SALES OFFICES - American Railcar Leasing
Contents
1. Operating amp ervice Manual SALES OFFICES Headquarters St Charles MO 63301 636 940 5000 Northeastern District 475 Market Street Elmwood Park NJ 07407 201 794 6828 nter Flow UREAIDE Southern District Pressure Differential Covered Hopper 1610 Woodstead Court Suite 230 The Woodlands TX 77380 3403 281 364 0190 Mid Western District 15 Spinning Wheel Road Suite 108 Hinsdale IL 60521 2983 630 325 4600 Canadian District 7 E m i ARL Canada Limited y gt 1 Avenue Holiday East Tower SHOR Suite 501 Pointe Claire Quebec H9R 5N3 E 514 697 5958 ARL makes no representations or warranties expressed or implied with respect to the contents hereof and assumes no contractual or other liability with respect to any use which customer may make of this Service Manual For further information telephone or write either the nearest representative of American Railcar Leasing LLC or phone directly to American Railcar Leasing LLC St Charles Missouri at 636 940 5000 O 2012 AMERICAN RAILCAR LEASING LLC PRINTED IN U S A GENERAL MAINTENANCE RUPTURE DISC ASSEMBLY The rupture disc assembly must be inspected annually or if the security seal is broken 1 Break the security wire and remove the four nuts securing the weather cover 2 Visually inspect the disc looking for signs of rupture tears or holes An air leak test can be performed by pressurizing the car body2. Large industrial plant systems which produce an adequate air flow may be used to operate the Pressureaide car provided they are equipped with a pressure regulator that limits the pressure to 20 psig an adequate water trap and a good filter NOTE WHEN USING ANY AIR SOURCE THE AIR MUST BE CLEAN FREE FROM OIL AND WATER AND ITS TEMPERATURE MUST NOT EXCEED 250 FAILURE TO DO SO MAY RESULT IN DAMAGE TO THE CAR S MEMBRANES dad CENTER FLOW PRESSUREAIDE CAR The Pressureaide car has two membranes in the bottom of each compartment Air directed through the membranes fluidizes the lading and pressurizes the car The fluidization breaks down the internal strength of the lading and the pressurization provides the energy to convey the lading To ensure the system works properly the air inlet side of the membranes must remain clean This requires that precautions be taken at the unloading site 1 Air inlet hose must be free of product and or other foreign material 2 Air supply should be clean and dry In situations where by pass air lines are used see Figure 5 a check valve and metering valve arrangement should be part of the system The purpose of the metering valve 1s to permit proper adjustment of air flow into and by the car while the check valve 1s to ensure against a backflow of lading into the blower package and the car s air inlet line in the event the air supply is interrupted during the unloading proces
3. Allow the blower to run a sufficient amount of tme to clean out the manifold and unloading site conveying lines 10 SHUT DOWN THE BLOWER 11 Open the blowdown valve on the A end of the car until all pressure 1s reduced to zero psig and air has stopped flowing out of the blowdown valve Disconnect flexible air and product hoses and secure all dust caps UNLOADING ASSISTS 1 Vibration The unloading system for the Pressureaide car will provide satisfactory cleanout with most commodities If unusual conditions exist which require vibration for cleanout contact your ARL representative 2 Fluidization The Pressureaide car is equipped with fluidizing membranes in each compartment The air used for pressurizing the car 1s adequate for fluidizing the lading and will provide complete cleanout when the recommended unloading procedures are followed PART V GENERAL MAINTENANCE ad CENTER FLOW PRESSUREAIDE CAR Ensure there is no pressure on any portion of the car before attempting to perform any maintenance Open the blowdown valve any fluidizing valve and any product valve before removing any dust caps ATTACH COMPRESSEDU AIR LINE HERE TOO CLEAR LINE PRESSUREO MANIFOLD O m PRESSURE OA EEN PETCOCKS A TERES TEST D TEST M GAUGE fu GAUGE Figure 11 Pressure Test Gauges PRESSURE GAUGES Refer to Figures 11 and 12 Calibration of the pressure gauges should be checked annually To do this in
4. Dust cap installed Adequate air supply Obstruction or air leaks 1n air supply line Blown rupture disc Leaking blowdown valve Leaking or prematurely opening pressure relief valve Leaking vacuum relief valve Leaking hatch covers Open blowdown by pass or product valves closed fluidizing valve ACTION REQUIRED Petcock on gauge line must be closed Check for clogged air line to gauge and clean if necessary Check pressure gauge calibration consult gauge manufacturer for instructions on calibrating gauges Check air inlet cleanout port and product line dust caps to ensure they are installed with gaskets intact See Page 5 for air requirements Remove obstruction and repair leaks See Page 11 for rupture disc service procedures Close valve If leakage persists clean seat Refer to service and repair procedures for pressure relief valve Page 12 With the car under pressure depress vacuum relief valve and release Repeat 2 3 times If this doesn t work depressurize the car and clean the valve seat Check to be sure all hatches are closed and cam levers are secure Clean hatch cover gaskets and gasket seats Replace hatch gaskets and broken cam levers 1f necessary See Page 13 for hatch adjustments Close blowdown by pass and product valves Open fluidizing valve 16 PART X Figure 1 CF 5650 Pressureaide Covered Hopper Car The CF 5650 Pressureaide covered hopper ca
5. amount of pipe compound to male threads only leaving the first thread clean Compound applied to female threads or used to excess can find its way into the valve causing leakage NOTE DO NOT OVERTIGHTEN 3 The opening pressure for the relief valve mounted on the roof of the car 1s 14 5 psig The opening pressure for the valve on the air inlet line 1s 16 psig If the opening pressures vary by more than 0 5 psig return the valve to American Railcar Leasing LLC 4 Do not paint oil or otherwise cover any interior or working parts of the pressure relief valves These valves do not require any lubrication or protective coating to work properly 12 ad CENTER FLOW PRESSUREAIDE CAR OPERATING INSTRUCTIONS amp CONTROLS UNLOADING CONTROLS Each compartment is equipped with a product discharge valve to regulate the flow of product entering the discharge manifold and an inlet valve for controlling fluidizing air to each hopper A check valve and by pass valve 1s installed in series in the air supply line where the air supply connects to the discharge manifold This arrangement permits conveying air to be metered into the discharge line 29 dad CENTER FLOW PRESSUREAIDE CAR OPERATING EQUIPMENT amp LOCATIONS AR BODY BLOWDOWN VACUUM RELIEF SAFETY RELIEF RUPTURE VALVE VALVE VALVE DISC HT AT B END END E CHECK VALVES PRODUCT MANIFOLD CLEAN OUT CHECK VALVES 4 locations DISCHARGE PRE
6. mm B END A X 4 I END y gt PRESSURE BY PASS PRODUCT AIR INLET BY PASS GAUGES AIR VALVE DISCHARGE near side AIR VALVE CONNECTION far side not shown one near side one far side not shown Note Near side refers to the side of the car with the manifold piping Far side refers to the side of the car opposite the manifold piping 14 27 ad CENTER FLOW PRESSUREAIDE CAR PART VI ad CENTER FLOW PRESSUREAIDE CAR CLEANING SPECIFICATION SHEET GENERAL CLEANING 5 Wash compartment by using a rotojet inserted l EE into the hatch opening or by a hand held hose son cm sra ears 1 Steam or grit blasting 1s not recommended as AIR MUST CONTINUE TO BE BLOWN Em a either may cause damage to the lining or THROUGH MEMBRANE BEFORE permeable membrane The most common DURING AND AFTER WASHING methods of cleaning hopper cars are dry cleaning by scraping residue off with plastic or wood NOTE scrapers and washing with water CARE MUST BE TAKEN NOT TO DIRECT A HIGH PRESSURE STREAM OF WATER AT 2 When entering the car a ladder should be THE INLET PIPE OF THE RUPTURE DISC used which 1s equipped with rubber or suitably ASSEMBLY LOCATED ON CAR S ROOF THIS padded feet to protect the permeable membrane COULD CAUSE DAMAGE TO THE DISC The ladder should not be allowed to rest on the membranes nor should workmen walk on them 6 When compartment has been washed allow Of course a ladder of adequate length should be air to be
7. Clean the gasket groove with a commercial adhesive remover to remove any residue then wipe down both sides of the new gasket and allow to dry 2 Apply a thin layer of Scotch Grip EC1357 Contact Adhesive to the bottom of the gasket Allow the adhesive to set until the surfaces become tacky 3 Install the gasket by slipping one edge into the dovetail Repeat this every 90 degrees Continue pressing the gasket into the dovetail with thumb pressure or the heel of your hand A small roller can also be used Make sure the gasket is properly seated 4 Wipe away any excess adhesive 5 Close the cover center on the hatch ring and latch all cam levers Check lever closing force PRESSURE GAUGES The pressure gauges must be calibrated on an annual basis Two tee connections are located on the back side of the pressure gauge housing These fittings connect the gauge inlet lines the pressure gauges and the petcocks 1 Remove the petcocks and connect calibrated test gauges to the tees If necessary the gauge inlet lines can be cleared with compressed air 2 Close all product and air valves except for one fluidizing valve 3 Connect an air supply line and pressurize the car to 10 0 psig 4 The pressure reading between the car gauge and the test gauge must be within 1 0 psig If the car gauge falls outside this range remove the gauge and replace 5 If there is no pressure reading stop the blower and open the blow down val
8. Width 10 7 3 16 10 3 Check to be sure fluidizing air valve is properly Height Rail to Bottom installed See Figure 6 of Discharge Outlets Light Car 12 13 16 12 13 16 13 13 Number of Hoppers Remove valve and inspect for obstruction E ME Flapper must be free If stuck replace valve Number of Outlets per Hopper 1 5 Number of Roof Hatches 8 Size of Roof Hatches 20 Dia Slope End Floor Sheet Slope Interior Floor Sheet Slope Side Slope Sheet fluidizing air valves Open both by pass air valves 5750 cu ft to the full open position and restart blower 1f shut Estimated Nominal Lightweight off If line can not be blown clear indicated by a Horizontal Curve Negotiability line pressure drop close by pass air valves and Uncoupled 150 ft 150 ft 180 ft 180 ft shut off blower CAUTION If the blower must be shut down before line 1s clear ensure the product valve on Excessive back pressure in receiving vessel Check receiving vessel for proper air vent Clean air filters 1f applicable O Dia 0 4509 39 45 Plugged line Immediately close all product valves and all C2 DA dl ak o the most empty compartment 1s open VALVE C a E The following reverse flow procedure may also be s cx mre ao JA 35 followed to clear a plugged line PRESSURE m E P AN sex feta SS Use ANDE D a 1 Open blowdown valve to depressurize car he p 5 SE ES Y P7 LI E TE S EM d 3 E ED L1 Leave va
9. hoses are intact 8 If the cleanout port has a flanged cover ensure its gasket 1s properly installed and all fasteners properly tightened If the cleanout port has a dust cap arrangement ensure the cap is properly installed its gasket 1s in good condition and a proper locking seal is applied to the operating levers 9 Ensure all valves are closed prior to loading product into the car If venting 1s required it may be provided for by opening the blowdown valve or a hatch Proper filters may be required to minimize dusting AFTER LOADING 1 Check all caps for secure installation 2 Ensure blowdown valve 1s closed 3 Ensure cover over pressure gauges 1s closed 4 All hatches must be closed and all holddowns properly engaged in the closed position CLEANING WASHING PROCEDURES PREPARATION 1 In plant confined space entry procedures must be followed to enter the car 2 Before opening hatches or removing caps open the blow down valve air inlet valve by pass valve and product valves to depressurize the car body and manifold system 3 Open all hatches on top of the car 4 Connect a positive displacement blower to the air inlet connections 5 Attach product discharge hoses to each side of the car to direct the flow of air water and residual product away from the personnel and the work area 6 Close the two by pass valves and open all of the fluidizing valves to the full open position 7 Open all of
10. the product valves 8 Remove the bolted cover plates from the clean out port on each compartment ad CENTER FLOW PRESSUREAIDE CAR CLEANING PROCESS 1 Start the blower to establish airflow through the membranes It is critical to maintain airflow during the cleaning process 2 Wet washing can be accomplished using a hand held hose or a roto jet inserted into an open hatch Move from hopper to hopper as necessary to clean entire railcar 3 After cleaning continue the airflow through the membranes until dry 37 CLEANING GENERAL INSTRUCTIONS amp CAUTIONS 1 In plant confined space entry procedures must be followed to enter the car 2 Ensure the car 1s not under pressure before opening hatches or removing caps Open the blow down valve air inlet valve by pass valve and product valves to depressurize the car body and manifold system then check the pressure gauges to confirm all readings are zero 3 If using ladders they must be equipped with rubber feet to protect the interior lining 4 Never place a ladder on the aeration membrane as damage will result 5 Avoid direct impingement of high pressure water on the safety relief valve vacuum relief valve and the rupture disc inlets located in the roof of the A and B hoppers dad CENTER FLOW PRESSUREAIDE CAR 6 Do not direct high pressure water at the membranes 7 Steam cleaning or grit based blast should never be employed on cars with
11. 0 25 psig or 0 5 inches Hg Its purpose is to protect the railcar s body from deformations due to atmospheric pressure changes It will not protect the railcar s body in the rare event the railcar must be vacuum unloaded If the railcar must be vacuum unloaded contact American Railcar Leasing 31 OPERATING INSTRUCTIONS amp CONTROLS BLOW DOWN VALVE The car 1s equipped with a blow down valve to depressurize the car body The valve 1s located on the A end of the car and 1s operated from ground level with a handle extension The valve is closed when the handle position 1s parallel to the valve body Note This valve discharges air and dust at high velocity Personnel must stand clear PRESSURE RELIEF DEVICES ad CENTER FLOW PRESSUREAIDE CAR The Pressureaide car is equipped with two self closing pressure relief valves a car body pressure relief valve and a manifold relief valve for the air inlet manifold The car body pressure relief valve 1s set to open at 14 5 0 5 psig The valve automatically closes when the pressure inside the car body is relieved The relief valve in the air inlet is set to open at 16 0 0 5 psig and will reseat when the pressure 1s relieved 30 PROTECTIVE LI COVER ad CENTER FLOW PRESSUREAIDE CAR VACUUM RELIEF Ol VALVE PRESSURE RELIEF O VALVE BLOWDOWN LI VALVE Figure 13 Safety Valves RUPTURE DISC Reference Figure 13 Inspect the rupture disc annu
12. C compartment See Figures 4 amp 6 2 Open the product valve on the compartment being fluidized 3 In general optimum unloading rates are obtained when the air inlet manifold pressure gauge reading is 1 to 3 psig higher than the car body pressure gauge reading Meter the product flow to suit the unloading system s capacity and to avoid plugging the conveying line by adjusting the product valve and by pass valve to obtain the best product to air mixture Long conveying distances generally require more by pass air than short conveying distances Check gauges to ensure proper pressures are being maintained 4 If one side of the hopper is empty and the other side has material use the four way fluidizing valve to direct air to the side that has material 1n it 5 A rapid drop in car body pressure normally indicates the compartment 1s empty Close the by pass and product valves while continuing to supply air Open and close the product valve at about twenty second intervals four or five times for final cleanout Use by pass air valve as needed 6 Open the fluidizing valve to the full open position on the next compartment to be unloaded Close all other valves on the car 7 Allow car body pressure to build to operating pressure 8 Repeat steps 1 through 7 for each compart ment ad CENTER FLOW PRESSUREAIDE CAR 9 After the last compartment is unloaded open both by pass valves and close all other valves
13. ECTOR 11 6 Place rupture disc Item 5 on inlet fitting Item 4 with crown up SYSTEM PRESSURE MUST BE AGAINST CONCAVE SIDE OF DISC 7 Carefully place outlet flange Item 2 in position Install bolts and nuts and torque evenly to 34 to 38 ft lbs Make sure flanges are not cocked DO NOT OVER TORQUE Angular seating surfaces help seal disc with minimum bolt loading Excessive tightening may damage the rupture disc 8 Install protective cover and torque second set of nuts to 20 to 25 ft Ibs 9 Install wire through holes 1n bolts and seal PRESSURE RELIEF VAVLED SETTING 14 5 PSIG APPLY FLAT WRENCH O THIS SURFACE PRESSURE RELIEF VALVEH SETTING 16 PSIG AIR INLET O MANIFOLD 3 LOOKING UP AT AIR LI INLET PIPING Figure 15 Pressure Relief Valves PRESSURE RELIEF VALVE Reference Figure 15 Pressure relief valves should have a regular program of visual inspection Build up of dirt and or foreign material around and in the valve as well as broken parts will adversely affect the valve s operating characteristics The valves should be checked annually to ensure they are opening at the specified pressures This dad CENTER FLOW PRESSUREAIDE CAR may be done with the valves installed on the car or they may be removed and bench tested 1 To remove valve unscrew by placing a flat jawed wrench on flats provided Do not use the valve outlet or cap as a lever 2 To reinstall the valve apply a moderate
14. EE De swmemwe e vemm pepe frewa NET cmo 19 NE 5 Check Valve applies to model 5000 s lE dns Check Valve models 5001 5003 5007 INT e ereenn oo m ee o a MEAN LR 4 V 4381 2 U 7457 Gasket 90038147 20 dad CENTER FLOW PRESSUREAIDE CAR MOUNTING O VIEW A VIEW LOOKING UPO AT MEMBRANE MEDIE Support Assy With Elbow As Shown 4U068701 4 U 0687 01 Membrane Support Assy With Elbow Rotated 180 4U068700 4 U 0687 00 90034612 EE EE 90004418 Parts List For Model 5007 NUMBER PER UNIT DESCRIPTION CATALOG NUMBER DRAWING NUMBER 1 8 Gasket amp Membrane Assy 50091430 4V 4636 00 L2 4 Membrane Support Assy With Elbow As Shown 4V463400 4 V4634 2A 4 Membrane Support Assy With Elbow Rotated 180 4V463401 4 V 4634 01 sz haen 9005259 ea w E a p EA um O 0004475 O SSS sone 9008170 LlokWaser j 9004259 21
15. Instructions at RS ED de us 7 POOE U EE ae ard ET be E G PSS oe es DOT E Re T ee 8 BUS ELM NO DEN EC TUO TE S EE E AS T ERLRI OTT 8 Ms MV o PERI te Ste ate exo seh ee acess sage geese ene 9 Unloading Assists Vibration and Fluidization 9 General Maintenance 10 Prosare A A a a 10 SUp5Hte IDSC yan cet RU ER E QU nao s RUP ie d eee el 11 Pressure Releet Viles ean ass odo a et o metodos grece mi B edel de ocn A 12 Je ENG RITU E TET RO Od ho eh teks RR Gas eat ee ee eee 13 rr 53 RA 15 Troubleshooting nnana aaa 16 O RR 19 Specification Sheet 24 ARL CF 5650 Pressureaide aa A O oe 25 Qe A edet ee aedes eee 26 Operation Equipment and Locations 359 cox ecR a eee EORR CR cda 27 Operation Instruction and Controls a an aaaea ee 29 Standard HatenArrancemecat oerien 5s dd ds A eto o nd 32 Hatch Lever Adjustment Instructions o o o ooo ooo oo 33 Unloadince Operio v2 seda tae SUAE ARCA Ad 34 UI ID PITT NN 36 General TVIESIICeD ance sc doc Sce BOR UR RUE oss ace One da da 39 TTOUDIESHOOUNG lr S EE RH RE dd 16 ad CENTER FLOW PRESSUREAIDE CAR INTRODUCTION J j Pi i l 4 f d ga e E j 4 r E E Y E 7 1 E a E K 2i 1 k h 1 h e i i M 1 a i n E i d i 1 1 1 my i w 1 i Figure 1 Center Flow Pressureaide Car The ARL Pressureaide pressure differential Center Flow covered hopper car is designed to handle dry bulk commo
16. Part of this program includes a thorough pre trip inspection prior to loading PRESSURE RELIEF VALVE RUPTURE DISC foe RELIEF VALVE LOCATED ON ROOF uM I FLUIDIZING AIR VALVES FLUIDIZING AIR VAVLES I PRODUCTO VALVE BC O Comp i D j a l T l A NENNEN T D Pg E l Tu _ 1 Exo Ae NA 1 3 PA oe J NOTES Vinge ea PRESSURE D AIR INLETO BY PASS AIR O ee VALVE ARE AE AIR INLETO VALVE pi NEAR SIDE PRODUCT O CLEAN OUT PORT DISCHARGE MANIFOLD PRESSUREO RELIEF VALVE CLEAN OUT PORT Figure 4 Operating Equipment PRE TRIP CHECKLIST BEFORE LOADING 1 If the car is to be cleaned follow the procedures on page 15 2 Ensure there is no water in the air manifold and that the product manifold and membranes are clean and dry 3 Inspect all hatch covers locking mechanisms and safety catches for proper operation Ensure gaskets are clean and in good condition 4 Inspect and operate all control valves product by pass air fluidizing air and blowdown to ensure they are in proper working condition 5 Inspect all dust caps Ensure gaskets are in place and 1n good condition Attachment chains and cam levers must be intact 6 Inspect pressure gauges and protective covers Be sure the gauges read zero with car depressurized and the cover 1s not broken 7 Inspect all rubber hoses to ensure the hose clamps are properly installed and tightened and that the
17. REMOVING ANY DUST CAP OPEN THE BLOWDOWN VALVE ANY FLUIDIZING VALVE AND ANY PRODUCT VALVE IF GAUGE READINGS ARE NOT ZERO CHECK FOR FAULTY GAUGES 4 By pass Air Controls A butterfly check valve arrangement is installed in the air supply portion of the manifold at each end of the car This permits air to be metered into the product discharge line The check valves are installed to prevent the back flow of lading 1f there 1s an interruption 1n the air supply 5 Blowdown Valve A manually operated blowdown valve is applied to the A end bulkhead to depressurize the car This valve is equipped with a handle extension to permit operation from ground level GENERAL UNLOADING INSTRUCTIONS NOTE BEFORE REMOVING ANY DUST CAP OPEN THE BLOWDOWN VALVE ANY FLUIDIZING VALVE AND ANY PRODUCT VALVE IF GAUGE READINGS ARE NOT ZERO CHECK FOR FAULTY GAUGES ad CENTER FLOW PRESSUREAIDE CAR Prior to hook up for unloading inspect car thoroughly to ensure 1 All hatches are secure See Figure 7 SAFETY LOCK A TYPICAL HATCH Figure 7 Loading Hatches 2 Blowdown valve is in closed position See Figure 8 BLOWDOWN VALVE L pe x Tar ap m TO CLOSE ER r SPRING LOADED THROTTLE HANDLE FABRICATED HANDLE Figure 8 Blowdown Valve 3 All product valves are closed 4 All fluidizing air valves and by pass air valves are closed 5 Pressure gauges are intact and petcocks are close
18. SSURE PORTS 4 locations CONNECTION RELIEF VALVE one each hopper one near side one far side not shown 28 gaa FI Bi RAE d nto A E ih OOO los CE SONS SENSN ws X a eae M EET c P c qe P iB ab I0 ADJUST THESEH LEVERS FIRST 5 16 CATCH HATCH HINGE PIN Figure 16 HATCHES Reference Figure 16 Hatch covers holddown assemblies safety catches and gaskets should be inspected prior to each loading Broken or missing parts should be replaced and all cam levers properly adjusted HATCH COVER INSTALLATION AND ADJUSTMENT Use this procedure to adjust existing hatch covers and for installing new hatch covers 1 With all cam levers disengaged center hatch cover on hatch ring Ensure the hatch hinge pin is installed This will center the cover along the centerline of the car then it can be moved to the right or left to center 1t across the car 2 Loosen set screw in the cam lever assemblies and adjust and engage the two cam levers located 90 from the hinge some cam lever assemblies are not equipped with set screws Both levers must be adjusted at the same time Rotate entire cam lever assembly clockwise to tighten and counter clockwise to loosen Levers should be adjusted so that each requires about 40 Ibs of force to lock down 3 Adjust remaining cam levers levers across from each other should be adjusted dad CENTER FLOW PRESSUREAIDE CAR d a gu v 5 Ey Li Sk 2 Cl A CO
19. UNTER CLOCKWISE LOOSEN Optional CCW CW CLOCKWISE TIGHTEN REQUIRES A 5 32 0 ALLEN WRENCH HATCH ADJUSTMENT Hatches simultaneously All levers should require approximately 40 lbs of force to engage 4 Recheck all cam lever forces some of the levers might require additional adjustment due to the gasket compression 5 Retighten all set screws HATCH GASKET REPLACEMENT There are two gasket designs 1n service Ensure you identify the proper arrangement before ordering gaskets for a hatch cover For Hatch Covers using a retaining ring See Figure 16 1 Remove cap screws and shakeproof washers Items 1 and 2 2 Remove gasket retainer Item 4 and old gasket Item 3 3 Thoroughly clean gasket retainer and seal on hatch cover and hatch ring 4 Install new gasket and reassemble 5 Adjust per Hatch Cover Installation and Adjustment instructions 13 A INNERO Neri GROOVE WALL N Figure 17 Hatch Cover Gasket OUTERO GROOVE WALL For Hatch Covers not using a retaining ring See Figure 17 1 Remove the worn gasket This may be facilitated by inserting a flat head screwdriver or knife blade along side of the straight outer groove wall and prying upward When enough gasket 1s exposed to grab onto pull remaining gasket from 1ts groove Do not pry from or damage the dovetailed inner groove wall 2 Clean the gasket groove with a good solvent such as methyl ethyl ketone to remove any
20. URE EXCEEDS 15 0 PSIG AND THE PRESSURE RELIEF VALVE DOES NOT OPEN SHUT OFF THE AIR SUPPLY BLEED PRESSURE FROM CAR AND DETERMINE REASON FOR PRESSURE RELIEF VALVE MALFUNCTION IFA MALFUNCTION OCCURS WHILE UNLOADING REFER TO TROUBLESHOOTING SECTION ON PAGE 16 3 When the car reaches the optimum operating pressure it 1s ready to unload The maximum car body operating pressure 1s 14 5 psig Optimum pressures will vary depending upon the unload sites pneumatic unloading system HATCH COVER ADJUSTMENT INSTRUCTION WRENCHABLE LEVER ADJUSTMENT The levers are designed to function as a wrench providing the abihty to adjust the closing force without additional tools 1 Center the cover on the hatch ring 2 Close the two levers at 90 degrees to the longitudinal centerline of the car 3 With the lever 1n the open position and the bolt upright lift the lever to engage the wrench feature with the flats on the nut 4 Turn the nut clockwise to increase the closing force or counter clockwise to decrease 5 Adjust the levers diagonally opposite 6 Proceed to the next pair of levers 7 Confirm the closing force on all levers and readjust as required 8 Cable seals may be applied to either holes in levers or hatch cover and ring HINGE BLOCK LEVER ADJUSTMENT 1 Center the cover on the hatch ring 2 Close the two levers at 90 degrees to the longitudinal centerline of the car 3 Loosen the 5 16 setscr
21. _ CS 25 4 HexNut O e 26 1 Rupture Disc Holder o ______ 27 1 Rupture Dise ee 28 4 BoltWithSealHole o 29 1 Rupture Disc Replacement Kit Includes Key Nos 20 21 and 27 50093596 2 J 5615 NOTE For replacement of rupture disc only Reference Page 11 Figure 14 of this manual for 8 Gasket For Hatch Cover For Retainer Type 90011238 pee C C G G C service and repair procedure order Rupture Disc Replacement Kit per Key No 29 For Cars Built Before January 2000 For Cars Built In January of 2000 And Later 23 dad CENTER FLOW PRESSUREAIDE CAR PART VIII dad CENTER FLOW PRESSUREAIDE CAR PARTS LIST SPARE PARTS SR 59 E me EEA wa E 1 y E a lt a E o s 2 E 2625 i F lt Lu Teo Pu wh gt e Zo A 2x6 ee A a ax ew LI T e P NON m o x UM E tr Zo nO e 2 gt N u gt l A O OF E 28 e SEE DETAIL A DETAIL A A END OF CAR 22 19 dad CENTER FLOW PRESSUREAIDE CAR MANIFOLD ASSEMBLY FOR CARS EQUIPPED WITH 5 PRODUCT LINE AND 4 AIR INLET LINE NUMBER PER CAR DESCRIPTION CATALOG NUMBER RA NUMBER EINUB NM 5 Alum KamLok Cap 5009980 al 6 Gasket 5 KamLok Cap MI eR T come pem 0 omm poem iced ETE CT EC ICI mew 000 ANI IC EE INC wemem FE vm De s wemeesus meme EN El e rezos mmm umm 14 6 A HoseCamp 3 000 Clamp 3 50093458 RVOT 0 De pmmmetesiue E
22. adhesive build up Wipe all surfaces of the new gasket with a clean solvent moistened rag to remove any dust or mold release agent that may be present Allow solvent to dry Coat the bottom of the groove with a uniform thin layer of adhesive such as 3M s Scotch grip 1300 Rubber Adhesive Allow a couple of minutes for adhesive to become tacky Install new gasket forcing 1t into the groove beginning at the inner groove wall at four points approximately 90 apart Continue forcing the gasket 1n the groove using hand and thumb pressure until gasket 1s uniformly seated in 1ts groove A small steel wheel roller may help facilitate the last step 3 After the gasket 1s 1n place be sure there 1s no excess adhesive exposed Remove any excess with a clean solvent moistened rag At this point the hatch cover should be reinstalled and or cammed shut to ensure sufficient pressure for complete adhesive contact Adjust per Hatch Cover Installation and Adjustment instructions Gay CENTER FLOW PRESSUREAIDE CAR ity CENTER FLOW PRESSUREAIDE CAR DUST CAPS OPERATING EQUIPMENT amp LOCATIONS Dust caps should be inspected prior to each loading AIR VALVES one each hopper PRODUCT VALVES one each hopper 1 Open the blowdown valve any fluidizing valve and product valve before removing any dust cap 2 Inspect for missing caps broken or missing cam levers gaskets and chains Replace items as required AT a
23. ally If the seal 1s broken remove the protective cover and check the disc Disc should be intact and in good condition If condition 1s in doubt pressurize the car to 10 psig and inspect for leakage Ifa leak is detected depressurize the car and replace the disc CAUTION SUBSTITUTE OR MAKESHIFT DISCS ARE NOT TO BE USED SEE THE PARTS LIST FOR SPECIFIED DISC RUPTURE DISC Figure 14 Rupture Disc Assembly DISASSEMBLY AND ASSEMBLY OF RUPTURE DISCS Reference Figure 14 1 Remove protective cover Item 1 by breaking sealing wire and removing four nuts 2 Inspect the rupture disc Item 5 to determine if it has ruptured or 1f there are any imperfections tears holes etc 3 If disc must be replaced remove flange Item 2 by removing four bolts and nuts Item 3 4 Foreign matter or rough surfaces may damage the rupture disc or cause leakage Clean seating surfaces of both inlet and outlet flanges Items 2 amp 4 before installing the rupture disc Polish with a fine emery cloth 5 When installing the rupture disc handle carefully Examine seating and prebulged surfaces DO NOT INSTALL A DAMAGED DISC Damage to seating area may cause leakage Damage to prebulged surface of disc may affect disc rating vacuum support is perma nently attached to concave side of disc If missing or damaged replace the disc with a new one NOTE DISCS ARE PACKAGED IN PROTECTIVE CONTAINERS DO NOT INSTALL SHIPPING PROT
24. blown through the membrane for an used as well as following procedures compatible additional 10 minutes then open the fluidizing with good safety practices air valve on the next compartment to be washed Scaftold brackets to assist in dry cleaning the car s o ds iu compartment interior can be provided if desired P TALE CENTERS si d nnn 5 S N OTE 7 Wash the remaining compartments following RESIDUE FROM CLEANING WILL END preceding instructions UP IN PRODUCT DISCHARGE 8 When all compartments have been washed MANIFOLD THIS RESIDUE CAN BE open all four fluidizing air valves and allow air to REMOVED THROUGH THE CLEANOUT blow through the membranes until interior of SACAMOS O T INCOR BYRE EN suo SPECIFICATIONS OUTLET CASTING OR BY PRESSURIZING THE CAR AND OPENING EACH 9 Shut off blower close and secure hatches and PRODUCT VALVE INDIVIDUALLY BERE ro Valve Oat Der ane CAUTION pee Cea dq IF THE CLEAN OUT PORT HAS A Starting at one end of the car open the product FLANGED COVER REPLACE CLEAN OUT valve for approximately two minutes to blow PORT FLANGE AND GASKET AFTER water and residue from the product line Close Number of Outlets per Hopper CLEANING TORQUE BOLTS TO 35 FT LBS the product valve pressurize the car and repeat 7 for the remaining compartments Size of Roof Hatches 20 DIA WASH PROCEDURE 8 p Slope End Floor Sheet 45 am
25. d If petcocks are open gauges will not give accurate readings HOOK UP ad CENTER FLOW PRESSUREAIDE CAR Prior to removing any dust caps open the blowdown valve any fluidizing valve and any product valve FAR SIDE HOOK UP AIR INLET O MANIFOLD 3 FITTING Figure 9 Air Inlet Manifold 1 Remove dust cap and connect air supply line to air inlet fitting Air supply can be connected to either side of the car See Figure 9 NOTE CARE MUST BE EXERCISED TO ENSURE AIR SUPPLY LINE IS CLEAN AND FREE OF CONTAMINATION 2 Remove dust cap from product discharge line on car and connect product line See Figure 10 3 Ensure all valves on the car are closed after hook up is completed 4 Attach grounding straps to both the car body and the product discharge line PRESSURIZATION 1 Open fluidizing air valve to full open position on the first compartment to be unloaded 2 Start the blower and pressurize the car Monitor the pressure with the car s pressure gauges one gauge reads car body pressure the other gauge reads air inlet pressure CAMLOCK FITTING O ALTERNATE HOOK UP PRODUCT O DISCHARGE O LINE PRODUCT LINE Figure 10 Product Discharge CAUTION IF DUST EMITS FROM THE CAR IMMEDIATELY STOP UNLOADING DEPRESSURIZE THE CAR MAKE A THOROUGH INSPECTION AND CORRECT THE PROBLEM IF ANY CRACKS ARE FOUND IN THE CAR S STRUCTURE CONTACT AN ARL REPRESENTATIVE IF THE CAR S BODY PRESS
26. dities With operating pressures up to 14 5 psig fast efficient unloading for long distances can be achieved Unloading rates up to 100 000 Ibs hour may be obtained depending upon the commodity and unloading system The Pressureaide car has many of the famous Center Flow car design features centerline loading unloading complete sanitation and ease of operation Designed to operate with standard positive displacement blowers this car may be used with equipment compatible with pressure sleds As safety is a prime consideration for American Railcar Leasing LLC the Pressureaide car is equipped with two pressure relief valves a rupture disc and a vacuum relief valve The Pressureaide car is unmatched by any railcar in its class when it comes to sanitation maintenance and unloading performance GENERAL MAINTENANCE cmi CENTER FLOW PRESSUREAIDE CAR The car must be depressurized before performing any maintenance function Open the blow down valve then one fluidizing one by pass valve and one product valve Confirm the pressure gauges read zero HATCH GASKET REPLACEMENT Remove the old gasket by inserting a flat head screwdriver along the outer wall of the gasket groove and prying underneath the gasket Take care not to gouge the metal surface Once enough of the gasket 1s exposed pull the remainder out by hand Do not pry against the inner wall of the gasket groove as this could result in damage to the dovetail 1
27. equired 11 When the hopper empties there will be a rapid drop in car body pressure 12 Close the product discharge valve 13 Move to the next hopper and open the air valve to the Full Open position 14 After unloading a hopper close the air valve and the by pass valve The car body will begin to pressurize for unloading the next compartment 15 Repeat the above process steps 3 14 for the next hopper to be unloaded 16 As this is a single compartment car some spillage may occur between hoppers during the unloading process To provide complete clean out repeat the above procedures for all compartments 17 After all hoppers are emptied open both by pass valves and close all other valves Allow supply air to thoroughly clean out the car s manifold and plants product conveying lines 34 2 Rupture Disc A rupture disc 1s applied to the car body as a back up safety device The disc is designed to rupture at 20 psig at 72 F and is located on the roof of the car 3 Lading Controls The product discharge portion of the manifold 1s equipped with a product valve at each hopper The air inlet portion of the manifold 1s equipped with a valve arrangement at each hopper to permit selective fluidization of the hoppers and prevent the car from losing pressure if the blower inadvertently shuts down or if it s necessary to disconnect the air inlet or product discharge hoses while the car is pressurized NOTE BEFORE
28. ew on the hinge block with a 5 32 allen wrench older models may not have set screws 4 Turn the cam lever clockwise to increase the closing force or counter clockwise to decrease 5 Adjust the levers diagonally opposite 6 Proceed to the next pair of levers 7 Confirm the closing force on the levers and readjust as required 8 Tighten the setscrews 1n the hinge block 9 Apply cable seals as required 33 dad CENTER FLOW PRESSUREAIDE CAR SIANDARD HATCH ARRANGEMENT The PD5650N 1s designed with 7 hatches and no interior bulkheads to allow for flood loading of the car The hatches are secured with 6 cam lever closures A safety catch 1s applied to the lever opposite the hinge of each cover The safety catch prevents opening the hatch when the car body 1s under pressure This lever must always be the last one opened The ends of the two opposing levers are drilled for the application of a security seal The hatch cover assemblies and gaskets must be inspected prior to each loading Any missing or damaged parts must be replaced and the cam levers checked for proper adjustment The lever closing force must be 40 pounds Inspect the gaskets to ensure they are clean and undamaged 32 UNLOADING 1 Open one by pass valve to its full open position Use the by pass valve on the A end of the car for the A or AC compartment and the by pass valve on the B end of the car for the B or B
29. interior lining 8 The most common methods for cleaning the interior of an ARL Pressureaide B car 1s using either of two proven methods wet washing or dry scraping If dry scraping use pliable plastic tools and use extreme care not to damage the lining or membranes 9 Entry into the car 1s gained through the manway openings Do not remove the plenum plates from the bottom of the car 36 PART IIl AIR REQUIREMENTS The Pressureaide car has been designed to operate with air supplies from 200 CFM to 1000 CFM CFM Cubic Feet Per Minute The air requirement for a particular system depends on the diameter and configuration of the conveying line and the characteristics of the material being conveyed To determine the air requirements for a specific unloading system furnish your ARL representative with the details of the system As a general guide for air requirements 1n low pressure pneumatic systems refer to the following chart PRODUCT LINE AIR SIZE VOLUME 4 inch pipe 440 CFM 680 CFM 1000 CFM 5 inch pipe 6 inch pipe CAUTION UNDER NO CIRCUMSTANCES SHOULD MORE THAN 1000 CFM BE USED TO PRESSURIZE THE CAR NOR SHOULD CAR PRESSURE EXCEED 14 5 PSIG Best results are obtained by using a positive displacement blower which will develop air flow CFM at a minimum of 14 5 psig However there are many other types of blowers and air compressors that produce adequate air flow to operate the Pressureaide car
30. lve open A B a e cre de n i 2 Close all product val eae T Dpi 34 Close all product valves 3 Close all fluidizing air valves 4 Open by pass air valves to the full open position 24 17 ad CENTER FLOW PRESSUREAIDE CAR CONDITION NO LADING FLOW OR REDUCED FLOW Cont CHECK FOR Plugged line continued Insufficient air flow or inadequate blower Rat holing material hanging on side walls and outlet membrane covered ACTION REQUIRED Open product valve on the most empty hopper Restart blower Close product valve and allow the pressure in the manifold line to build to the maximum capacity of the blower or to a maximum of 14 5 psig Rapidly open and close product valve until reverse flow starts Leave valve open until flow stops Close product valve and repeat When line pressure drops to a low pressure less than 2 psig for most systems with the product valve closed the line 1s clear When the plugged line has been cleared close product valve and open both by pass valves to clear manifold Open fluidizing valve Close blowdown valve to re pressurize car and proceed with unloading If the preceding procedures do not unplug the line it will be necessary to disassemble the unloading line Open one fluidizing valve Open blowdown valve depressurize car Open product valve on most empty compartment Close both by pass air valves Shut off blower Manually disassemble and clean out p
31. n out ports 10 Inspect the clean out ports Swab out any remaining water and residue Re install the quick disconnect caps or closure plates 11 Disconnect the air supply line 12 Close all valves Install and secure the quick disconnect caps on the air inlets and product discharge connections 38 dad CENTER FLOW PRESSUREAIDE CAR Figure 2 Standard 8 Hatch Arrangement For Models 5000 and 5001 Figure 2 shows the standard roof hatch and bulkhead arrangement for the models 5000 and 5001 Pressureaide cars Each compartment has two hatches located on the cars longitudinal centerline Intermediate bulkheads are designed to permit simultaneous loading of adjacent compartments from one hatch E 6 5 1 2 ERE 9 1 al 5 4 1 4 i 6 3 M 6 3 ae 9 1 LL 6 5 1 2 E LE ma E T y N l l l n a z EA A a L E IS i E E Figure 3 Standard 8 Hatch Arrangement For Models 5003 and 5007 Figure 3 shows the standard roof hatch and bulkhead arrangement for the models 5003 and 5007 Pressureaide cars Each compartment has two hatches located on the cars longitudinal centerline Intermediate bulkheads are designed to permit simultaneous loading of adjacent compartments from one hatch PART Il ad CENTER FLOW PRESSUREAIDE CAR PRE TRIP CAR INSPECTION The Pressureaide car is a special piece of equipment as such it requires regular preventative maintenance
32. nnections and the bolted plenums If dusting is observed stop the blower and depressurize the car Identify and correct the problem 6 Open one of the by pass valves to its full open position to establish flow through the discharge manifold Utilize the by pass valve at the A end for hoppers A AC and C For unloading the B and BC hoppers utilize the by pass valve on the B end of the car 7 Open the product valve and adjust it and the by pass valve as required to establish the optimal unloading rate 8 Monitor the car body pressure throughout unloading Pressure requirements will vary with the commodity being shipped and the unloading system The car body operating pressure must never exceed 14 5 psig dad CENTER FLOW PRESSUREAIDE CAR 9 Should the car body pressure exceed 15 0 psig and the pressure relief valve fails to open shut off the air supply and depressurize the car The pressure relief valve must be replaced prior to proceeding with the unloading operation 10 Typically optimum unloading rates are obtained when the air manifold pressure 1s 1 0 psig to 3 0 psig higher than the car body pressure Monitor the pressure at the gauges and adjust valves as required This is dependent on the product and unloading system A series of adjustments using the by pass valve may be required to obtain optimum product flow In general the longer the conveying distance the more by pass air 1s r
33. or on a test bench PRESSURE SETTINGS Car body valve 14 5 psig 0 5 psig Part V Air manifold valve 16 0 psig 0 5 psig 1 Pressure relief valve maintenance cannot be performed in the field If the start to discharge pressure falls outside the 0 5 psig tolerance the valve can be replaced in kind or returned to American Railcar Leasing for rebuilding This Lat V includes adjustment of the start to discharge pressure Oil and grease must be kept away from the FOE VA inside of the valve as it is designed to operate without M Part VIII lubrication 2 To remove the pressure relief valves use a TE A standard open end wrench to engage the flats on TT ar the bottom of the valve Do not apply force to the valve body or the discharge connection 3 Reinstall the valve by applying a moderate coating of pipe compound or plumber s tape to the male threads of the pipe connection Keep the compound away from the first few threads to prevent contamination of the valve car or piping DUST CAPS Inspect the chains gaskets and cam lever hardware on each dust cap Replace damaged or missing parts 40 dad CENTER FLOW PRESSUREAIDE CAR TABLE OF CONTENTS PAGE Introduction 42656 eodd ohio riores 2 Pre Trip Car Inspection o o o o o o o ooooo ooo 4 Air Requirements o 5 Operating Instructions 20 0 0 cc cece eens 6 Operating Cono ub o on be ore ee idR Canes a eS 6 General Unloading
34. p 43 EE CAUTION Slope Interior Floor Sheet 45 1 Connect a positive displacement blower with ENSURE HOSES ARE HOOKED UP TO BOTH Slope Side Slope Sheet 430 a minimum capacity of 450 CFM to the air inlet PRODUCT DISCHARGE CONNECTIONS TO Cubic Capacit 5650 cu ft connection DIRECT HIGH PRESSURE AIR AND RESIDUE Estimated Nominal Lightweight 66 900 Ibs 2 Close both by pass air valves and all four AWAY FROM WORK STATION Horizontal Curve Negotiability Uncoupled 180 ft fluidizing air valves Open all four product 10 With blower still operating open both air valves remove dust covers from each side of the by pass valves and then all four product line product discharge line and hook up hoses to valves Blow for two minutes then shut off direct air away from work station Open hatches blower Allow the car to depressurize Remove on top of car the product line and clean out the port cover 3 Starting at one end of car set the fluidizing air Inspect the discharge piping and the discharge valve to the full open position in the compart casting wipe out any remaining residue ment being washed 11 Ensure pressure gauges read zero disconnect bl air supply line and replace all dust caps Close 26 4 Start blower by pass valves and product line valves 15 PART VII TROUBLESHOOTING ad CENTER FLOW PRESSUREAIDE CAR CONDITION CAR WILL NOT PRESSURIZE OR WILL NOT REACH OPERATING PRESSURE CHECK FOR Proper operation of gauges
35. r is specifically designed and engineered to handle a wide variety of dry bulk fluidizeable products like flour in a safe and efficient manner Its clean bore design no interior bulkheads is well suited for flood load and pressure loading systems The Pressureaide car operates with internal pressures up to 14 5 psig which allows for faster unloading Safety is a priority with ARL each car is equipped with two 2 pressure relief valves a rupture disc and a vacuum relief valve dad CENTER FLOW PRESSUREAIDE CAR ARL CF 5650 PRESSUREAIDE INTRODUCTION 25 PART IX dad CENTER FLOW PRESSUREAIDE CAR dad CENTER FLOW PRESSUREAIDE CAR SPECIFICATION SHEET CONDITION CAR WILL NOT PRESSURIZE OR WILL NOT REACH OPERATING PRESSURE Cont PRESSURE TIGHT LOADING HATCH FOR PRESSURE DIFFERENTIAL CAR CHECK FOR ACTION REQUIRED Leakage from car body Contact an ARL representative Jammed check valve in air inlet portion of the Check valve is located in the air inlet portion of manifold the manifold Loosen bolts inspect and reposi tion QUICK RELEASE CAM LEVER CONDITION NO LADING FLOW OR REDUCED FLOW BASIC SPECIFICATIONS so s 55 5007 NAMING IE Length Over Strikers 56 11 567 11 62 5 1 4 62 5 1 4 Q Truck Centers 51 9 1 4 51 9 1 4 Jammed check valve or fluidizing air valve in air With blower running rapidly open and close Overall Height 15 4 13 16 15 5 9 16 15 5 9 16 lines valve Overall
36. roduct line between the car and the storage bin CAUTION Be sure product line is depressurized before attempting to disassemble Check for proper size blower Refer to guidelines on Page 5 Check blower for proper operation Consult blower manufacturer if required Contact ARL representative The membrane may be plugged Unload compartment using manual assist if required Contact an ARL representative 18 i CENTER FLOW PRESSUREAIDE CAR Parts List NUMBER PER UNIT DESCRIPTION CATALOG NUMBER DRAWING NUMBER am Lever Assy at Safety Catch 5W107206 5 W 1072 06 5W107205 5 W 1072 05 40 GasketRetainer 50093367 48 Cap Screw 9001868 CS 7 48 Shakeproof Washer 90004405 Z CS 8 8 HngePn 50092946 2K8956 9 16 War 900404 10 8 CotterPin 1 90007113 o 11 28 Cover Includes Gasket CT 50091016 4 U 4320 12 8 SafeyCath 50092947 3 K8981 00 15 1 Blowdown Valve Assy J 573833754 16 2 Tubing Meter Box25 Section 91002188 Pressure Gauge 19 1 Rupture Disc Assy Includes Key Nos 20 Through 28 50093602 3 J 5612 20 1 LeadWireSeal ll af 1 we gt o A A 22 4 StopNut lA lo 23 4 j WashrS S oo 24 1 RuptureDiscValveCover____________
37. s Unloading systems utilizing automation are special cases If the unloading system uses automated controls contact an ARLL representa tive Potentially undesirable situations may be avoided after a brief review of the railcar and its relationship with the system TO STORAGE BIN BYPASS O BLOWER Ol e PACKAGE METERING VALVE CHECK VALVE PRESSUREAIDE CAR Figure 5 Product Discharge With By Pass PART IV ad CENTER FLOW PRESSUREAIDE CAR dad CENTER FLOW PRESSUREAIDE CAR OPERATING INSTRUCTIONS OPERATING CONTROLS UNLOADING OPERATIONS 1 Pressure Relief Valves Refer to figures 4 and 6 The car is equipped with a pressure relief valve on the A end of the car body that is set to open at 14 5 0 5 psig The car is also equipped with a pressure relief valve on the air inlet manifold see figure 6 which 1s set to open at 16 0 5 psig PRESSURIZING THE CAR BODY amp UNLOADING Cont 18 Shut down the blower after the car and conveying lines are blown clean After the blower BY PASS AIR VALVE E stops depressurize the car body by opening the blow down valve An alternate method of ce E T ba Xo us Tem d 7 e CHECK VAVLE depressurizing the car body is to open the product valves bleeding pressure through the AIR INLET FITTING plant dust collection system When airflow has FLUIDIZING AIR VALVE stopped open one product valve and one fluidizing or by pass valve Ensure the press
38. stall test gauges to the fittings where the petcocks are located Hook up the blower s air supply line to the car s air inlet All valves except one fluidizing valve should be closed With the fluidizing valve in the full open position pressurize the car to 10 psig If the car body or manifold gauge deviates from the test gauge by more than one psig return the gauge to American Railcar Leasing LLC BOX E PROVISION FOR O0 t PADLOCK OR O P R R SEAL d ml c Aye PETCOCKS C Figure 12 Disconnected Tubing From Gauges If the pressure indicating needle does not move after the blower has been started stop the blower and relieve the pressure in the car by opening the blowdown valve Disconnect the fittings at the back of the gauges the blowdown valve and the air manifold Attach a compressed air line to the gauge line and blow the line clean Reassemble and check gauges 10 OPERATING INSTRUCTIONS amp CONTROLS PRESSURE RELIEF DEVICES A rupture disc assembly on the car body is a standard feature The rupture disc is a device that functions only once Itis set to burst at 20 0 psig Once the rupture disc bursts it is necessary to replace the burst disc inside the assembly xx LX eS ad CENTER FLOW PRESSUREAIDE CAR The vacuum relief valve balances pressure inside the car with outside conditions due to atmospheric changes This safety device 1s a self closing device that opens at
39. to 10 psig and using a soap solution 3 If the disc requires replacement depressurize the car and ensure the pressure gauges read zero 4 Remove the four bolts separate the flanges and discard the old rupture disc 5 Inspect and clean the disc seating surfaces on each flange removing any nick or burrs then lightly polish with emery cloth 6 Remove the new rupture disc from the packaging and visually examine to ensure 1t 1s in good condition Confirm the pressure rating 1s 20 psig The disc must be specifically manufac tured for use in the rupture disc holder assembly 7 Place the rupture disc on the inlet flange The convex side of the disc must be in the up posi tion so pressure inside the car will be against the concave side of the disc 8 Replace the upper flange Install the four bolts finger tight to ensure all components are properly aligned and seated Torque the nuts to 34 38 ft lbs Do not over tighten as damage to the rupture disc may occur 9 Reinstall the cover tighten nuts 20 25 ft lbs and install a new security wire with lead seal dad CENTER FLOW PRESSUREAIDE CAR Part 1 Part Il PRESSURE RELIEF VALVES Part II The pressure relief valves must be visually Part IV inspected as part of the preload inspection to remove any dirt or debris that may have collected in the discharge opening The discharge pressure must be tested annually The pressure test can be performed either on the car
40. ure gauges read zero then disconnect the air supply and product hoses Replace and secure the dust caps on the Product and Air inlet connections PRODUCT DETAIL OF FOUR WAY FLUIDIZING AIR VALVE r E x as 1 HT FLUIDIZING AIR VALVE PRODUCT DISCHARGE FITTING 19 Close all valves and hatches and apply tamper FOUR WAY VALVE a Ww ep 9 evident seals if required yes SIDE OPEN FULLY OPEN FLUIDIZING AIR PRODUCT VAVLE z LU o O W a o oc lt ui z MANIFOLD ASSEMBLY CHECK VAVLE PRESSURE RELIEF BY PASS AIR VALVE AIR INLET VALVE AIR INLET FITTING PRODUCT VALVE DIRECTION OF HANDLE O DETERMINES DIRECTION OF FLOW a CLEANOUT PORTS HOW THE FOUR WAY FLUIDIZING AIR VALVE OPERATES Figure 6 Manifold Assembly With Four Way Fluidizing Air Valve UNLOADING OPERATIONS PRESSURIZING THE CAR BODY amp UNLOADING 1 Open both by pass valves then start the blower to initiate air flow to the air manifold 2 Confirm that air 15 flowing freely to the silo truck or other receiving vessel An increase in manifold pressure or the opening of a safety relief valve 1s evidence of a plugged line 3 Open the air valve to the Full Open position for the hopper to be unloaded 4 Close both by pass valves to begin pressurizing the car 5 As the car body pressurizes check for leaks in the form of dusting at the clean out ports hatches piping and hose co
41. ve to allow the car to depressurize 6 Disconnect the fitting at the back of the gauge panel close the petcock and using compressed air blow back through the gauge line to clear away any product that may be causing a blockage 7 Reassemble the gauges and retest 39 CLEANING DRYING PROCESS 1 After all compartments have been cleaned be sure all the fluidizing valves are 1n the full open position to allow airflow through the membranes until the compartment 1s dry 2 Shut down the blower and allow dry residual air to vent from the car to avoid any potential for pressure to build in the car or manifold 3 Close and secure all hatches 4 Close the product valves and re install the caps or closure plates on the clean out ports 5 Restart the blower and pressurize the car to 10 psig 6 Open the product valve on an end compart ment and allow airflow for two minutes to clear any remaining water from the product line Close the valve and repeat the procedure on the next hopper ad CENTER FLOW PRESSUREAIDE CAR 7 After drying the last compartment open the by pass air and product valves and allow airflow for two minutes 8 Shut down the blower The car will depressurize through the product valves Ensure the pressure gauges read zero before going to step 9 Open blow down valve to ensure there 1s no pressure in the car body 9 Remove the discharge hoses and dust caps or closure plates from the clea
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