1 Material... · Web viewRL-HSE-0001/SP0016 HAZARDOUS MATERIAL HANDLING PROCEDURE Revision 02 AES ROC SAFETY MANAGEMENT SYSTEM 1 Use, Storage, Handling and Transfer of highly hazardous

RAS LAFFAN POWER COMPANY

RL-HSE-0001/SP0016

HAZARDOUS MATERIAL HANDLING PROCEDURE

Revision 02

AES ROC SAFETY MANAGEMENT SYSTEM

AES ROC Safety Management SystemHazardous Material Handling Procedure

RL-HSE-0001\ SP0016 Revision 02 September 2007

1 Use, Storage, Handling and Transfer of highly hazardous chemicals

1.1 PurposeEvery effort must be made to prevent the release of hazardous chemicals or fuels in the workplace. Unexpected releases of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals can result in major accidents and fatalities and therefore these chemicals must be strictly controlled in a disciplined manner. This procedure is provided according to AES and OSHA Safety Technical Guidelines to establish minimum requirements for the use, storage, handling and transfer of chemicals to assure a safe and healthful workplace.

1.2 ScopeThis program is applicable to AES Ras Laffan people conducting work for AES or AES properties.

1.3 General Requirementso This procedure applies to all operations, maintenance, contractor and visiting

service vendors entering, or performing work in, identified chemical areas.o All operating, maintenance and contract personnel will be informed of the

personal protective equipment requirements prior to working in identified Hydrochloric acid, liquid caustic area and other chemicals areas.

o To enter a chemical area, for the purpose other than defined above of this section, the minimum PPE, i.e., a hard hat, safety glasses, and safety shoe, must be worn.

Area Identificationo Identify all hydrochloric acid, liquid caustic and other chemical areas by striping

the area boundaries and mounting signs at key locations identifying the hazards and safety equipment requirements. Hydrochloric acid and liquid caustic areas include:

o All Hydrochloric acid and liquid caustic storage and identified distribution areas likely to cause leakage or splash of Hydrochloric acid and liquid caustic.

o Hydrochloric acid tank and liquid caustic tank unloading areas.o Other situations identified in each area as determined by Team Leaders or plant

safety committee.

Personal Protective Equipment:Appropriate personal protective equipment for operations and maintenance people will also include the following:

1. Chemical resistant splash suit 2. Face shield3. Goggles

RL-HSE-0001\SP0016: Hazardous Material handling Page 2 of 7



4. Respirator (as required)5. Rubber gloves6. Rubber boots7. Dust filter (as required)8. Full face mask (as required)

Limit Inventory of Chemicals:Conduct a thorough review of the chemical inventory and responsibly eliminate any material not essential to plant operations. An updated inventory list should be approved by the plant Manager.

Storage:

All Chemicals should be stored in proper containers as described by the manufacturer in MSDS. Chemical storage containers should be properly marked, and containers should be stored in an area specifically designated and marked for the storage of such chemicals. The location of the storage facility of each type of chemical should be consistent with the chemical type.

a. Acids:i. Store large bottles of acids on low shelves or in acid cabinets.

ii. Segregate oxidizing acids from organic acids, flammable and combustible materials.

iii. Segregate acids from bases and active metals (i.e. sodium, potassium, magnesium).

iv. Use bottle carriers for transporting acid bottles.v. Have spill control pillows or acid neutralizers available in the event of a spill.

b. Bases:i. Segregate bases from acids.

ii. Store solutions of inorganic hydroxides in polyethylene containers.iii. Have spill control pillows or caustic neutralizers available for spills.

c. Flammables:i. Store in approved safety cans or cabinets.

ii. Segregate from oxidizing acids and oxidizers.iii. Keep away from sources of ignition.iv. Keep fire extinguishing and spill control equipment readily available.

d. Oxidizers:i. Store in a cool, dry area.

ii. Store away from flammable and combustible materials, such as paper, wood, etc.

e. Compressed gases:




i. Store in a secure and upright position.ii. When not in use, secure cylinder cap.

iii. Use a cylinder cart, remove manifolds, secure cap, and chain to cart transport.

Handling of chemicals:

People handling chemicals should be trained in the proper use, handling, process safety management of potentially hazardous chemicals. Additionally, theChemical Storage and Handling Program should require the following components, at minimum, for the handling of chemicals:

i. Material Safety Data Sheets (MSDS) available in CCR to staff that work with chemicals.

ii. Prior to working with a chemical, always review the MSDS.iii. Personal Protective Equipment (PPE) must be worn when working with

chemicals.iv. Keep eyewash stations and safety showers, fire extinguishers, fire alarm

stations, and exits clear at all times when handling chemicals.v. Remove PPE, including gloves, after handling chemicals.

vi. Ensure chemicals are properly labeled.vii. Do not handle chemicals or use equipment unless properly trained and/or

qualified.viii. Use practices and equipment that minimize hazards.

2. Process Safety Management of Highly Hazardous Chemicals

2.1 Purpose Every effort must be made to prevent the release of hazardous chemicals or fuels in the workplace. Unexpected releases of toxic, reactive, or flammable liquids and gases in processes involving highly hazardous chemicals can result in major accidents and fatalities and therefore these chemicals must be strictly controlled in a disciplined manner. This procedure is provided to establish minimum requirements for the management of hazards associated with highly hazardous chemicals to assure a safe and healthful workplace.

2.2 Scope The Process Safety Management of Highly Hazardous Chemicals Program is applicable to the AES Ras Laffan.

2.3 Hazard Analysis

AES Ras Laffan will conduct an analysis of each process that is appropriate to the complexity of the process and that identifies, evaluates, and controls the hazards involved with the process.




i. List of chemicals being used at site

DESALINATION PLANTBelgard EVSodium sulphiteBellite M-8hydrochloric acid 32%Sulphomic Acid to clean demister REMINERALIZATION PLANT Lime stone 92%Caustic Soda 50%Hydrochloric Acid 32%Sodium Hexameta PhosphateActivated CorbonPoly Electrolyte for settling basinPoly Electrolyte for NaoCl plant DEMINERALIZATION PLANTHydrochloric Acid 32%Caustic Soda 50% Solution POWER PLANTHydrazine Hydrate 35%Tri-Sodium PhosphateDi-Sodium PhosphateAmmonia solution 24%Detergent for Compressor washing COOLING TOWER Di-Anodic DN 2480Flogard MS 6209Bio-Cide Spectrus NX1104Spectrus NX 1422 CLOSED COOLING WATER SYSTEMCorrshield NT4292Spectrus NX 1164




MSDS are available in CCR to evaluate the risk/ hazards involve with these chemical and its process, all concern people who want to work with these chemicals shall review the MSDS first.

2.4 Written Procedures

2.4.1 Spillage procedure

Policy:

This hazardous substances spillage procedure has been established to assure that AES people are familiar with the hazards of the chemicals with which they are working as well as to ensure that proper provisions are in place to control exposures to hazardous chemicals to safe levels. This program is intended to outline the procedures which will be taken at this facility to assure that the aforementioned goals are accomplished.

A. General precautions/requirements:

The precautions for handling and use of a chemical should be read carefully with respect to each active ingredient as stated on the label and in MSDS. Warnings and cautionary statements should be strictly observed, and first-aid measures noted before handling.

B. Warning notice:

A notice board with the words "DANGER CHEMICALS", "NO SMOKING, EATING OR DRINKING" must be clearly exhibited in a place that is easily visible within the premises.

C. Damaged containers:

Chemicals received in damaged containers must be kept separately and returned to the supplier or disposed off properly.

2.4.2 Procedure for cleaning up spills

Hazardous Chemical substance spillage may be cleaned up in the following way:

Spilled dusts and powders:Cover dust or powder spills with double their volume of absorbent material such as sand, soil or sawdust. Carefully sweep up absorbent material, using a broom,




into a disposable container. Solid waste should be disposed off according to the approved procedure for disposal of solid waste.

Spilled Liquid chemicals:Spillage of acid, caustic, cooling tower, Power block chemicals, REMI and DEMI plant chemicals, DESAL are chemicals and lubricants within secondary containment areas will be handled as per procedure laid down in the Safety manual Emergency Response Procedure and disposed off according to SCNER limits.

In case of spillage of chemical substances in areas other than secondary containment, cover liquid spills with an inert absorbent such as sand, soil or sawdust. After the liquid has been absorbed; carefully sweep it up using a broom, into a disposable container. Solid waste should be disposed off according to the approved procedure for disposal of solid waste.

2.4.3 Other Procedures:Procedures for Emergency Response which involves chemicals handling of Normal/ Emergency Operation, initial Start up, Normal/ Emergency Shutdown and operating limits, consequences of deviation in parameters of plant and steps required to correct or avoid deviation are available in CCR and Admin library.

Safety and health considerations, including properties and hazards presented by the chemicals used in the process, precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment usage guide lines can be find in the Plant Operating procedures and MSDS.

eferences:OSHA Standard 1910.119: Process safety management of highly hazardous chemicalsAES SAF 2.0 – Emergency PlanAES SAF 3.0 – Emergency Egress and ExitsAES SAF 4.0 – On-site Use, Handling, and Transfer of Hazardous Chemical MaterialsAES SAF 5.0 – Process Safety Management of Highly Hazardous ChemicalsAES SAF 6.0 – Chemical Spill/Release ResponseAES SAF 9.0 – Confined SpacesAES SAF15.0 – Personal Protective EquipmentAES SAF 23.0 – Contractor Safety


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