Cargo Discharge Procedures Setup Review

• Review: Review Kirby cargo handling procedures, standing orders, and transfer plan for updates and clarifications before performing tank barge discharge operations.

• Pre-Transfer Conference: Hold a pre-transfer conference with the facility's DOT PIC (Person In Charge) to ensure all procedures are adhered to and safety measures are discussed. This discussion should cover emergency procedures, communication protocols, and specific roles of personnel involved in the discharge.

• Declaration of Inspection (DOI): Complete and sign the DOI, an essential document that confirms all safety checks have been performed prior to commencing work.

Initial Setup

• Use the tank farthest from the cargo pump for the initial setup to facilitate optimal flow and reduce the likelihood of air pockets in the system.

Pump Priming Initiation Process

• Begin pump priming by opening the appropriate port or starboard tank valve fully to initiate liquid gravitational flow toward the pump. This step is critical to ensure that the pump is properly primed and operational.

• Ensure all barge valves are closed before starting cargo discharge transfer to prevent leaks and loss of product. The selected farthest tank helps push out any trapped air or vapor in the below-deck piping into the pump can, which is crucial for maintaining pump efficiency.

• Use the diagram available in the facility to verify which tank should be opened when priming the pump, ensuring clarity and avoiding mistakes.

• Once priming has begun, open the master suction valve for discharge transfer and pump priming to establish the flow.

Cargo Discharge Start-Up

• Start the barge pump engine and allow it to warm up; this helps to ensure the oil circulates properly and can prevent equipment failure.

• RPM Monitoring: During warm-up, monitor the engine RPM, allowing it to gradually reach a stable operational RPM according to the manufacturer's specifications, typically between 1200-1500 RPM, which is optimal for efficient cargo transfer operations.

• Once primed, close the cargo tank valve for the tank being used and open the tank valve closest to the pump.

• Communicate with the dock to confirm they are ready for the discharge operation, providing them with estimated times and any required safety updates.

• Power Take-Off (PTO): Engage the PTO slowly to avoid slamming into gear, which could cause mechanical damage. It’s important to monitor the engagement carefully. The PTO should generally be engaged at approximately 1200 RPM to ensure a smooth operation that minimizes the risk of sudden jerks affecting the system components. Once engaged, ensure the driveshaft is spinning before popping it into gear, checking for any signs of malfunction.

• Check for leaks around the pump cavity and monitor the pressure gauge to ensure safe operating conditions.

• Slowly open the discharge valve to allow for controlled liquid cargo flow, minimizing splashes and spills during the transfer.

Cargo Discharge Process

• Monitor the gauge stick for liquid level dropping in the tank; this is an important metric to ensure the discharge is progressing as expected.

• Once the pressure gauge reads 0 or slightly negative on the common vent line, open the vapor vent stack valve to safely release any built-up vapors.

• Verify product flow with DOT before reaching the maximum discharge rate, ensuring compliance with regulations.

• Increase RPMs appropriately (up to 1800 RPM) while maintaining regular leak checks, ensuring all safety protocols are followed. Begin discharging from the cargo tanks, ensuring to drop levels to a safe height, often around 3 feet, to prevent hazard spills and maintain operational safety.

Stripping Process

• Open tanks sequentially to strip cargo, focusing on one tank at a time, typically starting with the farthest to maximize efficiency.

• Ensure barge orientation allows for effective stripping and manage valve openings for smooth cargo flow, avoiding interruptions in the transfer process. Monitor for a steady flow, resembling a smooth river stream into the sump, indicating proper operation and management of the equipment.

• If it is necessary to regulate the discharge line pressure by pinching down the discharge valve do not exceed 40 psi.

Cargo Discharge Shutdown

• Ensure the last tanks are stripped sequentially, finishing with the final one, often the third starboard tank.

• Reduce RPMs gradually (back to about 1000 RPM) before completing the last cargo tank’s discharge to prevent sudden changes in pressure and flow.

• Communicate with the dock operator about reducing rates well ahead of time and acknowledge when discharge is complete to ensure coordination.

• Close the last tank valve securely and lower engine RPMs after ensuring all cargo has been discharged, pulling the PTO out of gear afterward to protect the engine.

Cargo Line Clearing

• After the discharge, cool down the engine while securing the barge, allowing for safe handling of all equipment.

• Follow Kirby's specific procedures for line clearing, ensuring pressure does not exceed 40 psi during these operations to prevent damage to the system.

• Have cargo inspector check cargo tanks thoroughly before clearing any hoses or arms, noting conditions and potential issues.

• Note the dock operator's name in the tankerman book as necessary for accountability and record-keeping.

Cargo Hose Disconnect

• Coordinate with the dock operator for readiness to disconnect hoses to ensure all parties are prepared.

• Ensure the wearing of appropriate protective gear to mitigate any risks during this process. Utilize taglines and position drip pans under connections to catch any residual liquids that may leak during disconnection.

• Loosen bolts starting from the bottom and moving up methodically, allowing residual liquids to drain properly and minimizing spillage. Once all bolts are loose and residual fluids are drained, ensure no binding on the dock hose/arm before disconnecting the top bolt to avoid failures or accidents.

• Carefully remove old gaskets and cover open hoses/headers with blank flanges and new gaskets or reinstall the ones provided by the dock to ensure system integrity after disconnection.