H.

VISHVANATHAN
M/s Meenakshi Safety Consultancy Services
Navi Mumbai 410206
Mob: 9869287053, 9082783567
Email: hvishvan@yahoo.com, hvishvan@meenakshisafety.com
 MAIN HAZARDS IN CHEMICAL INDUSTRIES
FIRE
EXPLOSION
TOXIC RELEASE

SAFE STORAGE AND HANDLING OF

HAZARDOUS CHEMICALS
TYPES OF STOTAGES
GENERAL
Cylinders, Drums, Barrels, Carboys
BULK
Vertical Tanks, Horizontal Tanks, Horton Sphere, Special tanks
 IMPORTANT TERMS USED WHILE
HANDLING HAZARDOUS CHEMICALS
HAZARDOUS CHEMICAL
A chemical which is explosive, flammable, poisonous, corrosive,
reactive or radio active and which requires special care in
handling them because of the hazards it poses to people and the
environment.
UN NUMBER
The UN is a four figure code used to identify hazardous
chemicals and is used for identification of chemicals transported
internally by road, rail and by air.
FLASH POINT
The minimum temperature at which the liquid gives so much
vapour that vapour, when mixed with air, forms an ignitable
mixture and gives a momentary flash on application of a small
pilot flame under specified conditions of test.
AUTO IGNITION TEMP.
The lowest temperature at which an ignition occurs in a mixture
of explosive gas without the aid of any external source
 FLAMMABLE (EXPLOSIVE) LIMIT AND
RANGE
LOWER EXPLOSIVE LIMIT (LEL)
Is the minimum concentration of vapour in air below which the
propagation of flame does not occur in contact with a source of
ignition.
UPPER EXPLOSIVE LIMIT (UEL)
Is a maximum concentration of vapour above which the
propagation of flame does not occur on contact with a source of
ignition.
FLAMMABLE (EXPLOSIVE) RANGE
Is the range between the LEL and UEL expressed in % of
Volume of air.
Visual example to show where on the scale % of LEL is measured

Methane - LEL: 5% by volume in Air / UEL: 17% by

volume in Air
 1.1 Explosives with a mass explosion hazard
UNITED NATIONS CLASSIFICATION 1.2 Explosives with a projection hazard
Class 1 1.3 Explosives with predominantly a fire hazard
1.4 Explosive with no significant blast hazard
1.5 Very insensitive explosives
2.1 Flammable gases
Class 2 2.2 Non flammable gases
2.3 Poison gases
3.1 Flashpoint below – 180C (00F)
SYSTEM

Class 3 3.2 Flashpoint – 180C and above but less than 230C (730F)
3.3 Flashpoint of 230C and up to 610C (1410F)
4.1 Flammable solids
Class 4 4.2 Spontaneously combustible materials
4.3 Materials that are dangerous when wet
5.1 Oxidizers
Class 5
5.2 Organic peroxides
6.1 Poisonous materials
Class 6
6.2 Etiologic (Infectious) materials
Class 7 Radioactive materials
Class 8 Corrosives
Class 9 Miscellaneous hazardous materials
 UN CLASS LABELS

The appropriate division number and compatibility The appropriate compatibility group is to be placed in this location, e.g. D.
group are to be placed in this location for divisions For goods of class 1 in division 1.4, compatibility group S, each package
1.1, 1.2, and 1.3, e.g. 1.1 D may alternatively be marked 1.4 S

Subsidiary risk labels

Subsidiary risk labels are as shown here, but they
should not bear the class number in the bottom
corner. For example:
 Toxicity Limits
TLV
TWA
STEL
CEILING
IDLH
LC50
LD50
TOXIC RELEASE
Gas
Pressurized liquid gas
Liquid
TLV (Threshold Limit Value)
Concentrations of air contaminants in the working environment to
which all workers are exposed repeatedly day after day without
adverse effect. Normally, it is the TWA concentration in ppm or
gm/m3 for a normal 8 hour work day or 40 hour workweek.

STEL (Short Term Exposure Limit)

It is defined as a 15 minutes time weighted average exposure, which
should not be exceeded at any time during a workday even if the 8
hours time weighted average is within the TLV. STEL should not
be > 15 minutes and not more than four times per day with an
interval of 60 minutes

IDLH (Immediately Dangerous to Life or Health)

The max. level to which a healthy worker can be exposed for 30
min. without suffering irreversible health effects or suffering
impairing symptoms.
 LD50 & LC50
LD50 is expressed as acute local toxicity or acute dermal toxicity.
LD50 for Acute Local Toxicity is that dose of substance which is likely
to cause death within 14 days 50% of both male and female young adult
albino rats, whereas LD50 for Acute Dermal Toxicity is the dose when
administered by cutaneous contact for 24 hours with the bare skin
albino rabbits, which is most likely to cause death within 14 days 50%
of the animals tested.

LC50 is expressed as acute toxicity on inhalation. It is that concentration

of the substance in air in the form of vapour, mist or dust which,
administered by continuous inhalation to both male and female young
adult albino rats for one hour, is likely to cause death within 14 days
50% of the animals tested.
 EFFECTS OF TOXIC RELEASE
ACUTE Short term exposure at high conc.
CHRONIC Long term exposure at low conc.
ACUTE EXPOSURE
• Irritation
• Narcosis
• Asphyxiation – Simple/ Chemical
• Systemic damage
SEVERITY OF EFFECTS
• Concentration
• Duration of exposure
• Toxic properties of material
 Routes of Entry of Chemicals

Ingestion

Inhalation

Skin Absorption
 TOXICITY DEPENDS ON

• Nature of the chemical

• Concentration in the
atmosphere
• Duration of exposure
• Route of entry of the chemical
• Size of the particles, and
• Individual susceptibility
SAFE STORAGE AND HANDLING OF
HAZARDOUS CHEMICALS
 STORAGE OF CHEMICALS IN BULK
• The tanks to be located safety to avoid problems due to
leakage and reaction with other chemicals stored nearby.
• The storage tank and foundation should be of suitable
material to prevent corrosion.
• Connections and openings to the tank should be minimum to
minimize leakages.
• The tanks should be fitted with vents/relief systems of
adequate capacity discharging to a safe height.
• The Drain Valve of the Dyke should be kept in closed
condition
• Rainwater from the Dyke should be drained off into storm
water drains.
• The name of chemical, type of hazard, emergency operational
instructions, antidote, first aid, etc. should be displayed
on/near each tank.
 STORAGE OF CHEMICALS IN BULK

• The tank should have provision for emergency evacuation

of its stock to a safer location in case of emergency
• Storage tank should have instruments to monitor its level,
pressure and temperature preferably with remote
indications at control room.
• An alert system should be available in case of abnormal
rise in level/pressure/ temperature.
• All level gauge/safety drain should be checked periodically
and monitored in good working order.
• Tank should have a dyke of suitable material and volume
110% of the volume of the largest storage tank.
 UNLOADING OF TANK TRUCKS/TANK WAGONS

• Quality of the chemical in the tanker should be ascertained to

avoid contamination of chemical already at storage.
• Unloading hose should be devoid of cracks and blisters and
be hydro tested at regular intervals.
• Same hose should not be used for unloading different
chemicals.
• Operating staff must use suitable PPE and clothing.
• There must be adequate illumination at site.
• Hose should be kept blinded when not in use.
• Before the tanker enters the Terminal premises, the tanker is
to be inspected for authorized entry and safe and sound
condition.
 UNLOADING OF TANK TRUCKS/TANK WAGONS

In case of flammable chemicals,

• the prime mover (engine) should be kept off.
• All cables and electric fittings shall be constructed, installed,
protected, operated and maintained to prevent risk of open
sparking
• Only Approved Flameproof fittings type should be used.
• Tankers entering plant are to be fitted with flame arresters.
• The unloading point should be located at a safe distance
outside the storage dyke.
• Coupling used for connecting hose to tanker must be leak
proof.
• The tanker and the hose are to be properly earthed before
starting unloading operations.
• Double earthing with Crocodile Clamps should be used.
• Unloading should be done in daytime only.
ELECTRICAL AREA CLASSIFICATION
 CLASSIFICATION OF HAZARDOUS AREA FOR
ELECTRICAL INSTALLATIONS
The classification of areas for electrical installations in
petroleum refineries and other similar areas where hazards
of explosion due to gases and vapours exist and in which
flammable gases and volatile liquids are processed stored or
loaded, unloaded and otherwise handled.

Areas have been divided into three main Zone

Zone 0
Zone 1
Zone 2
 CLASSIFICATION OF HAZARDOUS AREA FOR
ELECTRICAL INSTALLATIONS
Division-0 Area
•An area in which a hazardous atmosphere is continuously
present shall fall under this category.
•Since a hazardous atmosphere exist continuously any failure of
electrical apparatus installed in Division 0 area would almost
certainly lead to fire or explosion or both.
•It is recommended that the use of electrical apparatus should,
where practicable be completely excluded.
•when this is not practicable the recommendations laid down in
IS 5571 (guide for selection of electrical equipment for
hazardous areas) should be followed.
 CLASSIFICATION OF HAZARDOUS AREA FOR
ELECTRICAL INSTALLATIONS

Zone -1 Area
•An area in which a hazardous atmosphere is likely to occur
under normal operating condition shall fall under this category.
•This classification is applied to areas in which a hazardous
atmosphere is likely to occur at any time.
•practicable application of measures to prevent the occurrence
of a hazardous electrical condition at any time or in any
circumstances.
•Recommended types of electrical apparatus and wiring for use
in this areas are given in IS 5571.
 CLASSIFICATION OF HAZARDOUS AREA FOR
ELECTRICAL INSTALLATIONS
Zone -2 Areas
•An area in which a hazardous atmosphere is likely to occur only
under abnormal operating conditions shall fall under this
category.
•Applicable only where a fire and explosion hazard is unlikely
and may be caused only by simultaneous and improbable
occurrence of an arc or spark resulting from an electrical failure
and a hazardous atmosphere arising through failure of the
conditions of control.
•Any hazardous atmosphere resulting from an abnormal
occurrence is rapidly dispersed, so that its possible contact with
the electrical apparatus of minimum duration.
Thank You Very Much, Any
Questions Please
Severity of Shock
• Amount of current
• Duration of flow of current
• Path of flow of current
• Type of energy (AC/DC)
• Frequency ( in AC only)
• Environmental condition