Delivering

Happiness
 NSAT OBJECTIVES

 Help organizations in competence assessment, of

officers.
 Standardize the Safety requirement Process &
Protocols for the Indian Industry.
 To enhance the quality of officers.
 Set a benchmark to assess industrial safety
aptitude & proficiency of aspiring professionals
across India.

Delivering
Happiness
 ASSESSMENT

Technical Skills Leadership

Candidates
Assessment
based on
Goal orientation Problem solving

Communication skills

Delivering
Happiness
 ABOUT NSAT EXAM
•Score card will be issued to the candidate
who have scored more than 50% marks.

Prospective professionals may take NSAT as their

own choice to showcase themselves as better
than others.

Employers may consider NSAT score

professionals for carrier progression .

Delivering
Happiness
 EXAM PATTERN

Language English
No of questions
200 (MCQs with 4 options)
Duration 2 Hrs (120 Min)

10 modules designed by HPCL

Online computer based
Mode
MCQ test (auto-proctored) OH&S –questions

Environment –questions
Exam fee

Delivering
Happiness
 SYLLABUS- designed by HPCL in
accordance with NSC

I. General Aptitude English test, Logical reasoning, Leadership and

IT Proficiency

• II. Occupational Safety • Industrial Safety Management

and Health • Safety In Engineering Industry
• Safety In Construction Industry
• Chemical and process safety Management
• Quality control in OH&S
• Industrial hygiene and Occupational Health
• OH&S Legislation and Standards

III. Environment Legislations,

Environmental Management Systems,
Environmental Monitoring, Waste Management,
Global Warming, Energy Conservation,
Sustainability and Reporting

Delivering
Happiness
 THANK YOU
National Safety Council
…..Your safety is our passion…..

Delivering
Happiness
 NSAT Module III
Section 1- Chemical and Process Safety
Management
 Module 3-chemical and process safety
management

1. Process Safety Management

Process 2. Process Safety Events:

Safety
Managem 3. Process Safety Information
ent
(CCPS)
4. Safe Handling of Hazardous Chemicals

5. Management of Change
 Section 1 : Process Safety Management
(CCPS)
1. Strategic Approaches To Process Safety

Process Management
Safety
Managem 2. Risk Based Process Safety Design And
ent
(CCPS)
Improvement Criteria

3. Introduction To RBPS Management System

Pillars (Main Foundational Blocks)

 Process Safety Incident-which
triggered PSM

1. Flixborough - 1974, 28 fatalities -

Process
Safety
$167MM
Management 2. Seveso - 1976 - Contaminated
Countryside
3. Bhopal - 1984 -2000 fatalities
4. Piper Alpha Plat - 1988 -165 fatalities
 Process Safety Incident-which
triggered PSM

Process
Safety
Management
OSHA Develop PSM in 1991
Process Safety
Management is a
regulation, promulgated
by OSHA, intended to
prevent an incident like
the 1984 Bhopal Disaster

And…to Prevent Release

of:
• Toxic,
• Reactive,
• Flammable, or
• Explosive chemicals

13
Not Only PSM, But RMP

A great many industrial

facilities must comply
with OSHA's Process
Safety Management
(PSM) regulations as
well as EPA Risk
Management Program
(RMP) regulations (

14
 PSM vs. RMP - What’s the Difference?
• PSM- • RMP- Risk Management
• Protects the Workforce
Program
• Protects the Community
• Protects Contractors
• Protects the General
• Protects Visitors to the Public Around the Facility
Facility • Protects Adjacent
• Basically Protects the Facilities Such as Schools
Workplace & Hospitals

Indian law equivalent Indian law equivalent

EIA, environment impact
Manufacturing/storage of analysis
hazardous chemical
MAH 1997
15
The Standard Was Promulgated in 1991
- Is it Working?

16
 Process Safety Incident

1. BP Texas Refinery - 2005 -5 Workers,

US$1.6 billion
Process 2. Bunce field - 2005,
Safety 3. IOCL, Jaipur , 2009 - 12 Killed
Management
4. Deep water Horizon explosion in 2012
5. Beirut Explosion, 2020 - ,218 deaths
 Strategic Approaches to Process Safety Management
Standard
• What should I
s-based
do?
Strategy
Complian
• What do I have to
ce-based do?
Strategy
• How can I
Continuous
improve
Improveme
based on
Process nt-based
my
Safety Strategy
experience?
Management • How can I
Risk-
better
(CCPS) based
manage
Strategy
risk?
Understanding the risk associated with an activity requires answering the following
questions:
• What can go wrong?
• How bad could it be?
• How often might it happen?
 Process Safety Management
“a blend of engineering and management skills focused on preventing
catastrophic accidents and near misses, particularly structural
collapse, explosions, fires and toxic releases associated with loss of
containment of energy or dangerous substances such as chemicals
and petroleum products.”
A management system that is focused on prevention of,
preparedness for, mitigation of, response to, and restoration from of
chemicals or energy from a process associated with a facility. It may
Process
Safety be required by law of regulation or may be a voluntary program.
Management
4 Pillars
• Commit to process safety,
• Understand hazards and risk,
• Manage risk, and
• Learn from experience.
 Risk Based Process Safety Design and Improvement Criteria

Process
Safety
Management
(CCPS)

Pillars – Foundational Blocks

 OSHA Process Safety Design and Improvement Criteria

Process
Safety
Management
(OSHA)

Regulatory

14 ELEMENTS OF PSM
 Commitment to process safety
Commitment to process safety 1st Pillar (Foundational Block)
• Cornerstone of process safety excellence.
• Management commitment has no substitute. The entire organization
must make the same commitment.
• A workforce that is convinced that the organization fully supports safety
as a core value will tend to do the right things, in the right ways, at the
right times, even when no one is looking.
Process
• This behaviour should be consistently nurtured, and celebrated,
Safety throughout the organization.
Management • Once it is embedded in the company culture
(CCPS) • Process safety can help sustain the focus on excellence in the more
technical aspects of process safety.
i. Element – Process Safety Culture
ii. Element – Compliance with Standards
iii. Element – Process Safety Competency
iv. Element – Workforce Involvement
v. Element – Stakeholders Outreach

1st Pillars – Foundational Blocks

 Understanding Hazards and Risks

Organizations that understand hazards and risk are better able

to allocate limited resources in the most effective manner.
Industry experience has demonstrated that businesses using
hazard and risk information to plan, develop, and deploy stable,
lower-risk operations are much more likely to enjoy long term
Process
Safety success.
Management
(CCPS)

i. Element – Process Knowledge Management

ii. Element – Hazard Identification and Risk Analysis

2nd Pillars – Foundational Blocks

 Managing risk
Managing risk focuses on three issues:
1. Prudently operating and maintaining processes that pose the risk.
2. Managing changes to those processes to ensure that the risk
remains tolerable.
3. Preparing for, responding to, and managing incidents that do occur.
Managing risk helps a company or a facility deploy management
systems that help sustain long- term, incident-free, and profitable
operations.
Process
Safety i. Element – Operating Procedures
Management ii. Element – Safe Work Practices
(CCPS)
iii. Element – Asset Integrity and Reliability
iv. Element – Contractor Management
v. Element – Training and Performance Assurance
vi. Element – Management of Change
vii. Element – Operational Readiness
viii. Element – Conduct of Operations
ix. Element – Emergency Management

3rd Pillars – Foundational Blocks

 Learn from Experience
Learning from experience involves monitoring, and acting on,
internal and external sources of information. Despite a company’s
best efforts, operations do not always proceed as planned, so
organizations must be ready to turn their mistakes – and those of
others – into opportunities to improve process safety efforts.
The most cost-effective ways to learn from experience are to:
1. Apply best practices to make the most effective use of available
resources.
Process 2. Correct deficiencies exposed by internal incidents and near
Safety
Management misses.
(CCPS) 3. Apply lessons learned from other organizations.

i. Element – Incident Investigation

ii. Element – Measurements and Metrics
iii. Element – Auditing
iv. Element Management Review and Continuous
Improvement

4th Pillars – Foundational Blocks

 NSAT Module III
Section 2- Process Safety Events
(API 754)
 Reporting Process Safety Events

1. Terms, Definitions, Acronyms, And

Abbreviations
Process 2 Introduction-process safety incident
Safety
Events 3. Leading And Lagging Performance
(API 754)
Indicators
4. PSE Tier 1/ Tier 2 Determination Decision
Logic Tree
 Reporting Process Safety Events
Basic Definitions
Loss of primary Containment ( LOPC)
An unplanned or uncontrolled release of any material from
primary containment, including non-toxic and non- flammable
materials (e.g. steam, hot condensate, nitrogen, compressed
Process CO2 or compressed air).
Safety
Process Safety Event (PSE)
Events
(API 754) An unplanned or uncontrolled LOPC of any material
including non-toxic and non-flammable materials (e.g.
steam, hot condensate, nitrogen, compressed CO2 or
compressed air) from a process, or an undesired event or
condition that, under slightly different circumstances, could have
resulted in a LOPC of a material.
 Reporting Process Safety Events
Basic Definitions
Days away from work injury
Work-related injuries that result in the employee being away
from work for at least one calendar day after the day of the
injury as determined by a physician or other licensed health
professional..
Explosion
Process
A release of energy that causes a pressure discontinuity or
Safety
blast wave (e.g. detonations, deflagrations, and rapid
Events
releases of high pressure caused by rupture of equipment
(API 754)
or piping).
Recordable injury
A work-related injury that results in any of the following:
death, days away from work, medical treatment beyond first
aid, loss of consciousness, 48 hrs. of absence
 [Link] process safety incidents
Process safety incidents are rarely caused by a single catastrophic failure, but rather
by multiple events or failures that coincide. This relationship between simultaneous
or sequential failures of multiple systems was originally proposed by British
psychologist James T. Reason in 1990 and is illustrated by the “Swiss Cheese Model.”
In the Swiss Cheese Model, hazards are contained by multiple protective barriers each of
which may have weaknesses or “holes.” When the holes align, the hazard is released
resulting in the potential for harm.

Swiss • Hazards are contained by multiple Hazard

Protective “Barriers”

Cheese protective barriers.

“Weaknesses” or “Holes”
Model • Barriers may have weaknesses or “holes”.
• When holes align, the hazard passes
through the barriers resulting in the
potential for harm.
• Barriers may be physically engineered
containment or behavioural controls
dependent upon people. Harm

• Holes can be latent, incipient or actively “Swiss Cheese Model.”

opened by people.
 Christopher A. Hart in 2003 represented Reason’s model as a set of
spinning disks with variable size holes. This representation suggests
that the relationship between the hazard and the barriers is dynamic, with
the size and type of weakness in each barrier constantly changing, and the
alignment of the holes constantly shifting.
In both models, barriers can be active, passive, or
administrative/procedural. Holes can be latent, incipient, or actively
Spinning opened by people.
disks with
variable • Hazards are contained by multiple
protective barriers.
size
• Barriers may have weaknesses or “holes”.
holes. • When holes align, the hazard passes
through the barriers resulting in the
potential for harm.
• Barriers may be physically engineered
containment or behavioural controls
dependent upon people.
• Holes can be latent, incipient or actively Spinning disks with variable size
opened by people. holes
 3. Leading and Lagging Performance Indicators

In 1931, H.W. Heinrich introduced the

now-familiar accident pyramid based
upon his experience in the insurance
industry. The accident pyramid
represents two key concepts. One is that
safety accidents can be placed on a scale
representing the level of consequence,
and the second is that many precursor
Leading and
incidents occurred with lesser
Lagging
consequences for each accident that
Performance
occurred with greater consequences.
Indicators
Heinrich’s model represents a predictive
relationship between lower and higher
consequence personal safety events.
Top T-1 fatal,T-2 minor incident
Laging indicators; frequency rate
T-3 near miss ,T-4 at risk behavior
/severity rate /incidents rates
leading indicators –identifying and
investigating near misses /at risk
behaviours/safety audit /risk analysis
 3. Leading and Lagging Performance Indicators

In 1931, H.W. Heinrich introduced the

now-familiar accident pyramid based
upon his experience in the insurance
industry. The accident pyramid
represents two key concepts. One is that
safety accidents can be placed on a scale
representing the level of consequence,
and the second is that many precursor
Leading and
incidents occurred with lesser
Lagging
consequences for each accident that
Performance
occurred with greater consequences.
Indicators
Heinrich’s model represents a predictive
relationship between lower and higher
consequence personal safety events.
The difference between a loss of primary
containment event resulting in a Tier 1 or Tier 2
consequence is often due to time of day, wind
direction, absence of people, etc
 A T-1 PSE is an unplanned or uncontrolled release of any material, including non-
toxic and non- flammable materials (e.g. steam, hot condensate, nitrogen,
compressed CO2 or compressed air), from a process that results in one or more of
the consequences listed below:

• an employee, contractor or subcontractor “days away from work” injury and/or fatality;
• a hospital admission and/or fatality of a third-party;
• an officially declared community evacuation or community shelter-in-place;
• a fire or explosion resulting in greater than or equal to $25,000 of direct cost to the Company;
• a pressure relief device (PRD) discharge to atmosphere whether directly or via a downstream
destructive device that results in one or more of the following four consequences:
 liquid carryover;
 discharge to a potentially unsafe location;
 an on-site shelter-in-place;
 public protective measures (e.g. road closure);
Process • and a PRD discharge quantity greater than the threshold quantities in Table 1 in any one-hour
Safety Event period; or
(T-1 PSE) • a release of material greater than the threshold quantities described in Table 1 in any one-
hour period.

Tier 1 PSE Rate = (Total Tier 1 PSE Count / Total Work Hours) X 200,000
 Process
Safety Event
(T-1 PSE)
Reporting
criteria
 A T-2 PSE is an unplanned or uncontrolled release of any material, including non-
toxic and non-flammable materials (e.g., steam, hot condensate, nitrogen,
compressed CO2 or compressed air), from a process that results in one or more of
the consequences listed below and is not reported in Tier 1:

• an employee, contractor or subcontractor recordable injury;

• a fire or explosion resulting in greater than or equal to $2,500 of direct cost to
the Company;
• a pressure relief device (PRD) discharge to atmosphere whether directly or via a
downstream destructive device that results in one or more of the following four
consequences:
 liquid carryover;
 discharge to a potentially unsafe location;
 an on-site shelter-in-place;
 public protective measures (e.g. road closure);
Process • and a PRD discharge quantity greater than the threshold quantity in Table 2 in any
Safety Event one-hour period; or
(T-2 PSE) • a release of material greater than the threshold quantities described in Table 2 in
any one-hour period.

Tier 2 PSE Rate = (Total Tier 2 PSE Count / Total Work Hours) X 200,000
 Process
Safety Event
(T-1 PSE)
Reporting
criteria
 A Tier 3 PSE typically represents a challenge to the barrier system that progressed
along the path to harm, but is stopped short of a Tier 1 or Tier 2 LOPC
consequence. Indicators at this level provide an additional opportunity to identify and
correct weaknesses within the barrier system.

• Safe operating limit excursions;

• Primary containment inspection or testing results outside acceptable limits;
• Demands on safety systems;
• other LOPCs. or identify others that are meaningful to its operations. A Company
shall develop and use Tier 3 Indicators.
A Tier 3 PSE is counted for each Demand on Safety Systems event when one of
the following occurs:
1) activation of a safety instrumented system (SIS);
2) activation of a mechanical shutdown system;
Process
3) activation of a PRD (a pressure relief device ) not counted as Tier 1 or Tier
Safety Event
2, regardless of the phase of operation (e.g. start-up, shutdown, normal,
(T-3 PSE)
temporary, emergency shutdown, regeneration, batch mode).

Internal reporting structure ( leading indicators)

 Tier 4 performance indicators must reflect facility-specific barrier systems, facility-
specific performance objectives, and the maturity of any existing performance
indicators. ( administrative barriers) leading indicators
1. Process Hazard Evaluations Completion - revalidation hazard evaluations
completed on time by fully qualified teams.
2. Process Safety Action Item Closure - include items from incident investigations,
hazard evaluations or compliance audits.
3. Training Completed on Schedule
4. Procedures Current and Accurate—Percent of process safety required operations
and maintenance procedures reviewed or revised as scheduled.
Process 5. Work Permit Compliance—Percent of sampled work permits that met all
Safety Event requirements.
6. Safety Critical Equipment Inspection - Percent of inspections of safety critical
(T-4 PSE)
equipment completed on time. This may include pressure vessels, storage tanks,
piping systems, pressure relief devices, etc
7. Safety Critical Equipment Deficiency Management
8. Management of Change (MOC) and Pre-Start-up Safety Review (PSSR)
Compliance Completion of Emergency Response Drills
9. Fatigue Risk Management—Key measures of fatigue risk management systems
may include: percentage of overtime, number of open shifts, number of
extended shifts, number of consecutive shifts worked, number of exceptions, etc.
Internal reporting structure ( leading indicators)
 NSAT Module III
Section 3- Process Safety Information
(Ref: OISD GDN 206)
Process Safety Information
 Process Safety Information
(OISD STD 206)

• Process and other Chemical Information,

• Process Technology,
Process
Safety • Process Equipment,
Information •
 The Requirements of the Standard
- Hazard Determination
Determine:

 Chemicals in Your Process

 Process Chemistry
 Quantity of Chemicals in lbs
 Compare to Appendix A List with Threshold
Quantities (TQ’s)

43
 Process safety information
 Employers must complete a compilation of written
process safety information before conducting any
process hazard analysis required by the standard.
 The compilation of written process safety information,
completed under the same schedule required for
process hazard analyses, will help the employer and
the employees involved in operating the process to
identify and understand the hazards posed by those
processes involving highly hazardous chemicals.

44
 Process safety information

Process safety information must include

 Information on the hazards of the highly
hazardous chemicals used or produced
by the process,
 Information on the technology of the
process, and
 Information on the equipment in the
process.

45
Process safety information
Information on the hazards of the highly hazardous
chemicals in the process shall consist of at least the
following
• Toxicity,
• Permissible exposure limits,
• Physical data,
• Reactivity data,
• Corrosivity data, and
• Thermal and chemical stability data, and hazardous
effects of inadvertent mixing of different materials.

46
 The Requirements of the Standard
- Develop Toxicity Information
 Obtain Toxicity
Information on the
Chemical(s) in the
Process
 MSDS are Typical
Resource
 You May Need Other
References, NIOSH
Pocket Guide, ACGIH
TLV’s

47
 Chemical Hazards Information

Al Information typically found on MSDS :

1. Hazardous Material Information

2. Exposure Guidelines

3. Physical Data

4. Chemical Stability

5. Corrosive Data

6. Chemical Incompatibility

7. Hazardous Effects of Inadvertent Mixing

8. Thermal and Chemical Stability

MSDS A FILM

07-02-2024
49
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 Process safety information ology
Information

 You must know the following

 point for process safety :

 Process Chemistry

 Maximum inventory

 Safe upper and lower limits

 Consequences of deviation
 You must know the following

1. Ventilation Systems Design

2. Design codes and Standards Employed

3. Material and energy balances for Processes

4. Safety systems
Process safety information

Technology of the Process

1910.119(d)(2)

52
 Technology of the Process
Information on the technology of the process must include
at least the following:
• A block flow diagram or simplified process flow diagram,
• Process chemistry,
• Maximum intended inventory,
• Safe upper and lower limits for such items as
temperatures, pressures, flows or compositions,
• An evaluation of the consequences of deviations,
including those affecting the safety and health of
employees.

53
 The Requirements of the Standard
- Process Technology
 Block flow diagram or
process flow diagram
 Process chemistry
 Maximum intended
inventory
 Upper and lower limits
 Consequences of
deviations

54
 Information Pertaining to the Process.

1. .
Process safety information

Equipment in the Process

1910.119(d)(3)

56
 The Requirements of the Standard
- Process Equipment
 Materials of construction
 Process and instrument
drawings (P&ID’s)
 Electrical classification
 Relief system design
 Ventilation system design
 Design codes
 Material and energy
balances
 Safety systems

57
 The Requirements of the Standard
- Process Equipment
 Now:
 Identify Each Piece of
Equipment in the
Covered Process by
P&ID, Block Diagram
and Number Them
 Remember - Must
Follow Form
 Must be Able to Track
Each Number Through
the Entire Program

58
 Process Equipment information

1. Materials of Construction
2. Piping and Instrumentation Diagrams
(P&ID)
3. Electrical Classification
4. Relief System Design
5. Ventilation System Design
6. Design Codes and Standards
7. Material and Energy Balances
8. (Processes built after 1992)
9. Safety Systems
10. Design Codes
Process Equipment information

60
 Process equipment

 The employer shall document that equipment

complies with recognized and generally
accepted good engineering practices.
 For existing equipment designed and
constructed in accordance with codes,
standards, or practices that are no longer in
general use, the employer shall determine and
document that the equipment is designed,
maintained, inspected, tested, and operated in
a safe manner.

61
 Equipment Information

 Information concerning the technology of the

process &
 The equipment information must be compiled
prior to process hazard analysis initiation.
Conclude
 The compilation of the above described process
safety information provides the basis for
identifying and understanding the hazards of a
process and is necessary in developing the
process hazard analysis and may be necessary
for complying with other provisions of PSM
such as management of change and incident
investigations

63
 4. Safe handling of Hazardous chemicals
(OISD 114)
In the Petroleum and Natural Gas Production and
Processing Industry, a number of hazardous chemicals
are required to be stored and handled in appreciable
quantities. In view of the stringent product quality
requirement, various complex processes are
Process
Safety
introduced involving the handling of hazardous
Information chemicals
Inadequate awareness about the hazardous properties
of these chemicals and products may lead to serious
accidents which will affect the men at work and the
environment. The present standard will help in
facilitating the safe storage and handling of hazardous
chemicals and in avoiding accidents and occupational
diseases. process of manufacture.
 4. Safe handling of Hazardous chemicals
(OISD 114)-Key Definition

.Hazardous chemical
All chemicals can be Hazardous, If not properly
handled
Process For example water !
Safety Water as long as we take in mouth it is safe .
Information Try to take through nose , it will be fatal
Other example can be sugar .
So all chemicals are Hazardous as they have
potential harm you - So Does Std. cover all
chemicals ?
Is - there is legal definition for this ?
 4. Safe handling of Hazardous chemicals
(OISD 114)-Key Definition
.Hazardous chemical
MANUFACTURE, STORAGE AND IMPORT OF
HAZARDOUS CHEMICAL RULES-2000 (we need to refer
this )

Process Rule defines Hazardous chemicals means

Safety (e) "hazardous chemical" means-
Information any chemical which satisfies any of the criteria laid down in
Part I of Schedule I and is listed in Column 2 of Part II of
this Schedule;
Part 1 says If any chemical is toxic , flammable and
explosive it is hazardous chemical Part II column 2 gives
list of 684 chemicals which are toxics
any chemical listed in Column 2 of Schedule 2; Isolated
storage chemicals (30 types ) where quantity of storage is
more than threshold specified in law
 4. Safe handling of Hazardous chemicals
(OISD 114)-Key Definition
.
MANUFACTURE, STORAGE AND IMPORT OF HAZARDOUS
CHEMICAL RULES-2000 (we need to refer this )
Rule defines Hazardous chemicals means
(e) "hazardous chemical" means-
iii) any chemical listed in Column 2 of Schedule 3; threshold quantity
Process of a hazardous chemical in an industrial installation which are now
Safety grouped in 5 category that is
Information GROUP 1-TOXIC SUBSTANCES
GROUP -2HIGHLY TOXIC SUBSTANCES
GROUP 3-HIGHLY REACTIVE SUBSTANCES
GROUP 4-EXPLOSIVE SUBSTANCES
GROUP 5 - Flammable substances
Total 179 chemicals and 7 categories of flammable substance such
as gas , liquids etc. (all terms used in rule will be discussed
subsequently )
For All Practical reasons all chemicals refinery handles
are Hazardous
 4. Safe handling of Hazardous chemicals
(OISD 114)-Key Definition
.
One more Rule where Hazardous sentence is used
which is important to refinery is Petroleum rule 103 ,
which defines hazardous area as follows
An area shall be deemed to be a hazardous area, where
Process –
Safety
Information
(i) petroleum having flash point below 65 C or any
inflammable gas or vapour in a concentration capable of
ignition is likely to be present.
(ii) Petroleum or any inflammable liquid having flash
point above 65 C is likely to be refined, blended, handled,
stored at above its flash point.
Indirect it means any chemical whose flash point less
than 65 c is hazardous –
Categories of Hazardous Chemicals

1. Flammable
2. Oxidizers
3. Reactive- explosives /organic peroxides,
/water-reactive /pyrophoric
4. Corrosive
5. Toxic (Poisonous)
6. Radioactive
7. Non Compatibility
69
[Link] chemicals
• Flammable substances are those gases, liquids and
solids that will ignite and continue to burn in air if
exposed to a source of ignition.
• Many flammable and combustible liquids and solids are
volatile in nature; that is, they evaporate quickly and
are continually giving off vapours.
• The rate of evaporation varies greatly from one liquid
to another and increases with temperature. It is their
vapours combined with air, not the liquid or solids
themselves, that ignite and burn.
Chemical Categories

Flammable Chemicals

Agrochemicals and Security: Chemicals and Safety Chem-Safe-26

Flammable liquids &combustible
liquids
• Based on flash point this division is made
• What is flash point ?
• The flashpoint of a liquid is the lowest temperature at which
the liquid gives off enough vapour to be ignited (start burning)
at the surface of the liquid.
•Flammable Gases : Chemicals which in the gaseous state at
normal pressure and mixed with air become flammable and
the boiling point of which at normal pressure is 20oC or
below.

• Highly Flammable Liquids : Chemicals which have a flash

point lower than 23 o C and boiling point of which at
normal pressure is above 20 oC.
Flammable liquids &combustible
liquids
• flammable liquids have a flashpoint below 37.8°C (100°F).
• Combustible liquids have a flashpoint at or above 37.8°C
(100°F) and below 93.3°C (200°F).
• Flammable and combustible liquids are present in almost
every workplace. Fuels and many common products like
solvents, thinners, cleaners, adhesives, paints, waxes and
polishes may be flammable or combustible liquids.
• Everyone who works with these liquids must be aware of
their hazards and how to work safely with them.
 Chemical Categories: Flammable

Examples of flammable chemicals:

Flammable Solids Flammable Gases

Benzoyl peroxide Acetylene

Phosphorus (yellow) Ethylene Oxide
Calcium Carbide Butane
Picric Acids Hydrogen
Flammable liquids Ethane
xylene Propane
toluene
Gasoline Ethylene

8
Handling flammable chemicals
• Appropriate personal protective equipment (e.g., gloves, fire-
resistant or all cotton lab coat, and safety goggles) must be
worn when working with flammable/combustible liquids.
• Flammable/combustible liquids must never be heated using
open flames. Preferred heat sources include steam baths,
water baths, oil baths, hot air baths, and heating mantels.
• Flammable/combustible liquids should only be dispensed
under a fume hood. Ventilation is one of the most effective
ways to prevent the formation and concentration of flammable
vapors. 
Static electrical fires
Handling flammable chemicals
• When pouring from conductive containers with a capacity of 1
gallon (3.8 liters) or greater, make sure both containers involved
are electrically interconnected by bonding to each other and to
a [Link] friction of flowing liquid may be sufficient to
generate static electricity, which in turn may discharge, causing
a spark and ignition 
• Flammable/combustible liquids in containers with a volume
greater than 1 gallon (3.8 liters) should be transferred to
smaller containers that can be easily manipulated by one
person.
• Appropriate fire extinguishers must be available in areas where
flammables are used.
Controlling
Static Electricity

GROUNDING

BONDING
Storage Flammable/combustible
liquid
• Flammable/combustible liquid in quantities
exceeding a total of 10 gallons (38 liters) within
a laboratory must be stored in approved
flammable storage cabinets or safety cans.
• Flammable/combustible liquid stored outside
of flammable storage cabinets in the laboratory
should be kept to the minimum necessary for
the work being done.
• Flammable/combustible liquid stored in glass
containers shall not exceed 1 gallon (3.8 liters).
• Flammable storage cabinets and safety cans
must not be altered or modified..
Storage Flammable/combustible
liquid
• Safety cans with damaged screens must be taken out of service
immediately and repaired or replaced.
• Flammable liquids must only be stored in explosion-proof or
laboratory-safe refrigeration equipment.
• Flammable/combustible liquid containers, filled or empty, must
not be stored in hallways or obstructing exits.  Bulk waste
flammable/combustible liquids should be stored in safety cans.
• Flammables and combustibles must not be stored near
oxidizers, corrosives, combustible material, or near heat
sources. Make sure all chemicals stored near flammables and
combustibles are compatible.
Chemical Categories

Oxidizers
[Link]

• Oxidizing agents in addition to their corrosive

properties, are powerful oxidizing agents and
present fire and explosion hazards on contact with
organic compounds and other oxidizable
substances.

82
Chemical Categories: Oxidizers

• Store in a cool, dry place.

• Keep away from flammable and combustible
materials, such as paper or wood.
• Keep away from reducing agents such as zinc,
alkaline metals, formic acid.
Chemical Categories: Oxidizers

Examples of oxidizers:
Ammonium Dichromate
Nitrates
Ammonium Perchlorate
Periodic Acid
Ammonium Persulfate
Permanganic Acid
Benzoyl Peroxide
[Link] Chemicals
• Reactive are substances that have the potential to vigorously
polymerize, decompose, condense, or become self-reactive due
to shock, pressure, temperature, light, or contact with another
material.
• All reactive hazards involve the release of energy in a quantity or
at a rate too great to be dissipated by the immediate
environment of the reaction system so that destructive effects
occur
• Reactive chemicals include: 1) explosives, 2) organic peroxides,
3) water-reactives and 4) pyrophorics. Effective control is
essential to minimize the occurrence of reactive chemical hazard
3.1EXPLOSIVES
3.1. explosives- Reactive Chemicals
• A chemical that causes sudden, almost instantaneous
release of pressure, gas, and heat when subjected to
sudden adverse conditions. Heat, light, mechanical
shock, detonation, and certain catalysts can initiate
explosive reactions.
• Compounds containing the functional groups azide,
acetylide, diazo, nitroso, haloamine, peroxide, or
ozonide are sensitive to shock and heat and can
explode violently
3.1. explosives-safe handling and
storage
•  Appropriate personal protective equipment (e.g., face
shield, safety goggles, leather outer gloves, chemical
resistant gloves, fire-resistant or all cotton lab coat) must
be worn when working with explosives.
• Before working with explosives, understand their
chemical properties, know the products of side reactions,
know the incompatibility of certain chemicals, and
monitor environmental catalysts such as temperature
changes.
3.1. explosives-safe handling and
storage
• Containers should be dated upon receipt and when
opened. Expired explosives should be disposed of
• Explosives should be kept to the minimum necessary for
the procedure.
• If there is a chance of explosion, use protective barriers
(e.g., fume hood sash and safety shield) or other methods
for isolating the material or process.
• Explosives should be stored in a cool, dry, and protected
area. Segregate from other material that could create
3.2 Organic Peroxides

• These chemicals contain an -O-O- structure bonded to

organic groups. These compounds can be considered
as structural derivatives of hydrogen peroxide, H-O-O-
H, in which one or both of the hydrogen atoms have
been replaced by an organic group.
• Generally, organic peroxides are low-powered
explosives that are sensitive to shock, sparks, and heat
due to the weak -O-O- bond which can be cleaved
easily.
3.2 Organic Peroxides

• Some organic compounds such as ethers,

tetrahydrofuran, and p-dioxane can react with oxygen
from the air forming unstable peroxides. Peroxide
formation can occur under normal storage conditions,
when compounds become concentrated by
evaporation, or when mixed with other compounds.
• These accumulated peroxides can violently explode
when exposed to shock, friction, or heat. 
3.2 Organic Peroxides-safe
handling
• Appropriate personal protective must be worn when
working with organic peroxides
• Containers must be labeled with the receiving and
opening dates.
• Unopened material should be discarded within 1 year
and opened material should be disposed of
• Containers should be airtight, and stored in a cool, dry
place away from direct sunlight and segregated from
incompatible chemicals.
3.2 Organic Peroxides-safe
handling
• Peroxide-formers, liquid peroxides, or solutions should not be
refrigerated below the temperature at which the peroxide
freezes or precipitates. Peroxides in these forms are extra
sensitive to shock (never store diethyl ether in a refrigerator or
freezer).
• Unused peroxides should never be returned to the stock
container.
• Metal spatulas should not be used with peroxide-formers.
Only ceramic or plastic spatulas should be used. Contamination
by metal can cause explosive decomposition.
3.2 Organic Peroxides-safe
handling
• Friction, grinding, and all forms of impact, especially with solid
organic peroxides should be avoided.
• Never use glass containers with screw cap lids or glass
stoppers. Instead, use plastic bottles and sealers.
• Organic peroxides produce vapors during decomposition. This
can result in pressure build-up. The rapid increase in pressure
may cause explosive rupture of containers, vessels or other
equipment.
• Ignition sources must be avoided.  Organic Peroxides have a
Self-Accelerating Decomposition Temperature (SADT). Never
store organic peroxides where they may be exposed to
temperatures above the SADT..
•
[Link]-Reactives
• Water reactives react violently with water. Many
produce flammable hydrogen gas that can then
ignite when mixed with air (alkali metals,
organometallic compounds and some hydrides).
• Others give off large amounts of heat when mixed
with water, resulting in a violent reaction if the heat
produced is not sufficiency dissipated.

95
[Link]-Reactives
• Appropriate personal protective equipment must be
worn when working with water-reactives.
• Water-reactives should be stored under mineral oil in
a cool, dry place and isolated from other chemicals.
• Water-reactives must not be stored near water,
alcohols, and other compounds containing acidic OH.
3.4 Pyrophoric Chemicals
• Pyrophoric materials ignite spontaneously when
exposed to the oxygen and/ or moisture in air.
• Most commonly, pyrophoric iron fires occur during
shutdowns when equipment and piping are opened for
inspection or maintenance. Instances of fires in crude
columns during turnarounds, explosions in sulfur, crude
or asphalt storage tanks, overpressures in vessels, etc.,
due to pyrophoric iron ignition are not uncommon.
• How avoid These must be stored under water, mineral
oil or an inert dry atmosphere (e.g., nitrogen)
depending on the substance.
97/77
Chemical Categories

Pyrophoric Substances

Agrochemicals and Security: Chemicals and Safety Chem-Safe-32

Chemical Categories: Pyrophoric Substances

Safety pointers for pyrophoric substances:

• Store in a cool place.

• Store in containers that omit air.
• Beware of low humidity circumstances in which
static electricity may be high.
Chemical Categories: Pyrophoric Substances

Some examples of pyrophoric substances:

Boron
Cadmium
Calcium
Phosphorus (yellow)
Diborane
Dichloroborane
2-Furaldehyde
Chemical Categories

4.0 Corrosive chemicals

CHEMICAL CATEGORIES: CORROSIVE -ACIDS

Some pointers for safe storage of strong acids:

• Store large bottles of acids on low shelf or in acid
cabinets.
• Segregate oxidizing acids from organic acids,
flammables and combustible materials.
• Segregate acids from bases and active metals
such as sodium, potassium, etc.
• Use bottle carrier for transporting acid bottles.
• Have spill control pillows or acid neutralizers
available in case of spill.
Chemical Categories: Acids

Examples of strong acids:

Strong Oxidizing Acids Organic Acids

Chromic Acids Acetic Acid
Nitric Acid Phenol
Hydrobromic Acid Benzoic Acid
Perchloric Acid Trichloroacetic
Iodic Acid
Sulfuric Acid

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H2so4 tank can also catch fires

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Chemical Categories-corrosive

Bases
Chemical Categories: Bases

Some pointers for safe storage of strong bases:

• Store bases and acids separate from one another.

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

Agrochemicals and Security: Chemicals and Safety Chem-Safe-24

Chemical Categories: Bases

Examples of strong bases:

Ammonium Hydroxide
Calcium Hydroxide
Bicarbonates
Potassium Hydroxide
Carbonates
Sodium Hydroxide

Agrochemicals and Security: Chemicals and Safety Chem-Safe-25

Toxic (Poisonous) Chemicals
• Acutely toxic chemicals are those substances that pose
significant adverse health effects for immediate or
short-term exposures.
• The route of exposure that causes the adverse effect
may be inhalation, absorption (through skin, eyes, or
mucous membranes), or ingestion, depending on the
chemical
Toxic (Poisonous) Chemicals
Toxicity effects
• The OSHA lab standard defines Highly Hazardous
chemicals with acute toxicity effects as having the
following “lethal dose” (as determined by studies in
rats):
• LD50 - ingestion: < 50 mg/kg
LD50 - contact (24hrs): < 200 mg/kg
LD50 - inhalation: < 200ppm/1hr
• (LD50 is the amount of substance that causes fatality
in 50% of a test population of rats).
Occupational Exposure Limits
(OELs)
• TLV-TWA = Threshold Limit Value –
Time-Weighted Average (normally
worked out for an 8-hour work-day)
• STEL = Short-Term Exposure Limit
(a 15-minute limit)
• IDLH = Immediately Dangerous to Life
or Health (air-borne concentration limit
which is immediately dangerous to life
or health)
111
Hydrogen Sulfide
• Decomposition of materials, human waste
• Naturally present in some oil/gas reservoirs
• Rotten egg odor at low concentrations
• Possibly no warning at high concentrations
PPM Effect Time
10 Permissible Exposure Level 8 Hours
50 - 100 Mild Irritation - eyes, throat 1 Hour
200 - 300 Significant Irritation 1 Hour
500 - 700 Unconsciousness, Death 1/2 - 1 Hour
>1000 Unconsciousness, Death Minutes
This is major hazard in our industry –understand it
Hydrofluoric acid
• Highly corrosive ,can disolve glass ,oxides , hence
stored in special plastic container
• Highly toxic ,effects lungs, eyes, cause painless
burns , may lead to death

Chlorine
• Highly corrosive and toxic
• Used in Cooling towers , boilers etc in refineries
• (substituted by Sodium hypo chloride )
Chlorine

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Examples of Compounds with a
High Level of Acute Toxicity
• Acrolein • Methyl fluoro sulfonate
• Hydrogen cyanide • Sodium azide
• Hydrogen sulphide • Diazomethane
• Hydro fluoric acid • Nickel carbonyl
• Arsine • Sodium cyanide and
other cyanide salts
• Hydrogen fluoride
• Diborane (gas)
• Phosgene
• Dimethyl mercury
• Chlorine
• Nitrogen dioxide
Safe handling of toxic chemicals
• All locations within the laboratory where acutely toxic
chemicals are handled must be demarcated with designated
caution signs. This includes all fume hoods and bench tops
• Do not handle acutely toxic chemicals when working alone.
• Immediately close all containers of acutely toxic chemicals after
use.
• Due to the risk of splashes and equipment failures, not use a
syringe and needle to perform transfers of acutely toxic
chemicals in volumes of greater than 5 mL.
 Safe handling of toxic chemicals
• Do not dispense acutely toxic chemicals directly onto a
laboratory balance in the general lab space.
• Instead, transfer the material into a sealable pre-tared container
inside the fume hood; then take the sealed container to the
balance. Adjust the amount of material inside the container
until the desired mass is reached. Make all adjustments inside
the fume hood.
• The use of acutely toxic chemicals in laboratory animals may
require additional work practice controls.
• In addition to the minimum lab apparel use tight-fitting chemical
splash goggles, chemical-resistant gloves, or disposable lab coats
Radioactive material
Radioactive material
• Lock radioactive stock materials and sealed sources
in a secured container or a secured storage area
when not in use.
• labels radioisotope use rooms with Caution
Radioactive Material signs.
• Wear radiation monitor badges when appropriate.
[Link] Chemicals
• Accidental contact of incompatible chemicals can
result in:
• Generation of heat (acids and bases)
• Violent reaction (acrolein and acids or other catalyst)
• Formation of toxic vapours or gases (cyanide salt and
acid)
• Formation of a flammable gas (alkali metal and water)
• Fire or Explosion (perchloric acid and acetic anhydride)

120
Incompatible Chemicals
• Incompatible materials must be sufficiently
segregated in storage to prevent mixing during
fires, explosions, and natural disasters like earth
quakes.
• Accidents with incompatible materials often occur
during the inadvertent mixing of wastes in
laboratories.

121
Incompatible Chemicals
• Examples:

• Acids and metals

• Oleum and water
• Calcium carbide and water
• Strong acids and strong bases
• Sodium hypochlorite and ammonia

122
Compability chart

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• Most of definitions are now covered along
additional information's ,
• Now let us look in the Key issues which are high
lighted in the Std.

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[Link] THE NFPA PICTORIAL
REPRESENTATION OF HAZARD
NFPA pictorial representations consist of a diamond as shown in
the figure below, divided into 4 parts.
These parts, starting from left block (in clockwise direction),
represent
 Health Hazard,
 Flammability Hazard,
 Reactivity Hazard and
 Space for additional information such as water reactivity, oxidant and
radiation hazard.
The color codes for these hazards are :
Blue for health,
Red for flammability,
Yellow for reactivity and
colorless for additional information.

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Hazard Communication Labels
Other labels:
• NFPA 704
• Overall diamond shape
made up of four smaller
diamonds
• Each smaller diamond is a
different color
• Numbers within smaller
diamonds represent
severity of hazard

Source: OTIEC
Hazard Communication Labels
• NFPA 704 – hazards and severity ratings

FlammabilityBlue = Health Hazards

White = Other Special Hazards
Hazard 0= normal material that
W= reactivity to water
poses no health
OX = oxidizer
Yellow = Instability Hazards
Health Red 1==Flammability
slight hazardHazards
Instability
SA = simple asphyxiant
0= normally stableHazard Hazard
0=2will not burn hazard
= moderate
1 = slight hazard 1 =3flashpoint
= extremeabove
hazard200°F
2 = moderate hazard Other 2 = flashpoint between
4 = deadly hazard
Special 100 – 200°F
3 = extreme hazard
Hazard
4 = deadly hazard 3 = flashpoint below 100°F
4 = flashpoint less than 73°F
Source: OTIEC
Hazard Communication Labels

Source: OSHA
Hazard Communication Labels
• HMIS label
• Intended for “In-plant” (workplace) labeling compliance
• Color-coded bars
• Numerical scale, 0-4,
(Product identifier)
with 0 as lowest
hazard and 4 as
highest hazard HEALTH
• 0 = minimal hazard
• 1 = slight hazard FLAMMABILITY
• 2 = moderate hazard
• 3 = serious hazard PHYSICAL HAZARD
• 4 = severe hazard PERSONAL PROTECTION

Source: OTIEC
Hazard Communication Labels
• HMIS hazard indicators PPE Index:
A = safety glasses
B= safety glasses +
Flammability gloves
ratings:
C= Health ratings:
safety glasses + gloves + apron
(Product identifier) 0 = will not burn
D0 The
= = no
face second +space
significant
shield signifies
gloves risk
+ apron
E= 1 1 safety
== irritation/minor
chronic flashpoint
glasses >200°F
health+hazard +with
glovesinjury
dust
HEALTH an
2 2= =asterisk
F = safety
flashpoint
respirator (*) ≥100°F,injury
temporary/minor
butglasses
<200°F+ gloves + apron
Physical
3= major
+ dust Hazard
injuryratings:
respirator
FLAMMABILITY G= 403 safety
== life-threatening
flashpoint
normally
glasses +
<73°F
stable and
gloves + vapor
1= boiling point
normally
respirator >100°F,
stable, but
H = splash or flashpoint between
goggles + gloves + apron
PHYSICAL HAZARD 2 =
can
+ vapor
73°F
become unstable
respirator
unstableand 100°F
I = safety glasses + gloves + dust
PERSONAL PROTECTION 34 and
== explosive
flashpoint <73°F and
vapor respirator
J =4 splash boiling
= readily
gogglespoint <100°F
explosive
+ gloves + apron
Source: OTIEC
+ dust and vapor respirator
K = air-line hood or mask + gloves +
full suit + boots
X = ask supervisor or safety specialist
Hazard Communication Labels
Ammonium Hydroxide

HEALTH * 2
FLAMMABILITY 0
PHYSICAL HAZARD 0
PERSONAL PROTECTION

J
Source: OTIEC
4.2 HAZCHEM CODE
• This is an emergency action code for
fire and spillage. The significance of the
letters and the numbers indicated in this
code
• Mostly displayed of tankers carry the
chemical product , the requirement is
also highlighted Central mooter vehicle
act/rules
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 Rule 134:-
• (1) Every goods carrier used for transporting any
dangerous or hazardous goods shall be legibly and
conspicuously marked with an Emergency
Information Panel in each of the three places
indicated in Table below 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, namely:-

133
• (i) The correct technical name of the dangerous or
hazardous goods in letters not less than 50 mm high;
• (ii) The class label of the dangerous or hazardous goods
of the size of not less than 260 mm. square;
• (iii) The name 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 not less than
50 mm. 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 an emergency
involving such goods.
134
• (2) The information contained in sub rule (1) shall
also be displayed on the vehicle by means of a sticker
relating to the particular dangerous or hazardous
goods carried in that particular trip.
• (3) Every class label and emergency information
panel shall be marked on the goods carriage and shall
be kept free and clean from obstructions at all times.

135
136
137
Emergency Action Code (Hazchem Code)
Hazchem Scale For fire or spillage

1. Jets / Coarse Spray

2. Fog / Fine Spray
3. Foam
4. Dry Agent
P V
FULL
R
DILUTE
S BA (may be washed to
V
S BA for FIRE only drain with large
quantities of water)
T BA
T BA for FIRE only
W V FULL
X BA
CONTAIN
Y BA (Prevent spillage from
V
Y BA For FIRE only entering drains or
water course)
Z BA
Z BA For FIRE only
E PUBLIC SAFETY HAZARD CONSIDER EVACUATION 138
HAZCHEM Code
HAZCHEM Examples
Hazardous Substances

SAFETY TRAINING COURSE BY AKSHAYA KS IMPEX & CAIRN INDIA LIMITED

 Emergency Panel
• On the Panel we saw two more information
1. Hazard warning Signe
2. UN , Number

• UN NUMBER: The united nations number is

a four figure code used to identify hazardous
chemicals and is used for identification of
chemicals transported internally by road, rail
and by air.
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 .
5 CLASSIFICATION OF HAZARDOUS SUBSTANCES

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6.2.1 STORAGE IN BULK

The std. insists that following points should be given

due weightage to avoid any mishap. While storing bulk
storage hazardous chemicals , let review them

• Attempt should be made to find suitable less hazardous

alternate chemicals, to replace the hazardous chemical.
• The inventory of all hazardous chemicals for that matter
must be kept as minimum as possible.
• Replacement of chlorine with sodium hypochlorite
• Sulphuric acid with sulphonyl
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6.2.1 STORAGE IN BULK

• The tanks should be located so as not to pose

safety problems due to leakage and reaction
with other chemicals stored nearby.
• The environment at the location must be
compatible with the chemical stored.

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6.2.1 STORAGE IN BULK

• Oxidising Agents : Oxidising substances

must be stored away from all flammable
materials even if they are only slightly
flammable.
• Oxidising material must be kept away
from substance which are reducing
agents

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6.2.1 STORAGE IN BULK

• Water Sensitive Substances : These

substances react with water or steam to
produce flammable or explosive gases and
evolve heat, eg.. Conc. acids like sulphuric
acid, glacial ethnoic acid etc.
• Conc. Alkali like sodium hydroxide react
with water later to evolve heat.
• Such materials must not be stored in areas
where water flooding from pipe leakages or
leaky roofs can happen
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6.2.1 STORAGE IN BULK

• Toxic Substances : These substances

must be stored in well ventilated areas,
preferably cool and certainly away from
direct sun rays.
• Periodic checks should be organised for
all parts of storage areas. Extremely
toxic substances like TEL (Tetra Ethyl
Lead) must be stored separately under
strict security.
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6.2.1 STORAGE IN BULK

• Toxic Substances : These substances

must be stored in well ventilated areas,
preferably cool and certainly away from
direct sun rays.
• Periodic checks should be organised for
all parts of storage areas. Extremely
toxic substances like TEL (Tetra Ethyl
Lead) must be stored separately under
strict security.
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6.2.1 STORAGE IN BULK

• Corrosive Chemicals : The flooring of the area

where corrosive chemicals are stored, shall be
impervious and made of corrosion resistant
materials.
• The storage tank and foundation should be
of suitable material of construction to
prevent corrosion. Acid resistance
Flooring .
• Factory act rules gives lots precautions
which need to be ensured
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6.2.1 STORAGE IN BULK-petroleum products

• The connections and openings to the tank should be as minimum

as possible so that the possibility of leakage and maintenance
hazards are minimized.
• The tanks should be fitted with vents/relief systems of adequate
capacity discharging to a safe height. Capacity requirement in case
of high vapour evolution resulting from heating due to fire of
adjacent tank also should be considered.(OISD Std 106)
• Wherever atmospheric release of the vapour is not advisable, the
relief should be routed to a neutralising system. Flame arrestors
are recommended for the vents of atmospheric storage tanks
containing Class A (flash point less than 23 degree centigrade)
chemicals.
• The location of flame arrestor must be easily accessible for
periodic inspection to ensure that flame arrestor is free of any
choking.

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6.2.1 STORAGE IN BULK

• The connections and openings to the tank should be as minimum

as possible so that the possibility of leakage and maintenance
hazards are minimized.
• The tanks should be fitted with vents/relief systems of adequate
capacity discharging to a safe height. Capacity requirement in case
of high vapour evolution resulting from heating due to fire of
adjacent tank also should be considered.(OISD Std 106)
• Wherever atmospheric release of the vapour is not advisable, the
relief should be routed to a neutralising system. Flame arrestors
are recommended for the vents of atmospheric storage tanks
containing Class A (flash point less than 23 degree centigrade)
chemicals.
• The location of flame arrestor must be easily accessible for
periodic inspection to ensure that flame arrestor is free of any
choking.

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6.2.1 STORAGE IN BULK

• Each storage tank should have necessary instruments to

monitor its level, pressure and temperature preferably
with remote indications at control room or field
operators cabins. Abnormal rise in level / pressure /
temperature should alert control room by alarm. Quite
often, the level gauges pose problems of choking,
leakage from drain connections, leakage from broken
gauge glasses leading to accidents
• it is suggested to have guarded, illuminated level
gauges. Level gauges should have provision for in-situ
cleaning.

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6.2.1 STORAGE IN BULK

The tank should have a dyke of suitable material

(compatible with the chemical) of volume equal to the
volume of the larger storage tank. The dyke should have
facility to:
(a) drain off rain water into storm water channel ;
(b) route high volume spillage / leakage to suitable
neutralizing pit nearby ;
(c) discharge safe effluent to oily water system, as applicable.

The isolation valves on dyke drains should be located outside the

dyke.

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Tank Farm-bunds
Bunds should be sized to hold at
least 110% of the maximum
capacity of the largest tank.
Bund size should also allow
some latitude for the addition
of foam during response to the
emergency
Provision for rainfall/snowfall,
sprinkler water and firewater
should also be considered.

Snow-covered tank farm 155

 Tank Farm-bunds Tank Farm
It is normal to limit the
number of tanks in a single
bund to 60,000 m3 total
capacity.
Tanks storing incompatible
materials should have
separate bunds.
Tanks often have individual
bunds.

156
 Tank Farm-bunds design

Any openings for passage of pipelines through

the bund wall should be sealed (watertight)

Sealed openings
157
 Tank Farm- design

Certain specified safety distances

have to be maintained between –
the tanks within the same bund
the tank and the bund wall
the bund wall and the
loading/unloading facility/pumps Safety Distances
the bund wall and the road, plant,
or building.
There are statutory requirements for maintaining
the safety distances. (Refer the Petroleum Rules, 2002/OISD 118)
Inter-tank safety distance depends on the class of
flammable substance stored.
158
Remember…
Bund must satisfy one of two rules:

Individual Tank: Free bund must be 110% or greater

of the tank capacity.
Multiple Tanks: Free bund must be 110% or greater
of the largest tank and 25% or greater than the total
capacity of all the tanks in the group.
Bund should also be able to hold certain amount of
rainfall, sprinkler water and firewater/foam
accumulation.
Bund integrity should be maintained.
159
DYKED ENCLOSURES/WALL
• Dyked enclosure should be able to contain the complete
contents of the largest tank in the tank farm in case of any
emergency.
• Wall should be at least one meter height and shall not be
more than 2.0 m above average grade level inside.
• However, for excluded Petroleum, the minimum height of
dyke wall shall be 600 mm. .
• The dykes should be of earthen/stone construction having
trapezoidal cross-section. The dyke shall not have slope
steeper than 1.5 horizontal to 1.0 vertical.
• The top flat surface of dykes shall be at least 600 mm wide
for dykes upto 1m height. For dykes above 1m and upto 2m
height, top flat surface shall have 1000mm
• Pump stations should be located outside dyke areas by the
side of roads.
• Fire access roads should be provided to storage area.
• The storage tanks / area should have suitable fire
protection and fire fighting facility
• Adequate communication facility like public address /
telephone must be made available for interacting with
control room, fire stations, medical units etc
• The name of chemical, type of hazard, emergency
operational instructions, antidote first aid etc. should be
displayed near each tank.
• Electrical Safety : All cables and electric fittings shall
be constructed, installed, protected, operated and
maintained in such a manner so as to prevent risk of
open sparking
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 ELECTRIC INSTALLATION-CHAPTER IV
103. Hazardous area.-petroleum rules
• For the purpose of this chapter, an area shall be
deemed to be a hazardous area, where –
• (i) petroleum having flash point below 65 C or any
inflammable gas or vapour in a concentration capable
of ignition is likely to be present.
• (ii) Petroleum or any inflammable liquid having flash
point above 65 C is likely to be refined, blended,
handled, stored at above its flash point.
 104. Classification of hazardous area.

• (1) A hazardous area shall be deemed to be.-

• (i) a zone “0” area, if inflammable gas or vapors are
expected to be continuously present in the area;
• (ii) a zone “1” area, if inflammable gases or vapors are
likely to be present in the area under normal
operating conditions;
• (iii) a zone “2” area, if inflammable gases or vapors are
likely to be present in the area only under abnormal
operating conditions or failure or rupture of an
equipment.
• .
105. Extent of hazardous area.
• The extent of hazardous area shall be as laid down
in the fourth Schedule
• Generally In case of open air process area where normal
conditions exist in open areas,
• Zone 2 shall be 8m in all directions plus 16 m in
horizontal direction from source of hazard
• Area close to opening &Pit will be considered as
Zone 1(also area where class A product are
handled)
Extent of Hazardous Area
Extent of
Hazardous
Area

165
EXAMPLE OF HAZARDOUS AREA ZONES
This diagram shows how hazardous area zones may occur in typical circumstances.

Zone 2
Zone 1
Zone 0

UNVENTILATE
D
DECANTING OF FLAMMABLE LIQUID PETROL STATION FORECOURT GARAGE
FROM CONTAINER INSPECTION PIT
TO CONTAINER

FLAMMABLE
MATERIAL IN
ZONE 0 ZONE 1 ZONE 2
LIQUID FORM
 106. Fixed electric apparatus.

• (1) No electric apparatus shall be allowed in a zone “0” area:

• (2) All electric apparatus installed or used in a zone “1” area
shall be either. –
• (i) a flame proof or intrinsically safe apparatus of a type or
types approved in writing by the Chief Controller or
• (ii) an industrial-type apparatus housed in an enclosure or a
room which has been made safe by pressurizing or purging
with a plenum of atmosphere free from significant
concentration of any inflammable gas or vapour and so
arranged and inter blocked that in case of failure of the
pressurizing or purging agent, the electricity supply is
automatically cut off or a warning is automatically given to a
person in attendance who shall take suitable measures to
prevent a hazard.
106. Fixed electric apparatus.

• (3)
All electric apparatus installed or used in a zone “2’
area shall, be either

• (i) a non-sparking apparatus of a type approved by

the Chief Controller; or
• (ii) an apparatus of any of the types permitted under
sub-rule (2).
 .107-Fixed electric wiring. Conduits

(1) All conductors of an intrinsically safe circuit in connection with an

intrinsically safe apparatus installed in any hazardous area shall be so laid as
to prevent invasion of such circuit by current arising from contact or
electrostatic or electromagnetic induction from any other circuit. Conductors
of intrinsically safe circuits shall be effectively protected against mechanical
damage.
(2) All electric wiring in a hazardous area, other than the conductors of an
intrinsically safe circuit, shall be effectively sealed at all joints, mechanically
protected and adequately supported throughout its length and shall consist
of –
(i) approved armoured cable with correctly designed terminations, complete
with armour clamps, the armouring being carried and electrical clamps to
provide mechanical support to the cable and electrical continuity; or
 .107-Fixed electric wiring. Conduits

(ii) approved metal sheathed cable with correctly designed and

installed terminations;
(3) Insulated cables without metallic sheathing or armouring but
accommodated in a conduit shall not be buried in the open ground
in any hazardous area;
(4) The electric supply circuits of each electric pump in a hazardous
area shall be –
(i) separately protected by a fuse or circuit breaker set to operate
when the current in the circuit so exceeds the rated current for such
a period of time as to involve danger; and
(ii) provided with an individual isolating switch at the main supply
point for each electric pump including its integral lighting system, if
any.
 . 108 Earthing and bonding

• 4 ohms in the case of electrical systems and

equipment or a valve that ensures the operation of
the protective device in the electrical circuit,
whichever is lower, and
• (b) 10 ohms in the case of all non-current carrying
metallic parts of major electric apparatus or any
major metallic object.-
.
 .
108 Earthing and bonding
(2) All joints in pipelines, valves, plants, storage tanks
and associated facilities and equipments for
petroleum shall be made electrically continuous by
bonding or otherwise; the resistance value between
each joint shall not exceed 1ohm.
(3) A piping which is not in electrical contact with the
associated tank or vessel shall be efficiently
connected to such tank or vessel by a flexible
conductor and earthed.
109. Cathodic protection
(1) Cathodic protection system where employed shall
be designed and installed in accordance with the
current recognized practice
(2) (2) The metallic structures, pipelines, valves, plants
and associated equipment under cathodic
protection shall not be broken for repair or
maintenance unless a heavy gauge conducting
cable is clamped to each side of the intended break
6.3.1 UNLOADING OF TANK TRUCKS / TANK WAGONS

Before the tanker enters the industry premises, the

tanker is to be inspected for authorized entry and safe
& sound condition of the tanker, its contents and that
of the prime mover. Tankers entering plant are to be
fitted with flare arresters on their exhaust.

The quality of the chemical in the tanker should be

ascertained before unloading to avoid contamination of
chemical already at storage.

In case of flammable chemicals, the prime mover

(engine) should be kept of. The tanker should be
properly blocked from movement before connections
are made for unloading hazardous chemicals.
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6.3.1 UNLOADING OF TANK TRUCKS / TANK WAGONS

• In case of flammable chemicals, the unloading point should be

located at a safe distance outside the storage dyke. For details, refer
OISD- STD-118 on Layout.

• Pressurizing with air / inert gas for unloading should be avoided. It

is recommended to use pumps / vacuum systems for unloading.
Pumps should preferably be of seal less type and valves should be
of glandless types. Solid chemicals in bulk should be handled with
lifting machines and conveyors.

• Coupling used for connecting hose to tanker must be leak proof.

Flange connections are preferred. Where threaded connections are
used, the threaded portion should be properly preserved against
corrosion / wearing of threads and thoroughly inspected before
connections are made.

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6.3.1 UNLOADING OF TANK TRUCKS / TANK WAGONS

• In case of flammable chemicals, the unloading point should be

located at a safe distance outside the storage dyke. For details, refer
OISD- STD-118 on Layout.

• Pressurizing with air / inert gas for unloading should be avoided. It

is recommended to use pumps / vacuum systems for unloading.
Pumps should preferably be of seal less type and valves should be
of glandless types. Solid chemicals in bulk should be handled with
lifting machines and conveyors.

• Coupling used for connecting hose to tanker must be leak proof.

Flange connections are preferred. Where threaded connections are
used, the threaded portion should be properly preserved against
corrosion / wearing of threads and thoroughly inspected before
connections are made.

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6.3.1 UNLOADING OF TANK TRUCKS / TANK WAGONS

• The unloading hose should be devoid of cracks &

blisters and should be capable of withstanding whatever
pressure developed during unloading operation. The hose
should be hydro-tested at a frequency guided by
experience. Proper records of hydro-test should be
maintained.
• Same hose should not be used for unloading different
chemicals. Hoses for different chemicals should be
marked with different colour stripes for easy
identification.
• For flammable chemicals, the tanker and the hose are to be
properly earthed before starting unloading operation.
• Unloading should preferably be done in day time.

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6.3.1 UNLOADING OF TANK TRUCKS / TANK WAGONS

The operating staff must use suitable personal

protective clothing / equipment. Suitable breathing
canisters and first aid box must be available at site for
use in case of emergency.
Provision of sample quantity of water / neutralizing
medium to take care of leakage / spillage must be
made. Also steam and inert gas hose stations must be
available at unloading point.
There must be adequate illumination at site. Flame
proof fittings should be used wherever necessary.

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6.3.1 UNLOADING OF TANK TRUCKS / TANK WAGONS

• The unloading systems should have facility to vent / drain the remaining
chemical in the hose to a suitable safe point. The hose should be kept blinded
when hot in use. Thermal safety valve discharging to safe disposal or handling
facility should be provided.

• Before starting unloading, the ullage of the receiving tank should be checked.
Care should be taken to avoid overflow of tanks. Gas / chemical leak detection
system to sound an alarm at the control room/site may be provided wherever
possible, so that quick remedial measures can be taken. Wherever necessary,
quick/remote isolationvalves should be provided.

• Fire alarm and fire fighting facility commensurate with the chemical – as
mentioned in the data sheet (Chapter 6) should be provided at the unloading
point.

• Effective communication system like public address / telephone must be

available for communicating with the control room / fire station / health unit.

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6.3.2 UNLOADING OF DRUMS / CONTAINERS

Manual handling of drums / containers should be

minimized. It is preferable fork-lifters and suitable
cradles are used to handle drums.

Carboys containing hazardous chemicals should not

be subjected to impact.

Suitable protective clothing should be used while

handling drums / containers and the operators should
position himself such that he is in the upwind
direction so that even in case of accidental release of
chemical, he is safe.

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6.3.3. HANDLING OF CYLINDERS
,

181
 Main Hazards
 Impact from a falling cylinder
 Impact from the blast of a gas cylinder explosion or
rapid release of compressed gas
 Impact from parts of gas cylinders that fail or any
flying debris
 Contact with the released gas (e.g., chlorine)
 Fire resulting from the escape of flammable gas or
fluids such as LPG

182
Main Causes of Accidents
 Inadequate training and supervision
 Poor storage
 Inadequate ventilation
 Faulty equipment and/or design (e.g.,
badly-fitting valves or regulators)
 Poor handling
 Poor maintenance

183
Gas Cylinder Safety
• Safety must always be a primary goal when working
with gas cylinders – safety and knowledge go hand-
in-hand.
• Follow the Gas Cylinder Rules, 2004.

185
Gas Cylinder Safety
• When handling or using gas cylinders, you should
know the hazardous properties of the gas and the
safety precautions. (Refer MSDS)
• Do you know that…
• fluorine will violently ignite many substances,
• Silane burns on contact with air, or
• ammonia will decompose thermally into twice its volume?

186
 Gas Cylinder Safety
• While accepting gas cylinders from
vendor, ensure their dates are not
expired.
• Arrange the cylinder storage area so
that old stock is used first.
• Empty cylinders should be stored
separately and identified with clear
markings or a tag.
• Never change the colour of a gas
cylinder
187
Safe Storage
Each Storage area should be subject to unique risk assessment

 It is best to store gas cylinders in the open and

on concrete in a fenced compound with some
weather protection.
 In storage areas oxygen cylinders must be
stored at least 3 metres away/separated by a
fire wall from fuel gases such as acetylene,
propane, methane, etc.
 Full cylinders should be stored separately from
empties and empty oxygen cylinders should be
segregated from empty fuel gas cylinders.
 Other products should not be stored in the gas
storage areas especially not oil or corrosive
liquids, sources of ignition or flammable
materials.
 Ease of access into and around storage area,
such as provision of aisle >0.6m to prevent 188
domino effect.
Safe Storage
Each Storage area should be subject to unique risk assessment
 LPG cylinders have special requirements
including storage 3m away from other
gases.
 Pyrophoric and toxic gases should be stored
separately in locked, suitable ventilated
storage areas with restricted access.
 Protect gas cylinders from external heat
sources which may adversely affect their
mechanical integrity.
 Cylinders should be secured and properly
restrained, secure with straps or chains
connected to a wall bracket or other fixed
surface, or by use of a cylinder stand.
 Cylinders should be clearly labelled to show
contents and associated hazards. 189
 Safe Storage
Gas Cylinder Safety

Cylinders should be located away from any

source of ignition/ heat and, if possible, away
from the fire exits, elevators, walkways,
building egresses, unprotected platform
edges, or in locations where heavy moving
objects may strike or fall on them
Storage arrangements should be clearly
described in the emergency plan
Storage area must have good housekeeping
and adequate warning signs with fire fighting 190
190
equipment as necessary
Cylinder Incident Response
Where a cylinder has been damaged:
If it has been dropped or physically damaged
check it for leakage and deal with as for a
leaking cylinder
For handling acetylene cylinders should not
be moved unless it is clearly established that
there is no thermal disassociation
Clearly mark any cylinder that has been
exposed to excessive heat or physical impact
and contact the supplier

Report any damaged/leaking cylinder to supplier.

191
Cylinder Incident Response (Contd.)
Report any damaged/leaking cylinder to supplier
If a cylinder is leaking but the leak has not
ignited and it is safe to do so having
considered the specific properties of the gas:
 Eliminate all sources of ignition
 Ensure the valve is closed but do not over-tighten it
 Put the cylinder in a safe place that is well-ventilated –
keep it upright
 Mark the cylinder as faulty and not to be used
 Warn everyone in the area of the gas leak
 Inform the supplier
 Ensure the work area is thoroughly ventilated before
continuing with any work
 If a hydrogen cylinder is involved be aware that
hydrogen burns with an invisible flame so seek expert
assistance
192
Cylinder Incident Response (Contd.)

If a cylinder is leaking and it has ignited it

could explode
Evacuate the area to a minimum
distance of 100m.
Call the emergency services at once.

193
RULE 44: NO LICENCE NEEDED FOR FILLING AND
POSSESSION IN CERTAIN CASES

A) POSSESSION OF ANY CYLINDER FILLED

WITH A COMPRESSED GAS BY A CARRIER
OR OTHER PERSON FOR THE PURPOSE OF
TRANSPORT IN ACCORDANCE WITH THE
PROVISIONS OF THESE RULES;

(b) POSSESSION OF CYLINDERS FILLED WITH-

i) LIQUIFIED PETROLEUM GAS WHEN THE

TOTAL QUANTITY OF GAS DOES NOT EXCEED
100 KG AT A TIME;
 II) ANY OTHER FLAMMABLE BUT NON-TOXIC
GAS WHEN THE TOTAL NUMBER OF CYLINDERS
CONTAINING SUCH GAS DOES NOT EXCEED 25
OR THE TOTAL WEIGHT OF GAS DOES NOT
EXCEED 200 KG, WHICHEVER IS LESS, AT A
TIME;
III) ANY NON-FLAMMABLE NON TOXIC
GAS WHEN THE TOTAL NUMBER OF SUCH
CYLINDERS DOES NOT EXCEED 200 AT A
TIME;
IV) ANY TOXIC GAS WHEN THE TOTAL
QUANTITY OF SUCH CYLINDERS DOES NOT
EXCEED 5 AT A TIME;
V) ACETYLENE GAS CONTAINED IN
CYLINDERS IN DISSOLVED STATE WHEN
THE TOTAL QUANTITY OF SUCH CYLINDER
DOES NOT EXCEED 25 AT A TIME.
6.3,4 SAFE DISPOSAL OF EMPTY CONTAINERS OF
HAZARDOUS CHEMICALS AND HAZARDOUS WASTE

The safe disposal of hazardous chemical drums and

hazardous waste is covered by The Hazardous and Other
Wastes (Management and Trans-boundary Movement) Rules,
2016.

So let have look at some key provisions

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Definitions
• 17. “HAZARDOUS WASTE” means any waste which by reason of
characteristics such as physical, chemical, biological, reactive,
toxic, flammable, explosive or corrosive, causes danger or is
likely to cause danger to health or environment, whether alone
or in contact with other wastes or substances, and shall include
-
• waste specified under column (3) of Schedule I;
• waste having equal to or more than the concentration limits
specified for the constituents in class A and class B of Schedule II
or any of the characteristics as specified in class C of Schedule II;
and
• wastes specified in Part A of Schedule III in respect of import or
export of such wastes or the wastes not specified in Part A but
exhibit hazardous characteristics specified in Part C of Schedule
III;
 Definition
• 38“waste” means materials that are not products or
by-products, for which the generator has no further
use for the purposes of production, transformation or
consumption.
• Explanation.- for the purposes of this clause,
• waste includes the materials that may be generated
during, the extraction of raw materials, the processing
of raw materials into intermediates and final products,
the consumption of final products, and through other
human activities and excludes residuals recycled or
reused at the place of generation; and
• by-product means a material that is not intended to
be produced but gets produced in the production
process of intended product and is used as such;
CHAPTER II
PROCEDURE FOR MANAGEMENT OF HAZARDOUS AND OTHER
WASTES
• Rule 4 .Responsibilities of the occupier for
management of hazardous and other wastes.-
• For the management of hazardous and other wastes,
an occupier shall follow the following steps, namely:-
• prevention;
• minimization;
• reuse,
• recycling;
• recovery, utilization including co-processing;
• safe disposal.
How go about this
• Refer to the schedule I - given in process and see if
your industry falls in any one or more process , if
it is the case , waste generated in your company
will be categorized as hazardous waste.
Get the waste analysis done,
• and if the residual contain of chemical exceeds the
limit given in schedule ii , then we need to properly
dispose the waste as hazardous waste
CHAPTER II
PROCEDURE FOR MANAGEMENT OF HAZARDOUS AND OTHER
WASTES

• Rule 8 Storage of hazardous and other wastes.- (1)

The occupiers of facilities may store the hazardous
and other wastes for a period not exceeding ninety
days and shall maintain a record of sale, transfer,
storage, recycling, recovery, pre-processing, co-
processing and utilisation of such wastes and make
these records available for inspection:
• This can extended by Pollution control board in
following cases
8. Storage of hazardous and other wastes
(i) small generators (up to ten tonnes per annum) up to
one hundred and eighty days of their annual capacity;
(ii) actual users and disposal facility operators up to one
hundred and eighty days of their annual capacity,
(iii) occupiers who do not have access to any treatment,
storage, disposal facility in the concerned State; or
(iv) the waste which needs to be specifically stored for
development of a process for its recycling, recovery,
pre-processing, co-processing or utilisation;
(v) in any other case, on justifiable grounds up to one
hundred and eighty days
 Storage & Handling Of HW

Storage is the holding of waste safely for a temporary

period of time. At the end of the storage period, the
waste is treated, disposed of, or stored elsewhere.

Hazardous waste prior to treatment or disposal, must

be stored in containers, tanks, containment
buildings,, waste piles, or bags that comply with the
legal requirements.
Let us watch film

2/7/2024 Waste_Mgt_Overview
 Storage & Handling Of HW

Hazardous waste should be stored at the

authorized place for this purpose only.
2/7/2024 Waste_Mgt_Overview
Storage & Handling Of HW

2/7/2024 Waste_Mgt_Overview
 Storage & Handling Of HW

2/7/2024 Waste_Mgt_Overview
 Storage & Handling Of HW

 Signboards should be displayed at

appropriate locations.
2/7/2024 Waste_Mgt_Overview
 Storage & Handling Of HW

Appropriate measures should be taken to

prevent percolation of spills, leaks etc.

2/7/2024 Waste_Mgt_Overview
 Storage & Handling Of HW

The storage areas should be inspected daily for

detecting any signs of leaks or deterioration if any.

Adequate number of spill kits should be made readily

available.
2/7/2024 Waste_Mgt_Overview
 CHAPTER V
• [Link] and Labeling.- (1) Any occupier handling
hazardous or other wastes and operator of the
treatment, storage and disposal facility shall ensure
that the hazardous and other wastes are packaged in a
manner suitable for safe handling, storage and
transport as per the guidelines issued by the Central
Pollution Control Board from time to time. The
labelling shall be done as per Form 8.
HAZARDOUS WASTE LABEL

Waste_Mgt_Overview
 Transportation of Hazardous waste (Rule 19)

(1) The transport of the hazardous wastes shall be

in accordance with the provisions of these rules
and the rules made by the Central Government
under the Motor Vehicles Act. 1988 and other
guidelines issued from time to time in this
regard.
(2) The occupier shall provide the transporter with
the relevant information in Form 11, regarding
the hazardous nature of the wastes and
measures to be taken in case of an emergency
and shall mark the hazardous wastes containers
as per Form 12.

Waste_Mgt_Overview
6. What is MSDS?- film
A Material Safety Data Sheet (MSDS) is designed
to provide both workers and emergency personnel
with the proper procedures for handling or
working with a particular substance For Safe
handling of chemical
MSDS's include information such as physical
props. Chemical Props ,health effects, first aid,
reactivity, storage, disposal, PPE, and spill/leak
procedures etc..
These are of particular use if a spill or other
accident occurs.
MSDS's are meant for:

• Employees who may be occupationally exposed to a hazard

at work.
• Employers who need to know the proper methods for
storage, assessment, etc.
• Emergency responders such as fire fighters, hazardous
material crews, emergency medical technicians, and
emergency room personnel, etc.
SECTIONS (REACH FORMAT)
1. Identification of the substance/preparation and of the company
2. Hazard identification
3. Composition/information on ingredients
4. First-aid measures
5. Fire-fighting measures
6. Accidental release measures
7. Handling and storage
8. Exposure control/personal protection
9. Physical and chemical properties
10. Stability and reactivity
11. Toxicological information
12. Ecological information
13. Disposal consideration
14. Transport information
15. Regulatory information
16. Other information
MSDS a film

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 NSAT Module III
Section 5-Mangement of change
FILXBOROUGH
 Flixborough Explosion
REACTOR CONFIGURATION
This schematic view indicates the basis of
the incident.
MANAGEMENT OF CHANGE
 A process industry is subjected to continuous
modifications to achieve higher efficiency, improve
operability and safety, improve reliability,
improvement of the plant machineries and equipment
and to accommodate technical change.
 Any changes in the processing units/ facilities may
have the potential to destabilise existing safety and
to introduce new hazards.
 The hazards connected with any change are to be
identified and controlled efficiently through an
appropriate hazard management system.
 FOR WHICH GUIDE LINE IS MUST
 MANAGEMENT OF CHANGE
GUIDE LINE OBJECTIVES:
 Minimise the mishaps caused due to non-
compliance of procedures.
 Improve optimisation and utilisation of
facilities.
 Decrease downtime.

 Increase favourable public opinion.

 Increase knowledge of plants and process

activities
MANAGEMENT OF CHANGE
GUIDLINESSHOULD COVER FOLLWING
SITUATIONS
 change of process / technologies,
 change of hardware excluding replacements
(of same specification and kind),
 change of software,
 change of chemicals and
 change of catalysts,
 change of operating procedures,
 change in working environment.
 changes of personnel,
 MANAGEMENT OF CHANGE
The various types of changes that take place in a process
unit and related facilities are detailed below
 Equipment changes like addition, alteration or
removal of an equipment or a part of it from the
plant.
 Modifications in piping system and process
equipment, replacement of equipment or machinery
that differs from the original equipment.
 Change in metallurgy.

 Change in normal operating procedure, start-up, shut

down and emergency handling procedures.
 Introduction of new catalysts, additives, corrosion
agents, solvents in extraction processes etc.
 MANAGEMENT OF CHANGE
 Change in instrument which may include pressure,
temperatures, flow, set points, alarm points, speed,
logic and control parameters.
 Mechanical process or instrument system changes
made to increase production rates.
 Change of software in a computerised environment.
 Any other change requiring original design review
including service change and changing pipeline
scrapper station / delivery station to pumping or
pumping and storage tank station.
 Introduction of operation or maintenance personnel
who are new in respect of the process
 PROCEDURES CHANGES DUE TO
MODIFICATION OF PLANT/FACILITIES

 All modifications to be authorised by competent persons.

 There should also be a system of inspection of
modifications by a competent person to make sure the
work has been done as intended and is complete.
 The competent persons shall be nominated and notified
by the management of respective organisations / units.
 Implementation of any modification / change shall not
be done without the formal approval of the said
competent persons.
 There should be a system of documentation to record
the change
 There should be adequate training so that all personnel
concerned understood the system of control.
 PROCEDURES CHANGES DUE TO
MODIFICATION OF PLANT/FACILITIES

Any modification shall cover the following as minimum :

 Origination of modification proposal.
 Design philosophy.
 Scrutiny and approval procedure / safety assessment.
 Execution of the modification job.
 Training of the operating / maintenance personnel on
proposed modification.
 Commissioning.
 Updating of documents in line with the modification.
 Approved handing over / taking over procedure.
 Post commissioning review.
 As built record.
 Origination of Modification
Proposal
 Process plants and facilities requires continuous
updation to increase efficiency, improve operability and
safety.
 It is appropriate that the proposed modification is
considered critically. The following three queries shall
always be answered before finalising any proposal :
 Is it necessary ?
 Is it economic ?
 There is a possibility of introduction of new hazards as
the safeguard’s built in original design are changed.
 The modification proposal should therefore achieve
primary objective in a safe manner.
 Origination of Modification
Proposal
 Therefore, the following questions are to be
considered :
 How will the change impact the people and the
work environment ?
 Will people be able to construct / implement and
operate "the change" and work with "the
change" within an acceptable level of risk ?
 How will "the change" impact inspection &
maintenance activities ?
 Is "the change" going to adversely affect excess /
ingress for operation, inspection, maintenance,
emergencies etc.
Origination of Modification
Proposal
 Is there a better alternative?
 This necessitates the following to be checked
before finalising any such modification
proposal :
 The technical basis for the proposed change.
 Impact of change on safety, health and
working environment.
 Modification to operating procedures.
 Authorisation requirements by the competent
persons nominated and notified by the
management for the proposed change.
 Design Philosophy
The process design information should include
 a block flow diagram or a simplified process flow
diagram,
 the process chemistry with relief system
 process design material and energy balances are
available, also be
 consideration environmental requirements

 compliance with respect to safety, health and

environment.
The mechanical design information should include
 materials of construction,
 piping and instrumentation diagram (P&ID),
 area classification,

 design codes and standards employed

 equipment and piping specifications.
 Design Philosophy
 The provision of design and engineering
practice manual and applicable codes and
standards shall be followed while carrying out
any modification.
 Applicable statutory requirement shall also be
considered while firming up the design
philosophy.
 Ergonomics to be well taken care of during the
design stage of modification / change.
 Scrutiny/Approval
Procedure
 Design shall be verified after completion of the
first stage to confirm the following.
 Basic design meets the requirement of the proposal,
 Design is safe for expected conditions of use,
environment and also unintended uses and misuses.
 The above shall be confirmed with detailed process
hazard analysis.
 Compliance of the standards with regulatory
requirements, national and international standards , and
corporate practices.
 Review made by internal and external agency on the
problems faced from similar nature of design.
 Scrutiny/Approval Procedure
Verification after second stage shall confirm the following:
 Detail engineering has been carried out as per the
requirement of the modification.
 It meets the requirement of reliability, serviceability,
maintainability and safety as per national and
international standards.
 There will be least problem in fabrication, installation,
erection, assembly and availability of spare parts and
consumable items.
 Design shall be checked for fail safe characteristic
 Ensure modified system / changed system shall not
exceed design limitations of the existing relief system.
 Aesthetic specification shall also to be met.
 Standard materials comparable with existing plant
materials are only specified to the extent possible.
The system of approval by competent persons at various
stages to be fixed by the individual organisations
Execution of the Modification
Job Procedures
 Modification shall be taken up for
implementation
 only after availability of “Approved for
Construction” documents and materials
as per the bill of materials
 Approval of statutory authority for the
modification wherever applicable.
Training
 Training of the Operating/ Maintenance
Personnel on Proposed Modification
 The operating and maintenance personnel who are
responsible for operating and maintaining the
plant/facility shall be trained on the possible
 impact of the modification. This training should
include safe practices to
 be adopted after the proposed modification. Contract
employees whose job tasks will be affected by the
change in the process shall be informed of and
trained in proposed changes prior to the start-up of
the process.
 The plant manager or his authorised person to brief
and train the contractor personnel who will be
associated with this change.
Commissioning

 Plants/facilities shall be commissioned

after the job carried out is cleared by
multidisciplinary group approved by
management and completion certificate
is available.
 Licence from statutory authority,
wherever applicable, is obtained.
Updating of Documents in
line with Modifications

 Design basis, assumptions and important points of

design, bill of materials shall be provided in the
design document.
 The operating and maintenance manuals are
required to be reviewed in line with the
modifications. Changes if any need to be
incorporated prior to the commissioning of the
plant/facility.
 The Layouts, P&IDs, utility drawings, loop / one line
drawings, emergency response plan and PFDs are
also to be updated to incorporate changes arising out
of the modification.
 Necessary updation of disaster management plan to
be carried out for the proposed modification
Handing Over and Taking
Over procedure

There should be a transparent handing

over procedure by the executing
departments/agencies to the operating
department/[Link] should include
 Transfer of Facilities,
 Hardware,
 Manuals, Drawings etc
 Similarly department/agencies taking over
the facilities should also have a procedure
for the same.
Post Commissioning Review:

 After commissioning of the new/modified

facility, safety check-list to be prepared in
view of modification / change before
conducting any test run for evaluating the
modified facility
 Subsequently, a test run shall be conducted
to evaluate whether the modification have
achieved its desired objective or not.
 The results of such test run shall be recorded
As-built Records

 All modification records generated from

the proposal stage to commissioning
stage including design review,
construction documents statutory
approval shall be preserved in approved
and accepted locations for quick
references. As-built documents shall be
prepared incorporating all the approved
site changes.
ADDITIONAL REQUIREMENT FOR
MAJOR MODIFICATIONS
 PLANT REVAMP
 NEW CATALYST
 CHANGE IN SOLVENT
 CHANGE PROCESS TRIPS &
INTERLOCKS
 SOFTWARE
 SERVICE CHANGE
 CHANGE OF PERSONS
So to conclude
 in the life, as well in working area, change is
inevitable
 so learn to manage the change properly
have procedure laid down follow them, so
that change brings you more productivity and
happiness in the life

 Thanks
 aaraichur@[Link]
THANK YOU