Rpcl-Mps-Op 012 Chemical Handling Procedure Caustic

Rural Power Company Limited
Mymensingh Power Station

Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL Sodium Hydroxide RPCL-MPS-OP-012
HANDLING ROOM (NaOH)
PROCEDURE
Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

MYMENSINGH 210 MW COMBINED CYCLE POWER PLANT
Chemicals Handling Procedure

Sodium Hydroxide (NaOH)
Prepared By:
Revision Description By Date Approved Signature
MPS, RPCL Operation Procedure page 1 of 17

PROCEDURE
AMENDMENT RECORD
Revision Description Date Approved
OVERALL TABLE OF CONTENTS

PROCEDURE
Part Description Page

1.0 PURPOSES AND PREREQUISITES 5
2.0 SCOPE/APPLICABILITY 5
3.0 LIST OF ABBREVIATIONS 5
4.0 RESPONSIBILITIES FOR STORAGE AND HANDLING OF
CAUSTIC
5.0 CAUSTIC HANDLING PROCEDURE 7
5.1 PERSONAL PROTECTIVE EQUIPMENT 7
5.1.2 STORAGE 7
5.1.3 HANDLING 7
5.1.4 CAUSTIC UNLOADING PROCEDURE 7
6.0 PHYSICAL & CHEMICAL PROPERTIES 9
7.0 EMERGENCY RTESPONSE 10
7.1 FIRST AID MEASURES 10
7.2 FIRE FIGHTING MEASURES 11
7.3 ACCIDENTAL RELEASE MEASURES 11
7.4 HANDLING/ STORAGE MEASURES 12
7.5 PERSONAL PROTECTION MEASURES 12
8.0 TOXILOGICAL INFORMATIONS 13
8.1 SYMPTOMS OF TOXICATION 13
9.0 ECOLOGICAL INFORMATIONS 14
10.0 DISPOSAL CONSIDERATIONS 14
10.1 DISPOSAL OF WASTES 14
11.0 APPENDICES 15
1.0 PURPOSES AND PREREQUISITES:

PROCEDURE
The purpose of this procedure is to provide the safe handling of Caustic NaOH to the
concerned personnel in the plant. This procedure gives a complete guideline for the first aid
measures, accidental release measures and storage handling measures etc. This procedure is
provided for all laboratory experimentations and material handlings and should be considered
as a guide during the related operations.
2. SCOPE/APPLICABILITY:
This procedure identifies responsibilities, assigns specific duties and standardizes Operating
methods required for the safe and efficient operation of Mymensingh Power station, Rural
Power Company Limited. All operation personnel of Mymensingh Power station must follow
this operating procedure.
3.0 LIST OF ABBREVIATIONS:

Abbreviation Description
MSDS Material Safety Data Sheet
SCBA Self-Contamination Breathing Apparatus
NaOH Sodium Hydroxide
4.0 RESPONSIBILITIES FOR STORAGE AND HANDLING OF CAUSTIC:

PROCEDURE
DEPUTY MANAGER (CHEMICAL)

 He will be responsible for overseeing the unloading process to make sure it’s done as
per procedure.
ASSISTANT / JR. ASSISTANT ENGINEER (CHEMICAL)

 He will be responsible for completing the unloading process to make sure it’s done as
per procedure as shift personnel.
WORK ASSISTANT
 He will help Plant Engineer to carry out the unloading process safely.
ALL EMPLOYEES
It is the responsibility of all MPS employees to ensure that they:
Never dispose caustic improperly by pouring into site drainage systems, onto the
ground, or into storm sewers.
Never mix acid & caustic with hazardous waste.
OPERATIONS AND MAINTENANCE PERSONNEL

It is the responsibility of the Operations and Maintenance departments to ensure that
they:
 Take steps to prevent leaks and spills. Maintain machinery, equipment, containers
and tanks in good working condition. Ensure that proper procedures are followed
when handling all oils. Have sufficient quantities of absorbent materials available on
site at all times.
 Should a spill or leak occur, take the appropriate steps to contain/stop the spill/leak at
source. Where it is not possible to stop the leak then all practical steps should be
taken to transfer the contents of the leaking container to another container.
 Containment of oil spillage. Containment can be accomplished by erecting oil
absorbent booms or by spreading an absorbent material over the oil and surrounding
area. All used cleanup materials such as rags and absorbent booms should be removed
and stored in the designated container/area until transported to the designated disposal
area.

PROCEDURE
5.0 CAUTIC HANDLING PROCEDURE
5.1 PROTECTIVE CLOTHING AND EQUIPMENT

All personnel unloading caustic soda solution and acid must wear the following
personal protective equipment:
 Hard hat.
 Close fitting safety goggles
 Chemical resistant gloves
 Full face shield (in addition to safety goggles).
 Chemical resistant boots.
 Chemical protective suit (jacket and pants or coverall).
 The jacket should be buttoned up to the neck, the trousers worn outside the
boots, and the shirt sleeves sealed at the glove unless a job safety analysis
determines it is acceptable for the sleeve to be worn over the glove.
 The tank truck unloading operator (supplier) should wear the same protective
equipment and obey the safety precautions as per MPL HSE procedures
5.1.2 STORAGE
Caustic in any quantity, will be kept in an approved storage vessel and prominently labeled.
These containers will not be used for any other purpose.
 Caustic will not be stored near heaters, steam pipes or other sources of heat.
 All containers will be securely covered.
 Caustic kept on shelves, will normally not be stored higher than waist level.
5.1.3 HANDLING
Only properly trained employees will be given the responsibility of operating valves
or other equipment which control the movement of caustics.
Proper training will include at a minimum either past experience in this procedure or
having been trained by another employee or supervisor experienced and trained in
this procedure.
Authority provided protective equipment and clothing will be worn whenever acids or
caustics in harmful quantities may spill, splash, fly or drip upon the person handling
them. The quantity of acid or caustic handled will determine the kind and quantity of
such clothing and equipment. Minimum protection will be chemical goggles, gloves.
Any acid, caustic or other chemical come in contact with the eyes, they will be

PROCEDURE
thoroughly flushed with water and medical assistance obtained when needed.
Persons handling quantities of concentrated chemicals will have quick access to a

supply of water for diluting and washing off any chemical spilled on them or on their
clothing. Minimum protection will be a bucket of water. Where large quantities of
chemicals are handled, a large quantity of water will be readily available. Spills will
be cleaned up according to MSDS.
5.1.4 CAUSTIC UNLOADING PROCEDURE

 It is to be ensured that safety shower and eyewash station situated near unloading area
are in good working condition.
 Only unloading personnel who have been properly trained in the required safe
handling and first aid procedures for caustic soda solution should be assigned to
caustic soda unloading process.
 Once a tank truck is spotted, but prior to connecting, set the handbrake and chock the
wheels. Park the truck, beside the transfer pumps and makes sure the area is free from
obstruction.
 Suitable warning signs should be posted in the surrounding unloading area using
danger tape.
 Partly unloaded tank trucks should be moved with extreme caution. The high density
of 50% caustic soda solution, approximately 1.5 times that of water, may cause vessel
instability during movement.
 Unloading Operation Engineer and/or Operation Helper should confirm proper

unloading lines which are dedicated to a caustic soda solution storage tank.
 Tank trucks should be connected, unloaded, and disconnected in daylight, if possible.

Adequate lighting should be provided if these operations must be done at night.
 Before unloading, personnel should confirm the storage tank is properly vented, the
vent line is clear and open, and that the storage tank will hold the entire contents to be
unloaded.

PROCEDURE
 Tank trucks should be unloaded over an appropriately designed spill containment

area. The unloading Operation Engineer and/or Operation Helper should verify the
location of all fittings before unloading. The tank truck unloading operator (supplier)
should be familiar with these locations. It is recommended that you discuss with him
the specifics of the vehicle before beginning unloading operations.
 Close discharge of one pump and make sure the other discharge is open.
 Connect the hose between tank and pump suction.
 Make sure the vent cap for tank is kept open.
 Open the transfer valve and slowly open the tank discharge valve
 Run the pump to transfer caustic from tank truck to storage tank
 Observe the tank truck caustic level from time to time.
 Once the tank truck is empty, stop the pump to close the tank discharge
valve.
 Start the pump and run for some time to remove residual caustic from the
hose.
 After stopping the pump, de-couple the hose from the truck.
6.0 PHYSICAL AND CHEMICAL PROPERTIES
NaOH (50%):
Physical State (20°C) Liquid

Appearance Clear Colorless solution
Odor Odorless
pH value 14.0
Boiling Point 140°C @ 760 mm Hg
Melting point 12°C
Flash point Not applicable.

Auto-ignition temperature Not Applicable.
Explosion limits in air Not Applicable.
Density (20 °C) 1.53 kg/l

Solubility in Water Completely miscible with water.
Soluble in Alcohol, Ether

PROCEDURE
7.0 EMERGENCY RESPONSE

In case of any caustic spillage/release and human injuries due to physical contact or
inhalation, following emergency responses are needed to take as soon as possible. In
case of injury or persistent symptoms, immediately give first aid to the affected
person. Never give anything by mouth to an unconscious person.
7.1 FIRST AID MEASURES
In case of acid Inhalation
 Remove victim into fresh air.
 Allow the person to drink plenty of water.
 Take patient to hospital immediately
Skin Contact
 Remove contaminated clothing and rinsing.
 Rinse immediately with plenty of water. (Shower if necessary)
 Seek medical attention IMMEDIATELY.
Eye Contact
 Rinse immediately thoroughly and long (at least 15 min.) with plenty of water.
 Remove contact lenses if any.
 Take to eye doctor IMMEDIATELY.
 Keep rising or dripping the eye during transport.
Ingestion
 DO NOT INDUCE VOMITING. Rinse mouth with water.
 Take patient to hospital IMMEDIATELY.
 Never give anything by mouth to an unconscious person

PROCEDURE
7.2 FIRE FIGHTING MEASURES
Improper Extinguishing Media

 Powder, Carbon dioxide.
Special procedures
 Apply water spray or fog to cool nearby equipment.
 Avoid fire-fighting water to enter environment.
Special Protective Equipment for Firefighters
 Use self-contained breathing apparatus and wear protective clothes when in
close proximity to fire.
7.3 ACCIDENTAL RELEASE MEASURES

Personal precautions
 Evacuate all personnel immediate and ventilate area.
 Avoid breathing vapor and contact with skin, eyes and clothing.
 Wear recommended personal protective equipment.
Environmental precautions
 Shut leaks without risks.
 Protect spelled product as much as possible
 Prevent entry of product in public waste, sewers or soil.
 Notify authorities if liquid enters sewers or public waters
Methods for Cleaning Up
 Collect the spillage in closable, suitable and corrosion resistant disposal
containers.
 Flush residue with plenty of water.
 Neutralize with dilute aqueous weak acid.

PROCEDURE
7.4 HANDLING AND STORAGE MEASURES

Handling
 Avoid breathing vapor and contact with skin, eyes and clothing.
 Wear recommended personal protective equipment.
 Rinse contaminated material immediately with water.
 When diluting the acid solution, always pour the product upon the water. Never
add water into the product.
 Avoid heating, splashing and formation of vapor when dissolving the product.
Storage
 Keep only in the original container in a cool, well ventilated, fire proof and if
possible in dark place.
 Keep away from: Acids, Organic materials.
Packing material
 Stainless steel, Polyethylene, Propylene, PVC.
Improper packing material
 Corrosive to several metals.
7.5 PERSONAL PROTECTION MEASURES

Industrial Hygiene
 When using, do not eat, drink or smoke.
 Emergency eye wash fountains and showers should be available in the immediate
vicinity of any potential exposure.
Respiratory protection
 Ventilation, local exhaust.
 Respiratory protection equipment (Filter type ABEK).
Hand protection
 Gloves (Butyl rubber, Nitril rubber, natural rubber, Ethylene, PVC)

PROCEDURE
Eye protection
 Closed safety glasses or face field.
Skin and Body protection
 Corrosion-proof protective clothing.
8.0 TOXICOLOGICAL INFORMATIONS

8.1 SYMPTOMS OF TOXIC ATTACKS
Inhalation
 May be stinging to respiratory tract.
 Inhalation of the substance can cause lung problems.
 Symptoms include Sore throat, Cough, Shortness of breath.
Skin contact
 Stinging, severe Chemical burns upon contact with skin.
 Symptoms include Redness, Pain.
Eye Contact
 Stinging to eyes. Risk of serious damage to eyes.
 Symptoms include Pain, Redness, and bad vision.
Ingestion
 Stinging to mouth, throat and digestive system.
 Symptoms include Burns, Abdominal cramps, Vomiting, Diarrhea.
Other toxicological information
 Symptoms of lung problem mostly reveal after a few hours, intensified by
physical effort.

PROCEDURE
9.0 ECOLOGICAL INFORMATIONS

 Mobility: Product completely soluble in water.
 Bioaccumulation: No bio accumulation.
 Eco toxicity: Weak water pollutant, Product causes strong rise of pH-value of water
and soil.
10.0 DISPOSAL CONSIDERATIONS

10.1 DISPOSAL OF WASTES
Waste from residues/unused products
 The product has to be destroyed according to national or local legislation, by a
authorized company specialized in handling of hazardous waste products.
Removal contaminated packaging
 Packaging is used exclusively for the packing of the product. After use, empty and
close the package very carefully. In case of returning package, the empty package
can be offered back to the supplier.

PROCEDURE
TABLE OF CONTENTS
Part Description Page
11.0 APPENDICES 15
11.1 OPERATIONS PROCEDURE VALIDATION FORM 15

PROCEDURE
11.0 APPENDICES
11.1 OPERATIONAL PROCEDURE VALIDATION FORM
Name of (Operation):
Equipment or Systems Name: Chemicals Handling Procedure OF Sodium Hydroxide (NaOH)
Date:
Please check the alignment settings of this procedure and verify the accuracy and/or
correctness.
I have reviewed this procedure and can validate the alignment settings for its accuracy. This
procedure can therefore be released for operation for this equipment and/or system.
Signed:____________________________________
(Operation)

PROCEDURE

PROCEDURE

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Rural Power Company Limited

Mymensingh Power Station

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

Rural Power Company Limited

Chemicals Handling Procedure

Revision Description By Date Approved Signature

MPS, RPCL Operation Procedure page 1 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

Revision Description Date Approved

OVERALL TABLE OF CONTENTS

MPS, RPCL Operation Procedure page 2 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

Part Description Page

1.0 PURPOSES AND PREREQUISITES:

MPS, RPCL Operation Procedure page 3 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

3.0 LIST OF ABBREVIATIONS:

MSDS Material Safety Data Sheet

SCBA Self-Contamination Breathing Apparatus

NaOH Sodium Hydroxide

4.0 RESPONSIBILITIES FOR STORAGE AND HANDLING OF CAUSTIC:

MPS, RPCL Operation Procedure page 4 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

DEPUTY MANAGER (CHEMICAL)

ASSISTANT / JR. ASSISTANT ENGINEER (CHEMICAL)

OPERATIONS AND MAINTENANCE PERSONNEL

MPS, RPCL Operation Procedure page 5 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

5.0 CAUTIC HANDLING PROCEDURE

5.1 PROTECTIVE CLOTHING AND EQUIPMENT

MPS, RPCL Operation Procedure page 6 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

Persons handling quantities of concentrated chemicals will have quick access to a

5.1.4 CAUSTIC UNLOADING PROCEDURE

 Unloading Operation Engineer and/or Operation Helper should confirm proper

 Tank trucks should be connected, unloaded, and disconnected in daylight, if possible.

MPS, RPCL Operation Procedure page 7 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

 Tank trucks should be unloaded over an appropriately designed spill containment

6.0 PHYSICAL AND CHEMICAL PROPERTIES

Physical State (20°C) Liquid

Boiling Point 140°C @ 760 mm Hg

Melting point 12°C

Flash point Not applicable.

Density (20 °C) 1.53 kg/l

MPS, RPCL Operation Procedure page 8 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

7.0 EMERGENCY RESPONSE

MPS, RPCL Operation Procedure page 9 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

7.2 FIRE FIGHTING MEASURES

Improper Extinguishing Media

7.3 ACCIDENTAL RELEASE MEASURES

MPS, RPCL Operation Procedure page 10 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

7.4 HANDLING AND STORAGE MEASURES

7.5 PERSONAL PROTECTION MEASURES

MPS, RPCL Operation Procedure page 11 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date:

8.0 TOXICOLOGICAL INFORMATIONS

MPS, RPCL Operation Procedure page 12 of 17

Revision: 0 Date: 28 FEBRUARY 2017 Change: Date: