Transport of Dangerous Goods: Identification of Defects in Rail Tank Cars

**version April 2018**

Preface

Rail transport is very closely connected with the accessibility of seaports and industry and is therefore very important for our economy. During the last years, several serious rail accidents have happened in Europe involving the transport of dangerous chemical goods. Notwithstanding that statistically the likelihood of an accident related to the transport of dangerous goods is very low compared to other railway accidents, the potential consequences of these accidents are significant. Rail Undertakings and Chemical Companies carry out systematic inspections of Rail Tank Cars (RTCs) during which technical defects are observed; some of these defects have the potential of resulting in serious accidents.

In this context, VNCI (the Association of the Dutch Chemical Industry) presents this translation of the well-known Dutch guideline “Identification of Defects in Rail Tank Cars”. The initiators of this new edition are convinced that through education and the use of existing knowledge in the chemical industry and the rail sector, incidents such as drip leaks and small product spills can be reduced to a minimum. Because an incident, even a small one, can easily lead to major social inconvenience, such as the shutdown of rail traffic and the evacuation of stations, the benefit for residents, emergency services, and business is evident.

Despite the high degree of care during establishing this guideline, it does not pretend to be complete. Additions or suggestions are therefore more than welcome. This fits perfectly in the tradition of the chemical industry and the railway sector where continuous improvement is very important as is a responsible care attitude towards the community.

Colette Alma, director VNCI
Leidschendam – April 2018

Preface
3
VNCI | Transport of dangerous goods: Identification of defects in Rail Tank Cars
Introduction
6
Reporting Procedure in Case Detection of Defects
8
Not Included in This Edition
8
RID Dangerous Goods Classes
9
Orange Identification Plates (RID 5.3.2.)
10
Dangerous Goods Labels and Characteristics (RID 5.2/5.3)
11
Orange Band for Class 2 (RID 5.3.5)
12 White, Blue, and Red Placarding and Codes of RTCs
12
Explanation Identification of Defects in RTCs
14
Orange Plates
15
Dangerous Goods Labels
16
Product Identification Plates
17
RTCs (General)
18
RTCs for Liquids
20
Tank Inspection Time Interval and Other References
21
Construction of Tank and Chassis
22
Equipment for Loading and Unloading
23
Equipment on Top of the Tank
25
Loading and Unloading Devices on Top of Tank
26
Rail Hook Cable and Eye for Fixing Rail Hook for Loading/Unloading
27
Equipment for Loading and Unloading of Gas RTCs
28
Hydraulic Bottom Valve for Gas RTCs
29
Bottom Valve (Type Hydraulic P 160) for Gas RTCs
30
Bottom Valve Type Hydraulic for Gas RTCs
31
Bottom Valve Type Hydraulic
33
Bottom Valve Type Gestalt (Mechanic) (HWV 36)
34
Bottom Valve Type Gestalt (Part 2)
35
Hydraulic Bottom Valve Type Gestalt (HV 205)
36
Securing of Valve
37
Dry-Break Systems (Valves/Closing Devices)
38
Earthing Connections Between Tank and Chassis
39
Additional Information
40
White Belt for Automatic Ventilation for Liquid RTCs
41
RTCs Without Automatic Ventilation
42
Brake Pads
45
Adjustment of the Brakes in Relation to the Weight of the Wagon
47
Loading/Unloading - Do Not Use the Handbrake
48
Axle Boxes and Blade Suspension
49
Crash Buffers (TE 22) and Buffer Protection (TE 25)
50
Nitrogen as a Rinsing Agent
51
Yellow Tape with Black Letters
52
Earthing Connections
53
Graffiti
54
Dogstar Plug

Introduction

This new edition was initiated in August 2012 by VNCI in cooperation with all partners involved in the transport of dangerous goods in Rail Tank Cars (RTCs). The actual content of the booklet has been established after several sessions of the VNCI Working Group Logistics Safety. It was decided to make this booklet available as a digital file to interested people, who can add specific working instructions and use the booklet for internal use. This booklet is a reference guide and can be used during inspections of rail tank cars loaded with hazardous goods. Although the formal name of a tank wagon according to RID is “tank vehicle,” we will use the name "rail tank car" (RTC) in this document.

The primary target group of this reference guide are certified wagon inspectors of rail companies and operators of loading/unloading sites. Also, representatives of emergency response team inspectors and surveyors can make use of this information. Unlike previous versions, administrative aspects such as the preparation of waybills are NOT addressed in this booklet. The trend is that these administrative issues are carried out electronically more and more. Given the fact that the RID is revised every two years, possible changes in the regulations shall be considered. If necessary, the next issue of this booklet will be adjusted accordingly.

Regarding the loading/unloading of RTCs, it is recommended to use the CEFIC checklists for preventing leaks when filling or discharging rail tank wagons. Basically, manufacturers/suppliers of RTCs also have guidelines with instructions for correct and safe use. These guidelines shall always be consulted in case of dissolving defects. It is not allowed to use this booklet for commercial reasons, neither in printed form nor in digital or any other form. Suggestions for clarification/correction of these booklets can be submitted to the VNCI - for the contact address see the colophon on the back page.

Reporting Procedure in Case Detection of Defects

In case of incidents and detection of defects on public rail infrastructure that might compromise (public) safety, you shall alert the infrastructure manager immediately and inform them as fully as possible:

Who are you?
Where did the incident occur?
Which rail track?
Which dangerous goods/UN code?
What is happening and what do you observe?
Do you have information about train or wagon numbers?

Then take care of your own safety by leaving the incident area against the wind, and beware of other trains. Proceed as directed by internal emergency procedures and try to remain available to assist emergency services. Incidents that occur on non-public rail infrastructure (company sites) shall be reported and treated according to internal company and (if present) national procedures. Please respect the obligation to report serious defects to the authorities in accordance with dangerous goods legislation, e.g., RID 1.8.5. In case of leakages not on public rail infrastructure, the sender/shipper or receiver/consignee also has to report these incidents to national/local authorities, if applicable. In all cases, the consignor of the RTC shall also be informed.

Not Included in This Edition

This edition includes all dangerous goods classes of the RID except classes 1, 6.2, and 7; these classes require specific attention. Issues that are related to intermodal transport (tank containers) are not addressed in this edition as the loading and unloading of this type of transport equipment is quite different. Although the use of (GPS-) transmitters, to determine the exact location of RTCs (so-called track and trace systems) is increasing rapidly, this subject is not addressed in this booklet due to the diversity of these systems.

RID Dangerous Goods Classes

Substances are classified into certain RID classes depending on their properties:

Class 1
- Explosive substances and articles (not included)
Class 2
- Gases
Class 3
- Flammable liquids
Class 4.1
- Flammable solids
Class 4.2
- Substances liable to spontaneous combustion
Class 4.3
- Substances which emit flammable gas in contact with water
Class 5.1
- Oxidizing substances
Class 5.2
- Organic peroxides
Class 6.1
- Toxic substances
Class 6.2
- Infectious substances (not included)
Class 7
- Radioactive material (not included)
Class 8
- Corrosive substances
Class 9
- Miscellaneous dangerous substances and articles

Orange Identification Plates (RID 5.3.2)

On these orange plates, there are 2 numbers:

On top: The hazard identification number, which identifies the type of hazard of the relevant substance.
At the bottom: The UN number, which identifies the substance.

The hazard identification number for substances of classes 2 to 9 consists of 2 or 3 digits:

2: Emission of gas due to pressure or chemical reaction
3: Flammability of liquids (vapors) and gases or self-heating liquids
4: Flammability of solids or self-heating solids
5: Oxidizing (fire-intensifying) effect
6: Toxicity or risk of infection
7: Radioactivity
8: Corrositivity
9: (As 1st digit): Other hazards, e.g., environmentally hazardous substances. (As 2nd or 3rd digit): Risk of spontaneous violent reaction

Remark:

The risk of a spontaneous violent reaction in the sense of digit 9 includes the hazard of a substance and the coherent possibility of an explosion, decomposition, or polymerization reaction, resulting in the release of considerable heat or flammable and/or toxic gases. Doubling of a figure indicates an intensification of that particular hazard. If a hazard identification number is preceded by the letter “X,” it indicates that the substance will react dangerously with water.

Orange identification plates shall be attached on both sides of RTCs during the transport of dangerous goods (both for loaded and empty, uncleaned RTCs). The sizes of these plates shall be at least 40 by 30 cm, and adhesive labels are allowed.

Dangerous Goods Labels and Characteristics (RID 5.2/5.3)

RTC’s in which dangerous goods are transported should be equipped on both sides with one or more dangerous goods placards (stickers or plates). Dimensions are usually 250x250 mm, but may be reduced to 150x150 mm when space is insufficient (RID 5.3.1.7.4).

Class 2.1
Class 2.2
Class 2.3
Class 3
Class 4.1
Class 4.2
Class 4.3
Class 5.1
Class 5.2
Class 6.1
Class 8
Class 9

Each dangerous goods placard has a number corresponding to the hazard class (nature of the danger). The blow-off of stickers during transport is a known issue, so it's strongly recommended to use fixed dangerous goods placards/plates or attach stickers with a special glue.

Orange Band for Class 2 (RID 5.3.5)

RTC’s for liquefied, refrigerated liquefied, or dissolved gases shall be marked by an unbroken, 30 cm wide non-retro-reflective orange band, encircling the shell at mid-height.

White, Blue, and Red Placarding and Codes of RTCs

In case of defects, the RTC shall be equipped with the following placards:

White: Indicates a defect that needs to be repaired at the first opportunity (repair, maintenance, or inspection).
Blue: Indicates a defect that needs to be repaired before the RTC can be reloaded (model K). The RTC can still continue to the destination for unloading.
Red: Indicates a defect that needs to be repaired immediately before further operations of the RTC. Without supplementary restrictive measures guaranteeing safe onward movement, it is not allowed to transport the equipment any further.