Shashi Vardhan Pandey

B.Tech (Chemical Engg)

Accomplished more than 35 years in Oil & Gas industry
mainly in areas of Operation, Technical Services,
Project and HSE functions of IOCL refineries.

As an integral member of Oil Industry Safety

Directorate (MoP&NG) for almost a decade, carried out
Environment & Safety audits, preparation of Standards,
Incident Investigation and marine oil spill management
etc.

Presently involved in capacity building exercises

through experience sharing for executives working in
Oil, Gas and Chemical industry.
 SEMINAR TOPICS
DAY-1 DAY-2
Session1(AKA) Session-5 ( AKA)

➢ Introduction & Genesis ➢ Pressurised Gases

➢ Hazardous Chemicals & their impact on ➢ GCR & SMPV Rules

humans & environment
Session-6 (AKA)
Session-2 (SVP) ➢ Importance of Training, SOPs & Mgmt of
➢ Safe Storage & Handling of Hazardous Change.
Chemicals. ➢ Asset Integrity
➢ Regulatory Provisions
Session-7 (SVP)
Session-3 (AKA) ➢ Transportation of HAZCHEM (PPL , Road,
➢ MSIHC Rules Rail, Air & Waterways)

➢ Petroleum Products ➢ PPEs

Safety/Transportation
Session-8 (AKA/ SVP)
Session-4 (SVP) ➢ Experience Sharing
➢ Vapour Recovery Mgmt. ➢ Closing Session & Feedback
➢ Occupational Health Mgmt
Safe Storage & Handling
of
Hazardous Chemicals
Inadequate awareness about the
hazardous properties of chemicals and
products may lead to serious accidents
which will affect men at work and the
environment.
Safe storage and handling of chemicals is
essential to avoid accidents and
occupational diseases.
TYPES OF CHEMICALS
FLAMMABLE CHEMICALS
Flammable Gases : Gases which at 20oC and at standard
pressure of 101.3 KPa are:
(a) ignitable when in a mixture of 13 percent or less by
volume with air, or ;
(b) have a flammable range with air of at least 12
percentage points regardless of the lower flammable
limits.
Note: The flammability shall be determined by tests or
by calculation in accordance with methods adopted by
International Standards Organisation ISO Number 10156
of 1990 or by Bureau of Indian Standard ISI Number
1446 of 1985.
FLAMMABLE CHEMICALS

Extremely flammable liquids: Chemicals which have

flash point lower than or equal to 23oC and
boiling point less than 35oC.
Very highly flammable liquids : Chemicals which
have a flash point lower than or equal to 23oC
and initial boiling point higher than 35oC.
Highly flammable liquids : Chemicals which have a
flash point lower than or equal to 60oC but higher
than 23oC.
Flammable liquids : Chemicals which have a flash
point higher than 60oC but lower than 90oC.
FLAMMABLE LIMIT AND RANGE

Minimum concentration of vapour in air

below which the propagation of flame
does not occur in contact with a source
of ignition. This is called Lower Explosive
Limit (LEL).
Maximum concentration of vapour above
which the propagation of flame does not
occur on contact with a source of
ignition. This is called Upper Explosive
Limit (UEL).
FLAMMABLE LIMIT AND RANGE

This range of minimum to maximum

concentration is termed as Flammable range.
The flammable limits are not appreciably
changed by normal variations in atmospheric
pressure and temperature. However, at high
temperatures, the upper limit is raised and the
lower limit lowered, resulting in greater
flammable or explosive range. The effect of
high pressures on the limits is different for each
gas or vapour depending upon its nature.
EXPLOSIVES
Explosives mean a solid or liquid or substance
(or a mixture of substances) or an article.
(a) Which is in itself capable by chemical reaction
of producing gas at such a temperature and
pressure and at such a speed as to cause
damage to the surroundings.
(b) which is designed to produce an effect by heat,
light, sound, gas or smoke or a combination of
these as the result of non-detonative self
sustaining exothermic chemical reaction.
CORROSIVE CHEMICALS
Chemicals, which can cause damage to the
living tissue and/or chemically attack metallic
containers and structures are corrosive
chemicals.
OXIDISING SUBSTANCES (OXIDISER):
The substances which readily give of oxygen or
other oxidizing substances. They also include
materials that react chemically to oxidize
combustible materials that increases the
chance of fire or explosion. This reaction may
be spontaneous at either room temperature or
may occur under slight heating. These
materials can be severe fire and explosion
hazards.
PYROPHORIC SUBSTANCES
Chemicals which are so reactive that on
contact with air and its moisture,
oxidation/ hydrolysis occurs at such a rate
so as to cause ignition. Some of these
reactions liberate flammable gases.
ORGANIC PEROXIDES
Means an organic compound that contains
the bivalent –o-o- structure and which
may be considered to be a structural
derivative of hydrogen peroxide where
one or both of hydrogen atoms has been
replaced by an organic radical.
TOXIC CHEMICALS
Toxicity is the degree to which a substance is able to damage an exposed
organism. Chemicals having the following values of acute toxicity and
which owing to their physical & chemical properties, are capable of
producing major accident hazards :
ORAL TOXICITY DERMAL TOXICITY INHALATION TOXICITY
Medium lethal dose Medium lethal dose Medium lethal concentration
by oral route by the dermal route by inhalation route (four hrs.)
LD50 (mg/kg body (dermal toxicity)LD50 LC50 ( mg/l inhalation in
wt of test animals) (mg/kg body wt test animals) of test animals)
1. Extremely toxic < 5 < 40 < 0.5
2. Highly toxic 5-50 > 40 - 200 0.5-2.0
3. Toxic > 50 – 200 >200 – 1000 > 2 – 10
INCOMPATIBLE CHEMICALS
The chemical substances which in contact with
each other cause hazardous reactions which may
be violent or produce toxic materials.

TLV (THRESHOLD LIMIT VALUE)

The term refers to concentrations of air
contaminants in the working environment to
which it is believed, nearly all workers may be
exposed repeatedly day after day without
adverse effect. Normally, it is the time weighted
average concentration in ppm or gm/m3 for a
normal 8-hour work day or 40 hour workweek.
STEL (SHORT TERM EXPOSURE LIMIT

It is defined as a 15 minutes time weighted

average exposure, which should not be
exceeded at any time during a workday even if
the 8 hours time weighted average is within the
TLV.
Exposure at the STEL should not be longer than
15 minutes and should not be repeated more
than four times per day. There should be at
least 60 minutes interval between successive
exposures at the STEL.
DEFINITIONs
SYNONYMS: For common chemicals, several
chemical names and numerous trade names
may be applied to describe the chemicals
commonly used.
CAS NO. : Chemical Abstracts Service Registry
Number is a numeric designation assigned by
American Chemical Society’s Chemical Abstracts
Service and uniquely identifies a specific
chemical compound.
UN NUMBER: The United Nations Number is a four
figure code used to identify hazardous
chemicals and is used for identification of
chemicals transported by road, rail and by air.
 OSHA FORMAT - MSDS
 The identity of the chemical is defined in para 1 of
the safety data sheet .
 Important physical and chemical properties of
chemical given in para 2 of the safety data sheet.
 The fire & explosion data, reactivity data, health
hazardous data have been given vide para 3, 4 & 5
respectively.
 The preventive measures and emergency & first aid
measures and additional informations/references,
if any, are given in para 6,7& 8 respectively. Item 9
for manufacturer details.
ANSI FORMAT - MSDS
 Section 1- Identification  Section 9- Physical and
Chemical Properties
 Section 2- Hazard(s)
Identification  Section 10- Stability and
Reactivity
 Section 3-
Composition/Information  Section 11- Toxicological
Ingredients Information
 Section 4- First-Aid  Section 12- Ecological
Measures Information (non-mandatory)
 Section 5- Fire-Fighting  Section 13- Disposal
Measures Considerations (non-
mandatory)
 Section 6- Accidental
Release Measures  Section 14- Transportation
Information (non-mandatory)
 Section 7- Handling and
Storage  Section 15- Regulatory
Information (non-mandatory)
 Section 8-Exposure
Controls/Personal Protective  Section 16- Other Information
Equipment
NFPA DIAMOND
NFPA pictorial representations consist of a diamond
divided into 4 parts. These parts, starting from left
block (in clockwise direction), represent Health
Hazard, Flammability Hazard, Reactivity Hazard and
Space for additional information such as water
reactivity, oxidant and radiation hazard. The colour
codes for these hazards are :
Blue for health, Red for flammability, Yellow for
reactivity and colourless for additional information.
These are rated on a scale of 0 (no hazard) to 4
(extreme hazard).
The ratings for individual substances can be found in
the NFPA Fire Protection Guide to Hazardous Materials.
HEALTH
Rating 4 : A few whiffs of the gas or vapour could cause death or
the gas, vapour or liquid could be fatal on penetrating the fire
fighters normal full protective clothing which is designed for
resistance to heat. Only special protective clothing designed
to protect against the specific hazard should be worn.
Rating 3 : Materials extremely hazardous to health, but areas
may be entered with extreme care. Full protective clothing,
including self- contained breathing apparatus and no skin
surface should be exposed.
Rating 2 : Materials hazardous to health, but areas may be
entered freely with self-contained breathing apparatus.
Rating 1 : Materials only slightly hazardous to health. It may be
desirable to wear selfcontained breathing apparatus.
Rating 0 : Materials which on exposure under fire conditions
would offer no health hazard beyond that of ordinary
combustible material.
FLAMMABILITY
Rating 4 : Materials that in the form of dusts or mists readily form
explosive mixtures when dispersed in air. Shut off flow and
keep cooling water streams on exposed tanks or containers.
Rating 3 : Liquids, which can be ignited under almost, all normal
temperature conditions. Water may be ineffective on these
liquids because of their low flash points.
Rating 2 : Liquids which must be moderately heated before
ignition will occur. Water spray may be used to extinguish the
fire because material can be cooled to below its flash point.
Rating 1 : Materials that must be pre-heated before ignition can
occur. Water may cause frothing of liquids with this
flammability rating number if it gets below the surface of the
liquid and turns to steam. Water spray gently applied to the
surface will cause a frothing which will extinguish the fire.
Rating 0 : Non flammable
REACTIVITY
Rating 4 : Materials which in themselves are readily
capable of explosive decomposition or explosive
reaction at normal temperatures and pressures. If a
chemical with this hazard rating is in an advanced
or massive fire, the area should be evacuated.
Rating 3 : Materials which are capable of explosive
decomposition or of explosive reaction with strong
initiating source or which must be heated under
confinement before initiation. Includes materials
which are sensitive to thermal or mechanical shock
at elevated temperature and pressure or which
react explosively with water without requiring of
confinement. Fire fighting should be done from an
explosion-resistant location.
Rating 2 : Materials which are normally unstable and
readily undergo violent chemical change but do not
detonate. Includes materials which can undergo
chemical change with rapid release of energy at
normal temperatures and pressures. Also includes
those materials which may react violently with
water or which may form potentially explosive
mixtures with water. In advanced or massive fires,
fire fighting should be done from a protected
location.
Rating 1 : Materials which in themselves are normally
stable but which may become unstable at elevated
temperature and pressure or which may react with
water with some release of energy but not violently.
Caution must be used in approaching the fire and
applying water.
Rating 0 : Materials which are normally stable even
under fire exposure conditions and which are not
reactive with water. Normal fire fighting procedures
may be used.
Explanation for bottom space (Colourless) :
The bottom space is primarily used to identify
unusual reactivity with water. With a line through
its centre alerts fire fighting personnel to the
possible hazard in use of water. This bottom space
may also be used to identify a radiation hazard by
the symbol. Oxidising chemicals are identified in the
bottom space, as OXY.
HAZCHEM CODE:
Hazchem code provides vital information to fire
brigade and other emergency services on the action
to be taken to combat spillage, leakage or fire in an
emergency involving hazardous substance.
The Central Motor Vehicle Rules requires that the
vehicles transporting hazardous chemicals to display
Emergency Information Panel (EIP). The EIP requires
display of Hazchem code (also called the emergency
action code).
The Hazchem code consistst of a number from 1-4
(A) and any one of the letters – P, R. S, T, W, X, Y, Z
(B) followed by at times by the letter E .
ABE
The number (in place of A above) signify
extinguishing medium to be employed as given
below :
1. JETS 2. FOG 3. FOAM 4. DRY AGENT
The letters ( in place of B above) signify three
aspects viz.
1. Method of controlling spillage (a) By diluting
or (b) By containing
2. Personnal protective equipment to be worn
by the fire fighters
3. Reactive nature of chemicals
If letter E exists then, need for evacuation.
Example :
The Hazchem code for motor spirit (Petrol ) is 3YE as shown above.
3 – use foam only
Y – can be violently (V) reactive. Breathing apparatus + Protective Gloves to
be used in case of fire. Any spillage of the substance should be contained.
E – Consider evacuation as a first priority.
Industrial Chemical
Hazards
Growth of chemical industries led to increase in
the risk of occurrence of incidents associated
with hazardous chemicals.
Chemical accidents may originate in the
manufacturing or formulation facility, or during
the process operations at any stage of the
product cycle, material handling, transportation
and storage of HAZCHEM.
Vulnerability is sometimes compounded due to
the location of Major Accident Hazard (MAH)
industries closer to densely populated areas
 It is realised that effective Chemical Disaster
Management (CDM) is possible by the adoption
of preventive and mitigation strategies as most
chemical disasters are preventable in
comparison to natural disasters that are
difficult to predict and prevent.
 There are about 1666 MAH units in India,
handling a large number of chemicals as raw
materials, in processes, products, and wastes,
with flammable, explosive, corrosive, toxic
and noxious properties. Any accident involving
these may have an adverse impact on both the
community and the environment
Major Accident Hazards (MAH)
Installations

Major Accident Hazards (MAH) Installations

are defined as isolated storage, industrial
activity at site, handling including transport
through carrier or pipeline of hazardous
chemicals equal to or excess of threshold
quantities as defined in Chemical Accident
(Emergency Planning, Preparedness and
Response) Rules eg Ammonia 60 MT,
Flammable gases 50 MT, Hydrogen Sulfide 5
MT etc.
Trigger of Accident
Chemical accidents may originate in:
i) Manufacturing and formulation installations
including during commissioning, process
operations and maintenance.
ii) Material handling and storage in
manufacturing facilities and isolated storages;
warehouses and godowns including tank farms
in ports and docks and depots.
iii) Transportation (road, rail, air, water, and
pipelines).
Causes of Accidents

Chemical accidents in general, may

result from:
i) Fire.
ii) Explosion
iii) Toxic release.
iv) Poisoning.
v) Combinations of the above
Initiators of Chemical Accidents

A number of factors including human errors

could spark off chemical accidents with the
potential to become chemical disasters. These
are:
Process and Safety System Failures:
i) Technical errors: design defects, fatigue,
metal failure, corrosion etc.
ii) Human errors: neglecting safety
instructions, deviating from specified
procedures etc.
iii) Lack of information: absence of emergency warning
procedures, nondisclosure of line of treatment etc.
iv) Organisational errors: poor emergency planning and
coordination, poor communication with public,
noncompliance with mock drills/exercises etc., which
are required for ensuring a state of quick response
and preparedness.

Natural Calamities:
The Indian subcontinent is highly prone to natural
disasters, which can also trigger chemical disasters.
Damage to phosphoric acid sludge containment during
the Orissa super cyclone in 1999 and the release of
acrylonitrile at Kandla Port, during an earthquake in
2001, are some of the examples.
Terrorist Attacks/Sabotage:
Vulnerability to chemical disasters is
further compounded by likely terrorist
and warfare activities, which include
sabotage and attack on HAZCHEM
installations and transportation vehicles.
This can occur at sources or anywhere
and at any time.
Impact of Chemical Disasters

In addition to loss of life, the major

consequences of chemical disasters
include impact on livestock,
flora/fauna, the environment (air, soil,
water) and losses to industry.
Various chemical substances used in
operations can be hazardous due to their
toxicity, corrosiveness etc.
For their safe usage, detailed handling
procedures as given in operating manuals.
Further safety information manual (MSDS)
on chemicals need to be referred which
covers physical / chemical properties, fire
hazards, health/toxicological effects on
exposure, advice on protective
clothing/equipment and other handling
precautions.
Basic safety rules for chemicals handling
: Do’s:
 Treat all chemicals as toxic.
 Know the hazard before using the chemicals.
 Avoid breathing chemicals, dust or vapours.
 Avoid contact with eyes, bare skin or clothing.
 Use appropriate control measures and PPE’s.
 Keep away from any ignition source when handling
flammable substances.
 Store all drums on wooden pallets.
 Remove contaminated clothing in case of spill.Wash
the affected part of your body with plenty of water.
DO’s contd......
 While opening the drum, unscrew the cap slowly
to gradually release any internal pressure.
 In case of doubt, always consult your supervisor
regarding protective equipment to be worn
before handling any chemical.
 Keep Shovels and empty drums ready for
collection & storage of spilled solid catalyst /
chemicals.
 Ensure isolation of electrical connections from
outside the store room.
 Carry out periodic checks for healthiness of
Electrical Connections, Air conditioning System
& any leaks from drums.
Don’ts:

 Don't eat, drink and smoke at storage area.

 Don't touch chemicals with bare hands. Wear
protective gloves.
 Don't stockpile unused chemicals.
 Don't keep leaking or damaged containers.
 Don't mix products together.
 Don't remove chemicals from original container.
 Don't store near heat / flames / any source of
heat.
SAFETY IN STORAGE
&
HANDLING
GUIDELINES FOR SAFE STORAGE, HANDLING
& DISPOSAL OF CHEMICALS
 Safety at storage/handling of hazardous
chemicals depends mainly on effective safety
education/ training and efficient supervision.
 The operating staff must be aware of the
hazards involved, the location and operation of
safety equipment.
 Prohibition of carrying and use of ordinary
mobile phone in storage, operation and handling
area.
STORAGE IN BULK
The following points should be given due
weightage to avoid any mishap.
(i) Find less hazardous alternate chemicals,
as replacement. The inventory of all
hazardous chemicals be kept as minimum
as possible.
(ii) The tanks should be located so as not to
pose safety problems due to leakage and
reaction with other chemicals stored
nearby.
The environment at the location should be suitable
for the chemical stored. The storage area should
be declared as a prohibited area and should be
provided with fencing having at least two exits /
“No Smoking” and/or “Prohibited Area” display
boards, as applicable should be provided at site.
Oxidising Agents : Oxidising substances must be
stored away from all flammable materials and
also kept away from substance which are
reducing agents.
Water Sensitive Substances : These substances
react with water or steam to produce flammable
or explosive gases and evolve heat, eg.. Conc.
acids like sulphuric acid, Conc. Alkali like sodium
hydroxide react with water later to evolve heat.
 Toxic Substances : These substances must be
stored in well ventilated areas, preferably cool
and away from direct sun rays. Periodic checks
should be organised for all parts of storage areas.
Extremely toxic substances like TEL (Tetra Ethyl
Lead) must be stored separately under strict
security.
Incompatible Chemicals : Incompatible chemicals
should not be stored near each other.
 Corrosive Chemicals : The flooring of the area
where corrosive chemicals are stored, shall be
impervious and made of corrosion resistant
materials.
(iii) The storage tank and foundation should be of
suitable material of construction to prevent
corrosion.
(iv) Minimum connections and openings to the
tank to avoid leakage and maintenance hazards
(v) Tanks should be fitted with vents/relief
systems of adequate capacity discharging to a
safe height. Wherever atmospheric release of
the vapour is not advisable, the relief should be
routed to a neutralising system. Flame arrestors
are recommended for the vents of atmospheric
storage tanks containing Class A (flash point less
than 23 degree centigrade) chemicals.
(vi) Provision for emergency evacuation of its stock to a
safer location in case of emergency using suitable pump
out system. Use of double isolation valve in outlet line.
(vii) Necessary instruments to monitor level, pressure and
temperature preferably with indications at control room.
Abnormal rise in level / pressure / temperature and
leakage should alert control room by alarm.
(viii) Tank dyke of suitable material (compatible with the
chemical) of volume equal to the volume of the larger
storage tank. The dyke should have facility to:
(a) drain off rain water into storm water channel ;
(b) route high volume spillage / leakage to suitable
neutralizing pit nearby
(c ) discharge safe effluent to oily water system.
Dyke drains isolation valves should be located outside.
(ix)The storage tanks / area should have suitable fire
protection and fire fighting facility including fire
access road.
(x) Communication facility like public address /
telephone must be made available for interacting
with control room, fire stations, medical units etc.
(xi) Name of chemical, type of hazard, emergency
operational instructions, antidote, first aid etc.
should be displayed near each tank.
(xii) Electrical Safety : All cables and electric fittings
shall be constructed, installed, protected,
operated and maintained in such a manner so as to
prevent risk of open sparking.
STORAGE OF CHEMICALS IN DRUMS /
OTHER CONTAINER
The drum storage of hazardous chemicals (liquids) pose
potential hazard compared to bulk storage in that (a) each
drum of a cluster of drum can become a source of leakage;
(b) the drums normally being less resistant to fire would
collapse faster escalating and spreading of fire to other
drums of the stack.
Hence following guidelines Shall be considered in addition to
those discussed above:
(i) The drums should never be filled full with the liquid
chemical to take care of thermal expansion.
(ii) The drums should preferably be stored in a well ventilated
shed (preferably away from process units) with
impermeable floor sloping away from drums.
(iii) There should be provision to collect accidental spills for
safe disposal.
.

(iv) The drums should be stacked in a single tier with

lid position as recommended by manufacturer for
safe storage.
(v) Empty drums should be removed away and made
free of its contents and kept in safe place.
(vi) Periodic site inspection should be carried out to
ensure that there is no leakage from any of the
drums.
(vii) Where combustible solid materials are stored,
the dust content of the air must be kept below
the lower explosive limit. Efficient dust collection
system and good house keeping should be
ensured.
STORAGE OF COMPRESSED GAS
CYLINDERS
The nature of chemical gas apart from the high pressure
of storage amplifies the hazard of the storage gas
cylinders.
Recommended guidelines for storage of cylinders are:
(i) Cylinders should be protected adequately from
variation in temperatures. They should be stored in
cool, dry, well ventilated and covered place away
from steam pipes, furnace, boilers or any other
potential source of heat.
(ii) Cylinders containing flammable gases and toxic
gases shall be kept separated from each other and
from cylinders containing other types of gases be an
adequate distance or by a suitable partition wall.
(iii) Cylinders should be properly stacked taking care to
prevent knocking, dropping or rolling of cylinders.
(iv) Cylinder nozzle should be suitably protected against
damage. Lubricant should not be used on valves or
other fittings of cylinders containing gas.
(v) Liquefied gas cylinders should be stacked vertical so
that in case of defective regulator only gas would
escape.
(vi) The cylinder valves should be provided with security
cap on the outlet to act as a secondary means of
safeguard. If there is a leak in the valve which cannot
be rectified the cylinder should be removed to safe
open space for necessary remedial measures.
(vii) It is necessary that a) name of chemical ; b) state
of chemical as to gas or liquid ; c) pressure of the
contents ; d) date of filling and e) name and address
of the source (manufacturer) should be labelled on
the cylinders.
(viii) The due date of test for cylinder should be marked on the
metal ring inserted between the cylinder valve and cylinder
neck. If this date is over, the cylinder should not be accepted.
(ix) For inflammable gases, the cylinder storage area should be
made of non combustible materials and flame proof fittings
should be used.
(x) The floor level at storage area should be sufficiently above
ground level to prevent water logging and corrosion.
(xi) Filled and empty cylinders should be tagged and kept
separately.
(xii) The storage area should be fenced and marked as Prohibited
Area with NO SMOKING WARNINGS and should have at least two
exits.
(xiii) Periodic inspection of cylinders for ascertaining leakage should
be made. Automatic gas detectors where applicable should be
provided at suitable points so that in case of leakage with a
alarm at control room.
(xiv) Emergency kit, safety protective
equipment and clothing should be
available in close vicinity to storage area.
(xv)Adequate and suitable fire extinguishers
must be available at site.
(xvi)For proper identification of the
chemical all cylinders shall have the
proper colour as Rule 8 of The Gas
Cylinders Rules 1981.
UNLOADING OF TANK TRUCKS / TANK
WAGONS
(i) Tanker to be inspected for authorized entry and safe
& sound condition its contents before it enters the
industry premises. Tankers to be fitted with flame
arresters if required.
(ii) The quality of the chemical in the tanker should be
ascertained before unloading to avoid contamination
of chemical already at storage.
(iii) In case of flammable chemicals, the prime mover
(engine) should be kept off. The tanker should be
properly blocked from movement before connections
are made for unloading hazardous chemicals.
(iv) In case of flammable chemicals, the unloading point
should be located at a safe distance outside the
storage dyke. For details, refer OISD-STD-118 on
Layout.
(v) Pressurizing with air / inert gas for unloading should be
avoided. It is recommended to use pumps / vacuum
systems for unloading. Solid chemicals in bulk should be
handled with lifting machines and conveyors.
(vi) Coupling used for connecting hose to tanker must be
leak proof. Flange connections are preferred. Where
threaded connections are used, the threaded portion
should be thoroughly inspected before connections are
made.
(vii) The unloading hose should be devoid of cracks &
blisters. The hose should be hydro-tested periodically.
Proper records of hydro-test should be maintained.
(viii) Same hose should not be used for unloading different
chemicals. Hoses for different chemicals should be
marked with different colour stripes for easy
identification.
(x)For flammable chemicals, the tanker and the hose
are to be properly earthed/bonded before starting
unloading operation.
(x) Unloading should be done under personal
supervision of responsible staff authorized by the
management.
(xi) The operating staff must use suitable personal
protective clothing /equipment. Suitable breathing
canisters and first aid box must be available at site
for use in case of emergency.
(xii) Provision of water / neutralizing medium to take
care of leakage/spillage must be made. Also steam
and inert gas hose stations must be available at
unloading point.
(xiii) There must be adequate illumination at site.
(xiv)The unloading systems should have facility to vent/
drain the remaining chemical in the hose to a suitable
safe point. The hose should be kept blinded when hot in
use.
(xv) Before starting unloading, the ullage of the receiving
tank should be checked. Care should be taken to avoid
overflow of tanks. Gas/chemical leak detection system
to sound an alarm at the control room/site may be
provided wherever possible, so that quick remedial
measures can be taken. Wherever necessary,
quick/remote isolation valves should be provided.
(xvi) Fire alarm and fire fighting facility commensurate with
the chemical should be provided at the unloading point.
(xvii) Effective communication system like public address/
telephone must be available for communicating with the
control room / fire station /health unit.
UNLOADING OF DRUMS / CONTAINERS
This is in addition to the general precautions
(i) Manual handling of drums / containers should
be minimized. It is preferable fork-lifters and
suitable cradles are used to handle drums.
(ii) Carboys containing hazardous chemicals should
not be subjected to impact.
(iii) Suitable protective clothing should be used
while handling drums /containers and the
operators should position himself such that he is
in the upwind direction so that even in case of
accidental release of chemical, he is safe.
SAFE DISPOSAL OF EMPTY CONTAINERS
/ EXPIRED HAZARDOUS CHEMICALS
Safe disposal of empty containers of
hazardous chemicals should be done
based on guidelines given by the
manufacturers.
Safe disposal of hazardous chemicals
whose shelf life has expired, should be
done based on guidelines given by
manufacturer. As a precaution First-in &
First-out practice should be adopted to
ensure consumption of chemicals before
reaching their expiry date.
THANKS
for the
ATTENTION