How to Design the Best Loading-Arm

System for LPG Applications

ALL LPG TERMINALS ARE UNIQUE IN THEIR DESIGN AND LAYOUT, AND
OPW ENGINEERED SYSTEMS CAN MEET THE VARIETY OF DEMANDS THROUGH
ITS FULL PORTFOLIO OF LOADING-ARM SYSTEMS AND COMPONENTS
By David Morrow

Introduction
It wasn’t too terribly long ago – April of 2011, to be That’s where railcars come in. These transport vessels –
exact – that, according to the U.S. Energy Information which must be pressurized in order to keep the LPG in
Administration, a “mere” 2.33 million barrels of liquefied a liquefied state – generally have a capacity of between
petroleum gas (LPG), commonly known as propane, was 17,000 and 33,500 gallons (65,000 to 127,000 liters),
being transported monthly in the United States via railroad. which allows them to hold about 143,000 pounds
By January 2020, 10.17 million barrels of propane were (65 metric tons) of LPG. That means that a unit train with
transported in railcars. While the COVID-19 pandemic 100 high-capacity LPG-dedicated railcars can move 3.35
undoubtedly played a role in that number dropping to million gallons of product in one run.
less than 6 million barrels mid-year, monthly propane
The challenge in getting these high volumes of LPG safely
shipments did rebound to 7.73 million barrels by 2020’s
to and unloaded at the storage terminal is ensuring that
end, which was higher than at any point from January
pressure is not lost in the railcar, from the point at which
2010 to February 2016.
it is filled to the point at which it is unloaded. If pressure is
All of this means that there is always, particularly in recent lost, the LPG will begin to expand back to its gaseous state,
years, a large amount of LPG on the move in the U.S. which could result in an explosion.
The question is, why are railcars such a popular form of
For the operators of LPG storage terminals, this demands
transportation for LPG in bulk quantities, especially from
that they employ a loading-arm system that is compatible
the oilfield to storage terminals? The most basic answer
with the unique and stringent needs of LPG handling and
has much to do with physics: in its gaseous form, LPG has
transfer. This white paper will illustrate the best ways to
a volume that is 270 times that of its liquid state, making
design, outfit and operate the loading-arm system at an LPG
it much more efficient to transport it in its more compact
terminal with ensuring a reliably safe and efficient operation
liquid form.
the ultimate goal.
The Challenge
The most basic thing to acknowledge when designing a
Top Considerations for LPG
loading-arm system for an LPG terminal is that no two are Loading-Arm System Design
the same, with every site being unique in its operational
design and setup. Therefore, the terminals that are truly 1. D
 efine number of loading/unloading
able to achieve and maintain elevated levels of efficiency, positions
reliability, safety and ergonomic operation are those that
2. C
 hoose best spot for the risers to avoid
take all of the site’s specific needs into consideration when
possible obstructions
determining the best loading-arm system to install.
3. L PG must be unloaded through top of
There are a few foundational items to consider before
railcar via a manway
designing the loading-arm system. First, the overall number
of loading/unloading positions must be determined. After 4. W
 ork backward from connection points
that, the system designer must choose the best spot for based on input from terminal staff
the risers. When several loading arms will be used, all of
the risers must be located so that they do not interfere
with the operation of the arms. The arms must also be coupler in this area. The use of dry disconnects creates a
positioned so that they can be maneuvered around any “closed-loop” system that can help reduce the amount of
possible obstructions, as well as fit under a roof or canopy in LPG that is retained in or may leak from the hose when the
a covered setup. loading arm is disconnected from the stabber pipe.
Since LPG is transported in pressurized railcars, it must be The next consideration is whether or not any type of ancillary
unloaded through the top of the railcar via a manway that valving will be used. Typically, an emergency shutoff valve
is outfitted with hard connection points. To develop the (ESV) will be designed into the system. This makes sense
best loading-arm system design for the singular needs of when dealing with LPG since you will need a way to shut
the terminal facility, it is best to work backward from these off product flow in the case of an accident or broken valve.
connection points based on conversations you should have The simple reason for this is that when you’re dealing with a
with the terminal operator and staff. potentially hazardous situation, you don’t want a technician
Over the years, driven by the preferences of many LPG to be responsible for shutting off the product flow. There are
terminal operators to increase throughput rates, the areas of the country where LPG terminal operators do not to
manufacturers of pressure railcars have begun building their use ESVs, mainly based on the local regulatory requirements;
equipment with three angle valves located on the manway. again, asking the operator will let you know if they need to
Two of these angle valves attach to loading-arm product be part of the design.
lines that facilitate the unloading process – based on the Another ancillary component to ask about is the safety
simple fact that you can unload a railcar twice as fast with breakaway. This piece of equipment is designed to separate
twice as many lines – while the third valve is used to connect the loading hose from the railcar in the case of an accident
with a vapor-recovery/vent hose that helps pressurize the or a pull-away incident, which instantly halts the flow of
railcar during unloading. the LPG. Again, this is a safety feature that many terminal
The connection from the end of the loading-arm hose to the operators choose to use, but others do not. In the end, all of
angle valves is made through what is known as a “stabber these valving choices come down to the preferences of the
pipe.” Using Teflon® tape, the stabber pipe is threaded to site operator, as well as any local or state regulations and any
the end of the angle valve and tightened manually with site-specific design requirements.
a pipe wrench. The challenge here is ensuring that the Another challenge for the loading-arm system designer is
stabber pipe is attached correctly; if it isn’t, the integrity the actual position of the angle valves in the manway on
of the connection may be compromised, which increases the top of the railcar. The one or two product valves are
the chances that a product leak will occur. Also, the link always plumbed in a position that is parallel with the length
between the loading arm and stabber pipe is typically of the car. On the other hand, the vapor-recovery valve is
completed through a quick hammer-union connection, but situated in a perpendicular position, meaning it faces away
there is a growing trend toward the use of a dry-disconnect from the center of the railcar. This makes the position of the

2 How to Design the Best Loading-Arm System for LPG Applications

railcar critical as it arrives at the loading rack. Sometimes the So, with the average LPG terminal having 12 to 14
vapor valve may be positioned facing away from the loading unloading positions, and each position featuring three
platform or gangway; this means that an extra five feet of loading arms, there is a lot to consider when determining
hose should be designed into the system so that failure- the best loading-arm system to design and deploy. In the
causing strain isn’t put on the hose since it has to reach end, though, all loading arms do essentially the same
farther, and at an awkward angle, in order to reach the thing, it’s up to the terminal operator to decide how it
vapor valve. Not acknowledging this situation is a common needs to be done, and to identify and work closely with a
design mistake, and one that must be considered if a proper knowledgeable, reputable designer and manufacturer of
loading-arm setup is to be achieved. loading-arm systems in order to create the best solution.

The Solution
For more than 125 years, OPW has been defining what’s next in the transport and safe handling of high-value fluids
around the world, and OPW Engineered Systems is a leader in the design, engineering, manufacturing and servicing of
loading-arm equipment and systems. In the realm of the LPG terminal, and depending on the needs of the operator,
OPW recommends three types of top-loading arms:

•  “Bull Horn” Loading Arm: This configuration features a single

arm that divides into dual connections that can be attached to a
pair of product lines, giving the loading arm setup a “U” shape
reminiscent of a bull’s horns. This is probably the most common
terminal setup since it allows the combination of two product
connections into a single arm, which reduces the overall number
of arms that are required.

• Single-Line Boom Arm: These can be supported or unsupported

and feature a single product hose for those applications that do
not require dual-unloading capabilities. Available in 2-to 6-inch
sizes, these arms are designed for use in variable-reach applications,
specifically those with longer reach requirements that may put undo
strain on other loading-arm styles.

• “ A” Frame Loader: This style of loading arm is a popular choice

because of its flexibility, long reach and easy maneuverability. Its
design allows it to be stored in an upright, near-vertical position
away from the railcar for safe clearance, while crossover of any
obstructions can be readily achieved, which makes it ideal for rack
setups that feature dual unloading lines. During the unloading
process, it adjusts to the railcar’s elevation or tilt so that a tight
connection can be made to the valves in all instances. The arms
are available with 2- to 4-inch hoses with the frame constructed of
carbon steel, stainless steel or aluminum.

LPG Loading-Arm Equipment to Consider

Stabber Pipe Emergency Safety Breakaway Product Loading Arms Safety Breakaway
Shutoff Valve
Connection from Designed to separate the Two loading arm product Designed to separate the
the end of the Allows shut off of loading hose from the railcar lines are connected to angle loading hose from the railcar
loading-arm hose product flow in the in the case of an accident or valves in manway in the case of an accident or
to railcar angle valve case of an accident a pull-away incident a pull-away incident

How to Design the Best Loading-Arm System for LPG Applications 3

As a designer, engineer and manufacturer of complete
loading-arm systems, OPW also supplies all of the ancillary 5 Reasons to Choose OPW
components that the operator may desire. Loading-Arm Solutions
For the connection point between railcar and angle valve,
OPW offers a variety of stabber-pipe options that can be
1. O
 PW’s 125+-year commitment to protecting
selected based on the needs of the individual application.
people and the environment while enhancing
Though OPW does not make ESVs, it has the capability to
business performance
supply the “Snappy Joe” ESV (Model No. N562) from Fisher
Control Valves as part of its overall loading-arm package. 2. L ocal factory support combined with
The Snappy Joe ESV is an air-operated valve that is designed 100-plus years of field experience that
to close immediately when air pressure is lost. In addition, ensures the best outcome
the valve has a fusible link that automatically shuts the valve 3. In-house machining, welding, X-ray,
in the event of a fire. assembly, testing and packaging with all
In the safety breakaway arena, OPW has direct-pull and components “Made in the USA”
cable-release coupling models, both of which are designed 4. T
 he “OPW Promise” that guarantees the job is
to separate in the event of an unintended railcar pull- not completed until all expectations are met
away incident that could lead to an LPG release. When
separated, the safety breakaway’s non-return valve positively 5. S
 treamlined part selection that reduces
shuts down both ends of the connection for unbeatable ordering, delivery and installation time, along
protection for the equipment, site personnel, surrounding with maintenance, repair and inventory costs
communities and the environment.

Finally, OPW offers ground-verification monitors from Conclusion

Civacon, another OPW company. These monitors do not
It appears likely that the production, transport, storage
allow LPG transfer to commence if a proper ground is not
and use of LPG will continue to be a lynchpin in the U.S.
achieved, or if grounding is lost during the transfer process.
economy for the foreseeable future. Therefore, it remains
OPW’s ultimate goal for its LPG-terminal customers is to imperative that the terminals that receive LPG via rail must
compile enough from-the-field operational information to be outfitted with loading systems that can ensure its safe,
create a digital menu-based program that will aid in the reliable and efficient transfer from railcar to storage vessel.
creation of the perfect loading-arm system for the specific OPW aids in this process by developing and supplying
site. This menu will contain dropdown options where the loading-arm systems and components that have been
user will be able to select such things as type of loading engineered and designed to satisfy the needs of every
arms, what kind of couplings are being used, whether or not unique LPG-terminal installation.
ESVs and safety breakaways are being used and, if so, which
type are preferred, and a list of other ancillary components
that can be added to the system. This menu-driven approach
can also help ensure that every piece of the loading-arm
system will fit and operate together seamlessly, which is
critical to improving safety, reliability and efficiency.

About the Author:

David Morrow is Director of Sales for OPW Engineered Systems, Lebanon, OH, part of Dover Corporation’s OPW
division. He can be reached at [email protected] or (800) 547-9393. OPW Engineered Systems
is engineering what’s next through innovations designed to enhance safety, reliability, efficiency and business
performance for the hazardous-chemicals industry. OPW Engineered Systems designs and manufactures loading arms,
swivel joints, quick and dry disconnects and other related fluid-transfer equipment. For more information, please visit
opw-es.com.

4 How to Design the Best Loading-Arm System for LPG Applications