What exactly are On-Spot loading facilities ?

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On Spot loading facilities are filling stations for rail cars with a top loading system and a high filling capacity.  The filling of rail cars is similar to a flow line system (sequential procedure). The filling pipe is arranged inside the On Spot facilities on a hydraulically movable filling pipe slide.  The slide can be moved in the X and Y direction, and the filling tube is adjustable in the Z direction.The rail cars are put in place by a locomotive in front of the On Spot facility.

The first rail car is pulled in by a car pulling device or a remote-controlled shunting vehicle and positioned under the filling station. 

The filling pipe is moved from the control stand in the operator room located close to the track or between the tracks on a steel structure elevation of approx. 3,700 mm
(12 feet) and inserted into the rail car dome. Then, the rail car is loaded. 

When loading is complete the car pulling device/shunting vehicle positions the next rail car under the filling station. This goes on until the last rail car of a group of coupled rail cars has been loaded. 

Folding stairs are provided in front of and behind the filling station used to open and close the domes.  Flowrate and temperature signals are subject to calibration and  are generated through sensors, meters or weighbridges. In addition, these signals are data logged and can be remotely viewed in realtime or accessed in various time intervals. (at the filling station concerned). 


On Spot facilities are additionally split into run-through track facilities and dead-end track facilities. This, however, has relevance for the feeding of rail cars only. 


For On Spot facilities the track length must be twice the length of a group of coupled rail cars. 

Types of On Spot facilities:

On Spot facilities are differentiated by the number of tracks and filling stations.  Facilities range from single-track facilities with one filling station to double-track facilities with four or more filling stations. 
The design depends on the required daily and annual loading capacities and the square footage available for the coupled rail cars as well as the pump capacity.  

Our On Spot loading facilities to fill rail-bound tankers with liquid products are designed for high filling capacities. Filling pipes of up to DN 300 (NPS 12 inches) provide for loading capacities of up to 1,000 m3/h (4,400 gallons per minute) per loading point (filling station). Several products can be loaded at one station. To operate a double-track loading facility of 20,000 tons per day, only one or two operators are needed in the control station and another one or two helpers.

A sophisticated electronic control and interlocking system minimizes filling, setting and shunting times and operator error. 

A standard filling pipe of 730m3/h (3,200 gpm) filling capacity and four filling stations can transfer up to  2.920m3/h (12,800 gpm). In less than 15 minutes 4 rail cars of 73,000 litres (19,300 gallons) each can be loaded on average including the necessary setting time. So, not more than 3.75 minutes are needed per rail car.

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Annual capacities:

The table below gives a general overview of loading capacities depending on: Based on 73m3  rail cars, 45 minutes feed time and 350 working day/year

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Filling control

To avoid electrostatic charging while filling of the rail car takes place, the initial volumetric flow is limited to approx.  300 m³/h per filling station. 

To measure the volumetric flow, either a calibrated volumeter/mass flow meter or a weighbridge is used. 

The output signal of the data logging system is processed by the SPC and used to control the electro-pneumatic control valve. 

The filling control is used to:

  • pre-set loading quantities/rail car 
  • keep the flow rate
  • switch off automatically as soon as the pre-set quantities have been reached, in a controlled manner and free of pressure surges  (no dynamic pressure surges).

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