Chemical Hazard Mgnt_Program (Www.ebookByte.com)

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Chemical Hazard Hazard Management Management Procedure

Table of Contents 1.0 Objective 2.0 Scope 3.0 References 4.0 Responsibilities 5.0 Definitions 6.0 Legal Requirments 7.0 Guidelines Common to all Chemicals 8.0 Working with Chemicals with Specific Hazards 9.0 Hazard Communication 10.0 Training 11.0 Exposure Assessment and Medical Surveillance 12.0 Standard Operating Procedures 13.0 Documentation Control 14.0 Audit Requirements 15.0 Renewal Process 16.0 Deviation Process Attachment A: Chemical Chemical Purchase Purchase hazard information Form Attachment B: Hazmat Hazmat Labels Labels Attachment C: Incompatible Incompatible Chemicals Chemicals

Reference No. SHE-TSOH-04-1358 Rev. : 0

Title:Chemical Hazard Management Procedure

Page 3 of 23 1.0 Objecti ve The objective of Chemical Hazard Management Procedure is to provide general guidelines for hazardous materials: 1. Specification, ordering, purchase, handling, storage, use, transportation, emergencies and disposal; 2. Control of hazards; and 3. Hazard communication. 2.0 Scope 2.1 Scope This procedure establishes minimum requirements for all activities under effective control of KNPC. 2.2 Exclusions This document does not apply to chemicals enclosed in pipelines and bulk storage facilities, hydrocarbon transport vehicles, management and control of asbestos, gaseous substances emitted from stacks, fumes and mists and prescription medicine or drugs. 3.0 References 1. 2. 3. 4. 5. 6.

Environmental Requirements for the State of Kuwait, Environment Public Authority, Ministry of Oil, Kuwait, Environmental Requirements, Corporate Health Safety and Environment Standard 12, 19, 39, 40, 47, Kuwait Petroleum Corporation, OSHA PSM for Highly Hazardous Chemicals 29 CFR 1910.119 NFPA-30 Flammable & Combustible Liquids Code Shell reference doucment on safe handling of chemicals

4.0 Responsibilities Superintendent, Technical Support, Safety, Health & Environment is designated as competent person to administer and maintain the elements of this document. Line management in all KNPC departments has the responsibility to ensure implementation of guidelines relevent to them. Responsibility for keeping this document updated and providing overall direction and advice on the issue shall be with Manager, Safety, Health & Environment. Each individual (including contractor personnel) in KNPC is responsible for various provisions of this plan as relevant to his/her job. Users shall be aware of labeling system and shall understand information on MSD S. They shall follow safety instructions displayed in labels and MSDS, or as instructed. User division superintendent shall ensure all users are aware of nature, uses and hazards of the material. Users shall be properly trained on general handling of hazardous material and special training on highly hazardous materials applicable for a particular user. User division superintendent shall ensure the provision of required PPE and user compliance. PPE signs shall be displayed at locations wherever hazardous materials are handled or stored (e.g. eye goggles, gloves, and respiratory protection signs). Users shall check all empty containers, equipment and tools prior to use for the condition, cleanliness, and compatibility with the material.Suppliers, warehouse personnel, transporters



Page 4 of 23 and end users shall make sure that all hazardous material containers are properly labeled and identified. 5.0 Definitions Auto Ignit ion Temperature (AIT/IT): Minimum temperature required to initiate self-sustained combustion of a solid, liquid or gas in the absence of a source of ignition. Carcinogen : A substance capable of producing cancer, mutations of genes resulting in irregular, uncontrollable growth of abnormal cells in humans. Hazardous Chemicals (Chemicals): Elements or compounds or mixtures which are categorised for transportation and handling as follows: a. Physico - chemical Hazards: Explosive, oxidising and flammable b. Health Effects: Toxic, corrosive, irritant, sensitising, carcinogenic, mutagenic, toxic for reproduction and dangerous for the environment. c. Environmental Hazard: Substances with the potential to cause harm to the environment. The above definations includes similar terms such as hazardous materials, hazardous substances and highly hazardous materials. Combustible Liquid: A liquid having a closed-cup flash point at or above 1000F (37.800C) (eg. Diesel, Fuel oil) Combustible Liquid Flash Point 1000F (37.80C) & above Class II 100-140 0F (37.8-600C) Class III A 140-200 0F (60-93.30C) Class III B 200 0F (93.30C) & above Compressed Gases: Gases having an absolute pressure in the container exceeding 40psi (2.72 Kg/cm2) at 70oF(21.1oC), or having an absolute pressure exceeding 104psi (7.07Kg./cm2) at 130oF(54oC). Corrosive Material : Corrosive materials are liquids, gases or solids that can destroy human skin tissue, severely corrodes steel or other materials. Explosives: Explosives are chemical compounds, mixture, or device whose primary purpose is to function by explosion with substantial releases of heat and gas (eg. Dynamite). Flammable Gases: Flammable gases have flash point below room temperature and will form explosive mixture with air or oxygen within the lower & upper explosive limits (e.g. hydrogen, light hydrocarbons like propane & acetylene). Flammable Liquid: A liquid having a closed-cup flash point below 100 0F (37.80C) and having a Reid Vapor Pressure (RVP) not exceeding 40 psia (2068.6 mm Hg) at 100oF (37.80C). (eg. Naphtha, Gasoline) Flammable Liquid Class I A Class I B Class I C

Flash Point Below 1000F (37.80C) Below 730F (22.80C) Below 730F (22.80C) 73-100 0F (22.8-37.80C)

Boiling Point below 100 0F at or above 100 0F n/a

Flammable Solids: A Flammable solid is any solid material other than an explosive which is liable to cause fire through friction or retained heat from manufacturing or processing or that can be ignited readily and when ignited, burns so vigorously and persistently as to create a serious hazard. Flash Point (FP): Minimum temperature at which a flammable mixture of gas or vapor in air will momentarily flash when a source of ignition (spark) is introduced.



Page 5 of 23 Immediately Dangerous to Life and Health (IDLH): Minimum concentration of contaminant in air which is IDLH. Irritating Material: A liquid or solid, which upon contact with fire or exposure to air, gives off dangerous or intensely irritating fumes. Lethal Concentration (LC): Toxic concentration in air which cause death of test animals. Toxicity of a substance entering the body by ingestion or absorption is measured in Toxic and Lethal Doses (i.e. TD & LD for liquids, etc). Lethal Dos e (LD): Dose which killed test animals (ex. LD50 = dose or the amount that killed 50% of test animals) Lower Explosive/Flammable Limit (LEL/LFL): Minimum concentration of vapor or gas in air which will burn when a source of ignition (spark) is introduced. Material Safety Data Sheets (MSDS): An organised basic hazard information on individual chemicals for risk appraisal and instruction of personnel in an internationally agreed on format. 16 sections are defined for the listing of properties of products and other material including toxicological, ecological, physical, flammability and regulatory requirements and emergency and disposal measures. Mutagen: A substance capable of inducing genetic change which when transmitted to an offspring can result in heritable variation. Oxidizers: Oxidizers are materials that contain large amounts of chemically bound oxygen that is easily released, especially when heated, and that will stimulate the burning of combustible material. Personal Protective Equipment (PPE): Means all equipment and clothing which is intended to be worn or held by a person at work and which affords protection against one or more risks to health or safety. Protective includes, coverall, chemical suit, gloves, safety boot, safety spectacles, safety helmets, safety harnesses, respirators, life jackets etc. Poison A: A gas or vapour of a liquid of such a nature that a very small amount mixed in air is dangerous to life. (e.g. hydrogen cyanide, phosgene, nitrogen tetroxide). Poison B: Any substance (liquid, solid, paste or semi solid) known to be so toxic that a severe health hazard exists. (E.g. TEL/TML, parathion. Aniline). Preparation: Means mixtures or solutions of two or more chemicals. Radioactive Materials: Any material, or combinations of materials, that spontaneously emit ionizing radiation, and have a specific activity greater than 0.002 microcuries per gram. Reprotoxic Substances: Capable of producing irregularities in the reproductive system of either gender, the growth of a foetus (teratogenic) and chils. This includes the lactic period. Sensitisers: Substances which can induce changes in the respiratory system or on the skin. Once these changes have taken place, further exposure to the substance, sometimes to very small quantities causes the symptoms to return. Some persons are more susceptible to sensitisers than others. Substance: Any natural or artificial substance whether in solid, liquid or gaseous form or in the form of a gas or vapour including microorganisms. Substance Hazardous to Health : Any substance or preparation which are: a. Listed or must be classified according to the conventional method as very toxic, toxic, harmful, corrosive or irritant and required to display hazard warning symbols; b. Present in excess of an assigned exposure limit;



Page 6 of 23 c. d. e.

A biological agent; Dust of any kind in substantial quantity; Not a substance mentioned above but which creates a hazard to the health of members of the work force, which is comparable with the hazards created by substances above.

Threshold Limit Value (TLV): Atmospheric concentration of a contaminant to which, most workers may be exposed. TLV-Time Weighted Average (TWA): concentration of the contaminant in air over the normal work shift of 8 hours, to which workers can be exposed without respiratory protection in a 40-hour workweek. TLV-Short Term Exposure Limit (STEL): When exposed only for a short period of 15 minutes. This maximum concentration can be allowed to breathe 4 times during 8 hours with minimum 1-hour interval between exposures. Toxicity: Toxicity of a material entering the body by inhalation is measured in Toxic and Lethal Concentrations (i.e. TC & LC for gases, vapor or dust). Toxic Concentration (TC): Minimum toxic concentration in air which cause toxic effect. Toxic Dose (TD): Minimum dose to cause toxic effects Upper Explosive/Flammable Limit (UEL/UFL): Maximum vapor/gas to air concentration above which flame propagation will not occur, i.e. the mixture is “too rich” to burn. User: User shall mean the personnel involved in using, handling, storing, transporting and emergency response of hazardous materials. 6.0 Legal Requirements 6.1 National and International Protocols The chemical control policies KNPC shall be in harmony with Kuwait EPA requirements (in perticular chapter III, October 2002) and any applicable national and international legislation and protocols to which the State of Kuwait has subscribed.

7.0 Guidelines Common to Chemicals 7.1 Purchase Control and Approval for New Chemicals and New Chemical Use 7.1.1

It shall be the responsibility of the person specifying or ordering any hazardous chemical to ascertain if the chemical is really required or if its use can be eliminated by changing the process or its design. If the substance cannot be eliminated, possibility of substituting by safer alternative shall be looked into.

7.1.2

The hazards to health and to environment associated with chemicals shall be ascertained before delivery to sites is undertaken. It is important to note that different forms of the same substance may present different hazards. Identification of the hazards of chemicals is the basis for a risk assessment to be undertaken. The findings of the risk assessment will enable the person handling the chemicals to take the necessary measures to protect his health, safety and also to protect the environment.Such records shall be maintained in the form of Occupational Health Risk Register.



7.1.3

Page 7 of 23 It shall be the resposibility of the indenter of any chemical to complete “Chemical Purchase Hazard Information Form” (Appendix A). The form shall be submitted to the Superintendent, Technical Support, Safety, Health and Environment.

7.1.4

It shall be the responsibility of Purchase Division to specifically mention requirment for MSDS in the KNPC approved format as a mandatory part of any purchase of any hazardous material. MSDS submitted by the supplier shall be approved by the competent person before transportion of the material to KNPC sites.

7.1.5

The driver of any transport bringing hazardous chemicals to KNPC sites, will carry in person appproved MSDS. No gate pass shall be issued to KNPC sites without attaching a copy of approved MSDS. This will be the resposibility of the gate pass issuing authority. Contractor bringing any chemicals must submit “Chemical Purchase Hazard Information Form” to Superintendent, Technical Support, Safety, Health and Environment through his sponsor superitendent and obtain necessary approval.

7.2 General Precautions 7.2.1 7.2.2

7.2.3 7.2.4 7.2.5

Hazardous materials should be handled in closed systems wherever possible. Safety Shower/eyewash shall be available near the chemical handling area. It shall be painted in green & white and provided with green & white identification symbol visible from distance. Plant chemical shelters should be away from hazardous area. Overstocking of chemicals shall be avoided in unit chemical shelters. Expired material shall be disposed in compliance with KNPC and Kuwait Govt. environmental regulations. Waste material (including radioactive waste) shall be disposed in accordance with the KNPC Environmental Regulations.

7.3 Guidelines for Storage of Chemicals 7.3.1

The consequences of unplanned storage of chemicals can be disastrous for example it can initiate an explosion or the release of toxic fumes into the atmosphere should dissimilar chemicals come into contact with one another. Substances of different hazard classifications must not be stored together.

7.3.2

The following are general guidelines for storage of chemicals: a. Ensure that all containers are in good condition and properly labeled. b. Store incompatible chemicals separately. c. Segregate chemicals by hazard class (flammable liquids, oxidizers, etc.). d. Ensure that storage locations are dry and adequately ventilated. e. Flammables shall not be stored with any other types of hazardous substances. f. Store highly reactive or corrosive liquids in spill trays. g. Toxic substances shall not be stored with any other substance.

7.3.3

Separate storage areas shall be provided for “incompatible chemicals” as these chemicals may react together and create a hazardous condition because of this reaction (See Appendix- C).

7.4 Guidelines f or Safe Use of Chemicals 7.4.1 7.4.2 7.4.3 7.4.4

Knowledge of hazards associated with the materials Review of emergency procedures and ensure that necessary supplies and equipment for emergency response are available. Know the locations of safety equipment such as emergency shower, eyewash, fire extinguisher, fire alarm and emergency phone numbers. Wear appropriate personal protective equipment and take proper care for using them.



7.4.5 7.4.6 7.4.7

Page 8 of 23 Wear appropriate respiratory equipment when air contaminant concentrations cannot be sufficiently restricted by engineering controls. Keep work areas clean and uncluttered with chemicals and equipment properly labeled and stored. Always wash hands and other exposed skin after chemical use.

7.5 Tansportation and Handling within Work Site 7.5.1

Driver and other person transporting and handling chemicals shall be trained on handling chemicals and emergency response. Before transportation responsible personnel shall ensure labels on the container are intact and proper personal protective equipment are used. Copy of MSDS shall be carried during transportation. Incase of emergeny ECCC shall be contacted in telephone number 888.

7.6 Empty chemical containers: 7.6.1

A container is empty (according to U.S. EPA) when the residue left over is less than 2.5 cms at bottom or less than 3% ( for size less than 412.5 lits) and less than 0.3 % ( for size more than 412.5 lits). An empty container may be classified as hazardous depending on the nature of the material it contained. Guidelines for cleaning empty chemical container (SHE-TSOH-04-1322) shall be reffered for empty chemical container cleaning, reuse and disposal.

7.7 Guidelines fo r Chemicals Waste Management 7.7.1

Waste management shall be based on the principle of waste minimisation, following the waste management hierarchy of source reduction, reuse, recycling/recovery and disposal. KNPC solid waste management document SHE-ENVP-03-0006 shall be refered for details.

7.8 Emergency Response 7.8.1

Pre emergency plan shall be developed for emergencies like fire, spill, chemical exposure etc. before handling of hazardous chemicals. Equipment shall be maintained in the area to assist emergency response personnel e.g., eyewash and safety shower, fire fighting equipment and personal protective equipment. MSDS shall be available for reference. Employees shall be trained to handle emergencies. In case of emergency contact ECCC through telephone 888.

7.9 Chemicals with Specific Hazards 8.0 Working with Flammable/Combustibles 8.1.1

General Safety Measures

8.1.1.1 Common flammable and combustible liquids are crude oil, coal tars, hydrocarbons, alcohol, and their by-products. 8.1.1.2 Manufactured liquids and fluid commodities which contain flammable liquids, such as paints, floor polish, cleaning solutions, dryers and varnishes shall be considered as flammable liquids and classified according to the flash point of the mixture. 8.1.1.3 Precautions pertaining to their handling and use differ according to their flash points, volatility, and the amount of flammable liquid within the mixture. MSDS, operation manual, etc. stipulate these requirements. 8.1.2

Igniti on Sources

8.1.2.1 Smoking and carrying of matches, lighters and other spark or flame producing devices shall not be permitted in a building or area where flammable liquids are stored, handled, or used. The extent of the restricted area will depend on the type of



Page 9 of 23 products handled, the design of the building, and local conditions. Suitable ‘NO SMOKING’ and other signs shall be posted in buildings, and areas where smoking is prohibited. 8.1.3

Static Electric ity

8.1.3.1 Static electricity is a surface phenomenon due to electron exchange between two contacting surfaces. When the two surfaces are in close proximity to each other, the negative charge of excessive electrons on one surface is neuatralized the positive charge of the electron deficient surface. When the two surfaces are separated, the accumulated charge has no place to go, and is called static electricity. The accumulated charge on a given surface, because of its high potential, can flow to a near by conducting object, and if the magnitude of the charge is large enough, can generate spark which may ignite a potentially flammable mixture of gases. 8.1.3.2 Static electricity is generated by the contact and separation of dissimilar materials. For example, static electricity is generated when a fluid flows through a pipe or from an orifice into a tank. Figure 8.1 Recommended Practice on Bonding and Grounding Conductive nozzle in contact with Hose may be either Hose may be either conductin g or container- no other conducting or nonnon-conducting bonding necessary conducting

Metal plate bond the two containers

Metal containers

Metal plate bond the pump and the drum

Nozzle not in contact- a bond wire is necessary except where containers are inherently bonded to gether

Metal floor


Strips

fastened

to


Page 10 of 23 8.1.3.3 Grounding and bonding of flammable liquid containers shall be provided to prevent static electricity causing a spark as in Figure. 8.1.3.4 To avoid a spark from discharge of static electricity during filling operations, a wire bond shall be provided between the storage container and the container being filled, unless a metallic path between the containers is otherwise present. 8.1.3.5 Above ground tanks used for storage of flammable liquids shall be properly grounded. Ground wire is preferred to be uninsulated, so it may be easily inspected for mechanical damage. Petroleum liquids are capable of building up electrical charges when they flow through piping or agitated in a tank or a container, or subjected to vigorous mechanical movement such as spraying or splashing. Grounding wire shall be provided to drain off this static charge to ground as fast as it is generated. 8.1.3.6 High static charge shall be controlled by reducing the flow rates, avoiding violent splashing with side-flow fill lines and use of relaxation time. 8.1.4

Electric al and Electron ic Equipment

8.1.4.1 Electricity is a common source of ignition where flammable vapors exist. Hence, proper type of electrical equipment for these atmospheres (e.g. Explosion proof, Intrinsically safe) shall be installed and they shall be properly maintained as per hazard area classification. 8.1.5

Health and Flammabilit y Hazards

8.1.5.1 Most of flammable vapors are heavier than air and it can flow into pits, tank openings, confined areas, and low places in which they contaminate the normal air and, thus cause a toxic as well as explosive atmosphere. Oxygen deficiency may occur in closed containers, such as a tank, which has been closed for a long time and in which rusting has consumed the oxygen. 8.1.5.2 All containers shall be ventilated and tested for flammable, toxic and oxygen deficient atmosphere before man entry or any work. 8.1.6 Bulk l oading Road Tank Vehicles Bulk loading and road tank vehicles shall be as per company approved procedures written separately 8.1.6.1 Vehicles are to be loaded only with the class of products for which they are designed and authorized to carry. 8.1.6.2 The driver shall be aware of the hazards and trained for emergency actions. MSDS and minimum required emergency equipment shall be available in the cabin. 8.1.7 Containers and Portable Tanks for Handling Flammable Liquids 8.1.7.1 General 8.1.7.1.1 This Section shall apply only to the storage of flammable or combustible liquids in drums or other containers not exceeding 60 US gallons (227 lt.) individual capacity and those portable tanks not exceeding 660 US gallons (2500 lt.) individual capacity. Flammable and combustible liquid containers shall be in accordance with Table 8.1. 8.1.7.1.2 Each portable tank shall be provided with one or more approved devices installed in the top with sufficient emergency venting capacity to limit internal pressure under fire exposure conditions.



Page 11 of 23 Table 8.1 Maximum All owable Size of Containers and Portable Tanks Flammable Liquids Container Type

Combustible Liquids

Class I A

Class I B

Class I C

Class II

Class III

Glass or approved plastic Metal (ot her th an DOT Specifications) Safety cans

1 pt

1 qt

1 gal

1 gal

1gal

1 gal

5 gal

5 gal

5 gal

5 gal

2 gal

5 gal

5 gal

5 gal

5 gal

Metal drums (DOT specifications) Ap proved port able tanks

60 gal

60 gal

60 gal

60 gal

60 gal

600 gal

600 gal

600 gal

600 gal

600 gal

8.1.7.2 Storage Cabinet 8.1.7.2.1 Not more than 60 US gallons of Class I or II liquids nor more than 120 US gallons (454 lt.) of Class III Liquids may be stored in the storage cabinet. The cabinet shall be of approved type. 8.1.7.3 Storage Room 8.1.7.3.1 Storage rooms shall comply with the following specifications: a. Inside every storage room there shall be one clear aisle at least 3 feet (1 meter) wide. Containers over 30 US gallons (113.5 lt) capacity shall not be stacked one upon the other. Storage room shall be provided with approved type of natural or mechanical exhaust ventilation system. b. Storage room shall not have a door that opens into that portion of the building used by the public. 8.1.7.3.2 Dispensing of flammable liquid shall be by approved pump on self-closing faucet only. Construction, electrical wiring and ventilation of the room shall be suitable for area classification. 8.1.7.4 Storage Inside Buil ding s 8.1.7.4.1 Egress Flammable or combustible liquids, shall not be stored so as to limit use of exits, stairways or areas normally used for the safe egress of people. 8.1.7.4.2 Office Occupanci es Storage shall be prohibited except for quantities required to operate office equipment. Such storage shall be in closed metal containers and stored in a storage cabinet or in safety cans. 8.1.8 Flammable and Combustible Liquid Warehouses or Storage Buildings 8.1.8.1 The total quantity of liquids within a building shall not be restricted but the arrangement of storage shall comply as shown. 8.1.8.2 Containers in piles shall be separated by pallets or dunnage(mats) where necessary to provide stability and to prevent excessive stress on container wall.



Page 12 of 23 8.1.8.3 No pile shall be closer than 3 feet (1m) to the nearest structural beam obstruction and shall be 3 feet (1m) below sprinklers or other overhead fire protection systems.\ 8.1.8.4 Aisles of at least 3 feet wide shall be provided where necessary for reasons of access to doors, windows or emergency equipment.

Table 8.1 Indoor Cont ainer Storage Maximum per pile Protected Storage

Unprot ected Storage

Storage Level

Gallons

55 Gal Drums

Gallons

55 Gal Drums

IA

Ground & Upper Floors

2,750

50

660

12

IB


5,500

100

1,375

25

IC


16,500

300

4,125

75

II

Ground & Upper Floors Basement

16,500 5,500

300 100

4,175 75 Not Permitted

III

Ground & Upper Floors Basement

55,000 8,250

1000 450

13,750 250 Not Permitted

Class Liquid

of

Note: 1. Class 1 liquid shall not be stored in basements. 2. When 2 or more classes of materials are stored in a single pile, the maximum gallonages permitted in that pile shall be the smallest of the 2 or more separate maximum gallonages. 3. Aisles shall be provided so that no container is more than 12ft. from an aisle. Main aisles shall be at least 8ft. wide and side aisles at least 4 ft. wide. 4. Each pile shall be separated from each other by at least 4 ft. 8.1.9 Storage Outside Buildings Storage outside building shall confirm to the table . Table 8.2 Outdoor Con tainer Stor age Class Maxim um per Distance pile between piles (See note 1) (See note 2)

IA

US GAL 1,100

FT. 5

Distance to property line that can be built upon (See notes 3 & 4) FT. 20

Distance street, alley public way (See note 4) FT. 10

IB

2,200

5

20

10

IC II III

4,400 8,800 22,00

5 5 5

20 10 10

10 5 5

to or

Notes: 1. When 2 or more classes of materials are stored in a single pile, the maximum gallonage in that pile shall be smallest of the 2 or more separate gallonages. 2. Within 200 ft. of each container, there shall be a 12ft. wide access way to permit approach of fire control apparatus. 3. The distances listed apply to properties that have protection for exposures as defined. If there are exposures and such protection for exposures does not exist, the distance in column 4 shall be doubled.



Page 13 of 23 4. When total quantity stored does not exceed 150 percent of maximum per pile, the distances in columns 4 and 5 may be reduced 50 percent, but not less than 3 ft. 8.2 Flammable Solids Flammable solids such as sulfur and coke are handled in KNPC. While some safety features are bulit-in, it requires maintaining these in proper condition and good safety practices of employees to avoid fire or explosion. 8.2.1 General Precautions 8.2.1.1 The dust content of the flammable solid in air must be kept below the lower explosive limit (i.e. it should not obscure vision at 5ft distance or less). Water spray system shall be readily available. 8.2.1.2 In addition to right enclosures and dust collection systems, good plant housekeeping shall be maintained. 8.2.1.3 All sources of ignition shall be excluded from the area of a potentially explosive dust. The no smoking rule shall be rigidly enforced. 8.2.1.4 Wiring, lights and switches shall be in compliance with area classification. 8.2.3 Special Precautio ns 8.2.3.1 Spills in conveyor systems shall be cleaned as and when it occurs. Dust should not be allowed to rub against the moving parts. 8.2.3.2 Crew for cleaning shall be continuously in attendance during loading. After completion of loading, entire system shall be thoroughly cleaned. 8.2.3.3 Static electricity shall be prevented from accumulating by using antistatic material or any suitable method. 8.2.3.4 Substances, which give off flammable gases on contact with water, shall be stored in dry storage facilities. 8.2.3.5 Substances which are liable to spontaneous ignition shall be stored in sealed closed and leak proof containers and underwater or in an inert atmosphere. 8.3 Toxic Materials 8.3.1 Stor age 8.3.1.1 If any container is found to be leaking it has to be disposed by an approved disposal method only (Refer MSDS). Lids of the containers shall be properly closed. 8.3.1.2 Toxic materials shall not be stored near the sources of food or water etc. Food items, drinks, cigarettes etc. shall not be brought into storage rooms of toxic materials. Eating, drinking and smoking inside the storage rooms shall be strictly prohibited.

8.3.2 Handling 8.3.2.1 Handling of all toxic materials shall be done using appropriate protective equipment (Refer MSDS). In addition, tools used for handling the toxic materials or containers of toxic materials shall not be used for any other purpose before cleaning properly. 8.3.2.2 All contaminated clothes and tools to be cleaned at a separate cleaning room. Clothes worn during the working time shall not be worn afterwards.



Page 14 of 23 8.4 Corros ive Materials 8.4.1

Corrosive materials which can react with the skin causing burns similar to thermal burns, and/or which can react with metal causing deterioration of the metal surface. Acids and bases are corrosives (e.g. Hcl, H2SO4, and Caustic).

8.4.2

Following are special precaution for working with corrosives: a. Containers and equipment used for storage and processing of corrosive b. Materials shall be corrosion resistant. c. Eye protection, chemical handling suit and rubber gloves shall be used d. When handling corrosive materials. e. When mixing concentrated acids with water, add the acid slowly to Water. Never add water to acid. f. Acids and bases should be stored separately from each other. Organic acids should be stored with flammable materials, separate from oxidizers and oxidizing acids. g. An eyewash and safety shower shall be readily accessible to areas where corrosives are used and stored. In the event of skin or eye contact with corrosives, immediately flush the area of contact with cool water for 15 minutes. Remove all affected clothing. Seek medical assistance.

8.5 Radioacti ve Materials The section shall be read in conjuction with the KNPC Inspection Procedure IC-37: safe Practices for Industrial Radiography and IC-38: Procedure for Safe Transportation of Radioisotopes. KNPC Inspection shall ensure the following; The following basic rules shall be strictly enforced: a. The ionising radiation sources shall not be left unattended. b. Radiation film badge Dose Meter shall be used. c. The exposure area shall be identified, barricaded by rope or other effective means and radiation warning signs posted. d. Employees shall ensure availability of radiation meter at work site of radiography. e. Supertidenent Inspection & Corrosion shall be given 12 hours prior notice before starting any radiography work inside refinery. 8.5.1 Stor age 8.5.1.1 When not in use or transit, the containers shall be kept in the locked storage pit so as to minimize the risk of their coming into the possession of unauthorized and untrained persons. 8.5.1.2 The storage pit shall be surrounded by a fence on which warning notices are posted. The store shall be under the supervision of the authorized person who is responsible for keeping the source records. 8.5.2 Personnel Safety 8.5.2.1 Only authorized personnel holding valid ‘Radiation Work Permit License’ issued by Ministry of Health/Radiation Protection Division shall handle radioactive material. 8.5.2.2 The following safety equipment sahll be used when radiation work is to be executed: a. Film badges b. Radiation dose rate meter( Survey meters) c. Pocket Dose meter(Optional)



Page 15 of 23 8.5.3 Working on Sit e 8.5.3.1 Enclosure Where reasonably practicable, the radiography shall be carried out in a suitable enclosure, having a fence incorporating a lockable gate which must be kept locked whilst radiography is in progress. All except authorized persons will be excluded from the enclosure. When using Gamma-Ray sources, the dimensions of the enclosure shall depend on the type of equipment used and the nature or activity of the beam in relation to the article radiographed. Where X-rays are used these dimensions shall be governed by the operating conditions of voltage & current; other factors include beam filtration, the effectiveness of any collimator used to limit the size and direction of the useful beam. In both processes, there will be some attenuation of the radiation by the material of the work-place itself and local shielding such as concrete blocks or lead screens. The enclosure shall be adequately marked with suitable radiation warning signs when ionizing radiation are about to be used. 8.5.3.2 Suitably Marked Area Where it is not reasonably practicable to use a radiation enclosure, and the work has to be carried out on site, steps shall be taken to provide a suitably marked area encircled by a rope barrier. The barrier shall be set up at 0.25 millirems per hour distance from the source and shall exclude all except authorized persons. 8.5.3.3 Warning Signals In all cases adequate warning to all persons in the vicinity shall be given by lamps or audible signals or both when a sealed source is about to be exposed or when an Xray machine is about to be energized. In the case of X-ray machine it is mandatory that the means for giving warning shall be integrated with control circuitry, so that they operate automatically, and the equipment shall be unable to function unless they are so connected. 8.5.3.4 Dose Rate Measurement Measurement shall be made with an appropriate Dose Rate meter during radiography to ensure that dose rate at the barrier does not exceed 0.25 millirems per hour. 8.5.3.5 General Precautions The average person’s knowledge of radiation and its hazards is very limited. Therefore it is not enough to erect barriers and provide warning signals just to comply with the regualtion. The radiographer or an assistant shall maintain a strict vigil to prevent unauthorized persons entering the area. If this cannot be done, work involving ionizing radiation shall cease until these persons can be persuaded to keep out. 8.5.3.6 Monitoring Dose Rate Meters The meter shall be used to achieve the following objectives: a. To check initially that the safety barriers are positioned where the Dose rate is not greater than 0.25 millirems per hour. b. To monitor the Dose Rate at safety barriers, particularly when the radiographic technique varies, c. To check that a source exposure container is fully closed after use or that source is fully retracted as appropriate. d. To help locate a lost source, and monitor working conditions. 8.6 Special Precautions for Working with Oxidizers 8.6.1

Oxidizing materials which react with other substances by accepting electrons and undergoing reduction. This reaction may result in fire or explosion. The intensity of the reaction depends on the oxidizing- reducing potential of the materials involved. Oxidation reactions are the most frequent cause of chemical accidents (e.g. Nitrate, Chlorate, Permanganate, and Peroxide).



Page 16 of 23 8.6.2

Following are special precaution for working with oxidizers a. Knowledge of the reactivity of the materials involved in the experiment or process. b. Assure there are not extraneous materials in the area which could become involved in a reaction. c. Store properly, away from organic materials, flammable materials.

8.7 Working with Peroxidizables 8.4.1

Peroxidizables material reacts with oxygen to form peroxides which can explode with impact, heat, or friction such as removing a lid. Since these chemicals may be packaged in an air atmosphere, peroxides can form even though the container has not been opened. Examples of peroxidizables include ethyl ether, tetrahydrofuran, isopropyl ether, liquid paraffin (alkanes), and olefins (alkenes).

8.4.2

The following precautions are required along with other precautions similar to flammables: a. Date all peroxidizables upon receipt and upon opening. Unless an inhibitor has been added by the manufacturer, materials should be properly disposed of after 18 months from the date of receipt or 3 months from the date of opening. b. Do not open any container which has obvious crystal formation around the lid.

8.8 Working w ith Carcinogens 8.8.1

Carcinogens are substance capable of producing cancer, mutations of genes resulting in irregular, uncontrollable growth of abnormal cells in humans.

8.8.2

Following are special precaution for working with carcinogens a. Identify all work and storage areas where chemical carcinogens are present with appropriate signs: “Danger – Chemical Carcinogen Authorized Personnel Only.” b. Limit access to all work and storage areas where chemical carcinogens are present. c. Extreme care should be taken to avoid aerosols. d. Whenever possible work under a hood. e. Eating, drinking, smoking and food storage should be prohibited where chemical carcinogens are present. 9.0 Hazard Commun icatio n 9.1 Materi al Safety Data Sheets (MSDS) Policy and procedures for MSDS as documented in MSDS policy and procedures/document shall be followed. MSDS shall be readily available to personnel in each area where chemicals are used. Personnel must know where to find MSDS and how to read them. It shall be available for reference by the following people: a. All employees for information regarding chemical identity, health effects of exposure, handling precautions, and other hazard information. b. Occupational health resources, to plan and evaluate handling precautions, airborne chemical monitoring, and respiratory protection. c. Emergency response personnel, for information related to spill, fire and explosion d. People responsible for control measures medical personnel, for evaluating health effects and planning treatment for overexposure 9.2 Labeling and Marki ng of Hazardous Materials Containers or systems that hold hazardous materials shall display name of the material and the hazards of its contents by labeling and marking. This includes fixed storage, portable



Page 17 of 23 tanks, modules, drums, cans, bottles and tankers. Marking shall be according to Kuwait EPA regulation (Appendix No.10-3). Labels shall contain the following information. a. Name, address and telephone number of the person responsible for supplying the substance; b. Name of the substance or the trade name of the preparation; c. For a preparation, the constituents; d. Risk and safety measures. 9.3 Signage All areas whrere chemicals are stored, handled or used shall be sign posted as per KNPC sign procedure. The symbols shall be in accordance with Kuwait Environmental Public Authority. Text shall be in accordance with appropriate KNPC regulations. 10.0 Training Employees shall be provided with information and training to ensure that they are apprised of the hazards of chemicals in their work area. Such information shall be provided at the time of an employee's initial assignment to a work area where hazardous chemicals are present and prior to assignments involving new exposure situations. The training shall include: a. KNPC chemical hazard management Plan b. TLV of hazardous chemicals c. Signs and symptoms associated with exposures to hazardous chemicals d. The location and availability of known reference materials such as MSDS and how to read them e. Methods and observations that may be used to detect the presence or release of a hazardous chemical measures to protect from hazardous chemicals. f. The physical, chemical and health hazards of chemicals in the work area g. Measures employees can use to protect themselves from these hazards h. Emergency procedures for reporting and negotiating i. Waste management issues It shall be the responsibility of the custodian superintendent to make sure that all employees have been identified (including contract personnel) and training has been arranged for them. Employees (including contractors) regularly handling chemicals shall be provided one day intensive training. Sl # 1

Group

Jobs

Length

Record

Content

Regular (Field)

1 day

Training Passport

Knowledge of chemicals in use & hazards, MSDS use, hazard control, emergency preparedness, waste management

2

Occasionally coming in contact

Operator, Tank Truck Driver, Laboratory, Foreman, Technician, Mechanic, Supervisor Section Head, Superintendent, Engineer, Manager

3 4

Office Staff Janitorial


½ day

1 hr 1 hr

Training Record Sheet

Knowledge of chemicals in use & hazards, MSDS use, hazard control, emergency preparedness, waste management Hazard awareness Hazard awareness


Page 18 of 23 11.0 Exposure Assessment and Medical Surveillance All sites handling chemicals shall be routinely monitored. Exposure assessment shall be carried out as per KNPC exposure assessment program. All employees working with hazardous chemicals shall receive medical attention under the following circumstances: a. When the employee develops signs and/or symptoms that may be associated with a hazardous chemical to which the employee was exposed. b. When routine monitoring reveals an exposure above 50% TLV. c. When an event takes place in the work area such as a spill or leak, explosion or other occurrence resulting in the likelihood of a hazardous exposure. 12.0 Standard Operating Proc edures Standard Operating Procedures (SOPs) shall be developed by individual work group specific to each chemical. Development of SOPs shall be the responsibility of the custodian superintendent. SOPs shall describe the following: a. Hazard control (engineering & administrative) measures to be used. b. Personal protective equipment that to be worn. c. Available health and safety information resources and location. d. Decontamination procedures, including proper waste disposal practice. 13.0 Docum ent Contro l Each division at KNPC refineries shall maintain auditable records, to document its compliance with this plan. Training and purchase records must be retained in compliance with KNPC record management system. Their retention times shall be 5 years. 14.0 Audit Requirements Each operation at KNPC refineries shall establish and maintain a system for auditing compliance against this plan. Audit findings shall be documented and a system established to ensure that findings are appropriately addressed. Compliance to this procedure shall be audited annually by Superintendent Safety and Fire with custodian area superintendent. Audit findings shall be documented and appropriately addressed. 15.0 Renewal Process This plan shall be reviewed and revised as necessary at a minimum interval of 3 years from the date of the last revision or to reflect changes. 16.0 Deviatio n Proc ess Deviations from this procedure shall be authorized by Manager, Safety, Health and Environment after consultation with Technical Support Division. Deviations shall be documented, and the documentation must include the relevant facts supporting the deviation decision. Deviation authorisation shall be reviewed periodically and no less frequently than every 3 years.



Page 19 of 23 Append ix A: Chemic al Purc hase Hazard In formati on Form * Kindly complete this form with the best possible answers to your knowledge.

Sl.# 1 2 3 4 5 6 7 8 9 10 11 11 12 13

HAZARD EVALUATION What is the chemical? Why is the chemical required? Are there alternatavive chemicals that could be used? Justify that the selected chemical is least toxic among alternative chemicals. What is the hazard classification (see definitions) of chemical? Is MSDS of the chemical available at KNPC? Has an operating procedure specific to chemical been prepared? What control measures are suggested? Has any hazard communication requirement been specified? What training requirements have been specified? What waste handling methods have been suggested? Have any emergency procedures been prepared? Suggested work areas to be monitored? Which employees exposures should be monitored?

REMARKS

* to be completed by indenter and sent to Technical Support, Safety, Health and Environment

Name:

ID:

Signature:

Date:

Remarks (OH Section): Approved: Superintendent, Technical Support, Safety, Health & Environment Note 1: this form to be completed by indenter of any chemical (Technical Support Division can provide assistance) Note 2: no purchase order shall be issued without the approved copy of this form



Page 20 of 23 APPENDIX B: Hazmat Label s as menti oned in Kuwait Environmental public Auth orit y (KEPA). The same is appli cable fo r KNPC

Flammable Gas

Flammable Liquid

Flammable Solid

Explosive

Combustible

Dangerous

Corrosive

Toxic

Infectious

Oxidizer

Radioactive

Non-Flammable Gas

Marine Pollutant

Environment Hazard

Dangerous when Wet



Page 21 of 23 APPENDIX C: Incompatible Chemicals Chemicals Alkaline metals such as powdered aluminum or magnesium, sodium, potassium, etc. Acetic Acid Acetylene Ammonia, anhydrous Ammonium nitrate Aniline Bromine Carbon activated Copper Chlorates Chromic acid Chlorine

Chlorine dioxide Cumene hydroperoxide Flammable liquids Fluorine Hydrocyanic acid Hydrogen peroxide

Hydrofluoric acid, anhydrous Hydrogen sulfide Hydrocarbons (Butane, propane, benzene, gasoline, turpentine, etc.)


Keep out of contact with Carbon tetrachloride or other chlorinated hydrocarbon, carbon dioxide and the halogens.

Chromic acid, nitric acid, hydroxyl compounds, ethylene glycol, perchloricaid, peroxides, permanganates. Chlorine, bromine, copper, fluorine, silver, mercury. Mercury (In manometers for instance) chlorine, calcium hypochlorite, iodine, bromine, hydrofluoric acid anhydrous. Acids, metal powders, flammable liquids, chlorates, nitrates, sulfur, finely divided organic or combustible materials. Nitric acid, hydrogen peroxide. Same as for chlorine. Calcium hypochlorite and all oxidizing agents. Acetylene hydrogen peroxide. Ammonium salts, acids, metal powders, sulfur finely divided organic or combustible materials. Acetic acid, naphthalene, camphor, glycerin, turpentine, alcohol and flammable liquids in general. Ammonia, acetylene, butadiene, butane, methane, propane (or other petroleum gases), hydrogen, sodium carbide, turpentine, benzene, finely divided metals. Ammonia, methane, phosphine, hydrogen sulfide. Acids – Organic or inorganic. Ammonium nitrate, chromic acid, hydrogen peroxide, nitric acid, sodium peroxide, and the halogens. Isolate from everything. Nitric acid, alkalis. Copper, chromium, iron, most metals or their salts, alcohol, acetone, organic materials, aniline, nitro-methane, any flammable liquid, combustible materials. Ammonia, aqueous or anhydrous. Fuming nitric acid, oxidizing gases. Fluorine, chlorine, bromine, chromic acid, sodium peroxide.


Page 22 of 23 APPENDIX C: Incompatible Chemicals (Contd.) Chemical Iodine Mercury Nitric acid (concentrated) Oxalic acid Perchloric acid Potassium Potassium chlorate Potassium perchlorate (see also Chlorates) Potassium permanganate Silver Sodium Sodium Peroxide

Sulfuric acid


Keep out of contact with Acetylene, ammonia (aqueous or anhydrous) hydrogen. Acetylene, luminic acid, ammonia. Acetic acid, aniline, chromic acid, hydrocyanic acid, hydrogen sulfide, flammable liquids, flammable gases. Silver, mercury. Acetic anhydride, bismuth and its alloys, alcohol, paper, wood. Carbon tetrachloride, carbon dioxide, water. Sulfuric and other acids. Sulfuric and other acids. Glycerin, ethylene, glycol, benzaidehyde, sulfuric acid. Acetylene, oxalic acid, tartaric acid, fulminic acid, ammonium compounds. Carbon tetrachloride, carbon dioxide, water Ethyl or methyl alcohol, glacial acetic acid, acetic anhydride, bensaldehyde, carbon disulfide, glycerin, ethylene glycol, ethyl acetate, methyl acetate, furfural. Potassium chlorate, potassium perchlorate, potassium permanganate (or such compounds with similar light metals, as sodium, lithium, etc.)


Page 23 of 23 APPENDIX D:Chemi cal Hazards Management fl owch art

ORGANIZATION Indenting/ user Division

PROCESS DESCRIPTION

Requirement of chemicals/ safer alternatives, hazards identification, chemical purchase hazards information form (CPHI Form)

Vendor

Purchase Division

Ware house Division

Technical support SH&E

Safety & Fire –

Chemical Indenting

Old Chemical

CPHI Form approval

New Chemicall

MSDS approval

CPHI Form

Approval of CPHI form Supply of MSDS format for approval

in

Supply of MSDS

KNPC

Supply of new chemical

New chemical odering

Approved CPHI Form & MSDS Storage/ handling re uirement

Storage of chemicals

Labeling

Chemical communication

hazard

Use of Chemicals

Chemical handling

Disposal of chemicals

Disposal of chemical

Training MSDS

Emergency handling

Emergency handling

Exposure assessment medical surveillance


Sign posting

and

Exposure assessment


Chemical Hazard Mgnt_Program (Www.ebookByte.com)

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