Tank Container Foot Valve Handle Jamming: A Rising Global Issue...

The tank container industry is facing a significant challenge with the jamming of foot valve handles due to damaged foot valve linkage assembly or the thermoplastic properties of cargo. This issue has wide-ranging implications for safety, operations, and finances within the industry.

1. Safety Risks: The jamming of foot valve handles poses a serious safety risk in the tank container industry. When foot valves are jammed, they can obstruct the flow of fluid, resulting in potential accidents and equipment damage. This can lead to unforeseen incidents and compromise the safety of workers and infrastructure.
2. Operational Challenges: The impact of foot valve handle jamming extends to operational challenges. When foot valves are jammed, they can impair the functionality of valve and their associated systems. This can lead to reduced efficiency, increased downtime, and disruptions in the workflow of tank container operations.
3. Financial Implications: The issue of foot valve handle jamming has considerable financial implications for the tank container industry. Equipment damage, repairs, and potential accidents resulting from jammed foot valves can lead to increased maintenance costs. Additionally, the operational disruptions caused by foot valve handle jamming can result in lost productivity and revenue.

To address these challenges and mitigate the impact of foot valve handle jamming, it is crucial for the tank container industry to focus on preventive measures, regular inspections, and the use of high-quality foot valves. Implementing proper maintenance procedures, such as checking for damaged linkage assemblies and assessing the compatibility of cargo with thermoplastic properties, can significantly reduce the occurrence of jamming.?

By raising awareness of this issue and promoting best practices, the tank container industry can work towards minimizing safety risks, overcoming operational challenges, and avoiding unnecessary financial burdens. Together, industry professionals can collaborate and create a safer, more efficient, and sustainable environment for tank container.

Supplemental readings:

• Tank Container Parts: A Comprehensive Guide to Tank Container Equipment

https://www.pelicanworldwide.com/knowledge-center/blogs/tank-container-parts/

• Tank Container components.

https://www.budgetshippingcontainers.co.uk/info/tank-container-components/

• Perolo USA.

https://www.perolousa.net/v/vspfiles/files/TSI%20Catalog.pdf

Root Causes: Several factors contribute to foot valve jamming, including:

1. Corrosion and Rust: Exposure to corrosive substances or environmental conditions can cause rust buildup, hindering the movement of the valve components.

• Preventive and corrective action: Regularly inspecting and maintaining valves is crucial to prevent potential issues from escalating. Implementing scheduled routines for lubrication, cleaning, and replacement of worn components can help identify problems early on. It's important to conduct inspections on bottom and foot valves, especially when loading corrosive products that can cause rust and corrosion. Some depots may not disassemble fittings during tank cleaning, but it's beneficial for tank operators to arrange for this service every 6 months or after corrosive cargo loads. By proactively identifying and addressing valve problems, we can prevent incidents and accidents, ensuring the safety of all involved parties. Remember, if you're not inspecting, you're not truly aware of what's happening inside the valves.
• 2. Solid Product (Thermoplastic product): The Thermoplastic product got stuck inside the foot valve and Butterfly valve due to melting and solidifying during transportation. The consignee had to take the tank to the depot for heating to resolve the issue. However, the cargo solidified between the valves, making it difficult to open the Butterfly valve. This caused a problem for the plant, as shown in the pictures. Opening the Butterfly valve and removing the solid cargo was not a standard practice and could lead to contamination of the cargo.

• Preventive/corrective action: Pre-loading Heating: Consider pre-heating the tank container before loading the cargo. By heating the tank to a temperature above the melting point of the product, you can ensure that the cargo remains in a liquid state throughout transportation.
• Insulation: Improve insulation around the tank container to minimize heat loss during transportation, especially in regions with fluctuating temperatures. This can help maintain the cargo's temperature within the desired range and prevent solidification.

• Keep a close eye on the temperature: Install temperature monitoring systems to keep track of the temperature inside the tank container while it's on the move. This way, you can take immediate action if the temperature gets too close to the point where the cargo might solidify.
• Indeed, the vessel crew has the capability to monitor the tank's temperature even when it is sailing across the sea. Numerous methods and cutting-edge technologies are at their disposal for temperature monitoring. The choice of method depends on the specific equipment installed on the tank container and the vessel's own capabilities.
• One common method is through temperature sensors or probes installed on the tank container itself. These sensors(a telematics device equiped with GPS)can transmit temperature data wirelessly or via a wired connection to a monitoring system onboard the vessel. The crew can then access this data to monitor the temperature of the cargo throughout the journey.
• Additionally, some tank containers may be equipped with temperature monitoring systems that are integrated with the vessel's overall cargo monitoring system. This allows for real-time monitoring of temperature conditions for all cargo onboard.
• In my view, cargo tanks without a modern temperature monitoring system, such as GPS, face difficulties in physically monitoring the temperature gauge due to their location on the vessel. To overcome this challenge, I believe it would be beneficial to load such cargo into electric tanks equipped with a modern temperature monitoring system.
• Regular temperature monitoring is crucial, especially for thermoplastic cargoes that may solidify during transit, as it helps ensure the cargo remains within the specified temperature range to prevent solidification or other issues.

Check out this sample heating monitoring sheet below, which is perfect for keeping track of your heating system.

• Upon the arrival of thermoplastic cargo at the Point of Discharge (POD), it is essential for the consignee to be well-versed in the correct handling procedures. Typically, the cargo is transported to the depot for reheating, with continuous temperature monitoring throughout the entire process. While the tank is being heated at the depot to achieve the necessary temperature, special attention should be given to the movement of the foot valve handle. If there is any resistance or immobility in the foot valve, the depot must apply live steam to the foot valve for a period of 2-3 hours. This steam application helps melt any solidified product stuck between the foot valve and bottom valve, ensuring smooth operation. Some tanks come with heated foot valves that have an internal steam jacket or heating chamber surrounding the flow passage. This design guarantees that as the tank shell is heated, the foot valve also receives heat, further assisting in preventing solidification issues.
• The steam heated clean-flow valve, measuring 1 X 45° 3”, is a unique valve tailored for situations that demand steam heating to ensure the smooth flow of thick or solidifying substances. Let's delve into how this valve is steam-heated and pinpoint the possible locations of steam line connections.

Steam Heating Mechanism:

• The valve is equipped with an internal steam jacket or heating chamber surrounding the flow passage.
• Steam is supplied to this jacket or chamber, typically through ports or connections provided on the valve body.
• The steam circulates around the flow passage, transferring heat to the product inside the valve to prevent solidification or maintain flowability.

Steam Line Connections:

• Inlet Connection: Steam is supplied to the valve from a steam source via an inlet connection. This connection is typically located on the valve body and may include a threaded or flanged connection for attaching steam hoses or pipes.
• Outlet Connection: After circulating through the valve's heating chamber, the condensed steam or excess steam is discharged through an outlet connection. This connection allows for the removal of condensate and ensures continuous steam circulation.
• Steam Control Valve: Depending on the system design, a steam control valve may be installed upstream of the valve to regulate the flow of steam and control the heating temperature.
• Insulation: To minimize heat loss and ensure efficient heating, the steam lines connected to the valve may be insulated using thermal insulation materials.

3. Damaged Foot valve linkage assembly: In recent years, the occurrence of damaged foot valve linkage assemblies has become increasingly prevalent in the tank container industry. Often, this issue comes to light when plant operators encounter difficulty in opening the foot valve during loading or offloading at the plant. The causes can vary, ranging from damaged linkage assemblies to solidified product within the valve. However, despite these challenges, there are several corrective actions that can be implemented to address and mitigate this issue effectively.

• Taking Action to Address Foot Valve Issues: When you detect any problems with the foot valve, it's crucial to take immediate action. Notify the tank operator right away and provide them with high-resolution images to clearly illustrate the issue. Remember, if you don't have the technical expertise, it's best to avoid attempting any self-fixes. Instead, make arrangements for a skilled technician to visit the plant, especially if it's located near the depot. The technician will conduct a thorough review and take the necessary steps to resolve the problem. If the foot valve assembly is bent or damaged, it's recommended to replace it with standard parts from reputable suppliers like Fort Vale, Pelican, or Porollo. This should be your primary course of action. However, if replacement parts are not readily available and you urgently need to load cargo, you may try realigning or resetting the damaged components to restore the proper functionality of the valve. In cases where the issue is caused by solidified product, plants equipped with heating facilities can apply live steam to the foot valve for 1-2 hours. This will help facilitate the opening of the handle and often proves to be an effective solution. If your plant doesn't have heating facilities, it's advisable to return the tank to the depot for necessary repairs. Once all the required fixes are completed, the tank can be safely returned to the plant for offloading.

4. Electrical heating tank: Using electrical heating tanks for thermoplastic cargoes that solidify during transit can be a viable solution to prevent solidification. Here are some considerations:

1. Maintaining Temperature: Electrical heating tanks can maintain the cargo at a consistent temperature, preventing it from solidifying during transit. This ensures that the cargo remains in a liquid state and is ready for discharge upon arrival at the destination.
2. Product Integrity: Keeping the cargo in a liquid state helps maintain its integrity and prevents issues such as clogging of valves or pipelines due to solidification. This can reduce the risk of delays or complications during unloading.
3. Operational Efficiency: Electrically heated tanks offer operational efficiency by providing a reliable method to maintain cargo temperature without the need for external heating sources or additives. This simplifies the logistics process and reduces dependency on external factors.

using electrical heating tanks for thermoplastic cargoes can be an effective solution to prevent solidification during transit, ensuring product integrity and operational efficiency. However, it's essential to evaluate cost-effectiveness, compatibility, and safety considerations before implementing this solution.

Conclusion: Foot valve jamming in tank containers poses significant operational and safety challenges across the industry. By adopting proactive maintenance practices, promoting awareness, and fostering collaboration among stakeholders, we can mitigate the risks associated with this issue and ensure the smooth and efficient transportation of cargo worldwide.

Join the conversation: Have you encountered foot valve jamming issues in your tank container operations? Share your experiences and insights in the comments below. Let's work together to find solutions and improve industry practices. #TankContainer #Logistics #Maintenance #Safety #SupplyChain #PreventiveMaintenance #FootValveJamming