Rural Power Company Limited

Mymensingh Power Station

Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

Rural Power Company Limited

MYMENSINGH 210 MW COMBINED CYCLE POWER PLANT

Chemicals Handling Procedure

Sulfuric Acid ( H2SO4)

Prepared By:

Revision Description By Date Approved Signature

MPS, RPCL Operation Procedure page 1 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

AMENDMENT RECORD

Revision Description Date Approved

MPS, RPCL Operation Procedure page 2 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

TABLE OF CONTENTS

Part Description Page

1.0 PURPOSES AND PREREQUISITES 4
2.0 SCOPE/APPLICABILITY 4
3.0 LIST OF ABBREVIATIONS 4
4.0 RESPONSIBILITIES FOR STORAGE AND HANDLING OF 5
CAUSTIC
5.0 CAUSTIC HANDLING PROCEDURE 6
5.1 PROTECTIVE CLOTHING & EQUIPMENT 6
5.1.1 STORAGE 6
5.1.2 HANDLING 6
5.1.3 ACID UNLOADING PROCEDURE 7
5.1.4 PHYSICAL/CHEMICAL PROCEDURE 9
6.0 EMERGENCY RESPONSE 9
6.1 FIRST AID MEASURE 9
6.2 FIRE FIGHTING MEASURES 10
6.3 ACCIDENTAL RELEASE MEASURES 10
6.4 HANDLING & STORAGE MEASURES 11
6.5 PERSONAL PROTECTION MEASURES 11
7.0 TOXICOLOGICAL INFORMATIONS 12
7.1 SYMPTOMS OF TOXIC ATTACKS 12
8.0 ECOLOGICAL INFORMATIONS 12
9.0 APPENDICES 14

MPS, RPCL Operation Procedure page 3 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

1.0 PURPOSES AND PREREQUISITES

The purpose of this procedure is to provide the safe handling of Sulfuric acid. 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

PVC Polyvinyl Chloride

PPE Personal Protective Equipment

SCBA Self-Contamination Breathing Apparatus

H2SO4 Sulfuric Acid

MPS, RPCL Operation Procedure page 4 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

4.0 RESPONSIBILITIES FOR STORAGE AND HANDLING OF ACID

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 MPL employees to ensure that they:
 Never dispose acid & 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.

MPS, RPCL Operation Procedure page 5 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

5.0 SULPHURIC ACID 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 MPS HSE procedures
5.1.1 STORAGE
Acids, in any quantity, will be kept in an approved storage vessel and prominently
labeled. These containers will not be used for any other purpose.

 Acids will not be stored near heaters, steam pipes or other sources of heat.
 All containers will be securely covered.
 Acids, kept on shelves, will normally not be stored higher than waist level.

5.1.2 HANDLING

Only properly trained employees will be given the responsibility of operating valves
or other equipment which control the movement of acids and 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 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 and acid-
proof gloves. Any acid or other chemical come in contact with the eyes, they will be
thoroughly flushed with water and medical assistance obtained when needed.

MPS, RPCL Operation Procedure page 6 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

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. Fires of flammable acids and caustics will be
extinguished by the use of dry chemical or carbon dioxide extinguishers.

Before lifting or moving a carboy or other chemical container, it will be examined

carefully to see that it is not in a leaky or defective condition.

5.1.3 ACID 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 acid should be assigned to acid unloading
process.
 Only maximum of 15 ton of acid could be unloaded at a time. Once truck loaded with
acid containers is spotted, prior to connecting, set the handbrake and chock the
wheels. Park the trucks beside the transfer pumps and make sure the area is free from
obstruction. Also ensure the vehicle is parked in such a way that there is free space
for hose connection and disconnection, and there should not be any need to take the
hose around the tanker or wheels etc.
 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 98 % Sulfuric acid, approximately two 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 acid storage tank.
 Container trucks should be connected, unloaded, and disconnected in daylight, if
possible. Adequate lighting should be provided if these operations must be done at
night. Avoid unloading operation in stormy and rainy weather.

 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

MPS, RPCL Operation Procedure page 7 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

unloaded.
 Tank trucks should be unloaded over an appropriately designed spill containment
area. Make sure neutralizing chemical for example caustic flake and spill kit are
available nearby to handle leak or any such emergency.
 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.
 Make sure all the discharge valves of the acid containers are closed.
 Connect the hose between container and pump suction.
 Open the vent caps of each container.
 Open the transfer valve and slowly open the container discharge valve.
 Run the pump to transfer the acid from container to storage tank.
 Observe the level of acid in the container.
 After the container is empty stop the pump to close the container valve.
 Start the pump and run for some time to remove residual acid from the hose.
 Make sure the second container valve is closed and vent cap is opened.
 De-couple the hose from first tank and connect to second tank.
 Follow the same procedure for each container.
 After completion of unloading, wash the hose and containers thoroughly with
water.

MPS, RPCL Operation Procedure page 8 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

5.1.4 PHYSICAL AND CHEMICAL PROPERTIES

Sulfuric Acid:

Physical State (20°C) Liquid

Appearance Colorless to brown
Odor Odorless
pH value Not applicable/ Strong acid

Boiling Point 280°C @ 760 mm Hg

Melting point 3°C

Flash point Not applicable.

Auto-ignition temperature Not Applicable.
Explosion limits in air Not Applicable.

Density (20 °C) 1.84 kg/l

Solubility in Water Completely Soluble.
Soluble in Alcohol, Ether

 .
6.0 EMERGENCY RESPONSE
In case of any acid 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.
6.1 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.

MPS, RPCL Operation Procedure page 9 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

 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
6.2 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.
6.3 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.

MPS, RPCL Operation Procedure page 10 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

6.4 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.

6.5 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).

MPS, RPCL Operation Procedure page 11 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

Hand protection
 Gloves (Butyl rubber, Nitril rubber, natural rubber, Ethylene, PVC)
Eye protection
 Closed safety glasses or face field.
Skin and Body protection
 Corrosion-proof protective clothing.

7.0 TOXICOLOGICAL INFORMATIONS

7.1 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.

8.0 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.

MPS, RPCL Operation Procedure page 12 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

TABLE OF CONTENTS

Part Description Page

9.0 APPENDICES 14

9.1 OPERATIONS PROCEDURE VALIDATION FORM 14

MPS, RPCL Operation Procedure page 13 of 14

 Rural Power Company Limited
Mymensingh Power Station
Document Type: Location: Procedure Type: Document No:
CHEMICALS WTU CONTROL SULPHURIC ACID RPCL-MPS-OP-014
HANDLING ROOM
PROCEDURE
Revision: 0 Date: February 28, 2017 Change: Date:

9.0 APPENDICES

9.1 OPERATIONAL PROCEDURE VALIDATION FORM

Name of (Operation):

Equipment or Systems Name: Chemicals Handling Procedure OF SULPHURIC ACID

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)

MPS, RPCL Operation Procedure page 14 of 14