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Home / Industries / Bulk Chemical Loading / BenzeneBenzene (C6H6) Handling Design, Loading, and Installation.
Although no two Benzene Loading solutions will be identical, the product itself determines much of the critical design criteria that will ensure that optimum safety and productivity can work together in harmony.
What is Benzene? is a chemical that is a colorless or light yellow liquid at room temperature. It has a sweet odor and is highly flammable. Benzene evaporates into the air very quickly. Its vapor is heavier than air and may sink into low-lying areas. Benzene dissolves only slightly in water and will float on top of water.
In the United States, Benzene is typically a “tight-fill” (closed-loop) loading operation and is loaded into barges or rail cars via chemical hoses or marine loading arms. Benzene, if not handled properly can be fatal and Personal Protective Equipment (PPE) is required. Additionally, because operators are on top of the vehicles during the loading process, fall prevention is essential, not only for safety but increases throughput. Benzene is typically transported via barge, or a 10,000-gallon insulated or non-insulated general service tank car. The rails cars themselves are 9′ outside diameter with an overall length of ~47′, with a 6’ x 6′ or 8’ x 8’ centered crash box.
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View Full TextYour Project
Typically, as a starting point, we will need to know answers to these questions for your project
- The Railcar connection locations need flexibility – Do you know what the breadbasket connections look like?
- Are you using liquid and vapor arms/hose as two separate devices or a piggyback arm?
- Is the loading station indoors or outdoors?
- Is the loading area temperature controlled?
- How are you going to spot your railcars
Our highly trained technical sales team will undertake a detailed site survey prior to undertaking any work to check and clarify all dimensions, obstructions, access issues and other salient points. Our challenge is to provide the safest working environment – protecting operators and the equipment – while simultaneously enabling you to improve throughput and productivity.
Your Project Needs
Whether you are looking for a turn-key installation, on-site supervision or a maintenance program, SafeRack is positioned to assist you. We can do as little or as much as you need. Our project management and supervision team is the best in the business at supporting your company’s needs.
- Collaborative Design – Our loading platform specialists will work with you one on one, if you design to design the best loading solution for your specific needs
- Contract review – drawings and associated documents relating to the contract prior to site arrival
- Risk Assessment – Undertaking a site risk assessment
- Shipment Inspection – Detection of any shipping damage or abnormalities
- Material Receiving – Supervised off-loading and transport at site
- Installation Management – Supervised Installations and Coordination
- Start-up & Commissioning – On-site training for both users and maintenance personnel
Loading Arms
Generally speaking, SafeRack recommends rigid pipe loading arms where possible for the following reasons:
- Balanced throughout their movement envelope
- Designed not to hit the ground – protecting the asset and the operator
- Ergonomic – one man operation
- Fitted with manual or actuated valves.
- Fitted with optional purge/vent facilities
- Can be moved into position with ease and left hanging in the air while the operator prepares the tanker connection
- Parked neatly
Hoses require:
- Annual pressure test
- Are difficult to stow neatly when not in use
- Can be dropped
- Can be driven over
- Are very heavy to use if fitted with a valve at the tanker connection point
- Cannot be easily heated or have vent/purge valves fitted to it
- Prone to catastrophic failure
Typical Benzene Loading Platform
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Below are some of the loading and unloading solutions for illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs.
Benzene Loading Arms
Benzene is typically loaded into railcars via chemical hoses or loading arms. The current best loading practice is to use a 3″ chemical hose or a carbon steel loading arm with quick-acting coupling, often in the form of Hammer Unions with stabber pipe. The chemical hose or loading arm will have a top inlet with a control valve to ensure that it is self-draining after use and is supported along the length of a mechanical loading arm to improve handling; this is known as a by-pass arm. You can install one liquid and one vapor arm, or mount both the liquid and vapor hoses on one by-pass arm.
Break-away couplings can be fitted near the inlet of the hose for additional safety in the event of a premature departure.
Benzene Loading Gangways and Safety Cages
A wider access gangway (36″-48″ is preferable) as it helps improve access and egress to and from the vessel. In addition, a wider gangway will reduce the risk of the operator’s PPE getting caught, torn or damaged, and will improve productivity and safety. Powered gangway solutions are also an option, with both hydraulic and pneumatic solutions being commonly used. Each gangway will be fitted with a two-rail safety cage for the railcar crash box. This will be a centered 6’x6’ safety cage to sit directly over the cashbox. This will provide a safe, secure work environment for your operator when connected to their breathing apparatus
SafeRack’s GX SAS gangways use Retractalok power-assist technology allowing operators to raise or lower effortlessly, light as a feather to lift, and solid as a rock. Tested in the most critical applications, this revolutionary new gangway outperforms all others. Available in multiple lengths and widths.
Learn MoreMAXRack Elevating Safety Cage
As an alternative to our two and four-rail safety cages, some customers prefer our MAXRack elevating safety cages. The ultimate fall prevention solution engineered to keep operators safe and productive. Designed for both trucks or railcars, and available in multiple cage lengths and widths. Safe, durable, and easy to use. MAXRack is built rock-solid with galvanized steel column supports and lifting arms (cages can be Aluminum, Galvanized, or Stainless Steel depending on application) Available in two power options – Pneumatic Air Drive and Electric Drive (Explosion and Non-Explosion Proof).
Learn MoreBenzene Eye Wash/Drench Showers
ANSI guidelines state that an Eye Wash/Drench Showers need to be located 10 seconds or 55’ (16.8m) from contaminants or hazardous materials. Eyewash stations need to be on the same horizontal plane with no obstructions.
Therefore, we would propose the installation of a standard combination Drench Shower/Eyewash Unit, which will save limited space and fit easily into any work environment.
Benzene Spill Containment
Spill containment pans will be provided at the point of loading operations and is an essential piece of equipment in overall site safety and environmental protection. Benzene Grounding
Benzene is a flammable liquid, industry best practice includes the grounding of all vessels before starting the (un)loading process. - Vehicle grounding and bonding — ensure true grounding before product flow is permitted
- Explosion-proof enclosures — meet or exceed UL, CSA and Ex requirements
Benzene Safety Gates
Safety Gates will be installed at the top of stairs and any other openings to ensure operator safety at all times. YellowGate Safety Gates
SafeRack’s line of industrial safety gates is the most flexible product on the market with the ability span openings between 16” and 36” and is field adjustable with nothing more than a wrench. Learn More
Benzene Options
- Lighting – Lighting both over and under the platform will be provided. For overcast days or second shift, lighting is essential for improved safety and improved productivity.
- Platform & Canopies – Full platform canopies reduce exposure to the elements and improve the safe and productive loading operation from the operator’s perspective.
- Operator Shelter – Depending on your site requirements, consideration should be given to the requirement of an operator or guard building on the loading platform. This can be customized to meet specific site requirements.
- Wheel Chocks – Railcar Wheel Chocks provide fast blocking of all types of railcars and meet OSHA regulations to safely prevent railroad cars from moving during loading or unloading operations. This is a requirement by the Department of Homeland Security.
Personal Protective Equipment PPE Requirements
Eye/Face Protection: Wear chemical safety goggles. A face shield (with safety goggles) may also be necessary.
Skin Protection: Wear chemical protective clothing e.g. gloves, aprons, boots. Coveralls or long sleeve shirts and pants in some operations. Wear a chemical protective, full-body encapsulating suit, and self-contained breathing apparatus (SCBA). Suitable materials include: butyl rubber, neoprene rubber, Viton®, Viton®/butyl rubber, Barrier® – PE/PA/PE, Silver Shield® – PE/EVAL/PE, Trellchem® HPS, Trellchem® VPS, Saranex®™, Tychem® BR/LV, Tychem® Responder® CSM, Tychem® TK. The following materials should NOT be used: natural rubber, polyvinyl chloride. Recommendations are NOT valid for very thin neoprene rubber gloves (0.3 mm or less).
Respiratory Protection: Up to 5 ppm:
(APF = 10) Any chemical cartridge respirator with cartridge(s) providing protection against Benzene*; or Any supplied-air respirator*.
*Reported to cause eye irritation or damage; may require eye protection.
APF = Assigned Protection Factor
Recommendations apply only to National Institute for Occupational Safety and Health (NIOSH) approved respirators. Refer to the NIOSH pocket guide to chemical hazards for more information.
Use a local exhaust ventilation and enclosure, if necessary, to control the amount in the air. Consider using a corrosion-resistant exhaust ventilation system separate from other ventilation systems. It may be necessary to use stringent control measures such as process enclosure to prevent product release into the workplace. Use backup controls (e.g. double mechanical pump seals) to prevent the release of this material due to equipment failure. * For illustrative purposes only. Our experts will work with you and your team for a custom solution to suit your needs Customer Reviews
5 5After the design was complete it was delivered very quickly.I have nothing negative to say about the service I have received thus far. All the personnel I have dealt with thus far are pleasant, responsive and very knowledgeable. If we had not worked out a turnkey installation, I would have been forced to look elsewhere. After the design was complete it was delivered very quickly.
By Bret Grider from Bunge North America (OPD West) Inc on 8/8/165 5Product is of high quality and is fairly priced.If I ever required a urgent shipment, SafeRack would help expedite the process for me. The [salesperson], Caelin, was always readily available and willing to help provide me options for what I was looking for. The swing gate is easily adjustable and can be site installed to fit a wide range of dimensions. I would recommend this product not only for the reasons above but the company has been very responsive when ever I needed assistance.
By Mark D'Amario from Bird Construction on 2/8/185 5We needed a barrier gate to help us reduce rack damage, saving money and time in the future.It has not been delivered yet but is on its way. While we would love to have it here earlier we understand that product availability is not always immediate. We feel the salesperson explained that this barrier gate should drastically help reduce that!
By Steven Dew from Alpine Silica on 6/30/195 5Satisfied with our YellowGateThe whole process of buying went smooth.
By Terry Clapp from Imerys on 5/17/214 5All of my experiences with SafeRack have been positive.John Nance was an excellent salesperson, from the first time I spoke with John about the safety rack, we had several discussions via email along with phone discussions which were followed up by a site visit. I couldn’t have asked for a better person to deal with. When I asked John to find me a location where a safety rack is presently being used, he found a location close to us and made the arrangement for us to visit the site. All of my experiences so far with SafeRack can be described as positive. We are just in the process of preparing to install the unit which I expect it will be all up and ready to go by March 18, 2013. The installation certainly doesn’t look to be very difficult at this point. So far the customer service, sales, engineering, product quality and delivery has been excellent. Keep up the good work.
By Perry Coudenys from Sylvite Agri-Services on 3/11/135 5Extremely satisfied!Quality of service, materials, and facility. Saferack’s broad array of products and technical knowledge is second to none.
By Matt Merschbach from Nexans on 5/17/21Benzene 101
Things to know about Benzene
As an Aromatic in the Petrochemical family tree, Benzine is used to make plastics, resins, and nylon and synthetic fibers. Benzene is also used to make some types of lubricants, rubbers, dyes, detergents, drugs, and pesticides.
Benzene is widely used in the United States and ranks in the top 20 chemicals for production volume. It’s also a natural part of crude oil, gasoline, and cigarette smoke.
Benzene is colorless or light-yellow liquid at ambient temperature. It has a sweet odor, similar to gasoline, and is highly flammable. The chemical dissolves only slightly in water and will float on top of the water.
Benzene evaporates into the air very quickly. Its vapor is heavier than air and may sink into low-lying areas. However, in the event of a spill or leak, immediately put on an escape-type respirator and exit the area. Eliminate heat and ignition sources such as sparks, open flames, hot surfaces, and static discharge. Post “No Smoking” signs.
Transfer method is typically by barge with chemical or marine loading arms, but a limited quantity is transported by pipeline.
OSHA Permissible Exposure Limit (PEL) @ 5 parts per million
Is your plant or facility compliant with ANSI, OSHA, and local safety codes? We can help!
EMERGENCY EYEWASHES / SHOWER EQUIPMENT AND THE ANSI/ISEA Z358.1 – 2014 STANDARD
Following eye contact, you must start washing with water immediately to prevent permanent damage. In the event of skin contact, you must start washing with water immediately to prevent slow-healing chemical burns.
Are you aware that ANSI guidelines state that Eye Wash/Drench Showers need to be located 10 seconds or 55′ from contaminates or hazardous materials and located on the same horizontal plane, with no obstructions? If bottom loading/unloading, an additional shower should be located at grade as well. SafeRack provides the above equipment plus much more needed to keep employees safe and expedite bulk chemical loading and unloading.
OSHA Regulation Experts – Does your existing chemical safety equipment or chemical loading systems meet OSHA’s latest requirements? SafeRack’s professional technical sales consultants are available to meet with your team to make recommendations to keep your facility in front of OSHA’s ever-changing country and region-specific standards and regulations, including lifeline and trolley beam fall arrest systems, metal stairs, and access platforms.
Why SafeRack?
The SafeRack approach is a collaborative one. Let’s call it The SafeRack Way. We have, over many years amassed a great deal of experience and understanding of the safety aspects involved in loading road tankers and railcars, as well as the behavioral habits of the operators.
Experts In Chemical Loading
- Acetic Acid
- Acetic Anhydride
- Acetonitrile
- Acrolein
- Acrylic Acid
- Acrylonitrile
- Aluminum Chloride
- Aluminum Sulfate
- Ammonia
- Ammonium Hydroxide
- Ammonium Nitrate
- Aniline
- Benzene
- Benzyl Chloride
- Bromotrifluoromethane
- Butadiene
- Carbon Dioxide
- Caustic
- Chlorine
- Chloroform
- Chlorosulfonic Acid
- DEF (Diesel Exhaust Fluid)
- Diethylene Glycol
- Dimethylformamide
- Dodecylbenzene Sulfonic Acid
- Ethanol
- Ethyl Acetate
- Ethyl Chloride
- Ethylene
- Ethylene Dichloride
- Ethylene Glycol
- Ethylene Oxide
- Ferric Chloride
- Ferrous Chloride
- Hexane
- Hydrochloric Acid
- Hydrofluoric Acid
- Hydrofluorosilicic Acid
- Hydrogen Cyanide
- Hydrogen Peroxide
- Hydrofluoric Acid
- Hypochlorous Acid
- Isopropyl Acetate
- Liquid Argon
- Liquid Nitrogen
- Liquid Oxygen
- Maleic Anhydride
- MDI
- Methanol
- Methyl Chloride
- Methyl Ethyl Ketone
- Methyl Methacrylate
- Methyl Isocyanate
- Molten Sulphur
- Nitric Acid
- Oleum
- Phenol
- Phosphoric Acid
- Phosphorus Oxychloride
- Phosphorus Trichloride
- Polypropylene
- Renewable Diesel
- Sodium Cyanide
- Sodium Hydroxide
- Sodium Hypochlorite
- Styrene Monomer
- Sulfuric Acid
- Sulfur Dioxide
- Titanium Tetrachloride
- Toluene
- Toluene Diisocyanate
- Turpenitne
- UAN (Urea Ammonium Nitrate)
- UREA
- Vinyl Acetate
- Vinyl Chloride
- Xylene
- Zinc Chloride
- Agro-Chemical
- Specialty Chemical
- Petrochemical
North America’s largest loading terminal
World-leading designer, manufacturer, and installer of truck and railcar loading platforms
As one of the primary railcar loading points, Hardisty is one of the major crude oil hubs in North America and a major origination point of pipelines that export to the United States. SCS was asked to supply and construct a SafeRack crude oil loadout terminal spanning nearly half a mile. The USD Hardisty terminal can load up to two 120-railcar unit trains per day and consists of a fixed loading rack with 62 railcar loading positions enclosed, separate control, operator, and mechanical buildings, as well as a unit train staging area and loop tracks capable of holding multiple unit trains simultaneously. SCS also supplied and installed boom-supported loading arms with supply and vapor management systems.


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