Presentation on Risk invloved in transportation of hazardous chemical and flammable hydrocarbon and its management

1. Presentation on Risk invloved in transportation of hazardous chemical and flammable hydrocarbon and its management A Bairagi Production Manager Guwahati Refinery : Indian Oil Corporation Ltd

2. Risk Concept • Risk is defined as the uncertainity of occurence of • any unforseen event/activity in relation to the liklihood that may occur Risk comprises of two variables Likelihood of occurrence Magnitude of consequences 2

3. Likelihood • Very Likely -- Could happen frequently • Likely -- Could happen occasionally • Unlikely -- Could happen, but only rarely • Highly Unlikely -- Could happen but probably never will 3

4. Likelihood When evaluating the likelihood of an accident, a factor that will modify the likelihood category, is exposure. • Very Rare -- Once per year or less • Rare -- A few times per year • Unusual -- Once per month • Occasional -- Once per week • Frequent -- Daily • Continuous -- Constant 4

5. Individual Perceptions -- Risk is a very individual concept. -- It is different for every one. 5

6. Risk • Another thing to consider is that peoples’ • perceptions change as familiarity increases. • Therefore the perception of a • HAZARD and its RISKS also • changes. 6

7. RiskAssessment Risk: The possibility of an unwanted event occurring Likelihood: The chance of an event actually occurring. 7

8. Risk Assessment and Criteria • Risk criteria are to be applied within the context of a standard methodology. • Several countries have evolved criteria suitable to their requirements for the use of risk analysis as an aid to decision making 8

9. Risk Assessment and Criteria • Workable Risk criteria recognises that: • There is a level of risk that is so high that it is considered unacceptable or intolerable regardless of the benefits derived from an activity. • There is also a level of risk that is low enough as to be considered negligible. • Levels of risk in between are to be considered tolerable subject to their being reduced As Low As is Reasonably Practicable (ALARP). 9

10. Risk Assessment and Criteria - The ALARP Principle • Risks are only tolerable provided that : It can be demonstrated that all Reasonably Practicable measures have been implemented to reduce the risks. A reasonably practicable risk reduction measure is one where the costs of implementation are not grossly disproportionate to the risk reduction benefits achieved. 10

11. Optimal Point Cost of control Principle Of Economics Cost of losses 11

12. 12

13. Risk Assessment 13

14. Risk Assessment ‘QUALITATIVE’ Walk Through Audits Structured Safety Tours Safety Audits Group Risk Assessments Job Safety Analysis ‘WHAT IF’ Analysis Fault Tree analysis HAZOP QUANTATIVE’ Risk Analysis 14

15. Risk Analysis 15

16. ReleaseIncidents • Pump seal leaks • Rupture of a transfer pipe or hose • Valve seal leaks • Flange gasket leaks • Corrosion failure of vessels/pipes • Vessel failure - BLEVE • Over filling • Water draining 16

17. Escalations • Quantity of LPG release • Weather condition • Ignition sources • Operator response 17

18. Hazards • Vapour cloud formation and explosion Damage due to over pressure • FiresThermal damage • BLEVE - Overpressure - Rocketing tank parts - Fire ball 18

19. RISK ON HAZARDOUS CHEMICAL 19

20. CHEMICALS • SOLIDS • LIQUIDS • GASES • VAPOURS

21. Acts/Rules Industries handling hazardous chemicals are covered by the following Acts/Rules: • The Factories Act, 1948, as amended in 1987 • The Manufacture, Storage and Import of Hazardous Chemicals (Amendment) Rules, 2000 : (MSIHC Rules) • The Public Liability Insurance Act, 1991as amended in 1992 • The Central Motor Vehicles Rules, 1989 • The Railway Red Tariff Rules, 1960 as amended • The Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996

22. Chemical Hazard Due To • Inhalation • Ingestion • Skin Contact • Accidental

23. Ammonia : NH3 Routes of Entry : Inhalation, Skin or Eyes Effects of Exposure/ symptoms 700 ppm causes eye irritation and permanent injury may result if prompt medical remedial measures are not taken. 5000 ppm may cause death. Contact of the liquid with skin freezes the tissues and causes the caustic burns.Respiratory track irritant. Irritation to cornea and tearing, liquid contact with eyes, partial or total blindness if not treated immediately. Chemical burns and frostbite.

24. Ammonia : NH3 Personal Protective Equipment • Avoid contact with liquid or vapours • Provide rubber boots, safety goggles, self-contained breathing apparatus, gas mask and protective clothing in case of liquid ammonia.

25. Carbon mono oxide : CO Routes of Entry : Inhalation, Skin and Eyes Human systematic effects by inhalation, changes in psycho-physiological tests and preventing haemoglobin from binding oxygen. Contact of liquid CO with skin causes frostbite. Eye contact causes severe injury.

26. Carbon mono oxide : CO Personal Protective Equipment • Avoid contact with liquid or vapours. • Provide self-contained breathing apparatus, face shield or safety goggles, safety shoes, appropriate canister mask, rubber over-clothing, hand gloves.

27. Chlorine : Cl2 Routes of Entry: Inhalation, Ingestion, Skin and Eyes. Effects of Exposure/ Symptoms : Causes Eye irritation, sneezing, copious salivation, general excitement, restlessness. High concentration causes respiratory distress and violent coughing, often with retching. Death may result from suffocation.

28. Chlorine : Cl2 Personal Protective Equipment • Avoid contact with liquid or vapour. • Provide PVC gloves, gumboots, rubber overcoat, head mask, self-contained breathing apparatus.

29. Hydrogen : H2 Routes of Entry : Skin, Inhalation Effects of Exposure/ Symptoms: If atmosphere does not contain enough oxygen, inhalation causes dizziness, unconsciousness or even death. Contact with eyes or skin or liquid H2 causes freezing similar to burn.

30. Hydrogen : H2 Personal Protective Equipment • Avoid contact with liquid or gas • Provide safety goggles, face shied, insulated gloves and long sleeves, trousers Worn over high top shoes to shed spilled liquid, self-contained breathing apparatus containing air (never use oxygen).

31. Hydrochloric acid : HCl Routes of Entry : Inhalation, Ingestion, skin and Eyes Effects of Exposure/ Symptoms. Inhalation: The major effects of acute exposure to HCL are usually limited to upper Respiratory tract. Exposure to the gas causes cough, burning of the throat and larynx and Choking feeling, inflammation and ulceration of the nose, throat and larynx. Exposure to Higher concentration may cause laryngeal spasm, and oedema of the lungs and vocal Cords. Prolonged or repeated exposure may cause dental decolouration and erosion. Gastritis and chronic bronchitis have also been reported in exposed workers. Giddiness, Mental confusion and nausea.

32. Hydrochloric acid : HCl Skin contact: Cause skin burns and may produce keloid and rectile scarring. Facial burns May result in serious and disfiguring scars. Frequent contact with dilute acid may cause Dermatitis and photo-sensitisation may result from industrial contact. Eye Contact: Hydrochloric acid is a strong eye irritant and contact with the acid may Cause burns, reduced vision and total blindness. Ingestion: Ingestion of HCL causes severe burns and corrosion of mouth oesophagus and Stomach. Symptom include dysphasia, pain, nausea, vomiting , Diarrhoea and thirst. Circulatory collapse may occur and ingestion may lead to fatal effects from oesophagus or gastric necrosis.

33. Hydrochloric acid : HCl Personal Protective Equipment • Approved respirator, Safety goggles, neoprene, viton or butyl rubber glove and acid resistant outer clothing • Mechanical exhaust.

34. Hydrogen Sulphide : H2S Routes of Entry : Inhalation, skin & eyes Effects of Exposure/ Symptoms, Inhalation : If high concentrations are inhaled, hypernoea & piratory paralysis may occur. Very high concentration may produce pulmonary edema. Skin & eyes: Causes severe irritation.

35. Hydrogen Sulphide : H2S Personal Protective Equipment • Avoid contact with gas. • Provide rubber framed side covered goggles, approved respirator, rubber hand gloves, over-clothing and shoes.

36. Caustic Soda : NaOH Routes of Entry :Inhalation, Skin, Ingestion & Eyes. Effects of Exposure/ Symptoms - Inhalation : Causes small burns to upper respiratory tract & lungs, mild nose irritation. Ingestion : Causes severe damage to mucous membrane, severe scaring or perforation may occur. Eyes: Severe damage. Skin: Causes severe burns.

37. Caustic Soda : NaOH Personal Protective Equipment • Avoid contact with solid or liquid. • Provide side covered safety goggles, face shield, filter or dust-type respirator, rubber shoes and rubber hand gloves.

38. Sulphur-di-oxide : SO2 Routes of Entry : Inhalation, Eyes and Skin Effects of Exposure/ Symptoms Vapour causes irritation of eyes & lungs with severe choking. Liquid will cause frostbite. Vapours are poisonous, if inhaled.

39. Sulphur-di-oxide : SO2 Personal Protective Equipment • Avoid contact with liquid or vapours. • Provide air supplied mask or approved canister, safety goggles or face-shield, rubber hand gloves, shoes, aprons.

40. Sulphuric Acid : H2SO4 Routes of Entry: Inhalation, contact, ingestion Effects of Exposure/ Symptoms : Irritates eyes, nose, throat, dental erosion, skin and eyes, burn. Causes deep burn to tissue. Very dilute solution causes dermatitis. Exposure cause bronchitis.

41. Sulphuric Acid : H2SO4 Personal Protective Equipment • Rubber gloves, safety goggles, acid proof overalls. Provide safety shower, eyewash Fountain, self contained breathing apparatus.

42. Hazard Control To reduce hazardous exposure methods include • Mechanical ventilation • Process or personnel enclosure • Control of process conditions & modification • Administrative control • PPE

43. Storage • Limit quantity of material in storage • Appropriate warning signs. • Keep storage area separate from work areas. • Provision of leak detection and alarm systems • Store cylinders upright on a level, fire proof floor, secured in position to • Protect from damage • Keep valve cover on c) Keep filled cylinders separately from empty cylinders.

44. Handling • Move cylinders by hand truck or cart designed for that • Don’t lift cylinders by their caps • Don’t handle them with oily hands. • Don’t drop them or permit them to bang against each other. • Close all valves when, not in actual use. • Open & shut the valves at least once a day, while cylinder is in use, “to avoid valve freezing”. • Have emergency equipment readily available.

45. HAZCHEM CODIFICATION HAZCHEM Code is based on pictorial representations consist of a diamond, as shown in the figure, divided into 4 parts. These parts, starting from left block (in clockwise direction), represent Health Hazard, Flammability Hazard, Reactivity Hazard and Space for additional information such as water reactivity, oxidant and radiation hazard. The colour codes for these hazards are : blue for health, red for flammability, yellow for reactivity and colourless for additional information. The intensity of hazard is grouped into five classes with numerical indications as 0, 1, 2, 3 & 4 in the ascending order of hazard intensity. In the following lines, these hazard intensities are explained, with the numeral on the left indicating the hazard intensity.

46. Flammability (Red) Reactivity (Yellow) Health (Blue) W OXY W : Indicates possible hazard in use of water. OXY: Indicates oxidizing chemicals. HAZCHEM CODE

47. CLASSIFICATION OF HAZARDOUS SUBSTANCES The hazardous substances are classified into eight classes. These are as under : CLASS 1 EXPLOSIVES   CLASS 2 GASES,COMPRESSED, LIQUEFIED, DISSOLVED ORDEEPLY REFRIGERATED, INFLAMMABLE GASES, POISON (TOXIC) GASES.   CLASS 3 INFLAMMABLE LIQUIDS CLASS 4 INFLAMMABL SOLIDS, SUBSTANCES LIABLE TO SPONTANEOUS CONBUSTION; SUBSTANCES WHICH ON CONTACT WITH WATER EMIT INFLAMMABLE GASES. Division 4.1 Inflammable solids Division 4.2 Substances liable to spontaneous combustion. Division 4.3 Substances, which in contact with water, emit inflammable gases. CLASS 5 OXIDISING SUBSTANCES   Division 5.1 oxidizing substances   Division 5.2 Organic peroxides   CLASS 6 POISONOUS (TOXIC) AND INFECTIOUSSUBSTANCES   Division 6.1 Poisonous (toxic) substances   Division 6.2 Infectious substances   CLASS 7 RADIOACTIVE SUBSTANCES   CLASS 8 CORROSIVES For details, the Central Motor Vehicles Rules may be referred.

48. MATERIAL SAFETY DATA SHEET This section includes safety data sheets of most of the hazardous chemicals being used in Petroleum Industry. The data provided are compiled from various data sources as given in Reference. The identity of the chemical is defined in para 1 of the safety data sheet and important physical and chemical properties of each chemical have been given in para 2 of the safety data sheet. The fire & explosion data, reactivity data, health hazardous data have been given vide Para 3, 4 & 5 respectively. The preventive measures and emergency & first aid measures and additional information / references, if any, are given in Para 6,7 & 8 respectively. Individual data sheets are to be supplemented with the following as item 9 and 10. 9. MANUFACTURER’S / SUPPLIER’S DATA Name of Firm Contact Personin Emergency Mailing Address Telephone/Telex Nos.: Local Bodies involved. Telegraphic Address : Standard Packing Details / Ref. Other 10. DISCLAIMER Information contained in this material data sheet is believed to be. Itis up tothemanufacturer/seller to ensure that the information contained in the materialsafetydata sheet is relevant to the product manufactured or sold by him, as the casemay be.

49. RISK ON HYDROCARBON INDUSTRY

50. DEFINITIONS HAZARD SITUATION WITH A POTENTIAL FOR DAMAGE TO MEN, MACHINES AND ENVIRONMENT. EX : FIRE / EXPLOSION