Viral Panchal [email protected] 1. MAH Categorization for chemical industries June 2011, December 2011, May 2017 Major Accident Hazard Units Definition of Major Accident “Major Accident” means an incident involving loss of life inside or outside the site or ten or more injuries inside and/or one or more injuries outside or release of toxic chemical or explosion or fire of spillage of hazardous chemical resulting in ‘on-site’ or ‘off-site’ emergencies or damage to equipments leading to stoppage of process or adverse effects to the environment. Major hazard means that hazard which arises because of the hazardous nature of the substance and its storage quantity equals or exceeds the threshold quantity prescribed in MSIHC Rules 1989. ‘© Major hazards due to isolated storage or industrial activity that has the potential to cause extensive damage to men, materials or environment within or outside the site boundary, ‘+ The Statutes - Manufacture, Storage and Import of Hazardous Chemicals Rules 1989, Rule 68) of the Gujarat Factories (Amendment) Rules 1995 and the Chemical Accidents (EPPR) Rules 1996 have defined the term ‘major accident’. See Chapter-28 for these laws ‘+ The Bhopal disaster has remained at the top and opened eyes throughout the world regarding major chemical hazards, their consequences and controls. All such accidents, differing in the mode of happening and the chemical involved, have some common features as under: 1) They were uncontrolled events caused by fire, explosion or /and toxic release. 2) They resulted in death or/and injury of a large number of people, inside or/and outside the plant, or/and 3) They caused evacuation of people of the 4-surrounding area, or/and 4) They caused heavy damage to plant, property and environment. ‘© The storage, process, use and handling of such flammable, explosive or toxic chemicals pose high potential to cause disasters and are normally referred as major hazards. + Their potential is due to their inherent nature (property) of the chemicals, their quantity, type of process, way of handling or sudden failure of some part of the plant including vessel, equipment, fitting, pipe and vehicle. The main objectives of major hazard control system are: 1) To distinguish between minor and major accident potential and to set priority for identification and inspection of major hazard works first or more frequently. 2) To define and list the hazardous processes to identify the unit as MAH installation, ee —ommnemeoed, Page 1 of 119ee Viral Panchal [email protected] Safety in Chemical Industries PDIS-103 ‘To define hazardous chemical by defining its fire, explosion and toxicity criteria and to define their threshold quantities for storage and use to classify the work as MAH installation. 4) To make, enact and implement the law for MAH chemical works or isolated storage by providing statutory provisions and requirements. 5) To identify the major hazards, developing and utilising the special techniques like hazard and risk assessment, HAZOP, FTA, BTA, consequence analysis, vulnerability analysis, environmental impact assessment etc. as mentioned earlier and carrying out plant safety inspection by various methods mentioned in Part 2 & 4 of this Chapter. 6) To take all possible preventive measures based on identified major hazards to prevent the causes of such hazardous events. Training and education may be incorporated. 7) To foresee the consequences on the workers, public and environment in case if any possible major accident may occur, and to work outan emergency action plan to control and mitigate the effects, Safe operation of MAH installation Design, manufacture and assembly of components, 2. Process control, 3. Safety systems (sensors, controllers, pressure- relief, emergency shutdown, bunds, water- spray, fire detector etc.), 4, Monitoring of safety-related components and systems, Inspection, maintenance and repair, Effects of change, ‘Training of workers, exe Supervision 9. Control of contract work 2. Explain the function of following. December 2017, December 2018, May 2019 1) Overflow Pipe * For the overfilling safety a safe overflow pipe Is required. Its diameter should be slightly more than the inlet pipe diameter so that the overflow will be maintained if inlet flowis continued. ‘+ Ifthe Fundamentals of Industrial Safety and Health 18- 39 Safety in Chemical Industry diameter of the overflow pipe is smaller than that of the inlet pipe, continuing overflow may reach up to the top (may enter the vent) and damage the tank if the pressure is excessive, Connection of the overflow pipe should be 2 to 3 inches below the roof joint so that the material will come out (overflow) leaving some air space Page 2 of 119 —ommnemeoed,ee Viral Panchal [email protected] Safety in Chemical Industries PDIS-103 under the roof and the tank will never be subjected to the filling pressure. The overflow pipe should be extended unto bottom to disallow any free fall of the material and to discharge it in the dyke or any container safely. If the liquid is fuming or contains less toxic or less flammable vapour it should have a valve or a bend with water sealing arrangement (if water is permissible) so that during normal condition vapour will not come out from the overflow pipe. The valve will be open only at the time of filling and closed when the filling is over. HCl vapour should be passed (scrubbed) in water and oleum vapour (SO) in sulphuric acid. In process area, an overflow pipe ofa measuring tank or day tank should be connected with a return line to the storage tank or some other container for safe discharge. Tanks of pressurized gases or highly toxic or highly flammable material in bulk may not have overflow pipe. Instead, they will have high (safe) level alarm and feed pump trip device to stop the feed pump automatically at that level. The level alarm and feed-trip device (interlock) are a substitute of overflow pipe but if this device fails, an accident is possible. A simple overflow pipe isa safer engineering control. However, the judgement depends on many other factors (eg, type and quantity of material, storing parameters, flow, hazard, other safety, instrumentation and control etc.) and technical requirements. 2) Vent Pipe December 2012, December 2017, May 2019 While filling a tank, air has to come out. A vent pipe at the top is required for this, purpose. Itis also useful to depressurize the vessel before opening it. Its diameter should be sufficient for easy escape of the air. Vent pipe may have a bend or roof to prevent outside thing (rain, bird etc.) going inside. Vent pipe should have wire mesh, flame arrester or breather valve if any flammable content is in the tank. They should be kept clean to avoid choking. Normally flame arrester is suggested when the flash point of the content is below 23, °C. When explosive air mixture with vapor pressure is inside the tank, breather valve and flame arrester both are required. Flame arrester will disallow any spark to enter inside. Vent with breather valve or safety valve is required when the boiling point of the content is below atmospheric temperature. When the content is flammable, nitrogen blanketingis necessary otherwise inhalation of the breather valve will take air inside which may form explosive air mixture. To avoid such situation, large diameter tank has a floating roof just floating on the surface of the liquid (flammable), thus disallowing any air gap. Page 3 of 119 —ommnemeoed,L------ Viral Panchal [email protected] + Vent cooler (condenser cools the vent content and sends the liquid back to the vessel or receiver (e.g, methylene chloride). * Vent heater or pipe tracing (i mall diameter limpet steam pipe or coil is required to heat the content which can freeze on cooling (at ambient temperature) eg, phthalic anhydride. ‘© If the gas or vapor is toxic or corrosive, vent is connected with an appropriate scrubber, flare or incinerator. © Ifa flammable material isto be filled ina tank an inert gas (e.g, N2) purging is required before filling the material and inert gas blanketing after filling the material. * Where there is a possibility of vent choking due to sublimation or polymerization of the content inside, instead of vent pipe, safety valve or another device is necessary. ‘© In transferring pressurized gases like chlorine, ammonia, LPG, open vent is not possible and it is connected as a return line in a closed circuit and the vent valve is closed after filling up the tank. 3) Dyke or bund * This is required to restrict the spread of the leaking material, to safely contain within its periphery and to restrict the surface area of the leaking material in order to reduce its evaporation and for ease of firefighting or other emergency control activity. The contained material can be safely disposed off or ifit is burning, it can be extinguished casily by reaching up to dyke wall. If there is no dyke (or bund) the leaking material can come on the road or go in the plant and make more damage, ‘* Byppartition walls in dyke, reactive chemicals or chemicals of different flash points can be kept segregated. + Dyke wall should be safe, sound and leak proof. Its floor should have a slope with a pit in corner to provide a discharge valve which should be opened only when the rain water or the stored (leaked) chemical is to be safely discharged. + Dyke is always required if the liquid is stored at the atmospheric or low pressure and temperature. Refrigerated chemical when leaks, it remains liquid till it reaches its boiling point. Therefore, dyke is required for it.e.,, refrigerated ammonia. + For highly volatile gases or gases at high pressure, dyke Is not much useful and wire fencing is provided at a safe distance. For example, LPG, NGL, butane, butadiene, propane, ethane, methane, ethylene, ethylene oxide, hydrogen, acetaldehyde etc. are kept under vapor pressure where at the time of leakage, they spread rapidly and therefore their tanks are kept in open at a safe distance with fencing on four sides. Page 4 of 119 —ommnemeoed,| ‘+ The floor under such tank is given a slope so that dripping liquid may run away to avoid fire just underneath the tank. © While opening dyke discharge valve ofa flammable material, spark should be avoided otherwise fire can travel inside the dyke and catch the tank, ‘* Where possibility of explosion is there, impact or blast wall (thick, sound) should be provided near the tank. 4) Earthing and Bonding ‘© Electric systems and equipment should be earthed with resistance of 4 ohms or a value that ensures the safe operation of the protective device in the circuit whichever is lower. all non-current carrying metallic parts of electric apparatus or other metallic objects should be earthed with resistance of 10 ohms. + Alljoints in pipelines, valves, plants, storage tanks, associated facil jesand equipment for petroleum shall be electrically bonded with the resistance value between each joint not exceeding I ohm, 3. Materials Safety Data Sheet (MSDS) june 2011, June 2012, December 2011, December 2012, June 2013, May 2017, December 2017, December 2018, May 2018, May 2019 A. Format of MSDS: For proper identification of material hazards a material safety data sheet should be prepared and supplied with each chemical so that its safety precautions can be well understood. A specimen form is given below: 1) Chemical identity: 1. Name of the Chemical Formula ‘Synonyms ‘Trade name Chemical Classification Regulated identification Shipping Name, Codes/Label CAS No. pena a ren UN No. 10. ADR No. 111, Hazchem (BAC) No. 12, Hazardous Waste ID No. Viral Panchal Page 5 of 119 [email protected] eeL------ 13. Hazardous Ingredients and CAS No. 2) Physical & Chemical Data: 1. Appearance, State, Odour ete. 2. Specific gravity (Water = 1) 3. Vapour density (air = 1) 4. Boiling point 5. Melting/Freezing point 6. Vapour pressure 7. Solubility in water 8. Scrubbing/Neutralising/Inactivating media 9. pH 10. Others 3) Fire & Explosion Hazard Data: 1. Flash point 2. Autoignition Temperature 3, Flammable limits: LEL/UEL 4, ‘TDG Flammability 5. Explosion Sensitivity to Impact 6. Explosion Sensitivity to static electricity 7. Explosive material 8. Flammable material 9, Combustible and flammable Liquid 10. Pyrophoric material 11. Hazardous Combustion products 12, Hazardous Polymerisation 13, Corrosive material 14, Organic Peroxide 15. Oxidiser 16, Others 4) Reactivity Data: 1. Chemical stability 2. Incompatibility (Materials to avoid) 3. Reactivity 4. Hazardous reaction products Viral Panchal [email protected] Page 6 of 119 —ommnemeoed,5) Health Hazard Data: 1, TLV (ACGIH) 2. STEL/SET 3. LC50 or LDSO 4. Odour threshold 5. Caromogen? Poison? Liberates poisonous fume? 6. Routes of entry 7. Body parts that may be affected 8. Effects of exposure and symptoms 9. Emergency and first aid treatment 10. Engineering controls necessary for safe handling 11. NFPA Hazard signals 12, Special Health hazards. 6) Preventive Measures: 1. Ventilation required and type 2. Personal protective equipment required and type 3, Handling and storage precautions 7) Emergency and First-aid Measure: 1. Steps to be taken in case material is released or spilled. 2. Waste disposal method for solid, liquid and gaseous waste. 3. Fire, extinguishing media, special procedures and Unusual hazards. 4. Exposure - First-aid measures. Antidotes, Dosages. 8) Additional Information / References 9) Manufacturer / Supplier's Data: 1, Name of Firm 2. Mailing address 3. Telephone/Telex/Fax Nos. 4, Telegraphic address 5. Contact person in emergency 6. Local bodies involved 7. Standard packing 8, ‘Tremcard Details / Ref. 9. Other 10)Disel Viral Panchal [email protected] i —ommnemeoed, Page 7 of 119—ommnemeoed, 4. Eco Marking June 2011, December 2011, June 2012, December 2012, May 2017, December 2017, December 2018, May 2019 Eco mark is a certification mark issued by the Bureau of Indian Standards (BIS) for products which are ecologically safe and adheres to the standards prescribed by the BIS. It was first issued in 1991 by a resolution. It is issued by the Ministry of Environment and Forests. Products that meet the prescribed environmental criteria, as well as quality standards set by BIS, will be issued the ECOMARK label. Objectives of ECOMARK Label Scheme: 1) To offer an incentive to producers and importers to reduce the adverse impact of their products on the environment. 2) Toreward good initiatives companies, takein order to reduce the adverse environmental impact of their products, 3) To encourage consumers to be more environmentally aware in their day-to-day lives and urge them to take into account environmental factors also before making a purchase decision. 4) To promote environmentally-safe products among citizens. 5) To improve environmental quality and promote sustainable management of resources, 5. U.N. Number June 2011 UN classification June 2012, June 2013, May 2017 ‘The UN Globally Harmonized System of Classification and Labeling of Chemicals (GHS) is an international system created by the UN to address the classification of chemicals by types of hazard and harmonize hazard communication elements, including labels and safety data sheets. It aims at providing a basis for harmonization of rules and regulations on chemicals at national, regional and worldwide level, an important factor also for trade facilitation. GHS has been introduced to many countries /regions such as Europe, USA, China, Japan and Korea, ete via their own legislation or standards. UN GHS comprises standards for: ‘Classification of chemicals based on their hazards; ‘© Labeling requirements; ‘Safety Data Sheet Requirements; Viral Panchal Page 8 of 119 [email protected] eeUN (United Nations) Classification No: Class A,B, & C. Class; 1. Explosive Class; 2. Non-flammable & flammable gases. Class: 3. Flammable liquids Class: 4, Flammable solids (Readily combustible) spontaneously combustible substances, water- reactive substances Class: 5. Oxidizing materials Class; 6 Poisonous materials (class A, B & C Poisonous or toxic substances) Class; 7. Radioactive materials—white |, Yellow II or Yellow Ill Class; 8 Corrosive materials -Acids, corrosive liquids and alkaline caustic liquids Class; 9, Miscellaneous hazardous materials (These are materials which during transportation present a danger not covered by other classes 6. Safety & Risk Phrases June 2011 Regulation 9 of the CHIP (Chemicals Hazards Information and Packaging) Regulation, 1993, gives requirements for the labelling of substances and preparations dangerous for supply. These include the name and address of the supplier, information about the substance, symbols and risk and safety phrases L 38 (Approved Guide to the Guidance and Labelling of Substances an (j Preparations Dangerous for Supply) gives guidelines particularly on 1) the classification by physico-chemical properties, health effects and environmental effects; and 2) labelling by risk and safety phrases. These phrases are represented by number and their specific meaning indicating type of hazard in brief, Some phrases are represented by combined numbers. Safety Phrases Safety phrases, or S-phrases, consist of the letter $ followed by a number. S-phrases denote the appropriate safety precautions and measures to take in order to safely work with hazardous chemicals in the workplace. As the Globally Harmonized System of Classification and Labelling of Chemicals (GHS) is implemented, safety phrases (S-phrases) are being phased out in favour of hazard statements and precautionary statements. Ss 1. Keep locked up S + 2. Keep outof the reach of children S$: 3. Keep ina cool place S + 4. Keep away from living quarters S + 5. Keep contents under .. (appropriate liquid to be specified by the manufacturer) S : 6. Keep under ... (inert gas to be specified by the manufacturer) Si 7. Keep container tightly closed S$: 8 Keep container dry S + 9. Keep container in a well-ventilated place S + 10. Keep contents wet Viral Panchal Page 9 of 119 [email protected] ee —ommnemeoed,Risk Phrases Rephrases, also known as risk phrases, specify the particular danger(s) of a hazardous substance. The European Union (EU) currently requires that R-phrases appear on each label and MSDS data sheet for hazardous substances; however, both risk phrases and safety phrases (also known as S-phrases) are being phased out under the implementation of the Globally Harmonized System of Classification and Labelling of Chemicals (GHS). R i: 11, Explosive when dry R_: 12, Risk of explosion by shock, friction, fire or other sources of ignition R : 13, Extreme risk of explosion by shock, friction, fire or other sources of ignition R_: 14, Forms very sensitive explosive metallic compounds R_ : 15. Heating may cause an explosion R_: 16, Explosive with or without contact with air Ro: 17, May cause fire R_ + 18. Contact with combustible material may cause fire R_: 19, Explosive when mixed with combustible material R : 20, Flammable 7. Explain the Terms 1) STEL June 2011, December 2011, December 2018, May 2019 © STEL (Short Term Exposure Limit) ‘+ The maximum concentration to which workers may be exposed for a short period of time (15 minutes). 2) TWA June 2011, December 2011, December 2018, May 2019 3) PELs + Permissible Exposure Limits ‘* Specifies the maximum amount or concentration of a chemical to which a worker may be exposed. 4) TLVs December 2012, June 2013, May 2018 + Threshold Limit Values (TLVs) + Prepared by ACGIH volunteer scientists, * Denotes the level of exposure that nearly all workers can experience without an unreasonable risk of disease or injury. ‘+ Anadvisory limit; not enforceable by law * Generally, can be defined as ceiling limits, short-term exposure limits, and/or time- weighted averages + Usually equivalent to PELs Viral Panchal Page 10 of 119 [email protected] ee —ommnemeoed,6) n 8) ] L------ Safety in Chemical Industries PDIS-103 Hazard December 2012 Hazard is an inherent characteristicina materials, machinery or activity that can manifest in the form of exposure to the individual or environment leading to accident. A hazard is a potential source of harm. Substances, events, or circumstances can constitute hazards when their nature would allow them, even just theoretically, to cause damage to health, life, property, or any other interest of value. Flash Point December 2012, May 2018 Itis the lowest temperature at which a material gives off enough vapour near its surface to forma flammable air vapour (gas) mixture so that itcan be ignited ifa spark is available. ‘The lower flesh point indicates higher hazard as it can cause fire at a lower temperature. Itis expressed as Closed Cup (CC) or Open Cup (OC). CC value is slightly less than the OC value. Flammable range December 2012 Mixtures of dispersed combustible materials (such as gaseous or vaporized fuels, and some dusts) and oxygen in the air will burn only if the fuel concentration lies within well- defined lower and upper bounds determined experimentally, referred to as flammability mits or explosive limits. IDLH June 2011, December 2012, June 2013, December 2017, December 2018, May 2019 ‘+ Immediately Dangerous to Life or Health ‘* Concentration immediately dangerous to life or health from which a worker could escape without any escape-impairing symptom or any irreversible health effect (NIOSH /osHA). * It is a concentration at which a person can escape without the use of a respirator ‘within 30 minutes. This is used in selecting type of respirator etc. LD June 2013 * LD stands for "Lethal Dose”. ‘+ LD50 is the amount of a material, given all at once, which causes the death of 50% (one half) of a group of test animals. ‘+ The LDS0 is one way to measure the short-term poisoning potential (acute toxicity) of material * Toxicologists can use many kinds of animals but most often testing is done with rats and mice. * The LDSO can be found for any route of entry or administration but dermal (applied to the skin) and oral (given by mouth) administration methods are the most common. Viral Panchal Page 11 of 119 [email protected] —ommnemeoed,| ‘+ It is usually expressed as the amount of chemical administered (e.g, milligrams) per100 grams (for smaller animals) or per kilogram (for bigger test subjects) of the bodyweight of the test animal. 10)BLEVE June 2011, December 2017, December 2018, May 2019 Boiling Liquid Expanding Vapor Explosion 11)RELs * Recommended Exposure Limits © Recommended by NIOSH ‘Indicates the concentration of a substance to which a worker can be exposed for up toa 10hour workday during a 40-hour work week without adverse effects, however, sometimes based on technical feasibility © Based on animal and human studies ‘© Generally expressed as a ceiling limit, short-term exposure limit, or a time-weighted Average. * Often more conservative than PELs and TLVs 12)WEELs © Workplace Environmental Exposure Limits () + Developed by AIHA volunteers Advisory limits; not enforceable by law ‘© Typically developed for chemicals that are not widely used or for which little toxicity information is available 43)¢DL ‘© Company-Developed Limits * Developed by company scientists + Advisory limits; not enforceable by law * Usually based on only short-term studies of animals, * Generally intended for internal company use and sometimes for the customers 14) SCBA June 2013, December 2017, December 2018, May 2019 Self-contained breathing apparatus 15)UEL June 2013 Upper Explosive Limit 16)PLC June 2013, May 2017 Programmable logic Controllers 17)MPWP June 2013, December 2017, December 2018, May 2019 + Maximum Permissible Working Pressure Viral Panchal Page 12 of 119 [email protected] ee+ pressure vessel or plant is permitted to be operated or used under this rule and is, determined by the technical requirement of the process. 18)TREM ‘Transport emergency cards 19)PFD June 2013 Process Flow Diagrams 20)PVRV June 2011, May 2017 Pressure /Vacuum Relief Valve 21)P & ID June 2011, May 2017, May 2018 Process (Piping) and Instrumentation Diagram 22)NRV June 2011, May 2017 Non-Return Valve 23)NDI June 2013 National Democratic Institute 24)DCS May 2017, December 2017, December 2018, May 2019 Distributed Controlled System 25)DGFASLI May 2017 Directorate General of Factory Advisory Service & Labour Institute 26)MSTHCR May 2017 Manufacture, Storage & Import of Hazardous Chemicals Rules 27)MIC May 2017 ‘+ Minimum Inhibitory Concentration * The minimum (or minimal) inhibitory concentration (MIC) is the lowest concentration of a specific chemical that inhibits the growth of a specific microorganism. This term typically applies to chemicals called antibiotics, drugs that kill bacteria, and thus microorganisms called bacteria, The MIC Is typically stated in micrograms/miltiliter 28) AFFF June 2011, May 2017 Aqueous Film Forming Foam, Aqueous Fire Fighting Foam 29) BARC May 2017 Bhabha Atomic Research Centre 30)GPCB May 2017 Gujrat Pollution Control Board 31) PESO May 2017 Petroleum and Explosives Safety Organization —ommnemeoed, Viral Panchal [email protected] i ee Page 13 of 11932)Rem June 2011, May 2017 Rapid Bye Movement 33) TIC May 2017 ‘Temperature Indicator Controller 34)TWA December 2017, December 2018, May 2019 + Time-Weighted Average * The average concentration to which workers may be exposed: for a normal, 8-hour workday. 35) LEL December 2017, December 2018, May 2019 ‘+ Lower Explosive Limit * The Lower Explosive Limit (LEL) is the lowest concentration of a gas or vapour that will burn in air. The Lower Explosive Limit (LEL) varies from gas to gas, but for most flammable gases itis less than 5% by volume. 36)IR May 2018-Infrared 37)IRC May 2018-Road Safety Codes 38) CNG May 2018-Compressed Natural Gas 39)LNG May 2018-Liquefied natural gas 40)PNG May 2018-Pipe lined Natural Gas 41) PLC-Programmable logic Controllers 42) NFPA-National Fire Protection Association 43)SCADA-Supervisor Controlled & Administered Data Acquisition 44)PSV-Pressure Safety Valve 45)TIC-Temperature Indicator Controller 46)LIC -Level Indicator Controller A7)PIC- Pressure Indicator Controller 48) PRV - Pressure Relief Valve 49)DPC - Differential Pressure Cell 50)TDG - Transport of Dangerous Goods 51)MSDS~ Material Safety Data Sheet 52)EPR - Environment Protection Rules 53)EIA - Environment Impact Assessments 54)EPA — Environment Protection Act 55)MCC - Motor Control Centres 56)HRSG - Heat Recovery Steam Generation 57)DISH - Directorate of Industrial Safety & Health —ommnemeoed, Viral Panchal [email protected] i Page 14 of 119ee 58)KOD - Knock out Drum 59)PCV - Pressure Control Valve 8. NEPA Classification June 2011, December 2011, June 2012, June 2013, June 2013, May 2017, December 2017, May 2018, December 2018, May 2019 Explain NEPA Diamond with color code in Details + The National Fire Protection Association of US developed a hazard identification system for emergency responders called NFPA Diamond. + The NFPA diamond provides a quick visual representation of the health hazard, flammability, reactivity, and special hazards thata chemical may pose during any accident. or mishappening. ‘+ The NFPA diamond consists of four divisions which are typically color-coded with red on top indicating flammability, blue on the left indicating level of health hazard, yellow on the right for chemical reactivity, and white containing codes for special hazards, ‘+ Each division is represented using a numbering scale ranging from 0 to 4. A value of 0 means that the material poses essentially no hazard, whereas a rating of 4 indicates extreme danger. © The specifications of each division classification are listed below. Materials that will not burn under typical fire conditions (e.g, Carbon tetrachloride), including intrinsically non-combustible materials such as concrete, stone, and sand. 0 | Materials that will not burn in air when exposed toa temperature of 820°C (1,500 °F) for aperiod of 5 minutes. Materials that require considerable preheating, under all ambient temperature conditions, before ignition and combustion can occur (e.g, mineral oll, ammonia) Includes some finely 1 | divided suspended solids that do not require heating before ignition can occur. Flash point, at or above 93.3 °C (200 °F). Must be moderately heated or exposed to relatively high ambient temperature before 2__| ignition can occur (e.g, diesel fuel, paper, sulfur and multiple finely divided suspended Viral Panchal Page 15 of 119 [email protected] —ommnemeoed,solids that do not require heating before ig 93.3 °C (100 and 200 °F), jon can occur), Flash point between 37.8 and Liquids and solids (Including finely divided suspended solids) that can be ignited under almost all ambient temperature conditions (e.g, gasoline, acetone). Liquids having a flash [email protected] L------ 3 | point below 22.8°C (73 °F) and having a boiling point at or above 37.8°C (100 °F) or having a flash point between 22.8 and 37.8 °C (73 and 100 °F). Will rapidly or completely vaporize at normal atmospheric pressure and temperature, or 4_| #8 readily dispersed in air and will burn readily (e.g. acetylene, propane, hydrogen gas, diborane).Includes pyrophoric substances. Flash point below room temperature at 22.8 °C (73°F). | Poses no health hazard, no precautions necessary and would offer no hazard beyond that of ordinary combustible materials (e.g, wood, paper) 1 _| Exposure would cause initation with only minor residual injury (eg. acetone, sodium bromate, potassium chloride) Intense or continued but not chronic exposure could cause temporary incapacitation or 2 _| possible residual injury (e.g, diethyl ether, ammonium phosphate, carbon dioxide) 43 _| Short exposure could cause serious temporary or moderate residual injury (eg, liquid hydrogen, sulfuric acid) 4_| Wery short exposure could cause death or major residual Injury (eg, hydrogen cyanide, phosgene, methyl isocyanate, hydrofluoric acid) 9 Normally stable, even under fire exposure conditions, and is not reactive with water (e.g, helium, N2) 1 | Normally stable, but can become unstable at elevated temperatures and pressures (eg, propene) Undergoes violent chemical change at elevated temperatures and pressures, reacts 2 _| violently with water, or may form explosive mixtures with water (e.g. white phosphorus, potassium, sodium) 3 _| Capable of detonation or explosive decomposition but requires a strong initiating source, must be heated under confinement before initiation, reacts explosively with water, or will detonate if severely shocked (e.g, ammonium nitrate, hydrogen peroxide) Readily capable of detonation or explosive decomposition at normal temperatures and 4 _| pressures (eg. chlorine dioxide, manganese heptoxide, azidoazide azide, TNT) Special Hazard (White) ox. | Oxidizer that allows chemicals to burn without an air supply (eg, ammonium nitrate, hydrogen peroxide). w | Reacts with water in an unusual or dangerous manner (eg. cesium, sodium, diborane, sulfuric acid). ‘Simple asphyxiate gas (specifically helium, nitrogen, neon, argon) The SA symbol shall also sa__| be used for liquefied carbon dioxide vapor withdrawal systems and where large quantities of dry ice are used in confined areas COR | Corrosive chemical; strong acid or base (e.g, sulfuric acid, potassium hydroxide) ACID | Acid Viral Panchal Page 16 of 119 —ommnemeoed,ALK Alkaline —ommnemeoed, BIO Biological Hazard Radioactive Hazard cRYO Cryogenic substance L------ Viral Panchal [email protected] In the past some chemical manufacturers used NFPA diamonds on their products, butnow labels are required to use GHS labelling. 9. Disclosure of information to the worker by the occupier of a factory involving a hazardous process. May 2019, December 2018 Information to be given by occupier to workers in a hazardous process industry. ‘The occupier of a factory governed under Major Accident Hazard (MAH) category shall notify to all workers some information in relation to handling of hazardous materials or substance in the manufacturing, handling, storage, transportation or any other activity. Requirements under section 41-B, 41-C and 41-H of Indian Factories Act. ¥ 41-B: Compulsory disclosure of information to workers. ¥ 41-C: Specific responsibility of the occupier in relation to hazardous processes. ¥ 1-H: Right of workers to warn about imminent danger. Such information under 68-k, GFR, requires: 1. MSDSas per R68Qin respect of every hazard’s substance handled in the manufacture, transportation and storage in the factory. Their location and availability to the workers, List of hazardous processes carried on in the factory. Physical and health hazards arising from the exposure to or handling of substances. Safety and control measures taken for physical and health hazard. se ey Measures to be taken by the workers to ensure safe handling, storage, and transportation of hazardous substances, PPE required to be used by the workers. > 7. Meaning of various labels and marking on the containers of hazardous substance. 8. Signs and symptoms likely to be manifested on exposure to hazardous substances and to whom to report. 9. Measure to remove spillage or leakage of hazardous substances. 10. Role of the workers in the emergency plan and evacuation procedures. 11. Any other information necessary to ensure safety and health of workers like; 12. Quantity of solid, liquid and gaseous was generated per day, their characteristic and methods of their treatment, and disposal. Page 17 of 119ee Viral Panchal [email protected] Safety in Chemical Industries PDIS-103 13. The booklets, leaflets and the cautionary notice of displayed in the factory shall be in the language understood by the majority of the workers and also explain to them, 14. The Chief Inspector may direct occupier 10. EIA Report June 2011, December 2011, June 2013, May 2017, May 2017 Definition: As per "Environmental protection act-1986" promulgated through parliament legislation and governed by the ministry of Environment & Forests & Wild life, Govt, of India. Environmental Impact Assessment (EIA) as a tool used to identify the environmental, social and economic impacts of a project prior to decision-making, It aims to predict environmental impacts at an early stage in project planning and design, find ways and means to reduce adverse impacts, shape projects to suit the local environment and present the predictions and, options to decision-makers. Environmental Impact Assessment (EIA) is a process of evaluating the likely environmental impacts of a proposed project or development, taking into account inter-related socio- econor cultural and human-health impacts, both beneficial and adverse. By using EIA both environmental and economic benefits can be achieved, such as reduced cost and time of project implementation and design, avoided treatment/clean-up costs and impacts of laws and regulations. It is mandatory on all Hazardous chemical units to conduct an Environmental Impact Assessment (EIA) through a competent independent agency and submit the report prior to the execution of a project for new installation or expansion /addition /alteration of an existing facility, Objectives of Environmental Impact Assessment (EIA): EIA basically concerned with identifying& assessing the environmental consequences of developmental projects, plans, programs & policies in an attempt to ensure that the ‘best’ alternative for development is selected. Identifying and assessing the environmental impacts of development are complex tasks because of the diversity of impact which may be caused by human interference with environmental & social systems. Identification & assessment of these impacts require collection/ manipulation of large amounts of data, Although legislation and practice vary around the world, the fundamental components of an. EIA would necessarily involve the following stag 1) Sereening to determine which projects or developments require a full or partial impact assessment study; Page 18 of 119 —ommnemeoed,Viral Panchal [email protected] Safety in Chemical Industries PDIS-103 Scoping to identify which potential impacts are relevant to assess (based on legislative requirements, international conventions, expert knowledge and public involvement), to identify alternative solutions that avoid, mitigate or compensate adverse impacts on biodiversity (including the option of not proceeding with the development, finding alternative designs or sites which avoid the impacts, incorporating safeguards in the design of the project, or providing compensation for adverse impacts), and finally to derive terms of reference for the impact assessment; 3) Assessment and evaluation of impacts and development of alternatives, to predict and identify the likely environmental impacts of a proposed project or development, including the detailed elaboration of altern: ives; 4) Reporting the Environmental Impact Statement (EIS) or EIA report, including an environmental management plan (EMP), and a non-technical summary for the general audience. 5) Review of the Environmental Impact Statement (EIS), based on the terms of reference (scoping) and public (including authority) participation. 6) Decision-making on whether to approve the project or not, and under what conditions; and 7) Monitoring, compliance, enforcement and environmental auditing. Monitor whether the predicted impacts and proposed mitigation measures occur as defined In the EMP. Verify the compliance of proponent with the EMP, to ensure that unpredicted impacts or failed mitigation measures are identified and addressed ina timely fashion Important Information to Be Furnished in An EIA Report: + A detailed description of the process activity inclusive of information &technical data adequate to permit a careful assessment of Environmental Impact. ‘* Discussion on the probable impact on the environment including any impact on ecological systems and any direct or indirect consequence that may result from the proposed action. ‘© Any adverse environmental impact that cannot be controlled or avoided. ‘+ Alternatives to the proposed action that might avoid some or all the adverse environmental effects, including an analysis of the costs and environmental impacts of these alternatives * Afinal impact statement must include a discussion of the problems and objectives raised by other federal, state, and local agencies, private organizations and individuals during the draft statement review process. ee Page 19 of 119 —ommnemeoed,Steps Towards EIA: Impact identification, Prediction, Measurement, Evaluation and/or Interpretation. Identification of monitoring requirements & mitigating measures. Communication of Impact Information to Users such as Decision Makers, &Members of Public. 11. HAZCHEM codification June 2011, December 2011, June 2013, May 2017, May 2018 Hazchem (hazardous chemical) Code or BAC (Emergency Action Code) is an emergency code confirmed by the Health & Safety Executive, UK. ‘The HAZCHEM code (also called Emergency Action Code) gives 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 a hazardous substance. v ‘The HAZCHEM code for any chemical consists of three parts on an orange background. (a) Anumber 1 to 4. (b) A capital letter P to T or W to Z. (c) An optional letter E. A. Significance of Nos. 1 to 4 - (Types of extinguishers to be used): + Water jet + Water fog produced by a high-pressure atomizing jet directed upwards * Foam (Normal protein foam as used by all fire brigades) © Dryagent—commonly known as Dry chemical powder and vaporizing liquids are also in this category. B. Significance of Letters - P to T and W to Z (Except Q): Viral Panchal [email protected] L------ © Materials coded from P to T are those which may in an emergency be diluted & flushed down the nearest drain, © Materials coded from W to Z may not be diluted and must be contained, ‘+ Materials P & R, and W & X are those whose vapor or products of combustion are injurious to the human skin and for which full impervious protective clothing (generally nitride rubber) as well as (Self Contained Breathing Apparatus (SCBA) must be provided. + Materials § & T and Y & Z are those for which Breathing Apparatus (BA)alone is necessary. BA is frequently necessary for work in smoke and oxygen deficient atmospheres even when the chemical itself presents no hazard. Page 20 of 119 —ommnemeoed,c ‘+ Materials P,S, W& Y are capable of reacting violently either alone or with some other substance (e. g, water, air, metals or combustible materials) with which they may come in contact. Significance of Letters -E * The final and optional letter E calls for evacuation of all persons other than the fire brigade to 2 minimum distance of 200 meters from the incident spot, whether fire or spillage. This is used for materials which may be particularly hazardous, e,, explosive, super toxic, biologically active or radioactive. © EXAMPLE: Hazchem No. of Sodium cyanide 4X is and that of Vinyl chloride is 2WE. 12, Medical Examination and health records of workers employed in Hazardous processes, December 2011, December 2017, May 2019 Following provisions are given in the Factory act and corresponding Gujarat Factory Rules(68-1); Sub rule No. 1. Workers employed in a "Hazardous process" shall be medically examined by a qualified Factory Medical Officer (FMO), in the following manner. 0 2 3) 4 Viral Panchal [email protected] L------ Once before employment, to ascertain the physical fitness of the person to carry out the assigned job. Once in a period of 6 months, to ensure the health status of all the workers in respect of occupational health hazards to which they are exposed and also in cases where in the opinion of the FMO itis necessary to do so at shorter interval in respect of any worker. Examination by the CS within 15 days of first employment. It includes hematological test, Para nitrophenol in urine test, pulmonary function test and CNS test. Employment after such fitness certificate (by the Cs) only. The details of the pre-employment and subsequent medical examinations carried out as, a fore said shall be recorded in a register as per Form No. 32. ‘+ No person shall be employed for the first time without certificate of fitness in Form No, 33 granted by the FMO. ‘+ If the FMO declares a person “unfit” for being employed in any process covered under Sub rule (1) above, such a person shall have the right to appeal to the Factory inspector who shall refer the matter to the certifying surgeon whose opinion shall be final in this regard. * If the Inspector is also a certifying surgeon, then he may dispose of the application himself. Page 21 of 119 —ommnemeoed,Viral Panchal [email protected] * Any findings of the FMO revealing any abnormality or unsuitability of any person employed in the process shall be immediately reported to the ‘© The worker required to undergo medical examination under the said rules and for any medical survey conducted on behalf of the Central or State Government shall not refuse to undergo such examination. * Unfit worker shall be given alternate placement. He can be re-employed in the same process if declared fit by the CS. 13. Disclosure of information to the worker by the occupier of a factory involving a hazardous process. December 2017, May 2019 Information to be given by occupier to worker in a hazardous chemical industry ‘* The occupier of a factory governed under Major Accident Hazard (MAH)category shall notify to all workers following information in relation to handling of hazardous materials, or substance in the manufacture, handling, storage, transportation or any other activity. * Requirements under sections 41B, 41¢ & 41H of Indian factories Act. ‘+ 41B- Compulsory disclosure of information to workers * 416 Specific responsibility of the occupier in relation to Hazardous processes. ‘+ 41H: Right of workers to warn about imminent danger. ‘Such information u/r 68K, GER, requires: 1. Material Safety Data Sheet (MSDS) as per R68Q, in respect of every hazardous substance handled in the manufacture, transportation and storage in the factory. Their location and avallability to the workers. List of hazardous processes carried on in the factory. Physical and health hazards arising from the exposure to or handling of substances. Safety and control measures taken for above hazards. Measures to be taken by the workers to ensure safe handling, storage and transportation of hazardous substances. 6. PPE tobe used by the workers. 7. Meaning of labels and markings on the containers. 8 Signs and symptoms likely to be manifested on exposure to hazardous substances and to whom to report. 9, Measures to remove spillage or leakage of hazardous substances. 10. Role of the workers in the emergency plan and evacuation procedures. 11. Any other information necessary to ensure safety and health of workers. ee Page 22 of 119 —ommnemeoed,Viral Panchal [email protected] 12. Quantity of solid, liquid and gaseous was generated per day, their characteristics and methods of their treatment, and disposal. 13. On-site Emergency Plan and safety measurers required to be taken. This requires separate document. 14. Health Records should be made available the workers. 14. Explain the terms LC50, Explosive limits TLV. June 2012, May 2018 150: + LC stands for "Lethal Concentration”. * LC values usually refer to the concentration of a chemical in air but in environmental studies it can also mean the concentration of a chemical in water. ‘+ For inhalation experiments, the concentration of the chemical in air that kills 50% of the test animals in a given time (usually four hours) is the LCSO value. + LC50 is measured in micrograms (or milligrams) of the material per litre, or parts per million (ppm), of air or water; lower the amount, more toxic the material. * Used in the comparison of toxicities, LC5O values cannot be directly extrapolated from one specie to the other or to humans. '* Also called median lethal concentration or population critical concentration 50. TL: ‘+ Themaximum permissible concentration of a chemical intr in which a person can work for 8 hours continuously without ant harmful effect. 15. Explain the use of Following instruments: 1, Anemometer December 2012, December 2017, December 2018, May 2019 ‘An anemometer is a device used for measuring wind speed and direction. It is also a common weather station instrument. The term is derived from the Greek word anemos, which means wind, and is used to describe any wind speed instrument used in meteorology. 2. Atmometer or Evaporimeter Atmometer or evaporimeter is a scientific instrument used for measuring the rate of water evaporation from a wet surface to the atmosphere, Atmometers are mainly used by farmers and growers to measure evapotranspiration (ET) rates of crops at any field location, 3. Barometer December 2012, December 2017, December 2018, May 2019 A barometer is a scientific instrument that is used to measure air pressure in a certain environment. Pressure tendency can forecast short term changes in the weather. Many ee Page 23 of 119 —ommnemeoed,measurements of air pressure are used within surface weather analysis to help find mmemenmesel surface troughs, pressure systems and frontal boundaries 4. Dosimeter December 2012, December 2017, December 2018, May 2019 Aradiation dosimeter is a device that measures dose uptake of external ionizing radiation. ied worn by the person being monitored when used as a personal dosimeter, and is @ record of the radiation dose received. 5. Hydrometer December 2012, December 2017, December 2018, May 2019 A hydrometer is an instrument used for measuring the relative density of liquids based on the concept of buoyancy. They are typically calibrated and graduated with one or more scales such as specific gravity. 6. Hygrometer December 2012, December 2017, December 2018, May 2019 A hygrometer is an instrument used to measure the amount of water vapor in air, in soil, or in confined spaces. Humidity measurement instruments usually rely on measurements of some other quantities such as temperature, pressure, mass, a mechanical or electrical change in a substance as moisture is absorbed, 7. Manometer December 2012, December 2017, December 2018, May 2019 ‘Manometers are precision instruments that are used to measure pressure, which is the force exerted by a gas or liquid per unit surface area owing to the effects ofthe weight of that gas or liquid from gravity. 8, Rotameter December 2012, December 2017, December 2018, May 2019 A rotameter is a device that measures the volumetric flow rate of fluid in a closed tube. It belongs to a class of meters called variable-area flowmeters, which measure flow rate by allowing the cross-sectional area the fluid travels through to vary, causing a measurable effect. 9, Tensimeter December 2012 ‘Tensimeter an instrument used to compare the vapor pressures of two liquids, usually consisting of two sealed bulbs containing the liquids, each being connected to one limb ofa manometer. 10. Barograph A barograph is a barometer that records the barometric pressure over time in graphical form, This instrument is also used to make a continuous recording of atmospheric pressure, 11. Cryometer A cryometer is a thermometer used to measure very low temperatures of objects. Viral Panchal Page 24 of 119 [email protected]. Bolometer The bolometer is a device used for detecting and measuring the heat and radiation of Microwave energy or RF. It uses the temperature sensitive resistive element who resistance changes with the temperature. 43. Catch pot December 2012, December 2017, December 2018, May 2019 First of all, for those that don't know a catch pots a housing used to remove the bulk of the liquid before a coalescing filter. Sometimes if there is a large quantity or ‘slug’ of liquid it can flood the coalescing filter element and cause carry-over. 14. Bomb calorimeter ‘These are used to test the calorific value of solid and liquid fuels, which are traded based on these values. Fuels such as coal and oil must meet the regulations regarding the total calorific value, quality, and purity of the fuel, Bomb calorimetry can also test liquid fuels, such as gasoline and kerosene. 15. Bourdon Gauge one of the most widely used instruments for measuring the pressure of liquids and gases, ofall kinds, including steam, water, and air up to pressures of 100,000 pounds per square inch, 16. Calorimeter Calorimeter, device for measuring the heat developed during a mechanical, electrical, or chemical reaction, and for calculating the heat capacity of materials, 17. Dilatometer A dilatometer is a precision instrument for the measurement of dimensional changes in material as a function of temperature, Dilatometry can be used to test a wide range of material including traditional and advanced ceramics, glasses, metals, and polymers. 18, Pycnometer An apparatus for determining the density and co-efficient of expansion of a liquid 19. Pyrometer A pyrometer is an instrument that measures temperature remotely, ie. by measuring radiation from the object, without having to be in contact. 20. Salinometer A type of hydrometer used for determining the concentration of salt solutions by measuring their density. 24.Seismograph For recording earthquakes and phenomena associated with them. Viral Panchal Page 25 of 119 [email protected] ee —ommnemeoed,16. 22. Spectro Photometer A photometer for comparing two light radiation wavelength by wavelength. 23. Spherometer For accurate measurement of small thickness, or curvature of spherical surfaces, 24, Thermo barograph For measuring and recording atmospheric temperature and pressure, consisting of a thermograph and barograph. 25. Thermocouple For measurement of temperature 26. Thermograph A self-registering thermometer to record temperature variations during a period of time ona graph. 27. Thermometer For measurement of temperature viz. mercury thermometer, gas thermometer, pyrometer, resistance thermometer, thermocouple, Beckman thermometer, thermometer clinical, thermometer-maximum and minimum. 28. Thermopile For detecting and measuring heat radiation, 29, Thermostat For maintaining a constant temperature by the use of a device that cuts of the supply of heat when the required temperature is exceeded and automatically restores the supply when the temperature falls below that required. 30. Viscometer For the measurement of viscosity. 31, Measuring Vessel December 2012, December 2017, December 2018, May 2019 Some Definitions CAS No.: ‘+ Itis Chemical Abstracts Service number to providea single unique identifier with naming the chemical. ‘+ Eg.CAS No. foracetic acid is 64-19-7. ‘It does not indicate the hazards of a material. Boi g Point: ‘+ Itis that temperature at which the material changes from a liquid to a gas. * Below this point the liquid can evaporate to form vapour but at the BP the change from liquid to vapours faster. Viral Panchal Page 26 of 119 [email protected] ee —ommnemeoed,‘+ This increases the vapour concentration and its pressure. ‘+ This condition poses higher tisk of fire, explosion or toxicity. Melting Point: ‘+ Itis that temperature at which a solid material melts and becomes a liquid. ‘+ This information is useful for storage and handling purpose. ‘* A melted material may distort a container. Freezing Point: ‘Itis that temperature at which a liquid material freezes and becomes solid. ‘This information is useful for storage and handling purpose. ‘* Afrozen material may burst a container. Vapour Pressure: * It is the pressure (mm of Hg) upon atmosphere of the vapour of a material at fixed temperature (e.g. 20°C). ‘+ Higher vapour pressure indicates higher concentration and therefore high hazard due to fire or inhalation. Solubility: ‘+ Itis the ability of material to dissolve in water or other liquid (Solvent). * This information is useful to decide a scrubbing media, spill control or firefighting material and procedure. ‘* Such solvent should not be hazardous. Scrubbing neutralising or inactivating media: ‘© These are those materials (liquids) which dissolve or react with the hazardous material (gas, liquid or solids) to diminish its hazardous exposure e.g. caustic, water etc. ‘If this is not possible, proper absorbent be used eg. sand, sponge rubber etc. Flash Point: ‘Its the lowest temperature at which a material gives off enough vapour near its surface to forma flammable air vapour (gas) mixture so that it can be ignited ifs park isavailable, + The lower flash point indicates higher hazard as it can cause fire at a lower temperature. ‘+ Itis expressed as Closed Cup (CC) or Open Cup (0¢). © CC valueis slightly less than OC value. Auto-ignition Temperature: ‘* _Itis the lowest temperature at which a material begins to burn in air without any contact of spark or flame. During heating if the material decomposes, the decomposed chemical may auto-ignite at some other temperature. Viral Panchal Page 27 of 119 [email protected] ee —ommnemeoed,17. Viral Panchal [email protected] Flammable or Explosive Limits (LEL/UEL): ‘© The lowest concentration (percentage in air) of gas or vapour which will burn or explode if ignited, is called the Lower Explosive (or Flammable) Limit.e, LEL or LFL. ‘+The upper concentration (percentage in air) of gas or vapour which will burner explode if ignite, is called the Upper Explosive (or Flammable) Limite, UEL or UFL. + The range between LEL and UBL is called the Explosive (or Flammable) Range. ‘+ The fire or explosion risk lies within this range but not out of it. ‘© Below LEL the gas-air mixture is too lean to ignite and above UEL itis too rich to ignite. ‘+ Explosimeters are available to detect this range. * Detection should be of percentage of LEL and all safety devices (alarms, controls, trips etc.) should operate well below the LEL. Emergency information panel with Dimensions & Drawing. June 2013 Emergency Information Panel to be Displayed on Road Tanker ‘+ Emergency Information Panel to be displayed on Road Tanker in India, it is mandatory for the vehicles transporting hazardous chemicals to display Emergency Information Panel (EIP) with details and at places as specified under Rule134 of the Central Motor Vehicles Rules, 1989 as shown in the next figure. ‘+ Every goods carriage used for transporting any dangerous or hazardous goods shall be legibly and cons; ously marked with an emergency information panel in each of the three places as specified, so that the emergency information panel faces to each side of the carriage and to its rear and such panel shall contain the following information viz. + Thecorrect tech 50 mm high. ‘+ The United Nations class number for the dangerous goods in letters notes than100 mm high (Rule 137). ‘+ The class label of the dangerous or hazardous goods in the size of not less than250 mm I name of the dangerous or hazardous goods in letters not less than square, + Thename and telephone number of the emergency services to be contacted in the event of fire or any other accident in letters and numerals that are notless than 50mm high and the name and telephone number of the consignor of the dangerous or hazardous goods or of some other person from whom expert information and advice can be obtained concerning the measures that should be taken in the event of emergency. ‘+ Every class label and emergency information panel (E1P) shall be marked on the goods carriage and shall be kept free and clean from obstruction at all times, ee Page 28 of 119 —ommnemeoed,18, Safety in Chemical Industries PDIS-103 One practical problem encountered with the use of EIP is the selection of the substance identification number and the HAZCHEM code to be incorporated in the EIP when a tanker transports different chemicals in different compartments. The solution in such case is to incorporate the word "Multi-load” in the sections of EIP ear marked for "UN Number" and *HAZCHEM" and to label each compartment separately with the UN number and HAZCHEM code corresponding to the chemical in the compartment. ‘* ‘The emergency information panel (EIP) should have dimensions as shown in the next figure. (All dimensions are expressed in millimeters) Hazard Communication System. December 2017, December 2018, May 2019 ¥ Communication is one of the key words in Safety. Y Hazard communication system includes- According to OSHA, the purpose of the Hazard Communication Standard (HCS) is “to ensure that the hazards of all chemicals produced or imported are evaluated and details regarding their hazards are transmitted to employers and employees." The premise behind HCS is that employers and employees have the right to know the hazards and identities of the chemicals they are exposed to and what precautions they can take to protect themselves. 1) Formulation & issue of a Policy on Health & Safety. Nowa daysan integrated policy covering a third important & relevantaspects of Environment is also becoming prominent (ie HSE Policy). The latest provisions for the benefits of industries especially chemical manufacturing units. ‘The OH & S Policy Shall contain or deal with: 1. Declared intention & commitment of the top management to health, safety and environment and compliance of all the relevantstatutes. Viral Panchal Page 29 of 119 [email protected] ee —ommnemeoed,Safety in Chemical Industries PDIS-103 Organizational set up to carry out the declared policy assigning the responsibilities at different levels and Arrangements for making the policy effective. 3, Arrangement for making the policy effective. In particular the policy shall specially the following: 4. Arrangement for participation of worker 2. Intention of taking into account the health & safety performance of individuals at different level while considering thelr career development. 3. Fixing account stability for safety by contracts, sub contacts, transporter or any other services providers entering the factory. 4. Adoption of relevant techniques and methodologies such as audit, risk assessment etc with an execution periodically of minimum two yearto review the status on health, safety and environment followed by compliance of all remedial measures, 5. Stating its intention to integrate health, safety in all decision-making process including those dealing with procurement of plant, equipments, machineries and materials as well as selection, recruitment & placement personnel. 6 Arrangement for communicating, educating and __training/retraining of employees/contractors/other services provider at different levels and the neighbouring public wherever required. 2) Education, training, retraining & awareness programs include utilization of cable, TV network, exhibitions, demonstration classes, journals, bulletins, newsletters etc. 3) Review/discussion of OH & S aspects during management and also joint participative safety committee meetings with workers. 4) Issue of Safety Reports, Safe Operating Procedures (SOP's), Work instructions, Material Safety Data Sheets (MSDS), Product Safety booklets, Transport Emergency (TREM) cards, Emergency Preparedness Plan including mock-up exercises. 5) Qualitative description like health hazard, flammability hazard, reactivity hazard, Blectrical hazard, machinery hazard, fall or slipping hazard etc. 6) Display of Hazard, Warning and Cor indicating signs and posters as shown in fig. 7) TREM CARD (hazard information to be given to drivers of hazardous goods). 8) Safety and Risk Phrases. 19. Answer in a word /phrase/sentence. May 2018, 1) Name two parameters being monitored for Ambient Air? PM1o- Particulate Matter less than 10 microns PMs -Particulate Matter less than 5 microns $0z-Sulphur Dioxide Viral Panchal Page 30 of 119 [email protected] ee —ommnemeoed,