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Natural Gas & LPG

Safety and Access Solutions for LNG and Natural Gas Operations

SafeRack provides a full range of LPG loading platforms and loading racks designed to improve safety, efficiency, and compliance in natural gas operations. With extensive experience in LPG transportation and handling, our systems meet stringent industry standards, including NFPA 58, ensuring regulatory compliance and worker protection.

As facilities evolve with complex piping networks and high-traffic areas, SafeRack’s durable, modular crossovers, work platforms, and safety systems help maintain safe, efficient operations in LPG truck loading systems, LPG railcar loading equipment, and other bulk transfer applications.

  • NFPA 58-Compliant Solutions – Designed to meet industry safety and regulatory standards for LNG and LPG bulk loading safety.
  • Modular and Adaptable Systems – Reconfigurable platforms and crossovers accommodate evolving facility layouts, ensuring seamless integration into LPG loading platforms and transfer stations.
  • Enhanced Worker Safety – Provides secure access to complex piping networks and high-traffic areas while offering fall protection for LPG loading operations.
  • Efficient Loading and Unloading – Streamlines operations while reducing downtime and risk, improving throughput in LPG transportation and storage facilities.
Ray Evans Avatar
Natural Gas & LPG
Key Features of SafeRack’s LPG Loading Solutions:
  • Bullhorn Style Top Loading Arms: Ideal for pressurized top loading applications, these arms feature a tee at the end with two vertical drop tubes, allowing dual product connections using a single loading arm. This design provides flexibility and reach, accommodating various railcar configurations. 
  • NFPA 58 Compliant Systems: In collaboration with industry leaders, SafeRack has developed loading systems that comply with NFPA 58 standards. These systems offer safe access to railcars, maximize product flow, and include features like remote or automatic shutdowns in emergencies, such as fires or leaks. 
  • Hose Retriever Systems: To address challenges like hose wear and trip hazards, SafeRack provides hose retriever systems that keep loading hoses off the ground. This setup not only prolongs hose life but also enhances operator safety by preventing kinks and tangles. 
  • Comprehensive Loading Arm Solutions: SafeRack’s top loading arms are designed for efficient and safe transfer of LPG. Features include sufficient horizontal reach to access all compartments without repositioning and vertical movement to accommodate various vehicle heights. Options like vapor recovery systems and specialized fittings further enhance functionality. 

LPG Loading Characteristics

Railcar LPG Loading
  • Product Temperature: 30°F-100°F
  • Design Temperature: -20°F-110°F
  • Normal Operating Pressure 80 – 150 psig
  • Design Pressure – 250 psig
  • Railcar Connection Size – 2” f
  • Line/Arm Size – 4”x3”x2”, 3”x2”
  • Common Hazards – Freeze burns, collapsing railcars, flammable material
Truck LPG Loading
  • Product Temperature: 30°F-100°F
  • Design Temperature: -20°F-110°F
  • Normal Operating Pressure: 500 PSI
  • Hydro Test Pressure: 750 PSI
  • Railcar Connection Size: 2”
  • Line/Arm Size -3”x2”
  • Common Hazards – Freeze burns, collapsing railcars, flammable material

Products

NFPA 58 Compliant LPG Loading Systems

Meeting NFPA 58 Requirements

Many facilities are unaware of the full scope of NFPA 58 compliance requirements. To address this, SafeRack has partnered with Fisher Control Valves to engineer a fully compliant LPG loading station that enhances safety, efficiency, and emergency response capabilities.

Key Features of the NFPA 58 Compliant System:

  • Safe and Efficient Loading: Designed for LPG products (DOT 1075), NGLs, and other pressurized gases, ensuring safe access to the top of railcars.
  • Emergency Shut-off Valves (ESVs):
    • At the railcar connection points
    • Snappy Joe ESVs back on the rack
  • Remote or Automatic Shutdown: Triggers in case of fire, leaks, or railcar rollaway, without requiring operator intervention.
  • Integrated System: Seamless connection and operation of loading arms, gangways, safety cages, and ESVs for improved productivity and compliance.

LPG Railcar Connections and Loading Process

Railcar Connections:

  • Three Connections:
    • Two product connections (liquid lines)
    • One vapor connection
  • Connection Process:
    • Attach ESVs to the railcar’s liquid adaptor/line and vapor valves.
    • Connect vapor hoses to the ESVs.
    • Open the liquid adaptor and vapor valves.
    • Open liquid and vapor hose valves, along with other system valves, to form an open circuit.

LPG is a mixture of hydrocarbons, consisting mainly of propane, propene (propylene), and butane.

  • A simplified propane supply chain would include:
    • Production and Transportation
    • Bulk Plants and Customer Delivery (cylinder filling plants, bulk storage plants, and large industrial customers)
    • End-User Customers (final consumers)
  • Propane is delivered from terminals to distributors and re-sellers via truck, railcar, ship or barge, and sometimes by pipeline, especially on the East Coast and
    Mid-West.
  • Since propane is an odorless gas, when it’s transferred from storage vessels to the loading dock an odorant is injected (Methyl Mercaptan) to detect leaks or spills.
  • LPG and anhydrous ammonia tank cars are sealed pressure containers. Several fittings are mounted on the manway cover plate to facilitate loading, unloading, gauging and testing operations.
    • Two (2) product lines
    • One (1) vapor line

FAQ

How do SafeRack’s gangways improve safety during energy product loading and unloading?

SafeRack’s self-adjusting gangways provide safe, OSHA-compliant access to tank trucks, railcars, and barges transporting crude oil, natural gas liquids, and refined fuels. Equipped with four-rail safety cages and available in powered options, our gangways minimize fall risks and ensure safe, efficient loading and unloading in high-volume energy operations.

Can SafeRack’s loading arms handle corrosive and flammable materials?

Yes. SafeRack’s carbon steel loading arms are built to safely transfer a wide range of energy products, including crude oil, LNG, and petrochemicals. With PTFE-sealed swivel joints for chemical resistance and vapor recovery systems for EPA compliance, these arms are designed to withstand harsh environments while maintaining safety and efficiency.

How does SafeRack help prevent spills and environmental hazards at energy facilities?

SafeRack provides a range of spill containment solutions, including pans, berms, and wheel chocks, to capture leaks during the transfer of oil, gas, and petrochemicals. These systems help energy facilities stay compliant with EPA regulations while protecting workers and the environment from hazardous spills.

Why is grounding important in energy loading operations, and how does SafeRack help?

Grounding is critical in energy operations to prevent static discharge, which can ignite flammable vapors during the transfer of crude oil, LNG, and refined fuels. SafeRack’s grounding and bonding systems ensure a secure ground connection before product flow begins, reducing fire and explosion risks and maintaining compliance with OSHA and NFPA standards.

Can SafeRack customize safety platforms and access systems for energy facilities?

Absolutely. SafeRack offers customizable access solutions, including gangways, platforms, stairs, and fall protection systems, specifically designed for the complex needs of energy facilities. Our modular systems are built to withstand harsh environments while improving worker safety and operational efficiency.

Projects

What Customers Are Saying

★★★★★

Great vendor, great product at a fair value. Very responsive; all who were involved were very conscientious and helpful. Solid gate and just what we were looking for to satisfy our safety audit. All staff involved were simply fantastic. Shipping was prompt and product came in in perfect condition.

By Dale C. from Pinnacle Corrugated

★★★★★

We are saving about 4 weeks and a ton of money by going with this option. I am using the product as a platform for servicing a pressure vessel for ease and element of change out. I like the availability and how easy the product fit to my project. We are saving about 4 weeks and a ton of money by going with this option.

By Bill S. from SPX Flow Technology

★★★★

Significantly more robust than the competition's. Travis usually go back to me within a day if he didn't answer his phone immediately. I like the stamped steps as opposed to welded steps. The gangway latch is significantly more robust than the competition's. The pivot points on the gangway have bushings, this is where we've seen the majority of our issues.

By Kevin S. from St. Mary’s Cement

★★★★

We had complex, detailed specifications, and SafeRack was willing to create something that met our needs. Scott Hite was very responsive, the seal plate is fairly complex with many details to work through. I liked that SafeRack is willing to create" client specific designs. Benefits include speed in our loading operations."

By Plant E. from EOG

★★★★★

The ordering and installation process was almost seamless. We discovered a way to keep our employees safe and meet OSHA standards with an easy, moveable piece of equipment. The unit is easy to move and fits the needs of the area it was placed. Benefits of the unit: 1) Provides safe access to the trailers for our employees 2) Meets OSHA standards for fall protection 3) Appears basically maintenance free. Travis McCraine was informative and responsive. All of my questions were typically answered the next day. The ordering and installation process was almost seamless.

By Maria G. from Plymouth Tube

★★★★★

A quality product that will be seen by many when installed! A quality product that will be seen by many when installed! Benefits include stability, robustness, this product is going to make the existing catwalk look inferior!

By Fred I. from SPEC (Sarnia) Ltd.