The benefits that can be realized by the top unloading system with respect to personnel protection
are numerous. Note that these benefits are contingent to availability of a top access platform with
drop gangway (or equivalent). The person assigned to unload the tank car is not placed in a compromised
position when removing the plug from the valve outlet for hook-up to the transfer hose (or pipe). When
utilizing a bottom unloading system, it is very common for a person to strike their head, back, or
shoulders on the "belly," or undercarriage, of the tank car. The grab irons and ladder on the sides
of the tank car present similar potentials for injuries. The track rails can also contribute to trips or
sprains that may be incurred when departing from the bottom of the tank. These factors are especially
compounded when/if a problem, such as a leak, is encountered while attempting to connect to the tank car.
Potential for chemical exposure, in the form of material that may have leaked from the fittings under the tank
car while standing, or crouching, under the tank car. These factors are not present when transferring from the
top unloading valve. Access and egress are not impeded, and overhead obstructions are not present when working
on the tank car platform.
The general consensus amongst caustic soda tank car users is that a cost prohibitive amount of air is necessary
to unload a tank car from the top. The only air that would be needed to initiate transfer via pump would be sufficient
pressure to lift the caustic solution approximately 12.5 feet, or roughly 8.1 psi (10 pounds air pressure would
adequately 'prime' a pump). Once a pump prime has been established, the unloading will proceed I the same
timeframe as would be customary for unloading from the bottom. The manway, or, at a minimum, the one-inch
vent valve, should always be opened when unloading caustic soda by pump. If unloading has been performed
by air from the bottom of the tank car in the past, there would be an insignificant increase in the amount of air used.
With respect to environmental protection, top unloading of tank cars offers the benefits of gravity working in the
user's favor. A broken connection on the unloading hose (or pipe) from the top of the tank car will not result in the
potential loss of the entire tank contents, as gravity will serve to hold the contents in the tank car, assuming pump
transfer and proper venting of the tank. A similar type situation on the bottom unloading connection could very easily
result in the entire tank car contents being lost to the environment before a valve could be properly secured. This
type of situation also highlights the personnel protection benefits gained by top unloading vs. bottom unloading.
Incidental leaks from the threaded connections made when connecting to the transfer system also have the potential
to be minimized, if not eliminated, as improved positioning afforded by working on the top of the tank cars.