Unloading with dry-break couplings only

Background

AnQore aims to adhere to the highest possible standards with regards to safety of people and the environment. We expect the same attitude from our suppliers and customers. To ensure that our standards are met we conduct regular audits at suppliers and customer locations. If during these audits safety hazards are observed the engineering team of AnQore immediately takes action with the local team in order to improve the situation.

In this case AnQore was informed about a possible leak in a rail tank car (RTC). The RTC had returned empty from a customer location, where during unloading it showed signs of product leakage. This incident was immediately escalated to the AnQore engineers and a root cause analysis concluded that the discharge hose of the customer did not fully empty after disconnecting, causing a small amount of product to be accidentally released. An improvement project followed immediately.

Goals

• Ensure a safe and secure unloading process
• Protect people and the environment
• Advise customer organisation on the correct usage and sourcing of dry-break couplings
• Ensure ergonomic improvement for client employees

Process and highlights

After receiving the RTC in question, AnQore immediately initiated contact with the customer. Shortly thereafter, an investigatory visit to the customer site followed and a root cause analysis was conducted by the Marketing & Sales and Supply Chain people. A thorough Root Cause Analysis concluded that the customer’s unloading staff used a coupling system which was not up to AnQore’s high safety standards. After alignment, AnQore provided the customer with sourcing and operational support to transform the coupling system towards dry-break couplings, a proven technique for safe unloading. These couplings are a) selective towards the product for which it is intended, reducing the risk of unloading a wrong product into the storage tank, and b) close automatically when a hose is disconnected on purpose or by accident. No further incidents have been noted since the change. The next audit of the location was immediately scheduled in two years’ time.

Results

The new RTC is impressive and not just in terms of safety. It also represents progress and innovation in productivity and RTC design. The RTC is regarded as an ongoing development of the Wascosa safe tank car®, which was successfully introduced in 2010.

Objective	How it is effected
Ensure safe and secure unloading process	By enforcing to AnQore’s high quality standards, a secure and safe unloading process was deployed.
Protect people and the environment	By installing the new dry-break couplings spillage is prevented, reducing the risk of exposure.
Advise client on the usage and sourcing of couplings.	High standards achieved by providing guidance on how to source the best possible quality material.
Ensure ergonomic improvement for customer employees	Couplings require no bolting or wrench to connect tightly. The connection is almost plug and play, a big time and safety saving from the old way of working.

AnQore visits all customer sites on a regular basis to ensure the most up to date safety standards can be shared. In case incidents do occur AnQore engineers are dispatched to the location to offer support in improving safety. If a location would be regarded as unsafe, AnQore will not deliver.