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407-551m - Great Plains Manufacturing

1. supplied in any of several valve configurations See Ts a table at right Flow turn on and turn off sequencing is different for each hose configuration See A59b Valve at Outlet End Starting NH3 Tank Flow in the applicator Operator manual and Stopping Application on Esa page 29 ove S RI A59c Valve at Inlet End we eo Se IS A59d Valve at Both Ends Figure 5 Nurse Tank Hose Configurations Refer to Figure 6 A60 Nurse Tank Hose Body Hose data is printed on the full length of the hose The key information for operators is that the hose is designed for ANHYDROUS AMMONIA use and that the replace by REMOVE BEFORE date has not yet arrived e Figure 6 Do not rely exclusively on the expiration date Hose Data Stripe Inspect the hose for excess wear damage and other signs of imminent failure See hose checklist on page 23 a National Pipe Thread tapered Never disconnect anhydrous ammonia NPT fittings in routine use 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturin
2. 2013 07 15 Table of Contents Index 407 551M Table of Contents Index Great Plains Manufacturing Inc 28 NH Safety Starting Application 4 DANGER e NH Possible Chemical Hazard Anhydrous ammonia is now flowing into the ground Some routinely escapes to the atmosphere Check for leaks Take action if strong odor is detected or a leak seen Turn up wind Turn off flow Check gauges from tractor cab Engage emergency shut off valve if a leak is detected ANHYDROUS AMMONIA INHALATION HAZARD Minor odor during application is normal particularly if the tractor cab is ever down wind of recent passes Strong or irritating odor indicates a problem Conditions may not be suitable for application soil too dry cloddy and deeply cracked for example or there may be a system problem Field Turns a Before the turn set the MASTER switch OFF Leave the implement in the ground and continue forward movement Lift the implement at the turn point ANHYDROUS AMMONIA G DANGER Bigatti Major Spill Equipment Damage Hazards Do not turn too tightly The nurse tank could strike the implement be upset and leak On 2 Point and Pull Type applicators the nurse tank tongue could strike the caster tires On 3 Point applicators the nurse tank tires could strike sealers tine or knife shanks c Turn up wind for the next pass POWER FLOW CONTROL BOOMS MASTER
3. Opening this bleed valve WILL release the substantial amount of liquid NH3 presently trapped in the hose most likely as a spray Open the valve very slowly just until some fluid appears Leave the valve just slightly open Walk away up wind Stay away until the release concludes Carefully open bleed valve completely to confirm hose is discharged For dual cooler repeat step 9 through step 12 for the other hose Close all breakaway bleed valves 13 and page 42 and any nurse tank hose valves page 13 Disconnect the nurse tank half of the breakaway coupler at the Acme coupler page 11 Correct the cause of breakaway only if trivial to do in the field Consult the breakaway manual for re coupling instructions Neda A amonia INHALATION HAZARD Before Re connection Elevated Exposure Hazard Exercise extreme care Even if the nurse tank is undamaged sound and upright a breakaway event is not a normal re hitch situation A substantial NH3 bleed is required that WILL release a flow of liquid anhydrous ammonia under pressure If the wind is calm or light do not attempt to bleed the nurse tank hose Your field PPE is not sufficient a PPE Personal Protective Equipment 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index 35 Ga Ammonia Maintenance Safety Over half of NH3 accidents result from equipment fa
4. Stopping Application Plan your stops A safe stop requires depleting the anhydrous from the nurse tank withdrawal valve to the tines or knives a What is the wind direction b Suspend application per Suspending Application below c Puton your chemical gloves Be wearing your goggles d Carefully approach the nurse tank from up wind Expect some ammonia odor but if it is extremely strong there may be an above ground release in progress due to malfunction or part failure If so remain clear until the release subsides e When safe to do so shut off the nurse tank withdrawal valve page 16 f Re enter the tractor cab g Turn MASTER switch ON h Resume field application until reported rate begins to fall Increase rate to maximum to fully open Control Valve i Continue field application until both cooler and divider pressure gauges read zero j Facing into the wind raise the implement and stop k Set the MASTER switch to OFF Wait at least 1 minute for row line vapor to dissipate m Turn so that the wind is directly from the right ANHYDROUS AMMONIA AWARNING a Ball Valves Trapped NH3 Hazard Avoid routinely closing ball valves other than the nurse tank withdrawal valve with liquid NH in the lines Fluid is trapped in the line above the valve may trigger relief valves and can get trapped inside the valve ball unless it has a bleed port not yet common on nurse tank hoses See
5. Avoid Line Traps on page 37 and Avoid Ball Traps on page 38 A typical ball valve can trap enough NH to make a room the size of a two car garage uninhabitable concentrations above IDLH in moments When the ball valve is later opened while warm the NH is expelled at high pressure If the line is pointed at your face you could receive a fatal exposure n Open all bleed valves Standing up wind of each and making sure orifices point away from you slowly open bleed valves at e nurse tank hose inlet end page 13 e nurse tank hose outlet end page 13 e breakaway bleed valve or page 42 whichever is safer e cooler temperature gauge page 42 o Close all remaining operating valves e nurse tank hose inlet end page 13 e nurse tank hose outlet end page 13 e emergency shut off valve page 42 p Wait at least one hour before moving implement to any spot near unprotected people or livestock It will continue to out gas ammonia vapor for some time 2013 07 15 Table of Contents Index 407 551M Table of Contents Index Great Plains Manufacturing Inc 30 NH Safety Suspending Application These instructions are for brief stops in the field for example to make a phone call See also Stopping Application on page 29 a What is the wind direction b Turn MASTER switch OFF This turns On Off Valve off With On Off Valve off there is still a substantial amount of
6. 2 3 4 5 6 ON eS Nef Q Q A A A S RATE 2 OFF MAN DEC OFF A WV Boom ser merer vue rate 1 Rate 2 vo SELF W CAL CAL CAL CAL CAL CAL TANK TIME TEST IFA Zi 3 A Di BC 7 Ei EN 0 O CU Few on VoL AREA DATA al Teen votime E VE losse sp DN EN Meny ENTER A UL Ch CO D O RAVEN Sprayer Control SCS 450 NVM Figure 26 Typical Application Screen ANHYDROUS AMMONIA A WARNING INHALATION HAZARD Ammonia Vapor Release Occurs at Turns Avoid down wind turns Do not raise for turns if unprotected individuals or sensitive livestock are immediately down wind of the turn Stop instead Turning off NH3 flow prior to raising for turns does deplete some of the liquid ammonia in the applicator lines but not all of it and considerable vapor remains At turns there will be d Line up per your start of pass plan some release of NH3 vapor and possibly some NH3 liquid e Lower the implement into the ground Be prepared for it Minimize exposure to yourself and others f Set the BOOMS 1 switch ON Turn up wind immediately if a hazardous concentration of g Pull forward and complete the pass fumes reaches the tractor cab 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Anhydrous Application 29
7. 13 but that only bleeds the downstream side of a valve ball the outlet valve in this example See page 38 for information about ball traps The downstream side of this system line segment is equipped with a bleed valve page 13 The upstream side of the inlet valve is equipped with a hydrostatic relief valve page 14 If this line segment warms pressure can rise high enough to cause periodic releases at the relief valve This protects the segment from rupture but does not clear the line ANHYDROUS AMMONIA INHALATION HAZARD Valves Closed with NH3 Present Figure 29 NH3 Trapped in Line Clearing a Line Trap To clear a line segment with possible trapped NH3 A Move the equipment outdoors A If calm wait for wind A Stand up wind of the bleed valve A Point the bleed valve orifice down wind and away from all personnel A If it s a hose bleed valve make sure you can set the hose down with the valve still pointing in a safe direction A Open the valve very slowly Once any discharge is observed set any hose down depart up wind A Remain up wind until the discharge completes 2013 07 15 Table of Contents Index 407 551M Table of Contents Index Great Plains Manufacturing Inc 38 NH3 Safety Avoid Ball Traps ANHYDROUS AMMONIA 4 DANGER e amom IDLH Anhydrous Ammonia Exposure Hazard Beware of closed ball valves A ball valve can trap liquid NH3 If opened when
8. A single bleed valve may be located on the inlet or outlet side of the valve and only protects that side of the circuit when the valve is closed More rarely a shut off valve has bleed valves on both sides of the valve Study the location of all bleed valves on your nurse so tank and implement Bee Figure 8 ANHYDROUS A CAUTION di AMMONIA Bleed Valve Detail INHALATION HAZARD Suffocation Blinding and Burning Hazards Be up wind when operating a bleed valve Wear chemical gloves when operating a bleed valve Wear goggles when operating a bleed valve Do not place your body or head in front of the orifice Follow a check list when operating a bleed valve Open a bleed valve slowly 2013 07 15 Table of Contents Index 407 551M 14 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Refer to Figure 9 depicting a hydrostatic relief valve with a bleed valve for scale A63 Hydrostatic Relief Valve Hydrostatic relief valves may be found at multiple locations typically anywhere that NH3 could be trapped such as in a dual valve hose These are usually identified by a black polymer cap If the cap is missing the valve may have been activated at some time Hydrostatic relief valves are designed to open at pressures higher than the nurse tank pressure relief valve page 18 250 265 psi Normal excess pressure vents at the nurse tank pressure relief valve A release at a
9. NET A0 vele eerdekttgERLNEEESRRSEOEEEREE SNE 17 odor See eege 4 Squibb Taylor c cseseessesseesseeseeeseeeeeeees 32 Z acon i stainless steel EE i Ne 35 GE S BEIEN 16 stopping application sccscseeceeeeeeee 29 T T n orientation rOSe EE 3 substandard parts c sesscesseesseeeseees 35 UI Mie neen Orifice eee eecesesescssscesescststscenestatsceeeeseees 13 icat 016 0159 403 manual een 32 W suspending application 30 Orifice bleed valve n s 36 016 0159 831 manual en 1 orifice relief nnna 37 38 T 10 PSI ee ee ee 25 OSHA eege ee 4 tank temperature eects 25 1005 UN code acecxscticcsuarersiestnssseactc 4 ovldlzerg oeeeeeecccececeeeseseeseseeceseteteesesees ap Jonk upset EE 28 12 M 29 manual ergeet 1 tank NUISC EEN 6 J20 EE 17 P temperature 17 1325 8 Cap isiin iniinis 40 parking ee 9 temperature tank eee 25 GN aN es 19 parking plug ege 11 threshold gees d EE eege 19 PASS planning eseeeeseeeeseeeeeeeeee 27 TINGS gt gege EE EE E 32 KSE 19 Ge Ge see 4 27 tissue damage eeeesseeeeesessesseeeeeeeeeeee 5 ee ene en ee 19 Personal Protective Equipment D oy oN ne 5 93 1 635 3 EC NO ec 4 KA 25 trai ceeeeeeseeseeeseesseeseesseseesseeeseesseeseees 2 BOO OPM eegen 6 BEE ZER eer E EE 4 plug parking EE E tubingloop evescasccse ness cece edeeateeceteuce 35 3 1 0 diamond o eeeeeeessecseseseeseseteeeeteeees 5 plumbing single ssssssssssssssrsetsserseees 42 irns EE SE 0 een 17 EE g
10. ammonia A Have required documents A Inspect all equipment carefully prior to operations Applicator and nurse tank hardware must meet strict regulatory requirements and be in excellent working order Components must be within their expiration dates A Make sure all wash water tanks are full with fresh clean unfrozen water Change water daily A Perform all required maintenance Components with specific limited service lives must be periodically replaced A Turn off all hose end and shutoff valves prior to transport A Check applicator tines or knives In more challenging conditions tines or knives may wear prematurely causing stops for cleaning and unplugging increasing low level exposure to anhydrous ammonia A Have an extra set of safety equipment in the tractor cab Have readily available communications to summon professional aid in case of accident or release A Park the tank in outdoor shade on hot days and warm sunny days Never park near ignition sources Do not smoke A On hot days and warm sunny days do not stand down wind of the nurse tank Even if the air temperature is below 116 F 46 7 C parts of the tank may be above 116 F raising the tank pressure to above 250 psig and causing the relief valve to vent NH3 gas until the pressure falls A Use hitch safety pins Use safety chains A Follow operating instructions precisely Use checklists Do not skip steps A Close valve firmly but do not wren
11. any engineering enhancements ACAUTION Ammonia Exposure Hazard Fully discharge the system page 39 before removing an old valve Wear protective equipment If the implement was recently used or ammonia was trapped there could still be NH liquid or vapor behind the valve ANHYDROUS AMMONIA INHALATION HAZARD Do not attempt to repair or adjust a relief valve Hydrostatic relief valves are factory set and tested on specialized equipment to discharge at a specific pressure On the component being protected by the valve inspect the threaded hole after removing the valve If there are signs of corrosion replace the entire component Use pipe sealant when installing a replacement valve Use only pipe sealant specified for use with anhydrous ammonia such as RectorSeal No 5 Do not use tape Record the replace by date of the new valve in the Replacement Log section of the applicator Operator manual ANHYDROUS AMMONIA A CAUTION INHALATION HAZARD Ammonia Exposure and Rupture Hazards Always replace a relief valve with a valve A that is an external hydrostatic relief valve A that is specified for anhydrous ammonia service A that has the same NPT pipe thread size and A that is rated for the same discharge pressure as the valve removed or as otherwise specified by Great Plains or the manufacturer of the protected component Discharge pressure is specific to
12. for hose management the depicted cart has the Acme parking plug on top Make sure you understand the purpose of any tongue features When the nurse tank hose is attached check that wg the forward point at which it is secured to the tongue Figure 2 or cart frame is at least 3 feet 92 cm from the Nurse Tank Hitch implement break away with enough slack to elevate the hose at least 13 inches 33 cm above the implement breakaway Note Nutri Pro implements do not provide a lighting harness at the rear hitch as field operations do not require nurse tank lights If the nurse tank has lights make sure there is provision to secure that harness during field operations Note A Nutri Pro implement does not provide pass through connections for air hydraulic or electric brakes as field operations do not require brakes If the nurse tank has brakes rare make sure they can be set to off freewheeling and there is provision to secure the unconnected brake lines during field operations A54 Nurse tank cart tongues typically have unlimited vertical movement If the tongue pivots have stops make sure the clevis can be elevated to at least 48 inches 122 cm above ground for implement lift in field turns 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Nurse Tanks 11 Nurse Tank Front End A cart may have one or two tanks A two tank ca
13. hydrostatic relief valve indicates a malfunction or operator error Figure 9 Hydrostatic Relief Valve Hydrostatic relief valves are usually limited life components Nurse Tank Forward Fittings Refer to Figure 10 and Figure 11 A welded roll cage normally located at the top front of the tank contains all the operating and status fittings except the relief valve 80 page 21 and the drain valve amp 79 page 21 faa COOP ASSN CRUTION 1 Decals on the tank or protective structure may identify E L amp AMMONIA 555 555 5555 555 5555 the valves and fittings Valves may be color coded Make INHALATION HAZARD sure all operators know where each valve or fitting is g located Several of the valves have a similar mechanical appearance As the tank operator you will operate one of these fittings the withdrawal valve 66 and periodically check two others the pressure and float gauges You need to know the functions of all of the fittings in this Figure10 group for purposes of tank inspection and acceptance Nurse Tank Forward Fittings 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Nurse Tanks 15 Refer to Figure 11 some components shown exploded for clarity never remove any except the outlet cap A64 Outlet The inlet end of the nurse tank hose attaches to this fitting which is located at the withdrawa
14. may still be present Carefully bleed the line section before taking any other action It is also possible that the valve disc has deteriorated or has debris under the seat and is venting or leaking at normal operating pressures Any hydrostatic relief valve that fully opens pops must be removed and re tested or simply replaced 3 Carefully remove the dust cap 4 Check the replace by date stamped on the valve If it has passed replace the valve before next use 5 Clean any clogged weep holes If they cannot be cleaned replace the valve ANHYDROUS AMMONIA INHALATION HAZARD Ammonia Exposure Hazards amp A Wear safety equipment when inspecting or performing maintenance on relief valves Even if the line is bled NH3 liquid or vapor may still be present A Always bleed the system before removing a relief valve cap or performing any more detailed inspection or valve maintenance A Never stand in front of or look directly into a relief valve Use a mirror If an overpressure event or valve malfunction is imminent or in progress you can expect multiple valve activations The initial activation can blow debris as well as liquid ammonia into your face A Follow inspection and replacement instructions carefully Use the instructions on these two pages only if no separate instructions were supplied with the original and or replacement valve Figure 32 Uncapped Relief Valve Not
15. the valve location in the system Using a valve rated too high could result in bursting of system components and a major liquid NH release Using a valve rated too low could result in unexpected liquid NH release and material loss during application 2013 07 15 Table of Contents Index 407 551M 42 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Ga Appendix Single Cooler NH3 Plumbing See applicator Operator manual for legends dual cooler and section control diagrams Figure 33 Plumbing Single Cooler Single Section System 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index 43 gt La h Index A color code ee 16 17 full trailering eceeseeseeesseeseesteesees 10 accident ee 7 color code 14 FVC062 manual c cccccceessteeees 32 ACCUFIOW 25 combustible 5 16 G acids EE 5 commercial available 1 e Acme 10 11 13 15 17 36 contact IONS 6 oe EE eters K AG a ees tae eee 19 Continental eee ete ceteeeees A0 fot ees gasket EE 11 AIHA vececcecesececscsescecscsescecevscseseceveveesees 4 COPPET ee ee tt 35 gauge air in TANK oes eeeeeeeceeeececeeeeeeeeeeeeeeeeeaaes 16 eege OCH 5 level fixed an 17 Tea eg e Sg SS Gei Seege i level float o 18 EEN R SE Ee EE EE ammonium hydroxide 1 5 35 39 CSA EE 19 pressure tan ee TT 6 anhydrous ammonia ceseeeeeeseees 1 CSA B620 D 2
16. wind of them A top mount valve has a dip tube which collects the liquid NH3 Note that there is no pump Application flow is driven by a vapor pressure of the NH3 gas above and b gravity siphoning due to tank elevation In cold weather vapor pressure may be insufficient to support high application rates See page 25 for further information on cold weather operations D Be AY AOA NH3 GAS NH3 LIQUID a As there must be a gap between the dip tube inlet opening and the tank bottom there will be some amount of ammonia that cannot be withdrawn as liquid This is normal and also provides safety The residual liquid ensures that the tank contains only NH3 under positive pressure A DANGER d i ANHYDROUS be AMMONIA INHALATION HAZARD Explosion Hazard Stop application when the flow meter and cooler pressure gauges indicate that the liquid level in the nurse tank has reached the dip tube inlet Leave the residual NH in the tank Attempts to apply all of the liquid NH3 could cause air to be introduced to the tank creating a potentially combustible mixture Figure 12 Nurse Tank Withdrawal Valve we 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Nurse Tanks 17 Refer to Figure 13 some components shown exploded for clarity never
17. with other metals may be unstable or even explosive 2013 07 15 Table of Contents Index 407 551M 36 NH Safety Table of Contents Index Great Plains Manufacturing Inc Use a Mirror Refer to Figure 27 AMMONIA 4 CAUTION INHALATION HAZARD Blinding Choking and Respiratory Hazard Never look directly into an ammonia hose or fitting Use a mirror Always assume that ammonia is present in the system There are many ways it can hide and surprise you later See Avoid Trapped Anhydrous on page 37 ANHYDROUS Use a hand mirror to inspect hose ends piping ends gaskets vents and orifices About Bleed Valves Assume there is concentrated NH3 at any bleed valve unless you are completely certain which segment of a line is serviced by that bleed valve and that the line segment has been open to the atmosphere for some time When installed on operating valves it is not always immediately obvious what the bleed valve protects On globe valves a bleed valve near center line might be for venting upstream or downstream On older ball valves a bleed valve near center line might be for either side or even venting the ball cavity itself Refer to Figure 28 The purpose of a bleed valve is to perform a controlled release via an orifice of any fluid or gas trapped in a closed line prior to operating other valves or uncapping at a nearby Acme fitting If the line is discharged open
18. with proper current safety certification and current safety equipment and features Consult with your anhydrous ammonia supplier for safety information and correct safe handling transport and use of anhydrous ammonia Consult with local and regional authorities on Safe and legal use of anhydrous ammonia including emergency and environmental contacts and release reporting requirements Review any decals and manuals available for your nurse tank cart and for any of its components There may be separate manuals for the tank running gear indicators valves and fittings This manual covers typical operations for a representative NH3 nurse tank cart Compare the features and controls of your cart to the model cart so that there will be no confusion about instruction steps ACAUTON Control Variation Hazard If you are using multiple nurse tanks study each one separately Unless they are owned by you and known to be identical there is a high probability that there are differences between them even if they are all from the same terminal Trailing Nurse Tanks Only This manual and the applicator Operator manual do not cover operations with applicator anhydrous tanks ANHYDROUS AMMONIA INHALATION HAZARD A consistent system of callouts is used for most nurse tank cart components 3 character callouts in the range to refer to nurse tank cart components decribed on page 10 through page 22 Nu
19. 27 DGTINITONS A E A E N 3 Start of Pass Planning 27 Prepare for Emergencies ccccceceeeeeeseeeeeeeteeeeeeeeeeeees 3 Starting Application ccccecssseceessssteeeeesstneeeeeeees 28 Anhydrous Ammonia Information ENER KN NNN EN NNN 4 Field Turns tees dE 28 NHg Icons and Decals ccsesceseeseseeeseeeeeeeeteeentetees 4 Stopping Application ENEE 29 NFPA 704 3 1 0 hazmat diamond ccccccccccececeee 4 Suspending Application 30 DOT UN 1005 Class 2 2 hazmat placard ee eee 4 Unhitching Nurse Tank 31 ANHYDROUS AMMONIA Final Nurse Tank Unbitch 31 INHALATION HAZARD oeer 4 Exchanging Nurse Tanks A 31 General NH3 Information 4 Folding and Unfolding AA 31 NH3 Concentrations Parts Per Million 4 General Safety Rules eeseeeeeeeeeeeereerreereerreeree 32 Why Anhydrous Ammonia NH3 Difters 5 Breakaway Event cc ccciccitsestcerssenecsetseesenceceesnneeese 33 Personal Safety with Ammonia sssssssseseeeerneseerrrneeren 6 Ammonia Maintenance Safety een 35 Ammonia Emergency Action cccccceeeeeteeeeeeteeeeees 7 Incompatible Materials sssseeeeeeeeeeeeeeennn eneee 35 Ammonia Nurse TankS cssscccsseeeesscceessseeessceeenss 8 Incompatible Cleaners n 35 Nurse Tank Security EE ER 8 Usea Miror soretes eege eg eegend 36 Nurse Tank Gatefy 9 About Bleed Vahyes 36 Nurse Tank Cart Components 10 Avoid Trapped Anhydrous eicassesseticninsiencuusncimsudverriwecdns 37 S15
20. 3 ANSI 19 CT 19 goggles ee 6 SE E EE Oo nn OO ANSI K61 1 aaaaaonnnnonnsnnnnnnnnnnnnnnnennnne 19 D grease in valve uasssceceeer 41 ANSI K61 1 1999 een 23 DANGER defined scessssssesesseeeeeeees Be E E 4 applicator tank se secs eeeseeese terse E DEE 12 15 17 19 40 2 WEE 19 ASME EE 19 decal ee ee 2 H B Eelere ee 9 ball rap verse E a a a IS handwhes ede GEINT EE 35 decal mirror IMAGE seeceeeeseeses 11 hazardous D wees no 1 black Cap oeeeceeeccccecssseeeseeseeeeeseeeeseesees 14 deferring maintenance s 35 hazmat 1 bleach oo eeeeeeeceeeeceeceereeeteeeereneteteaees 35 definitions ENEE eeeeeee BS weandigede o A headland sirsiran 27 bleed valve 16 36 detection threshold 4 hose inspection 12 POSE E 13 diamond een 4 3 hose carrying EE ell TE 10 dip tube sanabaaeeadadsu ensassadaabadtarnnt 16 17 hydrostatic relief valve 14 25 40 ele 5 35 directions 3 hygroscopic 5 breakaway ccceecsescseseeteeeees 33 39 discharge 39 E Bregen 35 GOCUMONTS ees 32 bushing reducer ccceccceeseeseeeees 15 DOT E 4 19 23 E EE 4 6 29 a B620 aite a te caiessns enseuiare 19 down wind NENNEN 26 po see c drain valve eseseseeiseeiresereerreen 21 WE Ge T 1 S1800 EE 1 CAMU vsscecsck eek eieeocieaiesetndasceactarsszeas 35 dry ee ke ane S as a CAIGIUIM EE 35 ee 11 J eT cecccsesssssssseesevsssseevvesseseee g g NK 11 joint compound Ee 32 Gamada svecesdedisseesteeivde titi en 23 E K PAD INGICK sesein
21. 48 psi 60 F 16 C 93 psi 100 F 38 C 197 psi 116 F 47 C 250 psi ANHYDROUS AMMONIA A CAUTION INHALATION HAZARD Anhydrous Ammonia Exposure Hazard Keep the nurse tank cool Stay up wind of relief valves Check the tank pressure gauge In hot weather ammonia vapor releases can occur at a relief valve Normally over pressure releases occur at the nurse tank relief valve 80 page 21 It is designed to operate at a lower pressure than other hydrostatic relief valves in the system However with operating valves closed trapped NH3 could activate hydrostatic relief valves anywhere in the system Lower Operating Limit A manifold pressure of at least 10 psi is required for the AccuFlow to operate correctly If the static pressure prior to operation is not much above that it may fall below this limit when NH begins to flow 2013 07 15 Table of Contents Index 407 551M Table of Contents Index Great Plains Manufacturing Inc 26 NH3 Safety Wash Water Refer to Figure 23 Empty the 10 gallon implement First Aid Water tank Refill it with fresh clean water If the nurse tank cart is at hand refill the nurse tank wash water as well The water needs to be changed daily Water absorbs ammonia NH3 vapor from the air and becomes an ammonium hydroxide NH OH solution over time FIRST AID WATER When emptying wash tanks use the time and water to train ope
22. A Use only CDS JohnBlue Great Plains Raven and Squibb Taylor specified parts to repair implement components originally supplied by Great Plains Many common plumbing materials are incompatible with NH3 Joint compounds must be specified as ammonia resistant A Never mix anhydrous ammonia with other chemical liquids Reactions with many common materials can be violent and or produce highly toxic by products A If a fire threatens an anhydrous ammonia tank evacuate the area The tank may heat up faster than the relief valve can vent the rising pressure resulting in a catastrophic gas release and possibly an explosion 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Anhydrous Application 33 Breakaway Event Initially treat a breakaway coupler separation event as you would any other field emergency Perform the steps at Ammonia Emergency Action on page 7 Only then consider performing the steps on this page Although the breakaway coupler is designed to separate such breakaways are not routine events Upon a breakaway what to do about the breakaway coupler itself is the last consideration Priorities are 1 Protect Perform basic field emergency action which may included summoning emergency responders if a major release is in progress or the nurse tank is tipped over or is otherwise at risk of a major release 2 Assess If the nurse
23. PA 3 1 0 diamond for emergency response purposes NH3 does react with various materials and can produce hazardous by Bei products and or have hazardous side effects SR CORROSIVE NH is corrosive to a surprising number of metals see page 35 Repairs with incompatible parts are likely to result in malfunctions and a serious accident Brass parts in particular can fail rapidly from the inside out Mixing NH3 with some common household and agricultural chemicals can for example produce highly toxic gas Never mix NH3 with acids WIS A NH is attractive to criminals Do not leave a loaded tank unattended Secure your tank Clandestine lab operators steal NH3 from unattended nurse tanks Criminals and vandals often leave a tank in an unsafe State 2013 07 15 Table of Contents Index 407 551M Table of Contents Index Great Plains Manufacturing Inc 6 NH3 Safety Personal Safety with Ammonia A Carry personal flush water and wear Personal Protective Equipment PPE at all times when working with or near the nurse tank and when working with an applicator not known to be completely purged Minimum PPE is e Carry a sealed squeeze container with 8 10 fluid ounces 270 ml of clean water or saline solution e Wear non vented chemical splash goggles specified for use with anhydrous ammonia If you wear glasses make sure the goggles seal completely A vented full face mask provides extra splash prot
24. ST AID Irrigate continuously Get professional medical help as soon as possible W A T E R Do not stop with one flush Apply water until a physician takes over or instructs otherwise In particular do not use lotions ointments salves or creams They can trap the harmful agents under the skin A Close Valves Only if Not in Vapor Cloud Once clear of the cloud evaluate if it is safe to close any shut off valves not already closed DO NOT re enter vapor cloud DO NOT attempt leak spill control other than valve closure If Raven SCS 450 console is on set MASTER switch off Do not turn POWER switch off Prec A Escape Continue moving upwind of any uncontrolled release The wind may shift On a calm day the ammonia cloud expands in all directions A Notify Summon any aid required Notify local authorities of any uncontrolled release Protect the public Protect livestock if that can be done without further exposure A Stay in Contact Be available to responders with whatever information they require Do not attempt to correct the accident problem yourself Standard field PPE safety equipment is suitable only for normal operations and escape Field PPE is not safe for emergency response a PPE Personal Protective Equipment 2013 07 15 Table of Contents Index 407 551M Table of Contents Index Great Plains Manufacturing Inc 8 NH Safety A h Ammonia Nurse Tanks Use nurse tanks
25. Table of Contents Index Application Supplement Nutri Pro NH3 Safety Using Anhydrous Ammonia Safely m Great Plains Manufacturing Inc www greatplainsmfg com this symbol the subsequent instructions and warnings are serious Read this manual AND the operator s manual entirely When you see follow without exception Your life and the lives of others depend on it Illustrations may show implements and nurse tank that differ from those you are using ORIGINAL INSTRUCTIONS EN Copyright 2013 Printed 2013 07 15 407 551M Table of Contents Index Table of Contents Index Table of Contents Index Great Plains Manufacturing Inc Cover Index iii GE Us Table of Contents Read All Manuals ccccseecceceeeeeeceeeeeeeeeeeeeeeeeneeeseseenes 1 Cold Weather LOW FIOW ssssesseeseeseeeseeesrreerrser 25 Related Manuals Some for Opilons 1 Hot Weather Ventmg 25 Enhanced Vigilance Required eee 1 Avoid Dead Calm cecccecccceeceeeeeeeneeeteneeeseneeeeenaees 25 Missing Manual Hazard 1 Wash Water 26 Anhydrous Ammonia Education 2 Field Operation Safety ccccceccessseceessssteeeesssseeees 26 Trained Informed Personnel Only 2 DY TIET 27 Study All Decals ssisievsseseaitaseciesdsabeeaarsiseviarssceaccazensssd 2 Row Implement Adjustments sseeeeeeeseeeseenrnnneen 27 Be Aware of Signal Words cccccceeeseeeeeteeeteeeeeees 3 Sealer Adhustment AAA
26. YESO NO the cart manuals e Do you have the MSDS for the tank YESQ MO contents e Are UN 1005 placards on at least YESQ NOQ both sides and rear of the tank set e Are ANHYDROUS AMMONIA YESQ NOQ labels on at least both sides and the rear of the tank set e Are INHALATION HAZARD labels YESQ NOU on both sides of the tank set e Are all safety and instructional decals YESQ NOQ present and legible Does the tank have a fully legible YESQ NOQ manufacturer s name plate stating standards compliance e Is the tank compliant with YESQ NOQ ANSI K61 1 1999 or CGA G 2 1 1999 or later or other NH3 tank standard applicable in your jurisdiction e Is the tank filled to less than 85 full YESO NOQ e Does the ammonia contain at least Yesa NO 0 2 water e Do you have dealer supplier contact YESO NOQ information Figure 22 Checklists Matter Does the tank have a visible numeric lettered or other unique identifier Does the cart have a clevis hitch with 1 inch 2 5 cm pin Does the cart have two safety chains Does each tank outlet hose have a male 134 4 Acme fitting and cap Are the hoses in good condition free from cuts soft spots bulges blistering kinking flattening or indications that the hose is stretched or damaged at the coupling Is there at least 3 ft 92 cm of free cart hose from the front clamp tie and provision to elevate the slack at least 13 i
27. a dirienenn 14 EC INDEX oe eescestesseesesetenetneneseesees SE centers ested dunes 32 CAD MISSING E AO EC NUMBER ssemrsemomemremgueepg GNM EE 19 CAP valve oo eeeceseecsecsteeeseesseeeeseeeenees 40 education 2 L Cargo Tank CT csccssecsssecsteesseeessees 19 EHS sree dated adits 1 i carry hose sasssssssnsisisisseirisisinnene 13 EINECS wise ccctessstacectvestsacteseastsctteaerencs 4 peeks defined e S Cart nurse tank eeeeeeeeeeeeeeseeeeeeeeeneee 8 iullre el 7 fore e 10 CAS number neeesser 4 emergency response seisis 5 in MING nee CASTIN si 35 enclosed CAD oes eeseccseeecsseeeeeseeeeeeeeess By UN MAD eee cite aIr Oe CAUTION defined sees e Spatlese Ee ei CDS John Blue i EEN 1 a evel float gauge eeng 18 CDS JohnBlue ie 32 TRAG fKk O l ooo voce ooo coves 4 d ium S EE 35 COA cc cites pete atten 19 EXCESS FlOW valve eeeeesccsssteeseeeeeneeee 15 deeg SE D CGAG 24 19 exchange nurse jonk 31 edel ME 7 CGA G 2 1 1999 ooeeecccesecssecereeereees 23 expiration sesnnsnsesennensinnsnsnereee 32 M chain safety oo eee 10 OXPOSUME niinismniniisnii uiia innie 7 MAQNESIUM 35 checklists F maintenance cccceeeeteeeeeeeeeteeees 35 NH3 tank acceptance 23 E EE 3 7 MDMT ssecczs stances tavndeeecesetcttecs cenestenes 19 chemical burning 2 scceeeees B drstaidiwater Ge EE 21 oe MOMCULY een 35 children 32 fixed level gauge oe 17 MIOL ena 6 36 CHOLINE EE 35 flammable cae EE A mirror image de
28. able of Contents Index Anhydrous Ammonia Information 5 Why Anhydrous Ammonia NH3 Differs from typical liquid fertilizers ANHYDROUS AMMONIA INHALATION HAZARD A NH is intensely hygroscopic On contact with water such as unprotected skin eyes mouth airway and lungs it dissolves immediately desiccating the cells and forming ammonium hydroxide A NH is highly caustic Ammonium hydroxide formed on contact is a strongly corrosive alkaline solution resulting in severe chemical burning of skin and mucous membranes A NH is volatile NH boils at 28 F 33 4 C expanding by over 850 times It remains liquid in the nurse tank only because it is pressurized at up to 250 psi Leaks or above ground releases immediately cause an expanding gas cloud Tanks begin venting above 116 F 46 7 C A NH has a high heat of vaporization NH is a powerful refrigerant Evaporating boiling liquid NH may be at 100 F 73 C freezing whatever water it touches in addition to the other hazards This can freeze clothing to skin prolonging tissue damage A NH is combustible SS Although NH generally does not burn with a self sustaining flame in the field it is a significant fire hazard in closed areas and or if released near hot ignition sources such as during welding on implements A NH is reactive Although the reactivity is classified as 0 in the NF
29. akaway coupler manual are required reading for safe operations If you do not have the current edition of all manuals contact Great Plains for replacement copies The present manual 407 551M covers e General anhydrous ammonia information e Safety information specific to anhydrous ammonia e Using anhydrous nurse tanks safely e Nurse tank acceptance checklist Enhanced Vigilance Required Although a common useful and still economical agricultural fertilizer liquid or gaseous anhydrous ammonia NH3 is an extremely hazardous substance ANHYDROUS an EPA EHS hazmat amp AMMONIA ADANGER AMMONIA EPA EHS Extremely Hazardous Substance Despite the common odor anhydrous ammonia properties are dramatically different from those of household ammonia cleaning solutions dilute ammonium hydroxide NH4OH An uncontrolled release of NH3 can easily be fatal or cause permanent disabling injury If you are new to NH operations study everything you can about this chemical and how to use it safely Missing Manual Hazard The nurse tank s you own or are leasing may not have current manuals If so the nurse tank topics in this manual need your attention These pages cannot be a substitute for a complete and current nurse tank cart manual but they cover important information for using nurse tanks safely Related Manuals Some for Options 407 502M Nutri Pro NP30A Operator 407 313P Nutri Pro NP30A Par
30. als e n ee en eee 10 Avoid Line Trape eseeeeteteeesnenstsseeensesesnennnes 37 Nurse Tank Front End sscicaiisscniicarscnscacnarceissnedenendes 11 Clearing a Line Trap 37 A59 Outlet Hose Configurations DEE 12 Avoid Ball Traps See EE Eege 38 Nurse Tank Forward Fittings cccccsccceescsseeeeees 14 System Discharge sssssesesseseeeeerrreerrrrnnrtrnnnrnrn rnern 39 Nurse Tank Sides and Mid Gechon 19 Normal Discharge 2 eeeceeeeeeeeeeeeeeeeeeeneeeeees 39 Missing Nameplate ccccccceesceeceeeeeteeeeeeaes 19 Hydrostatic Relief Valve Maintenance e 40 Nurse Tank Rear End 22 Relief Valve INSPeCtion cc ceeeeeeseeeeeeeeeneeeeeeeeaees 40 Nurse Tank Acceptance A 23 Valve Replacement cccecceeeeeseteeeeeeeneeeeeeeeneeeees 41 Anhydrous Application ccccsccssseesseesseeeneeeees 25 PADD OMX aloes cscs EES 42 NH3 Temperature and Pressure Relationship 25 Single Cooler NH3 Piumbing eee 42 Get Expert Advice aise ccisscesciccisataesceeustianecdcisincnvaveleneres sche leg E E E E E E E EE 43 Weather Extremes cccesseecceeeeeseeceeeeenseeneneeeeeaees 25 Copyright 2010 2013 All rights Reserved Great Plains Manufacturing Inc provides this publication as is without warranty of any kind either expressed or implied While every precaution has been taken in the preparation of this manual Great Plains Manufacturing Inc assumes no responsibility for errors or o
31. cal EE 11 ClASS E E T E EE GENEE b9 M ss Ng Cap eu r eeeuegercht 40 elevis hitch n 10 e M ae 2 32 CLONING un 5 6 EMGSA cnctscensieecinccstce 1 MUCOUS MEMDrANE poe acts mee acticin 5 2013 07 15 Table of Contents 407 551M 44 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc MN gicietascicdbisisdissccvaseadjenseceeriateeers 19 S Vapor loug sek igEsteerREeEuEEABEEOSCeeR 7 N Safety chain ou eecccecseeseeteeseeteeeeees 10 VADOP VAV gt c5 cssdcccccscctstestensetecceieensnees 17 nameplate o on 9 19 safety training EE 2 VOM reeeeeeseeseeseesesteseesseseenssneeneneenseneens 32 TN 5 Eeler Ssi cance Segen 7 venting EE 5 NEPA 704 ccccccccccccceccccececcececcecceceececeeces 4 SCS 450 someone ererek raoin 1 Volatile irsinin 5 NHS eee a eeetennentastase A SOS 450 n 1 w NH4OH Ee 1 26 9 Semimounted eege 9 10 WARNING defined ssssscsssseeseees 3 ler NEE 4 Serial number tank sees 19 wash water cssecscsstesscseteeee 6 21 nitrogen sarikas 25 Set EE 35 watertank eerste 26 Note defined o ccceecccseseteeeeeeees 3 SINGIE cooler EE 42 water waeh sssi 6 NOTICE defined EE BOO SK N en SE EE 5 NPT ee q2 15 Slack hose erer E Wind ZE 25 nurse tank ou eee eeeeeeeeeeteeeeeeeeeeeeees 8 9 SMV SEENEN 22 wind direction 7 nurse tank exchange ceeeceeeeee au SOM drying En 25 withdrawal valve esssssesseesseeeeeeeseees 16 nurse tank unhitch 31 AS WE e y 0 Squibb
32. ch A Never allow a hose tube pipe end or vent opening to point at your face or body A Never use control valves as handles for moving hoses or climbing equipment A Route the emergency shutoff cord to the tractor cab prior to field operations A Expect small NH releases during connection disconnection when raising the implement out of the ground and after completion of application Stand up wind A Keep the implement down wind of unprotected persons livestock and open water after application ANHYDROUS AMMONIA INHALATION HAZARD 1005 e Have documents required by law liability carrier rules and entity policy e Have MSDS Material Safety Data Sheet and supplier documents for the anhydrous ammonia e Have any manuals for the nurse tank e Have the applicator Operator manual e Have the ammonia meter operator manual such as the 016 0159 403 Raven AccuFlow Operator manual e Have the coupler operator manual such as the FVC062 Squibb Taylor Flo Max manual S V A Do not have unsealed containers of food or drink near the tank implement or in the tractor Any released NH3 will combine with the water in the food or beverage A Do not move the implement indoors unless completely discharged of ammonia or the indoor area has two openings one up wind and reliable cross ventilation A Always assume that once used NH3 residues are present in implement hoses tubes and metering system
33. cing up but may also be installed at 45 with face tilted up or horizontal with face to front or side On a leased tank learn the reading to expect when the tank level reaches minimum usable It may be an indication above at or even below zero The gauge reading may be inaccurate if the tank is on a slope or has just been moved due to sloshing a om E Ge al n ZA fi ks NH3 GAS e a a Eer NH3 LIQUID Figure 15 Float Gauge 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Nurse Tanks 19 Nurse Tank Sides and Mid Section Refer to Figure 17 depicting a pre 1988 ASME nameplate A72 Tank Nameplate Locate and inspect this plate It may be anywhere on the tank but will be on the tank and not on the running gear or tongue It is often at top center Check that the plate is present and legible The 1966 vintage plate depicted at right has marginal legibility in places Do not accept a nurse tank with an illegible nameplate Do not accept a nurse tank that is not consistent with the requirements of anhydrous service See ANSI K61 1 CGA G 2 1 for a complete list of requirements but some key items to check for are e Manufacturer name e Repair stamp normally blank An R here indicates that the tank has been repaired by an au
34. d left pointing that way unattended If this is not possible get expert help 4 DANGER BR aii Upon Event Probable Chemical Hazard A 60 cc liquid release to air has already occurred Assume a major release is also in progress or imminent Act accordingly Request assistance from trained experts rather than risk blindness disfiguring disabling injury or death A breakaway event is most likely due to a major equipment failure such as nurse tank running gear fracture or a gross operator error such as towing turning too fast or departing level ground These cases can result in an immediate serious spill or result in a damaged tank at risk of leak at any time Even in the case of a basic operator error such as movement with only the nurse tank hose connected both implement systems and nurse tank hose at breakaway are fully charged with liquid NH3 right up to the checks in the breakaway halves The nurse tank side is under full tank pressurization The implement hose may be under pressure This was an unplanned event Wind direction may not be favorable for discharging and re coupling If the wind is light or calm do not attempt to bleed the breakaway coupler halves Your field PPE is not sufficient for the releases necessary a PPE Personal Protective Equipment 2013 07 15 Table of Contents Index 407 551M 34 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc
35. disconnected this liquid is likely at extreme pressures is emitted forcefully and vaporizes rapidly Al Yin ball valve can trap enough NH to reach IDLH vapor concentrations within moments in a space the size of a two car garage Anyone present could be burned blinded or receive serious or permanent lung injury If this happens in an enclosed space the consequences could be fatal Refer to Figure 30 Always assume a closed ball valve contains liquid NH3 under high pressure The flow gate of a traditional ball valve is a solid steel ball with a hole through it When closed the hole cavity is sealed by the side walls of the valve body If closed with the line full the ball cavity is full of NH3 If the valve is well constructed that fluid remains there indefinitely presenting future field and service hazards Note If the valve has a bleed valve and or relief valve those safety valves do not vent the ball cavity when a solid ball valve is closed One of them may vent just the downstream side of an orifice ball with the ball closed The emergency shut off valve page 42 supplied on Great Plains implements in October 2010 and later has a relief orifice on the downstream strainer side of the valve Nurse tank hoses are likely to have solid ball valves indefinitely Treat all ball valves as potential traps A Wear your PPE when servicing lines and fittings that are in an uncertain status A Fully bleed all lines
36. e In severe conditions such as exposure to salt corrosive chemicals or pollutants or if a valve has fully opened you may need to replace a hydrostatic relief valve sooner than 5 years 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Maintenance Safety 41 6 Inspect for dirt sand grease paint damage corrosion signs of tampering or insect activity If visible check the metal surface of the spring If debris cannot be easily cleared replace the valve If there are signs of damage replace the valve If there is any question replace the valve 7 Ifa valve is venting at normal operating pressures replace the valve 8 Never force a valve closed If a valve has remained open after operating or is leaking it is seriously contaminated or failed Replace the valve 9 Never attempt to protect a valve orifice with grease Grease can harden over time and or collect contaminants Either factor could prevent valve operation in an overpressure situation Never plug a relief valve outlet Relief valves are economical defense against serious ruptures and major releases Help a valve do its job of protecting you Valve Replacement The safest source for a replacement valve is Great Plains Check the latest edition of the Parts manual page 1 or the Great Plains internet parts lookup This assures a correct and compatible part that reflects
37. e purpose of this step is minimize atmospheric NH3 vapor while working at the rear hitch because you may not be able to conduct all unhitching and re hitching steps from up wind of all the tines or knives b Position the implement cross wind with the wind from the right tines or knives in ground c Use the rope to close the emergency shut off valve A18 page 42 d Put on your goggle and rubber gloves e Shut off the nurse tank withdrawal valve page 16 Leave the nurse tank hose valves 6 page 13 if any open f From up wind and with the orifice facing away from you slowly open the breakaway coupler inlet bleed valve page 42 g Stand clear and wait for the hoses to discharge h From the up wind side unscrew the nurse tank hose outlet coupler page 11 i Secure the nurse tank outlet coupler j Close all opened bleed valves k Release the nurse tank safety chains Remove the nurse tank hitch pin Folding and Unfolding AWARNING Loop Ammonia Exposure Hazard Allow no one down wind of the implement when folding and unfolding Applicator tubing loops may contain liquid NH3 that can drain out of tines or knives during wing movement This liquid can remain in the loops long after application has ended ANHYDROUS AMMONIA INHALATION HAZARD After parking overnight or longer any liquid present may be highly caustic ammonium hydroxide concentrated ND OP a solution of NH3 a
38. ection but is not a substitute for primary non vented eye protection e Wear long cuff chemical gloves specified for use with anhydrous ammonia Turn back the cuff ends to catch any liquids when arms are raised e Wear clothing made of heavy tightly woven fabric that can be closed at the neck and at the cuffs of long shirt sleeves and long pants Wear boots or high closed shoes e Have a mirror for inspecting ends of fittings ports and hoses Never point an NH3 source at your face e Great Plains strongly recommends carrying a wireless telephone or 2 way radio A Do not wear contact lenses when working with near anhydrous ammonia nor with equipment that may contain residual NH3 liquid gas NH3 can cause permanent eye damage faster than you can remove contacts for eye washing A Unfrozen wash water is required Completely replace water daily or more often in the 5 gallon 19 liter tanks on nurse tank cart and on implement Wash water tanks may be vented to allow the water out at the tap The vent allows NH gas to enter and gradually form an ammonia solution A Respirator Full face piece respirator protection is required for workers at fixed ammonia facilities but not for field operations Should you choose to use a full face respirator when operating the applicator be aware of two risk factors 1 Loss of Warning Filter cartridges may reduce ammonia odor preventing detection of malfunctions or dangerous fume concentra
39. eed 6 KEES A 400 DC Cap nsere 40 PONM sek ee EENE 4 bwo axle aaa 9 407 313P manual va 1 pressure gauge een Y u 407 502M Manual eeeeessssscecsssseeeeeeee 1 pressure limit IOW oe 25 UN 1005 4 407 613M manual a 1 DUMPS roerien ri in eie 16 E parte 85 407 613P manual a 1 R unhitch nurse tank eeeesceeeteeee 31 407 776M manual een 1 Raven EES 32 untrained personnel uo ssssnssooiei1ennn 32 417 199M manual ccccceeeeeeeeeee 1 FOACTIVE NEEN 5 UN1005 coccccceccccceccececcececcececceceececeeceees 11 417 199P manual _ ceeeeeeeeeees 1 FOG gesuegt e 16 OO CC dees geet sleep ede setevegee 33 reducer bushing 15 V 7664 41 7 CAS ooe eeeeecceeeeseeeessteeeeeeees 4 refrigerant Seege eegen ee 5 valve 82 0 0 relief orifice anana 37 38 Co lae U a E T 21 85 relief valve aese 17 21 EXCESS How En 15 repair STAMP oo eeeceecceseeseteeeeeeeeeeees 19 ee Seed i Z n hydrostatic eller I 14 RESPONSE Center eegend 3 relief TANK EE 21 right hand defined ccccecceeeeeeeee 3 vapor ean nah a wm i no Rn ee 17 rose orientation cccecceecseeseseeeeteeee 3 withdrawal En 16 running gear oo eeeeeeeecteeeteeeeeees 9 10 We ae 407 551M Table of Contents Index 2013 07 15 Table of Contents Index Table of Contents Index Table of Contents Index Great Plains Manufacturing Inc Corporate Office P O Box 5060 Salina Kansas 67402 5060 USA
40. eeding and discharge instructions carefully Beware of places in the systems where NH3 can be trapped Avoid Line Traps Refer to Figure 30 Any two line valves in the system if both closed with NH3 present can trap that ammonia indefinitely Line valves include tank withdrawal page 16 nurse tank hose valve page 13 check valves at a disconnected breakaway emergency shut off valve control valve at rate zero 30 page 42 On Off solenoid valve and aftermarket section valves In a properly designed system segments not open to the atmosphere are protected by hydrostatic relief valves but the operation of such valves only releases a small portion of the trapped ammonia Normal shut down instructions after closing the tank withdrawal valve are intended to bleed most of the system NH3 into the soil However there can still be substantial vapor in the system after that And if shut down procedures were not followed or the state of the equipment is unknown at time of servicing you need to assume that a closed valve represents a risk of trapped NH3 The illustration at right depicts a nurse tank hose page 12 in use and shut off while still full of liquid NH3 If this hose is removed to an enclosed space then opened it represents an extreme hazard Vapor concentrations could rise to well above IDLH levels in moments This example system line segment is equipped with relief orifice equipped ball valves page
41. esume that you have followed the steps at Stopping Application on page 29 and the nurse tank is unhitched per Final Nurse Tank Unhitch on page 31 For a breakaway event follow the instructions on page 33 up through breakaway re connection Then perform a normal shutdown other than nurse tank steps per page 29 The challenges in system discharge are e NH3 liquid can remain in the system after the recommended stopping procedures e NH liquid self cools as it evaporates slowing evaporation It can take a long time for all of it to turn to vapor particularly in cooler weather e Once there is only vapor in the system there is usually little gas movement to drive the rest of it out e The applicator tubing loops are usually the last to clear and may not fully clear See sidebar Even if no ammonium hydroxide forms the NHg vapor in the system dilutes slowly with air Harmless trace amounts noticed as occasional odor may remain indefinitely Normal Discharge At the completion of stopping application and nurse tank unhitching all line valves are closed and all bleed valves are open and have been that way for at least an hour Transport may also have occurred which aids clearing 1 Verify that all line valves are closed and all bleed valves open If this is not the case there is risk of trapped ammonia See Clearing a Line Trap on page 37 2 Carefully walk down wind of the implement Chec
42. exposure to NH3 vapor may exceed PEL Permissible Exposure Limits and also may induce olfactory fatigue adaptation Over time you become less sensitive to ammonia odor and may fail to recognize dangerously high concentrations 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Anhydrous Application 27 Dry Run Before activating the NH3 delivery cautious practice is to make one dry run pass including a turn in each direction This assures that tine or knife depth is set correctly hydraulics are working correctly the nurse tank cart is tracking without issue proper slack exists for all hoses and harnesses and the meter console is reporting correct field speed Row Implement Adjustments Make all applicator adjustments before charging the metering system with anhydrous ammonia e application depth e coulter depth e sealer adjustments Sealer Adjustment ACAUTION Ammonia Exposure Hazard Fine tune adjustments with dry runs prior to initial application Making adjustments after beginning application even with tines or knives left in the ground could cause your exposure to exceed PEL leading to health problems or injury ANHYDROUS AMMONIA INHALATION HAZARD If you need to make adjustments after application begins discharge the system and then lower the tines or knives into the ground Minimize your vapor expo
43. g Inc Table of Contents Index Ammonia Nurse Tanks 13 Refer to Figure 7 A61 Hose Valve s If the nurse tank hose has one or more valves study how they work A61b EEN Hose valves are typically hand wheel valves as shown A619 or lever valves Read any documents provided for the valves Have the terminal or dealer explain how the valves work ANHYDROUS AMMONIA INHALATION HAZARD Suffocation Blinding and Burning Hazards Figure 7 Never test an anhydrous ammonia hose valve unless you Hose Shut Off and Bleed Valves are absolutely certain the hose and valve bodies are empty or both hose ends are securely connected to sealed systems A A two valve hose can contain a substantial amount of NH even when completely disconnected See Avoid Line Traps on page 37 A Older ball valves can contain NH inside the ball when closed even though disconnected at both ends See Avoid Ball Traps on page 38 Follow instructions for bleeding and checking Never use a valve handle as a carrying handle Keep hands clear of bleed valves when carrying a hose Refer to Figure 8 A62 Bleed Valve s Hose valves typically have bleed valves The purpose of a bleed valve is to perform a controlled release via an orifice 2a of any fluid or gas trapped in the closed line prior to disconnect at a nearby Acme fitting
44. g to twist the hose Acme hose couplers are intended for hand tightening only Do not use tools to make the cart implement connection A liquid tight seal is made by the gasket in the male Acme fitting on the implement break away coupler Figure 3 Nurse Tank Front E A58 o Figure 4 Acme Hose Coupler ANHYDROUS AMMONIA INHALATION HAZARD Suffocation Blinding and Burning Hazards Never disconnect at an Acme coupler without first e shutting off the line at all valves and e bleeding the line at the connection Be up wind for all operations a Acme refers to the ANSI ASME B1 5 1997 screw thread which has a coarse trapezoidal thread profile b Acme collars may be aluminum but all internal coupler components must be NH3 safe typically stainless steel 2013 07 15 Table of Contents Index 407 551M 12 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc A59 Outlet Hose A59 Outlet Hose Configurations The hose itself and any crimped or swaged NPT q fittings are limited life components Check the remove after date on the hose Valves and other A59a No Valves fittings may also be limited life HWH A61b Valves are described on page 13 Hoses may be
45. ic roads or in populated areas A Transport slowly 20 mph 32 kph maximum A Never leave a loaded NH tank unattended Never leave a nurse tank unsecured A Know and follow the law applicable to anhydrous ammonia tanks transfer transport and application Some jurisdictions require permits and specific documents and equipment configuration for highway transport A Know how to perform a basic safety inspection of a nurse tank page 23 Do not fill or accept or fill a tank that fails inspection 2013 07 15 Table of Contents Index 407 551M 10 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Nurse Tank Cart Components For use with a Nutri Pro applicator the nurse tank must be a full trailering pull type with two or more axle running gear The Nutri Pro is not designed to pull a semi mounted tank Note Callout numbers A51 through A87 identify the same nurse tank components throughout this manual and the applicator Operator manual Cart Hitch Refer to Figure 2 A51 A Nutri Pro applicator requires a nurse tank with a clevis hitch having a locking 1 inch 2 5 cm pin See the applicator Operator manual for cart hitching and page 31 for unhitching A52 At least one safety chain is required In some regions regulations may already require two safety chains Each chain clasp and weld must be rated for the gross weight of the loaded cart A53 The tongue may have supports or caddies
46. ilure These accidents can be prevented with responsible stewardship and maintenance With most agricultural equipment using substandard parts or deferring maintenance until a part fails merely costs needless lost time and money With NH3 equipment using unapproved parts deferring maintenance or operating components past end of life could cost lives 4 DANGER e Suffocation Blinding Burning Freezing Disabling and Disfigurement Hazards Do not perform maintenance with anhydrous ammonia in the system Fully discharge the system of NH3 liquid and vapor before working on the implement See page 39 ANHYDROUS AMMONIA INHALATION HAZARD A Use only equipment that conforms to applicable regulations safety standards and manufacturer recommendations A Inspect equipment carefully and thoroughly prior to every use A Discharge implement of NH3 residues before performing maintenance Assume any liquid in tubing loops is extremely hazardous If not pure NH3 it is likely to be highly concentrated ammonium hydroxide NH4 OH A Maintain equipment as instructed Follow all safety guidelines Use only approved replacement components A Replace components as they reach their dated life spans Incompatible Cleaners A Unless the implement is free of all ammonia residues avoid cleaning the implement with products containing halogen compounds most commonly chlorine such as bleach or strong oxidizers such a
47. ing the valve may have no result or may release a small amount of NH3 vapor at low pressure Leave the valve open at the current position Move away up wind Return when the release concludes If the line is not discharged opening a bleed valve may release NH3 vapor at high pressure or NH3 liquid most likely as a spray If the there is liquid in the line segment completion of a bleed can take a long time As the fluid turns to vapor it chills the remaining fluid slowing evaporation Figure 27 Inspecting Fitting With Mirror AMMONIA 4 CAUTION INHALATION HAZARD Suffocation Blinding and Burning Hazards Be up wind when operating a bleed valve Wear chemical gloves when operating a bleed valve Wear goggles when operating a bleed valve Do not place your body or head in front of the orifice Follow a check list when operating a bleed valve Open a bleed valve slowly Leave it open until all fluid and vapor flow ceases This can take a long time ANHYDROUS Figure 28 Coupler Bleed Valve Detail 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Maintenance Safety 37 Avoid Trapped Anhydrous Before servicing anhydrous equipment or storing it near untrained individuals be absolutely certain that there is no liquid NH3 trapped in the system and no NH3vapor present or only trace amounts Follow bl
48. ing with or near anhydrous ammonia equipment must be fully trained on NH3 safety know exact procedures know regulations study all safety information provided for materials and equipment and must be provisioned with adequate personal safety equipment This training may be required by law in your locale This manual covers important information but is not a substitute for training If some terms in this manual are unfamiliar do not work with NH3 until they are If any topic at right is unfamiliar assume that the topic applies to your operations and your personal safety unless you have researched it and ruled it out e This manual is not a substitute for the MSDS and other safety documents provided with the NH3 itself e This manual cannot cover all national regional and local laws and regulations nor any organizational or liability carrier rules e This manual cannot cover operations for all nurse tanks e This manual and the Operator manual do not repeat all of the Raven AccuFlow or Squibb Taylor Flo Max manuals e This manual does not repeat full details of the industry standards that apply to anhydrous ammonia tanks and operations Study All Decals Anhydrous ammonia implements and tanks display more decals more detailed decals and more decals than typical farm equipment Have all operators inspect all decals before using the equipment Make sure all operators understand what hazards the decals iden
49. ings a It is worthwhile to learn if an excess flow valve is installed how to know if it has engaged and what the reset procedure is Also an incorrect configuration of undersize LD fittings on the outlet side of an excess flow valve could result in the valve failing to operate in the event of a breach If any reducer bushing or fitting present reconsider accepting the nurse tank b PPE Personal Protective Equipment 2013 07 15 Table of Contents Index 407 551M Index 16 NH3 Safety Table of Contents Great Plains Manufacturing Inc Refer to Figure 12 some components shown exploded for clarity never remove any except the outlet cap A66 Withdrawal Valve In field operations this valve is opened first and closed first ANHYDROUS AMMONIA S005 INHALATION HAZARD Ammonia Release Hazard Never open the withdrawal valve unless a all other valves and bleed valves are closed or b the implement is configured and ready for use Always be on the up wind side for valve operation Always open slowly Always check for signs of release when opening this valve The withdrawal valve is the application outlet valve It is usually located on the tank top but may be located on the bottom It is color coded red or orange The withdrawal valve may have an integrated bleed valve or relief valve Keep all bleed valves closed except during disconnections Be aware of relief valves and stay up
50. ion under DOT SP 13554 or CSA B620 ole EMERGENCY FIRS wu Figure 17 Nurse Tank Operations Decals 2013 07 15 Table of Contents Index 407 551M 20 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Refer to Figure 18 simulated contact information A75 Owner Contact Information Required by transport regulations on both sides of the tank On a leased tank verify that the tank owner s name address and phone numbers are present legible and up to date COOP ASSN This information may not be present or required on a CMP KS gz 555 555 5555 555 5555 tank that is operator owned INHALATION HAZARD A76 UN1005 Decal y Same as on page 11 Required by transport and hazardous materials regulations on both sides of the tank A77 INHALATION HAZARD Decal Required by transport and hazardous materials Figure 18 regulations on both sides of the tank This decal is for Nurse Tank Center all users and the general public A78 PPE Kit not shown A Personal Protective Equipment PPE kit must be supplied with each nurse tank cart In some locales this kit must be in a container affixed to the tank The kit must contain at least e chemical gloves e goggles suitable for anhydrous use If more than one person will be operating the tank in the field obtain a second kit See page 6 for more information on required and recommended PPE a PPE Pe
51. k for ammonia odor If pungent there is at least some pure NH3 vapor in the system and possibly some liquid Give the implement some time to vent If there is no or only mild odor check the applicator loops for visible fluid If only a few hours have elapsed since application ended this liquid is pure NH 3 Stay away until it has vaporized 3 From up wind check all the fittings and lines If any are cold more than a few degrees below ambient temperature liquid evaporation is still in progress or has only recently completed Give the implement more time to vent Steps continue on next page ANHYDROUS AMMONIA A DA N G z R amp INHALATION HAZARD Q Suffocation Blinding Burning Freezing Disabling and Disfigurement Hazards Do not perform maintenance with anhydrous ammonia in the system Fully discharge the system of NH liquid and vapor before working on the implement The applicator tubes are open to the atmosphere at the tines or knives When they don t clear immediately they are likely to absorb atmospheric moisture forming ammonium hydroxide NH OH in the tubes This liquid is highly caustic and can persist for weeks or months but remains liquid at ambient temperatures is harmless to the tubing and emits ammonia vapor slowly If there is liquid in the tubes and it is not cold it is likely to be an NH OH solution and not pure NH3 Figure 31 Applicator Loops 2013 07 15 Tab
52. l valve which itself may not be on the tank top See page 16 This may be a male Acme fitting and if so should have a an Acme cap on it when the hose is disconnected This Acme fitting may be a different size than the implement 134 4 fitting and if so will only accept one end of the hose If the hose connects with an NPT fitting it is not intended for routine disconnection A65 Excess Flow Valve This usually time dated fitting may not be present or may be internal to the withdrawal valve ee Its function is to substantially obstruct flow if an unusually high flow is detected such as a complete shearing of the hose or a major breach in the hose If present and correctly specified for the hose size and maximum application rate field operators do not normally interact with this fitting ANHYDROUS A AMMONIA A7 INHALATION HAZARD Ammonia Release Hazard Do not approach a breached hose In the event of a hose breach an excess flow valve does not completely shut off NH flow It reduces flow which may still be a substantial fraction of a gallon per minute This flow may or may not be marked by a visible cloud This flow rate is beyond the capabilities of field PPE Summon emergency responders Note An excess flow valve may also be present at the liquid filler valve or the vapor valve 70 Figure 11 Nurse Tank Outlet Fitt
53. le of Contents Index 407 551M 40 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Hydrostatic Relief Valve Maintenance Relief valves require scheduled replacement and periodic inspection Relief Valve Inspection Inspect relief valves seasonally and during periodic maintenance Check for cap present step 2 prior to each application from a fresh tank of anhydrous 1 Bleed the line at a relief valve before a detailed inspection See System Discharge on page 39 Refer to Figure 32 depicting cooler relief valve 2 Check that the rain dust cap is in place and fully seated Do not operate with a missing cap The cap keeps the spring mechanism outlet vent port and weep holes free of contaminants that could prevent valve operation in an over pressure situation A missing or dislodged cap also indicates that the valve may have operated or may be malfunctioning Understand and correct the reason for a dislodged cap prior to field operations Replacement caps are breakaway Continental 400 DC cooler Squibb Taylor 1325 8 ACAUTION Ammonia Exposure and Loss Hazards Understand and correct the reason for any lifted or missing hydrostatic relief valve caps If a cap is out of place that line section may have been closed with liquid NH present which later partially vented dislodging the cap ANHYDROUS AS AMMONIA 27 INHALATION HAZARD Liquid NH3
54. liquid NH3 downstream of all valves in the flow divider row application tubing and row applicators When stopped in ground this slowly warms vaporizes and is expelled into the soil See warning at right c Continue field application until the Flow Divider pressure gauge reads zero Wait at least another 5 minutes Turn up wind Leave the implement in the ground There is still considerable NH3 vapor in the lines that are open to the soil There may also be a modest amount of liquid in cold tubing loops ANHYDROUS AMMONIA INHALATION HAZARD AWARNING 2 Choking Hazard Never raise a recently operated implement when you are down wind of the implement Be or turn up wind if it is necessary to raise a working implement Wear your goggles A substantial amount of anhydrous ammonia is rapidly released if you do not allow time for it to bleed off underground The concentration could be high enough to cause irritation breathing difficulty or asphyxiation 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Anhydrous Application 31 Unhitching Nurse Tank The procedure is different for exchanging tanks vs concluding application Exchanging Nurse Tanks Consult with the nurse tank supplier and all nurse tank documents before unhitching or exchanging tanks a Suspend NH3 application per Suspending Application on page 30 Th
55. m is designed for vapor pressure and gravity delivery only ANHYDROUS AMMONIA INHALATION HAZARD Vapor pressure changes with ambient temperature see table at right In colder weather there may be insufficient pressure for higher application rates The Raven AccuFlow Installation and Operation manual has a temperature rate speed chart Wanns Unexpected Release Hazard Avoid hot weather or be extra vigilant about remaining upwind of the tank relief valve 80 page 21 In extremely hot weather the tank pressure relief valve will periodically vent NH when the vapor pressure exceeds 250 psi Tank temperatures above 116 F 47 C cause venting Hot Weather Venting ANHYDROUS AMMONIA INHALATION HAZARD Direct sun on the tank or parking the tank in a hot shed could result in relief venting well below an actual ambient temperature of 116 F Avoid Dead Calm The wind is your friend Normal anhydrous ammonia operations involve small releases of NH3 vapor Accidents malfunctions and serious operator errors can result in releases of liquid NH3 which turns into a rapidly expanding gas cloud You need to be up wind of all potential releases and that is only possible if there is at least a breeze to carry the fumes away from you NH Temperature and Pressure Relationship Degrees F C Pressure psi 28 F 33 C O psi O F 18 C 16 psi 32 F 0 C
56. missions Neither is any liability assumed for damages resulting from the use of the information contained herein Great Plains Manufacturing Inc reserves the right to revise and improve its products as it sees fit This publication describes the state of this product at the time of its publication and may not reflect the product in the future Trademarks of Great Plains Manufacturing Inc include Singulator Plus Swath Command Terra Tine Registered Trademarks of Great Plains Manufacturing Inc include Air Pro Clear Shot Discovator Great Plains Land Pride MeterCone Nutri Pro Seed Lok Solid Stand Terra Guard Turbo Chisel Turbo Chopper Turbo Max Turbo Till Ultra Till Verti Till Whirlfilter Yield Pro Brand and Product Names that appear and are owned by others are trademarks of their respective owners 2013 07 15 Cover Index 407 551M iv NH Safet Table of Contents Index Great Plains Manufacturing Inc 3 y 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index 1 Mi u Read All Manuals This Using Anhydrous Ammonia Safely manual is a companion manual supplied with the Operator manual for your Great Plains anhydrous applicator There are additional manuals covering the metering system breakaway coupler flow divider controller console and other system components This manual the applicator Operator manual the meter manual and the bre
57. n 33 cm above the implement breakaway If the implement is twin manifold or twin pump does the cart have twin hoses if not twin tanks Have means to secure both ends of the hose during transit to prevent damage to either hose or connections been installed Does the cart have rollover protection structures for all vents valves and gauges Are valves fittings and gauges rust free and showing no signs of leaks YESQ NOQ YESQ NO YESQ NO YESQ NO YESQ NO YESQ NO YESQ NO YESQ NO YESQ NO YESQ NO a If the tank does not have a plate or was not built to current standards you may require a special permit for highway transport such as DOT SP 13354 in the U S and CSA B620 in Canada tanks under the former Green Book program must transition to B620 b Regulations in some locales require tank owner information to be displayed on the sides of the tank in letters at least 2 inches high 2013 07 15 Table of Contents Index 407 551M 24 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Is the hose outlet valve tightly YESQ NOQ Are the tires inflated to specification YESQ NOQ closed not to exceed the maximum Are the tank inlet and outlet valves YESQ NOU pice suielisted ontac sidewalls tightly closed Is the to
58. nd atmospheric moisture rather than pure NH3 Assume any liquid in loops is extremely hazardous Take full NH field precautions ANHYDROUS AMMONIA INHALATION HAZARD ACAUTION Control Variation Hazard If you are using multiple nurse tanks study each one separately Unless they are owned by you and known to be identical there is a high probability that there are differences between them even if they are all from the same terminal Final Nurse Tank Unhitch a Conclude NH3 application per Stopping Application on page 29 The purpose of this step is minimize atmospheric NH3 vapor while working at the rear hitch because you may not be able to conduct all unhitching steps from up wind of all the tines or knives f From the up wind side unscrew the nurse tank hose outlet coupler page 11 g Secure the outlet coupler with the nurse tank s Acme parking plug h Close all opened bleed valves i Release the nurse tank safety chains j Remove the nurse tank hitch pin k Remove nurse tank from behind implement ON Figure 27 Applicator Loops 2013 07 15 Table of Contents Index 407 551M 32 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc General Safety Rules A Keep children untrained personnel and unprotected persons well away from equipment that uses anhydrous ammonia Children may not recognize or correctly react to the smell of
59. ngue of the trailer straight YESQ NOQ aan Are the liquid and vapor valves YESQ NOQ and in good condition labeled or color coded red orange Is the tank paint in good condition Is YESQ NO for liquid and yellow for vapor it free of peeling deep scratches Does the tank have Acme caps for YESQ NOQ a ang pe i PEN vapor and liquid valves might be rust or a leak Are all limited life components within YESQ NOQ Is the tank free of rust and dents an YESU NOU their dated service lives showing no signs of cracks or leaks Does the tank have an operating YESO NOO If the tank has been unattended and YESQ NOQ fixed liquid level float gauge unsecured is it free of any signs of Ce tampering AE Ste i am operating TESO NGE Is the cart frame free of deep rust YESQ NOQ P gauge cracks collision damage and other Is there a rust free functional YESQ NOQ signs of possible future failure f a pressure rallel valve Witiy a taii capi Does the cart appear to be in an up YESO NOQ Is a clearly labelled five gallon YESQ NOQ to date state of lubrication eg Are the tank and plumbing free of YESQ NOU any signs of leaks ee A Kater Does the cart have an SMV Slow YESO NOQ g H i Moving Vehicle reflector on the Are the tires the correct type and size YESO NOQ rear eeh EEN S Does the cart have any required YESQ NO yP i trailer license plate or tags Do the cart tires have at least YESQ NOU i JA inch 0 5 mm tread remaining te you lave all re
60. nitions The following additional terms are used throughout this manual NOTICE indicates a crucial point of information related to the preceding topic Read and follow the directions to remain safe avoid serious damage to equipment and ensure desired field results Note Useful information related to the preceding topic Right hand and left hand as used in this manual are determined by facing the direction the machine will travel while in use unless otherwise stated An orientation rose in some line art illustrations shows the directions of Up Back Left Down Front Right A consistent system of callouts is used for most implement and nurse tank cart components See page 42 for an applicator system illustration Prepare for Emergencies ADANGER U SA F L D A Keep emergency numbers for doctor ambulance hospital 4 FIRST AID and fire department near phone Know the reporting requirement for spills or releases of the chemicals you are using Have contact numbers available 848 5390 A For anhydrous ammonia operations have additional contact information for e national response center e regional state response center e local response center A Have a first aid kit for typical farm injuries but ignore it for anhydrous ammonia exposure The only first aid for anhydrous ammonia is water v e CS e ZS e D eg e e VW e H aaa 3 character callouts in the range to refer to Nu
61. operations to recapture NH3 gas from the top of the tank as liquid fills the bottom It is closed for all other operations A vapor return valve may have a time dated excess flow valve a PPE Personal Protective Equipment NH3 GAS bse ae ee S NH3 LIQUID Figure 13 Filler Valve and Pressure Gauge ACAUTION Ammonia Release Hazard At 120 F 40 C the vapor pressure reaches 250 psi Above this point the relief valve Con page 21 periodically operates and small NH3 releases occur ANHYDROUS AMMONIA INHALATION HAZARD 3 A71 RI E A na oye 8 NH3 GAS et eng oe ee a e NH3 LIQUID Figure 14 Fixed Gauge and Vapor Valve 2013 07 15 Table of Contents Index 407 551M 18 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Refer to Figure 15 some components shown exploded for clarity never remove any except the outlet cap A71 Liquid Level Float Gauge Check this gauge when accepting a tank It needs to be in sound mechanical condition legible and reading no higher than 85 This gauge has a mechanical float that is coupled to the indicator needle Float gauges typically report 0 100 percent of fill Float gauges are typically mounted at tank top fa
62. prior to servicing A Never carry a valve by the operating wheel or handle A Open ball valves when both sides of their lines are bled A Re check the bleed on at least one side of the opened valve A If closing a ball valve for storage or parking first wait for the valve to warm to ambient temperature to ensure that no liquid NH3 remains A Never point a hose at your face a PPE Personal Protective Equipment ANHYDROUS AMMONIA INHALATION HAZARD Legacy Solid Ball Valve Newer Orifice Ball Valve Valve Closed with NH3 Presen Lines Bled on Both Sides of Valve Valve Removed for Service Still Closed ol ADANGER Figure 30 Legacy Valve Ball Trap A Treat all closed valves as possible traps A Never open a closed valve in an enclosed area A Never point a closed valve at your face A If replacing a ball valve don t just check that the new valve is specified for NH3 service Replace orifice ball valves only with orifice ball valves Replace solid ball valves with orifice ball valves A Install an orifice ball valve correctly The orifice side points down stream in the direction of flow 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Maintenance Safety 39 System Discharge These steps are for clearing an implement for service or for storage near untrained persons These instructions pr
63. quired permits YESQ NOQ Do all tires have about equal tread penses wear Do you have contact information for YESQ NOQ Are the tires all free of signs of mis YESQ NOQ local regional and national D alignment uneven tread wear Emergency Response Centers indicating bent axles failing Do you have a mobile means of YESQ NO bearings etc summoning emergency aid such as Are the tire sidewalls free of signs of YESO NOQ a cell phone Is et adequate weathering wireless coverage along your entire route and in the field 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index 25 Uj Anhydrous Application Get Expert Advice Anhydrous ammonia is 82 Nitrogen the highest of any fertilizer The compound NH3 is normally a gas at ambient temperatures It is retained in the soil only by chemical reactions and physical mechanisms primarily reactions with soil moisture Consult with your agronomist about optimal application timing rate and depth based on proposed crop soil temperature soil moisture content and ambient temperature Non optimal applications can result in NH3 loss to the atmosphere soil drying and undesired long term changes in soil pH Weather Extremes Cold Weather Low Flow A DANGER e Catastrophic Release Hazard Do not take measures to boost pressure in cold weather Ad hoc boosting could create risk of line rupture or tank explosion The Great Plains syste
64. r side of the nurse tank The Nutri Pro implement also has a wash water tank See Ammonia Emergency Action on page 7 for further information about First Aid Water tanks A82 CAUTION AMMONIA Decal Required by transport and hazardous materials regulations on both sides of the tank This decal is for all users and the general public A80 Figure 19 Drain and Relief Valves ACAUTION Ammonia Release Hazard ANHYDROUS AMMONIA INHALATION HAZARD On a hot day remain up wind of the relief valve at all times Ona hill or if the tank is over filled or if the tank tips in an accident this valve can release liquid NH3 A CAUTION 7 AMMONIA 3 j Figure 20 First Aid Wash Water Tank 2013 07 15 Table of Contents Index 407 551M 22 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Nurse Tank Rear End Refer to Figure 21 A83 Unit Number An emerging regulation requires a visible cart unit identification string letters and or numbers on each cart in commercial service A84 CAUTION AMMONIA Decal Required by transport and hazardous materials regulations on both sides of the tank This decal is for all users and the general public A85 UN1005 Decal Same as on page 11 Required by transport and hazardous materials regulations on both sides and end of the tank A86 SMV Reflector Required for highway transpor
65. rators on tank operations and first aid rinsing procedures Field Operation Safety If field requirements permit you can minimize exposure to NH3 vapor with the following recommendations Refer to Figure 24 e Check the wind direction e Plan passes to be cross wind and turns up wind e Plan first pass on down wind side of field e Choose your first pass to allow you to be up wind while operating valves at the nurse tank and implement Opening the emergency shut off valve typically requires climbing on the implement from the right Starting with the wind from the right is optimal BCAUTION o AMMONIA INHALATION HAZARD Anhydrous Ammonia Exposure Hazard If field requirements result in any down wind operations A Use a tractor with a fully enclosed cab A tractor that is not fully enclosed exposes the operator to substantially more NH vapor particularly if field requirements result in downwind turns or downwind passes A Have an escape route up wind turn available for all down wind operations A Conduct end of pass operations to minimize above ground releases A Be mindful of the risks of olfactory fatigue You can get used to the odor and fail to notice when concentrations get dangerously high Figure 23 First Aid Water Station WIND Figure 24 Ideal Pass Planning ANHYDROUS AMMONIA 4 CAUTION INHALATION HAZARD Anhydrous Ammonia Exposure Hazard Repeated
66. remove any except the outlet cap A67 Liquid Filler Valve Do not open this valve Field operators need only confirm valve closed in sound mechanical condition and Acme cap secure This valve color coded red or orange is used only during tank fill at a terminal A68 Pressure Gauge This gauge reports the pressure usually in psi of the NH3 gas at the top of the tank The reading varies with tank and ammonia temperature A freshly filled tank reads between 50 and 250 psi at air temperatures above freezing Learn the relationship between temperature and vapor pressure Do not accept a tank with a malfunctioning gauge Refer to Figure 14 some components shown exploded for clarity never remove any except the outlet cap A69 Fixed Liquid Level Gauge Do not open this valve Field operators need only confirm that the valve at this fitting is closed and is in sound mechanical condition This gauge is a short dip tube with its lower end at the 85 fill level in the tank During filling if terminal personnel have any doubt about the reading on the float gauge 77 they may open the fixed gauge and see if what is released is gas or liquid This is a hazardous operation requiring terminal PPE A70 Vapor Valve Do not open this valve Field operators need only confirm that this valve is closed is in sound mechanical condition and that the Acme cap is secure This valve color coded yellow is used during fill
67. rse Tank Security Standard Tank Controls This manual and the applicator Operator manual assume standard unlocked tank fittings and controls are in use Figure 1 Typical NH3 Terminal ANHYDROUS AMMONIA INHALATION HAZARD Missing Information Hazard Take action to inform yourself The majority of anhydrous ammonia nurse tanks do not have an operator manual for the complete cart or for just the tank Any manual that is available may not accurately document the cart at hand due to expired component replacement and or complete tank replacement Field Operations Only This manual and the applicator Operator manual cover only nurse tank field operations Nurse tank terminal operations transport storage and detailed maintenance are beyond the scope of this manual 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Nurse Tanks 9 Nurse Tank Safety Many nurse tanks in use today were originally assembled by cart integrators who are no longer in that business or assembled by an implement dealer or by an end user Cart running gear often remains in service for decades with a periodic tank replacement at which time it is essentially a completely different nurse tank cart Hoses and various fittings are limited life components that are routinely replaced and the replacements may not precisely match the original par
68. rsonal Protective Equipment 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Nurse Tanks 21 Refer to Figure 19 and Figure 20 A79 Drain Valve Inspect this valve which may be merely a plug fitting Check for general mechanical condition and signs of criminal tampering Do not open this valve It is used only to fully drain the tank for major maintenance A80 Relief Valve Locate this valve It is on the tank top usually under a protective structure away from the operating valves It may be near the wash water tank Refilling the wash water tank often places you close to the relief valve Be up wind Check the pressure gauge before refilling the wash tank At high tank pressures the relief valve is designed to release NH3 until the pressure drops below 250 psi At 120 F 40 C the vapor pressure reaches 250 psi Above this point the relief valve periodically operates and small NH3 gas releases occur Refer to Figure 20 A81 First Aid Water Check that this tank is present Check that it was freshly filled Check that hose ends are secure Ensure that all operators know how the tank works Where is it How many hoses does it have Do not wait until an accident to learn which end of the hose is which Transport and materials safety regulations require this tank and the decal that identifies it The tank may be installed on the top o
69. rt often has a separate hookup for each tank A two tank two hose cart may be used with a dual cooler implement or a single meter implement one tank after another Refer to Figure 3 A55 UN1005 decal See page 4 This information is for trained users of the material and emergency responders A56 25 MPH mirror image decal This decal is for the benefit of the operator transporting the cart on public roads It reads legibly in a rear view mirror A57 Acme parking plug An acceptable nurse tank must have a means of securing the outlet end of each hose This is usually an Acme threaded plug mounted on the tank or tongue See the applicator Operator manual for hose hookup and unhitching Acme plugs typically do not have gaskets and do not make a Vapor Exposure Hazard gas tight seal Residual liquid or gas in the hose slowly vents at the plug Use valves to close lines Refer to Figure 4 A58 Acme Female Hose Coupler ANHYDROUS AMMONIA INHALATION HAZARD On a leased tank the terminal may supply no hose in which case you need to provide your own This end of the hose connects the tank withdrawal valve to the leading implement inlet at the breakaway coupler For use with a Nutri Pro applicator the outlet end of the hose must be equipped with a 134 4 female Acme fitting The outlet end of the hose has a swivel collar or shroud containing the female Acme fitting This allows connection without needin
70. s any oxi products NH3 can react violently with oxidizers and halogens and can produce toxic gases and or explosive compounds ANHYDROUS AMMONIA INHALATION HAZARD TIN A Trapped Anhydrous Hazard Never service fittings without certain knowledge that the lines and valves are fully discharged Implement systems can trap liquid NH between closed valves and inside closed valves even when the lines on both sides of the valve are discharged This NH3 would then be released under pressure when a fitting is cracked or a valve opened days weeks or months after last field operations If an unvented ball valve had been closed on a full line that liquid would be released under pressure and vaporize in seconds It can contain enough liquid NH3 to render a space the size of a two car garage uninhabitable NH3 concentration at IDLH within moments If either end of the valve is pointed at or near your face local concentration would dramatically higher The outcome could be blinding disfiguring disabling or fatal Incompatible Materials NH is corrosive to aluminum non anodized brass bronze cadmium calcium cast iron copper gold lithium magnesium mercury silver zinc alloys containing these metals as well as galvanized surfaces Repairs with incompatible parts are likely to soon result in malfunctions and a serious accident Brass parts can fail rapidly from the inside out Compounds formed
71. s are usually water or ice condensed from the air by the refrigerant effect of NH3 evaporation NH is a colorless liquid and is only a liquid at room temperature if chilled and or under pressure NH3 gas has a distinctive odor that provides warning of dangerous concentrations unless you have impaired sense of smell or develop olfactory fatigue adaptation due to extended low level exposure Safe field operations can keep exposures below permissible limits Unsafe operations accidents and malfunctions can result in exposures at ANY concentration ANHYDROUS AMMONIA INHALATION HAZARD NH Concentrations Parts Per Million 5 ppm Odor detection threshold most people 20 50 ppm Readily detectable odor 25 ppm NIOSH TWA Time Weighted Average exposure limit 35 ppm NIOSH STEL Short Term Exposure Limit 50 ppm OSHA PEL Permissible Exposure Limit 8 hour TWA 100 ppm Rapid eye and nose irritation 150 200 ppm General discomfort eye tearing No permanent health effects on short exposure AIHA ERPG 2 one hour exposure limit OSHA IDLH Immediately Dangerous to Life and Health 400 700 ppm Severe irritation of eyes ears nose and 200 ppm 300 ppm throat 1700 ppm Coughing bronchial spasms 2000 Dangerous could be fatal in less than 30 3000 ppm minutes 5000 Rapidly fatal escape may be impossible 10000 ppm 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc T
72. sure Start of Pass Planning Ideally you want NH3 to begin flowing out of the tines or knives right at the start of a pass with the tines or knives already in the ground This minimizes atmospheric releases Depending on wind direction tractor capability available headlands and field conditions there are several ways to start each pass A Capable Tractor Lower implement into ground at start of pass Pull forward to set them to operating depth Start meter flow Do not start moving until flow divider pressure gauge nears typical operating value B Headlands Available Any Tractor Lower implement to ground some distance ahead of the application area Move forward slowly As tines or knives enter ground start meter flow C No Headlands Marginal Tractor Lower implement to ground at start of pass Start forward movement then meter flow Move slowly until console rate display nears target rate Figure 25 Adjustments Note The procedures at left are not operating instructions or checklists They are outlines for planning pass starts See the step details in the applicator Operator manual ACAUTION amp INHALATION HAZARD S Anhydrous Ammonia Exposure Hazard When raising in field be facing into the wind or be turning up wind Even if NH3 flow was stopped some distance before the lift point the tines or knives will still be emitting NH3 vapor when out of the ground ANHYDROUS AMMONIA
73. t of any slow moving equipment A87 Lights not shown Figure 21 Nurse Tank Rear End Lights may be required in your jurisdiction If transporting at night or in daytime where daytime lights are required test the lights before departure Never tow an anhydrous ammonia nurse tank behind an implement on public roads 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Ammonia Nurse Tanks 23 Nurse Tank Acceptance Use this checklist in addition to any checklists provided by the tank manufacturer tank cart manufacturer and or anhydrous ammonia supplier If no other checklist is available print these pages to use a checklist when accepting a tank If another checklist is available this list may include one or more items omitted from the other lists Check them all Transport the tank separately from the implement Consult the towing vehicle and tank operator manuals for hitching the cart to a separate towing vehicle Hitch the tank to the implement at the field This topic is covered in the applicator Operator manual There are two pages for this checklist e Do you know the wind direction YESQ NO e Will you have with you in the field an YESQ NO operator manual or manuals for the cart tank and all fittings and controls if not see CAUTION on page 8 e Have the Nutri Pro operators studied
74. tank appears intact sound and stable determine the cause of the breakaway It is unlikely to be something simple that will allow a timely re coupling and resumption of application If and only if the nurse tank is safe to approach take the next steps to discharge both sides of the breakaway Discharge Implement 3 Perform the steps at Stopping Application on page 29 Remain up wind and clear of nurse tank while doing this 4 With the orifice pointing away from you and down wind slowly open the coupler bleed valve page 42 at the implement half of the breakaway coupler If you closed the emergency shutoff after breakaway each bleed will release liquid NH3 under pressure most likely as a spray Discharge Nurse Tank Hose 5 Position the tractor and implement near the nurse tank Stop up wind of the tank but slightly cross wind of the tank so that you are not exposed to residual implement fumes while working around the tank Face the tractor into the wind 6 From up wind approach the nurse tank Close the nurse tank withdrawal valve page 16 8 From up wind approach the nurse tank hose outlet end A58 page 11 9 Locate a bleed valve page 42 on the nurse tank half of a coupler Be careful not to touch or loosen the Acme coupler page 11 Bleed only one hose at atime 10 Position the outlet such that the bleed valve orifice points both away from you AND points down wind AND can be opened an
75. thorized facility Do not accept a repaired tank without an R stamp e 472s Tank serial number A729 MWAP Maximum Allowable Working Pressure 250 PSIG 125 F is minimum and typical for NH3 service e 4721 Type Must be AG N e A72u Official code U over W symbol Any other symbol here means the tank is not NH3 service e 7y Year of manufacture A tank made before 1999 may lack current safety features Do not use a tank made before July 1961 Do not use an undated tank Refer to Figure 17 A73 Safety Decals Study any safety decals Make sure all operators understand them and have learned safety procedures well enough that they know what to do without consulting the decals after an accident A74 Instructional Decals Study any operating information provided in decal form If the nurse tank cart has no manual informational decals may be the only formal documentation available Figure 16 Anhydrous Tank Nameplate A post 1988 nameplate will also e be fully welded onto the tank not riveted e specify the standard to which it was built usually ANSI K61 1 or CGA G 2 1 e explicitly specify for anhydrous ammonia use e specify MDMT Minimum Design Metal Temperature Missing Nameplate If there is no nameplate check for evidence of recertification within the last five years such as FMCSA Cargo Tank CT registration number or paper documentat
76. tify what the correct operational procedures are and what emergency actions to take DOT PHMSA MSDS ASME Nameplate ANHYDROUS AMMONIA INHALATION HAZARD ANSI K61 1 Insurer CGA G2 1 Policies Manual g i Manual NP30A NP40A NH3 Meter A DANGER HAVE EMERGENCY WATER AVAILABLE lax SAFETY COUPLER OPERATING INSTRUCTIONS A BLEED SYSTEM cone PRIOR TO ANY MAINTENANCE OR RE State Law State Regs Entity Policies Manual Nurse Tank Manual Coupler 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Read All Manuals 3 Be Aware of Signal Words Signal words designate a degree or level of hazard seriousness DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is limited to the most extreme situations typically for machine components that for functional purposes cannot be guarded WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury and includes hazards that are exposed when guards are removed It may also be used to alert against unsafe practices CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices Defi
77. tions 2 Over Confidence Typical respirators are intended for extended ow level exposure or escape from high levels They do not provide extended protection at or above IDLH 300 ppm a A vapor concentration Immediately Dangerous to Life or Health ANHYDROUS AMMONIA INHALATION HAZARD _ 1005 407 551M Table of Contents Index 2013 07 15 Great Plains Manufacturing Inc Table of Contents Index Anhydrous Ammonia Information 7 Ammonia Emergency Action A Have a plan Execute the plan AN HYD ROUS Expect the possibility of exposure or uncontrolled release in AM M 0 N l A any phase of setup transport or operations Have contact INHALATION HAZARD information at hand Know the wind direction at all times A Act Quickly Training matters You must know what to do and act without hesitation A Move or Turn Up Wind The first priority is to avoid exposure or stop further exposure On splash or spill get out of the vapor cloud Move up wind N Ifa leak is detected while operating in the field turn the tractor into the wind lower the implement into the ground and perform an emergency flow shut off Pull the rope If a breakaway occurred move the tractor some distance upwind from the disconnected nurse tank A Apply First Aid Treat exposures with water flushing and only water or saline solution unless instructed otherwise by a physician F FIR
78. tri Pro NH3 system components page 42 3 character callouts in the range to refer to nurse tank cart components pages 10 to 22 2013 07 15 Table of Contents Index 407 551M Table of Contents Index Great Plains Manufacturing Inc 4 NH Safety Uj Anhydrous Ammonia Information NH Icons and Decals Topics in this manual and the Operator manual that concern anhydrous ammonia safety are shown with these icons nearby NFPA 704 3 1 0 hazmat diamond see page 5 for details This information is for emergency responders and is typically displayed only at fixed anhydrous ammonia facilities terminals and not on nurse tanks or implements DOT UN 1005 Class 2 2 hazmat placard This information is for trained users of the material and emergency responders This decal identifies e Green Color non flammable but see 2 e Tank Icon content is a gas at ambient temperature and atmospheric pressure in the tank it may be a liquid e 1005 Material Identity Anhydrous Ammonia e 2 Hazmat Class Division 2 2 a non flammable gas that can ignite under some circumstances ANHYDROUS AMMONIA INHALATION HAZARD This decal is for all users and the general public General NH Information Fertilizer Type 82 0 0 Chemical formula NH3 CAS number 7664 41 7 EC NUMBER EINECS 231 635 3 EC INDEX NUMBER 007 001 00 5 NH3 is a colorless gas at room temperature any clouds observed in release
79. ts In as few as four years any original cart documentation may no longer accurately describe the cart in its current Example configuration Peeling and If you do not have a current up to date operator manual Missing for the nurse tank cart study the Ammonia Nurse Safety and Tanks section of this manual starting on page 8 Informational ANHYDROUS Decals AMMONIA Missing Information Hazard Many nurse tanks have no operator manual They may not have even a tank operator manual If there is a manual the cart may have been modified or the tank replaced Fittings are routinely replaced Study how the nurse tank works The tank configuration fitting hoses Exam ple indicators and controls may vary from the original Illegible documentation if any and vary from the typical tank or Missing described in the section Ammonia Nurse Tanks on page 8 Name A Do not fill accept or use a tank unless it conforms to Plate current regulatory and safety requirements and passes a careful inspection Print pages 23 and 24 to use as checklists If the answer to any of the items is no do not use the tank A Pull type two axle tanks only no semi mounted nurse tank carts A Maximum total capacity 3000 gallons Example A Never fill to more than 85 capacity Failing or A Never transport a nurse tank behind an implement on Outdated public roads Hose A Never park a tank on publ
80. ts 407 502M Nutri Pro NP40A Operator 407 313P Nutri Pro NP40A Parts 407 613M Nutri Pro NP3000A Operator 407 613P Nutri Pro NP3000A Parts 417 199M Nutri Pro NP4000A Operator 417 199P Nutri Pro NP4000A Parts 12 M 29 CDS John Blue IP 1300 1800 Impellicone parts 016 0159 403 Raven AccuFlow Operator manual 016 0159 831 Raven SCS 450 Installation Operation and Service manual Squibb Taylor Flo Max manual Raven SCS 450 Installation Operation and Service manual FVC062 016 0159 831 ANHYDROUS AMMONIA 4 DANGER A amona Suffocation Blinding Burning Freezing Disabling a aad Disfigurement Hazards Your life and health the lives and health of your workers and community the continued commercial availability of anhydrous ammonia and continuation of agricultural NH3 transport exceptions depend on you conducting meticulously careful operations 2013 07 15 Table of Contents Index 407 551M 2 NH3 Safety Table of Contents Index Great Plains Manufacturing Inc Anhydrous Ammonia Education A Read this safety information It may contain important information not found in your other reference materials A Have anyone operating or merely working near the implement read this safety information A Do not read only this safety information A A 20 minute video is no substitute for real anhydrous ammonia safety training Trained Informed Personnel Only Anyone work

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