Custom Fall Protection Systems

Propane Rail Unloading System – Equipment Supply & Integration

Sudbury, Ontario
Energy & Bulk Liquid Handling
$250k–$1M
Approval Drawings Custom Fabrication Design & Engineering Installation Safety System Integration

Factor Energy engaged our team to support the development of a new propane rail unloading facility in Sudbury, Ontario. While the client self-constructed the primary loading platform, we collaborated closely to supply and integrate critical safety, access, and transfer components—delivering a unified, compliant solution aligned with industry standards for hazardous material handling.

Challenge

The facility required a fully coordinated unloading system that could safely handle pressurized propane transfers while integrating with a customer-built platform and third-party piping. Equipment compatibility, access safety, and spill prevention were critical to achieving a compliant and reliable operation.

Key Constraints

  • Customer-constructed platform requiring precise interface coordination
  • Hazardous propane transfer with zero-spill tolerance
  • Integration of multiple manufacturers’ components
  • Compliance with applicable safety and operational standards

Risk

Managing fall exposure and pressurized propane connections during elevated rail unloading operations.

Workflow

Coordinating safe, efficient unloading operations across customer-built infrastructure and third-party equipment.

Compliance

Ensuring all access, transfer, and connection systems met applicable safety and hazardous materials standards.

Custom Solution

Designed for safety, operational performance, and compliance.

Equipment Supply & Integration

3 key elements
  • Supplied OPW Bullhorn liquid loading arms engineered for propane transfer
  • Supplied OPW vapor recovery loading arms for controlled vapor management
  • Integrated Novaflex HDC dry-break couplers and adapters for spill-free, pressure-safe connections

Access & Fall Protection

2 key elements
  • Provided Safe Harbor gangways and safety cages for compliant top-access
  • Designed operator protection systems aligned with hazardous material handling standards

Coordination & Execution

3 key elements
  • Coordinated piping layouts and flexible hose assemblies feeding the unloading platform
  • Collaborated closely with the client and equipment manufacturers to ensure system compatibility
  • Sequenced installation to align with customer-constructed platform and commissioning timelines

Key Deliverables

What was delivered end-to-end

Engineering & Planning

Coordinated equipment selection, layouts, and integration planning to align with the customer-built unloading platform.

Installation

Supported on-site installation sequencing to ensure proper fit, alignment, and system integration.

Safety & Compliance

Implemented compliant access, fall protection, and vapor control systems for safe propane transfer operations.

Commissioning

Verified system functionality and readiness for safe startup and long-term operation.

Project Highlights

Key moments and system details from the installation.

Propane Rail Unloading System – Equipment Supply & Integration highlight image
Railcar loading platform with integrated Safe Harbor gangway providing controlled top-access to tanker domes.
Propane Rail Unloading System – Equipment Supply & Integration highlight image
Elevated access system showing tracked gangway alignment over railcars during liquid transfer operations.
Propane Rail Unloading System – Equipment Supply & Integration highlight image
Platform-level view highlighting safety railings, grating, and integrated loading infrastructure.

Partners & Vendors

Trusted partners who contributed to this project.

OPW
Safe Harbor
Novaflex
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