull and cable release breakaway coupling options for use with your next bottom-feed system. These couplings provide maximum protection against spills during unexpected pull-away events, effectively shutting off hazardous fluid flow instantaneously. After the pullaway, staff can reconnect the system without shear pins, tools, or additional spare parts.
SafeRack
SafeRack provides comprehensive solutions for loading systems on the ground and above the tank through their portfolio of OSHA-compliant mobile platforms, spill containment solutions, and fall protection systems. Their RollAStep platforms combine mobility and versatility, accommodating evolving needs in and around loading bays and manufacturing facilities. Additionally, SafeRack offers a variety of spill containment systems, designed to capture accidental leaks or spills for rail or truck loading, ensuring a safe environment while handling hazardous materials. If a bottom-feed loading system is not possible, SafeRack also provides fall arrest and prevention solutions through harnesses and safety cages for maintaining safety at elevated working heights.
Civacon
Civacon ensures the safety of your loading station with its advanced grounding and bonding equipment. Its innovative Saf-T system offers options for grounding or bonding with ease of installation in mind to ensure protection as soon as possible.
Next Steps
With over 65 years of experience under our belts, our team can help upgrade your bottom-feed loading system to maximize efficiency without compromising worker safety. Looking for replacement parts in your current system? Our online shop site offers couplers and seal kits from OPW.
