Chemical Hazards

TSP-POGC-NIGC T.T.F.
COURSE SAFETY CODE

SUBJECT CHEMICAL HAZARDS P/TM/TRG/S.CH /001
Objectives: Upon completion of this course, the trainees should be able to:
 Define Chemical Fire & Explosion & Flammable Liquids.
 Describe Chemical Health & toxicity.
 Know about Chemicals and Gases.
Content:
* - Health, safety & environment policy
* - Introduction & Definition
* - Chemical safety
Section 1 - Ammine Type Additives
Section 2 - Ammonia
Section 3 - Aniline
Section 4 - Aromatic Oils
Section 5 - Carbon Dioxide
Section 6 - Carbon Monoxide
Section 7 - Caustic Soda
Section 8 - Carbon Tetrachloride
Section 9 - Chlorine
Section 10 - Cobalt Carbonyl
Section 11 - Furfural
Section 12 - Hydrochloric Acid
Section 13 - Hydrogen
Section 14 - Hydrogen Sulfide
Section 15 - Lead Fumes
Section 16 - Litharge
Section 17 - Mercury
Section 18 - Methyl Ethyl Ketone
Section 19 - Sulfur Dioxide
Section 20 - Sulfuric Acid
Section 21 - Tetra Ethyl Lead (TEL)
Section 22 - Trichloroethylene
Section 23 - Tri-Potassium Phosphate
Prepared by G. Eshghi Checked by Yeganeh Approved by T.T.F

F. Kashkhali Larijani
Date 6 July. 2000 Date 18 July. 2000 Date
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SUBJECT CHEMICAL HAZARDS CODE
P/TM/TRG/S.CH/001
HEALTH, SAFETY AND ENVIRONMENT POLICY STATEMENT
Total South Pars (TSP) recognizes the importance of meeting society’s needs, to protect the
health of the general public and employees, to provide a safe work place for employees and
contractors, and to protect the environment, all along the course of the TSP project
development.
These operations require a high degree of awareness among all members of the company
and its contractors. TSP is consequently fully committed to this HSE policy and standards,
which have been developed to achieve the objective the set forth.
These objectives which TSP considers of greatest importance are:
 Consideration of health and safety at work and respect for the Environment as
important as the economic performance of TSP PROJECT.
 Prevention of exposure to risk in all areas of its endeavors on the belief that any
accident can be prevented through continuous evaluation and improvement.
 Adoption of an attitude of openness and constructive dialogue with public authorities

and local communities to protect the Environment and to safeguard the Health, Safety
and Quality of life of those living or working in the vicinity of our operating facilities.
 Determination to make permanent progress in he field of Health, Safety and

Environment through training programs, consultation and implementation of internal
and external audits.
 Application of appropriate measures to minimize any adverse effects of its operations

on the Environment.
I am committed to improving the integrity of our operations and especially improving our safety
performance in accordance with the TOTALFINA Health, Safety and Environment Charter,
through adherence to the 10 basic HSE rules of the DGEP HSE policy.
M. AYLINES
General Manager
Total South Pars
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INTRODUCTION DEFINITION
The various chemicals handled and processed in our plants can be classified in terms of
hazards as below:
1. Fire & explosion hazards.
2. Toxicity hazards.
3. Reactivity hazards
1. FIRE & EXPLOSION HAZARDS:

In our plant we deal with highly inflammable liquids and gases at various temperature and
pressure. There exists a potential danger of fire at all the time and every care should be
taken to prevent its occurrence.
Chemistry of fire: there are three ingredients, which must simultaneously exist to cause a
fire.
1. Fuel
2. Air
3. Heat
To prevent fire it is therefore necessary that one or more of the above three ingradients
should be controlled as to be non-existent. When fire is started, one or the other of the
three factors is to be removed for the fire, to extinguish.
“The fire pyramid”. Oxygen, Heat, fuel and chain reactions are necessary components of a
fire. Speed up the process and an explosion results.
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Following are some of the possible causes for fire to take place.
1. Smoking & Matches: smoking is a dangerous practice where flammable or combustible
substances are handled. Remedy is to strictly on force, no smoking regulations.
2. Open Flame: Use of open flame, gas cutting & welding can cause hazard. Such jobs
should be permitted after making the area safer or with proper hot work permit and
adequate precautions.
3. Friction: Hot bearing, misaligned or broken machine parts. Jamming of material can
create spark to temperature. Proper maintenance and inspection is a remedy.
4. Electrical: The principal cause of industrial fires. Electrical equipment should be properly
designed and installed in flammable area. Electrical equipment and wiring should be
properly maintained to avoid any short-circuiting or spark.
Non-flame proof electrical equipment should not be brought in flammable area.
5. Hot Surface: Hot surface of heaters, furnaces, boilers can be a source of fire in the
event to leakage of flammable liquid or gases. Remedy is to avoid any leakage from
equipment/pipe line, to the soure of ignition.
6. Spontaneous Ignition: Only waste and rubbish or presence of combustible material in

the storage of material can cause spontaneous ignition.
7. Overheated Material: Abnormal rise in temperature in process or moving machine can

cause ignition & fired.
8. Static electricity: Static charge can develop during flow of liquids/vapors (hydrocarbon,
acids, steam etc.) or powder/solid substances.
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HEALTH & TOXICITY HAZARDS
Apart from other hazards in industries; occupational health hazards are also required to be
controlled. The occupational health hazards, which may adversely affect an employee, are
usually classified as follows:
1. Toxic chemical agents
2. Biological agents
3. Physical agents
Chemical agents in the form of a) Dusts b) Fumes c) Mists d) Vapor e) Gases.
Health hazards associated with biological agents are not associated directly with industries
in general.
Physical agents usually includes (I) noise (II) extreme temperature & humidity (III) abnormal
air pressure (IV) vibration (V) radiation.
Chemical substances reach the body as follows:

a) Inhalation
b) Skin contact
c) Ingestion
Control measure & precaution:

1) All leakages of gases, liquids, from plant should be controlled; the plant and equipment
should be maintained in good condition.
2) Spillage of chemical substances on floors should not be permitted. In case of any

spillage, the area should be thoroughly washed with water.
3) All drums, containers of chemicals should be kept closed to avoid any evaporation and
thus effecting the environment.
4) Housekeeping of plant should be improved. Rubbish, waste material, drums should be

removed from plant time to time.
5) All employees are advised to make use of personal protective equipment like hand
gloves, barrier cream etc. to avoid any skin contact with chemicals.
6) Washing the hands with any solvent or chemical is prohibited.
7) Employees can make use of gas mask or airline breathing mask on jobs, wherever there
are chances of exposure of gases or vapors while working.
8) Employees should get them medically checked and examined periodically at industrial
medical center as per schedule.
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CHEMICAL SAFETY
Safety department has prepared chemical safety data sheets of various chemicals used in
various plants. The chemical safety data sheets give useful information on hazardous
properties of chemicals & on safety aspects of handling individual chemical. These data
sheets can be used as data guide and reference for day operation and use. In this chapter
of safety manual we are putting only few important and hazardous chemicals.
Please find below the definition and meaning of various terms of properties used in data
sheets.
1. Flash Point:
The flash point of flammable liquid is the lowest temperature at which it gives off enough
vapor to form a flammable mixture with air near the surface of the liquid or within the tank or
container.
2. Explosive Limit:
The explosive range or limit includes all concentration of mixture of a flammable vapor or
gas in volume usefully.
Expressed in % by volume in which a flash will occur when the mixture ignited is the lowest.
Percentage at which thus occurs is the lowest explosive limit & a highest percentage is the
upper explosive limit. If such a mixture is confined and ignited, an explosion results.
3. Auto Ignition Temperature:

The auto ignition temperature of a substance whether solid, liquid or gaseous is a lowest
temperature required to initiate or cause self sustain combustion in the absence of a spark
or flame. The temperature varies considerably depending upon the nature, size and shape
of igniting surface and other factors.
4. Vapor Pressure:
Vapor pressure of a liquid is a pressure of a vapor at any given temperature at which the
vapor & liquid phases of the substances are in equilibrium in a closed container. Vapor
pressure varies with temperature and is useful in evaluating the relative tendency of any
given liquid to evaporate under any unknown set of conditions.
5. Threshold Limit Values (TLV):

Threshold limit values are set by the American Conference of Government Industrial
hygienist. (AGIH) according to the AGIH, these values represent condition under which it is
believed that nearly all workers may be repeatedly exposed day after day without adverse
affect.
For gases and vapors, the TL value is usually expressed in parts per million (ppm), i.e.
parts of the gas or vapor per million parts of air.
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For fumes & mists and for some dust, the TLV is usually given as milligrams per cubic
meter. (Mg/m3)
6. Minimal Lethal Dose & LD50 Test:

In experimental toxicology, it is common practice to determine the quantity of poison per
unit of body weight of experimental animal, which will have a fatal effect. The amount per
unit of body weight which will cause even one fatality in a group of experimental animals is
know as minimal lethal dose (MLD). A more commonly figure in experimental industrial
toxicolygy is the amount which will kill ½ of a group of experimental animals. This is known
as LD50 test: representing 50% fatalities.
INTERPRETATION OF HAZARD CODE SYMBOL
H – HEALTH
F – FIRE
R – REACTIVITY
1. LOW
2. MEDIUM
3. HIGH
4. EXTREME
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SECTION 1
AMINE-TYPE ADDITIVES
GENERAL
This section covers the basic points in the protection of personnel from the harmful effects
of the following additives:
1. Tenamene 2 (Dupont 22).

2. Dupont Metal Deactivator.
3. Primine 81-R and HO-4.
Many of these amine type additives are or may be used in various areas of the Refinery.
They have severe irritation effect on the skin and are considered toxic. These materials are
received in drums. The wearing of proper protective equipment is absolutely necessary
when handling these materials.
PRECAUTIONS
1. Use hand pump or similar equipment to avoid splashing when transferring these
materials from a storage drum to a portable container. Use an approved type of safety
can as a portable container to prevent leakage and splashing while in transit.
2. Wear face shield, P.V.C. gloves and P.V.C. suit when connecting or disconnecting lines
to storage vessels containing or having contained amine-type additives. Wear face
shield and P.V.C. gloves when drawing samples from storages drum.
3. Wear rubber knee boots when walking in an area that is contaminated as a result of an
additive spill or when specific job is such that an additive spill may occur.
4. Clean up leaks or spills of additives immediately.
5. Do not wear clothing contaminated with additives.
EMERGENCY TREAITMENT
1. Amine-type additives should be removed from the skin with soap and water at once
2. Report to the Refinery after washing.
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SECTION 2
AMMONIA (NH3)
GENERAL
Ammonia (NH3) is a colorless gas of characteristic odor. It liquefies under pressure and is
soluble in water. When liquid ammonia or ammonia solution is exposed to the air,
suffocating fumes are given off that are harmful to the eyes and respiratory organs.
Ammonia rapidly attacks the skin and is poisonous in pressure of about 150 pounds per
square inch. Ammonia gas is explosive in ordinary temperature and burns when mixed
with air in concentrations of 16 to 27% by volume. Its explosive properties are mild as
compared, for example, with gasoline vapors in air.
Ammonia is used principally in the refinery as a refrigerant in the F.C.C.U. Gas Recovery
plant, Lubricating Oil plant, Ice plant and Air Conditioning Plants, and on the Benches for
injection into the vapor lines for neutralization purposes.
Contact with ammonia causes severe skin burns and is extremely irritating to the eyes and
upper respiratory tract.
MAXIMUM ALLOWABLE CONCENTRATION

The currently accepted maximum concentration of ammonia is 95 parts million parts of air
for 8 hours exposure.
PRECAUTIONS
1. Rubber or P.V.C. gloves and goggles must be worn working on equipment containing
ammonia.
2. Gas masks equipped with an ammonia canister must be readily available to all
employees working in plants that use or store ammonia. The gas mask must be worn
by employees scheduled to work on leaks or when other conditions warrant.
3. All personnel who work on ammonia equipment should be familiar with emergency
procedures in case of serious leaks.
EMERGENCY TREATMENT
1. Wash liquid ammonia off the skin or clothing immediately after contact.
2. If eyes are involved wash them for at least 15 minutes with water. Report to the
Refinery Clinic for medical treatment.
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SECTION 3
ANILINE (C6H5NH2)
GENERAL
Freshly distilled Aniline is a colorless and oily liquid, which gradually turns brown on
exposure to air. It has a characteristic slightly aromatic odor. In refineries its use is
generally confined to that of a laboratory reagent and in printing.
Aniline enters the body chiefly by absorption through the skin and to a lesser degree
through inhalation of the vapors. The absorption of Aniline through the skin is quite rapid. It
acts principally on the blood and central nervous system in even moderate exposures. The
symptoms are cyanosis (blue color) of the lips, cheeks and ears and in some cases there
may be in addition a flushed face, weariness and irritability. With more severe exposure,
the cyanosis (blue color) may be very marked, accompanied by a peculiar grayish-bluish
tint. Other complaints are headache, dizziness, nausea, chills, rapid pulse, later a slow
pulse; irregular, rapid and shallow respiration.
Continuous exposure to Aniline may result in increasing pallor, loss of weight, weakness,
slow pulse, irregularities in blood pressure, headache, irritability, dizziness, insomnia and
tremors.

The maximum permissible concentration of Aniline vapor in the air for an eight-hour
working period is 5p.p.m.
PRECAUTION
Aniline should be handled so that skin contact is definitely avoided at all times:
1. Every care should be taken to avoid any possibility of spillage.
2. Impervious gloves and apron shall be worn as provided for this purpose.
3. Care should be taken to avoid the inhalation of Aniline vapors by using under a hood
with forced ventilation.
4. Clothing contaminated with Aniline shall be thoroughly washed before re-using.
In addition to the above, all employees who are liable to handle Aniline shall be cautioned
of its poisonous nature and shall be instructed as to the proper procedure in pipetting or
measuring this chemical and in disposal of the material after the rest.
EMERGENCY TREATMENT
1. In case of accidental spillage, remove all contaminated clothing immediately. The
contact areas of the skin should then be immediately cleaned with alcohol.
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2. Immediately after removing the contaminated clothing the employee should be dressed
in substitute clothing if necessary and then accompanied to the Refinery Clinic. In as
much as Aniline causes sudden failure of respiratory action the man should be under
constant observation from the time of the time of the accident by someone capable of
applying artificial respiration. A minimum observation period of four hours is absolutely
necessary.
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SECTION 4
AROMATIC OILS
GENERAL
Certain oils, which contain fairly concentrations of aromatic materials, require special
precautions in handling. The aromatic hydrocarbons covered in this section are Catalytic
Cracking Unit heavy cycle gas oil, clarified oil, and slurry.
PRECAUTIONS
1. The number of points of exposure and the number of employees engaged in handling
these materials shall be minimized.
2. Those employees who are working with these materials, or who are working on
equipment that contains them, must at all times wear the necessary protective clothing.
This may consist of only a pair of P.V.C. Gloves; or, it may consist of a complete P.V.C.
suit, goggles, rubber boots etc., depending on the circumstances.
3. While working under exposure to Aromatic Oils if ordinary work clothes should become
contaminated with these oils, they should be promptly changed, and the contaminated
clothing should not be re-used until the contamination has been removed.
4. Contact of the skin with these materials might cause skin to become irritated, and for
this reason, any such contacts must be thoroughly washed with soap and water. If any
irritation persists after washing, the employee should report to the Refinery Clinic.
5. These oils possess certain toxic characteristics that make it inadvisable to inhale the
vapors or fumes from them; therefore, employee should exercise care in opening
equipment, taking samples, etc., to minimize the quantity of vapor that is inhaled.
Standing on the windward side of any such operation may sufficient, but under other
circumstances such as cleaning vessels, drums or tanks it shall be necessary to wear
fresh air masks.
6. Spills and leakage of these materials should be avoided in loading and unloading
operations such as on tank trucks, tankers, drums and also when obtaining samples.
Any spillage, which happens to occur, should be cleaned up promptly, using care to
avoid skin contact and inhalation of the vapors.
7. Care shall be taken to insure complete removal of all aromatic oil from lines, pumps,
exchangers, etc., prior to the time that it is turned over to the mechanical forces for
opening and subsequent maintenance work.
This responsibility shall rest with the operating personnel and they shall develop
whatever procedure of steaming and flushing they deem necessary to carry out this
phase of the precautions.
8. When storage tanks having contained these aromatic oils, are removed from service for
cleaning, the Safety Section should be notified prior to start of work.
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9. The same general precaution should be exercised by the laboratory personnel as are
outlined above.
10. In particular, all handling of oils containing the aromatic materials, wherein any vapors
may be evolved, shall be carried out under a ventilated hood.
11. All samples shall be placed in closed containers, clearly and properly tagged for
identification, and they should be stored under ordinary room temperature.
EMERGENCY TREATMENT
Report any skin irritation from contact with aromatic oils to the refinery Clinic.
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SECTION 5
CARBON DIOXIDE (CO2)

GENERAL
Carbon dioxide (CO2) is a colorless, odorless gas and is generally regarded as a simple
asphyxiant. Carbon dioxide is present in all air, fresh or otherwise.
Carbon dioxide is not itself harmful, but if accumulates to such an extent that it replaces the
required oxygen, the absence of oxygen causes suffocation or asphyxiation.
Because carbon dioxide is heavier than air (density is 1.53 air is 1) it has a tendency to
settle to bottom of enclosure, tanks, sewers, etc., and does not diffuse rapidly. Liquid
carbon dioxide exists only at low temperatures or at normal temperatures and high
pressure. Solid carbon is extremely cold and causes burns if it contacts any part of the
body.
Carbon dioxide is manufactured at the refinery by reacting seashells with 85% H2SO4,
Carbon dioxide is used principally in the Refinery by Fire Services for the filling of fire
extinguishers. Small amounts are used by the hospital and the Soda Water plant. Carbon
dioxide being an inert gas can be used to purge drums and vessels.
PRECAUTIONS
1. Flush with air all drums and vessels that have been filled with inert gas and test for
oxygen content to be sure that sufficient oxygen is present before entering without a
fresh air mask. When necessary to enter a carbon dioxide contaminated area wear a
fresh air mask; or, if sufficient oxygen is present, use a gas mask equipped with an all
purpose (black) canister.
2. Store carbon dioxide cylinders in a cool place and where they will not be exposed to a
source of heat. (Including sunrays). Store or strap the containers in suitable racks to
prevent them from falling over.
3. Never permit anyone to enter a tank, drum, vessel, sewer or other enclosed space that
has been sealed for any appreciable length of time without first ventilating the
enclosure. Natural or forced draft ventilation should continue while workers are therein.
If ventilation is impracticable, all persons entering tanks, sewers, etc. must be equipped
with a fresh air mask, rescue harness, and under the constant observation of an outside
attendant.
EMERGENCY ACTION
1. If a person is overcome and has stopped breathing he should be removed to fresh air
immediately and given artificial respiration.
2. A doctor should be summoned at once.
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3. Artificial respiration should be continuous until the victim is recovered or until the doctor
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SECTION 6
CARBON MONOXIDE (CO)

GENERAL
Carbon monoxide is an odorless, tasteless, colorless gas, which is not irritating.
It is formed wherever there is combustion of any carbon containing fuel in a deficiency of
air. Carbon monoxide is found in inert gas, synthesis gas, Catalytic Cracking and
Plat former Units flue gas auto and internal combustion engine exhausts. It is slightly
heavier than air with a density of 1.250 where air is 1.
Carbon monoxide is an extremely dangerous poison. It readily accumulates in the blood

stream and prevents oxygen from being carried from the lungs into the tissues of the body.
As little as 0.10% - 0.20% carbon monoxide in air forms a dangerous exposure for one hour
and 0.40% in air is usually fatal in less than one half hour. Headache, drowsiness,
tiredness, confused actions, and dizziness are generally the first signs of carbon monoxide
poisoning, but a sometimes-total collapse occurs without prior symptoms. A special carbon
monoxide detector is available in the Safety Section and where concentrations of this gas
are known or suspected, they should be called upon to run tests to determine the actual
concentrations of this gas, particularly prior to entering contaminated actual concentration
of this gas, particularly prior to entering contaminated vessels.

Maximum allowable concentration of carbon monoxide is 50 parts of carbon monoxide per
million parts of air for an 8-hour exposure.
PRECAUTION
1. When carrying out operation where there is a possibility of generating carbon
monoxide, provide ventilation by using air movers, fresh air ducts, or open windows to
remove carbon monoxide. Provide the exhaust ventilation at the point where carbon
monoxide is being generated.
2. Do not operate vehicles with internal combustion engines inside closed buildings
without adequate ventilation.
3. When working in a carbon monoxide contaminated atmosphere, wear a gas mask
equipped with an all purpose (Black) canister in concentrations up to 2.0% for a period
not longer than 2 hours. Where concentration is above 2.0% a fresh air mask must be
used.
4. Do not enter a vessel containing inert gas, synthesis gas, or is suspected of containing
carbon monoxide without first obtaining a satisfactory gas test, conducted Safety
Section.
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EMERGENCY TREATMENT
Remove anyone overcome by carbon monoxide gas to fresh air. Give the patient artificial
respiration immediately. Call the Refinery Clinic as soon as possible.
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SECTION 7
CAUSTIC SODA (NaOH)

GENERAL
Caustic Soda (NaOH) called Sodium Hydrate or Sodium hydroxide, or Lye, is a white,
crystalline, brittle, and solid. It dissolves freely in water with the evolution of great heat.
Caustic Soda is used at many refinery units for washing and neutralizing various streams. It
has a markedly corrosive action upon body tissues. Its corrosive action causes burns and
frequently deep ulcerations. Mists and dusts of this compound cause burns and contact
with the eyes rapidly causes severe damage. Ingestion causes very serious damage to the
throat and stomach tissues with which contact is made. Extra precautions must be taken
when working with this material.
PRECAUTIONS
1. Store dry caustic soda in cool dry place. Keep containers plainly labeled and tightly
closed.
2. When handling dry or liquid caustic soda in any concentrations, when operating caustic
handling equipment, or when working on equipment containing or having contained
caustic soda, wear chemical type safety goggles and/ or face shields, P.V.C. hood,
gloves and P.V.C. suit. If the exposure might involve the feet, wear rubber ankle or
knee boots.
3. Provide an abundant supply of water near all caustic soda operation, preferably in the
form of emergency showers.
4. Whenever caustic solution is spilled wash it up immediately. Never leave spillage of this
material unattended.
EMERGENCY TREATMENT
If any part of the body has been contacted by caustic Soda wash it off quickly and
thoroughly with soap water.
1. If clothing has been contaminated remove it while under the shower and wash body
thoroughly.
2. If eyes are involved wash them for at least 15 minutes with water.
3. Report to the refinery Clinic for medical attention.
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SECTION 8
CARBON TETRACHLORIDE (CCl4)

GENERRAL
Carbon tetrachloride is a clear colorless liquid with a slightly sweetish odor.
It is non-flammable but extremely toxic. It acts as a depressant on the heart muscles and
produces degeneration of the heart, liver, kidneys and pancreas.
For these reasons its application at the refinery shall be strictly limited to only laboratory
use in small quantities as a starting agent. Cleaning agents containing carbon tetrachloride
shall not be sold.
Note: Where carbon tetrachloride had been used as a degreasing solvent less toxic
solvents (500 ppm.) Such as trichloroethylene (CH Cl C Cl2), or III trichloroethane, shall be
used under Controlled conditions.
Chronic exposure of the skin to Carbon Tetrachloride may lead to the development of an
extensive dermatitis of the dry, fissured type. Secondary infection may occur.

The current acceptable concentrations of Carbon Tetrachloride for persons exposed during
an eight hour day has been set at 10 ppm.
PRECAUTION
1. Employees shall at all times handle Carbon Tetrachloride so as to avoid inhalation of
the vapors.
2. Direct skin contact shall be avoided. Absorption through the skin may be prevented by
the use of P.V.C. aprons and gloves.
3. Clothing which has become wet with Carbon Tetrachloride should be removed at once.
4. Prolonged exposures shall be avoided as far as possible. Gas masks shall be worn if
prolonged exposure to excessive concentration is unavoidable.
EMERGENCY TREATMENT
1. The individual should be removed promptly from the contaminated atmosphere whether
unconscious or not.
2. Call the doctor.
3. Artificial respiration should be carried on if respiration ceases and oxygen administered
if the color is cyanotic (blue).
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4. Any clothing wet with Carbon Tetrachloride should be removed at once, as it can be a
source of further exposure.
5. Remove victim to the refinery Clinic.

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SECTION 9
CHLORINE (Cl2)
GENERAL
Chlorine at ordinary temperature is a greenish yellow gas with a characteristic-suffocating
odor (Specific Gravity 2.49, air is 1). It is shipped as a liquid under pressure in steel
containers. Liquid chlorine is amber colored oily liquid, which gasifies at atmospheric
pressure at temperatures above 28.5 ºF.
Neither the gas nor the liquid is flammable or explosive in itself. In refineries its principal
use is for water treatment although it may be used occasionally as a laboratory reagent.
Chlorine is extremely irritating to the membrane of the eyes and respiratory tract. In
sufficiently high concentration the gas may cause death. It produces no cumulative effects
and complete recovery from mild exposure usually from mild exposure usually occurs.
The greatest danger from chlorine occurs when there is a sudden exposure to a
concentration such as may occur from a broken valve or pipe particularly during unloading,
moving or connecting liquid chlorine containers. A small gas leak in a chlorine container or
line will gradually increase because of the corrosive action of chlorine.

The currently accepted maximum allowable concentration of chlorine is one part per million
parts of air.
PRECAUTIONS
1. All pertinent precautions in “Pressure Cylinders, Handling, Storage and Use” shall be
followed.
2. Gas mask with canister approved for chlorine solvent shall be provided for each person
unloading, moving or connecting chlorine containers. Extra masks and canisters shall
be maintained for emergency use nearly be worn in high concentrations.
3. Rubber or P.V.C. gloves shall be available. A suit of rubber or P.V.C. may be provided
where exposures to high concentrations are likely. When used, the suit should be
securely fasted about the neck at the wrists and ankles.
4. Before returning empty chlorine containers, close their valves and test for chlorine leaks
at the valve outlets by applying an ammonia water soaked rag attached to the end stick.
The formation of a white smokelike cloud rag attached to the end of a stick. The
formation of a white smoke like cloud will result if there is any chlorine gas leakage. If
no leakage is indicated, apply cap nuts to valve outlets and valve protection housings or
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caps securely in their proper places. These fittings should always be kept in place
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5. If it becomes necessary to warm a container, use great care because of the low fusion
point (157 degrees Fahrenheit) of the safety plugs in the valves of the containers. The
valves should never be heated.
6. Containers should be stored in an upright position, thus keeping the liquid away from
the valves. (one ton containers are usually stored horizontally because of the difficulty
of handling them in an upright position).
7. Reducing valves and gauges designed only for chlorine shall be used on containers.
8. Handling of chlorine leaks:
a) Keep on the windward side of the leak.
b) If the leak is extensive, promptly warn all persons in the path of the fumes to
move to a safer location.
c) Spray water freely on the escaping liquid. This forms chlorine hydrate, from
which the evaporation of gas is slow. Caustic soda dissolved in water adds to its
effectiveness as an absorbent of chlorine gas.
d) If the leak is above the liquid level, chlorine will escape as a gas.
Since water is not effective for gas leaks the container should be turned over to
brings the point of leakage below the level of the liquid.
e) If water is not immediately available, dig a trench to draw off the liquid to a lower
Spot, the object being to reduce the area of the surface of liquid from which
evaporation takes place. Loose earth, cement, lime, either fresh or slaked, and
textiles, wet or dry, especially bagging and felts, thrown on the liquid at once will
act as an absorbent or blanket and effectively retard evaporation.
f) When attempting to plug a leak in any manner, hands and body should be
protected against the escaping chlorine by the use of impervious P.V.C. gloves
and clothing. Fresh air mask should be worn under these conditions.
EMERGENCY TREATMENT
1. Remove the affected person at once to open air and away from all gas.
2. Place the patient flat on back. Do not exercise or excite him. Patient should be kept
warm.
3. If breathing has ceased, begin artificial respiration at once.

4. Call a physician.
5. Advise the patient to resist as much as possible the impulse to cough.
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SECTION 10
COBALT CARBONYL Co4 (CO)12

GENERAL
Cobalt Carbonyl is a toxic material. It is formed by the reaction of a cobalt containing
carbon monoxide. Cobalt carbonyl is a black crystalline solid at temperatures below 120º F
at 124º F it melts to form a liquid, which boils at 125º F. The solid and liquid are unstable in
the absence of carbon monoxide and decompose into carbon monoxide and cobalt metal.
Cobalt carbonyl soaked material is subject to spontaneous combustion. Skin irritation
results from contact with solid or liquid cobalt carbonyl and the fumes are highly toxic.
Cobalt carbonyl will be present in the Refinery processes where a cobalt catalyst is being
used and controls must be taken to guard against exposures to it.
Specifically cobalt and nickel carbonyl will be present in the reactor vessels of the Unifier
Section of the Catalytic Reformer No.1.

None specifically established, but cobalt carbonyl compares with carbon monoxide gas,
which has a M.A.C. of 50 ppm in air; 57.5 milligrams per cubic meter of air.
PRECAUTIONS
1. Avoid breathing vapors from cobalt carbonyl. Tanks or vessels, which contain cobalt,
must be steamed in order to decompose any cobalt carbonyl, which may be present. When
a necessity arises for entering tanks or vessels before they are steamed, wear a fresh air
mask even though a gas test shows the vessel to be free of carbon monoxide and
combustibles.
2. Avoid getting cobalt carbonyl in the eyes or on the skin. Wear goggles and P.V.C. gloves
and P.V.C. suits when handling or working near cobalt carbonyl or any other compound,
which might form cobalt carbonyl.
3. Special care shall be taken when attaching the catalyst discharge shute of the unifier
section of the Catalytic Reformer prior to unloading the reactor. In order to prevent possible
exposures to Cobalt Carbonyl, all purpose canister gas masks shall be worn personnel
when attaching the discharge shute.
4. After discharging catalyst from the reactor, an inspection shall be made by one person
using a fresh air mask to determine if any catalyst hold-up has occurred.
5. If Catalyst hold-up has occurred, it shall be cleared by personnel using a fresh air mask.
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6. When the reactor is free of catalyst, an air sample from the reactor interior shall be taken
by laboratory personnel for cobalt carbonyl analysis. Personnel shall be allowed to enter the
reactor without respiratory protective equipment only when such air analysis shows no
cobalt carbonyl.

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EMERGENCY TREATMENT
Remove anyone affected by or overcome by cobalt carbonyl fumes to fresh air.
Call the refinery Clinic immediately or remove the patient to the refinery Clinic.
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SECTION 11
FURFURAL (C4 H3 OCHO)

GENERAL
Furfural is a colorless to amber liquid with a distinctive odor similar to that of oil of bitter
almonds. It is used in the refinery as a solvent in the refining of lube oils.
Practical experience has demonstrated conclusively that under ordinary operating

conditions the use of Furfural is not hazardous to the health of employees because of its
low volatility. However, it may cause a smarting sensation of the skin and the liquid is
dangerous to the eyes.

Furfural is not readily convertible into vapors at ordinary temperatures, and, therefore, it is
difficult to build up substantial concentrations of it in the atmosphere. Maximum allowable
concentration has tentatively been set at 15 parts per million in air for an eight hour working
period.

Furfural is not ready convertible into vapors at ordinary temperatures, and, therefore, it is
difficult to built up substantial concentrations of it in the atmosphere. Maximum allowable
has tentatively been set at 5 parts per million in air for an eight hour working period.
PRECAUTION
1. Adequate ventilation should be provided so as to prevent a built up of vapors and
irritation to the eyes and mucous membranes.
2. Employees exposed to furfural should be instructed as to its effects and the safest
methods of conducting their operations.
3. No special protective clothing is needed that rubber or other protective type gloves
should be worn if the hands are to in repeated contact or immersion in Furfural. If there is
danger of liquid splashing in eyes acid goggles should be worn.
4. Any clothing or shoes, which become soaked with Furfural should be removed promptly
and the contacted parts of the skin washed thoroughly with soap and water.
5. Laboratory precautions to be taken are in general similar to those connected with the
handling of kerosene expect that additional care should be taken to avoid contact of furfural
with the skin.
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Before any pressure gauge or orifice meter is removed for test or repair, the valve
immediately adjacent to the main line should be closed and all lead lines vented. This is an
important precaution against the possibilities of entrapped vapor.

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MERCURY (Hg)
See part II Section 17.
CALIBRATION OF INSTRUMENTS
When calibration instruments using a manometer, care must be taken to prevent the
manometer fluids from blowing out.
DRAWINGS HYDROCARBONS OR CHEMICALS

Never permit the draining of hydrocarbons or chemicals from meter installations or control
valves on hot lines or over process equipment. Proper receptacles or drain piping should be
provided.
PITOT TUBES
All Pitot tubes which are inserted or withdrawn from process lines must be equipped with a
locking device in good condition.
When withdrawing Pitot tubes the proper written Instrument Section procedure must be
followed to prevent the pressure in the line from driving the Pitot tubes out.
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SECTION 12
HYDROCHLORIC ACID (HCl)

GENERAL
Hydrochloric acid (HCl) is a colorless gas or colorless, fuming liquid of pungent irritating
odor. It is strongly corrosive. It attacks all metals except gold and platinum and is, therefore,
usually handled in glass containers or in equipment with special acid lining.
Anhydrous hydrogen chloride is manufactured at the refinery and is used for butane
isomerization purposes. Small amounts of aqueous hydrochloric acid are prepared for
desalting refinery equipment by chemical cleaning.
Hydrochloric acid is an irritant to the mucous membranes of the eyes and respiratory tract
and a concentration of 35 parts per million causes irritation to the throat after short
exposures. More severe exposures result in pulmonary edema, and often-laryngeal spasm.
The acid solution is poisonous if swallowed.
Hydrochloric acid is not combustible (in air) but if to come in contact with common metals
Hydrogen is evolved which may from an explosive mixture.

The maximum permissible concentration of HCl is 3 part per million in air; 8 milligrams per
cubic meter of air.
PRECAUTIONS
1. All HCl containers should be safeguarded against mechanical injury, kept away from
oxidizing hazards, nitric acid and chlorates.
2. Avoid contact of metals from leakage.
3. When handling HCl, or operating equipment in decaling process or working on
equipment containing or having contained HCl, wear chemical type safety goggles and face
shields, P.V.C. hood, P.V.C. gloves and P.V.C. suit. Where it involves the feet, wear ankle
or knee boots.
4. Operation in the HCl plant should wear a minimum of a face shield, P.V.C. gloves, boiler
suit and rubber ankle boots for routine operation and inspection of equipment when outside
the control room.
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5. Provide an abundant supply of water near all operations using HCl; preferably in the form
of emergency showers.
6. Whenever HCl solution is spilled wash it up immediately, never leave spillage of this
material unattended.
7. Avoid all contact or inhalation of fumes by using a gas mask equipped with a canister to
protect against exposures to acid gases.

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EMERGENCY TREATMENT
1. If any part of the body has been contacted by hydrochloric acid wash if off quickly and
thoroughly.
2. If clothing has been contaminated, move it while under the shower and wash body
thoroughly.
3. If eyes are involved wash them for at least 15 minutes.
4. Report to the Refinery Clinic for medical attention.
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SECTION 13
HYDROGEN (H2)
GENERAL
Hydrogen (H2) is an odorless, tasteless and colorless gas. It is not irritating and it is not
toxic, but in high concentration it can cause asphyxiation.
Hydrogen is lighter than air and when released may accumulate under a ceiling or roof. In
pure state it will burn with a quite blue flame, but it forms an explosive mixture with air over
a much wider range of concentration than hydrocarbon gages. Explosive mixture result
when the hydrogen content in air is in the range of 4% - 75%. It therefore must be handled
with extreme caution.
Hydrogen gas may be found in the lead burning shop, laboratories, at the Catalytic
Reformer and Hydrofiner Units and attending piping, in acid handling areas, and as a
by product of corrosion of metals by sulfuric acid. It is also formed by contact of caustic with
certain metals such as zinc and aluminum.
PRECAUTION
1. Provide positive ventilation in all hydrogen storage areas and enclosed areas where
hydrogen is used.
2. Keep hydrogen containers tightly sealed and plainly labeled.
3. Before introducing hydrogen into a vessel, compressor, or any closed system, purge fully
with inert gas and continue purging until samples of gas from the system show not over
0.2% oxygen by ORSAT analysis. Be sure that air is not trapped in dead ends of piping or
equipment.
4. If hydrogen is to be burned have a source of ignition in operation before releasing the
hydrogen to assure the absence of an explosive mixture on ignition.
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SECTION 14
HYDROGEN SULFIDE (H2S)

GENERAL
Hydrogen sulfide is a colorless, poisonous gas, heavier than air (Specific Gravity 1.895 Air
is 1), with the odor of rotten eggs. Being heavier than air it may collect in low places.
However, it rapidly diffuses with air. We are interested mainly in the following sources of
Hydrogen Sulfide gas contamination at the Refinery; handling and storage of sour crude;
natural gas containing Hydrogen Sulfide; distillation and cracking plant areas processing
sour crude oil; and sulphur manufacturing plant.
Despite its characteristic odor of rotten eggs, the sense of smell cannot always be relied
upon to detected the presence of hydrogen sulfide gas. This sense may be lost in two to
fifteen minutes of exposure to concentration of hydrogen sulfide as low as 0.01% by
volume; that is, 100 parts of hydrogen sulfide per million parts of air, or 6.4 grains of
hydrogen sulfide per 100 cubic feet of air.
In all instances where hydrogen sulfide gas is suspected all the Safety Section and they will
conduct the required tests.
TYPICAL REFINERY LOCATIONS AND OPERATIONS WHERE H2S MAY BE

ENCOUNTRED.
H2S may be encountered at the following locations or in the following operations; however,
there may be other locations or operations where H2S may be present.
Care should be exercised to prevent exposure wherever and whenever H2S is suspect of
being present:
1. Areas around drainage ditches when draining water from tanks marked “poison Gas”
2. Areas around units charging “sour crude”
3. Cleaning tanks and stills = (distillation units)
4. Condenser boxes.
5. Gas Scrubbers.
6. Gauging tanks.
7. Sewers drains, and waste water disposal sumps.
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8. Sulphur production plant and plant area.

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MAXIMUM ALLOWABLE CONCENTRATION H2S

Period of exposure:
1. Maximum allowable concentration for example not exceeding 8 hours daily; 10 parts per
million.
2. Slight symptoms after exposure of several hours; 70 to 150 parts per million.
3. Maximum concentration that can be inhaled for 1 hour without serious consequence; 170
to 300 parts per million.
4. Dangerous after exposure of 30 minutes to 1 hour; 400 to 500 parts per million.
5. Fatal in exposure of 30 minutes; 600 parts per million.
6. Higher concentration cause death almost immedicately.
PRECAUTIONS
1. Prevent escape of vapors or fumes into the air of working places.
2. Maintain good ventilation.
3. Avoid gas whenever possible by working on the windward side of the outlet from which
the gas is escaping.
Caution: Do not stand over a thief or gauge hole on a tank under any condition.
4. In case gas line breaks suddenly hold your breath and get out of the danger zone at
once. Report the leak; keep others out of the dangerous area.
5. Using a prescribed breathing apparatus or gas mask test the atmosphere before entering
area suspected of being dangerous. Obtain and use proper material and equipment before
trying to repair any leak.
6. Never enter or work without gas mask protection in place where the atmosphere is
known to be contaminated with poison gas until the atmosphere has been tested and
declared “safe”
7. Gas mask protection must be used while testing such an atmosphere for the presence of
hydrogen sulfide and this protection must not be removed until the atmosphere has been
declared “safe”
8. Outside exposures where concentration of hydrogen sulfide exist in excess of 70 to
150 ppm and the worker is exposed to such concentration, several suitable canister type
gas masks must be worn.
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Caution: Although an atmosphere containing hydrogen sulfide tests within the safe
concentration limit (which would allow an employee to work safely for 8 hours without gas
mask protection) it is easily possible that the concentration may rise to dangerous
proportions in a particular area from time to time due to wind changes, air currents or to
increased sources of hydrogen sulfide. These factors must be seriously considered before
declaring an area “safe” even though a test may indicate it to be so at a particular time.

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9. Gauging tanks: (an outside exposure) where concentration of hydrogen sulfide might
built up and exceed 300 ppm it is required that the tank be declared to be “poison”, and a
suitable canister type or a self-contained oxygen mask must to be worn.
10. Inside Exposure: Inside of tanks-any tank where hydrogen sulfide has been present is
likely to built up dangerous concentration of hydrogen sulfide by reason of conditions such
as stirring up B.S. & W., changes of temperature due to the sun, and changes of air
currents. Where initial test indicates a concentration less than 20 ppm, it should be
remembered that conditions such as enumerated above may cause rapid increase in
concentration which should be guarded against by periodic test, the frequency of which
should be governed by the existing conditions.
Other confined spaces-where concentration of hydrogen sulfide in other confined spaces

exceeds 10 ppm, an approved type of gas mask shall be worn.
EMERGENCY TREATMENT
1. Immediate removal of the victim from poisonous atmosphere to fresh air.
2. If breathing has ceased, immediately administer artificial respiration and call for an
ambulance. Continue artificial respiration, combined with inhalation of oxygen if available
until patient is under a doctor’s care.
3. Keep the victim lying down, warm, and as comfortable as possible.
SURVEYS
Where and when sour crude are handled, periodic surveys shall be made by the Stocks
and Shipping Department personnel, in conjunction with the Area Safety Engineer, to
determine which tanks within the refinery contain excessive quantities of hydrogen sulfide
gas. The following procedure should be followed when a tank is being tested.
1. The lead acetate paper (method 1 under “Detection”) must be prepared and watched
closely by the safety Engineer while ascending the tank, and if hydrogen sulfide is detected.
A canister type gas mask be used immediately.
2. The Safety Engineer must use canister type gas mask protection while determining the
quantity of hydrogen sulfide present by Methods 2 under “Detection”.
PROPER MARKING
Standard “Poison gas” signs must be placed on any tank already equipped in which
poisonous gas is present in a concentration of 20 grains or more per 100 cubic feet
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(0.03%). Where tank age is grouped with a gas suction header and one gas regular serves
the group, if any tank in such a group is receiving products with poisonous vapors, it will be
necessary to consider all tanks of this group as being poisonous and danger signs and all
other precautions must be used. Non-poisonous oils when pumped to other tanks need not
be considered poisonous. In the latter event care must be exercised to prevent pumps
taking suction on the vapors.

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The standard sign reading: “Danger, Poison Gas, Wear Gas Mask on this Tank” must be
placed between the handrails of the stairs, and between the first and fifth treads above the
bottom of the stairway. These signs are not to be confused with “Bad Roof” signs, which
are placed higher than the “Poison Gas” sign. “Poison Gas” signs shall also placed across
walkways and all other approaches to tank or group of tanks where necessary, as revealed
by survey.
WORKING ON OR AROUND POISON GAS TANKS

Specified instructions regarding working on or around tanks marked with “Poison Gas” signs
are as follows:
1. When gauging tanks marked with “Poison Gas” sign, gaugers must at all times use
proper gas mask equipment from the time they pass a “Poison gas” sign until they
return past the sign. They should stand on the windward side of the gauge, if possible,
without climbing to the roof of the tank. Extreme care must also be exercised when
drawing off water from tanks marked with “Poison Gas” signs, and same precautionary
methods used as when gauging.
2. It will be permissible for inspection and repair groups to work on tanks marked with
“poison Gas” sign at any time if a work permit has first been issued, by the Area &
Performing Authorities, and the conditions listed thereon properly carried out. It is
strictly forbidden for anyone to work on a tank marked with a “poison gas” sign without
wearing a gas mask. If the concentration of hydrogen sulfide in any tank is such that a
gas mask might soon become useless no work is to be done on that tank when it is
moving. Each plant should determine which tanks fall into this classification and take
whatever steps are necessary to insure informing all employees engaged on such work.
3. When working on or around tanks containing poison gas, gas masks must be used as
specifically outlined in detail in “Instruction for using, testing, and maintaining air type
hose and canister masks”. Likewise, gas masks must be used when breaking into any
lines poisonous products.
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P/TM/TRG/S.CH/001
SECTION 15
Pb
LEAD FUMES
(From lead burning)
GENERAL
Lead (Pb) is a highly toxic material and its effect is accumulative. Severe exposure, or
relative minor exposures over a long period of time, to lead fumes or dust can be injurious
to health. Following are some of the symptoms of lead poisoning; headaches, dizziness,
loss of appetite and weight and constipation.
Since lead fumes and dusts are generated during lead burning operations, precaution must
be taken to prevent inhaling the fumes or swallowing dust in food or water.

Maximum allowable concentration for lead fumes is 0.15 milligrams per cubic meter of air.
PRECAUTIONS
1. When lead is burning in a room, tank, or other completely enclosed area, provide
positive ventilation by using air movers or fresh air ducts to remove lead dusts and/or
fumes. Always take a position upwind from the work to avoid any contact with lead dust
or fumes. Avoid working in corners of buildings. Whenever possible, do work under an
exhaust hood or out doors.
2. Keep floors and work bench tops clean and free of lead scraps. Avoid walking on lead
scraps as this grinds them into dust particles. Do not sweep floors with a dry broom.
Use water, or, if possible sweeping compound.
3. Wear chemical respirators or fresh air masks where ventilation or wind direction cannot
be controlled. Use only approved type respirators, which give adequate protection,
when lead burning.
4. Do not store or eat food indoors where lead is being burned. Wash hands and face
thoroughly before eating or smoking.
EMERGENCY TREATMENT
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When personnel complain of illness after they have been engaged in occupations during
which exposures to lead could have occurred, this procedure should be followed:
1. If on job, send worker to the Refinery Clinic immediately. If at home and the employee
has not called a physician, call one. In either event advise the Physician of the
possibility of exposure.
2. If, after diagnosis, lead poisoning is suspected this should immediately be brought to
the attention of the Safety Section.

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SECTION 16
(PbO)
LITHARGE
GENERAL
Litharge Plumose Oxide (Lead Monoxide) a heavy reddish yellow, odorless, tasteless,
scaley mass is definitely toxic and if in sufficient concentration will produce poisoning
through inhalation of the dust and to a much lesser degree by ingestion which may occurs
by transmission of the material from the hands, etc., to the mouth on account of improper
washing of the hands after handling this substance.

The maximum allowable concentration of litharge in the atmosphere is 0.15m.g. of lead per
cubic meter of air.
PRECAUTION
1. Handle in such a manner as to prevent the creation of dust in the atmosphere.
2. Dust respirators, goggles and gloves should be worn when shoveling and handling
litharge in quantity.
3. In the event of spillage, the spilled material shall be cleaned up with as little agitation as
possible.
4. After handling Litharge, workmen shall wash face, arms and hands thoroughly with
soap and water prior to eating.
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SECTION 17
MERCURY (Hg)
GENERAL
1. Mercury is a heavy, silvery metallic liquid. It is used in instruments (manometers, flow
meters etc.) throughout the refinery and also in various instruments and apparatus in
the laboratories. It is also used occasionally as reagent in chemical testing.
2. Mercury and its vapors are highly toxic and capable of producing acute or chronic
poisoning if ingested (taken orally) or its vapours are inhaled. It can also be absorbed
into the body through frequent or continuous contact with the skin.
CHARACTEISTIQUES OF MERCURY
1. Mercury has a high vapour pressure and emits vapours into the atmosphere at room
temperatures if let uncovered. (The boiling point of mercury, however, is 670ºF.)
2. Mercury amalgamates with gold, silver, copper, aluminum, Nickel and zinc at room
temperature and causes intergranular corrosion with alloys containing any of these
metals, e.g., brass, monel, etc.
3. Mercury in contract with ammonia and moist air can cause an explosion.
4. Mercury contaminates and destroys the active properties of some catalysts used in
refineries and chemical plants, particularly those used in Catalytic reforming and
Catalytic oxidation of SO2 to SO3.

A concentration of mercury of 0.1mg. in 1 cubic meter of atmosphere for an 8 hour –period
is Maximum Allowable or 0.01 ppm by volume in air.
PRECAUTIONS
The principal safety precautions against mercury poisoning is:
1. To prevent emission of its vapours into atmosphere.
2. To avoid skin contact with the mercury.
3. To avoid all possibilities of mercury inadvertently entering.
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Therefore, the following instructions should be strictly followed when storing, handling, or
working with mercury.
1. Mercury must be stored in closed containers, preferably of steel, cast iron or plastic.
When these are not available, special glass or earthenware containers can be used.
Ordinary glass containers, such as sample bottles etc. must not be used for this
purpose. Neither should drinking or eating receptacles, such as drinking fluid bottles or
cups, plates, dishes etc., be used to contain mercury.
2. Mercury should be stored in a cool place.

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3. When mercury has to be drained into open containers, a cover of water shall be
provided to blanket any emission of its vapors. Mercury must not be poured into drains,
etc.
4. Care should be exercised to avoid spillage. Any spillage of mercury on apparatus,
benches, floors etc. shall be cleaned promptly and where possible hosed down to
remove all traces of spilled mercury. Suitable gloves should be used in this operation.
Waste cotton, etc. used for this purpose should be disposed of or destroyed.
5. Food and drinking water shall not be kept or taken in any room where Mercury is being
used or stored. Neither shall tobacco in any from be taken into such rooms.
6. Workbenches on which Mercury is used shall be washed at the end of each working
day or at completion of work on the bench for the day.
7. Clothes, etc. used in filtering mercury must be disposed of or destroyed.
8. Flow meters, or any tubes etc. that had contained mercury shall not be cleared by
blowing through with air.
9. Distillation of mercury should be carried out in Mercury Distillation Equipment and under
a suitable hood having adequate ventilation. Mercury must not be in an open container
under any condition.
10. Adequate exhaust ventilation shall be provided in enclosed instrument repair shops to
remove mercury vapors.
11. Employees who have to work with mercury such as Laboratory or Instrument
Maintenance employees shall observe commonsense rules of personal cleanliness,
carefully washing hands soap water before eating, smoking, etc.
12. Wherever possible, floors and bench surfaces where mercury is stored or used shall be
smooth, of impervious material, suitably sloped to a collection sump and devoid of any
cracks or crevices so that droplets of any Mercury spilled can be thoroughly cleaned
and removed.
13. Employees working with or in rooms where mercury is used or stored shall undergo a
medical examination at 3 months interval.
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SECTION 18
METHYL ETHYL KETONE (CH3 CO CH2CH3)

GENERAL
Methyl Ethyl Ketone is a colorless liquid with a sharp, penetration odor. This odor is so
sharp that persons cannot work in concentrations, which would be high enough to be toxic,
but skin contact should be avoided.
Methyl Ethyl Ketone is used in the refinery as a component in some paint removers and as
a solvent in the dew axing of lube oils.

The currently accepted maximum concentration of M.E.K. is 200 parts per million parts of
air for 8 hours exposure.
PRECAUTIONS
The precautionary measures are in general the same for the manufacture and handling of
gasoline.
1. Adequate ventilation should be provided so as to prevent irritations of eyes and nose.
2. Employees exposed to M.E.K. should be instructed as to its effects and the safest
methods of conducting their operations.
3. Employees should not be permitted to enter tanks or other confined spaces that contain
M.E.K. without wearing approved respiratory apparatus (Blow man Fresh Air Mask).
Observe the same precautions as are stipulated for entering vessels, which have
contained gasoline.
4. No special protective clothing is needed except that rubber or other protective-type
gloves should be worn it the hands are to be in repeated contact or immersion.
5. Any clothing or shoes which become soaked with M.E.K. should be removed promptly
and the contacted pert of the skin washed thoroughly with soap a water.
6. Personal cleanliness in important.
7. Laboratory precautions: The precautions to be taken are in general the same as those
connected with the handling of gasoline.
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SECTION 19
SULPHUR DIOXIDE (SO2)

GENERAL
Sulphure Dioxide (SO2) is a colorless gas or liquid of pungent irritating odor. In the refinery
it is encountered in both a liquid and gaseous state. Its boiling points are 10ºC. SO 2 as a
gas is heavier than air with a specific gravity of 1.434 (air is 1). Sulphur dioxide is
manufactured at the Refinery and is used as an extraction agent in most.1, 2,3A,3B and 4
SO2 plants.
The gas is dangerous to the eyes, as it causes irritation and inflammation of the conjuctiva.
It has a suffocating odor and is a corrosive and poisonous material. In moist air or fogs it
combines with water to form sulphurous acid, but is only slowly oxidized to sulphuric acid.
Concentration of 6 to 12 parts per million cause immediate irritation of the nose and throat,
while 0.3 to 1ppm can be detected by the average individual. 3 ppm has an easy noticeable
odor and 20 ppm is the least amount, which is irritating to the eyes.10.000 ppm, is an
irritant to moist areas of the skin a few minutes of exposure.
It chiefly affects the upper respiratory tract and the bronchi. It may cause edema of the
lungs and glottis and can cause respiratory paralysis. This material is so irritating that is
provides its own warning to toxic concentrations. 400 to 500ppm are immediately
dangerous to life and 50 to 100 ppm is considered to be maximum permissible
concentration for exposures from 30 to 60 minutes.

The maximum permissible concentration of Sulphur Dioxide is 5 parts per million in air; 13
milligrams per cubic meter of air, for eight hours exposure.
PRECAUTIONS
1. Avoid all contact or inhalation of fumes by using a gas mask equipped with a canister
against exposures to acid gases. Operators or maintenance personnel when working in
the SO2 plants, upon the detection of any quantity of SO2 gas, should equip themselves
with the proper gas mask until the source of gas has been completely eliminated.
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2. If a line or other equipment containing sulphur dioxide should burst all persons in the
affected area must be evacuated immediately. Entry into the effected area can only be
permitted by use of a properly equipped canister gas mask.
3. If excessively high concentrations of SO2 gas exist, personnel entering the affected area
must wear self-contained fresh air masks. They also should be equipped with P.V.C.
gloves, suits and ankle boots.
4. In preparation of equipment for mechanical work, care shall be taken to insure complete
removal of all sulphur dioxide gas from lines, pumps, exchangers, etc., prior to the time
it is turned over to mechanical forces for opening and subsequent maintenance work.
This responsibility shall rest with the operating personnel.

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5. If a line or equipment should burst and spray liquid SO 2 throughout the area it should be
washed up immediately and flushed to the sewer. Large quantities of water should be
used, as the resulting solution will produce toxic and corrosive fumes.
EMERGENCY TREATMENT
1. Personnel who have shown toxic symptoms when exposed to sulphur dioxide should
immediately be removed to fresh air.
2. If eyes or other parts of body are involved they should be washed with copious
quantities of warm water.
3. Report to the refinery Clinic for immediate medical attention.
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SECTION 20
SULPHURIC ACID (H2SO4)

GENERAL
Sulphuric Acid (H2 SO4) is a heavy, oily, corrosive liquid. It varies from colorless to black
according to its purity. Contact with the body results in rapid determination of tissue causing
severe burns. In concentrated form, the form in which it is principally encountered in the
refinery , it acts as a powerful caustic to the skin destroying the epidermis and penetrating
some distance into the skin. This causes great pain and if much of the skin in involved, it is
accompanied by shock, and symptoms similar to those seen in severe bruns. Fumes or
mists of this material cause coughing and irritation of eyes and upper respiratory.

The maximum permissible concentration of sulphuric acid is 0.3 parts per million in air; 1
milligram per meter of air.
PRECAUTIONS
1. All sulphuric acid containers should be safeguarded against mechanical injury.
2. When handling sulphuric acid containers, when breaking into lines, vessels or drums,
etc. which contain or have contained H2SO4, wear chemical type goggles and face
shield attached to the safety helmet, P.V.C. hood; or acid type hood, P.V.C. gloves,
P.V.C. suit and knee boots.
3. Operators and maintenance personnel engaged in routine operation, inspection and
maintenance of plants and equipment in sulphuric acid service should wear as
minimum protection, a face shield attached to the safety helmet, P.V.C. gloves, boiler
suit and rubber ankle boots when outside of the control room or when passing through
sections of refinery units in sulphuric acid service.
4. In preparation of equipment for mechanical work, care shall be taken to insure complete
removal of all sulphuric acid from lines, pumps, exchangers, etc.
Prior to the time it is turned over to mechanical forces for opening and subsequent
maintenance work. This responsibility shall rest with the operating personnel and they
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shall develop whatever procedure of steaming and flushing they deem necessary to
carry out this phase of the precautions.
5. Provide an abundant supply of water near all operations using sulphuric acid, preferably
in the form of emergency showers.
6. Whenever sulphuric acid solution is spilled wash it up immediately. Never leave spillage
of this material unattended.
7. Avoid all contact or inhalation of fumes by using a gas mask equipped with a canister to
protect against exposure to acid gases.

P/TM/TRG/S.CH/001
EMERGENCY TREATMENT
1. Speed in removing sulphuric acid from contact with the body is of primary importance.
Immediately give prolonged applications of water to wash the material off the body.
2. If clothing has been contaminated remove it while under the shower and wash body
thoroughly. Use deluge type safety shower when available.
3. If eyes are involved, they should be immediately washed with copious quantities of
water for at least 15 minutes.
4. Do not attempt to neutralize the acid in contact with the skin.
5. Shock symptoms will often be noted in cases of severe or extensive burns. In such
case, put patient on his back, keep him warm not hot until physician arrives.
6. Report to the Refinery Clinic for immediate medical attention.
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P/TM/TRG/S.CH/001
SECTION 21
TETRAETHYL LEAD (TEL) Pb (C2H5)4

INSTRUMENTS USED TO DETERMINE THE AMOUNT OF HYDROCARBON VAPORS
IN THE ATMOSPHERE WILL NOT INDICATE THE CONCENTRATION OF LEAD IN THE
ATMOSPHERE. A SPECIAL INSTRUMENT IS REQUIRED FOR THE PURPOSE OF
DETECTING LEAD IN THE ATMOSPHERE.
GENERAL
Tetraethyl Lead (TEL) is a clear, colorless liquid having an unusual and distinctive odor,
which may be described as sweetish and sickening. TEL is extremely toxic and poisonous
when it gets into the body. TEL does not mix with water but is readily mixable with fats and
oils. Its solubility in fats and oils makes it especially dangerous since it can be readily
absorbed into the blood stream and nervous system through the skin. It may also enter the
body through inhalation of its vapors. TEL can be absorbed into the body through the
mouth by way of dirty hands. TEL is used in the Refinery and in laboratory to improve the
anti-knock qualities of gasoline.
When gasoline, containing TEL, is stored in tanks, small quantities of TEL will precipitate
out and accumulate in the sidewall scale and the sludge in the bottom of the tank. The
presence of this precipitated TEL in the sludge and sidewall scale is just as dangerous as
TEL itself in liquid from both the standpoint of tank the precipitated TEL will decompose into
other organic lead compounds, commonly referred to as “lead salts” are just as dangerous
as TEL should they be dissipated into the atmosphere in the form of dust particles and
inhaled, or if vaporized during the process of performing “hot “ work. Tanks, which have
contained leaded gasoline and which have been cleaned and declared to be “lead-hazard-
free” may not remain so. For instance, tanks with leaky bottoms; those containing concrete
or other absorbent materials cannot be declared “lead-hazard-free”.
Also tanks that have been once “lead-hazard-free” may again become dangerous from a
“lead-hazard” standpoint when steam is again introduced into the tank.
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4 micrograms of lead per cubic feet of air has been established as the maximum allowable
concentration for 8 hours working in such atmosphere.
PRECAITIONS
The toxic and poisonous nature of TEL requires that specific precautions be taken to
safeguard personnel.

P/TM/TRG/S.CH/001
The following sources of information and instructions shall be referred to:

1. The regulation of the Associated Ethyl Company Limited shall be followed with respect to
the handling, unloading, and blending of TEL in the refinery proper and in the laboratory.
Copy of these regulations shall be posted in the TEL blending plant laboratory.
2.The regulations of the TEL supplier shall be referred to and followed with respect to the
repair of TEL blending equipment, tanks, and lines.
3. Special regulations covered in another section of this Manual titled “Gas Freeing &
Cleaning Tanks Containing TEL “shall apply for cleaning, maintenance or repair of any
tank, barge, vessel, or pipeline which has contained or been used in the service of
manufactured products, or reagent, in the lead hazardous class. This includes but is not
limited to:
a) Tetra Ethyl Lead (T.E.L)
b) Solutions of Tetra Ethyl Lead in petroleum products.
c) Sodium Plumbite solution (doctor Solution)
EMERGENCY TREATMENT
Where personnel complain of illness after they have been engaged in occupations during
which exposure to lead could have occurred, this procedure should be followed:
1. If on the job, promptly call a physician. If at home and the employee has not called a
physician of the possibility of exposure.
2. If, after diagnosis, lead poisoning is suspected, this should immediately be brought to the
attention of the Safety Section.
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P/TM/TRG/S.CH/001
SECTION 22
TRICHLOROETHYLENE (C2HCl3)
GENERAL
Tricholoroethylene is a colorless liquid with a characteristic but not unpleasant odor similar
to the odor of chloroform. It is stable in the presence of air and is slightly heavier than air
with a density of 1.45 where air is 1. It has no flash point and is a slight hazard when
exposed to heat or flame. Though such conditions are difficult to procedure, flames or heat
should not be used in closed equipment, which contains any solvent residue or vapor.
Underwriter’s laboratories class Tricholoroethylene as non-flammable at ordinary
temperatures and moderately flammable at elevated temperatures.
Through installation of excessive amounts of vapor, trichloroethylene has toxic action. If the
concentration is kept down to values below 200 parts per million no toxic effect will occur.
Trichloroethylene will pass through the skin, but it is doubtful that such exposures will
result, in practice, in the absorption of sufficient quantity to be toxic. Continued contact of
the solvent with the skin will procedure dermatitis as will any which removes the natural
skin oils.
Because trichloroethylene dissolves greases it is under controlled conditions in the refinery

as a degreasing agent in cleaning metal parts such as electrical equipment, instruments,
valves, tools, etc.

The maximum allowable concentration of Trichloroethylene is 50 parts per million parts of
air.
PPRECAUTIONS
1. Tricholoethylene must not be used in an inclosed area or room that is not equipped with
a hood and exhaust fan.
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2. Trichloroethylene may be stored in the original containers for long periods of time without
change. Drums should be kept closed to prevent evaporation and should not be exposed to
extreme heat.
3. Operations employing tricholoroethylene should always be conducted in well ventilated
areas. Open-top degreasing should be carefully protected from direct drafts, which may
force the vapor out over the top of the tank.
4. When concentration of vapor requires mechanical ventilation, the system should be such
to draw the vapor away from the operation.
5. Canister type gas masks with an organic vapor canister are suitable for brief exposure to
low concentration of the vapor. They are approved for not more than 2 per cent.
6. Where the vapor concentration may be higher than 2% a fresh air supplied mask must be
used even for short exposures.

P/TM/TRG/S.CH/001
7. Where contact of the skin with liquid tricholoroethylene or its vapor is unavoidable or may
occur accidentally, synthetic rubber gloves -should be worn.
8. It is particularly important that employees thoroughly wash off all traces of the solvent
from the skin at the end work and change to clothing, which has not been exposed to
solvent.
9. Waste tricholoethylene is flammable and should generally be burned in a furnace or
spread on waste and burned on a burning ground. If it is burned, the products of
combustion will be acid, and care must be taken that do not contaminate the area.
EMERGENCY TREATMENT
1. In case of poisoning, a physician should be called at once and the victim should be
carried to fresh air.
2. If breathing has stopped or is present only in occasional gaps, artificial respiration should
be applied with inhalation of oxygen.
3. Clothing which has become saturated with trichloroethylene should be removed and the
victim wrapped in blankets to preserve his body heat.
4. The victim in no case should be allowed to walk but should be taken to the Refinery
Clinic in an ambulance.
5. If trichloroethylene has been splashed in the eyes, they should be washed out with a
large amount of water. Such cases should be promptly referred to the Refinery Clinic.
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P/TM/TRG/S.CH/001
SECTION 23
TRI-POTASSIUM PHOSPHATE (K3PO4)

GENERAL
Tri-potassium phosphate (K3PO4) is a white granular powder, which is used in the Refinery
Absorption plant as the absorbing medium for H2S removal. It is not a fire hazard. It has a
mild irritant effect on the skin.
PRECAUTIONS
P.V.C. gloves, dust goggles and or face shields should be worn when handling the
Tri-potassium Phosphate in powdered form. No other precautionary measures are
necessary.
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Chemical Hazards

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TSP-POGC-NIGC T.T.F.

COURSE SAFETY CODE

Prepared by G. Eshghi Checked by Yeganeh Approved by T.T.F

HEALTH, SAFETY AND ENVIRONMENT POLICY STATEMENT

These objectives which TSP considers of greatest importance are:

 Adoption of an attitude of openness and constructive dialogue with public authorities

 Determination to make permanent progress in he field of Health, Safety and

 Application of appropriate measures to minimize any adverse effects of its operations

1. FIRE & EXPLOSION HAZARDS:

Non-flame proof electrical equipment should not be brought in flammable area.

6. Spontaneous Ignition: Only waste and rubbish or presence of combustible material in

7. Overheated Material: Abnormal rise in temperature in process or moving machine can

HEALTH & TOXICITY HAZARDS

Chemical agents in the form of a) Dusts b) Fumes c) Mists d) Vapor e) Gases.

Chemical substances reach the body as follows:

Control measure & precaution:

2) Spillage of chemical substances on floors should not be permitted. In case of any

4) Housekeeping of plant should be improved. Rubbish, waste material, drums should be

6) Washing the hands with any solvent or chemical is prohibited.

SUBJECT CHEMICAL HAZARDS CODE

3. Auto Ignition Temperature:

5. Threshold Limit Values (TLV):

SUBJECT CHEMICAL HAZARDS CODE

6. Minimal Lethal Dose & LD50 Test:

INTERPRETATION OF HAZARD CODE SYMBOL

SUBJECT CHEMICAL HAZARDS CODE

1. Tenamene 2 (Dupont 22).

SUBJECT CHEMICAL HAZARDS CODE

MAXIMUM ALLOWABLE CONCENTRATION

SUBJECT CHEMICAL HAZARDS CODE

MAXIMUM ALLOWABLE CONCENTRATION

SUBJECT CHEMICAL HAZARDS CODE

SUBJECT CHEMICAL HAZARDS CODE

SUBJECT CHEMICAL HAZARDS CODE

SUBJECT CHEMICAL HAZARDS CODE

CARBON DIOXIDE (CO2)

SUBJECT CHEMICAL HAZARDS CODE

CARBON MONOXIDE (CO)

Carbon monoxide is an extremely dangerous poison. It readily accumulates in the blood

MAXIMUM ALLOWABLE CONCENTRATION

CAUSTIC SODA (NaOH)

SUBJECT CHEMICAL HAZARDS CODE

CARBON TETRACHLORIDE (CCl4)

MAXIMUM ALLOWABLE CONCENTRATION

SUBJECT CHEMICAL HAZARDS CODE

MAXIMUM ALLOWABLE CONCENTRATION

SUBJECT CHEMICAL HAZARDS CODE

3. If breathing has ceased, begin artificial respiration at once.

SUBJECT CHEMICAL HAZARDS CODE

COBALT CARBONYL Co4 (CO)12

MAXIMUM ALLOWABLE CONCENTRATION

SUBJECT CHEMICAL HAZARDS CODE

SUBJECT CHEMICAL HAZARDS CODE

FURFURAL (C4 H3 OCHO)

Practical experience has demonstrated conclusively that under ordinary operating

MAXIMUM ALLOWABLE CONCENTRATION

MAXIMUM ALLOWABLE CONCENTRATION

SUBJECT CHEMICAL HAZARDS CODE

DRAWINGS HYDROCARBONS OR CHEMICALS

SUBJECT CHEMICAL HAZARDS CODE

HYDROCHLORIC ACID (HCl)

MAXIMUM ALLOWABLE CONCENTRATION

SUBJECT CHEMICAL HAZARDS CODE